ELECTRONIC MODULAR CONTROL PANEL (EMCP) Caterpillar


Systems Operation

Usage:

Information for equipment:


GENERATORS
GENERATOR GP

Identification CONTROL PANEL SR4 GENERATOR MOUNTED
Abbreviations CONTROL PANEL SR4 GENERATOR MOUNTED
Symbols CONTROL PANEL SR4 GENERATOR MOUNTED
How To Read Control Panel DC Schematics CONTROL PANEL SR4 GENERATOR MOUNTED
Location Of Components CONTROL PANEL SR4 GENERATOR MOUNTED
Standard Components CONTROL PANEL SR4 GENERATOR MOUNTED
Optional Components CONTROL PANEL SR4 GENERATOR MOUNTED
Energize To Run Engine System CONTROL PANEL SR4 GENERATOR MOUNTED
Energize To Shut Off Engine System CONTROL PANEL SR4 GENERATOR MOUNTED
Latching Fuel Solenoid System CONTROL PANEL SR4 GENERATOR MOUNTED
Point To Point Wiring Diagrams CONTROL PANEL SR4 GENERATOR MOUNTED
D.C. Schematic (JIC) CONTROL PANEL SR4 GENERATOR MOUNTED
Wiring Diagram (Instrument Panel) CONTROL PANEL SR4 GENERATOR MOUNTED
Wiring Diagram (Subpan Side One) CONTROL PANEL SR4 GENERATOR MOUNTED
Wiring Diagram (Subpan Side Two) CONTROL PANEL SR4 GENERATOR MOUNTED
Control Panel Wiring Harness CONTROL PANEL SR4 GENERATOR MOUNTED
Customer/Contactor Wiring CONTROL PANEL SR4 GENERATOR MOUNTED
Standby Generator Wiring Diagram CONTROL PANEL SR4 GENERATOR MOUNTED
Identification ELECTRONIC MODULAR CONTROL PANEL (SR-4 GENERATOR MOUNTED)
Location Of Components ELECTRONIC MODULAR CONTROL PANEL (SR-4 GENERATOR MOUNTED)
Control Panel Operation ELECTRONIC MODULAR CONTROL PANEL (SR-4 GENERATOR MOUNTED)
Optional Modules ELECTRONIC MODULAR CONTROL PANEL (SR-4 GENERATOR MOUNTED)
Troubleshooting ELECTRONIC MODULAR CONTROL PANEL (SR-4 GENERATOR MOUNTED)
Service Procedures ELECTRONIC MODULAR CONTROL PANEL (SR-4 GENERATOR MOUNTED)
Identification SR4 GENERATOR MOUNTED CONTROL PANEL
Abbreviations & Symbols SR4 GENERATOR MOUNTED CONTROL PANEL
How To Read Control Panel DC Schematics SR4 GENERATOR MOUNTED CONTROL PANEL
Components SR4 GENERATOR MOUNTED CONTROL PANEL
Introduction SR4 GENERATOR MOUNTED CONTROL PANEL
Automatic Start/Stop Control Panel SR4 GENERATOR MOUNTED CONTROL PANEL
Manual Start/Stop Control Panel SR4 GENERATOR MOUNTED CONTROL PANEL
Operation FLOOR-STANDING SWITCHGEAR
Automatic Start-Stop FLOOR-STANDING SWITCHGEAR
Alternating Current Components Troubleshooting FLOOR-STANDING SWITCHGEAR
Automatic Start-Stop Troubleshooting FLOOR-STANDING SWITCHGEAR

Two New Self-Powered Digital Tachometers And Signal Generator Available 1987/05/01
Use 152-7143 Cable Assembly For Flash-Programming Generator Status Control Module{4450} 1999/02/01
A List Of Contacts For Caterpillar Product Support Is Available {1000, 4450, 7000} 2002/04/01

Instructions For EMCP II+ Field Retrofit Onto EMCP II Equipped Generator Sets{7490, 7451} Instructions For EMCP II+ Field Retrofit Onto EMCP II Equipped Generator Sets{7490, 7451}
Use of 8T5200 Signal Generator/Counter Group{0778, 0783, 0785} Use of 8T5200 Signal Generator/Counter Group{0778, 0783, 0785}
Installing Heli-Coil Inserts In Caterpillar Cylinder Heads{1117} Installing Heli-Coil Inserts In Caterpillar Cylinder Heads{1117}
Grounding Design Guide for Electric Power Generation Products {4450, 4459} Grounding Design Guide for Electric Power Generation Products {4450, 4459}
Winding Insulation Maintenance and Cleaning and Drying of the Generators {4450} Winding Insulation Maintenance and Cleaning and Drying of the Generators {4450}
Generator Bearing Service {4457} Generator Bearing Service {4457}

Systems Operation ELECTRONIC MODULAR CONTROL PANEL (EMCP)
Systems Operation SR4 GENERATOR
Systems Operation SR4 GENERATOR
Generator Operation SR4B Generators
General Information SR4B Generators
Component Descriptions SR4B Generators
Glossary SR4B Generators
Main Revolving Field Connections (All Except SR4B for 3500 Engines) Connection Diagrams: SR4 and SR4B Generators, Voltage Regulators, Options
Options (All Except SR4B for 3500 Engines) Connection Diagrams: SR4 and SR4B Generators, Voltage Regulators, Options
Main Revolving Field Connections (SR4B for 3500 Engines) Connection Diagrams: SR4 and SR4B Generators, Voltage Regulators, Options
Options (SR4B for 3500 Engines) Connection Diagrams: SR4 and SR4B Generators, Voltage Regulators, Options
General Information (All Except SR4B for 3500 Engines) Connection Diagrams: SR4 and SR4B Generators, Voltage Regulators, Options
General Information (SR4B for 3500 Engines) Connection Diagrams: SR4 and SR4B Generators, Voltage Regulators, Options
Generator Wiring Diagrams (SR4B for 3500 Engines) Connection Diagrams: SR4 and SR4B Generators, Voltage Regulators, Options
Main Stator and Voltage Sensing Lead Connections (All Except SR4B for 3500 Engines) Connection Diagrams: SR4 and SR4B Generators, Voltage Regulators, Options
Main Stator and Voltage Sensing Lead Connections (SR4B for 3500 Engines) Connection Diagrams: SR4 and SR4B Generators, Voltage Regulators, Options
Oil Field Generator Connections (SR4) Connection Diagrams: SR4 and SR4B Generators, Voltage Regulators, Options
Glossary SR4 Generator with VR3 or VR4 Voltage Regulator
General Information SR4 Generator with VR3 or VR4 Voltage Regulator
Component Descriptions SR4 Generator with VR3 or VR4 Voltage Regulator
Generator Operation SR4 Generator with VR3 or VR4 Voltage Regulator

Testing And Adjusting ELECTRONIC MODULAR CONTROL PANEL (EMCP)
Testing And Adjusting SR4 GENERATOR
General Information SR4B Generators
Troubleshooting SR4B Generators
Generator Set - Test SR4B Generators
Varistor - Test SR4B Generators
Rotating Rectifier - Test SR4B Generators
Winding - Test SR4 Generator with VR3 or VR4 Voltage Regulator
Resistor - Test SR4B Generators
Exciter Field - Flash SR4B Generators
Generator - Dry SR4B Generators
Insulation - Test SR4B Generators
General Information SR4 Generator with VR3 or VR4 Voltage Regulator
Troubleshooting SR4 Generator with VR3 or VR4 Voltage Regulator
Rotating Rectifier - Test SR4 Generator with VR3 or VR4 Voltage Regulator

Control Panel SR4 GENERATOR
Generator Bearing<BR> (Outside Bearing Type RFA) SR4 GENERATOR
Generator Bearing (Inside Bearing Type RFA) SR4 GENERATOR
Generator Removal SR4 GENERATOR
Alignment Of Single-Bearing Generators<BR> (Typical) SR4 GENERATOR
Rotor Assembly SR4 GENERATOR
Stator Assembly SR4 GENERATOR
Coupling - Install SR4B Generators
Coupling - Remove SR4B Generators
Bearing - Remove and Install SR4B Generators
Rotor - Remove and Install SR4B Generators
Generator - Align SR4B Generators
Generator - Install SR4B Generators
Generator - Remove SR4B Generators
Exciter - Remove and Install SR4B Generators
Bearing - Remove and Install SR4 Generator with VR3 or VR4 Voltage Regulator
Exciter - Remove and Install SR4 Generator with VR3 or VR4 Voltage Regulator
Generator - Remove SR4 Generator with VR3 or VR4 Voltage Regulator
Generator - Install SR4 Generator with VR3 or VR4 Voltage Regulator
Generator - Align SR4 Generator with VR3 or VR4 Voltage Regulator
Rotor - Remove and Install SR4 Generator with VR3 or VR4 Voltage Regulator
Coupling - Remove SR4 Generator with VR3 or VR4 Voltage Regulator

New Regulator And Field Coil Assemblies Used{1410,1405} 1981/11/23
Incorrect Connection Of Battery Charger Can Open Circuit Breaker And Damage Woodward 2301 Governor Control{1400,1401,4450} 1986/03/24
Alternator/Generator Output Test On The Engine{1401,1404,1405,1406} 1987/05/04
Two New Self-Powered Digital Tachometers And Signal Generator Available {7462} 1987/05/11
A List Of Contacts For Caterpillar Product Support Is Available {1000, 4450, 7000} 2002/03/25


Identification


Electronic Modular Control Panel (EMCP)

The model number of the Electronic Modular Control Panel (EMCP) is located on the name plate on the inside bottom of the control panel. The model number is based on panel options and generator ratings. This information is necessary for programming the ECM. There are seventeen characters in the model number and is similar to "EB3CAS3A1BASP1AE6"

The following is a description of the equipment which is specified by the model number.

NOTE: For the most accurate description and specifications, always check print 7C1000 that is included with the EMCP.


Model Number - First, Second And Third Character


Model Number - Fourth Character


Current Model Number - Fifth Character

NOTE: The above fifth character information applies to current Electronic Modular Control Panels with "2" or greater as the seventeenth character of the model number. For the correct settings, always check print 7C1000 that is included with the generator set.


Earlier Model Number - Fifth Character

NOTE: The above fifth character information applies to earlier Electronic Modular Control Panels with "1" as the seventeenth character of the model number. For the correct settings, always check print 7C1000 that is included with the generator set.

NOTE: The above fifth character information also applies to earlier Electronic Modular Control Panels with "0" as the seventeenth character of the model number. Except for the following: character G is a 3508 prime, character J is a 3512 prime and character L is a 3516 prime. For the correct settings, always check print 7C1000 that is included with the generator set.


Model Number - Sixth Character


Model Number - Seventh, Eighth And Ninth Character


Model Number - Tenth, Eleventh And Twelfth Character


Model Number - Thirteenth, Fourteenth And Fifteenth Character


Model Number - Sixteenth And Seventeenth Character

Abbreviations

Symbols

Components Location


7C1000 Control Panel
(1) ALM (alarm module) or SLM (synchronizing light module) optional. (2) ACM (AC meter module). (3) VAR (voltage adjust rheostat). (4) GS (governor switch) or SP (speed adjust potentiometer) optional. (5) SAS (start aid switch) optional. (6) ECM (engine control module). (7) Switch (display hold switch). (8) PLS (panel light switch) optional. (9) LTS (lamp/display test switch). (10) AVS (ammeter - voltmeter phase selector switch). (11) ESPB (emergency stop push button). (12) ECS (engine control switch).

NOTE: For location and specifications on components located on the engine, make reference to the respective Engine Service Manual.


Control Panel Interior
(1) ALM (alarm module) or SLM (synchronizing light module) optional. (2) ACM (AC meter module). (3) VAR (voltage adjust rheostat). (4) GS (governor switch) or SP (speed adjust potentiometer) optional. (5) SAS (start aid switch) optional. (6) ECM (engine control module). (8) PLS (panel light switch) optional. (9) LTS (lamp/display test switch). (10) AVS (ammeter - voltmeter phase selector switch). (11) ESPB (emergency stop push button). (12) ECS (engine control switch). (13) Fuses (F1 through F8). (14) Switch (overspeed verify). (15) F11 through F13 (fuses). (16) SMMS2 (starter motor magnetic switch two) optional. (17) SMMS1 (starter motor magnetic switch one). (18) CB (circuit breaker). (19) RPR (reverse power relay) optional. (20) AUX (auxiliary relay) optional. (21) 2301 (electronic governor speed control) optional. (22) TBC (terminal board C). (23) PR (preregulator) optional. (24) Fuse. (25) F9 (fuse) installed if optional PR is not provided. (26) AFCR (auxiliary fuel control relay). (27) F10 (fuse) for AFCR.

Operation


Electronic Modular Control Panel (EMCP)
(1) ALM (alarm module) or SLM (synchronizing light module) optional. (2) ACM (AC meter module). (3) VAR (voltage adjust rheostat). (4) GS (governor switch) or SP (speed adjust potentiometer) optional. (5) SAS (start aid switch) optional. (6) ECM (engine control module). (7) Switch (display hold switch). (8) PLS (panel light switch) optional. (9) LTS (lamp/display test switch). (10) AVS (ammeter - voltmeter phase selector switch). (11) ESPB (emergency stop push button). (12) ECS (engine control switch).

Controls Location And Function

The area of the control panel where ALM (1) is located, is used for different purposes. This area is used for an alarm module, a synchronizing lights module or a plain cover. These modules are described in the Optional Modules section.

NOTE: For point to point schematics and wiring diagrams, see the Schematics And Wiring Diagrams section.

AC Meter Module (ACM)

AC meter module (ACM) (2) has displays for AC volts - V, frequency - Hz, and AC amps - A. These displays indicate the status of the generator output.

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

To avoid personal injury due to electrical shock, make sure jumpers are installed correctly on the AVS.

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

Ammeter-voltmeter switch (AVS) (10) is used to select the phase of the volts and amps that are displayed on ACM (2). Positions 1, 2 and 3 of the AVS allow the operator to check generator output current and voltage for each of the phases 1, 2 and 3 respectively. Position 0 of the AVS removes generator voltages and currents from the ACM, however the ACM remains powered up.

If the voltage or current exceeds the programmed maximum, the display flashes the full scale value. Voltages below 1 VAC and currents below .1% of full scale are displayed as "0".

The frequency display (Hz) shows the frequency in hertz (cycles per second) of the electricity made when the generator set is in operation. There is a direct relation between the frequency of the electricity and the RPM of the generator set, as shown in following formula:

For frequencies above 99.9 Hz, the display flashes "99.9". Frequencies below 45 Hz are displayed as "LO".

Service Procedure C (Programming The ACM) gives details on the full scale currents and voltages that are programmed into the ACM. See the Testing And Adjusting section. If the ACM shows all dashes, the ACM has an internal fault. Replace the ECM.

Control Panel Face

Control switches ESPB (11) and ECS (12) are located below AC meter module (2). When red emergency stop push button (ESPB) (11) is pressed, the fuel is shut off and the air shutoff (if equipped) is activated. To restart, turn the ESPB until it releases. To the right of ESPB (11) is engine control switch (ECS) (12).

The ECS determines the status of the control panel. In the AUTOMATIC position (3 o'clock), the engine starts automatically whenever the remote initiating contact (IC) is closed. The engine also shuts down after the initiate contacts open. An adjustable cool down time is programmable to give a 0 to 30 minute cool down period before the engine shuts down. The cool down time is factory set at 5 minutes. In the MANUAL (run) position (6 o'clock), the engine starts and runs as long as the ECS is in this position. In the STOP position (9 o'clock), the fuel solenoid shuts the engine down after cool down. In the OFF/RESET position (12 o'clock), the engine shuts down immediately and any fault lights or diagnostic failure indicators are reset.

NOTE: The ECM and ALM do NOT turn off. If desired, battery drain is decreased by modifying the wiring of the ECS. When modified, the ECM and ALM turn OFF when the ECS is in the OFF/RESET position. To modify, remove the jumper wire which connects terminals 9 and 6 of the ECS. See the DC schematic (line 38) in the Schematics And Wiring Diagrams section.

Below ACM (2) is a row of control switches. Optional panel light switch (PLS) (8) turns ON and OFF the panel lamps. Lamp/display test switch (LTS) (9) turns ON all the control panel indicators, when in the TEST position. All lamps and display segments (displays show all 8's) in ECM (6), ACM (2) and in the optional alarm module (1) are lighted and the alarm horn in ALM (1) sounds for ten seconds maximum. Voltage adjust rheostat (VAR) (3) is used to adjust generator voltage to the desired level. Optional governor switch (GS) (4) is used to raise and lower engine speed when the governor has a speed adjust motor. If an electronic governor is used, a speed control potentiometer (SP) is mounted in this location.

Start Aid Switch

Start aid switch (SAS) (5) is an option that is present only on required generator sets. Two types SAS (5) exist:

Manual SAS - for metered shot ether start aid systems.

Automatic SAS - for continuous flow ether start aid systems.

On manual SAS types, when the SAS is placed and held in the ON position (momentary contact), the metered shot ether start aid system is activated. A specific amount of ether is metered into a holding chamber. When the SAS is released, a solenoid allows ether to flow to the engine. The metered shot ether start aid system deactivates when:

The contacts of the crank termination relay (CTR) open at an engine speed of approximately 400 rpm.

Or the engine coolant temperature is sufficient to open the start aid temperature switch (SATS).

Or the SAS is released.


NOTICE

Crank the engine before activating (SAS in ON position) the metered shot ether start aid system. Damage to the system is possible by activating the system when the engine is not turning.


On automatic SAS types, the continuous flow ether start aid system operates in the automatic or the manual mode. When the SAS is placed in the AUTO position, the automatic mode is activated. The system automatically injects ether only during the crank cycle. When the SAS is placed and held in the MAN position (momentary contact), the manual mode is activated. This allows the operator to control the amount of time ether is injected during cranking. The manual mode also allows the operator to inject additional ether after crank termination (used on cold running engines which continue to detonate). The continuous flow ether start aid system deactivates when:

The contacts of the crank termination relay (CTR) open at an engine speed of approximately 400 rpm (automatic mode only).

Or the engine coolant temperature is sufficient to open the start aid temperature switch (SATS).

Or the SAS is returned to the OFF position.

Engine Control Module (ECM)


Engine Control Module (ECM)
(7) Switch (display hold switch). (13) Display LCD. (14) Overcrank LED. (15) Low oil pressure LED. (16) Overspeed LED. (17) Emergency stop LED. (18) Overtemperature LED. (19) Reverse power LED.

The right side of the control panel contains engine control module (ECM) (6). This is the "brain" of the system and also displays fault conditions and key engine parameters.

Engine control module (ECM) (6) accepts information from the operator, magnetic speed pickup (MPU), pressure/temperature module and optional remote sources. This information is used to determine the "on/off" state of the engine's air, fuel and starting motor.

In the very basic operating conditions, the ECM receives a signal to run the generator set. The ECM then turns on the engine's fuel and starting motor. When the engine speed reaches the crank termination speed, the starting motor is disengaged. When the ECM receives a signal to stop the engine, it shuts the fuel off.

Features of the ECM are:

Cycle Crank - Programmable crank-rest-crank time periods (see Service Procedure A).

2301 Control - When the engine oil pressure increases past the low oil pressure setpoint, the ECM indicates to an electronic governor to increase the engine speed from idle to rated.

Cool Down - Upon receiving a signal to perform a normal shutdown, the ECM waits a preprogrammed amount of time and then the fuel control shuts the engine off.

Automatic Operation - While in the automatic mode, a remote initiate signal [when initiate contact (IC) closes] tells the ECM to start the engine. Upon loss of the signal, the ECM performs a normal shutdown.

Alarm Module Communication - The ECM transmits fault and alarm conditions to an alarm module.

Power Down - The electronic modular control panel (EMCP) system is designed to remove power from the ECM when the ECS is in the OFF/RESET position. On ETS systems, power down occurs approximately 70 seconds after 0 rpm is reached. On ETR systems, power down occurs immediately.

Fuel Solenoid Type - The ECM is programmed to work with either an energize to run (ETR) fuel system or an energize to shutdown (ETS) fuel system.

NOTE: For latching type fuel systems, the ECM is programmed in the ETS mode.

LED Display - Six LED's are located on front of the ECM to indicate overcrank shutdown, overspeed shutdown, low oil pressure shutdown, high coolant temperature shutdown, emergency stop and reverse power shutdown. The reverse power LED is a spare fault indicator when the reverse power relay option is not used.

Emergency Stop - If the ECM detects an emergency stop, the air and fuel control shut down the engine. LED (17) flashes.

Pressure/Temperature Module Malfunction - If the signal from the engine mounted oil pressure/temperature module is lost or unreadable, the fuel control relay (FCR) shuts down the engine and a diagnostic code is displayed. It is possible to program the ECM so that pressure/temperature module malfunctions are ignored (see Service Procedure A).

Speed Pickup Malfunction - If the ECM loses its magnetic pickup signal, the air and fuel control shut down the engine. A diagnostic code is displayed by the ECM.

Overcrank Protection - If the engine fails to start in a preprogrammed amount of time, the ECM halts the starting sequence and flashes LED (14). Another attempt at starting the engine is prevented until the ECS is turned to the OFF/RESET position.

Liquid Crystal Display (LCD) (13) - Service hours, engine speed, system battery voltage, engine oil pressure and engine coolant temperature are displayed in sequence in either English or metric units. Pressing switch (7) on the front of the ECM, stops the display on one of the engine parameters. Pressing the switch again resumes the display to normal sequencing. The display is also used to indicate diagnostic codes, to aid in troubleshooting. See Troubleshooting, Diagnosed Problems.

Lamp Test - When the ECM detects a lamp test, it turns ON all the LCD segments and LED's. If the lamp test signal lasts for more than 10 seconds, the ECM returns to normal operation.

Overspeed Protection - If the engine speed exceeds the overspeed setpoint, the air shut-off (if equipped) and fuel control solenoids shut down the engine. LED (16) flashes. The overspeed setpoint is lowered to 75% of its original value while the overspeed verify switch is depressed. To test the overspeed protection circuit, see Service Procedure H (Verify Overspeed Shutdown).

Low Oil Pressure Protection - If the engine oil pressure drops below the low oil pressure setpoint, the fuel control solenoid shuts down the engine. LED (15) flashes. There are two low oil pressure setpoints. One for when the engine speed is below the oil step speed. The other setpoint is for when the engine speed is above the oil step speed. See Service Procedure J (Verify Low Oil Pressure Shutdown).

High Coolant Temperature Protection - If the engine coolant temperature exceeds the high coolant temperature setpoint, the fuel control solenoid shuts down the engine. LED (18) flashes. See Service Procedure I (Verify High Coolant Temperature Shutdown).

ECM Sequence Of Operation (Normal Start-Stop)

Upon receipt of a signal to start, the ECM checks to assure that:

a. An emergency stop signal is not present.
b. All faults are reset.
c. All sensors are connected and operating properly.
d. No abnormal engine control switch signals are present.
e. The engine is not already running.
f. The ECM microprocessor is functioning properly.
g. The ECM is not in the programming mode.

The ECM does NOT allow the start sequence to begin and displays the proper diagnostic code when applicable, if an above fault condition exists. However, once the ECM is satisfied that conditions are normal, it energizes the starting motor relay (SMR) and run relay (RR).

For latching type fuel systems, when the starting motor magnetic switch (SMMS) is energized the latching fuel control solenoid (LFS) is also energized to turn the fuel ON. This momentary current flow through a special latch mechanism on the solenoid holds the solenoid in the ON position.

For energized to run (ETR) type fuel systems, the ECM also signals to turn on fuel (or the electronic governor) be energizing the fuel control relay (FCR) and run relay (RR).

If the cycle crank feature is enabled, the ECM automatically cranks-rests-cranks the engine for the adjusted time periods. If the generator set fails to start within the selected total crank time, the ECM executes an overcrank fault. If a fault condition occurs while the engine is cranking, the ECM terminates and locks out cranking. The ECM displays the applicable diagnostic code or lights the appropriate LED.

After the engine starts and has achieved the proper crank termination speed, the ECM de-energizes the starting motor by de-energizing SMR and energizes the crank termination relay (CTR). Once safe low idle speed oil pressure is achieved, the ECM signals the optional electronic governor to accelerate the generator set to rated speed, by energizing the 2301 relay.

The generator set runs as long as operating conditions remain normal and a signal to run is received by the ECM. The digital display of the ECM shows in sequence (each for a two second period): the engine lube oil pressure, water temperature, RPM, service hours and system DC volts. At the same time, the ECM monitors for any fault or abnormal conditions.

Upon loss of the run signal, the engine continues to run for an adjustable cool down period if the cool down feature is utilized. However, if the cool down feature is not used or if the ECM receives an off/reset signal, it immediately de-energizes the run relay. For energize to shutdown (ETS) and latching type fuel systems, the fuel circuit is energized at this point. For energized to run (ETR) type (or 2301) fuel systems, the fuel circuitry is de-energized.

If the signal to run returns before the engine stops, on ETR and ETS fuel systems, the ECM immediately goes back to the running state. The fuel is turned back ON, but the starting motor does not energize. For latching type fuel systems, fuel is not turned ON because the fuel solenoid does not latch without energizing the starting motor relay (SMR).

If restart does not occur, RPM continues to drop and a run signal is present, the ECM initiates cranking upon reaching zero rpm. Assuming that the run signal does not return and the engine speed continues to diminish until zero rpm is reached, the crank termination relay (CTR) de-energizes. Now the ECM and fuel control relay (FCR) are ready for an instant restart. For energize to shutdown (ETS) and latching type fuel systems, the fuel control relay (FCR) of the ECM de-energizes 70 ± 10 seconds after zero rpm is reached and engine oil pressure is zero or immediately upon receiving a signal to run.

ECM Sequence Of Operation (Fault Conditions)

If a fault condition occurs prior to starting the generator set the ECM:

a. De-energizes and locks out the starting motor circuit.
b. Assures that fuel is shut off.
c. De-energizes the run relay (RR) circuit.
d. Energizes the fault shutdown circuitry, including the engine failure relay (ENFR).

If a fault condition occurs while the generator set is running, the ECM:

a. Shuts off fuel.

For energized to run (ETR) engines, the fuel control circuitry is de-energized.

For energized to shutdown (ETS) and latching engines, the fuel control circuitry is energized. Then de-energized 70 ± 10 seconds after the engine reaches zero rpm.

b. Shuts off air. Air shutoff relay (ASR) is energized for: an overspeed, emergency stop, diagnostic codes 01, 04, 06 or if all six LED's are ON. The ASR is also energized if the engine remains running 10 seconds after the fuel is shut off. The ASR circuitry is de-energized 15 to 20 seconds after the engine reaches zero rpm.
c. Locks the starting motor relay (SMR) circuitry in the de-energized state.
d. De-energizes the run relay (RR) circuitry.
e. Energizes the fault shutdown circuitry, including the engine failure relay (ENFR).

If a fault occurs before or after the engine starts, the appropriate fault indicating LED flashes at 2 Hz or a diagnostic code is displayed to indicate the nature of the problem. The indicators remain on and the ECM remains in the fault mode until it receives a reset signal.

Control Panel Sequence Of Operation

NOTE: The ECM and ALM do NOT turn off. If desired, battery drain is decreased by modifying the wiring of the ECS. When modified, the ECM and ALM turn OFF when the ECS is in the OFF/RESET position. To modify the wiring, remove the jumper wire which connects terminals 9 and 6 of the ECS. See the DC schematic (line 38) in the Schematics And Wiring Diagrams section.

Normal Start-Stop Sequence

The four positions of the engine control switch (ECS) are: AUTO, RUN (MANUAL), COOL DOWN/STOP and OFF/RESET. The generator set cranks, terminates cranking and runs if: the ECS is in the AUTO position and a signal to run is received from a remote initiate contact (IC), or if the ECS is placed in the RUN position. If necessary and if the cycle crank feature is utilized, the generator set cycle cranks. Generator sets equipped with electronic governors run at low idle speeds until lube oil pressure has exceeded the low idle speed oil pressure setpoint. Then the 2301 relay contact of the ECM closes and the engine accelerates to rated speed. Generator sets with hydra-mechanical governors accelerate to rated speed immediately after crank termination.

When the generator is running, the ACM displays amps, volts and frequency. The operator makes voltage and frequency adjustment. The generator set runs until the signal to run is removed by either turning the engine control switch to COOL DOWN/STOP, OFF or the remote initiate contact (IC) opens. Once the ECS is moved to the OFF position, the generator set shuts down immediately. However, if the ECS is placed in the COOL DOWN/STOP position, or if in the AUTO position and the remote initiate contact opens, the generator set runs for a short time in the cool down mode, if the cool down feature was utilized. Otherwise, the generator set shuts down immediately. The generator set is then capable of immediate restart.

During a normal start, run, stop sequence of operation, the other optional features/functions operate as follows:

a. Prior to cranking, all displays are activated.
b. Prior to crank termination the ether start aid circuit is activated. The start aid switch (SAS) is now used by the operator to inject ether into the engine.
c. After crank termination:

The ether start aid circuit is deactivated, preventing ether injection.

The governor raise-lower switch (GS) circuit is activated, allowing changes to the governor speed setting.

The auxiliary relay is energized, to switch on customer high power loads such as exhaust fans.

NOTE: On engines equipped with continuous flow ether start aid systems and the automatic start aid switch (SAS), the operator is allowed to inject ether after crank termination.

Pressure/Temperture Module

The pressure/temperature module receives engine coolant temperature and engine oil pressure information. The pressure/temperature module then sends engine coolant and engine oil pressure information to the ECM.

There are two different pressure/temperature modules: earlier and current.

Earlier Pressure/Temperature Module


Earlier Pressure/Temperature Module
(1) Connector to EMCP. (2) Connectors to coolant temperature sensor. (3) Oil line to engine.

On earlier pressure/temperature modules, the engine oil pressure transducer mounts within the module. Oil line (3) connects the transducer to the engine. Wires connect the module to the engine coolant temperature sensor and the EMCP.

Current Pressure/Temperature Module


Current Pressure/Temperature Module
(1) Connector to EMCP. (2) Connectors to coolant temperature sensor. (3) Connector to engine oil pressure sensor.

On current pressure/temperature modules, the engine oil pressure transducer is NOT mounted within the module. Wires connect the module to the engine oil pressure sensor. The engine oil pressure sensor contains the transducer and mounts to the engine. Wires also connect the module to the engine coolant temperature sensor and the EMCP.

Optional Modules

Synchronizing Lights Module


Synchronizing Lights Module
(1) Synchronizing lights. (2) Synchronizing switch.

The optional synchronizing lights (SL) module is located on the control panel face (same location as for the optional alarm module). The SL module is not used when the panel is equipped with an electronic governor.

Synchronizing lights (SL) are used as an aid in manually paralleling generator units independent of load. Each of two lights are connected across the generator to the load side of the generator output circuit breaker. The voltage of two phases are measured and the lights indicate when the voltages are in phase. When the voltages are in phase, closing the circuit breaker puts the generator on-line with the other generator unit(s).

NOTE: For a complete explanation on how to parallel two units, make reference to the Operation and Maintenance Manual for SR4 Generators and Control Panels, Form No. SEBU6150.

Synchronizing Module Installation

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

To avoid electrical shock and personal injury, shut down all on-line generator sets before installing or repairing the synchronizing module.

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

NOTE: For connection of the synchronizing light module and connection of resistor taps in the module, see the Main Chassis Wiring Diagram in the Schematics And Wiring Diagrams section.

Make an orderly shut down of all generators connected to the system. Then connect synchronizing module wires to the terminals as follows:

a. Wire L1 to control panel terminal (L1).
b. Wire L3 to control panel terminal (L3).
c. Wire T11 to the load side of fuse F11.
d. Wire T13 to the load side of fuse F13.

The customer is responsible for providing proper wire and fusing to connect L1 and L3 to the load side of the generator output circuit breaker. Refer to the AC Schematic in the Schematics And Wiring Diagrams section.

Adjust the connection of wires T11 and T13 on the taps of synchronizing resistors (SLR1) and (SLR2) respectively as required for the particular generator AC voltage. Refer to the following chart and the Main Chassis Wiring Diagram in the Schematics And Wiring Diagrams section.


Synchronizing Resistor Tap Connection Chart

NOTE: Remove the synchronizing module cover for access to the resistor taps.

Example: For a generator with 400 volts line to line, T11 and T13 are connected to tap B on the respective SLR.

Synchronizing Lights Module - With Reverse Power Relay

NOTE: The synchronizing lights module (with reverse power relay) option looks and operates the same as the module without the reverse power relay with the exception of:

a. The reverse power relay (RPR) mounted on the control panel subpan.
b. The reverse power fault LED mounted on the front of the ECM.

For information on the synchronizing lights module, make reference to the previous section on the Synchronizing Lights Module.

Introduction

The reverse power relay (RPR) provides system protection when the generator set is in parallel with other units. If for some reason the engine loses power, the other parallel unit attempts to motorize (drive electrically) the engine and generator. As long as voltage is present at the generator leads, the voltage regulator maintains the field excitation. The engine and generator remain magnetically coupled and the generator then drives the engine. Instead of power going OUT, power flows INTO the failing generator. This reverse flow of power could possibly result in overloading of the other generators and the whole system.

The reverse power relay (RPR) is a single phase relay which is energized by power (amp-volts) in only one direction (power into generator instead of out). In a reverse power fault, the relay (RPR) (located on AC Schematic) closes its contact across RPR (5 and 6) (line 19) (located on DC Schematic). This causes the engine to shut down. If the generator output breaker is equipped with shunt trip, the generator is taken off line. See the Schematics And Wiring Diagrams section.

After the reverse power fault is corrected, the control is reset by turning the engine control switch (ECS) to the OFF/RESET position. Also reset the generator output breaker if equipped with shunt trip.

The operation of the RPR is tested by pushing the test button on the RPR while the generator is on load. Depress and hold the test button for 10 to 15 seconds (until time delay elapses).

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

To avoid personal injury from electrical shock, do NOT touch the high voltage terminal while adjusting the reverse power relay.

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

The relay trip point is field adjustable, but is normally factory set at approximately 15% of the generator rated kW (for on-line generators operating at 15% or more of rated kW).

Alarm Modules


Alarm Module (NFPA 110 ALM)
(1) Amber LED's. (2) Red LED's. (3) Horn. (4) Acknowledge/silence switch.

The alarm module (ALM) is an attachment located on the control panel face. Red LED's (2) and amber LED's (1) are the visual indicators. Horn (3) is the audible indicator.

There are four versions of the basic module. The modules are either alarm modules or a remote annunciator. The nomenclature remote annunciator is required but, it is the same basic module. The versions are:

* Standby NFPA 99 alarm module.
* NFPA 99 remote annunciator, used with standby NFPA 99 alarm module.
* Standby NFPA 110 alarm module, used with NFPA 110 remote annunciator panel. See Remote Annunciator Panel (NFPA 110).
* Prime power alarm module.

The only differences between these modules is in the graphics film on the front of the panel and the jumper wires on the rear. See the DC schematic in the Schematics And Wiring Diagrams section. The NFPA 99 remote annunciator also has a lamp test switch. The following description of operation refers to the alarm/remote annunciator module as the annunciator module.

The purpose of the alarm modules (ALM) is to give a warning of conditions that are becoming a problem before conditions are bad enough to shut down the engine or keep it from starting.

If, with the ECS in the COOL DOWN/STOP or AUTO positions, an alarm condition develops prior to or while the generator set is running, that condition is indicated by the optional alarm module and/or the remote annunciator.

Description Of Operation

NOTE: In the following description the word annunciator is used to mean either alarm module or remote annunciator module.

The annunciator module receives data from three sources: switch inputs, internal circuitry, and a serial data link from the engine control module.

Switch Inputs

Up to four inputs are available for switch (i.e., Low Fuel Level) connections. Switch inputs are activated when connected to battery negative (-B). See Table 1.

Internal Circuitry

Internal circuitry is used to determine and annunciate if the DC battery supply voltage is below the setpoint (factory set at 24 DCV).

Data Link

The annunciator module receives data from the engine control module by a serial data link. The items included in this data stream of information are:

1 - Coolant temperature has exceeded the high temperature alarm setpoint programmed into the engine control module.
2 - Oil pressure is below the low oil pressure alarm setpoint programmed into the engine control module.
3 - Coolant temperature is below the low temperature alarm setpoint programmed into the engine control module.
4 - The engine control switch is not in the AUTO or RUN position.
5 - Oil pressure is below the low pressure shutdown setpoint programmed into the engine control module.
6 - Coolant temperature has exceeded the high coolant temperature shutdown setpoint programmed into the engine control module.
7 - The engine failed to start (overcrank).
8 - The engine speed exceeded the overspeed setpoint programmed into the engine control module.
9 - The engine shut down due to a remote fault condition.
10 - The engine shut down due to a spare fault condition.
11 - The engine shut down due to an emergency stop condition.
12 - The engine shut down due to a diagnostic fault condition.

Data items 1 through 8 control the operation of the LED's and the horn as indicated in Table 1. Data items 9 through 12 control the operation of the horn only.

The maximum number of modules, alarm or CIM, connected to the serial data link is three. The maximum distance between a module and the ECM is 305 m (1000 ft).

LED And Horn Operation

When an alarm condition occurs, the LED corresponding to that condition flashes at 2 hertz and the horn sounds. If the alarm condition is NOT LATCHED, the LED and horn turn off as soon as the alarm condition ceases. If the alarm condition is LATCHED, the LED continues to flash until the acknowledge/silence input is activated. See Table 1 for LATCHED alarm conditions and the LED and horn functions for each operating mode.

Normally switch input 3 (terminal 10) and switch input 4 (terminal 11) only operate LED's 7 and 8. However, it is possible for switch inputs 3 and 4 to also operate the horn. To do so, connect terminal 10 (sw input 3) to terminal 3, and connect terminal 11 (sw input 4) to terminal 4.

Acknowledge/Silence

Activating the acknowledge/silence switch (4) causes the horn to cease and the LED to stay on continuously.

Data Link Malfunction

If the data link malfunctions, the LED's controlled by the data link flashes at 0.5 hertz. The switch controlled LED's function normally.

Lamp Test

Activating the lamp test switch results in sounding the horn and turning on all LED's continuously for 10 seconds or until the switch is deactivated.

Mode Selection

The annunciator module operates in one of the five modes described in Table 2. The modes are selected by connections made to the mode select inputs (terminals 5 and 6) and switch 2 input (terminal 9) as shown in Table 2.

Remote Annunciator Panel - NFPA 110


Alarm Module (NFPA 110 ALM)
(1) Amber LED's. (2) Red LED's. (3) Horn. (4) Acknowledge/silence switch.


NFPA 110 Remote Annunciator Panel
(5) Trouble light. (6) Horn. (7) Acknowledge/silence switch.

This remote panel functions in conjunction with the NFPA 110 alarm module. The alarm module is mounted in the left side of the control panel. When an alarm occurs on the alarm module or a fault occurs on the ECM, horns (3) and (6) sound in both the alarm module and the remote annunciator. Trouble light (5) lights in the remote annunciator panel. The appropriate alarm LED also lights in the alarm module or the appropriate fault LED lights in the engine control module (ECM).

When alarm acknowledge/silence switch (4) or (7) is pressed on either the remote panel or the alarm module, the horns on both cease sounding. Also, trouble light (5) on the remote panel goes out. The LED on the alarm module or ECM remains on. Another fault or alarm condition reactivates the horns, LED and light as before.

Trouble light (5) also acts as a test switch on the remote panel. When light (5) is pushed, horn (6) and light (5) turn on. The alarm module is not affected by the test switch.

Customer Interface Module (CIM)


Customer Interface Module (CIM)
(1) Relay board. (2) Electronic control.

Reference: For more information, see the Schematics And Wiring Diagrams section.

The CIM provides an interface (separate relay contacts) between the ECM and switchgear. The two major components of CIM are relay board (1) and electronic control (2). Electronic control (2) connects to the same serial data link as the alarm annunciator. CIM operation is similar to the alarm annunciator except that the data link information is decoded into discrete outputs. The outputs then drive the relays located on relay board (1). The relay contacts are used to sound a horn, flash a lamp or trigger some other action. Once an output is activated, it remains energized until the initiating conditions are cleared. If a malfunction in the serial data link occurs, all electronic control outputs (therefore all relays also) flash at 0.5 Hz.

The available serial data link information is:

- High coolant temperature alarm.
- Low oil pressure alarm.
- Low coolant temperature alarm.
- Engine control switch (ECS) NOT in auto.
- Low oil pressure shutdown.
- High coolant temperature shutdown.
- Overcrank.
- Overspeed.
- Diagnostic failure (ECM).

Application Guidelines

Lamp Test

When a lamp test signal is received, the CIM activates all outputs for 10 seconds or until test signal is deactivated. Two lamp test signals are possible, the CIM lamp test is activated when:

Terminal 5 is connected to terminal 7 of electronic control (2).

The ECM lamp test signal is received over the data link.

NOTE: CIM ignores the ECM lamp test signal when terminal 6 is connected to terminal 7 of electronic control (2).

Outputs:

- The relays on relay board (1) are fuse protected. The contacts are flashed silver and are rated at 1 amp 28 DCV. The relays draw 20 mA (at 24 DCV).
- The driver outputs of electronic control (2) are intended to drive incandescent lamps or relay loads. The driver outputs sink up to 600 mA (15 - 45 DCV).

Specifications:

- For CIM installation, the maximum distance between electronic control (2) and the ECM is 305 m (1000 ft).
- The operating voltage range is 15 to 45 DCV (24 DCV nominal)
- CIM is capable of operating with or without earth ground.
- The terminals on electronic control (2) are 6.4 mm (.25 in) push-on connectors.
- Customer connections at relay board (1) are 6-32 screw terminals.

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