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| Illustration 1 | g02118437 |
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(1) Display screen
(2) F4 Soft key (3) F3 Soft key (4) F2 Soft key (5) F1 Soft key (6) Control key (7) AC overview key (8) Engine overview key (9) Main menu (10) Warning Indicator lamp (yellow) (11) Alarms acknowledge key and silence key (12) Shutdown Indicator lamp (red) (13) Event reset key (14) Event log key (15) Run key (16) Auto key (17) Stop key (18) Escape key (19) Up key (20) Right key (21) OK key (22) Down key (23) Left key | |
The main component of the Electronic Modular Control Panel 4.3/4.4 ( EMCP 4.3/4.4) is the electronic control module (ECM). This section discusses the display, keys, and indicators on the control system panel of the ECM. The EMCP 4.3/4.4 panel is used for monitoring and controlling many of the generator set functions. Some of the functions include:
- Sending start and stop signals to the engine
- Providing visual and audible indications when warning or shutdown events occur
- Displaying engine information and AC generator set information
- Displaying Suspect Parameter Number (SPN) and Failure Mode Identifier (FMI) information for events
- Programming set points for the standard EMCP 4.3/4.4 (The set points for optional modules are set with the use of Cat ET.)
- Annunciator configuration is done within the EMCP 4.3/4.4
The following components can be found on the front panel of the ECM:
- Information Display
- Alarm Indicators
- Alarm Acknowledge/Silence Key
- Event Reset Key
- Function Keys
- Navigation Keys
- System Overview Keys
(1) Display Screen - Information from the EMCP 4 is displayed on the display screen. This screen is used for the following programming and display functions.
- Displaying AC parameter information of the generator set
- Displaying engine parameter information of the generator set
- Programming set points for the generator
- Displaying engine event information
- Displaying event codes from other modules
- Programming the display preferences of the EMCP 4.3/4.4
- Changing password levels of the EMCP 4.3/4.4
(10) Alarm Acknowledge/Silence Key - Pressing the alarm acknowledge/silence key will cause the horn relay output to turn off and silence the horn. Pressing the key will also cause any yellow or red flashing lights to turn off or to become solid depending on the active status of the alarms. The alarm acknowledge/silence key may also be configured to send out a global alarm silence on the J1939 Data Link which will silence horns on annunciators. However, other modules must be configured in order to listen to the global acknowledge.
(11) Event Reset Key - The event reset button will clear all inactive fault conditions.
Yellow Warning Light - The yellow warning light (10) is located directly above the alarm acknowledge/silence key (11). A flashing yellow light indicates that there are unacknowledged active warnings. A solid yellow light indicates that there are acknowledged warnings active. If there are any active warnings, the yellow light will change from flashing yellow to solid yellow after the alarm acknowledge/silence key is pressed. If there are no longer any active warnings, the yellow light will turn off after the alarm acknowledge/silence key is pressed.
Red Shutdown Light - The red shutdown (12) light is located directly above the event reset key (13). A flashing red light indicates that there are unacknowledged active shutdown events. A solid red light indicates that there are acknowledged shutdown events active. If there are any active shutdown events, the red light will change from flashing red to solid red after the alarm acknowledge/silence key is pressed. Any condition that has caused a shutdown event must be manually reset. If there are no longer any active shutdown events, the red light will turn off.
(2) F4 - Pressing the F4 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.
(3) F3 - Pressing the F3 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.
(4) F2 - Pressing the F2 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.
(5) F1 - Pressing the F1 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.
(15) RUN - Pressing the "RUN" key causes the EMCP 4.3/4.4 to enter the run mode.
(16) AUTO - Pressing the "AUTO" key causes the EMCP 4.3/4.4 to enter the auto mode.
(17) STOP - Pressing the "STOP" key causes the EMCP 4.3/4.4 to enter the stop mode or the cool down mode.
(18) Escape Key - The escape key is used during menu navigation in order to navigate up through the menu/submenu structure. Each key press causes the user to move backward (upward) through the menus. The escape key is also used in order to cancel of data entry screens during set point programming. If the escape key is pressed during set point programming, then none of the changes displayed on the screen will be saved to memory.
(21) OK Key - The OK key is used during menu navigation in order to move forward (downward) through the menu/submenu structure. The key is also used during set point programming in order to save set points changes. Pressing the OK key during set point programming causes set point changes to be saved to memory.
(6) Control Key - The control key will navigate the display to the screen that allows the user to monitor and/or adjust various special control features.
(9) Main Menu Key - The main menu will navigate the display to the main menu directly without having to navigate out of menus.
(14) Event Log - The event log button will navigate the display to the event log.
(19) Up Key - The up key is used in order to navigate up through the various menus or monitoring screens. The key is also used during set point entry. During numeric data entry, the key is used in order to increment the digits (0-9). If the set point requires selection from a list, then the key is used to navigate up through the list.
(20) Right Key - The right key is used during set point adjustment. During numeric data entry, the key is used in order to choose which digit is being edited. The key is also used during certain set point adjustments in order to select a check box or to deselect a check box. If a box has a check mark inside, then pressing the key will cause the check mark to disappear. If the box does not have a check mark inside, then pressing the key will cause a check mark to appear inside.
(22) Down Key - The down key is used in order to navigate down through the various menus or monitoring screens. The key is also used during set point entry. During numeric data entry, the key is used in order to decrement the digits (0-9). If the set point requires selection from a list, then the key is used to navigate down through the list.
(23) Left Key - The left key is used during set point adjustment. During numeric data entry, the key is used in order to choose which digit is being edited. The key is also used during certain set point adjustments in order to select a check box or to deselect a check box. If a box has a check mark inside, then pressing the key will cause the check mark to disappear. If the box does not have a check mark inside, then pressing the key will cause a check mark to appear inside.
(7) AC Overview - Pressing the AC overview key displays the first screen of AC information for the generator set. This initial information page contains various AC parameters that summarize the electrical operation of the generator set. Additional AC parameters can be viewed by pressing the down key multiple times.
(8) Engine Overview - Pressing the engine overview key displays the first screen of engine information. This initial information page contains various engine parameters that summarize the operation of the engine. Additional engine parameters can be viewed by pressing the down key multiple times.
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| Illustration 2 | g01101388 |
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 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 17 pairs of LED indicators on the front panel of the annunciator. 16 pairs of LED indicators are used to announce events, diagnostics, and ready signals. The 17th pair of LED indicators is used as a combined network/module status LED. The 17th pair of LED indicators can tell the operator if there is a problem with the J1939 data link connection.
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 warning is read over the data link, the annunciator will flash the yellow LED and the horn will sound. If the low engine oil pressure shutdown is read over the data link, the annunciator will flash the red LED and the horn will sound.
To acknowledge the shutdown and alarm conditions or to silence the horn, press the "Alarm Acknowledge" button that is located on the annunciator.
Test the LED indicators or the horn when the data link is connected or disconnected, by pushing "Lamp Test" button located on the annunciator.
The annunciator module can be customized in order to signal many different conditions that are related to the system. Each pair of LEDs 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 LEDs 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, UENR1210, "EMCP4.3/4.4".
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| Illustration 3 | g02708197 |
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(1) Emergency stop push button
(2) Fuel priming switch | |
Emergency Stop Push Button (1) - 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.
Fuel Priming Switch (2) - The fuel priming switch is used to activate the fuel priming pump.
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| Illustration 4 | g02680536 |
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(1) Fuel level gauge
(2) Fuel control switch (3) Fuel mode switch (4) Fuel overfill lamp | |
Fuel Leve Gauge (1) - Displays the level of fuel in the fuel tank of the power module. The level is displayed as a percentage.
Fuel Control Switch (2) - With this switch in the left position, the fuel pump will unload fuel from the tank. In the right position, the fuel pump will load fuel into the tank. This swich works with the fuel mode switch.
Fuel Mode Switch (3) - The position of the fuel mode switch determines if the fuel pump will automatically or manually transfer fuel to or from an external tank. The fuel transfer is determined by the fuel level in auto mode. If the fuel mode switch is manually held in the left position, then the fuel pump will operate regardless of the fuel level. The left position is the manual mode. The fuel mode switch is a three position switch.
Fuel Overfill Lamp (4) - The fuel overfill lamp will illuminate if the fuel tank of the power module is above 98 percent full. The fuel overfill lamp will illuminate if the pump has been locked out from pumping more fuel into the tank.
Fuel Transfer Control Functions
The fuel transfer system requires that customer fuel lines be connected from an external fuel tank to the power module.
While the control switches are in the Auto and Load positions, the fuel level will be maintained between 50% and 85% automatically. For example, when the fuel level drops to 50% or below, and EMCP 4 relay output will turn on the "load" relay. The load relay will power the fuel pump motor in the forward rotation. The forward rotation results in pumping fuel from the external supply into the fuel tank. Once the fuel level reaches 85% or higher, the pump motor will turn off automatically.
The following criteria must exist for the EMCP 4 to turn on the output for the "unload" relay:
- Control in Auto
- Control set for Unload
- Fuel level above 10%
The relay output will power the fuel pump motor in the reverse rotation. The reverse rotation results in pumping fuel from the fuel tank into an external tank. Once the fuel level drops to 10% or lower, the pump motor will turn off automatically. To continue unloading fuel until the tank is empty, refer to the "Manual Unload" section of this Operation and Maintenance Manual below.
With the toggle switch in the Load position, the operator must turn and hold the selector switch in the Man position. The operator has complete control of what level the fuel will be loaded to. The only thing that limits this operation is activation of the overfill switch.
With the toggle switch in the Unload position, the operator must turn and hold the selector switch in the Man position. The operator has complete control of what level the fuel will be unloaded to. There is no device that limits this operation so that the fuel tank can be emptied.
Note: Do not drain the fuel pump completely. Damage to the pump can occur if the fuel pump is drained completely.
Note: The fuel levels used for control are programmable.
Utility Multifunction Relay Panel
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| Illustration 5 | g02707522 |
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Utility Multifunction Relay | |
The optional Utility Multifunctional Relay (UMR) panel is intended for use only when paralleling the unit to the utility system. This provides protection primarily for the utility system but also includes one feature for generator protection (the 40Z element). The UMR detects a fault condition via three phase AC monitoring and then trips the 86 lockout relay on the panel. There are provisions also to accept a customer supplied (dry contact) signal, indicated as "utility transfer trip" to trip this 86 lockout relay. The 86 lockout relay directly trips the generator breaker open and signals the EMCP control to put the engine in stop/cooldown. When the unit is not setup for a utility paralleling application, the necessary UMR protections are suppressed or bypassed automatically to allow normal operation and avoid false alarms and trip/shutdowns.
UMR - The utility multifunction relay is a protective device. The UMR prevents damage to electrical components in the event of an electrical anomaly on the bus. The UMR monitors voltage, frequency, synchronization, and other parameters. The UMR is set up specifically to protect downstream electrical components when the power module is paralleled with a utility. Protection of upstream components, such as the generator used in the power module, is primarily provided by other onboard components. However, the UMR does provide one generator protection element, the 40Z (loss of field) impedance-based protection. The settings for the 40Z function are specific for the generator on this power module. The UMR relay is a modular component that can be removed. The relay can be removed by loosening the two thumbscrews, then by pulling out the relay assembly. The relay has adjustable pickup and adjustable time delay settings. The display on the utility multifunction relay contains a menu for different settings. Settings for the relay can be adjusted at the discretion of the user. The factory has programmed default settings that are based on the IEEE 1547 intertie protection standard but are not intended to provide protection for any specific utility, site, or device. The user has the responsibility to check with the local utility and/or conduct a system study to determine proper site-specific UMR settings.
Paralleled with Utility Lamp - The paralleled with Utility lamp will illuminate when both of the following conditions are true:
a. The utility breaker is closed
b. The generator breaker is closed
Utility Breaker Closed Lamp - The utility breaker lamp will illuminate when the utility breaker is closed. This requires customer provided signal wiring from the utility intertie breaker aux contact.
Utility Transfer Trip Lamp - The utility transfer trip lamp will illuminate to indicate that the transfer trip signal was or still is active.
86 Lockout Relay - device performs fast response fault clearance. The fault is cleared by opening the generator breaker and by placing the engine in cooldown if a fault occurs. The fault must be detected by the on-package utility multi-function relay (UMR) or the utility transfer trip signal.
Note: The EMCP control must be in "STOP" mode to allow the manual reset of the 86 lockout relay. Resetting the 86 lockout relay will also reset the UMR trip signal.
Transformers - Inside the UMR panel are the potential transformers (PTs) used to step down voltage from line voltage to 120 VAC both on the "line side" and "load side" of the generator breaker. These provide sensing voltage only for the UMR.
Fuses - The fuses for the secondary side of the potential transformers are located on the face of the UMR panel. The fuses for the primary side of the potential transformers are located in the lower terminal box on the Generator.
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| Illustration 6 | g02721276 |
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Customer Load Cable Connection Bus Bars (1) X1 Polarity Indicator Dot | |
The unit is designed for easy installation of the UMR panel. Wall mounted brackets are used to secure the panel to the wall near the right-hand side of the generator control panel. The unit has provisions to use a hoisting tool to position the UMR panel into place, allowing for a single person to install. An interconnect harness must be installed from the lower right-hand side of the generator control panel to the bottom side of the UMR panel.
Current transformers (CT) must be added, one for each phase (T1, T2, and T3), to the customer connection bus bars. The standard CT has a 1200:5 amp ratio and is a "relay class" CT. This allows for utility paralleling only at the higher rated voltages of the unit (400V or 480V). If paralleling at one of the lower voltages, consult the factory regarding CT selection. Prior to connecting the customer load cables, the CTs are to be mounted on the outside of the red "glastic" material, surrounding the bus bars, using the pre-drilled mounting holes. Wires (14AWG min.) must be added from those three current transformers to the six-position CT shorting terminal block located adjacent to the bus bars area. Install CTs per the illustration below with the X1 polarity indicator dot to identify the X1 wiring terminal of the CT and with the other polarity indicator dot (on the side of the CT) facing the generator.
The UMR must have software settings that are specific for the unit in which it is installed. Standard settings are for a nominal 480V, 60Hz system. Consult the factory regarding software settings.
For more detailed instruction on installation of the UMR panel, reference Operation and Maintenance Manual, SEBU8514, "XQ Auto Paralleling".
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| Illustration 7 | g02704819 |
| (1) Solar array panel | |
Solar Array Panel - One solar array panel is located on the roof of the power module (1).
Check wire connections for tightness and corrosion, and exposed areas for chaffing and wear on a regular basis. Module surface may be cleaned as needed using a soap and water. Abrasive chemicals cannot be used in the cleaning of your solar module. As the combination of water and electricity produces a large shock hazard, disconnect your solar panel from the charge controller or battery prior to any cleaning process and always wear protective rubber gloves and rubber sole shoes when working with electricity.
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| Illustration 8 | g02704821 |
Controller - The solar battery charging controller is located inside the upper generator terminal box.
During normal operation, the "charging" LED should always be ON solid during sunlight to indicate the solar array is contributing power to the controller. Also, the "battery status" green LED (one on the left) should either be ON solid (indicating batteries fully charged) or blinking (solar is charging) and the other two "battery status" LEDs (yellow and red) should remain off.
Battery type selection for XQ product is number 2 (Sealed). Temperature sensor for batteries is not used on XQ product.
Battery Connection - Battery "+/-" has an uninterrupted connection to the batteries. A two-pin connector is located near the batteries to allow isolation from the solar charging system if desired. If the connector is unplugged, the red "battery status" LED will be "ON" solid.
Definition - The EMCP and CDVR voltage regulator each have 4 preprogrammed settings groups for up to four different voltage and frequency machine ratings. A combination of two switch inputs to the EMCP will cause one of four settings groups in the EMCP to become "active" for a particular desired voltage and frequency rating. The engine must be stopped for the switch inputs to effect a change in settings group activation. The EMCP will then send the "active group number" to the CDVR via the "CAN" communication port. The CDVR reads the "active group number" sent from the EMCP and then activates the corresponding settings group within the CDVR. This eliminates field programming to change parameters, in multiple controls, in order to changeover the unit from one machine rating to the next. Benefits include:
- Quicker setup time to meet site requirements
- Reliable changeover method (all necessary settings changed over correctly every time)
- Anyone is capable of performing changeover
Operator Control – The two switch inputs to the EMCP come from a linkboard position switch (to detect "low voltage" or "high voltage" selection) and a two-position voltage/frequency selector switch (VFSS) inside the upper terminal box. The linkboard is placed in the desired position and then the operator uses the VFSS to select the desired rating. This allows for two different rating selections with the linkboard in the "low voltage" position and two different rating selections with the linkboard in the "high voltage" position. Once the selection has been made, the engine ECM, CDVR, and EMCP 4.4 are configured automatically to the new setting and the unit is ready to run. The only control not affected is the UMR. The UMR, if installed, has settings which do not automatically change over. These settings are based on nominal 480V, 60Hz. This will not cause a shutdown at the lower voltages, however, unless running in a utility paralleling mode.
Verification – To view the active rating selection in the EMCP before startup, press the "AC overview" button on the EMCP and then scroll all the way down in order to view which ratings have been selected.