Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2B {1408, 4490, 7418, 7426, 7451} Caterpillar


Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2B {1408, 4490, 7418, 7426, 7451}

Information for equipment:


ELECTRICAL AND STARTING SYSTEM
BOX GP

Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2B {1408, 4490, 7418, 7426, 7451} Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2B {1408, 4490, 7418, 7426, 7451}

Generator Lead Connections Can Rub Against The Terminal Box Or Each Other Generator Lead Connections Can Rub Against The Terminal Box Or Each Other

New Programmable Logic Control With In-Phase Monitor For Contactor Type Automatic Transfer Switches {4469} 1996/04/01


Electric Power Generation
All

Introduction

Reference: Systems Operations Troubleshooting/Testing and Adjusting, UENR7097, "EMCP4.2B"

Reference: Application and Installation Guide, LEBE0049, "EMCP 4.2B 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 4.2B.

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 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.


------ 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.


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 1g00104545

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 4.2B 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 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 4.2B 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.

Overview

Applicability



Illustration 2g03555536
EMCP 4.2B enclosure

This kit replaces the EMCP panels that are fitted in a generator-mounted enclosure with the dimensions mentioned in Illustration 2.

Features

As implemented, the EMCP 4.2B control offers more features and communication options than what was available with the earlier EMCP models. Refer to Application and Installation Guide, LEBE0049, "EMCP 4.2B Generator Set Control" for a complete description.

Required Documents

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

Power Requirements

This control is designed to operate on +12 or +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® Electronic Technician ( Cat ET) Service Tool communications adapter will add to the current draw.

Removal of the Existing Control

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. Troubleshooting 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 website.

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.

  • 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  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 2.

Table 2
Value  Unit  Recorded Value 
Engine Idle 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 3.



Illustration 3g03832675

Remove the Existing Panel

  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 4.2B panel, the governor/speed control should be removed from the original EMCP panel. Set aside the original EMCP panel for installation in the EMCP 4.2B panel.

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

Installation of the EMCP 4.2B Control

Perform the following procedure for installing the EMCP 4.2B control:

Install EMCP 4.2B Panel



Illustration 4g03557379
Enclosure hole information

The EMCP 4.2B has been built into the smallest of three enclosure sizes. EMCP 4.2B should fit any application that uses the type of enclosure shown in Illustration 4. The conduit entry holes on the bottom of the enclosure are standard in all three enclosure sizes.

Refer to Illustration 4 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 4.2B enclosure on top of the generator housing.

Wiring Diagrams



Illustration 5g03832680
Wiring diagram 1


Illustration 6g06052821
Wiring diagram 1

Note: Items shown as dashed lines are not included in the kit. The insulation for all wiring that is connected to the generator must have a 600 V rating.

Install Wiring From the Generator Set to EMCP 4.2B

The corrected schematic for the existing installation will be required to install the wiring to the EMCP 4.2B control. Also, the schematic for the EMCP 4.2B will be required to install the wiring to the EMCP 4.2B control. The EMCP 4.2B related schematics in this publication are Illustration 5, and Illustration 6.

Since the EMCP 4.2B can replace many different controls, the wire numbers on the existing wiring will likely not correspond with the EMCP 4.2B 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 4.2B, 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.

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

Install Existing Sensors

Note: PWM Sensors may not work with the EMCP 4.2B Control. Refer to the "Recommended Sensors" section for further information.

Use Illustration 5, and Illustration 6 for wiring of sensors. Refer to Systems Operations Troubleshooting/Testing and Adjusting, UENR7097, "EMCP4.2B" for sensor configuration.

Control Parameter Configuration

Configuration Parameter Default Values

For information on configuration of various sensors, refer to Application and Installation Guide, LEBE0049, "EMCP 4.2B Generator Set Control" found on Power Net.

Winding Ratings

Potential Winding Rating:

The EMCP 4.2B control can monitor directly 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 4.2B, 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. If there is a short on one of the connections to the control (Bus Voltage L1, L2, L3, and 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 primary winding to secondary winding the potential transformer.

The recommended Transformers can be found in Table 3.

Table 3
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 

Primary Winding Rating:

The EMCP 4.2B 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 A for use by the EMCP 4.2B. The current transformer ratio is set in the EMCP 4.2B 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.

Configuration Setup for "Generator AC Monitor"

To change the following parameters, use the instructions below as an example:

  1. Navigate to the EMCP 4.2B 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" field, enter a new value, and click "OK".

  4. Continue to the next parameter as needed.


    Illustration 7g03833187

  5. Double-click the Cat ET "Configuration Tool" icon.


    Illustration 8g03833191

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


    Illustration 9g03834431

  7. Enter new value.

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

  9. Refer to Systems Operation, UENR7097, "EMCP4.2B", "Password Entry" for how EMCP 4.2B has implemented security passwords.

  10. Refer to Systems Operation, UENR7097, "EMCP4.2B", "Real-Time Clock Programming - EMCP 4.2B only" for setting the time and date on the EMCP 4.2B control.

  11. The EMCP 4.2B control has not allocated inputs for battery charger fault detection. If it is necessary to monitor the battery charger status, and the battery charger status outputs, refer to Systems Operation, UENR7097, "EMCP4.2B", "Digital Input Programming" for instruction on how to implement digital inputs.

Validation

Electrical Validation

Power Off Tests

Note: The battery should not be connected.

TB designates the terminal blocks in the EMCP 4.2B control.

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 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 
Note: To check the continuity of the wiring from the generator output to the EMCP 4.2B, remove the three fuses (F10, F11, and F12 on 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. 
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 Test

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

Using terminal block 201 as BAT (-), check that there is BAT (+) voltage on the following points: (Refer to Illustration 4 for fuse terminal block identification)

  • Fuse 1 terminal 2

Verify that the EMCP 4.2B 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 the Fuel Solenoid wire from TB312. Make sure to isolate wire, to prevent short to ground.

  • 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.

  • Acknowledge the cranking cycle faults and reset the EMCP 4.2B control.

  • Connect the Fuel Solenoid wire to TB312 to allow the Fuel Solenoid to function.

  • Idle Speed Test - 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.

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

  • Press the E-Stop button to verify that the generator set stops.

Idle Speed Parameter Validation

  1. Press the "RUN" button on the EMCP 4.2B 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. This check is to confirm that 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. Any parameter value that is not close to the original parameter value data will need to be investigated and resolved before proceeding.

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

  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 shutdown immediately. Reconnect the engine speed sensor and cycle the power on the EMCP 4.2B 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 4.2B operates correctly when a low oil pressure or high coolant temperature event occurs. The engine set point verification procedure also verifies that the EMCP 4.2B 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 4.2B will issue a warning whenever the warning 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 4.2B 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 4.2B 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 shutdown.

  3. View the event by going to the EMCP 4.2B control event log. Reset the event.

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

Analog Inputs

There are two analog inputs from the generator set to the EMCP. The inputs are engine oil pressure and engine coolant temperature.

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).

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).

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 rpm to 1000 rpm. The default value is set at 300 rpm.

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 200 kPa (29 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 RPM to 1800 RPM. The default value is set at 400 RPM.

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.

Software Requirements

Flashing the EMCP 4.2B 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)

  • EMCP 4.2B ECM Flash File: 501-4291 Generator Set Software Gp

Recommended Sensors

The recommended sensors for the EMCP 4.2B 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 EMCP 4.2B 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 EMCP 4.2B 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 EMCP 4.2B 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 EMCP 4.2B 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 EMCP 4.2B 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 EMCP 4.2B 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 EMCP 4.2B 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 EMCP4.2B to properly read the sensor.

Available Hardware Add-ons

Annunciator

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 5
Parts for Annunciator 
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  Lock washer 
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-3402  Connector Socket 
8T-8737  Seal Plug 


Illustration 10g03834436
Front EMCP 4.2B Panel
(1) Annunciator
(2) Potentiometer
(3) E-Stop


Illustration 11g03834446
Annunciator connection

E-Stop

The E-Stop can be added to the control panel as a replacement part or upgrade part.

Table 6
Parts for E-Stop 
Qty  Part Number  Description 
442-6212  Stop Switch 
442-6215  Contact Block 
442-6217  Holder 
442-6219  Shroud 
443-2546  Adapter 


Illustration 12g03834772
E-Stop connection

Starter Motor Magnetic Solenoid (SMMS)

The Starter Motor Magnetic Solenoid can be added to the control panel as a replacement or upgrade.

Table 7
Parts for Starter Motor Magnetic Solenoid 
Qty  Part Number  Description 
125-1302  Magnetic Switch Gp 
5C-2890  Nut 
8T-4205  Hard Washer 


Illustration 13g03834773
(4) Mounting location for 125-1302 Magnetic Switch Gp (SMMS)


Illustration 14g03834774
Starter motor magnetic solenoid connection

Potentiometer

The potentiometer can be added to the control panel as a replacement or upgrade.

Table 8
Parts for Potentiometer 
Qty  Part Number  Description 
122-9458  Potentiometer 
4W-5972  Knob 
7C-4550  Seal 


Illustration 15g03833186
Wiring diagram for connecting the potentiometer

Caterpillar Information System:

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Lubrication of the Fuel Injection Pump on Certain C0.5, C0.7, C1.1, C1.5, and C2.2 Engines {1251, 1257, 1265} Lubrication of the Fuel Injection Pump on Certain C0.5, C0.7, C1.1, C1.5, and C2.2 Engines {1251, 1257, 1265}
C12.9 Marine Propulsion Engine Rear Gear Group - Time
C12.9 Marine Propulsion Engine Fuel System Pressure - Test
C12.9 Marine Propulsion Engine Finding Top Center Position for No. 1 Piston
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Identifying Oil Pumps on Certain 3400, C27, and C32 Engines {1304} Identifying Oil Pumps on Certain 3400, C27, and C32 Engines {1304}
Engine Oil Contains Elevated Lead (Pb) {1000, 1348} Engine Oil Contains Elevated Lead (Pb) {1000, 1348}
New Software Flash Does Not Contain B-Rating Option on Certain 3500 Marine Engines {1920} New Software Flash Does Not Contain B-Rating Option on Certain 3500 Marine Engines {1920}
A Slave Relay Should be Used for Customer Connections to EMCP 4 On Certain Generator Sets {1422, 4493} A Slave Relay Should be Used for Customer Connections to EMCP 4 On Certain Generator Sets {1422, 4493}
New Engine Oil Cooler Groups Are Used on Certain 3500 Marine Engines {1378} New Engine Oil Cooler Groups Are Used on Certain 3500 Marine Engines {1378}
3512C Engines for 785C Off-Highway Trucks with Dynamic Gas Blending Exhaust Has Excessive Black Smoke
New Seals Are Now Used for Certain C175 and 3500 Engines with Oil Mist Detection Systems {1336, 1336} New Seals Are Now Used for Certain C175 and 3500 Engines with Oil Mist Detection Systems {1336, 1336}
A New Spring for the Oil Filter Bypass Valve and for the Oil Cooler Bypass Valve is Now in Production {1306, 1306} A New Spring for the Oil Filter Bypass Valve and for the Oil Cooler Bypass Valve is Now in Production {1306, 1306}
3516B Generator Set Engines with Dynamic Gas Blending Calibration - <B>175-4998</B> Signal Converter
An Improved Monitor Display Group Is Now Used on Certain C32 Marine Engines {7490} An Improved Monitor Display Group Is Now Used on Certain C32 Marine Engines {7490}
New Exhaust Heat Shields Are Now Used on Certain 3500C Series Engines {1063, 1067} New Exhaust Heat Shields Are Now Used on Certain 3500C Series Engines {1063, 1067}
A New Turbocharge Heat Shield Group is Now Used for Certain 3512C and 3516C Engines {1052, 1073} A New Turbocharge Heat Shield Group is Now Used for Certain 3512C and 3516C Engines {1052, 1073}
3512B Generator Set Engines with Dynamic Gas Blending Speed Control - Test
3516B Generator Set Engines with Dynamic Gas Blending Direct Fuel Control Mode - Test
Different Housings are Used on 3400 Remanufactured Engines {1304} Different Housings are Used on 3400 Remanufactured Engines {1304}
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3500E Marine Engines Cylinder Head
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