ELECTRONIC MODULAR CONTROL PANEL (EMCP) FOR RENTAL GENERATOR Caterpillar


Systems Operation

Usage:

Components Location


Control Panel Face 3300 Family - 480 Volt
(1) ACM; AC meter module. (2) VAR; voltage adjust rheostat. (3) ECM; engine control module. (4) Switch; display hold switch. (5) PLS; panel light switch. (6) LTS; lamp test switch. (7) AVS; ammeter voltmeter phase selector switch. (8) ESPB; emergency stop push button. (9) ECS; engine control switch.


Control Panel Face 3300 Family - 600 Volt 3400 Family - 480 and 600 Volt
(1) ACM; AC meter module. (2) VAR; voltage adjust rheostat. (3) ECM; engine control module. (4) Switch; display hold switch. (5) PLS; panel light switch. (6) LTS; lamp test switch. (7) AVS; ammeter voltmeter phase selector switch. (8) ESPB; emergency stop push button. (9) ECS; engine control switch.


Control Panel Interior 3300 Family - 480 and 600 Volt 3400 Family - 480 and 600 Volt
(1) ACM; AC meter module. (2) VAR; voltage adjust rheostat. (3) ECM; engine control module. (5) PLS; panel light switch. (6) LTS; lamp test switch. (7) AVS; ammeter voltmeter phase selector switch. (8) ESPB; emergency stop push button. (9) ECS; engine control switch. (10) Fuses; F1 through F8. (11) Switch; overspeed verify. (12) Fuses; F9 through F14 for 3300 family, F9 through F11 for 3400 family. (13) TBC; terminal board C. (14) SMMS1; starter motor magnetic switch one. (15) CB; circuit breaker. (16) TS1; terminal strip 1, terminals 1 through 12. (17) TS2; terminal strip 2, terminals 13 through 30.

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

Operation


Control Panel Face - Typical
(1) ACM; AC meter module. (2) VAR; voltage adjust rheostat. (3) ECM; engine control module. (4) Switch; display hold switch. (5) PLS; panel light switch. (6) LTS; lamp test switch. (7) AVS; ammeter voltmeter phase selector switch. (8) ESPB; emergency stop push button. (9) ECS; engine control switch.


EMCP For Rental Generator Sets - Typical

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

Control Panel Face

Control switches ESPB (8) and ECS (9) are located below AC meter module (1). When red ESPB (8) 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 (8) is engine control switch (ECS) (9).

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 turns OFF when the ECS is in the OFF/RESET position.

Below ACM (1) is a row of control switches. Panel light switch (PLS) (5) turns ON and OFF the panel lamps. Lamp test switch (LTS) (6) turns ON all the control panel indicators, when in the TEST position. All lamps and display segments (display show all 8's) in ECM (3) and ACM (1) are lighted. Voltage adjust rheostat (VAR) (2) is used to adjust generator voltage to the desired level.

Engine Control Module (ECM)


Engine Control Module (ECM) - Typical
(3) ECM; engine control module. (4) Switch; display hold. (10) LCD display. (11) Overcrank LED. (12) Low oil pressure LED. (13) Overspeed LED. (14) High coolant temperature LED. (15) Emergency stop LED. (16) Reverse power LED.

The right side of the control panel contains engine control module (ECM) (3). This is the "brain" of the system and also displays fault conditions and key engine parameters.

Engine control module (ECM) (3) 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).

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.

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. For ETS systems, power down occurs approximately 70 seconds after 0 rpm is reached.

Fuel System Type - The ECM is programmed to work with an energize to shutdown (ETS) fuel system.

LED Display - Six LED's are located on the 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 (15) 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 Malfuction - If the ECM loses the 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 (11). Another attempt at starting the engine is prevented until the ECS is turned to the OFF/RESET position.

LCD Display (10) - 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 (4) on the front of the ECM, stops the display at 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 LED's and all segments of the LCD display. 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 (13) FLASHES. The overspeed setpoint is lowered to 75% of the original value while the overspeed verify switch is depressed. To test the overspeed protection circuit, see Service Procedure G (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 (12) 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 I (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 (14) FLASHES. See Service Procedure H (Verify High Coolant Temperature Shutdown).

ECM Sequence Of Operation (Normal Start-Stop)

Upon receipt of a signal to start, the ECM checks to make sure 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.

If an above fault condition exists, the ECM does NOT allow the start sequence to begin and displays the proper diagnostic code when applicable. However, once the ECM is satisfied that conditions are normal, it energizes the starting motor relay (SMR) 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 generator set accelerates to rated speed.

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 and the fuel circuit is energized.

If the signal to run returns before the engine stops, the ECM immediately goes back to the running state. The fuel is turned back ON, but the starting motor does not energize.

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. 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. Makes sure 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. 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

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. The hydra-mechanical governor accelerates the generator set 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/RESET or the remote initiate contact (IC) opens. Once the ECS is moved to the OFF/RESET position, the generator set shuts down immediately. However, if the cool down feature is utilized and the remote initiate contact opens when the ECS is in the COOL DOWN/STOP or the AUTO position; then the generator set continues to run for a short time. 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, all displays are activated prior to cranking.

AC Meter Module (ACM)

AC meter module (ACM) (1) 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) (7) is used to select the phase of the volts and amps that are displayed on ACM (1). 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 of 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 ACM.

Pressure/Temperature Module


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

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. Wiring and connectors (1), (2) and (3) link the module to the sensors and the EMCP.

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