The 356-5379 Alarm Module Gp May Fail on Certain Cat® Commercial Engines {7400} Caterpillar

The 356-5379 Alarm Module Gp May Fail on Certain Cat® Commercial Engines {7400}

Usage:

C15 C5E

Electric Power Generation: C175-16 GEN SET (S/N: WYB1-UP); C4.4 GEN SET (S/N: LC51-UP; GLD1-UP; MZT1-UP); C6.6 GEN SET (S/N: LC61-UP); C7.1 GEN SET (S/N: L7C1-UP; ETG1-UP)
Engine: 3412C (S/N: RTY1-UP); 3512C (S/N: YBD1-UP); 3516B (S/N: YAR1-UP; YBT1-UP); 3516C (S/N: SFJ1-UP; SEK1-UP)
Generator Set: C15 GEN SET (S/N: C5E1-UP; NAP1-UP); C18 GEN SET (S/N: EKW1-UP; NAW1-UP); C27 GEN SET (S/N: DWB1-UP; GDS1-UP); C32 GEN SET (S/N: JSJ1-UP; JAZ1-UP); C9 GEN SET (S/N: NBP1-UP)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

Early hour failure of the 356-5379 Alarm Module Gp. The failure mode is typically the module has no lights, unable to communicate, does not work, and internal defect open-shorted. Alarm panel inoperable, found green light flashing at bottom and RS485 annunciator circuit failed.

Solution

Removed the original 356-5379 Alarm Module Gp and replaced with a new 356-5379 Alarm Module Gp.

Reference: Application & Installation Guide, LEBE0006, EMCP 4.1, 4.2 GENERATOR SET CONTROL

Reference: Application & Installation Guide, LEBE0007, Cat® EMCP 4.3 and 4.4 Generator Set Control.

RS-485 Annunciator

The RS-485 Annunciator uses a custom master-slave communication protocol. The EMCP 4 controller will be the Master, and the RS-485 Annunciator(s) will be the slave(s). Configuration takes place within the EMCP 4. In Local application, the RS-485 Annunciator may be mounted on the Package generator set with the EMCP 4 to provide a complete package-mounted monitoring solution. The RS-485 Annunciator may also be mounted separately from the generator set to provide Remote indication of system operating and alarm conditions. The number of RS-485 Annunciators is limited by the RS-485 standard.

Network Communications Interface

EMCP 4 provides a dedicated, fully isolated RS-485 SCADA Data Link (Half Duplex) separate from the MODBUS port used on the EMCP 4
Operates at 19200 bits per second
Configuration is accomplished with the Cat Service Tool by connecting to the EMCP 4
RS-485 Annunciator communication is not compatible with third-party devices.

Annunciator Electrical Specifications

Control Power 12 VDC and 24 VDC nominal (9 VDC through 32 VDC acceptable)
Reverse voltage capability is -32 VDC for 1 hour at 70° C (158° F)
Over voltage capability is 80 VDC for 2 minutes at 70° C (158° F)
Single, 8-pin connector provides both power and communication
Designed to meet relevant European standards for EMI/RFI/Immunity without the use of external filtering

RS-485 ANNUNCIATOR CUSTOM ALARM GROUP CONFIGURATION

The RS-485 Annunciator LED is field-programmable by the EMCP 4 via the Cat Service Tool when configured for Alarm Group’s 01 and 02. Alarm Group’s 01 and 02 support customization of the 32 events for the 16 LED’s.

The service tool software must be installed on a Windows PC.

The Cat communication adapter must be connected between the PC and the CAN Primary data link on which the target EMCP 4 is connected.

RS-485 ANNUNCIATOR ALARM GROUPS

The RS-485 Annunciator supports four different Alarm Groups. Alarm Group 01, 02, 03, and Alarm Group 04. Two of these Alarm Groups, 03 and 04, are fixed and are not configurable and two Alarm Groups, 01 and 02, are reserved for custom event settings and are fully configurable. Selecting which of the four Alarm Groups to configure the RS-485 Annunciator is determined by the film that is placed on the front left panel. The Alarm Groups and the events that make up the films for each of the Alarm Groups are detailed below in Tables 24, 25, and 26. Configuring the RS-485 Annunciator to one of the four Alarm Groups is accomplished through the front panel of the RS-485 Annunciator.

ALARM GROUP SELECTION MODE (AGSM)

The RS-485 Annunciator supports an Alarm Group Selection Mode (AGSM) that provides the ability to configure the RS-485 Annunciator to monitor a predetermined set of 32 events communicated by the EMCP 4 through the dedicated RS-485 Annunciator Data Link. Alarm Group selection and assignment are determined by the desired functions of the RS-485 Annunciator (Custom or non-configurable) and the film that is placed on the front left panel that reflects the predefined events monitored by the RS-485 Annunciator.

When in AGSM, the top first four rows of LED’s will indicate which Alarm Group the RS-485 Annunciator has been assigned to by powering "on" both LED’s in each row, i.e. row 1 for Alarm Group 01, row 2 for Alarm Group 02, row 3 for Alarm Group 03, and row 4 for Alarm Group 04.

Note: The RS-485 Annunciator will be preprogrammed to Alarm Group 04.

The RS-485 Annunciator will continue to communicate to the EMCP 4 while in AGSM. Events received from the EMCP 4 while in AGSM will not be annunciated until AGSM has been exited only if the event that is received is an event in the selected Alarm Group. Once the RS-485 Annunciator has successfully been assigned to an Alarm Group, it shall receive and process any Event transmitted from the EMCP 4 to the assigned Alarm Group without power cycling the module. The Network Status LED’s will alternate flashing at a 2 Hz rate at all times while in AGSM.

Entering AGSM

The RS-485 Annunciator shall enter AGSM by depressing the two buttons on the front panel of the RS-485 Annunciator (Lamp Test and Alarm ACK) for 3 seconds. The RS-485 Annunciator shall acknowledge entrance of AGSM by flashing the top 4 rows of LEDs 4 times at a 1 second rate. After the 3 second period has timed out, the row representing the currently assigned alarm group address will be powered on, the remaining 11 rows of LEDs will not be powered on.

Reconfiguring/Selecting Alarm Group Address

While the RS-485 Annunciator is still in AGSM, the annunciator will cycle through the four Alarm Groups by pressing one of the two buttons on the front panel. Pressing the Lamp Test button will cycle up through the 4 Alarm Groups. Pressing the Alarm ACK button will cycle down through the 4 Alarm Groups.

Upon reaching Alarm Group 04 (row 4) while cycling down through the Alarm Groups with the Alarm ACK button, an extra Alarm ACK button press will bring the selection to Alarm Group 01 (row 1). Upon reaching the Alarm Group 01 (row 1) while cycling up through the Alarm Groups with the Lamp Test button, an extra Lamp Test button press will bring the selection to Alarm Group 04 (row 4).

When selecting a new Alarm Group address, the left column (red LED) will represent the previously configured Alarm Group selection. The right column (amber LED) will represent the currently selected Alarm Group. When AGSM is exited, the currently selected register address will be configured as the new Alarm Group.

Exiting AGSM

The Annunciator will exit AGSM under two possible conditions:

A time-out period without any button presses
Pressing and holding the two buttons (ACK and Horn buttons) for 3 seconds

After a period of 15 seconds without any button presses, the RS-485 Annunciator will automatically exit AGSM and disregard any changes made to the Alarm Group selection and remain configured to the Alarm Group prior to entering AGSM.

When an Alarm Group selection has been made and the two buttons are pressed (Lamp Test and Alarm ACK) and held in continuously for 3 seconds, the RS-485 Annunciator will update the current configured Alarm Group to the current selected Alarm Group and then exit AGSM. Be sure to pay attention to confirm that the group being saved is the correct Alarm Group.

After exiting AGSM under either one of the two exit conditions listed, the RS-485 Annunciator will flash all 16 rows of LEDs for 3 seconds at which time the RS-485 Annunciator will enter regular annunciation mode.