Power System – Fast Training

Program

Inst. Ahmed M.
A/Hafeez

SDLC PSD-FTP 1
SDLC PSD-FTP 2
 Block Diagram
EUI Engine with A3/A4

T/C
THERMOCOUPLE

CAN 2

SDLC PSD-FTP 3
 Block Diagram
MUI Engine without Engine ECM

T/C
THERMOCOUPLE

SDLC PSD-FTP 4
 Product Comparison
Olympian
Product
Current

Custom
Solutions
2001 4001 A6K
EMCP3

N/A
EMCP 3.1 EMCP 3.2 EMCP 3.3 EMCP 3.4

SDLC PSD-FTP 5
 Product Comparison
Caterpillar
Product
Current

EMCP-II EMCP-II+ EMCP-II+P

EMCP3

EMCP 3.1 EMCP 3.2 EMCP 3.3 EMCP 3.4

SDLC PSD-FTP 6
 Standard Configuration
EMCP 3.1 EMCP 3.2 EMCP 3.3 EMCP 3.4

Standard for Standard for Standard for Option

European N. American Caterpillar for full-
sourced sourced small large featured
product product product paralleling
No options Few options Many options Many options
SDLC PSD-FTP 7
 Standard Configuration
Olympian Cat < 1MW Cat 1 – 5.5MW

EMCP 3.1 Standard N/A N/A

EMCP 3.2 Option Standard N/A

EMCP 3.3 N/A Option Standard

EMCP 3.4 Option Option Option

SDLC PSD-FTP 8
 Publications
• System Operation, Troubleshooting, Testing &
Adjusting
– RENR7902

SDLC PSD-FTP 9
 EMCP3.1 Feature Summary
• Olympian Standard replaces 2000 series
• Communication
– Data link local to A3/A4 (J1939)
– Hardwire sensor input without ADEM3
• 1 Local Annunciator on CAN 1
• Functionality
– Fault log up to 20 faults
– 3 Phase Generator input Voltage
and Current
– Engine Controls
– Engine Protection
• High coolant Temp
• Low oil Pressure
• Overspeed
• Fail to Start
SDLC PSD-FTP 10
 EMCP3.1
• 6 discrete sinking inputs
I/O
– Digital In1 reserved for E-Stop
– Digital In2 reserved for Remote Initiate
• 2 analog resistive sender inputs
– Passive Analog1 for Oil Pressure (Non – A3)
– Passive Analog2 for Coolant Temperature (Non – A3)
• 1 Magnetic Pick-Up input
• 6 relay outputs
– Relay1 Normally Open for Starter Motor Relay
– Relay2 Normally Open for Fuel Control Relay

SDLC PSD-FTP 11
 EMCP3.2
Feature Summary
• Caterpillar <1MW standard replaces EMCPII
• Additional Communications
– MODBUS RTU remote to customer (RS-485)
– Module Data Link (J1939)
• Additional Functionality
– Over/Under Voltage and Freq Protection
Optional Modules
– Annunciator
– Discrete I/O
– Digital Voltage Regulator (CDVR)
– Remote Monitoring
• - 40°C Panel Option

SDLC PSD-FTP 12
 EMCP3.2
I/O
• Inputs
– 2 more spare discrete inputs (8 total)
– 1 spare Passive analog resistive sender inputs (3 total)
– 1 Magnetic Pick-Up input (like EMCP3.1)
• Outputs
– 2 additional relay outputs (8 total)
– 1 spare sinking Driver output (1 total)

SDLC PSD-FTP 13
 EMCP3.3
Feature Summary
• Caterpillar 1-5.5MW standard replaces EMCPII+
• Additional Functionality
– Advanced Engine Monitoring
• More Pressures and Temperatures from A3/A4
• Fuel Consumption
– Emergency Shutdown Override (DTO Flash file)
– 400 Hz Capable
• Additional Optional Modules
– Resistive Temperature Device (RTD)
– Thermocouple (TC)
• High Quality Display
• Additional Output
– 1 more spare sinking Driver output (2 total)

SDLC PSD-FTP 14
SDLC PSD-FTP 15
 CAN 2

CAN 1

Will look at CDVR Event Log but no

control.

SDLC PSD-FTP 16
 CAN 1 CAN 2

SDLC PSD-FTP 17
 System Interface I/O
Digital Inputs
• Discrete low side (sinking) inputs
• Set to activate on:
– Active High (normally closed contact)
– OR Active Low (normally open contact)
• Digital In 1 wired to ground through E-Stop Switch
• Digital In 2 wired to ground through Remote Initiate Switch
• Other Digital In can be configured to trigger pressure,
temperature, & level events

SDLC PSD-FTP 18
 System Interface I/O
Analog Inputs
• Resistive senders (0-2000 Ohm)
• Passive analog 1 for Oil Pressure (Non-A3)
• Passive Analog 2 for Coolant Temp (Non-A3)
• Passive Analog 3 spare (not EMCP3.1)

SDLC PSD-FTP 19
 Analog Inputs

SDLC PSD-FTP 20
 1 Wire Sender

SDLC PSD-FTP 21
 System Interface I/O
Speed Sensor
• Magnetic Pick Up (MPU) used to determine RPM
• MPU- and MPU+ shielded by ground wire
• Internal resistance of 142 Ohms
• Independent MPU used by EMCP3 only

SDLC PSD-FTP 22
 System Interface I/O
Mag Pickup

SDLC PSD-FTP 23
 System Interface I/O
Voltage and Current Sensing
• Three Phase Generator Current
– 0-5A RMS AC current input for 3.1 to 3.4
– IA Gen In, IB Gen In, IC Gen In, I Gen AC Common
• Three Phase Generator Voltage
– 0-600vac for 3.1 – 3.4
– VA Gen In, VB Gen In, VC Gen In, Gen AC Neutral
• Three Phase Buss Voltage (EMCP3.4)
– 0-600 VAC RMS AC voltage Input, 60Hz
– VA Bus In, VB Bus In, VC Bus In, Gen AC Neutral
SDLC PSD-FTP 24
 Voltage/Current Sensing Wiring

SDLC PSD-FTP 25
 System Interface I/O
Digital Outputs
• 300mA low side (sinking) drivers
• Convey On/Off information to operate relays,
solenoids, and indicator lamps
• Examples:
– Shore Power Control Relay
– Ether
– Pre-lube

SDLC PSD-FTP 26
 System Interface I/O
Digital Output Wiring
Batt + Digital
Output
(Spare)

Control Relay 2
(Shore Power)

69 68 3.2 has one Dig Out

Digital Digital 3.3 has two Dig Out
Out1 Out2
Pin 69 goes negative to
energize the relay.

SDLC PSD-FTP 27
 System Interface I/O
Relay Outputs
• Relay 1 through 6 are Form-A
– One Normally Open (NO) contact
• Relay 7 & 8 are Form-C
– One NO contact
– One Normally Closed (NC) contact
• Current Capabilities
– Switching DC Loads
• Maximum Current: 2 Amps at 30 DCV
• Minimum Current: 300 mA contact load
– Switching Resistive AC Loads
• 10 A @ 120 ACV
• 5 A @ 240 ACV
SDLC PSD-FTP 28
 System Interface I/O
Relay Outputs
• Relay1 configured for Starter Motor
• Relay2 configured for Fuel Control (Non-A3)
• All other Relays
– Controlled by corresponding digital selector

SDLC PSD-FTP 29
 System Interface I/O
Batt -
Relay Output Wiring
Batt - ADEM3

Relay
Circuit Breaker Output
Shunt Trip 7 (C)
PreLube
Relay Relay Relay Relay Relay Pump
Starter Motor
Output Output Output Output Output Relay
Mag Switch
2 (C) 3 (C) 5 (C) 6 (C) 7 (NC)
GEN
20
Relay Relay Relay Relay Relay CONN
Output Output Output Output Output
GEN Relay
24 2 (NO) 3 (NO) 5 (NO) 6 (NO) 7 (NO)
CONN Output
Batt +
8 (NC)
Batt + Batt +

TERMINAL STRIP

NO C NO C NO C NO C NO C NO C NO NC C NO NC C
51 61 48 58 35 43 33 41 32 40 26 27 2 15 25 1 14 24

Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Relay 6 Relay 7 Relay 8

SDLC PSD-FTP 30
 System Interface I/O
Desired Speed & Voltage
• A3/A4 systems
– Desired speed from EMCP3 to ECM over J1939 data
link
– Desired voltage from EMCP3 to CDVR over J1939
data link
• Non-A3/A4 EUI and PEEC systems
– Desired speed from potentiometer and speed brick
– Desired voltage from switch on voltage regulator or
over J1939. New firmware selectable.

SDLC PSD-FTP 31
 SPEED/VOLTAGE ADJUST MENU

SDLC PSD-FTP 32
 System Interface I/O
Data Links – CAN2.0 J1939
• Non-isolated, shielded data link for local
communication
• Main branch maximum 800 ft long (CAN2)
• Can1 132 Ft. (40 Meters)
• Local branches maximum 3.3 ft from main
• Terminating resistors required at extreme ends to
reduce reflection

SDLC PSD-FTP 33
 System Interface I/O
Data Links – CAN2.0 J1939
• CAN1 Data link from EMCP3 to:
– A3/A4
– Engine and Generator Service Connectors
– CDVR
– Thermocouple Module #2
• CAN2 Data link (not EMCP3.1)
– Annunciator Module
– Resistive Temperature Device/Thermocouple Module #1
– Discrete I/O Module

SDLC PSD-FTP 34
 System Interface I/O
Data Link - MODBUS
• MODBUS (Not EMCP 3.1)
– Communication with PC built into control strategy
– No need for communication module
• Optically isolated, half duplex RS-485 data link for
SCADA

SDLC PSD-FTP 35
T e r m in ta tin g
System Interface I/O T e r m i n ta ti n g
R e s is to r
1 2 0 O h m s
Modbus & CAN1 Wiring R e s is to r
1 2 0 O hm s

A C B A C B

J1939

Could have T/C module

PC

A d a p te r
RS-485

+ s h ld - + Co m - + - + - + s h ld - + - + - + s h ld - + s h ld - + -
50 42 34 5 4 3 52 65 8 7 1 3 2 A B D E G C F 50 42 34 8 9
C A N1 M O D B U S B a tte ry B a tte ry C A N1 B a tte ry C D L C A N1 C A N1 CDL
EMCP3 1 2 P i n C o nn 9 P in C o nn G e ne ra to r/E ng ine S e rvi c e A D E M 3 J1
CDVR C o nne c to r

SDLC PSD-FTP 36
 System Interface I/O
J1 70 Pin Connector
Key Key

Pin 1 Pin 13

Key
SDLC PSD-FTP 37
 Optional Modules

• Annunciator
• Discrete I/O
• Thermocouple (TC)
• Resistive Temperature
Device (RTD)

SDLC PSD-FTP 38
 Optional Module
Annunciator
Dealer configurable Lamp Test Button
with replaceable film •LED’s

Custom slide kit available •Horn

Alarm Acknowledge
16 LED pairs announce
events, diagnostics, and
ready signals
Horn and Silencer
LED pair indicates
network/module status

SDLC PSD-FTP 39
 Optional Module
Annunciator
• Can be installed remotely up to 800 ft
• Designed for one on CAN1 and three on CAN2
• Communicate over CAN2 with no discrete input point
wiring
• Each LED pair has four settings configured with Cat
Service Tool
– Suspect Parameter Number (SPN)
– Trigger Type (disabled, general event, specific event)
– Trigger Severity Level
– Failure Mode Identifier (FMI)

SDLC PSD-FTP 40
 Optional Module
Discrete I/O
• Mount on genset or remote
• System designed for 2 I/O Modules
• Configured with Cat Service Tool
• Communicate over CAN2 with no discrete
input point wiring
• Non-volatile memory allows for functionality
during set point configuration and
communication through CAN2

SDLC PSD-FTP 41
 Optional Module
Discrete I/O
• Reads 12 Discrete Inputs with 4 return channels
– Sinking input with external switch closure to BATT (-)
– Warning inputs will automatically reset as input goes non-active
– Shutdown inputs will reset when reset message received on
J1939
• Sets 8 Form-C Relay Outputs
– 2 Amp @ 30 VDC
– General event output activates for and alarm &/or shutdown
– Specific event output activates for programmed SPN and FMI
SDLC PSD-FTP 42
 Optional Module
TC & RTD
• Thermocouple (TC)
– Reads 20 inputs from type J or K thermocouples

• Resistive Temperature Device (RTD)

– Scans 8 inputs from platinum RTD sensors
– Sensor type 2, 3, or 4-wire RTD
– Sensor resistance of 100 ohms
– Temperature coefficient configurable for 5 types of platinum

SDLC PSD-FTP 43
 Expansion Data Link Terminating
Resistor
1 120 Ohms

SDLC
Batt+ 52 2

B a tt +
Batt - 65 3

B a tt -
C B A
CAN2 SH 63 CAN2 SH
4

EMCP3
CAN2 - 64
5 CAN2 -
CAN2 + 62 CAN2 +
6

Batt+ 1

Batt - 2

NC 3

CAN2 SH 4

CAN2 - 5

A n n u n c i a to r # 1
CAN2 + 6

Batt+ 1

CAN2 + 2

CAN2 - 3

PSD-FTP
Batt - 4

CAN2 SH 5
CAN2

D i s c r e te I/O NC 6

NC 7

NC 8

Batt+ 1

CAN2 + 2

CAN2 - 3

Batt - 4

CAN2 SH 5
R T D /T C
Optional Module Wiring

NC 6
C B A
NC 7

NC 8
120 Ohms
Resistor
44

Terminating
 Display Functions

• Navigation Keys
• Password Entry
• Event Viewing &
Clearing
• Setpoint programming

SDLC PSD-FTP 45
 Navigation Keys
Lamp
Test

Alarm
AC Acknowledge
Overview

Escape
Engine
Overview Enter

SDLC PSD-FTP 46
•TO RESET E-STOP: FROM MAIN MENU SELECT EVENT LOG.
•SELECT (PRESS ENTER) EVENT LOG THEN GENSET CONTROL

•FIND THE E-STOP ACTIVE EVENT AND PRESS ENTER. RESET WILL BE HIGHLIGHTED, PRESS ENTER AGAIN (Must be in
Stop)
•ResetSDLC
Engine Fault PSD-FTP 47
 Password Entry
• Level 1 for customer
• Level 2 for technician to program some set points
• Level 3 for resetting hours and energy meters (call
Caterpillar for password)
• Passwords time out in 10 min. of no activity

SDLC PSD-FTP 48
 FINDING PASSWORD SET

SDLC PSD-FTP 49
 Password Entry

AC OVERVIEW
CONFIGURE
I/O STATUS Press UP or DOWN to
highlight CONFIGURE

Press ENTER to select

CONFIGURE

SDLC PSD-FTP 50
 Password Entry

SECURITY
SETPOINTS
TIME/DATE Press UP or DOWN to
highlight SECURITY

Press ENTER to select

SECURITY

SDLC PSD-FTP 51
 Password Entry

DROP TO MIN LEVEL

ENTER LEVEL 1 OR 2
Press UP or DOWN to
highlight ENTER LEVEL 1
OR 2

Press ENTER to select

ENTER LEVEL 1 OR 2

SDLC PSD-FTP 52
 Password Entry

Press UP or DOWN to
ENTER PASSWORD
FOR DESIRED LEVEL increment/decrement
_ _ _ _ _ _ _ _ 0 highlighted digit
Press RIGHT or LEFT to
change position of
highlighted digit
Press ENTER to submit
password

SDLC PSD-FTP 53
 Password Entry
• Password length
– Maximum 16 digits
– Minimum 1 digit
– Disabled when 0
• EMCP3 displays padlock if level too low to
change parameter

SDLC PSD-FTP 54
 Service Maintenance Interval
• Programmed from the factory at 500 hrs or 180 days
• Needs level 3 password to reset the alarm
• Can reset the password level using ET
• This alarm will only turn on the alarm light not shut down the engine.

SDLC PSD-FTP 55
 Using ET To RESET MAINT SERV
INTERVAL

SDLC PSD-FTP 56
 Service Maintenance Interval

Service Maint Interval

SDLC PSD-FTP 57
 Password Level

SDLC PSD-FTP 58
 Service Maintenance Interval

SDLC PSD-FTP 59
 Event Viewing & Clearing
Flashing red light is
unacknowledged
shutdown event

Press ALARM
ACKNOWLEDGE to
EVENT LOG
silence horn and stop
ENGINE OVERVIEW
flashing
AC OVERVIEW

Press STOP to shut

down engine

Highlight EVENT LOG

and press ENTER

SDLC PSD-FTP 60
 Event Viewing & Clearing

EVENT LOGS 05
GENSET CONTROL 03
ENGINE CONTROL 02
Select ECM

Press ENTER to view

event log

SDLC PSD-FTP 61
 Event Viewing & Clearing

Fault 3 of 3 is Oil filter

blocked
ENGINE LOG 03/03
APPR HIGH OIL PRESS
OIL FILTER BLOCKED

Scroll up for previous

event

SDLC PSD-FTP 62
 Event Viewing & Clearing

Fault 2 of 3
Approaching High Oil
ENGINE LOG 02/03 Pressure
APPR HIGH OIL PRESS
OIL FILTER BLOCKED

Scroll up or down for

other events

SDLC PSD-FTP 63
 Event Viewing & Clearing

Fault 1 of 3 High Oil

Pressure
ENGINE LOG 01/03
HIGH OIL PRESS
APPR HIGH OIL PRESS

After condition has

been repaired, Press
ENTER

SDLC PSD-FTP 64
 Event Viewing & Clearing
RESET ALL EVENTS
will be highlighted if
condition repaired and
control in STOP
ENGINE LOG --/03
RESET ALL EVENTS
Press ESCAPE twice
HIGH OIL PRESS
to return to main
menu

Press ENTER to clear

fault and turn off
shutdown light

SDLC PSD-FTP 65
 Input Programming

Bat. (-)

SDLC PSD-FTP 66
 Inputs
To E-Stop input on Auto Start/Stop
Block

To REM INIT input on Auto Start/Stop Block

SDLC PSD-FTP 67
•The digital inputs are tied to hardwire inputs
•May be called Discrete Inputs on the print
•Inputs tied to negative (bat. -)

Discrete Input 3
(Hardwire Input)

May be programmed as Pressure, Temperature,

levels, or other events. Refer to Event Input
Programming RENR 7902 Software block
SDLC PSD-FTP 68
Select “Active High” or
Active Low”

Digital Input Programming Event Input Programming

The Digital Inputs block is used to select The Event Input will first be programmed as “Active High” or
whether the input is “Active High” (Normally “Active Low”. It should be left as “Active High”
Closed Contact) or “Active Low” (Normally
The time delay is the next function to be set. Use the scroll
Open Contact)
up/down keys to choose the next function.
The next function will be the “Suspect Parameter Number”.
You can choose between Pressures, Temperatures,
Levels, and Others (Pages 33-34).
After the SPN has been choosen, select the FMI. Can be High
Warning, Low Warning, High Shutdown, Low Shutdown,
and Status.

SDLC PSD-FTP 69
 Outputs

Hardwire
Relays

Software
Block

SDLC PSD-FTP 70
 Digital Outputs
Relay Output 8 is the last
relay out on the EMCP3.3

Hardware
outputs

Software
Blocks
Digital Sinking Driver
outputs 1 and 2

SDLC PSD-FTP 71
 The Digital Selector determines what
selected conditions cause the relay output
•Programmed using the digital selectors to become active.
•Maybe listed on the terminal strip as RO1 – RO8

Software block
Hardwire output

Output

Digital Selector conditions to activate relay

SDLC PSD-FTP 72
 Digital Selector Programming
There are 8 “Digital Selectors”, of those 6 are associated with the
relay outputs. Digital Selector #1 controls Relay output #3.
Digital Selector 7 and 8 control Digital Outputs 1 and 2.
Relay Output Programming
Relays programmed as “ Active High”. This is read
only on the newest version of software.

In the box to the left the Display Text column is what you will see on the
EMCP3 display. The condition is what controls the output of the Digital Selector.
Choosing “Input 1” will turn on the relay when the “Air Shutoff” is called on by the
control.
SDLC PSD-FTP 73
Engine Setpoint Verifications - Test
The engine Setpoint verification procedure verifies that the EMCP
3 operates correctly when one of the following faults occurs:
Engine overspeed
High coolant temperature
Low oil pressure.

SDLC PSD-FTP 74
Verification Procedure:
Overspeed:
Setpoint: Engine overspeed shutdown threshold.

Note: This is a password protected Level 3 setpoint but changing parameters with the
Caterpillar Service Tool does not require passwords.

1. Start the engine and run the engine at its rated speed.
2. Adjust the setpoint value to a value that is below the engine speed, and press the ENTER key.
An Engine Overspeed Shutdown event will immediately occur.
3. View the event in the Genset Control event log.
4. Reset the event.
5. Return the setpoint value to its original value.

SDLC PSD-FTP 75
 Low Oil Pressure
Setpoint: Low Engine Oil Pressure Shutdown Event Threshold

1. Start the engine and run the engine at its rated speed.
2. Adjust the setpoint value to a value that is above the oil pressure that is being displayed, and
then press the ENTER key.
A shutdown event will occur after the programmable time delay has expired.
3. View the event in the Genset Control event log.
4. Reset the event.
5. Return the setpoint value to its original value.

SDLC PSD-FTP 76
 High Coolant Temperature
Setpoint: High Engine Coolant Temperature Shutdown Event Threshold

1. Start the engine and run the engine at its rated speed.
2. Adjust setpoint value to a value that is below the engine coolant temperature that is
being displayed, and then press the ENTER key.
A shutdown event will occur after the programmable time delay has expired.
3. View the event in the Genset Control event log.
4. Reset the event.
5. Return the setpoint value to its original value.

SDLC PSD-FTP 77
A Case Study
Generator Overspeed Warning

SDLC PSD-FTP 78
SDLC PSD-FTP 80