Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2 {4490, 7610} Caterpillar


Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2 {4490, 7610}

Usage:

SR4B 1BN


Electric Power Generation
All

Introduction

Reference: Systems Operations Troubleshooting/Testing and Adjusting, UENR1209, "EMCP4.1/EMCP4.1 4.2"

Reference: Application and Installation Guide, LEBE0006, "EMCP 4.1, 4.2 Generator Set Control"

This Special Instruction contains necessary information for upgrading Electric Power Generator Set Control mounted panels that use the EMCP Engine Status Control (ECS), EMCP1 (per 7C-1000 Control Panel Chart), EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2.

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 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.

------ WARNING! ------

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

This kit is intended to replace EMCP Controls by using the existing generator-mounted enclosure.

Features

As implemented, the EMCP 4.2 control offers more features and communication options than what was available with the earlier EMCP models. Refer to Application and Installation Guide, LEBE0006, "EMCP 4.1, 4.2 Generator Set Control" for a complete description.

Required Documents

Refer to the following documents for review prior to installation.

Table 1
Media 
Systems Operations, Troubleshooting, Testing and Adjusting, UENR1209, "EMCP4.1/EMCP4.2" 
LEBE0006 EMCP 4.2 Application and Installation Guide 

Power Requirements

This control is designed to operate on 24 V, DC only. Current draw of the control package is less than 2.0 amps. External solenoids, loads driven by the control's relays and connection of a Caterpillar ET communications adapter will add to the current draw.

Safety

Lock Out / Tag Out

------ WARNING! ------

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.




Illustration 1g03858739

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the battery disconnect location before you service the equipment. The warning tags are available from your Caterpillar dealer.

Electrical Safety

Note: Do not operate or work on a generator set unless you have read and understand the instructions and warnings in this manual and the EMCP 4.2 Application and Installation Guide. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Cat Dealer for replacement manuals. Proper care is your responsibility.

Electrostatic Discharge Awareness


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 (grounding mat, anti-static wrist strap and so on).

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

  • 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 or 70-pin connector on the back of the control is the most vulnerable area to ELECTROSTATIC DISCHARGE (ESD). While handling the EMCP 4.2, extra attention is required at the back of the control. The control may become damaged or inoperable if extra care is not taken.

Removal of the Existing Control

Resolve Existing Issues

  • Resolve any existing issues with the control, the generator set, or the wiring between them. If the existing installation has generator set or control issues, these issues should be repaired prior to performing a control upgrade. Troubleshooting a failure will only become more difficult after the new control is installed. If the control has failed, it may not be possible to perform some of the following tasks.

  • Use the documentation appropriate for the control. The document should be available on SIS web.

  • 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 schematic conforms to the old control as it has been installed. 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. Mark up the schematic to reflect the control as it is installed. Continuity should be < 10 ohms. Voltage is 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 2.

Table 2
Value  Unit  Recorded Value 
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 3.

Table 3
Value  Unit  Recorded Value 
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 website 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 2g03858747

Remove the Existing Control

------ WARNING! ------

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.


------ WARNING! ------

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.


------ DANGER! ------

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 and isolated from the utility power and any other power source. Ensure that proper lock out and tag out procedures are followed.

  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 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. When all the wires have been labeled, disconnect the wires from the terminal blocks.

  6. Disconnect the conduit and spiral wrap from the original EMCP panel. Ensure that none of the wiring is damaged during removal of the conduit or spiral wrap.

    Note: Do not remove any wiring from the conduit or spiral wrap.

  7. If the governor/speed control is going to be reused in the EMCP 4.2 panel, the governor/speed control should be removed from the original EMCP panel.

  8. Remove the original EMCP panel from the generator enclosure.

Installation of the EMCP 4.2 Control

Parts List

Table 4
Contents of the 467-4168 Electronic Panel Gp 
QTY  Part Number  Description 
457-1582  Panel Harness As 
467-4169  Panel Harness As 
459-1873  Terminal Marker As 
15  3S-2093  Cable Strap 
9X-8256  Washer 
095-0827  Lockwasher 
103-6272  Seal 
208-8469  Locknut 
442-0635  Bracket As 
3E-2286  Contact Strip 
5C-2890  Nut 
8T-4205  Hard Washer 
9Y-6027  Ceramic Fuse 
105-7543  Fuse Block 
115-1322  Terminal 
115-2538  End Cover 
22  116-5140  Terminal 
125-9969  Rail 
203-9007  Nut 
225-3322  Screw 
264-2957  Screw 
270-2679  Lockwasher 
314-9101  End Bracket 
355-9019  Generator Set Electronics Gp 
448-1934  Spacer 
499-6725  Plate 

Control Module Installation



Illustration 3g06100307
(1) EMCP Control
(2) 499-6725 Plate

Mounting 499-6725 Plate is provided to give the installer an additional option for mounting the EMCP. Refer to Illustration 3 for measurements.

Terminal Block Installation



Illustration 4g03856802
EMCP 4.2 Terminal Block-Rail mounting

Refer to Illustration 4 for layout of the Terminal Block Assembly.

Control Harness Installation

Once the wire 467-4169 Panel Harness As has been installed , use Table 5 for wire to Terminal Block Assembly.

Table 5
Control Harnesses 
467-4169 Panel Harness As  Wire Number/Color  Terminal Block Number 
196-E6 GY  404 
185-E5 BR  403 
11  183-E7 PU  402 
13  180-E4 OR  401 
16  P735-E35 E-CBL2 WH  306 
18  101-E18 RD  104 
26  R957-E42 BK  313 
27  L925-E43 PU  314 
31  A368-E13 BR  405 
37  R952-E38 E-CBL3 BK  308 
38  R951-E37 E-CBL3 RD  307 
39  184-E8 BU  408 
46  P734-E34 E-CBL2 BK  305 
47  A367-E12 GN  406 
48  R955-E41 BK  312 
51  R954-E40 BK  311 
52  101-E17 RD  103 
55  A775-E15 BK  310 
56  P733-E33 E-CBL2 RD  304 
57  A364-E11 YL  407 
58  101-E19 RD  105 
60  200-E10 BK  201 
61  101-E16 RD  104 
65  200-E9 BK  201 
66  G404-E30 E-CBL1 RD  303 
67  G405-E31 E-CBL1 BK  302 
70  A774-E14 BK  309 
457-1582 Panel Harness As  Wire Number/Color  Terminal Block Number 
101-G1 RD  105 
200-G2 BK  202 
457-1582 Panel Harness As  Splice together  467-4169 Panel Harness As 
F711-G8 GN  Splice together  F711-E27 GN 
F712-G5 YL  Splice together  F711-E22 YL 

The schematic for the existing installation and the schematic for the EMCP 4.2 is required to install the wiring to the EMCP 4.2 control. Since the EMCP 4.2 can replace many different controls, the wire numbers on the existing wiring will likely not correspond with the EMCP 4.2 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 4.2, 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 it is certain that a wire will not be used, it can be pulled out of the conduit and discarded.

Note: All wiring connected to generator output must have an insulation rating of 600 V.

Wiring Diagrams



Illustration 5g03856806
Wiring Diagram 1


Illustration 6g03856808

Items shown as dashed lines are not included in the kit.

Note: Replacing the oil pressure sensor, engine speed sensor, and coolant temperature sensor may be necessary if the existing sensors are not compatible with the EMCP4.2 or have failed.

Install Existing Sensors

Note: PWM Sensors will not work with the EMCP 4.2 Control. For more information refer to the section "Recommended Sensors".

Use Wiring Schematic Illustration 5 and 6 for help in the wiring of sensors. Use the reference document (UENR1209) for sensor configuration.

Control Parameter Configuration

Configuration Parameter Default Values

For information on configuration of various sensors, reference Application and Installation Guide, LEBE0006, "EMCP 4.1, 4.2 Generator Set Control" which can be found on Power Net.

Winding Ratings

Potential Winding Rating

The EMCP 4.2 control can directly monitor generator voltages up to 600 V. Voltages more than 600 V must use potential transformers or an ATB (AC Transformer Box) to scale the generator voltage to less than 600 V.

Secondary Winding Rating

Whether the generator is wired directly to the EMCP 4.2, or when potential transformers or an ATB is used, it is recommended that fuses at the appropriate voltage rating be installed. Fuses are connected to the load bus generator tab as shown in Illustration 6. If there is a short on one of the connections to the control (Bus Voltage L1, L2 and L3, Neutral), a fuse will blow to protect the generator, control, and personnel. If potential transformers are used, the voltage ratio is set in the Potential Transformer Secondary Winding Rating setting. The value of this rating depends on the turns ratio of the potential transformer's primary winding to secondary winding.

Primary Winding Rating

The EMCP 4.2 control must use current transformers to measure generator output current. The current transformers must scale the generator output current from, 0 to 1 or 0 to 5 amps for use by the EMCP 4.2. The current transformer ratio is set in the EMCP 4.2 parameter settings. Use (Configuration Setup for "Generator AC Monitor") shown above, as a path to access the current primary and secondary winding rating parameter using CAT ET.

The recommended Transformers can be found in Table 6.

Table 6
Part Number  Description  Rating 
122-6585  Current Transformer As  1000:5 Amps, 600 Volt, Stud terminals 
365-1431  Link and Bearing As  3000:5 Amps, 600 Volt, Stud terminals 
357-1219  Transformer  1500:5 Amps, 600 Volt, Stud terminals 
128-0115  Current Transformer As  3500:5 Amps, 600 Volt, Stud terminals 
122-6591  Current Transformer As  4000:5 Amps, 600 Volt, Stud terminals 
122-6586  Current Transformer As  1200:5 Amps, 600 Volt, Stud terminals 
122-6587  Current Transformer As  1500:5 Amps, 600 Volt, Stud terminals 
122-6588  Current Transformer As  2000:5 Amps, 600 Volt, Stud terminals 
122-6589  Current Transformer As  2500:5 Amps, 600 Volt, Stud terminals 
122-6590  Current Transformer As  3000:5 Amps, 600 Volt, Stud terminals 
117-9721  Current Transformer As  200:5 Amps, 600 Volt, Stud terminals 
117-9722  Current Transformer As  300:5 Amps, 600 Volt, Stud terminals 
117-9723  Current Transformer As  400:5 Amps, 600 Volt, Stud terminals 

Configuration Setup for "Generator AC Monitor"

To change the following parameters, refer to the following instructions:

  1. Navigate to the EMCP 4.2 screen in Cat ET, and click "Configuration Tool".

  2. Navigate to desired parameter "Generator AC Monitor", and double-click the "desired parameter line of choice" to change "VALUE".

  3. In the (Change Parameter Value) box, enter new value and click "OK".

  4. Continue to the next Parameter as needed.


    Illustration 7g03856922

  5. Double-Click CAT ET (Configuration Tool) Icon

    Analog Inputs

    There are two analog inputs from the generator set:

    • Engine Oil Pressure

    • Engine Coolant Temperature

    High Coolant Temperature Shutdown

    This can be found listed as Analog Input #2 High Shutdown Event Threshold. The range of this parameter is 95 -120 °C or 203-248°F. The default value is set at 108°C.

    Low Oil Pressure Shutdown Event Threshold

    This can be found listed as Analog Input #1 Low Shutdown Event Threshold. The range of this parameter is 13.4 - 880 kPa. The default value is set at 150 kPa.



    Illustration 8g03856929


    Illustration 9g03856951

  6. Select the value of the parameter that is being modified. Enter the new value and click "OK" to change

  7. Program the parameters into the EMCP 4.2 control using the parameter data that was obtained in 3.4 Baseline Generator Set Operating Parameters.

  8. For information on how to set the time and date on the EMCP 4.2 control, refer to Systems Operations Troubleshooting Testing and Adjusting, UENR1209, "EMCP4.1/EMCP4.2".

  9. This control has not allocated inputs for battery charger fault detection. If it is necessary to monitor the battery charger status and the battery charger provides status outputs, refer to Systems Operations Troubleshooting Testing and Adjusting, UENR1209, "EMCP4.1/EMCP4.2" for instruction on how to implement digital inputs.

Validation

Electrical Validation

Power Off Tests

The battery should not be connected.

Check for continuity between the following points (TB designates the terminal blocks in the EMCP 4.2 control):

Table 7
From PIN  To PIN 
Battery (+) lug  TB 101 
Battery (-) lug  TB 201 
Remote Initiate Contact 1 (IC)  TB 310 (Optional Feature) 
Remote Shutdown Contact 1 (PSS)  TB 309 (Optional Feature) 
Air Shut Off Relay coil 2  TB 312 (Optional Feature) 
Fuel Solenoid coil 2  TB 312 
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 

Note: To check the continuity of the wiring from the generator output to the EMCP 4.2, remove the three fuses (F10, F11, F12 in Illustration 6) to isolate the wiring from the generator. Replace the fuses after the continuity checks have been completed.

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

Power On Test

Perform the following procedure for power-on test :

  1. 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.

  2. Using terminal block 201 as (-) Battery, check that there is (+) Battery voltage on the following points: (See Illustration 4 Schematic for fuse terminal block identification)

  3. Fuse 1 terminal 2.

  4. Verify that the EMCP 4.2 control is powered up

Operational Validation

Cranking Cycle, E-Stop Test

This test will verify that the generator set cranking cycle can be stopped with the E-Stop button. To prevent the engine from starting, disconnect wire from TB312. Make sure to isolate wire, to prevent short to ground.

  1. Push 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

  2. Acknowledge the cranking cycle faults and reset the EMCP 4.2 control.

  3. Connect wire to TB312 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

This 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

Perform the following procedure for idle speed parameter validation:

  1. Push the "RUN" button on the EMCP 4.2 control panel. The generator set should start and run at idle speed.

  2. Check the coolant temperature as the generator set starts and verify that it is close to the block temperature of the generator set. This check is done to determine if the coolant temperature sensor and related wiring is functional.

  3. Allow the coolant temperature to stabilize, then read the following parameters from the ECM display:

    Engine speed - RPM

    Battery Voltage - Volts

    Engine oil pressure - kPa or psi (circle which)

    Engine coolant Temperature - °C / °F (circle which)

  4. Any parameter that is not the same as the original data value data will need to be investigated and resolved before proceeding.

  5. Press the "Stop" button on the EMCP 4.2. The generator set should come to a controlled stop.

  6. 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 shutdown immediately. Loss of engine speed results in an "Unexpected Engine Shutdown" fault. To recover from this fault, remove power from the EMCP 4.2 control by removing Fuse 1 to remove power from the control, and then reinstall the fuse.

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

  4. Disconnect the engine speed sensor from either terminal 302 or 303. The generator set should shutdown immediately. Reconnect the engine speed sensor and cycle the power on the EMCP 4.2 by removing Fuse 1 to remove power from the control, and then reinstall the fuse.

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

Engine Set point Verification

The engine set point verification procedure verifies that the EMCP 4.2 operates correctly when a Low Oil Pressure or High Coolant Temperature event occurs. The engine set point verification procedure also verifies that the EMCP 4.2 operates correctly when an Engine Overspeed event occurs.

Low Oil Pressure and High Coolant Temperature each have two events, Warning and Shutdown. The EMCP 4.2 will issue a warning whenever the warning threshold is reached and a shutdown whenever the shutdown threshold is reached. This verification procedure will modify configuration set points used in normal operation. The steps below outline 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: 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 which 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 (Analog Input #1 Low Shut down Event Delay Time set point)

  3. View the event by going to the EMCP 4.2 event log.

  4. Reset the event

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

Overspeed Verification

Perform the following procedure on overspeed verification:

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

  2. Adjust the set point value for Engine Overspeed Set point to a value that is below the speed that the generator set is running at. An Engine Overspeed Set point event will occur immediately after the set point is changed, and the generator set will shut down.

  3. View the event by going to the EMCP 4.2 Control event log.

  4. Reset the event.

  5. Return the set point value for the Engine Overspeed Set point to the original value.

Overspeed Verification

Perform the following procedure on overspeed verification:

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

  2. Adjust the set point value for Engine Overspeed Set point to a value that is below the speed that the generator set is running at. An Engine Overspeed Set point event will occur immediately after the set point is changed, and the generator set will shut down.

  3. View the event by going to the EMCP 4.2 Control event log.

  4. Reset the event.

  5. Return the set point value for the engine overspeed set point to the original value.

Analog Inputs

There are two (2) Analog inputs from the generator set:

  • Engine Oil Pressure

  • Engine Coolant Temperature.

High Coolant Temperature Shutdown - This can be found listed as Analog Input #2 High Shutdown Event Threshold. The range of this parameter is 95 - 120°C or 203 - 248°F. The default value is set at 108°C.

Low Oil Pressure Shutdown Event Threshold - This can be found listed as Analog Input #1 Low Shutdown Event Threshold. The range of this parameter is 13.4 -880 kPa. The default value is set at 150 kPa.

Automatic Start/Stop

Configuration of the Automatic Start/Stop parameters is done in ET via the parameters shown below.

Cycle Crank Configuration

This can be found listed as Crank Duration. The range of this parameter is 1 - 60 seconds. The default value is set at 10 sec.

Cycle Crank Rest Interval

The range of this parameter is 1 - 60 seconds. The default value is set at 5 sec.

Maximum Number of Crank Cycles

The range of this parameter is 1 - 99. The default is set to 1.

Cool down Configuration

This can be found listed as Cool down Duration.

The range of this parameter is 0 - 30 minutes. The default value is set at 5 minutes.

Crank Termination Speed Configuration

This can be found listed as Crank Terminate RPM.

The range of this parameter is 100 - 1000 RPM. The default value is set at 300 RPM. Battery Voltage Monitor

Idle Speed Oil Pressure Shutdown

This is listed as Low Idle Low Engine Oil Pressure Shutdown Event Threshold. The range of this parameter is 20 - 420 kPa. The default value is set at 200kPa.

Low Idle Low Engine Speed Oil Pressure Warning Event Threshold

The range of this parameter is 22 - 462 kPa. The default value is set at 2. The value of this parameter should be set at least 110% of the value of the Idle Speed Oil Pressure Shutdown parameter.

Oil Step Speed

This is listed as Low Engine Oil Pressure Step Speed. The range of this parameter is 400 - 1800 RPM. The default value is set at 400 RPM.

Overspeed

This can be found listed as Engine Overspeed Set point. The default value is set at 1540 RPM. This value is generator set specific

Software Requirements

Flashing the EMCP 4.2 requires the following hardware and software:

  • The Caterpillar ® Service Tool software installed and licensed on a PC.

  • A Caterpillar Communication Adapter.

  • A 9-pin round Deutsch connector service connection to the Primary Data link (CAN 1).

Use the following files when flashing or configuring:

EMCP 4.2 ECM Flash File: Can be found on SIS web, ELEK GP-A6001 PN: 355-9019 Generator Set Electronics Gp

Recommended Sensors

The recommended sensors for the EMCP4.2 upgrade are listed below:

  • Coolant temperature sensor

  • Oil pressure (Gauge) sensor

  • Oil temperature sensor

Coolant Temperature Sensor

The physical and electrical connections of 7X-1043 Temperature Sensor Gp are listed below:

Physical Connection - #6 STOR (9/16-18) male thread and use 214-7568 O-Ring Seal.

Electrical Connection - Use mating connector 8T-8731 Connector Plug.

The configuration parameters of coolant temperature sensor (Analog Input #2) for the EMCP4.2 are listed below:

  • Signal type is voltage output.

  • Supply voltage given is 5 Volt.

  • Signal range is between 0.5 to 4.5 Volts.

  • Data identification through engine coolant temperature.

  • Minimum data range is −3.442° C (25.80440° F).

  • Maximum data range is 238.982° C (462.16760° F).

Note: All configuration parameter values are in metric (SI) units (degrees Centigrade, kPa) even though the user display may be in English units.

The connections of sensor wire for EMCP4.2 are listed below:

  • Signal (White) wire is connected to terminal block 307.

  • Ground (Black) wire is connected to terminal block 308.

  • Supply (Orange) wire is connected to terminal block 306.

Note: Terminal block 308 (Sensor Ground) must be tied to Battery Ground (terminal block 204) in order for the EMCP4.2 to properly read the sensor.

Oil Pressure (Gauge) sensor

The physical and electrical connections of 246-8150 Pressure Sensor are listed below:

Physical Connection - Use 1/8-27 NPT (National Pipe Thread) male thread

Electrical Connection - Use M4 studs and 2L-8065 Ring Terminal (12-10 AWG), 2L-8075 Ring Terminal (16 -14 AWG), 7N-9194 Terminal Ring (22 - 18 AWG)

The configuration parameters of oil pressure sensor (Analog Input #1) for the EMCP4.2 are listed below:

  • Signal type is resistive sender.

  • Configuration code is map #2.

  • Data identification through engine oil pressure.

The electrical connection for a resistive sensor on Analog Input #1 is given as follows:

  • Terminal block 304 is connected to either terminal of temperature sensor (resistance sensors do not have a polarity).

  • Terminal block 305 is connected to remaining terminal.

Note: Terminal block 305 (Sensor Ground) must be tied to Battery Ground (terminal block 204) in order for the EMCP4.2 to properly read the temperature sensor.

Oil Temperature Sensor

The physical and electrical connections of 106-0735 Temperature Sensor Gp are listed below:

Physical Connection - #8 STOR (3/4-16) male thread and use 3K-0360 O-Ring Seal.

Electrical Connection - Use 155-2260 Connecting Plug Kit (deutsch connector 3 pin).

The configuration parameters of oil temperature sensor (Analog Input #3) for EMCP4.2 are listed below:

  • Signal type is voltage output.

  • Supply voltage given is 5 Volt.

  • Signal range is between 0.5 to 4.5 Volts.

  • Data identification through engine oil temperature.

  • Minimum data range is −23.671° C (−10.60780° F).

  • Maximum data range is 118.926° C (246.06680° F).

Note: All configuration parameter values are in metric (SI) units (degrees Centigrade, kPa) even though the user display may be in English units.

On the EMCP4.2 kit, Analog Input #3 has not been brought out to terminal blocks. The pins on the 70-pin connector are given as below:

  • Analog Input #3 (+) - 30

  • Analog Input #3 (-) - 29

Note: Analog Input #3 (-) must be tied to Battery Ground (terminal block 204) in order for the EMCP4.2 to properly read the sensor.

Available Hardware Add-ons

Annunciator



Illustration 10g03857449
Front EMCP 4.2 Panel


Illustration 11g03857450

The EMCP Annunciator serves to display generator set system alarm conditions and status indications. The annunciator can be mounted with the generator control or in a desired remote location.

Table 8
Annunciator Parts List 
QTY  Part Number  Description 
422-1193  Film 
303-5893  Alarm Module Gp 
9x-8256  Washer 
095-0827  Lockwasher 
5C-2890  Nut 
244-9613  Gasket 
265-4123  Connector Receptacle As 
203-9007  Nut 
270-2679  Lockwasher 
155-2267  Connector Plug As 
134-2540  Resistor As 
Optional  130-4676  Electrical Wire 
Optional  130-4673  Electrical Wire 
Optional  206-3985  Wire 
Optional  206-3986  Wire 
9X-3401  Connector Pin 
9X-3401  Connector Pin 
8T-8737  Seal Plug 

E-STOP



Illustration 12g03857452
E-STOP Connection

The E-STOP is used to perform a hard shutdown of the engine in the event of an Emergency. Use the recommended Parts listed in Table 9, for replacement.

Table 9
E-STOP Parts List 
QTY  Part Number  Description 
442-6212  Stop Switch 
442-6215  Contact Block 
442-6217  Holder 
442-6219  Shroud 
443-2546  Adapter 

Starter Motor Magnetic Solenoid (SMMS)



Illustration 13g03857453
Starter Motor Magnetic Solenoid mounting location


Illustration 14g03857454
Starter Motor Magnetic Solenoid Connection

The Starter Motor Magnetic Solenoid acts as a switch control from the EMCP , to allow the engine to crank. The recommend replacement is listed in Table 10.

Table 10
Starter Motor Magnetic Solenoid Parts List 
QTY  Part Number  Description 
125-1302  Magnetic Switch Gp 
5C-2890  Nut 
8T-4205  Hard Washer 

Potentiometer



Illustration 15g03858757
Wiring diagram for connecting the potentiometer

The Potentiometer can be used to adjust the Engine Speed manually. Use the recommended parts list in Table 11.

Table 11
Potentiometer Parts List 
QTY  Part Number  Description 
122-9458  Potentiometer 
4W-5972  Knob 
7C-4550  Seal 

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