Dokumen - Tips - Emcp 43 44

PPLIC TION ND INST LL TION GUIDE
EMCP 4.3, 4.4

GENERATOR SET CONTROL

Table of Contents
FOREWORD.........................................................................................................1
1 GENERAL INFORMATION .....................................................................1
1.1 INTRODUCTION...............................................................................................................1
1.2 APPLICATIONS ...............................................................................................................1
1.3 REFERENCES .................................................................................................................3
2 SAFETY INFORMATION.........................................................................4

2.1 ELECTRICAL SAFETY ......................................................................................................4
2.2 ELECTROSTATIC DISCHARGE AWARENESS .......................................................................4
3 INSTALLATION.......................................................................................5
3.1 MOUNTING LOCATION .....................................................................................................5
3.2 OPERATING T EMPERATURE RANGE ..................................................................................5
3.3 POWER REQUIREMENTS..................................................................................................5
3.4 BATTERY CHARGER .......................................................................................................6
3.5 ELECTRICAL CONNECTIONS ............................................................................................7
3.6 EUI ENGINES .................................................................................................................7
3.7 EMCP 4.3 AND 4.4 ELECTRICAL DIAGRAMS .....................................................................8
3.8 WINDING CONNECTIONS ...............................................................................................11
3.9 T RANSFORMER CONNECTIONS ......................................................................................12
3.10 WIRING REQUIREMENTS................................................................................................15
3.11 SHIELDED AND COMMUNICATION WIRING ........................................................................16
4 INITIAL OPERATION AND USER ORIENTATION...............................17
4.1 TYPES OF EVENTS ........................................................................................................17
4.2 USING THE CAT SERVICE T OOL .....................................................................................17
4.3 VIEWING SYSTEM PARAMETERS ....................................................................................19
Supported Parameters............................................................................................................ 19
Engine Overview .................................................................................................................... 20
AC overview........................................................................................................................... 22
Genset Overview.................................................................................................................... 24
Bus Overview (EMCP 4.4 Only) .............................................................................................. 24
4.4 VIEWING AND ADJUSTING PREFERENCES.........................................................................25
Setting The Preferences Using The EMCP 4 Display............................................................... 25
Changing the EMCP 4 Contrast When the Display is Unreadable............................................. 27
Changing The EMCP 4 Display to Technician English.............................................................. 27
Changing The EMCP 4 Display to the Primary Language......................................................... 28
Setting the Preferences Using the Service Tool ....................................................................... 28
4.5 CONFIGURING T IME /DATE .............................................................................................29
Changing The Time / Date...................................................................................................... 29
Changing Date Format............................................................................................................ 32
4.6 ADJUSTING GENERATOR SET PARAMETERS ...................................................................33
Generator Output Voltage....................................................................................................... 33
Engine Speed......................................................................................................................... 33
Idle/Rated............................................................................................................................... 35
Engine Sensor Versus Data link.............................................................................................. 36
Engine Oil Pressure................................................................................................................ 39
Engine Coolant Temperature .................................................................................................. 43

4.7 STARTING AND STOPPING THE GENERATOR SET .............................................................46

Starting The Engine................................................................................................................ 46

EMCP 4 Remote Start ............................................................................................................ 47

Stopping The Engine .............................................................................................................. 47

Emergency Stop..................................................................................................................... 49

EMCP 4 Remote Stop............................................................................................................. 51
4.8 ENGINE SETPOINT VERIFICATION ...................................................................................51
Procedure For Overspeed Verification..................................................................................... 51
Procedure For Low Oil Pressure Verification............................................................................ 52
Procedure For High Coolant Temperature Verification ............................................................. 52
4.9 ENGINE OPERATING HOURS ..........................................................................................53
Updating Engine Operating Hours........................................................................................... 53
5 HANDLING EVENTS .............................................................................55

5.1 CONFIGURING EVENT RESPONSES .................................................................................56
5.2 CHANGING AN EVENT RESPONSE CONFIGURATION .........................................................58
5.3 RESETTING I NDIVIDUAL ACTIVE EVENTS FOR THE EMCP 4...............................................61
5.4 RESETTING ALL ACTIVE EVENTS FOR A SINGLE MODULE .................................................63
5.5 RESETTING ALL ACTIVE EVENTS FOR ALL MODULES .......................................................64
5.6 RESETTING EVENTS FOR ENGINE ECMS WITHOUT PRIMARY CAN DATA LINK SUPPORT ......65
5.7 T ROUBLESHOOTING RESETTING EVENTS ........................................................................65
Not in Auto Warning................................................................................................................ 65
Service Maintenance Interval.................................................................................................. 66
6 SECURITY.............................................................................................70
7 SETPOINTS...........................................................................................74
7.1 CONFIGURING SETPOINTS .............................................................................................74
7.2 SETPOINT SUB-MENUS .................................................................................................76
7.3 SETPOINTS ON THE CAT SERVICE T OOL..........................................................................76
Setpoint Categories................................................................................................................ 77
8 DIGITAL INPUTS...................................................................................80

8.1 PROGRAMMING DIGITAL I NPUTS USING THE DISPLAY .......................................................82
Viewing the Current Digital Input Status................................................................................... 82
Configuring Digital Inputs for Status Parameters...................................................................... 84
Configuring Digital Inputs for System Events ........................................................................... 87
Configuring Digital Inputs for SCADA Data link ........................................................................ 91
Disabling Digital Inputs ........................................................................................................... 93
8.2 PROGRAMMING DIGITAL I NPUTS USING THE CAT SERVICE TOOL .......................................95
Configuring Digital Inputs for Status Parameter........................................................................ 96
Configuring Digital Inputs for System Events ........................................................................... 97
Configuring Digital Inputs for SCADA Data link ...................................................................... 101
Disabling Digital Inputs ......................................................................................................... 101
9 ANALOG INPUTS ...............................................................................102

9.1 PROGRAMMING ANALOG INPUTS USING THE DISPLAY ....................................................104
Viewing the Current Analog Input Status ............................................................................... 104
Configuring Analog Inputs for Resistive Mode........................................................................ 105
Configuring Analog Inputs for PWM Mode ............................................................................. 109
Configuring Analog Inputs for Current Mode .......................................................................... 113
Configuring Analog Inputs for Voltage Mode.......................................................................... 117
Disabling Analog Inputs ........................................................................................................ 121
9.2 PROGRAMMING ANALOG INPUTS USING THE CAT SERVICE T OOL ....................................122
Configuring Analog Inputs for Resistive Mode........................................................................ 123
Configuring Analog Inputs for PWM Mode ............................................................................. 126

Configuring Analog Inputs for Current Mode .......................................................................... 129

Configuring Analog Inputs for Voltage Mode.......................................................................... 133

Disabling Analog Inputs ........................................................................................................ 136
9.3 ANALOG INPUT MAPS .................................................................................................137
Warnings and Shutdowns ..................................................................................................... 145
Unsupported Analog Input Sensor Ranges ............................................................................ 145
Sensor Range is Smaller than Setpoint Options..................................................................... 145
Sensor Range is Larger than Setpoint Options, But Usable Range is Not ............................... 146
Sensor Range is Larger than Setpoint Options, And Usable Range is Larger Than Setpoint
Options ................................................................................................................................ 147
10 DIGITAL OUTPUTS.............................................................................148
10.1 PROGRAMMING DIGITAL OUTPUTS USING THE DISPLAY .................................................148
Viewing the Current Digital Output Status.............................................................................. 149
Configuring Digital Outputs for Status Parameters ................................................................. 150
Configuring Digital Outputs for System Events....................................................................... 153
Configuring Digital Outputs for SCADA Data link.................................................................... 157
Disabling Digital Outputs....................................................................................................... 158
10.2 PROGRAMMING DIGITAL OUTPUTS USING THE CAT SERVICE T OOL .................................160
Configuring Digital Outputs for Status Parameters ................................................................. 160
Configuring Digital Outputs for System Events....................................................................... 162
Configuring Digital Outputs for SCADA Data link.................................................................... 163
Disabling Digital Outputs....................................................................................................... 164
11 ANALOG OUTPUTS ...........................................................................165

11.1 PROGRAMMING ANALOG OUTPUTS USING THE DISPLAY ................................................165
Viewing the Current Analog Output Status............................................................................. 165
Configuring Analog Outputs for Voltage mode ....................................................................... 167
Configuring Analog Outputs for Current mode........................................................................ 170
11.2 PROGRAMMING ANALOG OUTPUTS USING THE CAT SERVICE TOOL ................................173
Configuring Analog Outputs for Voltage mode ....................................................................... 174
Configuring Analog Outputs for Current mode........................................................................ 176
12 PWM OUTPUTS ..................................................................................179

12.1 PROGRAMMING PWM OUTPUTS USING THE DISPLAY .....................................................179
Viewing the Current PWM Output Status............................................................................... 179
Configuring PWM Outputs .................................................................................................... 180
12.2 PROGRAMMING PWM OUTPUTS USING THE CAT SERVICE T OOL ....................................184
13 PARALLELING (EMCP 4.4 ONLY).....................................................187
13.1 PARALLELING FUNCTIONS ...........................................................................................187
Dead Bus Arbitration............................................................................................................. 187
Synchronizing....................................................................................................................... 187
Load Sharing........................................................................................................................ 187
Load Shed............................................................................................................................ 187
Load Sense/Load Demand.................................................................................................... 187
13.2 PARALLELING (SYNCHRONIZING ) MODES OF OPERATION ...............................................187
Automatic Paralleling (Auto Synchronizing) ........................................................................... 187
Manual Paralleling (Manual Synchronizing) ........................................................................... 188
Sync Check Mode ................................................................................................................ 188
13.3 HARD WIRED DEAD BUS ARBITRATION ........................................................................188
Purpose ............................................................................................................................... 188
Wiring .................................................................................................................................. 188
Basic Operation.................................................................................................................... 190
Enabling Dead Bus Arbitration .............................................................................................. 191
Viewing Parameters.............................................................................................................. 192
Controlling Parameters ......................................................................................................... 193
Configuring Parameters........................................................................................................ 193

13.4 HARDWIRED LOAD SENSE L OAD DEMAND DETAILS .......................................................194

Purpose ............................................................................................................................... 194
Wiring .................................................................................................................................. 194
Basic Operation.................................................................................................................... 195
Enabling Load Sense Load Demand ..................................................................................... 197
13.5 SYNCHRONIZING DETAILS ...........................................................................................201
Sync Mode Switch................................................................................................................ 201
Automatic Synchronizing....................................................................................................... 202
Manual Synchronizing........................................................................................................... 202
Check Synchronizing............................................................................................................ 203
Generator Sensing Fault....................................................................................................... 203
Synchronization Gain Tuning Procedure................................................................................ 209
13.6 REAL AND REACTIVE L OAD SHARING IN ISLAND MODE DETAILS .....................................212
Purpose ............................................................................................................................... 212
Wiring .................................................................................................................................. 212
Basic Operation.................................................................................................................... 212
Sharing Lines (KW & KVAR)................................................................................................. 213
Enabling Load Sharing.......................................................................................................... 213
Load Sharing Gain Tuning .................................................................................................... 220
13.7 LOAD SHED ...............................................................................................................222
Purpose ............................................................................................................................... 222
Basic Operation.................................................................................................................... 222
13.8 BREAKER SELECTION .................................................................................................223
14 MODIFIABLE TEXT STRINGS ............................................................224
14.1 LANGUAGE SUPPORT .................................................................................................224
14.2 PROGRAMMING MODIFIABLE T EXT STRINGS USING THE CAT SERVICE T OOL ....................225
15 SAVING AND RESTORING SETPOINTS ...........................................229
15.1 SAVING EMCP 4 CONFIGURATION DATA.............................................................229
Fleet Configuration Option .................................................................................................... 230
ECM Replacement Option .................................................................................................... 230
15.2 LOADING EMCP 4 CONFIGURATION DATA ....................................................................231
16 PROGRAMMABLE CYCLE TIMER ....................................................234

16.1 CONFIGURING THE PROGRAMMABLE CYCLE TIMER USING THE DISPLAY ..........................236
16.2 CONFIGURING THE PROGRAMMABLE CYCLE TIMER USING THE CAT SERVICE T OOL ..........239
17 REDUCED POWER MODE .................................................................242
ACTIONS TO ENABLE RPM........................................................................................................ 242
18 PROGRAMMABLE KW RELAY FUNCTION ......................................244

18.1 CONFIGURING THE PROGRAMMABLE KW RELAY FROM THE DISPLAY ..............................245
18.2 CONFIGURING THE PROGRAMMABLE KW RELAYS USING THE CAT SERVICE TOOL ............248
19 CAN DATA LINKS...............................................................................250
19.1 PRIMARY CAN DATA LINK (CAN 1).............................................................................250

Primary CAN Wiring.............................................................................................................. 250

Network Topology................................................................................................................. 250
19.2 ACCESSORY CAN DATA LINK (CAN 2) ........................................................................ 252
Accessory CAN Wiring.......................................................................................................... 252
Network Topology................................................................................................................. 252
20 OPTIONAL MODULES........................................................................254

20.1 CAN ANNUNCIATOR ...................................................................................................255
Annunciator Features............................................................................................................ 255
Annunciator Specifications.................................................................................................... 256
Annunciator Wiring ............................................................................................................... 257
LED Colors........................................................................................................................... 258
CAN Annunciator Software Configuration.............................................................................. 258
Global Acknowledge............................................................................................................. 259
ECU Instance Number.......................................................................................................... 259
Configuring Annunciator LED Behavior.................................................................................. 259
Trigger Condition.................................................................................................................. 262
Severity Level....................................................................................................................... 263
Suspect Parameter Number.................................................................................................. 264
20.2 RS-485 ANNUNCIATOR ...............................................................................................264
Annunciator Features............................................................................................................ 264
Annunciator Specifications.................................................................................................... 265
RS-485 Annunciator Wiring................................................................................................... 265
RS-485 Annunciator Deutsch Connector Pin Configuration .................................................... 266
LED Colors........................................................................................................................... 267
Lamp Test Function.............................................................................................................. 267
Alarm Acknowledge.............................................................................................................. 268
RS-485 ANNUNCIATOR ALARM GROUPS.......................................................................... 268
Alarm Group Selection Mode (AGSM)................................................................................... 268
Entering AGSM .................................................................................................................... 269
Re-configuring/Selecting Alarm Group Address ..................................................................... 270
Exiting AGSM....................................................................................................................... 270
RS-485 Annunciator Custom Alarm Group Configuration ....................................................... 270
Severity Level....................................................................................................................... 271
Suspect Parameter Number.................................................................................................. 272
Alarm Groups....................................................................................................................... 272
Configuring Custom Alarm Groups using Cat Service Tool..................................................... 275
20.3 T HERMOCOUPLE MODULE ...........................................................................................282
Thermocouple Features........................................................................................................ 282
Thermocouple Specifications ................................................................................................ 283
Thermocouple Wiring............................................................................................................ 284
Thermocouple Physical Layout ............................................................................................. 285
Thermocouple Module – Configuration.................................................................................. 286
Configuring Thermocouple Inputs.......................................................................................... 287
20.4 RTD MODULE ............................................................................................................288
RTD Features....................................................................................................................... 288
RTD Specifications............................................................................................................... 289
RTD Wiring .......................................................................................................................... 290
RTD Physical Layout ............................................................................................................ 291
RTD Module – Configuration................................................................................................. 291
Configuring RTD Inputs ........................................................................................................ 292
20.5 DISCRETE I/O MODULE ...............................................................................................293
Discrete I/O Features............................................................................................................ 293
Discrete I/O Specifications.................................................................................................... 294
Discrete I/O Wiring ............................................................................................................... 295
Discrete I/O Physical Layout ................................................................................................. 296
Discrete I/O - Configuration................................................................................................... 296
Configuring Digital Inputs...................................................................................................... 298
Configuring Relay Outputs.................................................................................................... 299

FOREWORD
This Application and Installation Guide describes the EMCP 4.3 and 4.4 series electric
power generator set controls.
Some data used in this guide is generalized and is provided only for the purpose of
comparison or illustration. Also, PC application screenshots and EMCP 4 screen images
may be actual screens or simulated and are shown for illustrative purposes only. These
images may not be identical to those seen by the user. Screen images of the EMCP 4
may differ from the actual screens depending on flash file language, setpoint
configuration, or series of the EMCP (4.3 versus 4.4).
In various places throughout this document, reference is made to the release date of the
EMCP 4 software. This information can be found by connecting to the subject module
®
using the Cat Service Tool, and viewing the ECM Summary (this is the default startup
screen). The release date is found in the field entitled Software Group Release Date.
See Figure 1, showing the release date for a Thermocouple module.
Figure 1: EMCP Software Release Date
Other product specific information and data is available from a variety of sources. For
more information, contact the Cat Dealer or dealer TC nearest you.
The information in this document is the property of Caterpillar Inc. and/or its subsidiaries.
Any copying, distribution, transmission to others, and any use except that for which it is
loaned is prohibited without written permission.
CAT, CATERPILLAR, ADEM™A4, their respective logos, “Caterpillar Yellow” the “Power
Edge” trade dress as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

Application and Installation Guide EMCP 4.3, 4.4 Generator Set Control
1 GENERAL INFORMATION
1.1 INTRODUCTION
Caterpillar has developed a product line of Generator Set Controls for use in the
Electronic Modular Control Panel 4 (EMCP 4). They are available in four versions based
on Generator Set Control feature sets.
The EMCP 4 Generator Set Control, or GSC, is the primary controller within the
Generator Set Control system. The EMCP 4 line of Generator Set Controllers includes
EMCP 4.1, 4.2, 4.3, and 4.4. Appendix B shows a full view of the EMCP 4.3 and 4.4.
This Application and Installation Guide is intended to cover the EMCP 4.3 and 4.4
Generator Set Control and its application in generator set systems. It also includes
information on optional add-on modules. The intended audience for this guide includes
Cat generator set system designers, Caterpillar service support personnel, Cat Dealers
and Service Technicians, contractors, and customers.
1.2 APPLICATIONS
The EMCP 4 product line of generator set controllers is designed for use in a wide range
of applications. They can be used on standby and prime Cat brand power diesel
generator sets. The configurability of the controllers allows them to be used, in some
cases, on other applications such as Marine auxiliary generators, switchgear
applications, industrial engines and generator sets, and gas generator sets.
Most of the information in this document applies to all applications. However, the
document was written with Cat brand diesel generator sets in mind. Please contact your
Cat support representative for questions regarding different applications.
Note: Proper application of EMCP 4.4 paralleling controllers is critical; along with the
technical requirements outlined elsewhere in this guide, please consider the following
commercial requirements:
1. The EMCP 4.4 is primarily intended for applications whose aggregate current of
paralleled units is 6000A or less (the green portion of Table 1 and Table 2).
2. Contact Caterpillar A&I Engineering for consideration of applications whose
aggregate current of paralleled units is between 6000A and 10,000A (the yellow
portion of Table 1 and Table 2). Application in this range without the express
written permission of Cat A&I are prohibited.
3. Applications whose aggregate current of paralleled units exceeds 10,000A are
prohibited (the pink portion of Table 1 and Table 2).
4. EMCP 4.4 paralleling is intended for low voltage generator set applications only
(less than 1000V); Cat floor-standing control or switchgear should be utilized for
medium and high voltage applications.
©2010 Caterpillar
All rights reserved. Page 1

Number of Generator Sets

Unit
rating in
ekW 2 3 4 5 6 7 8 9 10
250 752 1128 1504 1879 2255 2631 3007 3383 3759
300 902 1353 1804 2255 2706 3157 3608 4059 4511
350 1052 1579 2105 2631 3157 3684 4210 4736 5262
400 1203 1804 2406 3007 3608 4210 4811 5413 6014
450 1353 2030 2706 3383 4059 4736 5413 6089 6766
500 1504 2255 3007 3759 4511 5262 6014 6766 7518
550 1654 2481 3308 4135 4962 5789 6615 7442 8269
600 1804 2706 3608 4511 5413 6315 7217 8119 9021
650 1955 2932 3909 4886 5864 6841 7818 8796 9773
700 2105 3157 4210 5262 6315 7367 8420 9472 10525
750 2255 3383 4511 5638 6766 7893 9021 10149 11276
800 2406 3608 4811 6014 7217 8420 9623 10825 12028
900 2706 4059 5413 6766 8119 9472 10825 12178 13532
1000 3007 4511 6014 7518 9021 10525 12028 13532 15035
1100 3308 4962 6615 8269 9923 11577 13231 14885 16539
1250 3759 5638 7518 9397 11276 13156 15035 16915 18794
1400 4210 6315 8420 10525 12630 14734 16839 18944 21049
1500 4511 6766 9021 11276 13532 15787 18042 20297 22553
1750 5262 7893 10525 13156 15787 18418 21049 23680 26312
2000 6014 9021 12028 15035 18042 21049 24056 27063 30070
2250 6766 10149 13532 16915 20297 23680 27063 30446 33829
2500 7518 11276 15035 18794 22553 26312 30070 33829 37588
2750 8269 12404 16539 20673 24808 28943 33077 37212 41347
3000 9021 13532 18042 22553 27063 31574 36084 40595 45105
Table 1: Total Current in Amperes for Multiple Gensets at 480V AC and 0.8 pf
©2010 Caterpillar

Number of Generator Sets

Unit
rating in
kVA 2 3 4 5 6 7 8 9 10
250 722 1083 1443 1804 2165 2526 2887 3248 3608
300 866 1299 1732 2165 2598 3031 3464 3897 4330
350 1010 1516 2021 2526 3031 3536 4041 4547 5052
400 1155 1732 2309 2887 3464 4041 4619 5196 5774
450 1299 1949 2598 3248 3897 4547 5196 5846 6495
500 1443 2165 2887 3608 4330 5052 5774 6495 7217
550 1588 2382 3175 3969 4763 5557 6351 7145 7939
600 1732 2598 3464 4330 5196 6062 6928 7794 8660
650 1876 2815 3753 4691 5629 6567 7506 8444 9382
700 2021 3031 4041 5052 6062 7073 8083 9093 10104
750 2165 3248 4330 5413 6495 7578 8660 9743 10825
800 2309 3464 4619 5774 6928 8083 9238 10392 11547
900 2598 3897 5196 6495 7794 9093 10392 11691 12990
1000 2887 4330 5774 7217 8660 10104 11547 12990 14434
1100 3175 4763 6351 7939 9526 11114 12702 14289 15877
1250 3608 5413 7217 9021 10825 12630 14434 16238 18042
1400 4041 6062 8083 10104 12124 14145 16166 18187 20207
1500 4330 6495 8660 10825 12990 15155 17321 19486 21651
1750 5052 7578 10104 12630 15155 17681 20207 22733 25259
2000 5774 8660 11547 14434 17321 20207 23094 25981 28868
2250 6495 9743 12990 16238 19486 22733 25981 29228 32476
2500 7217 10825 14434 18042 21651 25259 28868 32476 36084
2750 7939 11908 15877 19846 23816 27785 31754 35724 39693
3000 8660 12990 17321 21651 25981 30311 34641 38971 43301
Table 2: Total Current in Amperes for Multiple Gensets at 400V AC and 0.8 pf
1.3 REFERENCES
The System Operation Testing, Troubleshooting, and Adjusting manual (UENR 1210) is
also available for EMCP 4.3 and 4.4 Generator Sets. The genset Operations and
Maintenance manual contains details for specific products.
©2010 Caterpillar

2 SAFETY INFORMATION
2.1 ELECTRICAL SAFETY

DO NOT operate or work on a generator set unless you
have read and understand the instructions and warnings in
the Operation and Maintenance Manual. 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.
2.2 ELECTROSTATIC DISCHARGE AWARENESS

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/handling the control:

• Handle equipment correctly. Use ESD protective packaging and material
handling containers that are anti-static and provide discharge protection
and electric field suppression.
• Use protective devices: ESD-protective workstations and/or work
surfaces (grounding mat, anti-static wrist strap, etc).
• Keep all plastic items away from the devices. Any plastic item is a
potential static generator. This includes candy wrappers, foam cups,
synthetic carpet, foam cushions, etc.
• 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.
Caution: The 120-pin connector (and additional 70-pin connector for EMCP 4.4) 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.
Note: Locking out the genset does not remove voltage on the EMCP 4.4 at the bus
voltage sensing leads.
Consult the Electrostatic Discharge Association for proper procedure during particular
situations: http://www.esda.org.
©2010 Caterpillar

3 INSTALLATION
3.1 MOUNTING LOCATION

When selecting a mounting location for the EMCP 4, consider the following:
• Protection from high-voltage and high-current devices.
• Protection from devices which may produce electromagnetic
interference.
• Protection from excessive vibration. The EMCP 4 controls are designed
to withstand normal generator set vibrations. They should not be
mounted directly to the engine block.
• Protection from direct exposure to water. Once installed, the EMCP 4
controllers are sealed to a level of IP Level 56 for resistance to moisture.
Suitable for Flat Surface Mounting in a Type 1 Enclosure only.
3.2 OPERATING TEMPERATURE RANGE

EMCP 4 has a continuous operating temperature range of –20°C to +70°C
ambient.
3.3 POWER REQUIREMENTS

The EMCP 4.3 and 4.4 require a nominal voltage of 12 VDC or 24 VDC. A DC to DC
converter may be needed for 12VDC applications. If batteries are used for operating
power, a charging source such as an alternator or dual-mode battery charger is
necessary to maintain a stable supply voltage. The maximum power consumption of the
4.3 and 4.4 with all I/O at maximum power drain will not exceed 10A at 24VDC.
Regional electrical codes must be followed. In the case of standby operation, follow the
regional requirements for installing standby power systems. An example of this is the
National Fire Protection Association (NFPA) guidelines for emergency power systems.
When connecting the EMCP 4 to the DC power source, make sure that there is only one
common connection to the negative potential of the power source. Make extra effort to
avoid any ground loops in the DC electrical system. A single point common ground for
sensitive electronics is recommended at the negative battery terminal or Power
Distribution Box.
Avoid daisy-chaining power supply connections from one device to another. This builds
resistance from one Battery (-) point to the next, effectively building a potential difference
between two different reference points. Each electronics subsystem and major engine
subsystem should have its own DC network so that they do not interfere with each other
(see Figure 2).
As shown in Figure 2, all sensitive electronics are electrically isolated from higher current
loads, such as the starter motor. All electronics have a COMMON POWER BUS and SINGLE
POINT REFERENCE. This point is the genset customer ground connection. The CHASSIS
GROUND should be bonded separately to the customer ground connection and not be
used as the electronics reference.
©2010 Caterpillar

The sensitive electronics, such as sensors and control modules, have isolated power
source paths. High current loads such as starters and solenoids can cause interference
and possibly damage to low current loads, such as controllers and sensors.
Caution: Extra effort must be made to keep the high current and low current loads
electrically separated.
Figure 2: Generator Set Network Isolation
The two types of loads may share common Battery (+) and Battery (–) connections but,
they should not be electrically connected at any other point. This strategy ensures
maximum isolation between high current and low current loads.
The battery DISCONNECT SWITCH is located on the negative side of the battery supply.
3.4 BATTERY CHARGER

If a battery charger is to be used, it should be connected on the battery side of the
disconnect switch. Most battery chargers are not to be used as power supplies. Proper
battery charger operation requires that the actual battery load be present.
If battery charger fault condition wiring is connected to the EMCP Digital Inputs and
these Digital Inputs are set to DISABLED, then any battery charger faults or events will
not be broadcast or annunciated on the network. See Chapter 8.
©2010 Caterpillar

3.5 ELECTRICAL CONNECTIONS

The EMCP 4.3 has one 120-pin connector on the back of the control (not all of the 120
pins are used). The EMCP 4.4 has the same 120-pin connector on the back of the
control as the EMCP 4.3 and an additional 70-pin connector (not all of the 70 pins are
used). The 70-pin connector on the EMCP 4.4 is not the same as the 70-pin connector
on the EMCP 4.1 and 4.2.
Figure 3 and Figure 4 show:
• All possible connections
• What pins are used for connections
• How each pin is connected for each control version
3.6 EUI ENGINES

For EUI engines, the Oil Pressure and Coolant Temperature sensors will typically be
wired to the engine ECM and the EMCP 4 will get that information from the engine ECM
via the Primary CAN Data Link. Ensure the EMCP 4 Oil Pressure and Coolant
Temperature setpoints are configured for Data Link.
In order for the genset to function properly in Cooldown mode, some setpoints in the
EMCP 4 must be coordinated with some ADEM setpoints. For gensets where the engine
ECM controls cooldown, the cooldown time should be set to 0 seconds in the EMCP. For
gensets where the engine ECM does not control cooldown, the cooldown time should be
set to 0 seconds in the engine ECM.
©2010 Caterpillar

3.7 EMCP 4.3 AND 4.4 ELECTRICAL DIAGRAMS
©2010 Caterpillar

Figure 3: EMCP 4.3 and EMCP 4.4 120-Pin Connector Electrical Diagram
©2010 Caterpillar

Figure 4: EMCP 4.4 Electrical Diagram
©2010 Caterpillar

GENERATOR TEMPERATURE SCREEN

• Generator Phase A Winding Temperature
• Generator Phase B Winding Temperature
• Generator Phase C Winding Temperature
• Generator Front Bearing Temperature
• Generator Rear Bearing Temperature
GENERATOR ENERGY SCREEN

• Total kW
• % kW
• Total kVA
• % kVA
• Total kVAr
• % kVAr
VIEW NOMINAL SETTINGS SCREEN

• Rated Voltage
• Rated Frequency
• Rated Real Power
• Rated Apparent Power
©2010 Caterpillar

GENSET OVERVIEW
The Genset Overview screen displays a combination of engine and generator parameters on
one convenient screen. Soft keys provide quick links to the AC Overview and Engine Overview
screens. The following parameters are displayed on the Genset Overview screen:
GENSET OVERVIEW
• Engine Operating State (Initialization, Pre-
Crank, Starting, Running, Pre-Cooldown,
Cooldown, Stopping, Stopped, Idling; many
states are transient and only briefly active,
and some states may not occur in some
configurations)
• Engine Oil Pressure
• Engine Coolant Temperature
• Battery Voltage, as measured at the
connector entering the EMCP 4
• Engine Speed
• Engine Operating Hours
• Average Line-Line AC Voltage
• Average Current
• AC Frequency
• Power Factor
• Power Factor Lead/Lag status
• Total Generator Real Power – kW
• Percent Real Power – as a percent of
Generator Rated Power setpoint
BUS OVERVIEW (EMCP 4.4 ONLY)

The Bus Overview screens display various bus parameters. A soft key provides a quick link to
the AC Overview screen. The following parameters are displayed on the Bus Overview
screens:
BUS OVERVIEW SCREEN
• Bus AC Frequency
• Average Bus Line-Line AC Voltage
• Average Bus Line-Neutral AC Voltage
• Bus Line-Line Voltages: A-B, B-C, C-A
• Bus Line-Neutral Voltages: A-N, B-N, C-N
©2010 Caterpillar

4.4 VIEWING AND ADJUSTING PREFERENCES

The EMCP 4 display can be used for monitoring the generator status, viewing and
resetting events, and configuring setpoints. There are several preferences to alter how
you view the data on the display. These include: display contrast, units used to display
pressure, units used to display temperature, units used to display volume, circuit breaker
symbol (EMCP 4.4 only), and displayed language (to select between the customer
language and Technician English).
Note: These preferences do not affect operation of the EMCP 4 or the data as viewed in
the Cat Service Tool. They only affect how the text and data is converted and displayed
on the EMCP 4 display.
SETTING THE PREFERENCES USING THE EMCP 4 DISPLAY

On the EMCP 4 display, the Preferences menu is
located at the bottom of the Main Menu.
For any preference, press OK KEY to accept
the change (or ESCAPE KEY to reject the

change) and return to the Preferences menu.
©2010 Caterpillar

PREFERENCES
CONTRAST This determines the darkness of the pixels on the display. A minimum
contrast setting (reached by pressing and holding the down or left arrow)
effectively blanks the screen, and a maximum contrast setting (reached by
pressing and holding the up or right arrow) effectively darkens the entire
screen. To change the contrast if the screen is unreadable due to a
misconfiguration or ambient conditions, see CHANGING THE EMCP 4
CONTRAST WHEN THE DISPLAY IS UNREADABLE.
PRESSURE This allows pressure parameters (such as Engine Oil Pressure) and
setpoints (such as Low Engine Oil Pressure Event Threshold) to be shown in
either kPa, psi, or bar. Select the desired unit with the up or down arrows, or
the Function keys.
TEMPERATURE This allows temperature parameters (such as Engine Coolant Temperature)
and setpoints (such High Engine Coolant Temperature Event Threshold) to
be shown in either Celsius (Centigrade) or degrees Fahrenheit. Select the
desired unit with the up or down arrows, or the Function keys.
VOLUME This allows volume parameters (such as Fuel Volume) to be shown in Liters,
Imperial Gallons, or US Gallons. Select the desired unit with the up or down
arrows, or the Function keys.
CIRCUIT This allows the graphic for the circuit breaker to be either the ISO symbol, or
BREAKER the US symbol. Select the desired symbol with the left or right arrows.
SYMBOL
(EMCP 4.4 only)
LAMP TEST
When this selection is highlighted, pressing and holding the OK KEY
will darken all pixels on the screen and illuminate all LEDs on the face of the
controller.
LANGUAGE This allows the display to be switched between Technician English (always
listed first) and the customer language (always listed second, and written in
the font of the customer language). The below example shows the language
selection in the German language flash file. Select the desired language with
the up or down arrows. To change the language to Technician English,
regardless of the current screen, and without needing to read the text, see
CHANGING THE EMCP 4 DISPLAY TO TECHNICIAN ENGLISH.
The LANGUAGE setting has been conveniently located at the bottom of the Preferences menu,
which is at the bottom of the Main Menu.
©2010 Caterpillar

CHANGING THE EMCP 4 CONTRAST WHEN THE DISPLAY IS UNREADABLE
1. Press the MAIN MENU key
2. Scroll DOWN until scrolling stops
3. Press the OK KEY (this will take you into the Preferences Menu)
4. Press the OK KEY again (this will take you into the Contrast selection)
5. Press and hold either LEFT ARROW or RIGHT ARROW until the text
and graphics become visible
6. Press the OK KEY to accept the adjustment
CHANGING THE EMCP 4 DISPLAY TO TECHNICIAN ENGLISH
1. Press the MAIN MENU key
2. SCROLL DOWN until the scrolling stops
3. Press the OK KEY (this will take you into the Preferences Menu)
4. SCROLL DOWN until the scrolling stops
5. Press the OK KEY (this will take you into the Language selection)
6. Press the UP ARROW key until the scrolling stops
7. Press the OK KEY to select TECHNICIAN ENGLISH

The EMCP 4 language setting is changed back to TECHNICIAN ENGLISH.
Similar steps can be followed by a customer who is unfamiliar with English, to change
the language setting back to their primary language:
©2010 Caterpillar

To change the time/date, do the following:
At MAIN MENU scroll DOWN to CONFIGURE.
Press the OK KEY .
Scroll DOWN to TIME / DATE.
Press the OK KEY .
To begin editing the time, press the OK KEY

while the current time is selected.
Select a digit using the LEFT ARROW or RIGHT ARROW
To change the selected digit use the UP ARROW or DOWN ARROW
To accept changes, press the OK KEY . To reject changes, press the ESCAPE KEY .
©2010 Caterpillar

TO CHANGE THE DATE FROM THIS POINT
Press the ESCAPE KEY again to return to the

SET TIME / DATE screen.
Press the DOWN ARROW key to put the box

around the date.
Alternately, pressing the DATE softkey from the Set
Time screen will bring up this screen
To begin editing the date, press the OK KEY while the current date is selected.
Select a digit using the LEFT ARROW or RIGHT ARROW .
To change the selected digit use the UP ARROW or DOWN ARROW .
To accept changes, press the OK KEY . To reject changes, press the ESCAPE KEY .
©2010 Caterpillar

CHANGING DATE FORMAT

The data format can be set to either display in the form Month/Day/Year or the form
Day/Month/Year. This procedure must be performed on the EMCP 4 display; it cannot
be done using the Cat Service Tool.
Note: This preference does not affect operation of the EMCP 4 or the data as viewed in
the Cat Service Tool. It only affects how the date is displayed on the EMCP 4 display
and the format of the event time stamps.
To change the date format, do the following:
At MAIN MENU scroll DOWN to CONFIGURE.
Press the OK KEY .
SCROLL DOWN to TIME / DATE.
Press the OK KEY .
Press the DOWN ARROW key to highlight the

date format.
Press the OK KEY .
Select the format using the LEFT ARROW or RIGHT ARROW or soft keys, then press
the OK KEY to accept, or the ESCAPE KEY to reject, the change.
©2010 Caterpillar

4.6 ADJUSTING GENERATOR SET PARAMETERS

On many gensets, the engine speed, generator output voltage, and idle/rated status can
be adjusted from the display of the EMCP 4. This ability is dependent upon the engine
interface strategy and input/output configuration.
GENERATOR OUTPUT VOLTAGE

If the genset is equipped with a Cat Digital Voltage Regulator (Cat DVR), then the
generator output voltage setpoint can be adjusted from the display of the EMCP 4,
provided the Cat DVR is programmed to allow this control. In order for the VOLTAGE
ADJUST to work via CAN, the AVR VOLTAGE CONTROL DESIRED INPUT CONFIGURATION
setpoint in the Cat DVR must be programmed for CAN INPUT. If that setpoint is set to
SWITCH, the VOLTAGE CONTROL from the EMCP 4 will NOT WORK.
ENGINE SPEED
If the genset is equipped with an ADEM A3 or A4 governor, then the engine speed
setpoint can be adjusted from the display of the EMCP 4, provided the A3 is
programmed to allow this control. In order for the SPEED ADJUST to work via CAN, the
DESIRED THROTTLE INPUT CONFIGURATION setpoint in the A3 or A4 must be programmed
for CAN INPUT. If that setpoint is set to PWM, the SPEED CONTROL from the EMCP 4 will
NOT WORK.
PROGRAMMING THE GENERATOR OUTPUT VOLTAGE AND ENGINE SPEED

From the MAIN MENU select CONTROL.
Press the OK KEY .
From the CONTROL MENU, select VOLT /HZ CONTROL.
©2010 Caterpillar

Press the OK KEY .

The speed and voltage adjust screen will be
displayed. The small arrow below the bar indicates
the value of voltage or speed relative to the setpoint.
Numerical values, along with percentages away
from the setpoints, are also shown for reference.
To adjust the generator voltage from this screen:
Press the F1 KEY to DECREASE the generator voltage.
Press the F2 KEY to INCREASE the generator voltage.

To adjust the engine speed from this screen:
Press the F3 KEY to DECREASE the engine speed.
Press the F4 KEY to INCREASE the engine speed.
The EMCP 4 will broadcast an engine speed bias based on the adjustment that is made.
When the engine speed is adjusted, then that value will remain until either it is adjusted
again or until the control is power-cycled.
For the EMCP 4.3, if an Analog or Digital Input is programmed for desired engine speed,
this can affect the desired engine speed along with the Function keys. If the EMPC 4.3 is
power cycled, then any bias made by a Digital Input, or change from the Function keys
will not be saved. However, the bias from the analog input will be there when it powers
back up.
For the EMCP 4.4, if the controller is in Auto, the Sync Mode Switch is in Check, or the
circuit breaker is closed (in Load Share or Load Control mode), then the Function keys,
Digital and Analog Inputs programmed for desired engine speed will not affect engine
speed. If the EMCP 4.4 is in Manual mode with the CB open, or if the Sync Mode Switch
is in the Off position, then the desired engine speed works just like the EMCP 4.3.
Unlike the setpoints or preferences (i.e. contrast), any changes to this screen take effect
immediately. The OK KEY and ESCAPE KEY do not serve to accept or cancel

changes.
©2010 Caterpillar

UPDATING ENGINE HOURS

At MAIN MENU SCROLL
SCROLL DOWN to CONFIGURE
Press the OK KEY .
Scroll DOWN to ENGINE OPERATING HOURS
Press OK KEY .
(if pressing OK has no effect, then Level 3 access
has not been obtained)
Current ENGINE HOURS are displayed.

To edit the ENGINE HOURS, Select a digit using the
LEFT ARROW or RIGHT ARROW

To change the selected digit use the UP ARROW
or DOWN ARROW .
To accept the changes, press the OK KEY . To reject the changes, press the ESCAPE KEY
Again, press the OK KEY to confirm, or the
ESCAPE KEY to reject the changes.
©2010 Caterpillar

5 HANDLING EVENTS
The EMCP 4 shows previous and current events from both the EMCP and external
modules. These events are organized into logs for each physical EMCP 4 module.
The logs include:
STATUS EVENTS Recent event history (See Chapter 20)
GENSET CONTROL Events for the EMCP 4 GSC
ENGINE CONTROL Events for a Primary CAN Data Link-compatible engine
ECM
DIGITAL AVR Events for the Cat Digital Voltage Regulator (Cat DVR)
THERMOCOUPLE Events for the Thermocouple Module
EXTERNAL I/O Events for the Discrete Input/Output (DIO) module
RTD MODULE Events for the Resistive Temperature Device (RTD) module
SCR MODULE Events for Engine Aftertreatment systems
The Genset Control Log stores events generated by the EMCP 4. Any other event is
stored within the module that generated the event. Even if the EMCP annunciates an
event, it does not mean that the EMCP logs that event. It may be within another
module’s log.
Each log is visible only if the module is connected to the appropriate data link, either the
Primary data link or the Accessory data link, and is communicating with the EMCP 4.
The list of Event Logs can be viewed by pressing the Event Log key or via the
View Submenu. Select the log you wish to view and press OK to view the events.
The EMCP 4 supports more than one instance of some of the above modules. (See
Chapter 20, for the number of modules supported by each of the EMCP models). Those
modules are uniquely identified with a number at the end of the log name.
The module number is software-configured, and is called the module’s ECU INSTANCE
NUMBER. The ECU Instance Number can be viewed and modified by the Cat Service
Tool. See the appropriate sub section of Chapter 20, for the expansion module in
question, to see how to program the Instance Number.
An event in the EMCP 4 Genset Control Log can be in one of three states; PRESENT,
ACTIVE, or INACTIVE.
©2010 Caterpillar

PRESENT This state is only applicable to the Genset Control Log. PRESENT means
that the condition that caused the event is still present. The condition needs
to be addressed before the event can be reset.
Note: This state only applies to Genset Control events. Other modules will
not have Present in logs.
ACTIVE The event was previously in a “Present” state, but it is no longer present. It
has been latched by the event system and needs to be reset before the
engine can be restarted.
Within the Genset Control Log, the condition that caused the event is still
affecting the system, but may be reset. (See Sections 5.3 to 5.6 on how to
Reset Events). Warning type events automatically reset when the condition
that caused the event is resolved and will never be Active.
Within any log other than the Genset Control Log, the condition that caused
the event is affecting the system. The event may, or may not, be resettable.
If the Reset All command fails to reset the event, then this event is still
occurring and must be resolved before the event can be reset.
Note: Many events go from Present to Active when the engine is shutdown
and may reoccur once the engine starts running again. Further action may
be required to resolve the issue.
INACTIVE The event has happened at some time in the past but is no longer affecting
the system. Inactive events are stored for historical purposes only.
5.1 CONFIGURING EVENT RESPONSES

The category of event, as well as other behavior when an event occurs, can be
configured via a group of EMCP 4 setpoints called EVENT RESPONSE CONFIGURATIONS.
An example of an event response configuration is LOW ENGINE LOW OIL PRESSURE
WARNING EVENT RESPONSE CONFIGURATION. This setpoint determines what actions the
EMCP 4 takes when it receives an event.
Note: Event Response Configuration is only valid for the EMCP 4, not any other
modules.
Each EVENT RESPONSE CONFIGURATION type setpoint can either be viewed or edited. By
default, VIEW is highlighted. These setpoints can only be edited when the ECS is in the
Stop mode.
©2010 Caterpillar

The following is a list of all the possible options for an event response configuration:
WARNING Creates a Warning event in the event log and lights the amber LED.
The engine will not shut down. A Warning event will reset by itself
(i.e. it will go from the “Present” state to the “Inactive” state) as soon
as the condition that caused it goes away.
AUDIBLE ALERT Determines whether this event will also trigger an audible horn. If so,
the event activates any relays that are programmed for Horn Control
(see Chapter 10). If no relay is programmed for Horn Control, no
action will be taken; the EMCP 4 does not have an internal horn.
Audible Alert can only be programmed if either a Warning or
Shutdown is also programmed.
SOFT SHUTDOWN Creates a Shutdown event in the event log, lights the red LED, and
shuts the engine down after the cooldown period has expired (see
Section 4.7: Starting and Stopping the Engine).
HARD SHUTDOWN Creates a Shutdown event in the event log, shuts the engine down
immediately and lights the red LED.
BREAKER #1 TRIP Activates a Breaker #1 Trip, which can be programmed for a Relay
Output or Digital Output for external use. Breaker #1 usually refers to
the Generator circuit breaker.
BREAKER #2 TRIP Activates a Breaker #2 Trip, which can be programmed for a Digital
Output or Relay Output for external use. Breaker #2 may refer to a
second circuit breaker.
FAULT PROTECTION Suppresses the event unless the engine is running and the Fault
TIMER ENABLED Protection Timer has expired (this prevents nuisance events during
startup, or ones that are not relevant when the engine is stopped).
ACTIVE ONLY Creates an Active Only event in the event log. Active Only events
are for informational purposes only. They typically do not light the
Amber LED or behave like a Warning (although many events can be
configured to do so). When the condition goes away, the event
disappears from the event log.
Note: Not all options are available for all setpoints. For example, the Engine Low Oil
Pressure Warning event cannot be configured as a shutdown, because there is a
separate event (Engine Low Oil Pressure Shutdown) dedicated for that purpose.
Likewise, events cannot be generated for any and all conditions. For example, a Low
Engine Coolant Temperature Shutdown is meaningless and cannot be generated.
©2010 Caterpillar

5.2 CHANGING AN EVENT RESPONSE CONFIGURATION

To change an event response configuration, the control must be in STOP mode.
Here are the steps to access event response configurations on the EMCP 4 display.
At the MAIN MENU, scroll DOWN to

CONFIGURE
Press the OK KEY .
Scroll DOWN to ALL SETPOINTS
Press the OK KEY .
Scroll DOWN to EVENTS
Press the OK KEY .
©2010 Caterpillar

PROGRAMMABLE CYCLE TIMER

Setpoints related to configuring Programmable Cycle Timers. See Chapter 16..
ELECTRONIC CONTROL MODULE REDUCED POWER MODE
Setpoints related to a power-saving mode of the EMCP 4 called Reduced Power
Mode. See Chapter 16.
SERVICE MAINTENANCE INTERVAL
Setpoints related to configuring and resetting the timers used to indicate a service
needed warning. See Chapter 16.
KW RELAY SETPOINTS
Setpoints related to configuring the behavior of the Trip Point function, which is used
to indicate that the generator is approaching overload.
DIO INPUTS
These setpoints are not currently used. Currently programmed in the DIO module.
DIO OUTPUTS
These setpoints are not currently used. Currently programmed in the DIO module.
CONFIGURATION DATA
Contains the Engine Serial Number setpoint, which is read-only.
DISPLAY PREFERENCES
Setpoints determining the units used on the EMCP 4 display. Note that this does not
affect the data as viewed on the Cat Service Tool. See Section 4.4
©2010 Caterpillar

8 DIGITAL INPUTS
The EMCP 4.3 and 4.4 have eight programmable Digital Inputs and four isolated
programmable Digital Inputs. The user programmable Digital Inputs are referenced to
Battery (-) and will see a change in state at ~3VDC with a 1VDC hysteresis. The isolated
user programmable Digital Inputs are all referenced to a common signal that is user
supplied and will see a change in state at ~4VDC. This user supplied reference should
be wired to pin 118 on the 120-pin connector of the EMCP 4.3 and 4.4.
In addition to the user programmable Digital Inputs, the EMCP 4.3 and 4.4 have
dedicated Digital Inputs, both isolated and non-isolated. The dedicated isolated Digital
Inputs are all referenced to a common signal that is user supplied and is the same as the
user supplied reference wired to pin 118 on the 120-pin connector of the EMCP 4.3 and
4.4.
Table 6 outlines which functions are assigned to each of the dedicated inputs. A “Y”
under a controller name indicates that the input is supported, while an “N/A” indicates it
is not.
EMCP EMCP Onscreen
Input Dedicated function
4.3 4.4 Label
Dedicated Digital #1 Y Y A Emergency Stop
Dedicated Digital #2 Y Y B Remote Initiate
Dedicated Digital #3 N/A Y C Gen CB Aux “A”
Dedicated Digital #4 N/A Y D Gen CB Aux “B”
Dedicated Isolated
N Y A Group Start*
Digital #1
Dedicated Isolated
N Y B Gen CB Bell Alarm
Digital #2
Dedicated Isolated
N Y C Gen CB Trip Manual Command
Digital #3
Dedicated Isolated
N Y D Gen CB Close Manual Command
Digital #4
Table 6: Dedicated Input Assignments
*If using Group Start, Reduced Power Mode should NOT be used.
The other inputs are linked to functions that are called SYSTEM EVENTS and can be
configured to trigger warnings or shutdowns in the EMCP 4. System Event
configurations determine the EMCP 4 response to any supported event. For more
information on Event Response Configurations, see Chapter 55.1.
The programming of the Digital Inputs starts by selecting a “Usage Type“. The rest of the
programming is dependent upon what Usage Type is selected. Figure 17 summarizes
the paths possible for Programming a Digital Input.
©2010 Caterpillar

Figure 17: Digital Input Programming Paths
The Usage Type of DISABLED is used to completely disable the input. No status will be
shown, and no action will be taken by the EMCP 4.
The Usage Type of STATUS is used to make certain system conditions be known by the
EMCP 4; an example of a system condition is the Generator Breaker status.
The Usage Type of SYSTEM EVENT is used to inform the EMCP 4 of system conditions
that require the EMCP 4 to trigger an event.
The Usage Type of SCADA DATA LINK is used to bring in data to the EMCP 4 for
express use by the SCADA data link. EMCP 4 will not take any action or trigger any
events on such an input.
The Digital Inputs of the EMCP 4 are tied to an internal pull-up resistor inside the
controller. Therefore, if a Digital Input is UNCONNECTED, the Digital Input will sit at a
PHYSICAL HIGH state. See Figure 18. Note that a Digital Input wired to battery positive will
always remain Active if programmed for Active High, and will always remain Inactive if
programmed for Active Low.
A battery negative input should be switched to each EMCP 4 Digital Input for proper
operation.
If an ACTIVE HIGH configuration is desired, the ground or battery negative input
should be wired through a normally-closed switch.
If an ACTIVE LOW configuration is desired, the ground or battery negative input
should be wired through a normally-open switch.
©2010 Caterpillar

Figure 18: Valid States of Digital Input Wiring and Configuration
Note: Improper configuration of these inputs can cause a false event to be triggered, or
cause an event to not be triggered when desired.
8.1 PROGRAMMING DIGITAL INPUTS USING THE DISPLAY

The steps to configure the Digital Inputs for each of the Usage Types are described
below.
VIEWING THE CURRENT DIGITAL INPUT STATUS

To view the current status of a Digital Input, go through the following menu options:
AT THE MAIN MENU, scroll DOWN TO VIEW
Press the OK KEY .
Scroll DOWN to I/O STATUS
Press the OK KEY .
©2010 Caterpillar

Scroll DOWN to DIGITAL INPUTS
Press the OK KEY .
The status of all Digital Inputs is shown.

A dash under an input number (or letter) indicates
an input that is programmed, but inactive. A large
“X” under an input number (or letter) indicates an
input that is disabled. A number (or letter) under an
input number (or letter) indicates an input that is
programmed and active.
With the LEFT ARROW or RIGHT ARROW , select the DIGITAL INPUT that you want to
view, then press the OK KEY .
The programmed parameters of the selected Digital

Input are shown.
©2010 Caterpillar

CONFIGURING DIGITAL INPUTS FOR STATUS PARAMETERS

Command or Status parameters are used to control specific functions within the control
system or to make certain conditions within the system be known. To configure a Digital
Input as a Command or Status Parameter, go through the following menu options:
AT THE MAIN MENU, scroll DOWN TO

CONFIGURE
Press the OK KEY .
Scroll DOWN to INPUTS & OUTPUTS
Press the OK KEY .

Alternately, access to the INPUTS & OUTPUTS
submenu is accessible from ALL SETPOINTS.
Press the OK KEY to access DIGITAL INPUTS.
Select the DIGITAL INPUT that you want to program
Press the OK KEY .
©2010 Caterpillar

Press the OK KEY to highlight the current

configuration (DISABLED, STATUS, SYSTEM EVENT,
OR SCADA).
Scroll DOWN to STATUS
Press the OK KEY .
Scroll DOWN to ACTIVE STATE

ACTIVE STATE.
Select the ACTIVE STATE that you want to program

and
Press the OK KEY .
Scroll DOWN to STATUS TYPE

STATUS TYPE.
©2010 Caterpillar

Select the STATUS TYPE that you want to program
Press the OK KEY .
Any Digital Input can be configured for any one of the Status parameters in Table 7:
ECS in Run* Inhibit Cooldown
ECS in Auto* Raise Voltage
ECS in Stop* Lower Voltage
Inhibit Generator Breaker Closure (4.4) Raise Speed
Sync Mode Switch in Manual (4.4) Lower Speed
Sync Mode Switch in Auto (4.4) Auto Load Fuel
Sync Mode Switch in Check (4.4) kVAr Power Sharing Inhibit (4.4)
Idle Mode Command Start Aid Timer Bypass
*If a Digital Input is programmed for ECS in Auto, or Run, or Stop, and a
maintained switch latches that input to make it active, the front panel
buttons will not have any effect.
Table 7: Digital Input Status Choices
©2010 Caterpillar

CONFIGURING DIGITAL INPUTS FOR SYSTEM EVENTS

System Events are used to know when specific conditions are reached and to alert the
control system of warning or shutdown conditions. To configure a Digital Input as a
System Event, go through the following menu options:
AT THE MAIN MENU, scroll down to CONFIGURE
Press the OK KEY .
SCROLL DOWN to INPUTS & OUTPUTS
Press the OK KEY .

Alternately, access to THE INPUTS & OUTPUTS

and
Press the OK KEY .
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OR SCADA).
Scroll DOWN to SYSTEM EVENT
Press the OK KEY .

ACTIVE STATE

and
Press the OK KEY .
Scroll DOWN to EVENT DELAY.

EVENT DELAY.
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Select the EVENT DELAY that you want
Press the OK KEY .
Scroll DOWN to EVENT PARAMETER
Press the OK KEY to edit the current STATUS

PARAMETER.
Select the type of EVENT PARAMETER that you want

to program (Pressures, Temperatures, Levels, or
Others)
Press the OK KEY .

Select the EVENT PARAMETER that you want to
program
Press the OK KEY .
Scroll DOWN to EVENT TRIGGER.

EVENT TRIGGER.
©2010 Caterpillar

Select the EVENT TRIGGER that you want
Press the OK KEY .
Press the ESC KEY .
Scroll DOWN to EVENT RESPONSE.
Press the OK KEY .
Select the EVENT RESPONSE that you want
Press the OK KEY .
©2010 Caterpillar

Any Digital Input can be configured for any one of the System Event parameters in Table 8:
Pressures Others
Engine Oil Pres Custom Event
Gas Pressure Air Dmpr Closed
Temperatures Batt Chrgr Fail
Eng Coolant Temp Fuel Leak
Engine Oil Temp Earth Fault
Exhaust Temp Earth Leakage
Gen Rear Brg Tmp Bat Chg Sys Volt
Gen Windg #1 Tmp Gen Bkr Closed (EMCP 4.3 only)
Levels Gen Bkr Open (EMCP 4.3 only)
Eng Coolant Lvl Gen Current
Engine Oil Level Gen Output Power
Fuel Level In Man Chrg Comb
Ext Tank Fuel Lvl EPS Supply Load
Emrg Stop Switch
Table 8: Digital Input System Events
CONFIGURING DIGITAL INPUTS FOR SCADA DATA LINK

When a Digital Input is configured for SCADA Data Link, the state of the input will be
placed into the appropriate MODBUS register. No alarms or warnings will be generated
by the EMCP. To configure a Digital Input for SCADA Data Link, go through the following
menu options:
AT THE MAIN MENU, scroll down TO

CONFIGURE
Press OK KEY
SCROLL DOWN to inputs & outputs
Press OK KEY

©2010 Caterpillar

Press OK KEY to access DIGITAL INPUTS

and
Press the OK KEY .

OR SCADA).
Scroll DOWN to:
SCADA
Press the OK KEY .

ACTIVE STATE.
©2010 Caterpillar

Press the OK KEY .
For information on reading the status of Digital Inputs via MODBUS, please refer to the
SCADA documentation.
DISABLING DIGITAL INPUTS

To disable a Digital Input, go through the following menu options:
AT THE MAIN MENU, scroll down TO

CONFIGURE
Press the OK KEY .
SCROLL DOWN to INPUTS & OUTPUTS
Press the OK KEY .

©2010 Caterpillar


and
Press the OK KEY .

OR SCADA).
Scroll DOWN to DISABLED
Press the OK KEY .
Note: If a Digital Input is set to Disabled, then any faults or events on that input will not
be broadcast or annunciated on the network.
©2010 Caterpillar

8.2 PROGRAMMING DIGITAL INPUTS USING THE CAT SERVICE TOOL

The EMCP 4 Digital Inputs can be configured using the Cat Service Tool. The key to
programming them is to program the setpoints related to each input in order from top to
bottom. To program an input, do the following steps:
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Section 4.2.
2. Select Digital Inputs on the left.
3. Determine which input is to be configured. For example, all of the setpoints for
Digital Input #1 have the text “#1” in their name.
4. Next follow the steps below according to which Usage Type is desired.
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PPLIC TION ND INST LL TION GUIDE

EMCP 4.3, 4.4

2 SAFETY INFORMATION.........................................................................4

4.7 STARTING AND STOPPING THE GENERATOR SET .............................................................46

5 HANDLING EVENTS .............................................................................55

8 DIGITAL INPUTS...................................................................................80

9 ANALOG INPUTS ...............................................................................102

Configuring Analog Inputs for Current Mode .......................................................................... 129

11 ANALOG OUTPUTS ...........................................................................165

12 PWM OUTPUTS ..................................................................................179

13.4 HARDWIRED LOAD SENSE L OAD DEMAND DETAILS .......................................................194

16 PROGRAMMABLE CYCLE TIMER ....................................................234

18 PROGRAMMABLE KW RELAY FUNCTION ......................................244

Primary CAN Wiring.............................................................................................................. 250

20 OPTIONAL MODULES........................................................................254

Figure 1: EMCP Software Release Date

Number of Generator Sets

Number of Generator Sets

2.1 ELECTRICAL SAFETY

2.2 ELECTROSTATIC DISCHARGE AWARENESS

Take the following precautions while installing/removing/handling the control:

3.1 MOUNTING LOCATION

3.2 OPERATING TEMPERATURE RANGE

3.3 POWER REQUIREMENTS

Figure 2: Generator Set Network Isolation

3.4 BATTERY CHARGER

3.5 ELECTRICAL CONNECTIONS

3.6 EUI ENGINES

3.7 EMCP 4.3 AND 4.4 ELECTRICAL DIAGRAMS

Figure 4: EMCP 4.4 Electrical Diagram

GENERATOR TEMPERATURE SCREEN

GENERATOR ENERGY SCREEN

VIEW NOMINAL SETTINGS SCREEN

BUS OVERVIEW (EMCP 4.4 ONLY)

4.4 VIEWING AND ADJUSTING PREFERENCES

SETTING THE PREFERENCES USING THE EMCP 4 DISPLAY

For any preference, press OK KEY to accept

the change (or ESCAPE KEY to reject the

CHANGING THE EMCP 4 CONTRAST WHEN THE DISPLAY IS UNREADABLE

1. Press the MAIN MENU key

2. Scroll DOWN until scrolling stops

6. Press the OK KEY to accept the adjustment

CHANGING THE EMCP 4 DISPLAY TO TECHNICIAN ENGLISH

1. Press the MAIN MENU key

2. SCROLL DOWN until the scrolling stops

4. SCROLL DOWN until the scrolling stops

6. Press the UP ARROW key until the scrolling stops

7. Press the OK KEY to select TECHNICIAN ENGLISH

To change the time/date, do the following:

At MAIN MENU scroll DOWN to CONFIGURE.

Press the OK KEY .

To begin editing the time, press the OK KEY

Select a digit using the LEFT ARROW or RIGHT ARROW

To change the selected digit use the UP ARROW or DOWN ARROW

TO CHANGE THE DATE FROM THIS POINT

Press the ESCAPE KEY again to return to the

Press the DOWN ARROW key to put the box

Select a digit using the LEFT ARROW or RIGHT ARROW .

To change the selected digit use the UP ARROW or DOWN ARROW .