- Electric Power Generation
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Introduction
This Special Instruction contains information for installing the AssetIQTM for commercial generator set systems on Caterpillar and non-Caterpillar products. The system consists of an ECM and harness used to monitor the 3-phase voltage and current from the generator, maintain a service hour meter, and detect and report battery voltage. The data are:
- Generator voltage
- Battery voltage
- Generator frequency
- Engine service hours (diagnostic clock)
- Generator current
The system also provides support for optional sensors including an engine speed MPU sensor, an engine oil pressure sensor, and an engine coolant temperature sensor, creating a scalable solution to electronic generator set monitoring.
The system will report this data, along with any diagnostic information, on the main data link to be received by a recording ECM such as Product Link.
Important Safety Information
Do not perform any procedure in this special instruction until this special instruction has been read in entirety, and understood. 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 be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions. |
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. |
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. |
Electrostatic Discharge Awareness
NOTICE |
---|
ECM 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/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 70-pin connector on the back of the control is the most vulnerable area to electrostatic discharge (ESD). Extra attention to the back of the control is necessary when handling the EMCP 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.
System Overview
Illustration 1 | g03836662 |
System diagram (1) Fuel flow monitoring (not included in kit) (2) Product Link PL522 (not included in kit) (3) J1939 (CAN) output for Cat ET (4) Engine speed MPU (5) Engine oil pressure sensor (6) Engine coolant temperature sensor (7) Generator phase current transformers (not included in kit) (8) 3-phase voltage current transformers feed directly into ECM (600 V max) |
Applicability
The AssetIQTM Generator Set System is offered for use on a generator set, for both Caterpillar and non-Caterpillar brands. This kit can be retrofitted to many brands and types of equipment, and is offered as an aftermarket attachment, potentially providing a fleet solution for equipment owners.
Electrical Requirements
This control is designed to operate on 12 VDC or 24 VDC which will hereafter be referred to as BAT (+) and BAT (-). Current draw of the control package is less than 2 A.
Remote Monitoring Requirements
Remote monitoring requires a telematics system, such as Product Link, to be installed on the system that will transmit the data off board. Refer to Special Instruction and Application and Installation publications for the Product Link device to be used with this kit.
Features
The AssetIQTM generator set system kit provides or enhances the minimum functionality to a mechanical generator set engine system. Installation of this kit will allow support for electronic monitoring by:
- reading and reporting generator voltage
- calculating and reporting generator frequency
- reading and reporting generator current
- reading and reporting the battery voltage
- maintaining and reporting a service hour meter
Installation of optional sensors provides additional functionality. This additional support currently includes:
- reading and reporting engine speed using an optional magnetic pick-up sensor
- reading and reporting oil pressure using an optional active PWM analog sensor
- reading and reporting coolant temperature using an optional passive analog resistance sensor
Engine Parameters as shown in Caterpillar Electronic Technician (Cat ET) | |
---|---|
Parameter | Unit |
Engine Oil Pressure | kpa |
Engine Coolant Temperature | Degrees C |
Battery Voltage | V |
Engine Speed | rpm |
Diagnostic Clock | hours |
Generator Average Line AC RMS Voltage | Va |
Generator AC Frequency | Hz |
Generator Overall Power Factor | N/A |
Generator Overall Power Factor Lagging | N/A |
Generator Total Real Power | kW |
Generator Total Apparent Power | kW |
Preparing the Engine
- The engine must be on a smooth, level surface that will support the weight of the engine.
- Turn OFF the engine with the KEY switch to the OFF position.
Show/hide table
Illustration 2 g00104545 - Use proper Lock out and Tag out procedures. Attach a "Do Not Operate" warning tag to the engine start switch or the controls before you perform any service to the engine. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar Dealer.
Parts List
Note: All the parts in Table 2 can be ordered individually.
Contents of 481-2120 Generator Installation Group (AssetIQTM) | ||
---|---|---|
Qty | Part Number | Description |
1 | Generator Set Control Group | |
1 | Generator Set Electronics Group | |
6 | Bolt | |
6 | Locknut | |
12 | Washer | |
1 | Control Harness Assembly | |
1 | Film | |
100 | Cable Strap | |
1 | Wiring Diagram | |
1 | Connector Plug Assembly | |
2 | Connector Socket | |
1 | Plug Lock Wedge | |
1 | Film | |
Optional Components | ||
1 | Electrical Installation Group | |
1 | Field Installation Group | |
1 | Coolant Temperature Sensor Group | |
1 | Oil Pressure Sensor Group | |
1 | Speed Sensor Group | |
1 | Cable Assembly |
Installation of Electronic Control Module (ECM)
Illustration 3 | g03837116 |
ECM mounting dimensions |
Depending upon the mounting location, it may be necessary to fabricate a bracket to mount to the ECM. Refer to Illustration 3 to fabricate a bracket for the ECM in a location that meets these requirements:
- Access to a fused source of Bat (+) power
- Access to Bat (-)
- Access to the main data link(s) on the engine
- Mounting the ECM on the engine is not allowed due to the excessive vibration
The hardware for mounting the ECM provided in the kit are listed in Table 3.
ECM Mounting Hardware | |||
---|---|---|---|
Qty | Part Number | Part Name | Description |
6 | Bolt | Bolt, M6×1.0×25, Hex Head | |
6 | Locknut | Hex, Nylock, M6×1.0 | |
12 | Washer | Washer, Flat, 6.6 ID×12.0 OD×2.0 T |
Perform the following procedure for installing the ECM:
- There are six mounting points on the plate to which the ECM is attached. Drill a hole to accommodate a size M6 bolt that corresponds to each mounting point.
- Use a 6V-8490 Bolt, two 9X-8256 Washers, and a 208-8469 Locknut at each mounting location of the ECM.
Main Wiring Harness
Illustration 4 | g03837140 |
Main wiring harness schematic |
Illustration 5 | g03837142 |
Main wiring harness current and voltage generator schematic |
The main harness schematic, shown in Illustration 4 and Illustration 5, is included with the 457-1577 Control Harness Assembly.
Note: During installation, it is important to protect wiring in key locations. Key locations are any area where the wiring could be nicked or cut and come in contact with the chassis. Avoid installation practices where there could be excessive flexing, chafing, or cutting of the wiring.
Generator Voltage Harness
Illustration 6 | g03837145 |
Generator voltage harness wiring diagram (9) (10) Location for installing fuses |
Due to the variations in length requirements, the generator voltage harness must be assembled at installation, as shown in Illustration 6, using the components that have been provided in the kit, as listed in Table 4. This harness will connect to connector "E-C12" as shown in the Illustration 5.
Note: Install the fuses near generator output tabs and keep wiring, on unprotected side of fuses, short. Refer to Illustration 6.
481-2121 Electrical Installation Group (Gen Voltage Harness) | |||
---|---|---|---|
Qty | Part Number | Part Name | Description |
1 | Wiring Harness | Harness Assembly - Gen V (EMCP4.2 - AssetIQTM) | |
3 | Ring Terminal | Terminal - Insulated (ring-Crimp Type) | |
3 | Fuse | Fuse, 2 A | |
1 | Fuse Block | Block - Fuse | |
2 | Screw | ||
2 | Hard Washer | Washer - Hard | |
2 | Locknut | ||
460 | Electrical Wire | Wire - Bulk (Electrical) | |
3 | Ring Terminal | Terminal - Insulated (ring-Crimp Type) | |
3 | Bolt | ||
3 | Hard Washer | Washer - Hard | |
3 | Locknut |
Generator Current Harness
Illustration 7 | g03837169 |
Generator current harness wiring diagram |
Due to the variations in length requirements, the generator current harness must be assembled at installation, as shown in Illustration 7, using the components that have been provided in the kit, as listed in Table 5. This harness will connect to connector "C11" as shown in the main wiring harness. To build this harness, there are three current transformers needed that are sized to the generator output current. Refer to Illustration 7. Secondary current can be 0-1 A or 0-5 A. Cat ET must be used to configure the AssetIQTM ECM for either 0 to 1 or 0 to 5 A to match the current transformer secondary current rating. This harness will connect to connector "C11" as shown in the Illustration 5.
481-2122 Field Installation Group (Gen Current Harness) | |||
---|---|---|---|
Qty | Part Number | Part Name | Description |
1 | Connector Plug Assembly | Plug As - Connector (4) | |
4 | Connector Socket | ||
1 | Plug Lock Wedge | Wedge - Plug Lock (4) | |
|
Wire | Wire - Bulk (Electrical) | |
4 | Ring Terminal | Terminal - Insulated (Ring - Crimp Type) |
Generator Current Transformers Available from Caterpillar | ||
---|---|---|
Part Number | Part Name | Description |
Current Transformer Assembly | 200:5 A, 600 V, stud terminals | |
Current Transformer Assembly | 300:5 A, 600 V, stud terminals | |
Current Transformer Assembly | 400:5 A, 600 V, stud terminals | |
Current Transformer Assembly | 1000:5 A, 600 V, stud terminals | |
Current Transformer Assembly | 1200:5 A, 600 V, stud terminals | |
Current Transformer Assembly | 1500:5 A, 600 V, stud terminals | |
Transformer | 1500:5 A, 600 V, stud terminals | |
Current Transformer Assembly | 2000:5 A, 600 V, stud terminals | |
Current Transformer Assembly | 2500:5 A, 600 V, stud terminals | |
Current Transformer Assembly | 3000:5 A, 600 V, stud terminals | |
Transformer | 3000:5 A, 600 V, stud terminals | |
Current Transformer Assembly | 3500:5 A, 600 V, stud terminals | |
Current Transformer Assembly | 4000:5 A, 600 V, stud terminals |
Engine Speed Sensor Harness
Illustration 8 | g03837353 |
Engine speed sensor harness wiring diagram |
Due to the variations in length requirements, the engine speed sensor harness must be assembled, as shown in Illustration 8, using the components that have been provided in the kit, as listed in Table 7. This harness will connect to connector "C3" as shown in the Illustration 8, and Illustration 4.
481-2125 Field Installation Group (Speed Sensor) | |||
---|---|---|---|
Qty | Part Number | Part Name | Description |
1 | Speed Sensor Group | Sensor Group - Speed (Magnetic) (Low Output) | |
1 | Connector Plug Assembly | Plug Assembly - Connector (2) | |
2 | Connector Socket | Socket - Connector | |
1 | Plug Lock Wedge | Wedge - Plug Lock (2) | |
1 | Connector Receptacle Assembly | Receptacle Assembly - Connector (4) | |
3 | Connector Pin | Pin - Connector | |
1 | Seal Plug | Plug - Seal | |
1 | Receptacle Lock Wedge | Wedge - Receptacle Lock (4) |
Engine Oil Pressure Sensor Harness
Illustration 9 | g03837624 |
Oil pressure sensor harness wiring diagram |
Due to the variations in individual installations, the engine oil pressure sensor harness will need to be assembled, as shown in Illustration 9, using the components that have been provided in the kit, as listed in Table 8. This harness will connect to connector "C4" as shown in Illustration 9, and Illustration 4.
481-2124 Field Installation Group (Oil Pressure Sensor) | |||
---|---|---|---|
Qty | Part Number | Part Name | Description |
1 | Pressure Sensor Group | Sensor Gp - Pressure (1200 kpa, M12×1.5) | |
1 | O-Ring Seal | Seal-O-Ring - STOR (ISO Metric M12) | |
1 | Connector Plug Assembly | Plug As - Connector (3) (Key 4) | |
3 | Connector Socket | Socket - Connector | |
1 | Connector Receptacle Assembly | Receptacle As - Connector (4) | |
4 | Connector Pin | Pin - Connector | |
1 | Receptacle Lock Wedge | Wedge - Receptacle Lock (4) |
Engine Coolant Temperature Sensor Harness
Illustration 10 | g03837627 |
Coolant temperature sensor harness wiring diagram |
Due to the variations in individual installations, the engine coolant temperature sensor harness will need to be assembled, as shown in Illustration 10, using the components that have been provided in the kit, as listed in Table 9. This harness will connect to connector "C5" as shown in Illustration 10, and Illustration 4.
489-3082 Temperature Sensor Group (Coolant) | |||
---|---|---|---|
Qty | Part Number | Part Name | Description |
1 | Temperature Sensor Group | Sensor Group - Temperature (PWM 500 HZ 8V) | |
1 | O-Ring Seal | Seal-O-Ring - STOR SAE 9/16-18) | |
1 | Connector Plug Assembly | Plug Assembly - Connector (3) | |
1 | Plug Lock Wedge | Wedge - Receptacle Lock (3) | |
7 | Connector Socket | Socket - Connector |
Installation of the Sensors
Illustration 11 | g03823057 |
Sensor orientation |
If the sensor has an opening for the fluid being measured, the opening must face downward after installation such that debris is not able to collect in the sensor opening.
Software Requirements
Flashing the ECM requires the following hardware and software:
- Caterpillar® Service Tool software installed and licensed on a PC
- Caterpillar Communication Adapter
Use the following files when flashing or configuring:
- ECM Flash File: 3555019.fls
- Configuration File: Midrange_2014-11-26_07.25.00.XML
Note: Configuration file is most recent .xml file and is subject to change.
Configuration of the Installed System
The ECM has been preconfigured for the coolant temperature and oil pressure parameters. Configuration of the system requires that the number of teeth in the engine should be configured under "Flywheel Teeth", using Cat ET.
Illustration 12 | g03837629 |
Engine speed monitor ECM mounting hardware |
If the number of flywheel teeth is unknown or if an accessory drive gear is being sensed, the engine RPM must be determined either from the dashboard tachometer or a handheld tachometer. The number of flywheel teeth can be calculated as follows:
Illustration 13 | g03823063 |
Flywheel teeth computation |
Validation of the Installed System
Power OFF Tests
This check will be performed on the AssetIQTM generator system to validate that the following wires have been terminated correctly. For this check, verify that the 70-pin harness is disconnected from the ECM. The 70-pin harness includes the extension harnesses and sensors. Using a digital volt meter set to measure ohms, perform the following resistance checks:
Testing the Engine Magnetic Pickup:
- Connect the positive lead to "C1" pin-66.
- Connect the negative lead to "C1" pin-67.
- The resistance should read 175 ± 20 ohms.
Testing the Data Link Connection:
- Connect the positive lead to "C8" pin-G.
- Connect the negative lead to "C8" pin-F.
- The resistance should read 60 ohms.
Testing the Current Sensing Harness:
- Current sensing harness must be connected for this test "C11 to C13".
Positive lead | Negative lead | Resistance reading |
---|---|---|
C1-39 | C1-31 | 10 ohm or less |
C1-39 | C1-47 | 10 ohm or less |
C1-39 | C1-57 | 10 ohm or less |
Testing the Voltage Sensing Harness:
- Remove Fuses 1, 2, and 3.
Positive lead | Negative lead | Resistance reading |
---|---|---|
C1-7 | C1-13 | Infinite |
C1-7 | C1-11 | Infinite |
C1-7 | C1-9 | Infinite |
4 | Neutral Tab | 1 ohm or less |
- When finished with each individual check, reinstall the three fuse resistance from C1-7 to C1-9, 11, 13 should be less than 10 ohms.
Power ON Tests
Before connecting the battery, perform the following checks on the oil pressure sensor and the coolant temperature sensor. Using a digital volt meter set to measure DC V, perform the following checks:
Battery Check (Refer to Illustration 4):
- Connect the positive lead to "C23" pin-1.
- Connect the negative lead to "C23" pin-2.
- The voltage should read 24 V.
- Connect Battery power by connecting "C23" to "C2".
Oil Pressure Harness (Refer to Illustration 9):
- Connect the positive lead to "C17" pin-1.
- Connect the negative lead to "C17" pin-2.
- The voltage should read 5 V.
- Connect "C17" to the oil pressure sensor.
Coolant Temperature Harness (Refer to Illustration 10):
- Connect the positive lead to "C30" pin-A.
- Connect the negative lead to "C30" pin-B.
- The voltage should read 5 V.
- Connect "C30" to the coolant temperature sensor.
Functional Validation
- Remove the "Do Not Operate" warning label and lock from the ignition.
- Connect the AssetIQTM system to Battery(+) and Battery(-). Connect a Communications Adapter to the 9-pin service port on the AssetIQTM harness.
- Connect to the AssetIQTM system in Cat ET and start the engine to which the sensors are connected.
- With the Engine running, verify that the following parameters are being reported.
- Oil Pressure
- Coolant Temp
- Battery Voltage
- Engine Speed
- Diagnostic Clock
- Let the engine run for 5 minutes,
- Verify that the coolant temperature has increased after running.
- Verify that the oil pressure is within specification at idle.
- Increase the throttle on the engine and verify that engine speed increases.
- If any of the parameters report as unavailable, check that all electrical connections between the sensor and the harness.
- If a parameter reports a "Voltage Below Normal" diagnostic, check the wires for a short circuit.
- If a parameter reports a "Voltage Above Normal" diagnostic, check the wires for an open circuit.