Procedure to Upgrade EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.3{4490} Caterpillar

Electric Power Generation: All

Introduction

ReferenceSystems Operations Troubleshooting/Testing and Adjusting, UENR1210-01, "EMCP4.3/4.4 "

ReferenceApplication and Installation Guide, LEBE0007, "EMCP 4.3/4.4 Generator Set Control"

This Special Instruction provides information about the installation of the EMCP 4.3 control.

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. Proper care is your responsibility.

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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.

Overview

Applicability

The kit upgrades the electric power generator set control mounted panels. The panels use the EMCP Engine Status Control (ECS), EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3.

Note: The EMCP 4.3 generator set retrofit kit is not applicable to marine installations.

Note: If needed, use the 7C-1000 Control Panel Chart .

The kit is fitted in a generator mounted enclosure with the following dimensions:

Illustration 1	g03555536

The enclosure included with the kit has three conduit holes in the bottom while some of the original controls only have two. The third hole can be blocked, if necessary. In addition to the control replacement, the kit will be necessary to replace the oil pressure sensor, engine speed sensor, and coolant temperature sensor. These devices, along with electrical connectors, are included in this kit. The EMCP 4.3 control has been configured for the use of the sensors that are to be installed.

In various areas of this document, there will be references to generator set or engine. The terms are to be used interchangeably.

Required Documents

The required documents are available on the Caterpillar Service Information System web site or the Electronic Media Center web site. Review and print the required portions of the documents for reference prior to installation.

Power Requirements

The control is designed to operate on 24 VDC only. Current draw of the control package is less than 2 A. External solenoids, loads driven by the control relays, and connection of a Cat ET communications adapter, will add to the current draw.

The high current loads and low current loads must be kept electrically separated.

New Features

As implemented, the EMCP 4.3 control offers more features and communication options than what was available with the earlier EMCP models. Refer to Application and Installation Guide, LEBE0007, "EMCP 4.3/4.4 Generator Set Control" for a complete description.

Safety

Electrostatic Discharge Awareness

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NOTICE
The EMCP 4 control contains components that are sensitive to electrostatic discharge (ESD). An electrostatic charge can damage the control resulting in EMCP 4 breakdown or improper operation. Take the following precautions while installing, removing, and handling the control.

• Handle equipment correctly. Use ESD protective packaging and material handling containers that are anti-static and provide discharge protection and electric field suppression.

• Use protective devices. ESD - protective workstations and/or work surfaces that include a grounding mat anti-static wrist strap.

• Keep all plastic items away from the devices. Any plastic item is a potential static generator. The plastic includes candy wrappers, foam cups, synthetic carpet, and foam cushions.

• The anti-static bag cannot function as a static dissipating mat.

• DO NOT use an anti-static bag for any other purpose than to enclose a product.

The 120-pin connector and 70-pin connector for EMCP 4.3 on the back of the control is the most vulnerable area to electrostatic discharge (ESD). While handling the EMCP 4, extra attention is required to the back of the control. The control may become damaged or inoperable if extra care is not taken.

Consult the Electrostatic Discharge Association for proper procedure during particular situations at http://www.esda.org.

Removal of the Existing Control

The general steps to remove an existing control are as follows.

1. Resolve any existing issues with the control, the generator set, or the wiring between the control and the generator set.

2. Perform a voltage and continuity check to insure that the schematic conforms to the as-built condition of the existing installation.

3. Record the generator set parameters at idle and rated speed.

4. Record the baseline operating parameters of the generator set.

5. Remove the existing panel.

Resolve Existing Issues

Resolve any existing issues with the control, the generator set, or the wiring between the control and the generator set.

If the existing installation has generator set or control issues, both must be repaired prior to performing a control upgrade. Trouble shooting a failure will only become more difficult after the new control is installed. Performing the following tasks may not be possible if the control has failed.

Use the documentation appropriate for the control. The documentation should be available on the service information system web sight.

Check the control for stored diagnostic codes and repair the issues that are causing the codes.

As much as practical, insure that the control and generator set are working without issues.

Voltage and Continuity Check

Perform a voltage and continuity check to determine that the installed schematic conforms to the earlier control. An accurate schematic of the existing installation will be required when installing the new control.

• Using a voltmeter, connect the negative lead to ground.

• Measure the voltage at every point shown on the schematic that is connected to battery (+).

• Check continuity for every point on the schematic that is connected to ground (terminal blocks 201 through 208).

• Mark up the latest schematic with any changes that have occurred since the original installation.

Note: The tolerance for the continuity is < 10 ohms. The tolerance for the voltage is the Vbat +/- 0.5 V.

Determine Idle and Rated Speed Parameters

Record the generator set parameters when the generator is at idle and rated speed.

The value of the generator set parameters will be needed to verify that there are no problems after the installation of the new sensors.

Start the generator set and force the generator to remain at idle. The governor must be disconnected or disabled. When the coolant temperature has stabilized, record the following values listed in Table 1.

Table 1

Value	Unit
Engine Idle Speed	RPM
Engine Oil Pressure	psi / kPa
Engine Coolant Temperature	C / F

Enable the generator set to go to rated speed. When the coolant temperature has stabilized, record the values listed in Table 2.

Table 2

Value	Unit
Engine Rated Speed	RPM
Engine Oil Pressure	psi / kPa
Engine Coolant Temperature	C / F

Baseline Generator Set Operating Parameters

Record the existing baseline operating parameters of the generator set.

Use documentation found in the service information system web sight to determine how to access the generator set parameters. The parameters will be needed to program the new control. Record the data for the list of parameters that are shown in Illustration 2.

Illustration 2	g03557376

Remove the Existing Panel

Use the following procedure to remove the existing panel.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Bodily contact with electrical potential can cause bodily injury or death. To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.

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Working with electrical circuits is hazardous. Bodily contact with electrical potential will cause personal injury or death. Ensure that personnel are trained in proper operating procedures in order to ensure safe operation.

1. Insure that the generator has been disconnected / isolated from the power line and is locked and tagged out.

2. Disconnect the AC power from the battery charger.

3. Disconnect the battery charger from the battery.

4. Disconnect the battery from the generator set.

5. Inspect the wiring coming out of the conduit that enters the bottom of the panel. All of the wires must be labeled with the number of the terminal blocks that the wires are connected to. Ensure that the terminal block numbers match the wire numbers. The labeling is shown on the schematic for the existing installation. The wire numbers are critical in determining where to connect the wires in the EMCP 4.3 panel. When all of the wires have been labeled, disconnect the wires from the terminal blocks.

6. Leave the wires that are in the conduit or spiral wrap and remove the wires from the bottom of the panel.

7. If the governor/speed control is going to be reused in the new panel, the governor/speed control should be removed from the old panel and set aside for installation in the new panel.

8. Remove the old panel from the generator enclosure.

Installation of the EMCP 4.3 Control

The general steps to install the EMCP 4.3 control are as follows:

1. Install the new EMCP 4.3 panel.

2. Install wiring from the generator set to the EMCP 4.3.

3. Install the new engine speed sensor, coolant temperature sensor, oil pressure sensor, and the required new wiring.

4. Perform power off electrical tests.

5. Perform power on electrical tests.

6. Install the control parameter configurations that are required.

7. Perform the idle speed engine parameter verification.

8. Perform the E-Stop validation.

9. Perform the rated speed validation.

Install EMCP4.3 Panel

The EMCP 4.3 has been built into the smallest of three enclosure sizes. EMCP 4.3 should fit any application that uses this type of enclosure. The conduit entry holes on the bottom of the enclosure are standard in all three enclosure sizes.

Refer to Illustration 3 for information to mark the location of the mounting points for the new enclosure on the generator enclosure. Some installations only have two conduit holes, others will have three.

Drill the indicated holes then mount the EMCP 4.3 enclosure on top of the generator housing.

Illustration 3	g03557379
Enclosure hole information

Install Wiring From the Generator Set to EMCP 4.3

The corrected schematic for the existing installation will be required to install the wiring to the EMCP 4.3 control. Also, the schematic for the EMCP 4.3 will be required to install the wiring to the EMCP 4.3 control. The EMCP 4.3 related schematics in this publication are Illustration 6, Illustration 7, Illustration 8, and 9.

Since the EMCP 4.3 can replace many different controls, the wire numbers on the existing wiring will likely not correspond with the EMCP 4.3 terminal blocks.

The wire numbers on the existing wiring along with the schematic for the existing control will help to identify the function for each wire. Using the schematic for the EMCP 4.3, find the corresponding function and the terminal block number. Connect each wire to the correct terminal block. In many installations there will be wiring that is not used. If the wire will not be used, the wire can be pulled out of the conduit and discarded.

Fuel Control Valve Operation

If the fuel control valve was originally wired for "Energize to Run", no changes to the EMCP 4.3 control are required. If the fuel control valve was originally wired for "Energize to Stop", then the wire from terminal block 7 to terminal 7 of the fuel control relay (FCR), must be moved to terminal 3 of the FCR. Refer to Table 3.

Table 3

Fuel Control Valve Function Energize to Run	Connect	To
Energize to Run	Terminal Block 7	FCR, terminal 7	As shipped
Energize to Stop	Terminal Block 7	FCR, terminal 3	Optional

The EMCP 4.3 control can directly monitor generator voltages up to 600 V. Voltages in excess of 600 V must use potential transformers or an AC transformer box (ATB) to scale the generator voltage to less than 600 V. If potential transformers are used, the voltage ratio is set in the EMCP 4.3 parameter settings.

Use the following steps to access the primary winding rating parameters using Cat ET.

1. Navigate to the EMCP 4.3 screen. Click on "Generator AC Monitor".

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Illustration 4	g03585240

2. Click on "Generator Potential Transformer Primary Winding Rating".

3. Type the desired value in the "Value" field. Cat ET will automatically update the control.

Use the following steps to access the secondary winding rating parameters using Cat ET.

1. Navigate to the EMCP 4.3 screen. Click on "Generator AC Monitor".

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Illustration 5	g03585242

2. Click on "Generator Potential Transformer Secondary Winding Rating".

3. Type the desired value. Cat ET will automatically update the control.

Note: Fuse protection is needed if the generator is wired directly to the EMCP 4.3 or if potential transformers or an ATB is used. Fuses with rating of five amps or less, with the appropriate voltage rating, must be installed immediately after the connection to the generator.

The EMCP 4.3 control must use current transformers to measure generator output current. The current transformers must scale the generator output current from 0 A to 5 A for use by the EMCP 4.3. The current transformer ratio is set in the EMCP 4.3 parameter settings.

Use the following steps to access the primary winding rating parameters using Cat ET.

1. Navigate to the EMCP 4.3 screen. Click on "Generator AC Monitor".

2. Click on "Generator Current Transformer Primary Winding Rating".

3. Type the desired value. Cat ET will automatically update the control.

Use the following steps to access the secondary winding rating parameters using Cat ET.

1. Navigate to the EMCP 4.3 screen. Click on "Generator AC Monitor".

2. Click on "Generator Current Transformer Secondary Winding Rating".

3. Click on the desired value.

Install New Sensors

Install the three new sensors and related wiring. The new sensors are as follows:

• Coolant temperature

• Oil pressure

• Engine speed

The sensors have been provided to insure compatibility with the EMCP 4.3 control.

The oil pressure and coolant temperature sensors included with the kit are active PWM sensors. The sensors require a supply voltage and ground and the output is a pulse width modulated signal that is read by the EMCP 4.3. A three wire 371-6415 Electrical Cable is included with the sensor kit. The cable has a red (+8 V), black (negative) and white (analog input positive) wire.

The oil pressure sensor is an "absolute" as opposed to a "gauge" sensor. An absolute pressure sensor measures pressure using vacuum as a reference. The sensor will read atmospheric pressure (14.7 psi) when there is no apparent pressure being applied to the gauge. When the generator set is not running, this gauge will read 14.7 psi (101 kPa) even though the generator set has no oil pressure.

The oil pressure settings for idle speed, oil step, and rated speed must each be increased by 14.7 psi (101 kPa) to be valid. Therefore, the calculation for "psi" is 14.7 psi + normal gauge reading (psi) = absolute pressure gauge in psi.

For metric readings, the calculation would be 101 kPa + normal gauge reading (kPa) = absolute pressure gauge in kPa.

The following is an example. If the idle speed oil pressure was measured at 117 kPa (17 psi), the absolute pressure gauge reading will be 117 kPa (17 psi) + 101 kPa (14.7 psi) = 219 kPa (31.7 psi).

When configuring the oil pressure transducer parameters in the EMCP 4.3 control, use the following data:

• 5% duty cycle = 13.4 kPa (2 psi)

• 90% duty cycle = 844.4 kPa (122 psi)

When configuring the coolant temperature sensor parameters in the EMCP 4.3 control, use the following data:

• 10% duty cycle = −40° C (−40° F)

• 90% duty cycle = 120° C (248° F)

On some installations, the Woodward Governor shares the engine speed magnetic pickup unit (MPU) with the EMCP control. A new MPU has been included with the kit to allow the EMCP 4.3 and the Woodward Governor to each have a dedicated MPU.

Refer to Systems Operation, SENR3535, "Service Procedure F - Speed Sensor Adjustment" for installation and setup of the new MPU.

The MPU engine speed sensor uses only two wires (white and black) of the supplied cable.

Install the sensors at the appropriate points on the generator set. Connect the sensors to the EMCP 4.3 control as per the schematic shown in Illustration 6, Illustration 7, and Illustration 8.

Electrical Tests of the EMCP 4.3 Control

The following is a general list of electrical tests used to validate the operation of the EMCP 4.3 control:

• Power off electrical tests

• Power on electrical tests

• Control parameter configuration

• Idle speed generator set parameter verification

• E-Stop validation

• Rated speed validation

Power Off Tests

The battery should not be connected.

"TB" designates the terminal blocks in the EMCP 4.3 control.

Note: The engine speed sensor, in Table 4, is for use by the EMCP 4.3 control. The engine speed sensor, in Table 4, does not apply to the MPU that may be used for the speed control governor.

Note: The engine speed sensor, in Table 4, is for use by the electronic governor only.

Note: Ensure that no voltage is present, remove the three fuses that isolate the wiring from the generator output to the EMCP 4.3. Fuse removal will allow continuity checks of the wiring. Replace the fuses after the continuity checks have been completed.

Note: The validation assumes that potential transformers or an ATB is not being used.

Check for continuity between the following points that are listed in Table 4.

Table 4

FROM PIN	TO PIN
Battery (+) lug	TB 101
Battery (-) lug	TB 201
Remote Initiate Contact 1 (IC)	TB 14 (Optional Feature)
Remote Initiate Contact 2 (IC)	TB 201 (Optional Feature)
Remote Shutdown Contact 1 (PSS)	TB 22 (Optional Feature)
Remote Shutdown Contact 2 (PSS	TB 201 (Optional Feature)
Battery Charger (+) terminal	TB 3
Battery Charger (-) terminal	TB 201
Starter Motor (+) terminal	TB 24
Starter Motor (S) terminal	TB 24
Engine Failure remote monitor	TB 13 (Optional Feature)
Air Shut Off Relay coil 1	TB 6 (Optional Feature)
Air Shut Off Relay coil 2	TB 201 (Optional Feature)
Fuel Solenoid coil 1	TB 7
Fuel Solenoid coil 2	TB 201
Start Aid Solenoid coil 1	TB 10 (Optional Feature)
Start Aid Solenoid coil 2	TB 201 (Optional Feature)
Governor Synchronizer Motor (+) terminal	TB 9 (Optional Feature)
Governor Synchronizer Motor (-) terminal	TB 8 (Optional Feature)
Electronic Governor Enable terminal	TB 11 (Optional Feature)
Engine Speed MPU white wire (terminal 2)	TB 302
Engine Speed MPU black wire (terminal 1)	TB 303
Oil Pressure Sensor orange wire (terminal A)	TB 307
Oil Pressure Sensor yellow wire (terminal B)	TB 306
Oil Pressure Sensor green wire (terminal C)	TB 305
Coolant Temperature Sensor orange wire (terminal 1)	TB 311
Coolant Temperature Sensor black wire (terminal 2)	TB 310
Coolant Temperature Sensor white wire (terminal 3)	TB 309
Engine Speed MPU white wire (terminal 2)	TB 323
Engine Speed MPU black wire (terminal 1	TB 324
Electronic Governor Actuator (EGA) (+) terminal	TB 327
Electronic Governor Actuator (EGA) (-) terminal	TB 326
Speed Adjust Potentiometer (terminal 1)	TB 43
Speed Adjust Potentiometer (terminal 2 and 3)	TB 42
Fuse T1 protected terminal	TB 401
Fuse T2 protected terminal	TB 402
Fuse T3 protected terminal	TB 403
Generator Enclosure TB 50	TB 408
Generator Enclosure TB 51	TB 405
Generator Enclosure TB 52	TB 406
Generator Enclosure TB 53	TB 407

Power On Tests

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Working with electrical circuits is hazardous. Bodily contact with electrical potential will cause personal injury or death. Ensure that personnel are trained in proper operating procedures in order to ensure safe operation.

Connect the battery terminals to the battery. Connect the battery charger to the battery and insure the battery charger is connected to an AC source.

Refer Illustration 6 schematic for fuse terminal block identification. Using terminal block 201 as ground, check that there is (+) battery voltage on the following points:

• Fuse 9 terminal 2

• Fuse 8 terminal 2

• Fuse 7 terminal 2

• Fuse 6 terminal 2

• Fuse 5 terminal 2

• Fuse 4 terminal 2

• Fuse 2 terminal 2

• Fuse 1 terminal 2

Verify that the EMCP 4.3 control and annunciator panels have powered up.

Control Parameter Configuration

Program the parameters into the EMCP 4.3 control using the parameter data that was obtained in ""Baseline Generator Set Operating Parameters" ".

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210, "Password Entry" for information about EMCP 4.3 implemented security passwords.

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210, "Real Time Clock Programming" for information about how to set the time and date on the EMCP 4.3 control.

The EMCP 4.3 control does not have inputs for battery charger fault detection. Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210, "Digital Input Programming" for instructions on how to set up digital inputs to monitor the battery charger status.

Control Operation Validation

The following tests are to confirm the proper operation of the controls of the unit.

Generator Set Start and Idle Checkout

Cranking Cycle Tests

The following steps provide information to conduct cranking cycle tests.

1. Remove Fuse 6. Removing the fuse will prevent the fuel control relay (FCR) from:
   • Activating and causing the fuel control valve from opening

   • Generator set from starting

   • Allow full testing of the cranking cycle

2. If the observed generator set cranking cycle is not what is desired, review the times that have been set in the "Cycle Crank Time" configuration.

3. The battery charger is to be disconnected while the generator set is cranking. Observe the battery charger and note that the battery charging current drops to zero when the generator set is cranking.

4. Acknowledge the cranking cycle faults and reset the EMCP 4.3 control.

Cranking Cycle and E-Stop Test

The following are steps to conduct the "Cranking Cycle" and "E-Stop" tests.

1. The E-Stop test will verify that the generator set cranking cycle can be stopped with the E-Stop button. The generator set must not start since the FCR has been previously disabled.

2. Press the "RUN" button and allow the generator set to go through the first crank/rest cycle. When the second crank cycle begins, press the E-Stop button to verify that the generator set can be stopped.

3. Acknowledge the cranking cycle faults and reset the EMCP 4.3 control.

4. Replace "Fuse 6" to allow the fuel control relay (FCR) to function.

Idle Speed Tests

Disconnect or disable any speed governor to prevent the generator set from running at rated speed.

Idle Speed, E-Stop Test

The idle speed and E-stop test will verify that the generator set can be stopped at idle speed with the E-Stop button.

1. Press the "RUN" button and allow the generator set to start and run at idle speed.

2. Press the E-Stop button to verify that the generator set will come to a controlled stop.

Idle Speed Parameter Validation

1. Press the "RUN" button on the EMCP 4.3 control panel. The generator set will start and run at idle speed.

   Check the coolant temperature as the generator set starts and verify that temperature is close to the block temperature of the generator set. The check is to confirm if the coolant temperature sensor and related wiring is functional.

2. Allow the coolant temperature to stabilize and then read the following parameters from the "EMCP" display.
   • Engine speed

   • Battery voltage

   • Engine oil pressure

   • Engine coolant temperature

3. All parameters values must be near the values recorded from ""Baseline Generator Set Operating Parameters" ". Any parameter value that is not close to the original parameter value data will need to be investigated and resolved before proceeding. Regarding this section, the "Idle Speed Parameter Determination" must be investigated and resolved before proceeding.

4. Press the "Stop" button on the EMCP 4.3. The generator set should come to a controlled stop.

5. Correct any issues that prevented the generator set from starting, idling, or verification of the idle speed parameters.

Engine Speed Sensor Loss Test

The engine speed sensor loss test will verify that the generator set will stop if the engine speed sensor fails.

1. Push the "RUN" button and allow the generator set to start and run at idle speed.

2. Jumper terminal 302 to terminal 303. The generator set should shut down immediately. Loss of engine speed results in an "Unexpected Engine Shutdown" fault. To recover from the fault, press the RESET button that is located on the front of the EMCP 4.3.

3. Restart the generator set and allow the generator to run at idle speed.

4. Disconnect the engine speed sensor from either terminal 302 or 303. The generator set should shut down immediately. Reconnect the engine speed sensor and cycle the power on the EMCP 4.3.

5. Reconnect or enable the governor to allow the generator set to run at rated speed.

Rated Speed Tests

1. Push the "RUN" button on the EMCP 4.3. The generator set should crank, start, and run at idle speed while building oil pressure. The EMCP 4.3 and governor will bring the generator set to rated speed once idle speed and oil pressure conditions have been met.

2. After the generator set comes up to rated speed, monitor the coolant temperature as the temperature rises. When the coolant temperature has stabilized, check the engine rated speed operating parameters. Compare the engine rated speed operating parameters listed below against the values recorded in ""Determine Idle and Rated Speed Parameters" ".
   • Engine Rated Speed

   • Engine Oil Pressure

   • Engine Coolant Temperature

3. Put the EMCP 4.3 into the stop mode. Observe that the engine speed is reduced to idle while the generator set cools down for the period recorded as "Cooldown Duration".

4. Correct any issues that prevented the generator set from starting, idling, running at rated speed, cooling down or recording the rated speed parameters.

Remote Operation Tests

The remote operation tests will validate the control capability to start and stop the generator set using the remote control inputs.

Each of the following tests will require a jumper wire connected to ground. Connect a wire to terminal 201 to use for this purpose.

E-Stop Test

1. Use the EMCP 4.3 run button to start the generator set and allow the generator to come up to speed. Do not wait for the generator set to warm up.

2. Using the ground wire, touch terminal 22 and verify that the generator set stops running.

3. If a remote E-Stop switch is part of the installation, connect the switch to the control using terminal 22 in the EMCP 4.3 control panel. Start the generator set and allow to come up to rated speed. Press the remote E-Stop switch to verify that the switch works as intended.

4. Correct any issues that prevented the generator set from starting, idling, running at rated speed, cooling down or stopping.

Remote Initiate Test

1. With the generator set stopped, and the EMCP 4.3 control in "Auto", touch the ground wire to terminal 14. The generator set should crank, start, idle, and run at rated speed.

2. If a remote initiate switch is part of the installation, connect the switch to the control using terminal 14 in the EMCP 4.3 panel. Press the remote initiate switch to verify that this switch works as intended.

3. Stop the generator set using the Stop button on the EMCP 4.3 control panel.

4. Correct any issues that prevented the generator set from starting, idling, running at rated speed, cooling down or stopping.

Engine Set Point Verification

The engine set point verification procedure verifies that the EMCP 4.3 operates correctly when a low oil pressure or high coolant temperature event occurs. The engine set point verification procedure also verifies that the EMCP 4.3 operates correctly when an engine over speed event occurs.

Low oil pressure and high coolant temperature each have two events, "Warning" and "Shutdown". The EMCP 4.3 will issue a warning whenever the warning threshold is reached. The EMCP 4.3 will issue a shutdown whenever the shutdown threshold is reached. The verification procedure will modify configuration set points used in normal operation. The following information outlines how to perform the low oil pressure shutdown and high coolant temperature shutdown procedures. A similar process can be used for low oil pressure warning and high coolant temperature warning, along with low idle, low oil pressure.

During this procedure, each configuration set point should be recorded prior to adjustment then returned back to the original setting after the set point has been verified.

The following conditions are required before the engine set points are verified:

• The set points must be correct for the generator set application.

• No shutdown events should be present. If necessary, troubleshoot, correct, and reset any shutdown events.

Low Oil Pressure Verification

Note: The low oil pressure shutdown is disabled during start-up and while the generator set is not running by the "Fault Protection Timer" (FPT). The fault protection timer starts timing when crank terminate rpm is reached during the starting sequence. The fault protection timer will then run for a programmed time. The time is determined by the "Engine Start Fault Protection Activation Delay Time" set point. Make sure that the fault protection timer has elapsed before starting the "Low Oil Pressure Verification".

1. Start the generator set and run the generator set at rated speed.

2. Adjust the set point value for "Analog Input #1 Low Shutdown Event Threshold" to a value that is above the oil pressure at which the generator set is operating. The shutdown event will occur after the programmable time delay. The time delay is referred to as the "Analog Input #1 Low Shutdown Event Delay Time" set point.

3. View the event by going to the EMCP 4.3 event log. Reset the event.

4. Return the set point value for "Analog Input #1 Low Shutdown Event Threshold" to the original value.

High Coolant Temperature Verification

Note: "Analog Input #2 High Shutdown" is disabled during start-up and while the generator set is not running by the "Fault Protection Timer" (FTP). The fault protection timer starts timing when the "Crank Terminate" rpm is reached during the starting sequence. The fault protection timer will then run for a programmed time (the "Engine Start Fault Protection Activation Delay Time" set point). Make sure that the fault protection timer has elapsed before starting the "High Coolant Temperature Verification".

1. Start the generator set and run the generator set at rated speed.

2. Adjust the set point value for "Analog Input #2 High Shutdown Event Threshold". Set the parameter to a value that is below the engine coolant temperature that the generator set is operating at. The minimum value for the set point is 49° C (120° F). The generator set may have to run for a few minutes to get the temperature above the minimum value. The shutdown event will occur after the programmable time delay (the Analog Input #2 High Shutdown Event Delay Time set point)

3. View the event by going to the EMCP 4.3 control event log. Reset the event.

4. Return the set point value for "Analog Input #2 High Shutdown Event Threshold" to the original value.

Over Speed Verification

1. Start the generator set and run the generator set at rated speed.

2. Adjust the set point value for "Engine Over Speed Setpoint" to a value that is below the speed that the generator set is running at. An engine over speed set point event will occur immediately after the set point is changed. The generator set will shut down.

3. View the event by going to the EMCP 4.3 control event log. Reset the event.

4. Return the set point value for the "Engine Overspeed Setpoint" to the original value.

Illustration 6	g03557489
Typical example of a schematic for this application. Refer to Illustration 8 for the legend.

Illustration 7	g03557492
Typical example of a schematic for this application. Refer to Illustration 8 for the legend.

Illustration 8	g03557493
Typical example of the wiring diagram for this application.

Installation notes for Illustration 8. Illustration 8 is an example of the wiring of the original EMCP 1 drawings. The current transformers are wired so the current is 180 degrees out of phase with the voltage causing a power factor of -1. The solution is to swap the white 51, 52, and 53 leads with the black leads that are all labeled as 50.

Illustration 9	g03580612

Parameter Configurations Using Cat ET

The parameters discussed in this section are accessed with Cat ET. The factory default values that are provided are programmed into the EMCP 4.3.

Illustration 10	g03557494

Crank Attempt/Successful Start Counter Configuration

The parameter indicates the level of security required to modify configuration parameters. The default value is set to "0" (no security) which means that everyone has access to the parameters.

Illustration 11	g03557496

Engine Serial Number

Illustration 12	g03557498

Click on "Configuration Data" to display the "Engine Serial Number" information.

Engine Service Hours

Configuration of the "Engine Service Hours" is done by selecting the "Information" tab. Then, from the drop-down menu, click "Current".

Illustration 13	g03557501

Display Preferences

Illustration 14	g03557502

Service Maintenance Interval

Illustration 15	g03557504

Analog Inputs

There are two analog inputs from the generator set to the EMCP. The inputs are engine oil pressure and engine coolant temperature. The default values of the two analog inputs are listed below.

Low Shutdown Event Threshold

"Low Shutdown Event Threshold" is listed as "Analog Input #1 Low Shutdown Event Threshold". The range of the parameter is 13.4 kPa (2 psi) to 880 kPa (128 psi). The default value is set at 150 kPa (22 psi).

Illustration 16	g03735719

Note: The Minimum and Maximum Data Range units for pressure are kilo Pascals (kPa). The Minimum and Maximum Data Range units for temperature are Centigrade Degrees. Although it is possible to display this data in English units or SI (Metric) units, all parameters that are configured by the user must be entered in SI (Metric) units. The user must change the displayed units to SI (Metric), configure the parameter, and if desired, change the displayed units back to English. For more configuring information, see Application and Installation Guide, LEBE0007, "EMCP 4.3/4.4 Generator Set Control".

High Coolant Temperature Shutdown

"High Coolant Temperature Shutdown" is listed as "Analog Input #2 High Shutdown Event Threshold". The range of the parameter is 95° C (203° F)to 120° C (248° F). The default value is set at 108° C (226° F).

Automatic Start/Stop

Configuration of the automatic start/stop parameters is done using Cat ET. The parameters are discussed in the following sections.

Cycle Crank Configuration

The "Cycle Crank Configuration" is listed as "Crank Duration". The range of the parameter is 1 to 60 seconds. The default value is set at 10 seconds.

Cycle Crank Rest Interval

The range of the parameter is 1 to 60 seconds. The default value is set at 5 seconds.

Maximum Number of Crank Cycles

The range of the parameter is 1 to 99. The default is set to 1.

Cool down Configuration

The "Cool down Configuration" is listed as "Cooldown Duration". The range of the parameter is 0 to 30 minutes. The default value is set at 5 minutes.

Crank Termination Speed Configuration

The "Crank Termination Speed Configuration" is listed as "Crank Terminate RPM". The range of the parameter is 100 to 1000 rpm. The default value is set at 300 rpm.

Engine Fuel Type Configuration

The "Engine Fuel Type Configuration" value will always read "Diesel", cannot be changed, and will not affect the operation of a gas generator set.

Illustration 17	g03565819

Battery Voltage Monitor

Illustration 18	g03565797

Digital Inputs

Illustration 19	g03557506

Digital Outputs

Illustration 20	g03565796

Engine Coolant Temperature Monitor

The default value is set at "Sensor".

Illustration 21	g03557507

Engine Oil Pressure Monitor

Idle Speed Oil Pressure Shutdown

The "Idle Speed Oil Pressure Shutdown" is listed as "Low Idle Low Engine Oil Pressure Shutdown Event Threshold". The range of the parameter is 20 kPa (3 psi) to 420 kPa (61 psi).The default value is set at 207 kPa (30 psi).

Low Idle Low Engine Speed Oil Pressure Warning Event Threshold

The range of the parameter is 22 kPa (3.2 psi) to 462 kPa (67 psi). The default value is set at 241.3 kPa (35 psi). The value of the parameter must be set at least 110% of the value of the "Idle Speed Oil Pressure Shutdown" parameter.

Oil Step Speed

The "Oil Step Speed" parameter is listed as "Low Engine Oil Pressure Step Speed". The range of the oil step speed parameter is 400 to 1800 RPM. The default value is set at 400 RPM.

Illustration 22	g03557512

Engine Speed Monitor

Ring Gear Teeth

The "Ring Gear Teeth" parameter is listed as "Flywheel Teeth". The range of the ring gear teeth parameter is 110 to 260. The default value is set at 183.

Over Speed

The "Over Speed" parameter is listed as "Engine Overspeed Setpoint". The default value is set at 1540 RPM. The engine over speed set point value is generator set-specific.

Illustration 23	g03557513

Enhanced Engine Monitor

The default value for "Number of Engine Cylinders" is set at 1.

Illustration 24	g03557514

Maintenance and Operation

CAN Annunciator Operation

The OCP CAN annunciator serves to display system alarm conditions and status indications. The CAN annunciator has been designed for use on the OCP accessory CAN data link. The CAN annunciator may be used in either local or remote applications. The CAN annunciator provides customers with enhanced site flexibility.

In local application, the CAN annunciator may be mounted on the package generator set with the OCP to provide a complete package-mounted monitoring solution.

The CAN annunciator also may be mounted separately from the generator set. A remotely mounted annunciator provides remote indication of system operating and alarm conditions.

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210, "Annunciator Module" for annunciator features, specifications, wiring, and comprehensive discussion of annunciator features.

Illustration 25	g03558841
Cat service tool CAN 2 annunciator default configuration values dialog

Illustration 26 provides the location of the status light indicators for the module network system on the annunciator. Refer to Table 5 for an explanation of the status lights.

Illustration 26	g03558919

Table 5

Module Network Status
Status Light	Explanation
Red solid	CAN 2 data link diagnostic. The module is wired wrong (Data Link), wrong cable, or no terminating resistor.
Green solid	CAN 2 data link OK
Green flashing	No CAN 2 data link diagnostic, but no communication detected.
Red/Green alternating	No application software loaded

Icon list

Illustration 27	g03558842

General kit information

The EMCP 4.3 supports flashing (field-programming) of software for all of the modules. The flashing is done by using the Cat Service Tool software and a Cat communication adapter. The primary datalink (CAN 1) service connector must be used for modules connected to the primary data link. The accessory datalink (CAN 2) service connector must be used for modules connected to the accessory data link. Refer to the generator set package documentation for the location of the service connectors.

Software and Hardware Required

The following hardware and software are required to flash the EMCP 4.3:

• Cat Service Tool software installed and licensed on a PC

• Cat communication adapter

• A 9-pin deutsch service connection to the "Primary Datalink (CAN 1)"

• A 9-pin deutsch service connection to the "Accessory Datalink (CAN 2)"

• The new application software flash file for the EMCP 4.3

Use the following files to flash or configure the appropriate component.

EMCP 4.3 ECM

The flash file name is 4424808_00.fls

The configuration file name is Not Programmed_FLTCFG_2013-08-16_14.02.06.xml.

Note: The configuration file is the most recent .xml file and is subject to change.

Annunciator ECM Information

The flash file name is 2978331.fls

The configuration file name is 1003B183HW_ECMREP_2013-08-16_13.53.14.xml.

Note: The configuration file is the most recent .xml file and is subject to change.

Programming New Configurations

EMCP 4.3 Control

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Illustration 28	g03560896

1. Connect to the EMCP 4.3, using the Cat Service Tool, to the CAN 2 port.

   The message, "No data is available. Load from the ECM now?", will appear. Click "No".

   1. Select the "Service" tab.

   2. Select "Copy Configuration"

   3. Select "Fleet Configuration".

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Illustration 29	g03560898

2. After the desired changes are completed, click "Load from File" at the "Fleet Configuration" dialog to save the file.

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Illustration 30	g03560916

3. Navigate to the .xml file. Click "Open". Refer to the "General Kit Information" for the most recent (.xml) configuration file. A dialog will appear to confirm the file was loaded. Refer to Illustration 30.

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Illustration 31	g03560917

4. Select which control configuration data that is to be programmed into the EMCP 4.3 by clicking the box that is to the left of the parameter. A check mark must appear next to the parameter that is to be added. If a parameter is not desired, do not click that parameter. If the box has a check mark, but that parameter is not desired, click the box again to remove the check mark for that parameter. Refer to Illustration 30 as an example of having the boxes checked next to the desired parameters. After any selection changes are completed, click "Program ECM" from the bottom of the ECM Replacement dialog to load the file into the EMCP 4.3.

The dialog in Illustration 32 will appear to confirm that programming the ECM is completed.

Illustration 32	g03560918

Annunciator Control

The annunciator control is only accessible through the CAN 2 port/Accessory Datalink. In the case of the annunciator, ECM replacement should be used via the CAN 2 port/Accessory Datalink only.

Saving the Current Annunciator Control Configuration

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Illustration 33	g03560920
Cat Service Tool EMCP 4.3 summary dialog

1. Connect to the EMCP 4.3, using the Cat Service Tool, to the CAN 2 port. From the "Service Tool" menu, select the following.

   1. Select the "Service" tab.

   2. Select "Copy Configuration"

   3. Select "ECM Replacement".

      Refer Illustration 33.

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Illustration 34	g03560922

2. The Cat ET dialog shown in Illustration 34 will appear. The dialog will have the message "No data is available. Load from the ECM now?". Click "Yes" .

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Illustration 35	g03560923

3. Select "Alarm Module #1" from the ECM list. The alarm module will allow the software to connect to the Annunciator.

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Illustration 36	g03560924

4. The system will load the annunciator configuration.

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Illustration 37	g03560928

5. After the data is loaded, the current file parameters will be displayed.

6. Select which control configuration data that is to be programmed into the EMCP 4.3 by clicking the box that is to the left of the parameter. A check mark must appear next to the parameter that is to be added. If a parameter is not desired, do not click that parameter. If the box has a check mark, but that parameter is not desired, click the box again to remove the check mark for that parameter. Refer to Illustration 30 as an example of having the boxes checked next to the desired parameters.

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Illustration 38	g03560998

7. After the desired changes are completed, click "Save to File" to save .xml the file. Make sure to note where the file is stored.

Programming New Configurations on the Annunciator Control

1. Connect to the EMCP 4.3, using the Cat Service Tool, to the CAN 2 port. From the "Service Tool" menu, select the following.

   1. Select the "Service" tab.

   2. Select "Copy Configuration"

   3. Select "ECM Replacement".

      Refer Illustration 33.

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Illustration 39	g03561017

2. After the desired changes are completed, click "Load from File" to save the file.

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Illustration 40	g03561019

3. Navigate to the desired file and click "Open". Refer to the "General Kit Information" for the most recent configuration file (.xml). The software will confirm that the file has been opened. Refer to Illustration 40.

4. Select which control configuration data that is to be programmed into the EMCP 4.3 by clicking the box that is to the left of the parameter. A check mark must appear next to the parameter that is to be added. If a parameter is not desired, do not click that parameter. If the box is checked, but that parameter is not desired, click the box again to remove the check mark for that parameter. Refer to Illustration 30 as an example of having the boxes checked next to the desired parameters.

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Illustration 41	g03561020

5. After the desired changes are completed, click "Program ECM" to load the file into the EMCP 4.3.

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Illustration 42	g03561022

6. The dialog in Illustration 42 will appear.

7. Click "Yes".

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Illustration 43	g03561023

8. Next, select "Alarm Module #1" from the list of controls.

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Illustration 44	g03561026

9. Allow the software to configure the set parameters to the annunciator.

10. The software will confirm the programming of the control.

Illustration 45	g03561028