EMCP 3 to EMCP 4.1/4.2 Cat ® Retrofit Instructions{4490} Caterpillar

Electric Power Generation: All

Introduction

This Special Instruction will guide the user with step-by-step instructions for replacing a factory installed EMCP 3 with an EMCP 4.1 or an EMCP 4.2 and configuring an EMCP 4.1 or EMCP 4.2 on to a current production Caterpillar generator with an existing EMCP 3 installed.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Do not operate or work on this engine or generator set unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the warnings and instructions could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

Hardware

The EMCP 4.1/4.2 was designed to use the same 70-pin connector, pin assignment, and sheet metal cutout that is currently used on the EMCP 3. This design will allow the EMCP 4.1/4.2 to service replace factory installed EMCP 3 controllers. The EMCP 4.1 will replace the EMCP 3.1 and the EMCP 4.2 will replace either an EMCP 3.2 or EMCP 3.3. The current EMCP 3 wiring harness may not provide support for the additional functionality on the EMCP 4. Additional wiring may be required to utilize the added functionality. Refer to Table 3 for the 70-pin connector pin assignment.

Configuration of EMCP Controller

Increased usability and functional enhancements on the EMCP 4 family of controllers have made it necessary to remove some setpoints from the EMCP 4 that were previously configurable on the EMCP 3. When attempting to program an EMCP 3 ECM or Fleet replacement file onto an EMCP 4 using Caterpillar Electronic Technician (Cat ET), user will be ask to confirm that they want to proceed with the automatic conversion of setpoints. After the conversion is completed a programming summary of the changes is available for the user to review.

ET 2013A and older requires users to manually convert setpoints for Analog and Digital Inputs, and Digital and Relay Outputs. However, ET 2013B and newer automatically converts setpoints for Analog and Digital Inputs, and Digital and Relay Outputs when programming an EMCP 3 replacement file onto an EMCP 4 module.

Note: The automatic conversion process is only intended to be an aid when replacing an EMCP 3 with an EMCP 4 module. This process will convert most setpoints needed to match the configuration previously programmed on an EMCP 3. It is recommended that all setpoints be manually verified after the conversion is completed, and the control settings should be checked prior to placing the EMCP 4 in service.

EMCP 4 Automatic Configuration

Step 1 - Save the EMCP 3 Replacement File

Save an ECM or Fleet replacement file using Cat ET and the installed EMCP 3 controller:

• Navigate to the pull-down menu:"Service" > "Copy Configuration"

There are two options:

• Fleet Configuration

• ECM Replacement

Illustration 1	g03409851
Selecting Configuration File Type

Fleet Configuration Option

Select the "Fleet Configuration" option when there is a need to save and copy general data to several ECMs (non-module-specific). The Fleet Configuration tool works similar to the ECM Replacement tool, except for module-specific data such as the engine serial number and hours.

ECM Replacement Option

Select the "ECM Replacement" option when there is a need to save specific information such as engine hours.

Save a File

Download a copy of the "EMCP 3" configuration replacement file (Fleet or ECM replacement as .xml file) from the installed controller, and then save the file to the computer desktop. The replacement file can be downloaded by selecting "Load from ECM" at the bottom of the Cat ET screen. The configuration file saved will be used to configure the "EMCP 4" that is replacing the "EMCP 3".

If the controller can't be accessed to save a new version, a saved file from the dealer files, SIS, or a similar installation can be used.

Illustration 2	g03409853

Step 2 - Load the EMCP 3 Replacement File onto the EMCP 4

• Install the EMCP 4.x replacement module and establish communications via Cat ET.

• Select from the Service Tool menu: "Service" > "Copy Configuration" > "ECM Replacement" or "Fleet Configuration" (based on replacement file type saved in ""Save the EMCP 3 Replacement File" ").

• When prompted, select the ECM replacement file saved to the desktop (as done in ""Save the EMCP 3 Replacement File" "). The ECM replacement file can also be uploaded by selecting "Load from File" at the bottom left of the Cat ET window.

• Once the correct ECM replacement file has been selected, select "Program ECM" at the bottom left of the Cat ET window. A message like the one in Illustration 3 will appear. To continue with the automatic conversion, select "Yes".

• Cat ET will perform a data comparison test prior to programming the EMCP 4 with the selected ECM replacement file. Once Cat ET has completed the programming, a list of parameters and/or setpoints that was not programmed onto EMCP 4 by the selected file will be displayed for the user's review.

Note: The following message appears after the data programming is completed to alert the user that in order to save a new ECM replacement file the user must first select "Load from ECM" and then select "Save to File".

Illustration 3	g03409885

• After selecting "OK" to acknowledge that programming is completed, the user can select "Print" to save, print, or preview the list of parameters that could not be programmed onto the EMCP 4.

A list of all the setpoints that were programmed via the automatic conversion can be obtained in the following location:

• For Windows XP: C:\Documents and Settings\All Users\Application Data\Offboard Information Products\Service Tool Logs\EMCP Conversion Log Files

• For Windows 7: C:\Program Data\Offboard Information Products\Service Tool Logs\EMCP Conversion Log Files

Illustration 4	g03409887

Reference: Automatic Conversion of Analog Inputs, Digital Inputs, Digital Outputs, and Relay Outputs

The information about conversions in this section is part of the automatic process in ET (2013B and newer) when programming an EMCP 3 replacement file onto an EMCP 4 module. This information is for reference only.

Note: It is recommended the user manually confirm all setpoints on the EMCP 4 after both the EMCP 3 replacement file has been loaded and after the manual conversion process has been completed for total generator controller accuracy and for safe operations.

Analog Inputs

The EMCP 3.2/3.3 consists of three analog inputs. The first two are dedicated for specific parameters and the third is configurable. The third analog input on EMCP 3.2 and EMCP 3.3 is labeled as the SPARE ANALOG INPUT.

• Analog Input #1: Dedicated for ENGINE OIL PRESSURE

• Analog Input #2: Dedicated for ENGINE COOLANT TEMPERATURE

• Analog Input #3: Spare input configured to for ENGINE OIL TEMPERATURE by default, however is commonly used for Fuel Level

With the completion of automatic configuration for EMCP 4, as described in ""EMCP 4 Automatic Configuration" ", the configuration setpoints for Engine Oil Pressure and Engine Coolant Temperature will be automatically configured as a sensor (analog input) or Datalink respectively.

If the configuration setpoints for Engine Oil Pressure or Engine Coolant Temperature is configured for Datalink on the EMCP 3, then Analog Input #1 and #2 on the EMCP 4 will be disabled respectively.

If the configuration setpoints for Engine Oil Pressure or Engine Coolant Temperature is configured as Sensor on the EMCP 3, the setpoints for Analog Input #1 and #2 on the EMCP 4 will be configured for Engine Oil Pressure and Engine Coolant Temperature respectively. The analog inputs warning and shutdown thresholds are also automatically configured based on EMCP 3 Engine Oil Pressure and Engine Coolant Temperature-specific setpoints.

Note: Warning and Shutdown thresholds are in kPa for pressures and °C for temperatures.

Digital Inputs

The following explains the automatic conversion that is done via Cat ET.

Emergency stop and Remote Initiate

Digital inputs for E-Stop and Remote Initiate on both the EMCP 3 and the EMCP 4 are dedicated digital inputs and not configurable for other purposes.

On the EMCP 3, E-Stop is dedicated Digital Input #1 and Remote Initiate is dedicated Digital Input #2. The active state (High or Low) for both E-Stop and Remote Initiate digital inputs are configurable through the "Digital Input" submenu.

On the EMCP 4, the E-Stop input has been renamed "Digital Input A" (while remaining pin 70) and remote Initiate has been renamed "Digital Input B" (while remaining pin 55). E-Stop is configurable using the service tool or display. The Active State configuration for E-Stop is located under the "Auto Start/Stop" menu. Remote Initiate on the "EMCP 4" has been set to Active Low and is not configurable. The Remote Initiate input must be connected through a normally open (NO) contact to battery negative for proper operation. The contact will close to initiate a start.

Digital Inputs and Event Input Functions Numbering Offset

Digital inputs on the EMCP 3 are numbered 1 through 8, which include dedicated Digital Inputs 1 and 2 for E-Stop and Remote Initiate, respectively. This setting created a numbering offset with the Event Input Functions that the user needed to take into account when configuring a digital input. When configuring a digital input on the EMCP 3, the correlating Event Input Functions had to be decremented by two. This resulted in a difference of 2 between the number of the digital input and the corresponding event input function.

On the EMCP 4, the digital input numbering layout has changed removing the dedicated digital inputs from the numbering layout. When programming an EMCP 3 replacement file onto an EMCP 4 module, ET will automatically convert the EMCP 3 digital input setpoints based on the table below.

Note: Unique and rarely used values found on the EMCP 3 have been removed from the values available in the EMCP 4 for digital input configuration. For example "Fire Extinguisher Pressure" has been removed. If values such as Fire Extinguisher Pressure were programmed on EMCP 3, the automatic conversion will leave this input as disabled. If such a value is needed, they can be programmed as custom events with custom text strings for the display.

Digital and Relay Outputs

The following explains the automatic conversion that is done via Cat ET.

EMCP 3 Digital Selector and Relay to EMCP 4 Digital Output and Relay Output Programming

The EMCP 3 Digital Selectors performed like a 12 position switch that pointed to different options that would enable the output to activate. Each of the Digital Selectors has a unique set of ten options plus two additional options (Disabled and Datalink) for configuring the digital selector associated with that digital output. See Appendix for more details about the EMCP 3 Digital Selectors Input Options

On the EMCP 3, digital selectors #1-6 are used to configure the options or conditions that will activate Relay Outputs #3-8. Refer to Tables 3-8 for Digital Selectors 1-6. Similar to configuring the digital inputs, there is a numbering offset with the relay outputs as Relay Outputs #1 and #2 are dedicated for Starter Motor Relay and Fuel Control.

On the EMCP 3, digital selector #7 and #8 are used to configure the options or conditions that will activate Digital Outputs #1 and #2.

On the EMCP 4, the relay output numbering layout has changed removing the dedicated relay outputs from the numbering layout. When configuring relay outputs, a digital selector is no longer used and there is no offset to consider. Programming Relay Output #1 will take place in Relay Output #1 setpoint location

The EMCP 4 has increased the amount of selectable relay output options and/or conditions, allowing for a more versatile output configuration. With the EMCP 4, both digital and relay programmable output parameters select from the same list of either Command Status/Parameters or System Events.

Note: On the EMCP 4, If the engine operating state input is configured for hardwired input, Relay Outputs #1 will have to be used for Starter Motor Relay. A Starter Motor misconfiguration shutdown will be generated if Relay Output #1 is not configured properly.

Automatic Start/Stop

The "Automatic Start/Stop" submenu on the EMCP 3 supports Engine Type Configuration and Engine Controller CAN Data Link Configuration setpoints. These setpoints have been removed from the EMCP 4 "Automatic Start/Stop" submenu. The behavior implied by from these general setpoints in EMCP3 is controlled by function-specific setpoints in EMCP 4.

The EMCP 4 includes configuration support for Emergency Stop Switch Active State in the "Automatic Start/Stop" submenu. Emergency Start/Stop Switch has been moved to "Automatic Start/Stop" submenu, as it does not fall under the programmable digital inputs on the "EMCP 4".

Appendix

EMCP 3 Digital Selectors