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Title: Caterpillar Emcp 2 Manual Author: reliefwatch.com Subject: Download Caterpillar Emcp 2 Manual - EMCP II Alarm Module Remote Annunciator Serial Data Link Cat Data Link EMCP II SPECIFICATIONS EMCP II SYSTEM HIERARCHY DRAWING CIM (maximum of 3 modules) CCM EMI Immunity IEC 801-2, IEC 801-3, IEC 801-4, EN 5082-2 Enclosure NEMA 1, IP22 Humidity 0 to 100% relative humidity Impervious to: salt. Oct 15, 2018 The Cat® EMCP 4.2B offers fully featured power metering, protective relaying and engine and generator control and monitoring. Engine and generator controls, diagnostics, and operating information are accessible via the control panel keypads; diagnostics from the EMCP 4 optional modules can be viewed and reset through the EMCP 4.2B. 2.2 Complete installation with the 'Web Gate' function connection Figure 2: Complete Installation If the EMRP3 is directly supplied by the batteries of the generator set, add a voltage regulator 24VDC/24VDC and that. EMCP II Alarm Module Remote Annunciator Serial Data Link Cat Data Link EMCP II SPECIFICATIONS EMCP II SYSTEM HIERARCHY DRAWING CIM (maximum of 3 modules) CCM EMI Immunity IEC 801-2, IEC 801-3, IEC 801-4, EN 5082-2 Enclosure NEMA 1, IP22 Humidity 0 to 100% relative humidity Impervious to: salt spray, fuel, oil and oil additives, coolant.
Usage:
Control Panel 145-9410 or 145-9411
(1) GSC; generator set control. (2) GS; governor switch or SP; speed potentiometer (optional). (3) SAS; starting aid switch (optional). (4) ECS; engine control switch. (5) ALM; alarm module (optional). (6) CAM; custom alarm module (optional) or SLM; synchronizing lights module (optional). (7) PLS; panel light switch (optional). (8) ESPB; emergency stop push button. (9) VAR; voltage adjust rheostat.
This Owner's Manual covers two types (ETR and ETS) of Electronic Modular Control Panel II (EMCP II) for field installation. Each EMCP II can be identified by the part No. which is located on a nameplate attached to the inside floor of the control panel.
- *145-9410 EMCP II, used with engines that have an energized to run (ETR) type of fuel system.
- *145-9411 EMCP II, used with engines that have an energized to shutoff (ETS) type of fuel system.
The Electronic Modular Control Panel II (EMCP II) is located on top of the generator distribution housing. The control panel consists of a main panel with indicators, meters and control switches. This control panel may be equipped with optional modules to match the customers needs and requirements. The left side of the control panel contains the Generator Set Control (GSC). This is the 'main' component of the system and also displays generator output, fault conditions and key engine parameters.
Generator set control (GSC) (1) - See the topic Generator Set Control in this section.
Speed potentiometer (SP) or governor switch (GS) (2) - optional - The governor switch is used to raise or lower the engine speed and frequency when the governor is equipped with a speed adjust motor. If the engine is equipped with an electric governor, a speed potentiometer is mounted in this location.
Starting aid switch (SAS) (3) - optional - The starting aid switch is used to inject ether into the engine for starting in cold weather conditions. This switch (when moved to the ON position) energizes the starting aid solenoid valve (SASV) and meters a specific amount of ether in a holding chamber. When the switch is released, the solenoid releases the ether to the engine.
NOTICE |
---|
Crank the engine before activating (keep SAS in OFF position) the metered shot start aid system. Damage to the engine is possible by activating the system when the engine is not turning. |
Engine control switch (ECS) (4) - The engine control switch determines the status of the control panel. In the Automatic position (3 o'clock), the engine will start automatically whenever a remote initiating contact is closed. The engine will shutdown after the initiating contact opens and after a programmable cooldown time has elapsed. The cooldown time can be programmed to give a 0 to 30 minute cooldown period before the engine shuts down.
In the Manual Start position (6 o'clock), the engine will start and run as long as the ECS switch remains in this position.
In the Stop position (9 o'clock), the fuel solenoid shuts the engine down, after a programmable cool down time period has elapsed.
In the Off/Reset position (12 o'clock), the fault lights are reset and the engine shuts down immediately.
Alarm module (ALM) (5) - optional - The function of the alarm module is to provide a visual and audible warning of engine conditions before they become severe enough to shut the engine down or keep it from starting.
Custom alarm module (CAM) (6) - optional - The purpose of the custom alarm module is to annunciate faults, alarms or other conditions from customer supplied inputs.
Panel light switch (PLS) (7) - The panel light switch turns the panel lights ON or OFF.
Emergency stop push button (ESPB) (8) - The emergency stop push button is used to shut down the engine during an emergency situation by shutting off the fuel and activating the optional air shutoff (if equipped).
Voltage adjust rheostat (VAR) (9) - The voltage adjust rheostat is used to adjust the generator output voltage to the desired level.
Generator Set Control (GSC)
The left side of the control panel contains the Generator Set Control (GSC). This is the 'main' component of the system, and also displays generator output, generator set functions, fault conditions and key engine parameters.
The GSC accepts information from the operator, magnetic pickup, oil pressure and water temperature sensors, and optional remote sources. This information is used to determine the 'on/off' state of the engine's air, fuel, and starter.
In the very basic operating conditions, the GSC receives a signal to run the generator set. The GSC turns on the engine's fuel and starter. When the engine speed reaches the crank termination speed, the starter is disengaged. When the GSC receives a signal to stop the engine, it shuts the fuel off.
GSC Features And Functions
For the wiring diagram and jumper wire location, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
Fault Indicators
The eight fault indicators, located on the front of the GSC, are used to show and describe a fault that is present.
- * The yellow fault alarm indicator FLASHES when the GSC detects a fault that is an alarm condition. The engine continues to run and start. The fault alarm indicator is accompanied by an alarm fault code that is shown on the upper display when the alarm codes key is pressed. For fault code descriptions, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
- * The red fault shutdown indicator FLASHES when the GSC detects a fault that is a shutdown condition. The engine is shutdown if it is running and it is not allowed to start. The fault shutdown indicator is accompanied by a diagnostic fault code that is immediately shown on the upper display. For fault code descriptions, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
- * The six red dedicated shutdown indicators represent the following shutdown conditions: low oil pressure, emergency stop, high water temperature, engine overspeed, low coolant level, and engine overcrank. When the GSC detects a fault in one of these conditions, the dedicated shutdown indicator (that corresponds to the fault) FLASHES. The engine is shutdown if it is running and it is not allowed to start.
There are no fault codes associated with the dedicated shutdown indicators because each indicator has an interpretive label. The conditions required for each dedicated fault and the results of each dedicated fault are as follows:
Low Oil Pressure (1) - The engine oil pressure drops below the setpoints for low oil pressure shutdown that are programmed into the GSC. There are two low oil pressure setpoints, one for when the engine is operating at idle speed and the other for when the engine is at rated speed. The low oil pressure indicator FLASHES, the engine is shutdown and it is not allowed to start.
Emergency Stop (2) - The operator presses the emergency stop push button (ESPB) on the instrument panel. The emergency stop indicator FLASHES, the engine is shutdown and it is not allowed to start.
High Water Temperature (3) - The engine coolant temperature rises above the setpoint for high water temperature shutdown that is programmed into the GSC. The high water temperature indicator FLASHES, the engine is shutdown and it is not allowed to start.
Engine Overspeed (4) - The engine speed exceeds the setpoint for engine overspeed that is programmed into the GSC. The engine overspeed indicator FLASHES, the engine is shutdown and it is not allowed to start.
Low Coolant Level (5) - The engine coolant level drops below the probe of the optional coolant loss sensor. The engine coolant level indicator FLASHES, the engine is shutdown and it is not allowed to start.
Overcrank (6) - The engine does not start within the setpoint for total cycle crank time that is programmed into the GSC. The overcrank indicator FLASHES and the engine is not allowed to start.
NOTE: The GSC can be programmed to override the shutdown for low oil pressure, high water temperature, and the low coolant level faults. When overridden, these faults are treated as alarm conditions. The corresponding dedicated shutdown indicator is ON CONTINUOUSLY (instead of flashing) and the engine continues to run and start (instead of shutting down).
The dedicated shutdown indicator that is ON CONTINUOUSLY means that the setpoint for shutdown has been exceeded, but the GSC is programmed to override the shutdown condition and treat the fault as an alarm condition. As provided from the factory, the GSC treats low oil pressure, high water temperature and low coolant level as shutdowns. For programming procedures, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
Display
Upper display (1) and lower display (2) of the GSC provide information about the generator set.
- * Upper display (1) shows AC voltage, current, and frequency of one phase of the generator output. Each phase can be viewed one at a time by pushing phase select key (4). Upper display (1) is also used to show the various fault codes for system faults. For more information on fault codes, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
- * Lower display (2) shows system battery voltage, engine hours, engine speed, engine oil pressure, and engine coolant temperature. The value for one of these conditions is shown for two seconds and then the display scrolls to the value for the next condition. A small pointer identifies the engine condition that corresponds to the value that is showing. When the engine meter key (3) is pressed, the lower display (2) stops scrolling and continuously shows one particular value. Now the pointer flashes above the condition whose value is showing. When engine meter key (3) is pressed a second time, the display (3) will return to scrolling.
- * The relay status indicator is on the lower display also. When a GSC relay is activated, the corresponding relay indicator (K1, K2, etc.) is shown on the lower display (2). When a relay is not activated, the corresponding indicator (K1, K2, etc.) is not shown. For a description of the relay functions, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
Both displays are used for programming functions when in the service mode. For more information, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
Keypad
Keypad (3) is used to control the information that is shown on the upper display (1) and the lower display (2). The seven keys of keypad (3) have two sets of functions, normal functions and service functions. For a description of the service functions of the keys, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
The normal functions of the keys are:
Leftmost Key (4) - This key only functions when the GSC is in service mode. This key is used to scroll right.
Phase Select Key (5) - Selects which phase of the generator output is displayed on the GSC. Pressing this key allows the operator to check the voltage, current, and frequency of each phase one at a time.
Engine Meter Key (6) - Pressing this key stops the scrolling of engine conditions on the lower display (2). One particular engine condition continuously shows its value. The pointer for the particular engine condition flashes to indicate scrolling is stopped. Pressing the key again, resumes the scrolling of engine conditions.
Lamp Test Key (7) - Performs a lamp test on the GSC and the optional alarm module for a maximum of ten seconds, if held pressed. On the GSC: the eight fault indicators are ON CONTINUOUSLY, every segment of the upper display (1) and the lower display (2) are ON. On the optional alarm module: all of the indicators are ON and the horn sounds.
Alarm Codes Key (8) - If a fault alarm indicator (11) is FLASHING, pressing this key causes the upper display (1) to show the corresponding alarm fault code. Pressing this key again, resumes the showing of generator output information on the upper display (1). If the fault alarm indicator(s) (11) are OFF, this key has no function. For more information on alarm fault codes, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
Exit Key (9) - This key only functions when the GSC is in service mode. For more information on service modes, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
Service Mode Key (10) - Pressing this key causes the GSC to enter service mode. For more information on service modes, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
Synchronizing Lights Module (If Equipped)
Synchronizing Lights Module
(1) Synchronizing lights. (2) Synchronizing switch.
The optional synchronizing lights module is mounted on the right side of the control panel.
Synchronizing lights are used as an aid in paralleling units at no load and under load. Each of two lights are connected across the generator to the load side of the generator circuit breaker. Together, they indicate when the voltages are in phase so the circuit breaker can be closed to place the generator on line with the load.
For all wiring and installation information, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
Synchronizing Lights Module With Reverse Power Relay (If Equipped)
The synchronizing lights module with reverse power relay is the same as the synchronizing lights module with the following exceptions:
- * The reverse power relay is mounted on the control panel interior.
- * A reverse power fault is indicated by the Fault Shutdown Indicator on the front of the GSC.
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The reverse power relay is a single phase protective relay which is energized by power (amps-volts) in only one direction (power into generator instead of out). In a reverse power fault, the relay closes its contacts causing the engine to shutdown, taking the generator off line. The reverse power relay is equipped with a test switch and adjustments.
For additional information, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
Alarm Module (If Equipped)
The alarm module (optional) is located on the right side of the control panel. The function of the alarm module is to provide a visual and audible warning of engine conditions before they become severe enough to shut the engine down or keep it from starting.
One basic alarm module is used to satisfy the requirements of standby NFPA 99 alarm module, standby NFPA 110 alarm module, NFPA 99 remote annunciator panel, and prime power alarm. This is accomplished by using different inputs to the module, and different decals on the front of the module to indicate alarms or shutdown conditions.
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Refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines, for all wiring and installation information as well as a listing of Indicators and Alarm (Horn) functions to meet NFPA requirements for the application.
The front of the alarm module consists of:
- * Four amber indicators which can (depending on module configuration) indicate High Coolant Temperature, Low Coolant Temperature or Low Coolant Level, Low Oil Pressure, Generator On Load, Charger Malfunction, Low Oil Level and Low Fuel Level.
- * Four red indicators which can indicate a Not In Auto condition, Low DC Voltage, Air Damper Closed, Low Oil Pressure Shutdown, Overcrank Shutdown, High Coolant Temperature Shutdown, and Overspeed Shutdown.
- * An audible alarm and Acknowledge/Silence switch. For more detailed information, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
Custom Alarm Module (If Equipped)
The custom alarm module (CAM) (optional) is located on the right side of the control panel. The function of the alarm module is to provide a visual and audible warning of customer supplied inputs conditions before they become severe enough to shut the engine down or keep it from starting. The CAM is equipped with a horn, alarm silence switch, a lamp test switch and 8 switched inputs for customer use.
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For all wiring and installation information as well as input signal names, refer to the service manual SENR5809, Electronic Modular Control Panel II (EMCP II) For MUI Engines.
NOTE: A basic version of the CAM also exists. The basic version does not have a horn, an alarm/silence switch or a lamp test switch. The basic CAM is to be used with an existing fully equipped CAM or an existing alarm module (ALM).
The front of the alarm module consists of:
- * Four amber indicators are used to display alarm conditions.
- * Four red indicators are used to display shutdown conditions.
Usage:
Options can be retrofitted to the EMCP II+. The following optional items are available for purchase at the parts department. The items must be wired per the service manual SENR5832, Electronic Modular Control Panel II+ (EMCP II+) For MUI Engines. To complete the installation, it is the responsibility of the installer (dealer service personnel) to provide the miscellaneous terminals, wires, tie wraps and hardware. If there are any questions concerning the application of any options, refer to the service manual SENR5832, Electronic Modular Control Panel II+ (EMCP II+) For MUI Engines.
NFPA 99 Alarm Module
To determine the proper jumper configuration, refer to the service manual SENR5832, Electronic Modular Control Panel II+ (EMCP II+) For MUI Engines.
One 130-3349 Control Group
One 9Y-0947 Annunciator Film
NFPA 110 Alarm Module
To determine the proper jumper configuration, refer to the service manual SENR5832, Electronic Modular Control Panel II+ (EMCP II+) For MUI Engines.
One 130-3349 Control Group
One 7C-9130 Film
One 8C-4646 Jumper Strap
Prime Power Alarm Module
To determine the proper jumper configuration, refer to the service manual SENR5832, Electronic Modular Control Panel II+ (EMCP II+) For MUI Engines.
One 130-3349 Control Group
One 9Y-9776 Film
Custom Alarm Module With Horn
One 130-3332 Control Group
One 130-3326 Film
Emcp Ii
One 130-3327 Film
Custom Alarm Module Without Horn
One 130-3324 Control Group
One 130-3326 Film
One 130-3328 Film
2301A Governor Controller (4P-2788)
One 4W-5971 Potentiometer
One 4W-5972 Knob
One 4W-8790 Fuse Block
One 7C-4550 Seal - Rotating Shaft
One 7E-7845 Film - DC Fuse
One 7T-0037 Fuse
One 131-5453 Governor Control Assembly
Governor Raise/Lower Switch
One 7N-8008 Switch
524/1724 Governor Controller (7E-1232)
Starbound player space station. One 3K-3782 Fuse
One 4W-5972 Knob
One 4W-8790 Fuse Block
One 7C-4550 Seal - Rotating Shaft
One 7E-1246 Potentiometer
One 9Y-9782 Film - Identification
One 131-5455 Control Assembly
Starting Aid Switch
9D-3721 Switch, Manual SAS (2 position)
Overvoltage Relay
123-4944 Relay, 208 Volt
123-4945 Relay, 240 Volt
123-4946 Relay, 416 Volt
123-4947 Relay, 480 Volt
126-0558 Relay, 600 Volt
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Overcurrent Relay
112-7959 Relay, 3 Phase Overcurrent Relay
Reverse Power Relay
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5N-5510 Reverse Power Relay, 0-480 Volt
7C-4378 Reverse Power Relay, 600 Volt
Synchronizing Light Module
106-5171 Synchronizing Module Group, 0-480 Volt
106-5169 Synchronizing Module Group, 600 Volt
Dustproof Kit (121-4705)
Three 5L-5180 Washer - Sealing
Two 5L-5840 Washer - Sealing
Two 7C-2954 Gasket - Module
Two 7C-4550 Seal - Rot Sft
One 7C-4910 Seal - Washer
One 103-6272 Seal - Control
Auxiliary Or Engine Failure Relay
128-3326 Relay Group; 3PDT Relay, Socket, Spring
Remote Annunciators
These items are intended for remote mounting.
7E-8270 Instrument Panel Group, 2 Light NFPA 110
7C-5296 Instrument Panel Group, 8 Light NFPA 99 (Small Box)
131-1960 Instrument Panel Group, 8 Light CAM
131-1961 Instrument Panel Group, 16 Light CAM
131-1962 Instrument Panel Group, 8 Light NFPA 99 (Large Box)
131-1963 Instrument Panel Group, 16 Light NFPA 99
Emcp 4.2 Operation Manual
144-8325 Instrument Panel Group, 8 Light EMCP RAN
131-1965 Instrument Panel Group, 16 Light NFPA 110 (EMCP RAN & CAM)
Customer Interface Module (CIM)
This item is intended for remote mounting.
9Y-6496 Control Group
Customer Communication Module (CCM)
This item is intended for remote mounting.
117-6170 Control Group