- Engine:
- 3208 (S/N: 29A449-UP; 30A514-UP; 5YF213-UP)
- 3304 (S/N: 6YB233-UP; 3TC530-UP; 4PC233-UP; 83Z530-UP)
- 3306 (S/N: 2ZC238-337; 5JC348-UP; 85Z348-UP)
- 3406 (S/N: 75Z275-1808)
- 3408 (S/N: 78Z140-UP)
- 3412 (S/N: 2WJ30-UP; 81Z779-UP)
- 3508 (S/N: 1ZF418-674; 5XM23-UP; 3LS197-UP; 23Z420-UP; 70Z549-UP)
- 3512 (S/N: 3YF320-690; 6PM28-UP; 67Z486-UP)
- 3516 (S/N: 4XF222-UP; 5SJ65-UP; 7KM22-UP; 25Z420-UP; 73Z133-UP)
- G3406 (S/N: 1RK32-UP)
- G3412 (S/N: 3NK38-UP)
- G3516 (S/N: 4EK12-UP)
- G3520B (S/N: CWD1-UP)
- 3304 (S/N: 6YB233-UP; 3TC530-UP; 4PC233-UP; 83Z530-UP)
- Electric Power Generation:
- G3520C (S/N: CWW1-UP; CWY1-UP)
Introduction
The following Special Instruction gives detailed guidelines for mounting the EMCP II remotely at wire lengths of 50 feet, 300 feet and 600 feet. Lengths that are greater than these distances were not considered practical. Length of the wire was a factor in this consideration. Cost was also a factor. The instructions should be read and understood before any work is done.
Glossary
Alternating Current (AC) - An alternating current is an electric current that reverses direction in a circuit at regular intervals.
American Wire Gauge (AWG) - AWG is a measure of the diameter of electrical wire. AWG is also a measure of the current carrying capacity of electrical wire. When the AWG number is smaller, the diameter of the wire is larger. When the AWG number is larger, the diameter of the wire is smaller.
Capacitive Coupling - A capacitive coupling is the transfer of electric charge between adjacent conductors.
CAT Data Link - The data link is an electrical connection for communication with other onboard microprocessor based devices that use the data link.
Customer Communication Module (CCM) - The CCM stops, starts and monitors power systems by a remote computer. The CCM converts the information from the CAT Data Link to RS-232 format. The distance of the CAT Data Link's communication is increased by the circuitry of the CCM.
Conduit - A conduit is a tube or a duct for enclosing electrical wires or cables.
Electronic Control Module (ECM) - The ECM controls the engine speed with Electronic Unit Injection.
Electronic Modular Control Panel II (EMCP II) - The EMCP II is a generator set control and a metering device.
Electromagnetic Interference (EMI) - The EMI is an undesirable combination of transmitted electrical energy and magnetic energy. The EMI usually causes a reduction in performance in the electrical systems.
Flyback Diode - A flyback diode is an electronic device that restricts the current flow in order to suppress a voltage spike.
Ground - A ground is a reference point for an electrical system. A ground may be the frame of the generator set, the steel of an installation, or the earth.
Generator Set Control (GSC) - The GSC has direct control of the generator set. The GSC also monitors the generator set. The GSC is the main module of the EMCP II.
Inductance - Inductance is the property of a circuit or component that produces voltage. Voltage can be produced within the circuit or from an adjacent circuit. The voltage is produced by a change in current in either of the circuits.
Inductive Noise - Inductive noise is unwanted voltage that is caused by inductance.
Potential - Potential is voltage in an electric circuit that is measured with respect to a specified reference point in the circuit.
Pulse Width Modulation (PWM) - A PWM is an electronic signal that consists of pulses that vary in width. The duration of the pulse varies according to the system that is being sensed by the PWM. The signal's frequency and the signal's amplitude remain constant.
Radio Frequency Interference (RFI) - The RFI is caused by undesirable electrical energy that is transmitted in the frequency range of the radio waves. The RFI often causes a reduction in the performance in the electrical systems.
Engine Speed Sensor - This device generates a signal that is based on the speed of the engine crankshaft.
Guidelines
Note: The guidelines include both the EMCP II and the EMCP II+.
- The EMCP II and the EMCP II+ use a "dual ground reference" strategy for protection from inductive current spikes. The GSC and GSC+ relay module connections RM27 and RM28 are used for this purpose. RM27 is called the flyback ground. It has internal diode protection from inductive current spikes. RM28 is a clean, unprotected ground reference. RM27 and RM28 must each have separate, unbroken electrical connections to the genset common ground point. This is usually located at the negative battery post of the starter motor pinion solenoid. RM27 and RM28 should not be electrically connected at any other point.
- The EMCP II must have an isolated path to the genset's negative battery terminal, usually located at the negative battery post of the starter motor pinion solenoid. No other components can be connected to this path.
- The negative terminal of the GSC or related components must not be connected to the generator frame or to other ground structures. Other related components are the sensors and the ECM. Local codes or laws may require a connection between the battery negative terminal and the generator set's frame. The connection should be made at only one point. The connection point should not be at the GSC.
- The correct gauge of wire and type of wire must be used. Using the correct wire avoids excessive losses in voltage to the GSC and losses to the engine's solenoids.
- A shielded twisted triad cable or a shielded twisted pair cable is required for the engine sensors.
- At lengths that are greater than 100 feet, the signal from the CAT Data Link requires a boost from the CCM.
- All the shields of the shielded cable must be connected to the battery negative terminal of the GSC only. The shields should not be connected to the sheet metal. When the cable terminates at junction boxes, the shields must be connected to each other in order to maintain a continuous path.
- All of the inductive components must have a flyback diode that is installed. The diode should be installed directly across the components' positive terminals and negative terminals for maximum suppression.
- All wire to the GSC and cable to the GSC must not be installed in the same conduit. Cables and wires that contain AC signals or potentially high voltage signals should be kept separate.
- Lengths of wire that are 600 feet long should be considered as the maximum. Variations in the sensor signals may result in unacceptable inaccuracy at lengths of wire that are greater than 600 feet.
Wiring Requirements
| 50 Foot Requirements | |||
|---|---|---|---|
| Component | Wire Size (AWG) | Type Of Wire | Connections (1) |
| Three-Wire Sensors (oil pressure, coolant temperature, oil temperature, and coolant loss) | 16 | Shielded twisted triad cable is recommended. For conduits inside facilities, use Belden 8618. For the engine harness, use the 4G-2556 Shielded Cable . The cable must be resistant to fuel and oil. The cable must have a temperature range from minus 40°C (40°F) to plus 125°C (257°F). |
Deutsch DT type of connectors are recommended. If Spring Spade or Ring Terminals are used, the connection between the terminals and the wire should be crimped and soldered. |
| Two-Wire Components (Magnetic Speed Sensors And The CAT Data Link) | 16 or 18 | Shielded twisted pair cable is recommended. For conduits inside facilities, use the 123-2376 Electrical Cable or the 3E-4594 Electrical Cable . For the engine harness, use the 6V-2744 Wire . The cable must be resistant to fuel and oil. The cable must have a temperature range of minus 40°C (40°F) to plus 125°C (257°F). |
|
| GSC Power | 10 | Stranded wire normally used on engine harnesses. The cable must be resistant to fuel and oil. The cable must have a temperature range of minus 40°C (40°F) to plus 125°C (257°F). |
The leads of the cable should have Spring Spade Terminals or Ring Terminals. The connection between the wire and the terminal should be crimped and soldered. |
| Engine Solenoids (Air Shutoff) | |||
| ( 1 ) | The number of connections must be kept to a minimum. |
| 300 Foot Requirements | |||
|---|---|---|---|
| Component | Wire Size (AWG) | Type Of Wire | Connections (1) |
| Three-Wire Sensors (oil pressure, coolant temperature, oil temperature, and coolant loss) | 16 | Shielded twisted triad cable is recommended. For conduits inside facilities, use Belden 8618. For the engine harness, use the 4G-2556 Shielded Cable . The cable must be resistant to fuel and oil. The cable must have a temperature range of minus 40°C (40°F) to plus 125°C (257°F). |
Deutsch DT type of connectors are recommended. If Spring Spade or Ring Terminals are used, the connection between the terminals and the wire should be crimped and soldered. |
| Two-Wire Components (Magnetic Speed Sensors And The CAT Data Link) | 16 or 18 | Shielded twisted pair cable is recommended. For conduits inside facilities, use the 123-2376 Electrical Cable or the 3E-4594 Electrical Cable . For the engine harness, use the 6V-2744 Wire . The cable must be resistant to fuel and oil. The cable must have a temperature range of minus 40°C (40°F) to plus 125°C (257°F). At lengths that are greater than 100 feet, the signal requires a boost from the CCM. The boost is required for the CAT Data Link. The battery's positive terminal of the CCM should be connected at the GSC. The battery's negative terminal of the CCM should also be connected at the GSC. |
|
| GSC Power | 8 | Stranded wire normally used on engine harnesses. The cable must be resistant to fuel and oil. The cable must have a temperature range of minus 40°C (40°F) to plus 125°C (257°F). |
The leads of the cable should have Spring Spade Terminals or Ring Terminals. The connections between the wire and the terminal should be crimped and soldered. |
| Engine Solenoids (Air Shutoff) (2) | 8 or 16 | ||
| ( 1 ) | The number of connections must be kept to a minimum. |
| ( 2 ) | When the air shutoff is the only engine solenoid that is connected to the GSC, the air shutoff relay may be mounted remotely with the GSC. 8 AWG is required to connect the air shutoff relay to the solenoids. If any other engine solenoids are connected, the 9X-8124 Magnetic Switch Assembly must be used for all solenoids. The switch must be mounted on the engine. 16 AWG may be used to connect the switches to the GSC. |
| 600 Foot Requirements | |||
|---|---|---|---|
| Component | Wire Size (AWG) | Type Of Wire | Connections (1) |
| Three-Wire Sensors (oil pressure, coolant temperature, oil temperature, and coolant loss) | 16 | Shielded twisted triad cable is recommended. For conduits inside facilities, use Belden 8618 or the equivalent. For the engine harness, use the 4G-2556 Shielded Cable . The cable must be resistant to fuel and oil. The cable must have a temperature range of minus 40°C (40°F) to plus 125°C (257°F). |
Deutsch DT type of connectors are recommended. If Spring Spade or Ring Terminals are used, the connection between the terminals and the wire should be crimped and soldered. |
| Two-Wire Components (Magnetic Speed Sensors And The CAT Data Link) | 16 or 18 | Shielded twisted pair cable is recommended. For conduits inside facilities, use the 123-2376 Electrical Cable or the 3E-4594 Electrical Cable . For the engine harness, use the 6V-2744 Wire . The cable must be resistant to fuel and oil. The cable must have a temperature range of minus 40°C (40°F) to plus 125°C (257°F). At lengths that are greater than 100 feet, the signal requires a boost from the CCM. The boost is required for the CAT Data Link. The battery's positive terminal of the CCM should be connected at the GSC. The battery's negative terminal of the CCM should also be connected at the GSC. |
|
| GSC Power | 8 | Stranded wire normally used on engine harnesses. The cable must be resistant to fuel and oil. The cable must have a temperature range of minus 40°C (40°F) to plus 125°C (257°F). |
The leads of the cable should have Spring Spade Terminals or Ring Terminals. The connections between the wires and terminals should be crimped and soldered. |
| Engine Solenoids (Air Shutoff) (2) | 16 | ||
| ( 1 ) | The number of connections must be kept to a minimum. |
| ( 2 ) | The 9X-8124 Magnetic Switch Assembly must be used for all solenoids. The switch must be mounted on the engine. |
Wire Selection
The wire for both the GSC and the air shutoff solenoid was selected for the minimum gauge. The wire for the GSC and the air shutoff solenoid was selected for the lowest series resistance that was acceptable. Illustration 1 was used to determine the gauge of the wire for 50 feet, 300 feet and 600 feet of wire. The air shutoff solenoid is the only engine solenoid that is connected to the GSC in most of the engines that have the EUI. For the engines that are constructed with the MUI, the fuel solenoid could be connected to the GSC. The shunt trip coil could also be connected to the GSC. Certain solenoids will be activated by pushing the emergency stop button. These solenoids are the air shutoff solenoid, the shunt trip solenoid, and the fuel solenoid. In this case, it is necessary to consider the voltage drop of the wire and the solenoids. This ensures that the requirements for the minimum voltage are met. The intermittent duty solenoids will overheat if the solenoids' voltage is too low.
 | |
| Illustration 1 | g01021631 |
(RW1) Resistance from pinion solenoid to GSC. (RW2) Resistance from air shutoff relay to air shutoff solenoid. (RW3) Resistance of return path from GSC. (RW4) Resistance of return path from solenoid or circuit breaker. (RW5) Resistance from GSC relay module to circuit breaker shunt trip coil. (RW6) Resistance from GSC relay module to fuel solenoid. | |
Note: If the gauges of wire are smaller than the specifications, damage may occur to the engine solenoids. If the requirements for wiring are not followed, damage may occur to the engine solenoids.
Shielded twisted triad cable was selected for the four sensors. The four sensors are the oil pressure sensor, the coolant temperature sensor, the oil temperature sensor, and the coolant loss sensor. The shielded twisted pair cable was selected for the CAT Data Link and the magnetic speed sensor. These cables were chosen for maximum protection against inductive noise. The cables are also protected from electromagnetic interference and radio frequency interference. The shield greatly reduces the amplitude of any unwanted voltages on the signal wire. If the shields are connected to sheet metal, the connections are susceptible to loose bolts, corrosion, etc. The faulty connections increase the resistance of the shield. Faulty connections also reduce the effectiveness of the shield. Illustration 2 demonstrates the effectiveness of shielded cable.
 | |
| Illustration 2 | g01021594 |
One disadvantage of the shielded cable is the effect of the capacitance on the twisted wires within the cable. As the length of the cable increases, the overall capacitance between the wires, and between the wires and the shield increase proportionately. The waveforms of the pulse width modulation are rounded when the length of the cable is increased. The waveforms are from the oil pressure and the coolant temperature. Due to the construction of the shielded cable, this capacitance is predictable. The capacitance is able to be repeated from one installation to another installation. Table 4 shows the effect of the capacitance of the cable at 600 feet.
| Component | Characteristics Of The Pulse Width Modulation With The Short Engine Harness | Characteristics Of The Pulse Width Modulation With the 600 Foot Harness |
|---|---|---|
| Oil Pressure Sensor | 56.00% 410 kPa (59.4 psi) |
58.16% 430 kPa (62.4 psi) (5.1% error) |
| Coolant Temperature Sensor | 71.40% 81.1°C (177.98°F) |
69.84% 78.9°C (174.02°F) (-2.7% error) |
The oil pressure sensor was affected more than the coolant temperature sensor. The default setpoint of the oil pressure sensor is at 206 kPa (30 psi). At 206 kPa (30 psi), the error would only be about 10 kPa (1.5 psi). The default setpoint should not require any readjustment when you are using 600 foot lengths of wire. If the lengths of wire are greater than 600 feet, variations in the pulse width modulation signal may result in unacceptable inaccuracy.
Battery's Return Connections
A ground loop for the GSC occurs whenever the battery's return path includes part of the signal path and part of the frame or the sheet metal. It may be necessary to ground the generator's neutral terminal to the generator set frame or to the earth. In many cases, the load of the Alternating Current is also connected to the frame or to the sheet metal. This also forms a ground loop. The frame will conduct a portion of any neutral current. In some cases, the battery's negative terminal will also be connected to the frame through such components as alternators or starter motors. If the negative terminals of the GSC are connected to the frame, the same ground loop is shared. Electric noise from the generator will be conducted into the GSC. Electric noise from the generator will be conducted into any component that is communicating with the GSC. The negative terminals of the GSC or related components must not be connected to the frame. The negative terminals of the GSC or related components must not be connected to the same ground as the neutral terminal (Alternating Current). Refer to Illustration 3.
 | |
| Illustration 3 | g01021606 |
A common, objectionable practice is connecting the negative terminals of several of the components in series. High series resistance is a problem with this strategy of connection. An increased sensitivity to inductive noise is another problem with this strategy of connection. High series resistance can cause excessive voltage differences between the negative terminals of the components. Table 5 shows the Caterpillar specifications for voltage drops across crimped terminals. The specifications are for soldered terminals or unsoldered terminals.
| AWG Of The Wire | The Current Tested. | Allowed Voltage Drop | Resistance Of The Connector |
|---|---|---|---|
| 18 | 7 | 0.1 | 0.014 |
| 16 | 10 | 0.1 | 0.010 |
| 14 | 15 | 0.1 | 0.007 |
The GSC must have a unique path to the negative terminal of the pinion solenoid of the engine. The number of connections in the junction boxes must be kept to a minimum. For greater reliability and lower resistances, all crimped terminals must be soldered.
Flyback Diodes
Inductive noise is more noticeable when the negative terminals of many components are connected in series. Many of these components are inductive. If the flyback diodes are not installed correctly, these components cause electrical noise and possible damage to the sensitive electronic equipment. Inductive noise is transferred from one component to another component when the negative terminals are in series. Flyback diodes are often arranged in groups away from the component that is being suppressed. Since inductive noise is high energy and high frequency, inductive noise is easily coupled in a capacitive manner from wire to wire. The inductive noise occurs more often when the wires are long and bunched together in an orderly fashion. All of the inductive components must have a flyback diode that is installed across the positive terminals and the negative terminals for maximum suppression. The flyback diode prevents the coupling of the inductive electricity to the adjacent wires.
Routing Of The Wire
Care is required when you are installing the electronic type of cable in the conduit. Unlike power and lighting cable, electronic cables have relatively small conductors and light insulation. The electronic type of cable is not capable of withstanding as much strain during installation. Only one quarter of the area of the conduit should be used at lengths over 100 feet.
Remote Modules
The length of wire between the GSC and an Alarm Module, Relay Driver Module, or Customer Interface Module has previously been limited to 1000 feet. Testing to only 600 feet has been done at this time. When lightning strikes near an alarm module that is installed in a different facility from the GSC, voltage spikes that are strong enough to disrupt communications appear on the wires. To solve this problem, connect a voltage transient suppressor such as a 1W-9070 Diode Assembly from the data link to the negative terminal. Connect the 1W-9070 Diode Assembly at both the GSC and the remote module. The terminals of the 1W-9070 Diode Assembly may need to be modified to fit the particular application. Follow the procedure below to modify the 1W-9070 Diode Assembly for use on the EMCP Alarm Modules. Illustration 4 shows a typical example of how to connect the 1W-9070 Diode Assembly to a remote module. In Illustration 4, the diode assembly is used to protect a Remote Alarm Module from voltage spikes on its data link and power supply.
Procedure to Modify the 1W-9070 Diode Assembly
| Parts Needed | ||
| Part Number | Description | Quantity |
| 1W-9070 | Diode Assembly | 2 |
| N/A | 18 AWG - 22 AWG Butt-Splices with Heat Shrinkable Insulation | 2 |
| 5P-2321 | Terminal (Spring Spade) 14 AWG - 16 AWG |
1 |
| N/A | 18 AWG Insulated Wire | 100 mm (4 inches) (approximately) |
| Tools Needed | |
| Tool Description | Quantity |
| Sharp Knife | 1 |
| Crimping Tool | 1 |
| Wire Cutter | 1 |
| Wire Stripper | 1 |
| Needlenose Pliers | 1 |
Procedure
 | |
| Illustration 4 | g01020156 |
1W-9070 Diode Assembly . | |
- Remove one of the two ring terminals from each of the two 1W-9070 Diodes Assemblies . In order to leave the maximum amount of lead attached to the diode, make these cuts as close as possible to the terminals.
- At the center of each 1W-9070 Diode Assembly , score the diode's protective tubing. Remove the protective tubing from the end of each diode where the terminal has just been removed.
- Crimp the two butt splices on the cut ends of the two diodes. When crimping the butt splices, ensure that the diode leads reach the center of the butt splices. To ensure that the diode leads reach the center of the butt splices, you may have to hold the splices with pliers while applying pressure.
- From the 100 mm (4.0 inch) piece of 18 AWG wire, cut the following two lengths of wire:
- 38 mm (1.5 inch)
- 50 mm (2 inch)
Strip the ends of both pieces of wire.
- 38 mm (1.5 inch)
- Crimp one end of each of the two wires into the 14-16 AWG spade terminal.
- To complete the assembly, crimp the remaining ends of the two wires into the free ends of the two butt splices.
- The ring terminals on the 1W-9070 Diode Assembly may need to be filed slightly in order to fit the terminal block. Also, as more terminals are added to the terminal block, check the terminal screw length to ensure that there is adequate thread engagement.