Professional Documents
Culture Documents
September 2004
Systems Operation
Troubleshooting
Testing and Adjusting
EMCP 3
CNB1-Up (Generator Set)
CMC1-Up (Generator Set)
BRK1-Up (Generator Set)
CAL1-Up (Generator Set)
FDN1-Up (Generator Set)
i01658146
Troubleshooting Section
Introduction
General Information .............................................. 40
Service Tools ........................................................ 41
Diagnostic Capabilities ......................................... 42
Diagnostic Trouble Code List ................................ 43
General Information
SMCS Code: 4490
g01030625
Illustration 1
Block diagram of a generator set with EMCP 3 and EUI Engine
RENR7902 5
Systems Operation Section
g01035964
Illustration 2
Block diagram of a generator set with EMCP 3 and MUI Engine
6 RENR7902
Systems Operation Section
i02155374
Component Location
SMCS Code: 4490
g01095847
Illustration 3
EMCP 3 Control Panel - Face Of Front Panel
(1) Electronic Control Module (ECM) for the (4) Either Start Aid Switch (SAS) (optional) (8) Alarm Acknowledge/Silence Switch
Generator Set (5) Speed Potentiometer (SP) (optional) (9) Alarm Horn
(2 ) Annunciator Module (ALM) (6) Emergency Stop Push Button (ESPB) (10) Panel Lights
(3) Panel Light Switch (PLS) (7) Lamp Test Switch
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Systems Operation Section
g01095834
Illustration 4
EMCP 3 Control Panel -Subpanel
(1) AC Terminal Strip (5) Discrete Input Output (I/O) Module or
(2) DC Terminal Strip Resistive Temperature Device (RTD)
(3) Switchgear Option Terminal Strip Module
(4) Discrete Input Output (I/O) Terminal Strip
8 RENR7902
Systems Operation Section
i01990626
g01045431
Illustration 5
(1) Display Screen (7) Lamp Test Key (13) Scroll Right Key
(2) AC Overview Key (8) Run Key (14) Enter Key
(3) Engine Overview Key (9) Auto Key (15) Scroll Down Key
(4) Yellow Warning Lamp (10) Stop Key (16) Scroll Left Key
(5) Red Shutdown Lamp (11) Scroll Up Key
(6) Alarm Acknowledge/Silence Key (12) Escape Key
STOP – Pressing the “STOP” Key (10) will cause the Alarm Indicators
engine to enter the “STOP” mode.
Yellow Warning Light – A flashing yellow light
Scroll Up – The Scroll Up Key (11) is used to indicates that there are unacknowledged active
navigate up through the various menus or monitoring warnings. A solid yellow light indicates that there
screens. The Scroll Up Key is also used during are acknowledged warnings active. If there are any
setpoint entry. During numeric data entry the Scroll active warnings, the yellow light will change from
Up Key is used in order to increment the digits (0-9). flashing yellow to solid yellow after the alarm Alarm
If the setpoint requires selection from a list, the Scroll Acknowledge/Silence Key (6 )is pressed. If there are
Up Key is used to navigate through the list. no longer any active warnings, the yellow light will
turn off after the Alarm Acknowledge/Silence Key (6 )
Escape – The Escape Key (12) is used during is pressed.
menu navigation in order to navigate up through the
menu/sub-menu structure. Each key press causes Red Shutdown Light – A flashing red light indicates
the user to move backwards/upwards through the that there are unacknowledged active shutdown
navigation menus. The Escape Key is also used events. A solid red light indicates that there are
to cancel out of data entry screens during setpoint acknowledged shutdown events active. If there
programming. If the Escape Key is pressed during are any active shutdown events the red light will
setpoint programming, none of the changes made on change from flashing red to solid red after the Alarm
screen will be saved to memory. Acknowledge/Silence Key (6 ) is pressed. Any
condition that has caused a shutdown event must
Scroll Right – The Scroll Right Key (13) is used be manually reset. If there are no longer any active
during setpoint adjustment. During numeric data shutdown events, the red light will turn off.
entry, the Scroll Right Key is used to choose which
digit is being edited. The Scroll Right Key is also
used during certain setpoint adjustments to select
Digital Inputs
or deselect a check box. If a box has a check mark
Note: There are 8 digital inputs on “EMCP 3.2” and
inside the box, pressing the Scroll Right Key will
“EMCP 3.3”. There are 6 digital inputs on “EMCP
cause the check mark to disappear, disabling the
3.1.”
function. If the box does not have a check mark
inside the box, pressing the Scroll Right Key will
Digital Input #1 – Digital Input #1 is used for the
cause a check mark to appear, Enabling the function.
emergency stop. This input should be wired to
GROUND through an Emergency Stop switch.
Enter – The Enter Key (14) is used during
The input can be set to activate on an active high
menu navigation to select menu items in order to
(normally closed contact) or an active low (normally
navigate forward/downward in the menu/sub-menu
open contact). If the operator wants to operate the
structure. The Enter Key is also used during setpoint
genset in the Reduced Power Mode, The Emergency
programming in order to save setpoints changes.
Stop must be configured for Active Low Refer to:
Pressing the Enter Key during setpoint programming
Testing and Adjusting , “Electronic Control Module
causes setpoint changes to be saved to memory
generator Set) Configure”Activating the emergency
stop input will cause the generator set to stop
Down – The Down Key (15) is used to navigate
immediately or prevent the generator set from
down through the various menus or monitoring
starting. Once Digital Input #1 goes active, the engine
screens. The Down Key is also used during setpoint
will not start until the event is reset. Refer to: System
entry. During numeric data entry the Down Key is
Operation , “Event Resetting”
used in order to decrement the digits (0-9). If the
setpoint requires selection from a list, the Down Key
Digital Input #2 – Digital Input #2 is used for
is used to navigate down through the list.
remotely starting and stopping the generator set.
This input should be wired to GROUND through
Scroll Left – The Scroll Left Key (16) is used during
a Remote Initiate switch. The input can be set to
setpoint adjustment. During numeric data entry,
activate on an active high (normally closed contact)
the Scroll Left Key is used to choose which digit is
or an active low (normally open contact). If the input
being edited. The Scroll Left Key is also used during
is active and the engine mode switch is in AUTO, the
certain setpoint adjustments to select or deselect
engine will attempt to start and run. Once the input
a check box. If a box has a check mark inside the
becomes inactive the engine will enter into cooldown
box, pressing the Scroll Left Key will cause the check
(if programmed) and then stop.
mark to disappear, disabling the function. If the box
does not have a check mark inside the box, pressing
the Scroll Left Key will cause a check mark to appear,
enabling the function.
10 RENR7902
Systems Operation Section
Table 1
Diagnostic Log Entry Format Table
Description
Suspect Parameter Number (SPN)(1)
Failure Mode Indicator (FMI) (2)
Table 2
Monitoring Features
The Thermocouple Module monitors twenty “Type-J”
or “Type-K” thermocouple inputs. All monitored
values are available on the communication link as
read-only information. Temperatures are configured
to indicate the “SAE J1939” Suspect Parameter
Number (SPN) transmitted by each temperature
input.
Table 3
SPNs Available for Configuration of Temperature Inputs
SPN Description
52 Engine Intercooler Temperature
105 Intake Manifold 1 Temperature
110 Engine Coolant Temperature
(continued)
12 RENR7902
Systems Operation Section
(Table 3, contd)
171 Ambient Air Temperature
172 Air Inlet Temperature
173 Exhaust Gas Temperature
174 Fuel Temperature
175 Engine Oil Temperature 1
176 Turbo Oil Temperature
441 Auxiliary Temperature 1
442 Auxiliary Temperature 2
1122 Alternator Bearing 1 Temperature
1123 Alternator Bearing 2 Temperature
1124 Alternator Winding 1 Temperature
1125 Alternator Winding 2 Temperature
1126 Alternator Winding 3 Temperature
1131 Intake Manifold 2 Temperature
1132 Intake Manifold 3 Temperature
1133 Intake Manifold 4 Temperature
1135 Engine Oil Temperature 2
1137 Exhaust Gas Port 1 Temperature
1138 Exhaust Gas Port 2 Temperature
1139 Exhaust Gas Port 3 Temperature
1140 Exhaust Gas Port 4 Temperature
1141 Exhaust Gas Port 5 Temperature
1142 Exhaust Gas Port 6 Temperature
1143 Exhaust Gas Port 7 Temperature
1144 Exhaust Gas Port 8 Temperature
1145 Exhaust Gas Port 9 Temperature
1146 Exhaust Gas Port 10 Temperature
1147 Exhaust Gas Port 11 Temperature
1148 Exhaust Gas Port 12 Temperature
1149 Exhaust Gas Port 13 Temperature
1150 Exhaust Gas Port 14 Temperature
1151 Exhaust Gas Port 15 Temperature
1152 Exhaust Gas Port 16 Temperature
1153 Exhaust Gas Port 17 Temperature
1154 Exhaust Gas Port 18 Temperature
1155 Exhaust Gas Port 19 Temperature
1156 Exhaust Gas Port 20 Temperature
1157 Main Bearing 1 Temperature (engine)
1158 Main Bearing 2 Temperature (engine)
(continued)
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Systems Operation Section
(Table 3, contd)
1159 Main Bearing 3 Temperature (engine)
1160 Main Bearing 4 Temperature (engine)
1161 Main Bearing 5 Temperature (engine)
1162 Main Bearing 6 Temperature (engine)
1163 Main Bearing 7 Temperature (engine)
1164 Main Bearing 8 Temperature (engine)
1165 Main Bearing 9 Temperature (engine)
1166 Main Bearing 10 Temperature (engine)
1167 Main Bearing 11 Temperature (engine)
1172 Turbocharger 1 Compressor Inlet Temperature
1173 Turbocharger 2 Compressor Inlet Temperature
1174 Turbocharger 3 Compressor Inlet Temperature
1175 Turbocharger 4 Compressor Inlet Temperature
1180 Turbocharger 1 Turbine Inlet Temperature
1181 Turbocharger 2 Turbine Inlet Temperature
1182 Turbocharger 3 Turbine Inlet Temperature
1183 Turbocharger 4 Turbine Inlet Temperature
1184 Turbocharger 1 Turbine Outlet Temperature
1185 Turbocharger 2 Turbine Outlet Temperature
1186 Turbocharger 3 Turbine Outlet Temperature
1187 Turbocharger 4 Turbine Outlet Temperature
1212 Engine Auxiliary Coolant Temperature
1800 Battery 1 Temperature
1801 Battery 2 Temperature
1802 Intake Manifold 5 Temperature
1803 Intake Manifold 6 Temperature
2433 Right Manifold Exhaust Gas Temperature
2434 Left Manifold Exhaust Gas Temperature
Table 4
Configuration Parameters for Each Input
Description Default Value Range
Input #n – Suspect Parameter 0 Any SPN listed in Table 3
Number (SPN)
Input #n - Type Not Installed Not Installed
Type-J
Type-K
Input #n – High Temperature 95 0 to 1735 C
Shutdown Threshold
Input #n – High Temperature 85 0 to 1735 C
Warning Threshold
Input #n – Low Temperature -200 -200 to 800 C
Warning Threshold
Input #n – High Temperature 1 0 to 120 seconds
Shutdown Delay Time
Input #n – High Temperature 1 Range = 0 to 120 seconds
Warning Delay Time
Input #n – Low Temperature 1 Range = 0 to 120 seconds
Warning Delay Time
Specifications i02015971
Table 5
Configuration Parameters for Each Input
Setpoint Parameter Range Default
Input #nn Active State Configuration Active Low Active
Active High State
Low
Input #nn Time Delay 0 to 120 sec. 0 sec.
Input #nn Suspect parameter Number (SPN) Any SPN Supported by EMCP 3 N/A
Input #nn Failure Mode Identifier (FMI) Any FMI supported by EMCP 3 N/A
Table 7
Configuration Parameters for Each Output
Setpoint Parameter Range
Output #nn Suspect Parameter Number (SPN) Any SPN supported by EMCP 3
Output #nn Triggger Condition Disabled
Condition Exists - Specific
Diagnostic - General
Diagnostic - Specific
High Shutdown - Specific
High Warning - Specific
Low Shutdown - Specific
Low Warning - Specific
Shutdown - General
Warning - General
Warning or Shutdown - Specific
Warning, Shutdown or Diagnostic - General
Warning, Shutdown or Diagnostic - Specific
The operating voltage range is 9 VDC to 32 VDC. Each of the 8 inputs have sensor diagnostics in order
The nominal voltage is 12 VDC or 24 VDC (external to detect open or short circuits that go to the RTD
power supplies). The output relay contacts are rated sensors. Overtemperature warnings and Shutdowns
for 2A @ 277 VAC, 5A @120 VAC and 5A @ 30 VDC. as well as Undertemperature warnings are detected
by comparing the measured temperature to the Low
The ambient operating temperature is -40°C to 70°C. Warning, the High Warning, the High Shutdown
temperatures stored in the module. All of these
diagnostic messages are broadcast on the “J1939”
i02014957
data link. The ECM reads these messages and
Resistive Temperature Device annunciates and/or performs engine shutdown
appropriately. Any of the inputs can be disabled in
Module order to prevent unnecessary diagnostic faults.
General Information
The Resistive Temperature Device (RTD) Module
is a temperature scanner capable of reading eight
Platinum RTD inputs. The eight Platinum RTD inputs
can have two, three, or four-wire configurations.
The RTD Module is also capable of generating
diagnostics. The diagnostics that are generated
by the RTD Module are maintained in non-volatile
memory. Storing the diagnostics in non-volatile
memory will make the diagnostics available following
a power loss.
18 RENR7902
Systems Operation Section
Table 8
Diagnostic Log Entry Format Table
Description
Suspect Parameter Number (SPN)(1)
Failure Mode Indicator (FMI )(2)
Time of Last Occurrence
Date of Last Occurrence
Time of First Occurrence
Date of First Occurrence
Engine Run Hours First Occurrence
Engine Run Hours Last Occurrence
Number of Occurrences
Security to Clear Log Entry
(1) See Table 10 for possible code numbers.
(2) See Table 9 for possible code numbers.
Table 9
RTD Module Diagnostics - FMI Codes
FMI Description
0 RTD Input #n High Temperature Shutdown
4 RTD Input Sensor #n Short Circuit
5 RTD Input Sensor #n Open Circuit
15 RTD Input #n High Temperature Warning
17 RTD Input #n Low Temperature Warning
Monitoring Features
The RTD Module monitors eight Platinum RTD
inputs. All monitored values are available on the
communication link as read-only information.
Temperatures are configured to indicated the SAE
J1939 Suspect Parameter Number (SPN) transmitted
by each temperature input.
Table 10
Table 11
Specifications i02014506
There are seventeen pair of LED indicators on Custom events that originate from sensing devices
the annunciator’s front panel. Sixteen pair of LED that do not communicate on the J1939 Data Link
indicators are used to announce events, diagnostics, need to have their dry contacts wired to EMCP3
and ready signals. The seventeenth pair of LED spare digital inputs or wired to an unused input on
indicators is used as a combined network/module the optional Discrete I/O Module. For information
status LED. The seventeenth pair of LED indicators on programming EMCP3 spare digital inputs see
can tell the operator if there is a problem with the System Operation, “Digital Input Programming”. For
J1939 data link connection. information on programming the Discrete I/O Module
see System Operation, “Discrete Input/Output
Module”.
Basic Operation
Each pair of LED indicators on the annunciator Suspect Parameter Number (SPN)
consists of two of the following three colors: green,
yellow, and red. For example, a pair of red and Choose the SPN from Table 12.
yellow LED indicators may be configured for Engine
Oil Pressure. If a low engine oil pressure Warning is Trigger Type
read over the data link, the Annunciator will flash the
Yellow LED and the audible horn will sound. If the low The Trigger Type may be set as Disabled, General
engine oil pressure Shutdown is read over the data Event, or Specific Event.
link, the Annunciator will flash the Red LED and the
audible horn will sound. Disabled – Disabling the Trigger Type disables
the LED pair. When disabled, the LED pair will not
To acknowledge the Shutdown and Alarm conditions respond to any data link message.
or silence the horn, press the “Alarm Acknowledge”
button that is located near the middle of the General Event – If General Event is chosen, the
Annunciator. SPN does not matter. General Event is used when
it is desired that the LED pair illuminate for any
To test the LED indicators or test the horn when the Warning, Shutdown, High, or Low.
data link is connected or disconnected, hold in the
“Lamp Test” button that is located near the top of the Specific Event – Specific Event is used when
Annunciator. the LED pair is to be associated with a specific
system parameter such as oil pressure or coolant
Configuration temperature.
Table 13
FMI Number Description
Failure Mode Identifier (FMI) Codes Short Description
0 Data Valid but Above Normal Operational Range - Most Severe Level High Shutdown
1 Data Valid but Below Normal Operational Range - Most Severe Level Low Shutdown
2 Data Erratic, Intermittent or Incorrect N/A
3 Voltage Above Normal or Shorted to High Source N/A
4 Voltage Below Normal or Shorted to Low Source N/A
5 Current Below Normal or Grounded Circuit N/A
6 Current Above Normal or Grounded Circuit N/A
7 Mechanical System Not Responding or Out of Adjustment N/A
8 Abnormal Frequency, Pulse Width or Period N/A
9 Abnormal Update Rate N/A
10 Abnormal Rate of Change N/A
g01093231
Illustration 6
Adding Optional Remote Annunciator.
g01093228
Illustration 7
Connection details for devices in parallel with remote annunciator.
• One System Control And Data Acquisition The Primary Data Link supports appropriate SAE
(SCADA) Data Link J1939 Broadcast Parameter Group Numbers (PGN)
and Suspect Parameter Numbers (SPN) for engine
Note: The “EMCP 3.1” has one Primary Data Link. and genset data.
The “EMCP 3.2” and “EMCP 3.3” have two Primary
Data Links and a single SCADA data link.
RENR7902 27
Systems Operation Section
The SCADA Data Link is used for communication Note: There are primary and secondary speed inputs
with a System Control And Data Acquisition (SCADA) for the EMCP 3 The speed inputs can be a pulse
system, and for support of a service tool connection. width modulated signal or the speed inputs can be
transmitted over the Data Link. The speed inputs
The SCADA Data Link uses the Modbus Protocol are configurable as primary or secondary with the
with an RS-485 half duplex hardware layer operating Electronic Technician. If the primary speed input fails
at a minimum of 2.4k bits per second. All data items the EMCP 3 will acknowledge and respond to the
are accessed as Modbus registers. Data that is less secondary input. If the primary speed input fails and
than 16 bits occupies a single register. Larger data the secondary input is disabled, the engine will go
occupies consecutive registers to allow access using to the idle speed setting.
single request.
The EMCP 3 receives the following information from
The SCADA Data Link is a Master/Slave Data Link. the engine ECM:
The SCADA controller Service Tool or customer
software will be the master and the genset controls • Engine Oil Pressure
will be slaves on the Data Link.
• Engine Coolant Temperature
The SCADA controller can connect directly to the
genset control or it may be connected remotely • Left Exhaust Manifold Temperature
through a modem using a RS485 to RS232 converter.
Passwords levels are used to restrict access to the • Right Exhaust Manifold Temperature
genset control.
• Intake Manafold Temperature
Each genset control on the SCADA Data Link has a
unique Modbus Address. A setpoint is available to • Oil Temperature
select the address for the genset control.
• Fuel Pressure
In order to use a modem connection to the SCADA
Data Link, the modem must be pre-configured with • Boost Pressure
all necessary communication parameters and set to
automatically answer. No modem handshaking or • Oil Filter Differential Pressure
control is performed by the genset controls.
• Fuel Filter Differential Pressur
• Air Filter Differential Pressure
• Fuel Consumption
The above information is shown on the display
screen of the EMCP 3. The information is used by the
EMCP 3 in order to monitor the system for events.
28 RENR7902
Systems Operation Section
The EMCP 3 also displays diagnostic codes from • The operator presses the “STOP” Key.
the ECM as a convenience to the operator. See
Troubleshooting, “Diagnostic code Trouble Code • The control is in “AUTO” and the remote initiate
List” for more information on the management of input (IC) becomes inactive.
diagnostic codes by the EMCP 3 and ECM.
• The operator presses the “AUTO” Key and a
stop command is sent via the RS-485 SCADA
i02195508
Data Link.
System Operation 2. After receiving the stop signal, the EMCP 3 checks
SMCS Code: 4490 that there are no present system faults.
a. On MUI engines, the EMCP 3 activates the There are 3 levels of password protection on
starting motor relay (SMR) and the fuel control the EMCP 3 control panel. All of the adjustable
relay (FCR). parameters are associated with a specific level
of security required to make an adjustment to the
b. On EUI engines, the EMCP 3 activates the parameter.
starting motor relay (SMR) and sends a start
signal to the Engine ECM via the J1939 The passwords only affect changing parameters from
Primary Data Link. The Engine ECM activates the EMCP 3 control panel. Changing parameters
the fuel control relay (FCR). with the Caterpillar Service Tool does not require
passwords
4. The EMCP 3 cycle cranks the engine until the
cycle crank time reaches the setpoint for total The level of password protection that is required for
crank time or until the engine starts. each setpoint is identified on the parameter setpoint
entry screen. A security level identification number
5. The EMCP 3 deactivates the starting motor relay “1”, “2”, or “3” next to a padlock symbol is displayed
(SMR) a when the engine speed reaches the on the parameter setpoint entry screen. A Level 3
setpoint for crank terminate speed. security is used for the most secure setpoints and
Level 1 security is used for the least secure setpoints.
Engine Stopping Procedure
If the EMCP 3 is currently at the required level of
1. The EMCP 3 will receive an engine stop signal. protection when viewing a parameter, the padlock
The signal will be one of three. will not appear.
RENR7902 29
Systems Operation Section
If a parameter is displayed with a padlock but no d. Press the “ENTER” key in order to select
security level identification number next to it, the “ENTER LEVEL 1 or 2”. “ENTER PASSWORD
parameter cannot be changed from the EMCP 3 FOR DESIRED LEVEL” is displayed. Also
display. shown is a 16 digit display with 0 highlighted at
the far right.
Level 1 and Level 2 passwords are disabled when
shipped from the factory. On initial start up of the e. Press the “UP” or “DOWN” key in order to
EMCP 3, Level 1 and Level 2 passwords can be user increment or decrement the highlighted digit
defined if desired. to the desired number.
Drop to Minimum Security Level f. Press the “RIGHT” key in order to highlight
the next character to be entered. Press the
“UP” or “DOWN” key in order to increment or
The first option on the security screen is “DROP TO
MIN LEVEL”. “DROP TO MIN LEVEL” refers to a decrement the highlighted digit to the desired
number.
process of placing the “EMCP 3” into the lowest level
of security authorized. This would be used when
leaving the control. If “DROP TO MIN LEVEL” is not g. Continue until the correct password has
been entered for the corresponding level.
initiated manually, the control will automatically revert
When all digits of the password are correctly
to minimum level after 10 minutes.
entered press the “ENTER” key. The current
level of password protection is displayed and
1. From the “MAIN MENU”, press the “UP” key or
parameters can be set.
the “ DOWN” key to highlight the “CONFIGURE”
menu.
Note: The EMCP 3 will go to the highest level of
security authorized by a correctly entered password.
a. Press the “ENTER” key in order to select
“CONFIGURE”. “SECURITY” will be
Note: The password can be up to 16 digits, but does
highlighted.
not have to be 16 digits. The password can be as
b. Press the “ENTER” key in order to select few as 1 digit. The password is entirely determined
by the user.
“SECURITY”. “DROP TO MIN LEVEL” will be
displayed.
Note: A password is not required if changing
parameters with Caterpillar Service Tool
c. Press the “ENTER” key to select “DROP TO
MIN LEVEL”
Enter level 3 password
d. The “EMCP 3” will now be at the minimum
level of security 1. From the “MAIN MENU”, press the “UP” key or
the “DOWN” key to highlight the “CONFIGURE”
Note: The current level of security for the EMCP 3 is menu.
displayed at the top of the display any time the EMCP
3 is in the “SECURITY” screen. a. Press the “ENTER” key to select
“CONFIGURE”. “SECURITY” will be
Enter Level 1 or 2 Password highlighted.
a. Press the “ENTER” key in order to select c. Press the “DOWN” key in order to highlight
“ENTER LEVEL 3”. Press “ENTER” to select
“CONFIGURE”. “SECURITY” will be
“ENTER LEVEL 3 ”.
highlighted.
d. A 16 digit number is shown and “ENTER
b. Press the “ENTER” key in order to select
RESPONSE” is highlighted. Copy this number
“SECURITY”. “DROP TO MIN LEVEL” will be
highlighted. and call the factory to obtain a factory provided
response code to enter into the EMCP 3.
c. Press the “DOWN” key in order to highlight
“ENTER LEVEL 1 OR 2”
30 RENR7902
Systems Operation Section
e. When the factory response is received from g. Continue until the desired password is
the factory, press “ENTER” to select “ENTER displayed.
RESPONSE”. “ENTER RESPONSE” is
displayed. Also shown is a 16 digit entry field h. Press the “ENTER” key. The password is now
where the factory provided password will be set.
entered.
Note: To change level 2 password, substitute
f. Press the “UP” or “DOWN” key in order to “CHANGE LEVEL 2 PSWD” for “CHANGE LEVEL 1
increment or decrement the highlighted digit to PSWD” in step 1.d above.
the correct factory provided password.
Note: To disable a security level, set the password
g. Press the “RIGHT” key in order to highlight to a single zero.
the next character to be entered. Press the
“UP” or “DOWN” key in order to increment or
i02011357
decrement the highlighted digit to the correct
password. Event Viewing
h. Continue to set all 16 digits until the factory SMCS Code: 4490
provided password is displayed.
Information from the EMCP 3 is displayed on the
i. When all digits of the factory password are display screen (1). The arrow keys on the keypad are
correctly entered, press the “ENTER” key. The used in order to navigate through the main menu.
current level (LEVEL 3) of security is displayed Press the UP key (11) or the DOWN key (15) in order
and parameters can be set. to highlight the main menu options.
Note: A password is not required if changing Press the “Enter” key (14) in order to select one of
parameters with Caterpillar Service Tool the main menu options. The arrow keys are used in
order to view one of the setpoints.
Change level 1 or level 2 password
The EMCP 3 panel will power up to the main menu
1. From the “MAIN MENU”, press the “UP” key or screen. If the EMCP 3 panel is already powered up,
the “DOWN” key to highlight the “CONFIGURE” press the “Escape” key (12) in order to return to the
menu. main menu.
a. Press the “ENTER” key in order to select The event system uses the following terms to
“CONFIGURE”. “SECURITY” will be describe the status of an Event:
highlighted.
PRESENT – The condition causing the event is
b. Press the “ENTER” key in order to select present and affecting system behavior.
“SECURITY”. “DROP TO MIN LEVEL” will be
highlighted ACTIVE – The event was previously present but it is
no longer. It has been latched by the event system
c. Make sure that the current level of security is and needs to be reset before the engine can be
at least as high as the level of the password to restarted.
be changed.
INACTIVE – The event was active at some time
d. Press the “DOWN ” key to highlight “CHANGE but is no longer active and is not affecting system
LEVEL 1 PSWD.” Press the “ENTER” key to behavior
select “CHANGE LEVEL 1 PSWD”
Perform the following steps in order to view one of
e. “CHANGE LEVEL 1 PSWD” is displayed. the events.
Press the “UP” or “DOWN” key in order to
increment or decrement the highlighted digit to 1. From the main menu, highlight “Event Log”.
the desired new password.
2. Press the “ENTER” key (14).
f. Press the “RIGHT” key in order to highlight
the next character to be entered. Press the 3. Select an ECM and press the “ENTER” key (14).
UP or “DOWN” key in order to increment or
decrement the highlighted digit to the desired 4. In order to scroll through the Events, use the “UP”
number. and “DOWN” keys.
RENR7902 31
Systems Operation Section
i02011347
Event Resetting
SMCS Code: 4490
i01990612
Setpoint Programming
SMCS Code: 4490
g01045431
Illustration 8
(1) Display Screen (9) Auto Key
(2) AC Overview Key (10) Stop Key
(3) Engine Overview Key (11) Scroll Up Key
(4) Yellow Warning Lamp (12) Escape Key
(5) Red Shutdown Lamp (13) Scroll Right Key
(6) Alarm Acknowledge/Silence Key (14) Enter Key
(7) Lamp Test Key (15) Scroll Down Key
(8) Run Key (16) Scroll Left Key
Main Menu The setpoints may require changing when the EMCP
3 is moved from one engine to another engine.
Information from the EMCP 3 is displayed on the The setpoints may also require changing in order
Display Screen (1). The arrow keys on the keypad to satisfy the requirements of the installation. The
are used in order to navigate through the main menu. setpoints that are stored in the EMCP 3 must match
Press the Scroll Up Key (11) or the Scroll Down the specified setpoints of the particular generator set.
Key (15) in order to highlight one of the main menu The setpoints are programmable. See the Testing
options. and Adjusting, “Electronic Control Module (Generator
Set) - Configure”.
Press the Enter Key (14) in order to select one of
the main menu options. The arrow keys are used in
order view or to select one of the setpoints listed on
the main menu.
• Engine Coolant Level The digital outputs have diagnostics for a short to
battery when the driver is on and diagnostics for a
• Engine Oil Level open circuit when the driver is off. If a short to battery
persists for 5 seconds, the driver will be disabled until
• Fuel Level the condition goes away.
• ATS in Emergency Position 1. To program the Active State of the Digital Output,
go through the following menu options:
• Battery Charger Failure
• Main Menu
• Generator Breaker Closed
• >Configure
• Utility Breaker Closed
• >Setpoints
• Fuel Leak Detected
• >I/O
• Custom Event
• >Digital Outputs
4. After the SPN is chosen, the Failure Mode
Identifier (FMI) is the next setting. The following 2. Select the Digital Output that you want to program.
FMI’s are available: Press the Enter Key.
• High Warning (example: High Temperature 3. Press the Enter Key again. The current
Warning) configuration will be highlighted.
• Low Warning (example: Low Temperature 4. Use the Scroll Up Key and the Scroll Down Key
Warning) in order to change the current configuration to the
desired setting.
• High Shutdown
5. Press the Enter Key to save the setting.
• Low Shutdown
Programming the Digital Selectors
• Status
There are 8 digital selectors. The digital selectors
i02184156 determine what conditions cause the Digital Outputs
to become active. Only two of the digital selectors
Digital Output Programming are associated with digital outputs.
Digital Selector # 7
Programming the Spare Analog
Digital Selector #7 controls Digital Output #1. The Input
available configuration options for Digital Selector
#7 are shown in table 14. To program the Spare Analog Input, go through the
following menu options:
Table 14
Digital Selector # 7 Configuration Options • Main Menu
Display Text Condition • >Configure
Disabled Disabled
• >Setpoints
Use Input #1(1) Disable Shore Power(1)
Use Input #2 Start Aid • >I/O
Use Input #3 Breaker #1 • >Spare Analog Input
Use Input #4 Breaker #2
The Spare Analog Input setpoints are shown below.
Use Input #5 Low Oil Pressure Warning
Use Data Link Input Use SCADA Data Link Enable/Disable
Command
(1) Default
If you intend to use the Spare Analog Input, the
Enable/Disable setpoint must first be enabled. If you
Digital Selector # 8 do not intend to use the Spare Analog Input, the
Enable/Disable setpoint MUST be disabled. If the
Digital Selector #8 controls Digital Output #2 The Spare Analog Input is enabled and not being used,
available configuration options for Digital Selector diagnostic codes will be logged
#8 are shown in table 15.
Suspect Parameter Number (SPN)
Table 15
Digital Selector # 7 Configuration Options The following SPN’s are available:
Low Shutdown Threshold 1. To program the Active State of the Relay Output,
go through the following menu options:
This is a numerical value entry.
• Main Menu
Low Shutdown Time Delay
• >Configure
This is a numerical value entry.
• >Setpoints
• >I/O
• >Relay Outputs
2. Select the Relay Output that you want to program.
Press the Enter Key.
4. Use the Scroll Up Key and the Scroll Down Key Digital Selector # 2
in order to change the current configuration to the
desired setting. Digital Selector #2 controls Relay Output #4 The
available configuration options for Digital Selector
5. Press the Enter Key to save the setting. #2 are shown in Table 17.
Table 17
Programming the Digital Selectors
Digital Selector # 2 Configuration Options
There are 8 digital selectors. The digital selectors Display Text Condition
determine what conditions cause the Relay Outputs
to become active. Only six of the digital selectors are Disabled Disabled
associated with Relay Outputs. Use Input #1 Horn Control
Table 19 Table 21
Digital Selector # 4 Configuration Options Digital Selector # 2 Configuration Options
Display Text Condition Display Text Condition
Disabled(1) Disabled(1) Disabled Disabled
Use Input #1 Common Warning Use Input #1 High Coolant Temperature
Warning
Use Input #2 Overspeed Shutdown
Use Input #2 Crank Alert
Use Input #3 Engine Started
Use Input #3 ECU Fault Reset
Use Input #4 Crank Alert
Use Input #4 High Coolant Temperature
Use Input #5 ECM Fault Reset Shutdown
Use Data Link Input Use SCADA Data Link Use Input #5(1) Start Aid(1)
Command
(1)
Use Data Link Input Use SCADA Data Link
Default
Command
(1) Default
Digital Selector # 5
i01988040
The EMCP 3 will keep track of the time and the date 13. Use the Scroll Right Key (13) or Scroll Left
with an internal real time clock with a battery backed Key (16) in order to highlight the digit to be
up memory. The time and the date will be maintained programmed.
by the internal battery even when the control battery
power is disconnected. 14. Press the Scroll Up Key (11) or Scroll Down
Key (15) in order to increment or decrement the
After the internal battery fails, the real time clock highlighted digit to the desired number.
will continue to keep time only when the control
battery power is connected. If the control power 15. Continue until the correct date has been entered.
is disconnected, the real time clock must be When all digits of the date are correctly entered,
reprogrammed when the control is repowered. press the Enter Key (14). “SET DATE” is shown
with the newly programmed date highlighted.
1. From the “MAIN MENU”, press the Scroll Up
Key (11) or the Scroll Down Key (15) in order to 16. Press the Escape Key (12) three times to return
highlight the “CONFIGURE” menu. to the “MAIN MENU”.
Troubleshooting Section
When the engine-generator, or any source to
Introduction which the engine-generator is synchronized to, is
operating, voltages up to 600V are present in the
control panel.
i02196307
Do not short these terminal with line voltage to
General Information ground with any part of the body or any conduc-
tive material. Loss of life or injury could result
SMCS Code: 4490 from electrical shock or injury from molten met-
al.
i02174153
Service Tools
SMCS Code: 0785
Table 22
Illustration 10
g00874165 6V-3000 Sure Seal Repair Kit
Danger Label for Electrical Shock (Outside of North America) 175-3700 Deutsch DT Style Connector
Repair Kit.
4 mm Hex Wrench
The Cat VR6 presents an electrical shock/electro- 237-5130 Digital Multimeter with infrared
cution hazard. This hazard will cause serious in- thermometer
jury or death. 257-9140 Fluke 80 Series Digital Multimeter
• Clear active diagnostic codes and clear logged • A time stamp will display the first occurrence of
diagnostic codes the problem.
i02015216
Table 23
Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting topic
Number (SPN) Identifier (FMI) String
38 0 External Tank High Fuel EXT TANK HIGH Digital Input Circuit
Level Shutdown FUEL LEVEL S/D Fault and Analog Input
Circuit Fault
38 1 External Tank Low Fuel EXT TANK LOW Digital Input Circuit
Level Shutdown FUEL LEVEL S/D Fault and Analog Input
Circuit Fault
38 3 External Tank Fuel Level EXT TANK FUEL Analog Input Circuit
Sensor Short High LEVEL SENSOR Fault
SHORT HIGH
38 4 External Tank Fuel Level EXT TANK FUEL Analog Input Circuit
Sensor Short Low LEVEL SENSOR Fault
SHORT LOW
38 15 External Tank High Fuel EXT TANK Digital Input Circuit
Level Warning HIGH FUEL LVL Fault and Analog Input
WARNING Circuit Fault
38 17 External Tank Low Fuel EXT TANK Digital Input Circuit
Level Warning LOW FUEL LVL Fault and Analog Input
WARNING Circuit Fault
(continued)
44 RENR7902
Troubleshooting Section
STOP.
RENR7902 55
Troubleshooting Section
Test Step 2. CHECK THE SETPOINTS. Repair: It is unlikely that the EMCP 3 has failed.
Exit this procedure and perform this procedure
A. View the setpoints (Crank Duration, Crank again. If the failure is not found, replace the EMCP
Cycle Rest Interval, and Maximum Number of 3.
Crank Cycles). Make a note of the setpoints.
See Testing and Adjusting, “Electronic Control STOP.
Module (Generator Set) - Configure”. Compare
the setpoints against the default setpoints of the • NOT OK – The wiring is not correct.
particular generator set.
Repair: Repair the wiring or replace the wiring.
Expected Result: Reset the genset. Resume normal operation and
verify that the problem has been corrected.
The setpoints are correct.
STOP.
Results:
Test Step 4. Check communications
• OK – The setpoints are correct for your particular between EMCP 3 and Engine ECM. (EUI
genset. Proceed to Test Step 3 for MUI engines. Engines Only)
Proceed to Test step 4 for EUI engines.
A. Use the CAT ET to Verify the Fuel enable input on
• NOT OK – The setpoints are NOT correct. the Engine ECM is configured for "CAN Input".
Repair: Reprogram the setpoints. Reset the B. Refer to the Genset Electrical System Schematic
genset. Resume normal operation and verify that in the Service Manual and check the Data Link
the problem has been corrected. wiring between the EMCP and the Engine ECM.
See Troubleshooting, “Data Link Circuit Fault”
STOP.
Results:
Test Step 3. Inspect the 2301A Governor
Power Source and Wiring. (MUI Engines • OK – The Data Link wiring is correct. The EMCP
Only) 3 may have failed.
Refer to the Genset Electrical System Schematic in Repair: It is unlikely that the EMCP 3 has failed.
the Service Manual for an accurate representation of Exit this procedure and perform this procedure
the genset that is being serviced. again. If the failure is not found, replace the EMCP
3.
A. Verify the Emergency Stop Push Button is not
pressed STOP.
B. Verify pin 58 on the EMCP 3 is connected through • NOT OK – The wiring is not correct.
a normally open contact on the emergency stop
switch to battery positive. Repair: Repair the wiring or replace the wiring.
Reset the genset. Resume normal operation and
C. Verify the Fuel Control Relay Output on pin 38 verify that the problem has been corrected.
of the EMCP 3 is connected to terminal 2 on the
2301A Governor and verify the in line fuse is not STOP.
open.
Expected Result:
Results:
A. Determine the conditions that caused the The engine speed can be viewed and adjusted from
overspeed condition. the EMCP 3 Display Screen.
A overspeed was caused by a occurrence known to • OK – The engine speed can be viewed and
the operator and the operator would like to put the adjusted from the EMCP 3 Display Screen.
genset back into service.
Repair: Adjust the engine speed to meet site
Results: requirements. Resume normal operation and verify
that the problem has been corrected.
• OK – The operator can determine the cause
for the overspeed condition, the condition has STOP.
been repaired and the operator wants to put the
genenset back into service. • NOT OK – The engine speed cannot be adjusted.
Proceed to test step 7
Repair: Reset the genset. Resume normal
operation and verify that the problem has been • NOT OK – The engine speed reads zero on the
corrected. EMCP Display Screen.
A. View the Engine Speed Monitor and Generator Test Step 4. CHECK THE SYSTEM BY
Desired Engine Speed Request setpoints. Make a USING THE SPEED POTENTIOMETER.
note of the setpoints. See Testing and Adjusting, (MUI ENGINES ONLY)
“Electronic Control Module (Generator Set) -
Configure”. Compare the setpoints against the A. With the engine running, adjust the speed of the
default setpoints of the particular generator set. engine by turning the speed potentiometer.
The setpoints are correct. The engine can be adjusted to the desired speed.
Results: Results:
• OK – The setpoints are correct for your particular • OK – The engine speed can be adjusted.
genset. Proceed to test step 3 for EUI engines.
Proceed to test step 4 for MUI engines Repair: Adjust the engine speed to meet site
requirements. Resume normal operation and verify
• NOT OK – The setpoints are NOT correct. that the problem has been corrected.
Test Step 3. VERIFY ENGINE SPEED CAN Test Step 5. CHECK THE RESISTANCE OF
BE VIEWED AND ADJUSTED FROM THE THE ENGINE SPEED POTENTIOMETER.
EMCP 3 (EUI ENGINES ONLY) (MUI ENGINES ONLY)
Verify the engine speed can be viewed and adjusted A. Shut down the engine.
from the EMCP 3 Display Screen.
B. Disconnect the speed potentiometer from the
terminals “11” and “12” on the 2301A Governor.
58 RENR7902
Troubleshooting Section
C. At the speed potentiometer, measure the Repair: The EMCP 3 may have failed. It is unlikely
resistance of the speed potentiometer. that the EMCP 3 has failed. Exit this procedure and
perform this entire procedure again. If the problem
Expected Result: remains, replace the EMCP 3. See Testing And
Adjusting, “ Electronic Control Module (Generator
The resistance should be adjustable between 0 and Set) - Replace”.
100 ohms.
STOP.
Results:
• NOT OK – The harness wiring with the incorrect
• OK – The resistance of the sensor is correct. resistance measurement has failed. Replace
Proceed to Test Step 6. the failed harness from the 2301A governor
to the speed potentiometer or repair the failed
• NOT OK – The resistance of the speed harness from the 2301A governor to the speed
potentiometer is not correct. potentiometer. Resume normal operation and
verify that the problem has been corrected. STOP.
Repair: Replace the speed potentiometer. Resume
normal operation and verify that the problem has Test Step 7. CHECK J1939 DATA LINK
been corrected. BETWEEN THE EMCP 3 AND THE
ENGINE ECM (EUI ENGINES ONLY)
STOP.
Refer to the Genset Electrical System Schematic in
Test Step 6. CHECK THE SPEED the Service Manual and check the Data Link wiring
POTENTIOMETER HARNESS FOR A between the EMCP 3 and the Engine ECM. For more
OPEN CIRCUIT. (MUI ENGINES ONLY) information on troubleshooting the Data Link, see
Troubleshooting, “Data Link Circuit Fault ”.
A. Disconnect the speed potentiometer harness from
the 2301A governor. Results:
B. Check for an open circuit. Check the resistance • OK – The J1939 Data Link wiring is correct.
from the wire connected to terminal “11” of the
2301A governor to the same wire number at the Repair: The EMCP 3 may have failed. It is unlikely
speed potentiometer. The resistance should be 5 that the EMCP 3 has failed. Exit this procedure and
ohms or less. perform this entire procedure again. If the problem
remains, replace the EMCP 3. See Testing And
C. Check for an open circuit. Check the resistance Adjusting, “ Electronic Control Module (Generator
from the wire connected to terminal “12” of the Set) - Replace”.
2301A governor to the same wire number at the
speed potentiometer. The resistance should be 5 STOP.
ohms or less
• NOT OK – The wiring is not correct
Expected Result:
Repair: Repair the Data Link wiring or Replace the
When the resistance is measured between the wire Data Link wiring. Resume normal operation and
connected to terminal “11” of the 2301A governor to verify the problem has been corrected.
the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less. STOP.
Results:
STOP.
60 RENR7902
Troubleshooting Section
Test Step 4. CHECK THE SYSTEM BY Test Step 6. CHECK THE SPEED
USING THE SPEED POTENTIOMETER. POTENTIOMETER HARNESS FOR A
(MUI ENGINES ONLY) OPEN CIRCUIT. (MUI ENGINES ONLY)
A. With the engine running, adjust the speed of the A. Disconnect the speed potentiometer harness from
engine by turning the speed potentiometer. the 2301A governor.
• OK – The engine speed can be adjusted. C. Check for an open circuit. Check the resistance
from the wire connected to terminal “12” of the
Repair: Adjust the engine speed to meet site 2301A governor to the same wire number at the
requirements. Resume normal operation and verify speed potentiometer. The resistance should be 5
that the problem has been corrected. ohms or less
• NOT OK – The engine speed cannot be adjusted When the resistance is measured between the wire
with the speed potentiometer. Proceed to test step connected to terminal “11” of the 2301A governor to
5 the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less.
Test Step 5. CHECK THE RESISTANCE OF
THE ENGINE SPEED POTENTIOMETER. When the resistance is measured between the wire
(MUI ENGINES ONLY) connected to terminal “12” of the 2301A governor to
the same wire number at the speed potentiometer
A. Shut down the engine. connector, the resistance should be 5 ohms or less.
Results: STOP.
• OK – The resistance of the sensor is correct. • NOT OK – The harness wiring with the incorrect
Proceed to Test Step 6. resistance measurement has failed. Replace
the failed harness from the 2301A governor
• NOT OK – The resistance of the speed to the speed potentiometer or repair the failed
potentiometer is not correct. harness from the 2301A governor to the speed
potentiometer. Resume normal operation and
Repair: Replace the speed potentiometer. Resume verify that the problem has been corrected. STOP.
normal operation and verify that the problem has
been corrected. Test Step 7. CHECK THE J1939 DATA
LINK BETWEEN THE EMCP 3 AND THE
STOP. ENGINE ECM (EUI ENGINES ONLY)
Refer to the Genset Electrical System Schematic in
the Service Manual and check the Data Link wiring
between the EMCP 3 and the Engine ECM. For more
information on troubleshooting the Data Link, see
Troubleshooting, “Data Link Circuit Fault ”.
RENR7902 61
Troubleshooting Section
• OK – The J1939 Data Link wiring is correct. The generator was place into a mode other than
AUTO by the operator or by a Modbus RS-485
Repair: The EMCP 3 may have failed. It is unlikely SCADA data link message .
that the EMCP 3 has failed. Exit this procedure and
perform this entire procedure again. If the problem Results:
remains, replace the EMCP 3. See Testing And
Adjusting, “ Electronic Control Module (Generator • OK – STOP.
Set) - Replace”.
i02183223
STOP.
Generator Output Sensing
• NOT OK – The wiring is not correct
Circuit Fault
Repair: Repair the Data Link wiring or Replace the
Data Link wiring. Resume normal operation and SMCS Code: 4490
verify the problem has been corrected.
System Operation Description:
STOP.
If the engine is running and the EMCP 3 is receiving
AC voltage and current information but not processing
i02177111 any AC measurements. then the “GENERATOR
Generator Control Not in OUTPUT SENSING CIRCUIT FAULT” is made
active. The EMCP 3 has failed.
Automatic Warning
Perform the following procedure: Electronic Control
SMCS Code: 4490 Module (Generator Set) - Replace
Note: The severity of the overcurrent condition will Repair: Reset the genset. Resume normal
determine if a warning or shutdown event occurs. operation and verify that the problem has been
corrected.
Conditions Which Generate This Code:
STOP.
The code for generator overcurrent is generated
when the EMCP 3 determines that a generator • NOT OK – The setpoints are NOT correct.
overcurrent condition has occurred.
Repair: Reprogram the setpoints. Reset the
Test Step 1. TALK TO THE OPERATOR genset. Resume normal operation and verify that
the problem has been corrected.
A. Determine the conditions that caused the
overcurrent condition. STOP.
Expected Result:
i02178029
• NOT OK – The setpoints are NOT correct. • NOT OK – The generator output frequency cannot
be adjusted with the speed potentiometer. Proceed
Repair: Reprogram the setpoints. Reset the to test step 5
genset. Resume normal operation and verify that
the problem has been corrected. Test Step 5. CHECK THE RESISTANCE OF
THE ENGINE SPEED POTENTIOMETER.
STOP. (MUI ENGINES ONLY)
Test Step 3. VERIFY FREQUENCY CAN A. Shut down the engine.
BE VIEWED AND ADJUSTED FROM THE
EMCP 3 (EUI ENGINES ONLY) B. Disconnect the speed potentiometer from the
terminals “11” and “12” on the 2301A Governor.
Verify the generator output frequency can be viewed
and adjusted from the EMCP 3 Display Screen. C. At the speed potentiometer, measure the
resistance of the speed potentiometer.
Expected Result:
Expected Result:
The generator output frequency can be viewed and
adjusted from the EMCP 3 Display Screen. The resistance should be adjustable between 0 and
100 ohms.
Results:
Results:
• OK – The generator output frequency can be
viewed and adjusted from the EMCP 3 Display • OK – The resistance of the sensor is correct.
Screen. Proceed to Test Step 6.
64 RENR7902
Troubleshooting Section
• NOT OK – The resistance of the speed Test Step 7. CHECK J1939 DATA LINK
potentiometer is not correct. BETWEEN THE EMCP 3 AND THE
ENGINE ECM (EUI ENGINES ONLY)
Repair: Replace the speed potentiometer. Resume
normal operation and verify that the problem has Refer to the Genset Electrical System Schematic in
been corrected. the Service Manual and check the Data Link wiring
between the EMCP 3 and the Engine ECM. For more
STOP. information on troubleshooting the Data Link, see
Troubleshooting , “Data Link Circuit Fault ”.
Test Step 6. CHECK THE SPEED
POTENTIOMETER HARNESS FOR AN Results:
OPEN CIRCUIT. (MUI ENGINES ONLY)
• OK – The J1939 Data Link wiring is correct.
A. Disconnect the speed potentiometer harness from Proceed to test step 8
the 2301A governor.
• NOT OK – The wiring is not correct
B. Check for an open circuit. Check the resistance
from the wire connected to terminal “11” of the Repair: Repair the Data Link wiring or Replace the
2301A governor to the same wire number at the Data Link wiring. Resume normal operation and
speed potentiometer. The resistance should be 5 verify the problem has been corrected.
ohms or less.
STOP.
C. Check for an open circuit. Check the resistance
from the wire connected to terminal “12” of the Test Step 8. CHECK THE VOLTAGE
2301A governor to the same wire number at the INPUT FUSES.
speed potentiometer. The resistance should be 5
ohms or less A. Check the three fuses on the AC voltage inputs of
the EMCP 3.
Expected Result:
Expected Result:
When the resistance is measured between the wire
connected to terminal “11” of the 2301A governor to The fuses should not be open.
the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less. Results:
When the resistance is measured between the wire • OK – The fuses are not open. Proceed to test step
connected to terminal “12” of the 2301A governor to 9
the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less. • NOT OK – One or more of the fuses are open.
Results: Repair: Check for a shorted component or
damaged wiring. Troubleshoot and repair the
• OK – The harness functions properly. Proceed to problem. See the Generator Set Wiring Diagram
test step 8 for your particular genset. After the problem has
been repaired, replace the fuses.
• NOT OK – The harness wiring with the incorrect
resistance measurement has failed. Replace STOP.
the failed harness from the 2301A governor
to the speed potentiometer or repair the failed Test Step 9. CHECK THE GENERATOR
harness from the 2301A governor to the speed VOLTAGE OUTPUT.
potentiometer. Resume normal operation and
verify that the problem has been corrected. STOP. A. Open the circuit breaker or remove the load.
D. Check for one or more damaged wires between Conditions Which Generate This Code:
the EMCP 3 voltage inputs and the voltage input
fuses. See the Generator Set Wiring Diagram for The code for generator overvoltage is generated
your particular genset. when the EMCP 3 determines that a generator
overvoltage condition has occurred.
Expected Result:
Test Step 1. TALK TO THE OPERATOR
The wiring and the connectors should have been
good. A. Determine the conditions that caused the
overvoltage condition.
Results:
Expected Result:
• OK – NO problem was found with the connectors
or with the wiring. A overvoltage was caused by a occurrence known to
the operator and the operator would like to put the
Repair: The EMCP 3 may have failed. It is unlikely genset back into service.
that the EMCP 3 has failed. Exit this procedure and
perform this entire procedure again. If the problem Results:
remains, replace the EMCP 3. See Testing And
Adjusting, “ Electronic Control Module (Generator • OK – The operator can determine the cause
Set) - Replace”. for the overvoltage condition, the condition has
been repaired and the operator wants to put the
STOP. genenset back into service.
Repair: Reset the genset. Resume normal Repair: Adjust the generator output voltage to
operation and verify that the problem has been meet site requirements. Resume normal operation
corrected. and verify that the problem has been corrected.
STOP. STOP.
• NOT OK – The overvoltage condition was not • NOT OK – The generator output voltage cannot
caused by a occurrence known to the operator. be adjusted. Proceed to test step 4
Proceed to Test Step 2
Test Step 4. CHECK CAT DATA LINK
Test Step 2. CHECK THE SETPOINTS. BETWEEN THE EMCP 3 AND THE
VOLTAGE REGULATOR
A. View the Generator Overvoltage setpoints. Make
a note of the setpoints. See Testing and Adjusting, Refer to the Genset Electrical System Schematic in
“Electronic Control Module (Generator Set) - the Service Manual and check the Data Link wiring
Configure”. Compare the setpoints against the between the EMCP 3 and the Voltage Regulator. For
default setpoints of the particular generator set. more information on troubleshooting the Data Link,
see Troubleshooting , “Data Link Circuit Fault ”.
Expected Result:
Results:
The setpoints are correct.
• OK – The Data Link wiring is correct.
Results:
Repair: Refer to the appropriate voltage regulator
• OK – The setpoints are correct for your particular service manual and perform an operational check
genset. of the voltage regulator. Replace the voltage
regulator if necessary. Resume normal operation
Repair: Reset the genset. Resume normal and verify the problem has been corrected.
operation and verify that the problem has been
corrected. STOP.
STOP.
i02178170
The generator output voltage can be adjusted from If the current rises above the Generator Reverse
the EMCP 3 Display Screen. Power Percentage Threshold setpoint value, the
reverse power timer will begin timing. When the timer
Results: expires, the Generator Reverse Power event is made
active (if the current has been above the threshold
• OK – The generator output voltage can be level continuously while timing). If the current drops
changed from the EMCP 3 Display Screen. below the Generator Reverse Power Percentage
Threshold, the Generator Reverse Power event will
be made inactive and the timer will be reset.
RENR7902 67
Troubleshooting Section
If a reverse power condition is detected, “GEN Repair: Reprogram the setpoints. Reset the
REVERSE POWER SHUTDOWN” or “GEN genset. Resume normal operation and verify that
REVERSE POWER WARNING” will be displayed on the problem has been corrected.
the EMCP 3 in order to inform the operator of an
reverse power condition. STOP.
Note: The severity of the reverse power condition will Test Step 3. CHECK THE POLARITY OF
determine if a warning or shutdown event occurs. THE CURRENT TRANSFORMERS
Conditions Which Generate This Code:
Expected Result:
Results:
Repair: Install the current transformers as shown Repair: Reset the genset. Resume normal
on the wiring diagram for your particulart genset. operation and verify that the problem has been
Reset the genset. Resume normal operation and corrected.
verify that the problem has been corrected.
STOP.
STOP.
• NOT OK – The underfrequency condition was not
caused by a occurrence known to the operator.
i02178486
Proceed to Test Step 2
Generator Underfrequency Test Step 2. CHECK THE SETPOINTS.
Warning
A. View the Generator Underfrequency and
SMCS Code: 4490 Generator Desired Engine Speed Request
setpoints. Make a note of the setpoints. See
System Operation Description: Testing and Adjusting, “Electronic Control Module
(Generator Set) - Configure”. Compare the
If the frequency drops below the Generator setpoints against the default setpoints of the
Underfrequency Percentage Threshold setpoint particular generator set.
value, the underfrequency timer will begin
timing. When the timer expires, the Generator Expected Result:
Underfrequency event is made active (if the
frequency has been below the threshold level The setpoints are correct.
continuously while timing). If the frequency rises
above the Generator Underfrequency Percentage Results:
Threshold, the Generator Underfrequency event will
be made inactive and the timer will be reset. • OK – The setpoints are correct for your particular
genset. Proceed to test step 3 for EUI engines.
If a underfrequency condition is detected, “GEN Proceed to test step 4 for MUI engines
UNDERFREQUENCY SHUTDOWN” or “GEN
UNDERFREQUENCY WARNING” will be displayed • NOT OK – The setpoints are NOT correct.
on the EMCP 3 in order to inform the operator of an
underfrequency condition. Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
Note: The severity of the underfrequency condition the problem has been corrected.
will determine if a warning or shutdown event occurs.
STOP.
Conditions Which Generate This Code:
Test Step 3. VERIFY FREQUENCY CAN
The code for generator underfrequency is generated BE VIEWED AND ADJUSTED FROM THE
when the EMCP 3 determines that a generator EMCP 3 (EUI ENGINES ONLY)
underfrequency condition has occurred.
Verify the generator output frequency can be viewed
Test Step 1. TALK TO THE OPERATOR and adjusted from the EMCP 3 Display Screen.
• OK – The operator can determine the cause for Repair: Adjust the generator output frequency to
the underfrequency condition, the condition has meet site requirements. Resume normal operation
been repaired and the operator wants to put the and verify that the problem has been corrected.
genenset back into service.
STOP.
RENR7902 69
Troubleshooting Section
• NOT OK – The generator output frequency cannot Test Step 6. CHECK THE SPEED
be adjusted. Proceed to test step 7 POTENTIOMETER HARNESS FOR AN
OPEN CIRCUIT. (MUI ENGINES ONLY)
• NOT OK – The generator frequency reads zero on
the EMCP Display Screen. Proceed to test step 8 A. Disconnect the speed potentiometer harness from
the 2301A governor.
Test Step 4. CHECK THE SYSTEM BY
USING THE SPEED POTENTIOMETER. B. Check for an open circuit. Check the resistance
(MUI ENGINES ONLY) from the wire connected to terminal “11” of the
2301A governor to the same wire number at the
A. With the engine running, adjust the generator speed potentiometer. The resistance should be 5
output frequency by turning the speed ohms or less.
potentiometer.
C. Check for an open circuit. Check the resistance
Expected Result: from the wire connected to terminal “12” of the
2301A governor to the same wire number at the
The generator output can be adjusted to the desired speed potentiometer. The resistance should be 5
frequency. ohms or less
• OK – The generator output frequency can be When the resistance is measured between the wire
adjusted. connected to terminal “11” of the 2301A governor to
the same wire number at the speed potentiometer
Repair: Adjust the generator output frequency to connector, the resistance should be 5 ohms or less.
meet site requirements. Resume normal operation
and verify that the problem has been corrected. When the resistance is measured between the wire
connected to terminal “12” of the 2301A governor to
STOP. the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less.
• NOT OK – The generator output frequency cannot
be adjusted with the speed potentiometer. Proceed Results:
to test step 5
• OK – The harness functions properly. Proceed to
Test Step 5. CHECK THE RESISTANCE OF test step 8
THE ENGINE SPEED POTENTIOMETER.
(MUI ENGINES ONLY) • NOT OK – The harness wiring with the incorrect
resistance measurement has failed. Replace
A. Disconnect the speed potentiometer from the the failed harness from the 2301A governor
terminals “11” and “12” on the 2301A Governor. to the speed potentiometer or repair the failed
harness from the 2301A governor to the speed
B. At the speed potentiometer, measure the potentiometer. Resume normal operation and
resistance of the speed potentiometer. verify that the problem has been corrected. STOP.
Repair: Repair the Data Link wiring or Replace the Repair: The wiring or the connections the are
Data Link wiring. Resume normal operation and damaged. Check for damaged wiring between
verify the problem has been corrected. the fuses and the generator output bus. See the
Generator Set Wiring Diagram for your particular
STOP. genset. Repair the wiring or replace the wiring.
Resume normal operation and verify the problem
Test Step 8. CHECK THE VOLTAGE has been corrected.
INPUT FUSES.
STOP.
A. Check the three fuses on the AC voltage inputs of
the EMCP 3. Test Step 10. CHECK THE VOLTAGE
INPUT CONNECTIONS
Expected Result:
A. Shut down the engine.
The fuses should not be open.
B. Remove the EMCP 3 harness connector from the
Results: EMCP 3.
• OK – The fuses are not open. Proceed to test step C. Check the EMCP 3 harness connector. See
9 Testing And Adjusting, “Electrical Connector -
Inspect”.
• NOT OK – One or more of the fuses are open.
D. Check for one or more damaged wires between
Repair: Check for a shorted component or the EMCP 3 voltage inputs and the voltage input
damaged wiring. Troubleshoot and repair the fuses. See the Generator Set Wiring Diagram for
problem. See the Generator Set Wiring Diagram your particular genset.
for your particular genset. After the problem has
been repaired, replace the fuses. Expected Result:
A. Open the circuit breaker or remove the load. • OK – NO problem was found with the connectors
or with the wiring.
B. Start the engine and run the genset.
Repair: The EMCP 3 may have failed. It is unlikely
C. Measure the voltage between all three AC input that the EMCP 3 has failed. Exit this procedure and
fuses. perform this entire procedure again. If the problem
remains, replace the EMCP 3. See Testing And
Expected Result: Adjusting, “ Electronic Control Module (Generator
Set) - Replace”.
The line to line voltage should measure the rated
voltage of the genset. STOP.
If a undervoltage condition is detected, “GEN • NOT OK – The setpoints are NOT correct.
UNDERVOLTAGE SHUTDOWN” or “GEN
UNDERVOLTAGE WARNING” will be displayed on Repair: Reprogram the setpoints. Reset the
the EMCP 3 in order to inform the operator of an genset. Resume normal operation and verify that
undervoltage condition. the problem has been corrected.
The code for generator undervoltage is generated Verify the generator output voltage can be adjusted
when the EMCP 3 determines that a generator from the EMCP 3 Display Screen.
undervoltage condition has occurred.
Expected Result:
Test Step 1. TALK TO THE OPERATOR
The generator output voltage can be adjusted from
A. Determine the conditions that caused the the EMCP 3 Display Screen.
undervoltage condition.
Results:
Expected Result:
• OK – The generator output voltage can be
A undervoltage was caused by a occurrence known changed from the EMCP 3 Display Screen.
to the operator and the operator would like to put the
genset back into service. Repair: Adjust the generator output voltage to
meet site requirements. Resume normal operation
Results: and verify that the problem has been corrected.
Repair: Reset the genset. Resume normal Test Step 4. CHECK CAT DATA LINK
operation and verify that the problem has been BETWEEN THE EMCP 3 AND THE
corrected. VOLTAGE REGULATOR
Test Step 5. VERIFY VOLTAGE SENSING B. Start the engine and run the genset.
CIRCUITS
C. Measure the voltage between all three AC input
Verify all three phases of generator output voltage fuses.
are shown on the EMCP 3 Display Screen.
Expected Result:
Expected Result:
The line to line voltage should measure the rated
All three phases of generator output voltage are voltage of the genset.
shown on the EMCP 3 Display Screen
Results:
Results:
• OK – The voltages are correct and the problem
• OK – All three phases of generator output voltage remains. Proceed to Test Step 8.
are shown on the EMCP 3 Display Screen
• NOT OK – One or more of the voltages are NOT
Repair: Refer to appropriate voltage regulator correct.
service manual and perform an operational check
of the voltage regulator. Resume normal operation Repair: The wiring or the connections the are
and verify that the problem has been corrected. damaged. Check for damaged wiring between
the fuses and the generator output bus. See the
STOP. Generator Set Wiring Diagram for your particular
genset. Repair the wiring or replace the wiring.
• NOT OK – All phases of voltage are not shown on Resume normal operation and verify the problem
display. Proceed to test step 6 has been corrected.
The wiring and the connectors should have been Genset maintenance records indicate that the
good. maintenance interval has been exceeded and
maintenance is required
Results:
Results:
• OK – NO problem was found with the connectors
or with the wiring. • OK – Records indicate service is required. Perform
the required maintenance and reset the Service
Repair: The EMCP 3 may have failed. It is unlikely Maintenance Interval in order to indicate when the
that the EMCP 3 has failed. Exit this procedure and genset will need to be serviced again. STOP.
perform this entire procedure again. If the problem
remains, replace the EMCP 3. See Testing And • NOT OK – Records indicate service is not
Adjusting, “ Electronic Control Module (Generator required. Proceed to Test Step 2
Set) - Replace”.
Test Step 2. CHECK THE SETPOINTS.
STOP.
A. View the setpoints (Service Maintenance Interval
• NOT OK – The problem was with the connectors Hours), and (Service Maintenance Interval Days)
or with the wiring. and make note of the setpoints. See Testing and
Adjusting, “Electronic Control Module (Generator
Repair: Repair the connectors or replace the Set) - Configure”. Compare the setpoints against
wiring harness. Resume normal operation and the default setpoints of the particular generator
verify that the problem has been corrected. set.
Conditions Which Generate This Code: Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
The Service Maintenance Interval code is generated the problem has been corrected.
when the EMCP 3 determines a need for engine
service based on engine hours or the number of days STOP.
since last service, whichever occurs first.
B. Reconnect all harness connectors. If the battery voltage drops below the Low Battery
Voltage Warning Threshold setpoint value, the low
C. Reset the genset. battery voltage event timer will begin timing. When
the low battery voltage event timer expires, the Low
D. Operate the genset. Battery Voltage event is made active (if the battery
voltage has been below the event threshold level
E. Check the status of the diagnostic code. continuously while timing). If the battery voltage rises
above the Low Battery Voltage Event Threshold, the
Expected Result: Low Battery Voltage event will be made inactive and
the timer will be reset.
The diagnostic code is not active.
If a battery undervoltage condition is detected, “LOW
Results: BATTERY CHARGING SYS VOLT WARN” or “LOW
BATTERY VOLTAGE WARNING” will be displayed
• OK – The diagnostic code is not active. The on the EMCP 3 in order to inform the operator of an
diagnostic code does not exist at this time. The undervoltage condition.
initial diagnostic code was probably caused by a
poor connection or a short at one of the connectors Note: The severity of the battery over/under voltage
that was disconnected and reconnected. Resume condition will determine if a warning or shutdown
normal operation. STOP. event occurs.
• NOT OK – The code is active. The diagnostic code Conditions Which Generate This Code:
has not been corrected. The ECM may have failed.
This code is generated when the measured battery
Repair: It is unlikely that the ECM has failed. Exit voltage value goes above or below the programmed
this procedure and perform this procedure again. thresholds for a configurable duration.
If the cause of the failure is not found, replace
the ECM. See Testing and Adjusting, “Electronic Test Step 1. PERFORM THE INITIAL
Control Module (Generator Set) - Replace”. CHECK.
STOP. A. The battery and charging system are located on
the engine. Use ET to Check for active diagnostic
codes on the engine ECM. If any codes are
i02179474
present, correct the engine diagnostic codes first.
Charging System Expected Result:
SMCS Code: 1401; 1405
No other diagnostic codes or indicators are active
System Operation Description: on the engine ECM.
Repair: It is unlikely that the ECM has failed. Exit Test Step 2. Check for Shorts in the
this procedure and perform this procedure again. Modbus RS-485 SCADA Data Link
If the cause of the failure is not found, replace Harness
the ECM. See Testing and Adjusting, “Electronic
Control Module (Generator Set) - Replace”. A. Disconnect all connectors from the suspected
data link.
STOP.
B. Measure the resistance between (data link +) and
data link −).
i02180062
Data Link Circuit Fault C. Measure the resistance between ( data link +) and
chassis ground.
SMCS Code: 4490
D. Measure the resistance between ( data link −) and
System Operation Description: chassis ground.
Note: There are three data links associated with the Expected Result:
EMCP 3. The Data Links are the (J1939 Accessory
Data Link), (J1939 Primary Data Link), and the The resistance is greater than 20,000 Ohms for each
(Modbus RS-485 SCADA Data Link). Refer to measurement.
Systems Operation, “General Information” for details.
This procedure checks for an open circuit or a short Results:
circuit in one of the Data Links
• OK – Proceed to Test Step 5
Note: Use the wiring diagram for your particular
genset in order to troubleshoot the Data Links. • Not OK – There is a short circuit in the harness
or connectors.
Test Step 1. Inspect the Electrical
Connectors and the Wiring Repair: Repair the wiring or replace the wiring.
B. Thoroughly inspect the EMCP 3 connector, Test Step 3. Check the Resistance
the service tool connector, and all other through the Modbus RS-485 SCADA Data
connectors in the circuit for the data link. Refer to Link Harness
Troubleshooting, “Electrical Connectors - Inspect”
for details. A. Disconnect all connectors from the suspected
data link.
Expected Result:
B. Use a suitable piece of wire to short (Data Link +)
All connectors, pins, and sockets are completely and ( Data Link −) at the EMCP 3.
inserted and coupled. The harness and wiring are
free of corrosion, of abrasion, and of pinch points. C. Measure the resistance between (Data Link +)
and (Data Link −) at all other connectors in the
Results: circuit for the data link.
Test Step 4. Check for Shorts in the J1939 Repair: It is unlikely that the ECM has failed. Exit
Data Link Harness this procedure and perform this procedure again.
If the cause of the failure is not found, replace
A. Disconnect all connectors from the suspected the ECM. See Testing and Adjusting, “Electronic
data link. Control Module (Generator Set) - Replace”.
Repair: Exit this procedure. Troubleshoot the Test Step 4. CHECK IF THE DIAGNOSTIC
active code or indicator. Refer to the engine CODE REMAINS
Troubleshooting manual for your particular genset.
A. Inspect the harness connectors and clean the
STOP. contacts of the machine harness connectors.
A. View the Digital Input setpoints. Make a note C. Reset the genset.
of the setpoints. See Testing and Adjusting,
“Electronic Control Module (Generator Set) - D. Operate the genset.
Configure”. Compare the setpoints against the
default setpoints of the particular generator set. E. Check the status of the diagnostic code.
Results: Results:
• OK – The setpoints are correct for your particular • OK – The diagnostic code is not active. The
genset. Proceed to Test Step 3 diagnostic code does not exist at this time. The
initial diagnostic code was probably caused by a
• NOT OK – The setpoints are NOT correct. poor connection or a short at one of the connectors
that was disconnected and reconnected. Resume
Repair: Reprogram the setpoints. Reset the normal operation. STOP.
genset. Resume normal operation and verify that
the problem has been corrected. • NOT OK – The code is active. The diagnostic code
has not been corrected. The ECM may have failed.
STOP.
Repair: It is unlikely that the ECM has failed. Exit
Test Step 3. CHECK THE DIGITAL INPUT this procedure and perform this procedure again.
WIRING If the cause of the failure is not found, replace
the ECM. See Testing and Adjusting, “Electronic
A. Check the wiring to the corresponding digital Control Module (Generator Set) - Replace”.
inputs for an unwanted short circuit. The short can
be to the battery negative (“B-”). Carefully check STOP.
ALL wires that are connected to the appropriate
digital input for abrasion or worn spots in the
i02180829
insulation that could be causing the short. Check
the wires in the generator control panel. Check
the wires in the engine harness. Refer to the
Digital Output Circuit Fault
appropriate wiring diagrams for the circuit that is SMCS Code: 4490
being checked.
System Operation Description:
Expected Result:
Digital Outputs are used to convey on/off information
The wiring is correct. from the Genset Control for energizing loads such as
relays, solenoids, and indicator lamps. The digital
Results: output must not be connected directly to battery
positive (B+).
• OK – No problems can be found with the digital
input wiring. Proceed to test step 4 Conditions Which Generate This Code:
• NOT OK – The digital input wiring is defective. This code is occurs when the digital output wiring is
shorted to battery positive (B+).
Repair: Repair the wiring or replace the wiring.
Test Step 1. CHECK FOR A SHORTED
Proceed to test step 4 HARNESS
A. Turn the key start switch and the disconnect
switch to the OFF position.
80 RENR7902
Troubleshooting Section
B. Disconnect the harness connector from the EMCP Repair: Repair the digital output device or replace
3. the digital output device.
The engine speed sensor is mounted on the flywheel Repair: Exit this procedure. Troubleshoot the
housing of the engine. active code or indicator. Resume normal operation
and verify that the problem has been corrected.
The sensor creates a sine wave signal. The signal
is created from passing ring gear teeth. The rate of STOP.
the signal is one pulse per tooth. The sensor sends
the sine wave signal to the EMCP 3. The frequency Test Step 2. CHECK THE SETPOINTS.
of the signal is directly proportional to the speed of
the engine. A. View the Engine Speed Monitor Setpoints. Make
a note of all the setpoints. See Testing and
Conditions Which Generate This Code: Adjusting, “Electronic Control Module (Generator
Set) - Configure”. Compare the setpoints against
This code is generated when the EMCP 3 the default setpoints of the particular generator
has determined that an incorrect signal from set.
the engine speed sensor has occurred or a
overspeed/underspeed condition has occurred. Expected Result:
STOP.
Note: The Engine Speed Sensor is commonly B. Disconnect the harness connector from the EMCP
referred to as magnetic pickup. 3.
Test Step 1. PERFORM THE INITIAL C. At the EMCP 3 harness connector, measure the
CHECK. resistance from contact “66” to contact “67”.
No other diagnostic codes or indicators are active. • OK – There is probably an intermittent problem.
Proceed to Test Step 4.
Results:
• NOT OK – The harness wiring or the speed sensor
• OK – No other diagnostic codes or indicators are has failed. Proceed to Test Step 4.
active. Proceed to Test Step 2
Test Step 4. CHECK FOR AN
• NOT OK – Another diagnostic code is active or an INTERMITTENT FAULT.
indicator is active.
A. Press the Stop Key on the EMCP 3 control.
• OK – A speed sensor diagnostic code does not When the resistance is measured between contact
appear on the EMCP 3 display. This step has “1” of the sensor harness connector and contact “66”
corrected the problem. STOP. of the EMCP 3 harness connector, there should be
5 ohms or less.
• NOT OK – A speed sensor diagnostic code
appears on the EMCP 3 display. Proceed to Test The resistance from contact “2” of the sensor harness
Step 5. connector to contact “67” of the EMCP 3 harness
connector should be 5 ohms or less.
Test Step 5. CHECK THE RESISTANCE
OF THE ENGINE SPEED SENSOR. The resistance from contact “66” to contact “67” of
the EMCP 3 harness connector should be greater
A. Disconnect the sensor from the engine harness. than 5000 ohms.
The sensor remains fastened to the engine.
Results:
B. At the connector of the sensor, measure the
resistance between contact “1” and contact “2”. • OK – The harness functions properly. Proceed to
Test Step 7.
Expected Result:
• NOT OK – The ciruit with the incorrect resistance
The resistance should be between 100 to 350 ohms. measurement has failed. Replace the failed
harness from the sensor to the EMCP 3 connector
Results: or repair the failed harness from the sensor to the
EMCP 3 connector. STOP.
• OK – The resistance of the sensor is correct.
Proceed to Test Step 6. Test Step 7. CHECK THE SHIELD AND
THE CONNECTORS.
• NOT OK – Replace the sensor.
A. Press the Stop Key on the EMCP 3 control.
Repair: Refer to Testing And Adjusting, “Speed
Sensor (Engine) - Adjust”. B. Disconnect the sensor from the engine harness.
The sensor remains fastened to the engine.
STOP.
C. Disconnect the harness connector from the EMCP
Test Step 6. CHECK THE HARNESS FOR 3.
AN OPEN OR A SHORT.
D. The harness has a shield (bare wire) which
A. Press the Stop Key on the EMCP 3 control. protects the sensor signal wire from electrical
interference. This shield must be securely
B. Disconnect the sensor from the engine harness. fastened and the shield must make a good
The sensor remains fastened to the engine. electrical connection to ground.
C. Disconnect the harness connector from the EMCP E. Check that the shield is securely fastened to
3. ground.
D. Check for an open circuit. Check the resistance F. Check the connection between the sensor and the
from contact “1” of the sensor harness connector mating harness connector. Refer to Testing and
to contact “66” of the EMCP 3 harness connector. Adjusting, “Electrical Connector - Inspect”.
The resistance should be 5 ohms or less.
Expected Result:
E. Check for an open circuit. Check the resistance
from contact “2” of the sensor harness connector The shield should be securely fastened. The
to contact “67” of the EMCP 3 harness connector. connection between the sensor and the mating
The resistance should be 5 ohms or less. harness connector should be secure.
RENR7902 83
Troubleshooting Section
• OK – No damage is present. Reinstall the engine C. Start and run the engine at rated speed.
speed sensor. Adjust the sensor.
D. Measure the AC signal voltage of the engine
Repair: For more information, refer to Testing And speed sensor.
Adjusting, “Speed Sensor (Engine) - Adjust”.
Expected Result:
Proceed to Test Step 9.
The voltage should be equal to 2 ACV or greater.
• NOT OK – Damage is present. Replace the engine
speed sensor. Results:
Repair: Refer to Testing And Adjusting, “Speed • OK – The voltage is equal to 2 ACV or greater.
Sensor (Engine) - Adjust”. The speed sensor circuit is correct. STOP.
The EMCP 3 determines the engine speed, in rpm, Repair: Refer to the engine Troubleshooting
from the Magnetic Pickup (Engine Speed Sensor) manual to for more information on engine
input pins, detects diagnostics on the sensor, unexpected engine shutdowns for your particular
and annunciates an engine over/under speed genset.
condition. The engine speed sensor used for these
determinations is an independent sensor to be used STOP.
by the EMCP 3 only.
• NOT OK – Another diagnostic code is active or an
Conditions Which Generate This Code: indicator is active.
While the engine is running, if engine speed suddenly Repair: Exit this procedure. Troubleshoot the
becomes zero and the Auto Start/Stop function block active code or indicator. Resume normal operation
has not initiated a shutdown, an “UNEXPECTED and verify that the problem has been corrected.
ENGINE SHUTDOWN” event will be activated.
STOP.
Test Step 1. TALK TO THE OPERATOR
A. Determine the conditions that caused the
unexpected shutdown.
Expected Result:
Results:
STOP.
Expected Result:
Results:
Testing and Adjusting • Moisture can enter the connector through the
wire insulation.
Section
5. Check for dirty contacts or corroded contacts.
Electrical Connector - Inspect • Check each contact of the connector for a snug
fit by using a new pin and socket. The new
SMCS Code: 7553-040 contact should stay connected if the connector
is held with the contacts that are facing down.
Intermittent electrical problems are often caused by
poor connections. Use the following checks as a i02148670
reference for inspecting connectors.
Wiring Harness (Open Circuit)
1. Check the connection of the connectors.
- Test
• Ensure that the locking rings are properly SMCS Code: 1408-081
locked.
An open is a failure of an electrical circuit that
• Ensure that locking clips are used on Sure Seal results in no flow of electrical current. An open
connectors.
circuit is usually caused by failed electrical wires
or a poor connection of electrical connectors. If an
• Ensure that the center of the connector is tight. electrical wire or a connection is broken, the flow of
electrical current through the circuit is interrupted. A
• Ensure that the connector pins and sockets normally closed circuit will have less than 5 ohms of
align properly.
resistance. The following procedure explains the test
for an open circuit:
2. Check the wires at the connector.
Reference: For a complete electrical schematic,
• Ensure that the wires enter the back of the refer to Electrical System Schematic for the genset
connector straight.
that is being serviced.
• Ensure that each wire is properly crimped into TEST FOR AN OPEN CIRCUIT.
the proper connector contact.
1. Identify the connectors and the wire numbers of
• Ensure that each connector contact is properly the suspect circuits. Use the Electrical System
locked into the connector contact. When the
Schematic of the genset to identify the circuits.
connector contact is locked properly, the contact
(wire) cannot be pulled out of the connector
2. Turn the disconnect switch to the OFF position.
body without excessive force.
3. Disconnect the components and the ECM from
3. Check each wire for nicks or signs of abrasion
the wiring harness.
in the insulation.
4. At one of the disconnected harness connections,
4. Check for moisture at the connector.
place a jumper wire from the contact of the
suspect wire to frame ground.
• Check for damaged connector seals or lost
connector seals.
5. At the other connector of the genset harness, use
the multimeter probes to measure the resistance
• Check for missing or loose wire hole plugs. from the contact of the suspect wire to frame
ground.
• Check for wires that do not enter the connector
properly.
Expected Result: The resistance is less than 5
ohms.
• If the wires enter the connector at an angle,
there may not be a good seal between the
OK – The resistance is less than 5 ohms. The
connector and the wire insulation.
harness circuit is correct.
86 RENR7902
Testing and Adjusting Section
Stop. Stop.
NOT OK – The resistance is greater than 5000 NOT OK – The resistance is less than 5000
ohms. There is an open in the genset harness. ohms. There is a short in the genset harness. The
short is between the suspected wire and the wire
Repair: Repair the genset harness or replace the with the lowest resistance measurement.
genset harness.
Repair: Repair the genset harness or replace the
Stop. genset harness.
Stop.
i02148682
Reference: For a complete electrical schematic, Note: The wye configuration of external potential
refer to Electrical System Schematic for the genset transformers (PT’s) is preferred for 4-wire wye
that is being serviced. generators because of the greater accuracy
when loads are unbalanced. With the open delta
TEST FOR A SHORT CIRCUIT. configuration, some power parameters can not be
determined. These parameters are real power phase
1. Identify the connectors and the wire numbers of A, B, C and power factor phase A, B, C. For maximum
the suspect circuits. Use the Electrical System accuracy, the open delta configuration of external
Schematic of the genset to identify the circuits. PT’s should be used only for 3-wire delta generators.
g01047743
Illustration 14
Wye Configuration Of External Potential Transformers (PT) On 4-Wire Wye Generator
This configuration allows the accurate measurement of all power parameters by the EMCP 3 including when the loads are unbalanced and
neutral current is present. All power parameters are shown on the display of the EMCP 3.
g01047744
Illustration 15
Open Delta Configuration Of External Potential Transformers (PT) On The 3-Wire Delta Generator
This configuration allows the accurate measurement of power parameters by the EMCP 3 including when the loads are unbalanced and
circulating current is present. The real power phase A, B and C can not be determined. The power factor phase A, B and C can not be
determined. The phases are not shown on the EMCP 3 display.
88 RENR7902
Testing and Adjusting Section
g01047747
Illustration 16
Open Delta Configuration Of External Potential Transformers (PT) On The 4-Wire Wye Generator
This configuration results in less accurate measurement of all power parameters by the “EMCP 3” when the loads are unbalanced and neutral
current is present. Real power phase A, B, C and power factor phase A, B, C can not be determined and are not shown on the “EMCP 3” display.
g00289497
Illustration 17
Speed Sensor
(1) Speed sensor
(2) Locknut
(A) Air gap
g01045431
Illustration 18
(1) Display Screen (7) Lamp Test Key (13) Scroll Right Key
(2) AC Overview Key (8) Run Key (14) Enter Key
(3) Engine Overview Key (9) Auto Key (15) Scroll Down Key
(4) Yellow Warning Lamp (10) Stop Key (16) Scroll Left Key
(5) Red Shutdown Lamp (11) Scroll Up Key
(6) Alarm Acknowledge/Silence Key (12) Escape Key
• Event Input Function a. Press the Enter Key (14) in order to select
“PREFERENCES”. “CONTRAST” will be
• Event Output Function highlighted.
• Generator AC Power Monitor d. Press the Enter Key (14) in order to select
“BACKLIGHT”. Adjust the backlight as needed.
• Generator Over Current Use the Scroll Left Key (16) or the Scroll Right
Key (13) in order to adjust the backlight. Press
• Generator Over/Under Frequency the Enter Key (14)to save.
• Generator Over/Under Voltage e. Press the Scroll Down Key (15) in order to
highlight “PRESSURE”.
• Generator Reverse Power
f. Press the Enter Key (14) in order to select
“PRESSURE”. Use the Scroll Left Key (16) or
Discrete Input Output (I/O) the Scroll Right Key (13) in order to highlight
“kPa”, “PSI”, or “BAR”.
• Digital Inputs
g. Press the Enter Key (14) in order to save the
• Digital Outputs selection.
• Relay Outputs h. Press the Scroll Down Key (15) in order to
highlight “TEMPERATURE”.
• Spare Analog Input
i. Press the Enter Key key (14) in order to select
Network “TEMPERATURE”. Use the Scroll Left Key (16)
or the Scroll Right Key (13) in order to highlight
• Data Link - SCADA “°C”, or “°F”.
1. In order program the display preferences, go n. Press the Scroll Down Key (15) in order to
through the following menu options. highlight “LANGUAGE”.
2. Press the “ESCAPE” key (12) in order to go back o. Press the Enter Key (14) in order to select
to the main menu. “LANGUAGE”. Use the Scroll Left Key (16) or
the Scroll Right Key (13) in order to highlight
3. From the main menu, press the Scroll Up Key (11) “ENGLISH”, or the other language that is
or the Scroll Down Key (15) in order to highlight available.
the “PREFERENCES” option.
p. Press the Enter Key (14) in order to save the
selection.
92 RENR7902
Testing and Adjusting Section
q. Press the Escape Key in order to go back to 11. Use the Scroll Up Key (11) and the Scroll
the main menu Down Key (15) in order to change the current
configuration to the desired setting.
Programming The Setpoints 12. Press the Enter Key (14) in order to save the
setting.
The engine/generator setpoints affect the proper
operation and serviceability of the engine, and the
accuracy of information shown on the display screen. 13. Repeat steps 9 through step 12 in order to
program all of the Automatic Start/Stop setpoints.
The EMCP 3 setpoints are programmed at the
factory.
14. After all of the Automatic Start/Stop Setpoints are
programmed correctly, press the Escape Key (12)
The setpoints may require changing when the EMCP
in order to go back to the “CONTROL” menu.
3 is moved from one engine to another engine.
The setpoints may also require changing in order
15. The next block of setpoints to program is the
to satisfy the site requirements. The setpoints that
Automatic Voltage Regulator (AVR) Request
are stored in the EMCP 3 must match the specified
setpoints of the particular generator set. block. Press the “DOWN” Key (15) in order to
scroll through the setpoint options until “AVR
DESIRED VOLTAGE” is highlighted.
See the Setpoint Tables following these procedures
for a complete list of all the setpoint blocks. All of the
16. Press the Enter Key (14) in order to select “AVR
setpoints listed in the tables should be verified and
DESIRED VOLTAGE”
reprogrammed if required.
17. Repeat step 9 through step 12 in order to program
The first setpoint block to program is the Automatic
all of the Automatic Voltage Regulator (AVR)
Start/Stop Block. The Automatic Start/Stop Block is
part of the Control Category. Request Setpoints.
6. Press the Scroll Down Key (15) in order to scroll 23. Continue to program the rest of the setpoints until
each setpoint in every setpoint category have
through the setpoint options until “CONTROL” is
been checked and programmed as required.
highlighted.
CONTROL
Automatic Start/Stop
Table 24
Setpoints - Automatic Start/Stop(1)
Setpoint Max Factory
Min Value Units Description
Name Value Default
Fault protection time delay prevents
Engine start fault protection sec.
0 300 30 shut down during start up fro low
activation delay time
oil pressure etc.
Table 25
Setpoints - AVR Desired Voltage Request(2)
Setpoint
Min Value Max Value Units Factory Default Description
Name
The Maximum Generator Output
voltage Bias Percent is the
Maximum Generator maximum value above and below
Voltage Output Bias 0 100 % 5 the Nominal Voltage that the
Percentage EMCP 3 will send a request for
when adjusting the voltage from
the control screen.
The Generator Nominal Output
Generator Nominal
100 50000 V 100 Voltage is the desired output
Output Voltage
voltage of the generator set.
(2) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Maximum Generator Output Voltage Bias Percent e. Press the Enter Key to select “MAXIMUM
GEN OUTPUT VOLTAGE BIAS PERCENT”.
The following settings will only apply if there is a “MAXIMUM GEN OUTPUT VOLTAGE BIAS
CDVR installed on the generator. PERCENT” is displayed with the current
voltage bias percent.
Note: It is possible to set the “MAXIMUM GEN
OUTPUT VOLTAGE BIAS PERCENT” from 0 to f. Press the Scroll Up Key or the Scroll Down
100% but the CDVR will only allow the voltage to Key in order to increment or decrement the
change by a maximum of 15%. highlighted digit to the desired value.
1. From the “MAIN MENU”, press the Scroll Up g. Press the Scroll Right Key or the Scroll Left Key
Key or the Scroll Down Key to highlight the in order to highlight the next character to be
“CONFIGURE” menu. entered. Press the Scroll Up Key or the Scroll
Down Key in order to increment or decrement
a. Press the Enter Key in order to select the highlighted digit to the desired value.
“CONFIGURE”. “SECURITY” will be
highlighted. h. Continue until the desired “MAXIMUM GEN
OUTPUT VOLTAGE BIAS PERCENT” is
b. Press the Scroll Down Key in order to highlight entered. When the “MAXIMUM GEN OUTPUT
“SETPOINTS”. Press the Enter Key in order to VOLTAGE BIAS PERCENT” is correctly
select “SETPOINTS”. entered, press the Enter key.
c. “AUTOMATIC START/STOP” will be Note: The voltage bias percent setpoint will
highlighted. Press the Scroll Down Key in order determine the amount of voltage change for each
to highlight “AVR DESIRED VOLTAGE” key press on the voltage control screen. A higher
value will result in a larger change in voltage per key
d. Press the Enter key in order to select “AVR press. A lower value will result in a smaller change
DESIRED VOLTAGE”. “MAXIMUM GEN in voltage per key press.
OUTPUT VOLTAGE BIAS PERCENT” will be
displayed. Generator Breaker Control
Table 26
Setpoints - Generator Breaker Control(22)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Generator Breaker
Closing Pulse Active 0.1 10 sec. 1.0
Time
Generator Breaker
Closing Pulse Rest 0 60 sec. 1.0
Interval
Generator Breaker
Maximum Closing 1 120 sec. 60
Time
Generator Breaker
Maximum Opening 1 20 sec. 3
Time
Generator Breaker
N/A N/A N/A 0
Lockout Status
(22) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 27
Setpoints - Generator Desired Engine Speed Request(27)
Setpoint Min Max Factory
Units Description
Name Value Value Default
The Maximum Engine Speed Range is
the maximum value above and below the
Maximum Engine Speed rpm
0 2000 100 Nominal Engine Speed that the EMCP 3
Range
will send a request for when adjusting the
speed from the control screen.
Generator Nominal Output
40 500 Hz 50
Frequency
(27) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Transfer Switch
Table 28
Setpoints - Transfer Switch(33)
Setpoint Max Factory
Min Value Units Description
Name Value Default
Generator/Utility Automatic
N/A N/A N/A 1
Transfer Enable Status
Loss of Utility Event Notification sec.
0 30 10
Delay Time
Utility to Generator Transfer sec.
1 60 3
Delay Time
Generator to Utility Transfer
1 60 min. 180
Delay Time
Generator to Utility Fast sec.
1 60 10
Transfer Delay Time
Utility to Generator Transfer
Failure Warning Event 1 240 sec. 60
Threshold
Utility to Generator Transfer
Failure Shutdown Event 1 240 sec. 90
Threshold
Generator to Utility Transfer
Failure Warning Event 1 240 sec. 60
Threshold
(33) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 29
Setpoints - Utility Breaker Control(34)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Utility Breaker Closing sec.
0.1 10.0 1.0
Pulse Active Time
Utility Breaker Closing sec.
0 60 15
Pulse Rest Interval
Utility Breaker Maximum sec.
1 20 60
Closing Time
Utility Breaker Maximum sec.
1 20 3
Opening Time
Utility Breaker Lockout
N/A N/A N/A 0
Status
(34) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
RENR7902 97
Testing and Adjusting Section
Table 30
Setpoints - Battery Voltage Monitor(3)
Setpoint Min
Max Value Units Factory Default Description
Name Value
High Battery Voltage
12 50 VDC 29.4
Warning Event Threshold
High Battery Voltage
Warning Event Notification 0 240 sec. 30
Delay Time
High Battery Voltage
12 50 VDC 30.0
Shutdown Event Threshold
High Battery Voltage
Shutdown Event Notification 0 240 sec. 30
Delay Time
Low Battery Voltage
0.0 25.0 VDC 23.4
Warning Event Threshold
Low Battery Voltage
Warning Event Notification 0 240 sec. 30
Delay Time
Low Battery Charging
System Voltage Warning 0 30 VDC 26
Event Threshold
Low Battery Charging
System Voltage Warning sec.
0 240 30
Event Notification Delay
Time
(3) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 31
Table 32
Setpoints - Engine Coolant Temperature Monitor(10)
Setpoint Factory
Min Value Max Value Units Description
Name Default
Engine Coolant Temp
N/A N/A N/A 0 Select Sensor or Data Link
Sensor Configuration
High Engine Coolant
120 °C
Temp Warning Event 85 °C (185 °F) deg. 100 °C (215 °F)
(248 °F)
Threshold
High Engine Coolant
Temp Warning Event 0 30 sec. 15
Notification Delay Time
High Engine Coolant
120 °C
Temp Shutdown Event 85 °C (185 °F) deg. 120 °C (225 °F)
(248 °F)
Threshold
High Engine Coolant
Temp Shutdown Event 0 30 sec. 15
Notification Delay Time
Low Engine Coolant
Temp Warning Event 0 °C ( 32°F) 36 °C (99 °F) 21 °C (70 °F)
Threshold
Low Engine Coolant
Temp Warning Event 0 30 sec. 10
Notification Delay Time
(10) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 33
Setpoints - Engine Oil Pressure Monitor(11)
Setpoint Factory
Min Value Max Value Units Description
Name Default
Engine Oil
Pressure Sensor N/A N/A N/A 0 Select Sensor or Data Link
Configuration
Low Engine Oil
Pressure Warning 34 kPa (5 psi) 420 kPa (61 psi) kPa 160 kPa (40 psi)
Event Threshold
Low Idle Low
Engine Oil Pressure
34 kPa (5 psi) 420 kPa (61 psi) kPa 160 kPa (20 psi)
Warning Event
Threshold
Low Engine Oil
Pressure Warning sec.
0 30 10
Event Notification
Delay Time
Low Engine Oil
Pressure Shutdown 34 kPa (5 psi) 420 kPa (61 psi) kPa 34 kPa (30 psi)
Event Threshold
Low Idle Low
Engine Oil Pressure
34 kPa (5 psi) 420 kPa (61 psi) kPa 160 kPa (10 psi)
Shutdown Event
Threshold
Low Engine Oil
Pressure Shutdown sec.
0 30 10
Event Notification
Delay Time
Low Engine Oil When the engine speed is
Pressure Step 400 1800 rpm 1350 below this setpoint, the Low
Speed Idle setpoint is used.
(11) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 34
Setpoints - Engine Speed Monitor(12)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Flywheel Teeth 95 350 N/A 350
Engine Over Speed rpm
400 4330 400
Shutdown Threshold
Engine Under Speed rpm
400 4330 4330
Warning Event Threshold
Engine Under Speed
Warning Event Notification 0.0 20.0 sec. 2.0
Delay Time
Engine Under Speed rpm
400 4330 4330
Shutdown Event Threshold
Engine Under Speed
Shutdown Event 0.0 20.0 sec. 2.0
Notification Delay Time
(12) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 35
Setpoints - Enhanced Engine Monitor (31)
Table 36
Setpoints - Service Maintenance Interval(31)
Min
Setpoint Name Max Value Units Factory Default Description
Value
Service Maintenance
0 2000 hours 500 hours
Interval Hours
Service Maintenance
0 365 days 180 days
Interval Days
(31) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
RENR7902 101
Testing and Adjusting Section
EVENTS
Diagnostics Configuration
Table 37
“PRESSURE” Setpoints - Diagnostics Configuration(15)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Air Filter
Differential
Pressure Sensor X X X X X X
Diagnostic
Response Config
Engine Oil
Pressure Sensor
X X X X X X
Diagnostic
Response Config
Fire Extinguisher
Pressure Sensor
X X X X X X
Diagnostic
Response Config
Fuel Filter
Differential
Pressure Sensor X X X X X X
Diagnostic
Response Config
Engine Oil
Filter Differential
Pressure Sensor X X X X X X
Diagnostic
Response Config
Starting Air
Pressure Sensor
X X X X X X
Diagnostic
Response Config
(15) Each setpoint in the Diagnostics Configuration block is used in order to program a system response to the associated Suspect Parameter
Number/Failure Mode Identifier (SPN/FMI) for any internal source.
Table 38
“TEMPERATURE” Setpoints - Diagnostics Configuration(15)
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
Ambient Air
Temp Sensor
Diagnostic X X X X X X
Response
Config
Engine
Coolant
Temp Sensor
X X X X X X
Diagnostic
Response
Config
Engine Oil
Temp Sensor
Diagnostic X X X X X X
Response
Config
Exhaust
Temp Sensor
Diagnostic X X X X X X
Response
Config
Right Exhaust
Temp Sensor
Diagnostic X X X X X X
Response
Config
Left Exhaust
Temp Sensor
Diagnostic X X X X X X
Response
Config
Generator
Bearing #1
Temp Sensor
X X X X X X
Diagnostic
Response
Config
(15) Each setpoint in the Diagnostics Configuration block is used in order to program a system response to the associated Suspect Parameter
Number/Failure Mode Identifier (SPN/FMI) for any internal source.
Table 39
“LEVEL” Setpoints - Diagnostics Configuration(15)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Engine
Coolant
Level Sensor
X X X X X X
Diagnostic
Response
Config
Engine Oil
Level Sensor
Diagnostic X X X X X X
Response
Config
Fuel Level
Sensor
Diagnostic X X X X X X
Response
Config
External
Tank Fuel
Level Sensor
X X X X X X
Diagnostic
Response
Config
(15) Each setpoint in the Diagnostics Configuration block is used in order to program a system response to the associated Suspect Parameter
Number/Failure Mode Identifier (SPN/FMI) for any internal source.
Table 40
“OTHER” Setpoints - Diagnostics Configuration(15)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Accessory
Data Link
Diagnostic X X X X X X
Response
Config
Digital Output
#1 Diagnostic
X X X X X X
Response
Config
Digital Output
#2 Diagnostic
X X X X X X
Response
Config
Engine Speed
Sensor
Diagnostic X X(16) X X
Response
Config
Generator
Output
Sensing
System X X X X X X
Diagnostic
Response
Config
Primary
Data Link
Diagnostic X X X X X X
Response
Config
SCADA
Data Link
Diagnostic X X X X X X
Response
Config
(15) Each setpoint in the Diagnostics Configuration block is used in order to program a system response to the associated Suspect Parameter
Number/Failure Mode Identifier (SPN/FMI) for any internal source.
(16) Setpoint Is Not Adjustable
Engine Protection Events Configuration Note: Table 41 lists the available options for each
“PRESSURE” setpoint. The options that are available
The Engine Protection Events Configuration block for each setpoint are designated by an “X” in the
is used to configure the desired response for any option column.
engine protection event generated by the genset
control.
Table 41
“PRESSURE” Setpoints - Engine Protection Events Configuration(17)
Loss
Setpoint Audible Soft Hard Breaker Breaker Trip Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 #2 Only
Utility
High Air Filter
Differential
Pressure
X X X X
Warning Event
Response
Config
High Air Filter
Differential
Pressure
Shutdown X X X X X
Event
Response
Config
Low Air Filter
Differential
Pressure
X X X X X
Warning Event
Response
Config
Low Air Filter
Differential
Pressure
Shutdown X X X X X X
Event
Response
Config
Low Engine
Oil Pressure
Warning Event X X X X X
Response
Config
Low Engine
Oil Pressure
Shutdown
X X X X X X
Event
Response
Config
High Fuel Filter
Differential
Pressure x x x X
Warning Event
Response
Config
High Fuel Filter
Differential
Pressure
Shutdown X X X X X
Event
Response
Config
Low Fuel Filter
Differential
Pressure
X X X X X
Warning Event
Response
Config
(continued)
106 RENR7902
Testing and Adjusting Section
Table 42
Table 43
Table 44
“OTHER” Setpoints - Engine Protection Events Configuration(17)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Air Damper
Closed Event x X X
Response
Config
Emergency
Stop
Shutdown
X X(16) X X
Event
Response
Config
Engine Failure
to Start
Shutdown
X X(16) X X
Event
Response
Config
Unexpected
Engine
Shutdown
X X(16) X X
Event
Response
Config
Engine
Over Speed
Shutdown
X X(16) X X
Event
Response
Config
Engine
Under Speed
Warning Event X X X X X
Response
Config
Engine
Under Speed
Shutdown
X X X X X X
Event
Response
Config
Fuel Tank
Leak Event
X X X X
Response
Config
Service
Maintenance
Interval
X X
Warning Event
Response
Config
(17) Each setpoint in the Engine Protection Events Configuration block is used in order to program a system response to the associated
Suspect Parameter Number/Failure Mode Identifier (SPN/FMI) for any internal source.
(16) Setpoint Is Not Adjustable
RENR7902 113
Testing and Adjusting Section
Table 45
Setpoints - Generator Protection Events Configuration(18)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
High
Generator
Bearing #1
Temp Warning X X X X
Event
Response
Config
High
Generator
Bearing
#1 Temp
X X X X X
Shutdown
Event
Response
Config
Low
Generator
Bearing #1
Temp Warning X X X X X
Event
Response
Config
Low
Generator
Bearing
#1 Temp
X X X X X X
Shutdown
Event
Response
Config
Generator
Over Current
(Amp)
Warning X X X X
Event
Response
Config
Generator
Over Current
(Amp)
Shutdown X X X X X
Event
Response
Config
(continued)
114 RENR7902
Testing and Adjusting Section
Table 46
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
High Ambient
Air Temp
Warning Event X X X X x
Response
Config
High Ambient
Air Temp
Shutdown
X X X X X
Event
Response
Config
Low Ambient
Air Temp
Warning Event X X X X
Response
Config
Low Ambient
Air Temp
Shutdown
X X X X X
Event
Response
Config
(continued)
116 RENR7902
Testing and Adjusting Section
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
Automatic
Transfer
Switch in
Normal X X X
Position Event
Response
Config
Automatic
Transfer
Switch in
Emergency X X X
Position Event
Response
Config
Battery
Charger
Failure
X X X
Diagnostic
Response
Config
High Battery
Voltage
Warning Event X X X X
Response
Config
High Battery
Voltage
Shutdown
X X X X X
Event
Response
Config
Low Battery
Voltage
Warning Event X X X X X
Response
Config
Low Battery
Charging
System
Voltage X X X X X
Warning Event
Response
Config
Generator
Breaker
Failure to
X X X X X
Open Event
Response
Config
(continued)
RENR7902 117
Testing and Adjusting Section
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
Generator
Breaker
Failure to x
X X X X
Close Event
Response
Config
Generator
Breaker
Open Event X X X
Response
Config
Generator
Breaker
Closed Event X X X
Response
Config
Utility Breaker
Failure to
Open Event X X X X X
Response
Config
Utility Breaker
Failure to
Close Event X X X X X
Response
Config
Utility Breaker
Open Event
X X X
Response
Config
Utility Breaker
Closed Event
X X X
Response
Config
Emergency
Shutdown
Override
Mode Active X(16) X
Warning Event
Response
Config
Engine in
Cooldown
Event X X X
Response
Config
(continued)
118 RENR7902
Testing and Adjusting Section
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
Engine Speed-
Generator
Output
Frequency
X X X X
Mismatch
Warning Event
Response
Config
Event Input
Function
#1 High
X X X X X
Warning Event
Response
Config
Event Input
Function
#1 High
Shutdown X X X X X X
Event
Response
Config
Event Input
Function
#1 Low
X X X X X
Warning Event
Response
Config
Event Input
Function #1
Low Shutdown
X X X X X X
Event
Response
Config
Event Input
Function
#1 Event X X X X
Response
Config
Event Input
Function
#2 High x
X X X X
Warning Event
Response
Config
Event Input
Function
#2 High
Shutdown X X X X X X
Event
Response
Config
(continued)
RENR7902 119
Testing and Adjusting Section
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
Event Input
Function
#2 Low
X X X X X
Warning Event
Response
Config
Event Input
Function #2
Low Shutdown
X X X X X X
Event
Response
Config
Event Input
Function
#2 Event X X X X
Response
Config
Event Input
Function
#3 High
X X X X X
Warning Event
Response
Config
Event Input
Function
#3 High
Shutdown X X X X X X
Event
Response
Config
Event Input
Function
#3 Low
X X X X X
Warning Event
Response
Config
Event Input
Function #3
Low Shutdown
X X X X X X
Event
Response
Config
Event Input
Function
#3 Event X X X X
Response
Config
(continued)
120 RENR7902
Testing and Adjusting Section
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
Event Input
Function
#4 High
X X X X X
Warning Event
Response
Config
Event Input
Function
#4 High
Shutdown X X X X X X
Event
Response
Config
Event Input
Function
#4 Low
X X X X X
Warning Event
Response
Config
Event Input
Function #4
Low Shutdown
X X X X X X
Event
Response
Config
Event Input
Function
#4 Event X X X X
Response
Config
Event Input
Function
#5 High
X X X X X
Warning Event
Response
Config
Event Input
Function
#5 High
Shutdown X X X X X X
Event
Response
Config
Event Input
Function
#5 Low
X X X X X
Warning Event
Response
Config
(continued)
RENR7902 121
Testing and Adjusting Section
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
Event Input
Function #5
Low Shutdown
X X X X X X
Event
Response
Config
Event Input
Function
#6 High
X X X X X
Warning Event
Response
Config
Event Input
Function
#6 High
Shutdown X X X X X X
Event
Response
Config
Event Input
Function
#6 Low
X X X X X
Warning Event
Response
Config
Event Input
Function #6
Low Shutdown
X X X X X X
Event
Response
Config
Event Input
Function
#6 Event X X X X
Response
Config
Event Input
Function
#7 High
X X X X X
Warning Event
Response
Config
Event Input
Function
#7 High
Shutdown X X X X X X
Event
Response
Config
(continued)
122 RENR7902
Testing and Adjusting Section
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
Event Input
Function
#7 Low
X X X X X
Warning Event
Response
Config
Event Input
Function #7
Low Shutdown
X X X X X X
Event
Response
Config
Event Input
Function
#7 Event X X X X
Response
Config
Event Input
Function
#8 High
X X X X X
Warning Event
Response
Config
Event Input
Function
#8 High
Shutdown X X X X X X
Event
Response
Config
Event Input
Function
#8 Low
X X X X X
Warning Event
Response
Config
Event Input
Function #8
Low Shutdown
X X X X X X
Event
Response
Config
Event Input
Function
#8 Event X X X X
Response
Config
(continued)
RENR7902 123
Testing and Adjusting Section
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
High Fire
Extinguisher
Pressure
X X X X
Warning Event
Response
Config
High Fire
Extinguisher
Pressure
Shutdown X X X X X
Event
Response
Config
Low Fire
Extinguisher
Pressure
X X X X X
Warning Event
Response
Config
Low Fire
Extinguisher
Pressure
Shutdown X X X X X X
Event
Response
Config
Generator
Control Not
in Automatic
X X X
Warning Event
Response
Config
Loss of
Utility Event
X X X
Response
Config
Utility to
Generator
Transfer
Failure X X X X
Warning Event
Response
Config
(continued)
124 RENR7902
Testing and Adjusting Section
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
Utility to
Generator
Transfer
Failure
X X X X
Shutdown
Event
Response
Config
Generator to
Utility Transfer
Failure
X X X X
Warning Event
Response
Config
(19) Each setpoint in the “Other System Events Configuration” block is used in order to program a system response to the associated Suspect
Parameter Number/Failure Mode Identifier (SPN/FMI) for any internal source.
(16) Setpoint Is Not Adjustable
Table 47
Table 48
Setpoints - Event Output Functions(14)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Event Output
Settings for event output
Function #NN N/A N/A N/A 0
functions #1- #30
Trigger Condition
Event Output
Function #NN Settings for event output
N/A N/A N/A 100
Suspect Parameter functions #1- #30
Number
(14) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Event System
Table 49
Setpoints - Event System(20)
Setpoint Factory
Min Value Max Value Units Description
Name Default
Event Warning
Condition
Response Auto N/A N/A 1
Reset Enable
Status
Event Audible
Alert Response
N/A N/A N/A 1
Auto Reset
Enable Status
Event Loss of
Utility Response
N/A N/A N/A 1
Auto Reset
Enable Status
Event Breaker #1
Trip Response
N/A N/A N/A 1
Auto Reset
Enable Status
Event Breaker #2
Trip Response
N/A N/A N/A 1
Auto Reset
Enable Status
(20) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 50
Setpoints - Enhanced Generator Monitor(31)
Setpoint Factory
Min Value Max Value Units Description
Name Default
Generator Winding
Temp Sensor Not Installed
Installation Status
Number of
Generator Bearing 0 2
Temp Sensors
(31) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Generator AC Monitor
Table 51
Setpoints - Generator AC Monitor(21)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Generator Configurations can be
Generator
“Star/Wye”, “Delta/3 Wire”, “Delta/4
Connection N/A N/A N/A Star/Wye
Wire”, “Single Phase 2 Wire”,
Configuration
“Single Phase 3 Wire”
Generator
Potential
Transformer 1 50000 V 1
Primary Winding
Rating
Generator
Potential
Transformer 1 150 V 1
Secondary
Winding Rating
Generator Current
Transformer
1 7000 A 75
Primary Winding
Rating
Generator Current
Transformer
1 5 A 5 Can only be set to 1 or 5
Secondary
Winding Rating
Number of
0 200 N/A 4
Generator Poles
Generator Rated Frequency can be set to 50Hz,
N/A N/A Hz 60
Frequency 60Hz or 400Hz
Generator Rated
100 50000 V 100
Voltage
Generator Rated
1 50000 kW 1
Power
Generator Rated
1 50000 kVA 1
Apparent Power
(21) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
• Per phase kVAr (for star/wye confutations) Note: Per phase quantities (kW, kVAr, KVA, and
Power Factor) will be monitored for 3-phase, 4-wire
• Total kVAr star-connected configurations)
Table 52
Setpoints - Generator AC Power Monitor(31)
Setpoint Factory
Min Value Max Value Units Description
Name Default
Customer Password
Security Level to Reset
0 4
Generator Energy
Meters
(31) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 53
Setpoints - Generator Over Current(23)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Generator Definite
Time Over Current
Threshold for the Over Current
(Amp) Warning 80 130 % 100
Warning
Event Percentage
Threshold
Generator Inverse
Time Over Current
(Amp) Shutdown 0.05 10.00 sec. .27 Time multiplier setpoint
Event Time
Multiplier
Generator Definite
If current is above this setpoint
Time Over Current
value for the specified time
(Amp) Shutdown 100 300 % 125
(setpoint #4) there will be an over
Event Percentage
current shutdown.
Threshold
Generator Definite
Time Over Current
(Amp) Shutdown 0.1 20.0 sec. 10 Time delay for setpoint #3
Event Notification
Delay Time
(23) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 54
Setpoints - Generator Over / Under Frequency(24)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Generator Over
Frequency
Warning Event 80 120 % 105
Percentage
Threshold
Generator Over
Frequency
Warning Event 0 120 sec. 10
Notification Delay
Time
Generator Over
Frequency
Shutdown Event 80.0 120 % 110
Percentage
Threshold
Generator Over
Frequency
Shutdown Event 0 120 sec. 2
Notification Delay
Time
Generator Under
Frequency
Warning Event 80.0 120.0 % 95.0
Percentage
Threshold
Generator Under
Frequency
Warning Event 0 120 sec. 10
Notification Delay
Time
Generator Under
Frequency
Shutdown Event 80.0 120.0 % 90.0
Percentage
Threshold
Generator Under
Frequency
Shutdown Event 0 120 sec. 4
Notification Delay
Time
(24) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 55
Setpoints - Generator Over / Under Voltage(25)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Generator Over
Voltage Warning
100 125 % 105
Event Percentage
Threshold
Generator Over
Voltage Warning sec.
0 120 10
Event Notification
Delay Time
Generator Over
Voltage Shutdown
100 125 % 110
Event Percentage
Threshold
Generator Over
Voltage Shutdown sec.
0 120 2
Event Notification
Delay Time
Generator Under
Voltage Warning
60 100 % 95.0
Event Percentage
Threshold
Generator Under
Voltage Warning sec.
0 120 10
Event Notification
Delay Time
Generator Under
Voltage Shutdown 60 100 % 90.0
Event Threshold
Generator Under
Voltage Shutdown sec.
0 120 4
Event Notification
Delay Time
(25) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 56
Setpoints - Generator Reverse Power(26)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Generator
Reverse Power
Warning Event 1 20 % 5
Percentage
Threshold
Generator
Reverse Power
Warning Event 0 30 sec. 10
Notification Delay
Time
Generator
Reverse Power
Shutdown Event 1 20 % 10
Percentage
Threshold
Generator
Reverse Power
Shutdown Event 0 30 sec. 10
Notification Delay
Time
(26) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 57
Setpoints - Digital Inputs(5)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Activating the E-STOP input
E-STOP Active Low Active High N/A Active Low will cause the generator set to
stop immediately.
Setpoint allows for starting
and stopping the genset from
a remote location.
If input is active and the engine
REMOTE
Active Low Active High N/A Active Low mode switch is in “AUTO”, the
INITIATE
engine will attempt to start and run.
Once the input becomes in-active,
the engine will enter into cooldown
(if programmed) and then STOP.
The inputs can be set to
PRESSURES
Air Filter Differential Pressure
Engine Oil Pressure
Fire Extinguisher Pressure
Fuel Filter Differential Pressure
Oil Filter Differential Pressure
Starting Air Pressure
TEMPERATURES
Digital #3(6) Active Low Active High N/A Active Low Ambient Air Temp
Engine Coolant Temp
Engine Oil Temp
Exhaust Temp
Rear Bearing Temperature
Right Exhaust Temperature
Left Exhaust Temperature
LEVELS
Engine Coolant Level
Engine Oil Level
Digital #4(6) Active Low Active High N/A Active Low Fuel Level
External Tank Fuel Level
Digital #5(6) Active Low Active High N/A Active Low OTHER
Active Low Active High Active Low Air Damper Closed
Digital #6(6) N/A
ATS in Normal Position
Digital #7(6) Active Low Active High N/A Active Low ATS in Emergency Position
Battery Charger Failure
Generator Breaker Closed
Utility Breaker Closed
Digital #8(6) Active Low Active High N/A Active Low
Fuel Leak Detected
Custom Event
(5) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
(6) The “Digital Inputs” parameter can only be set to “Active High” or “Active Low” in order to initiate a High Warning, Low Warning, High
Shutdown. Low Shutdown or Status.
Digital Outputs
Table 58
Setpoints - Digital Outputs(7)
Setpoint Max
Min Value Units Factory Default Description
Name Value
Digital Output #1 Active
N/A N/A N/A 0
State Configuration
Digital Output #2 Active
N/A N/A N/A 0
State Configuration
(7) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Relay Outputs
Table 59
Setpoints - Relay Outputs(29)
Setpoint Factory
Min Value Max Value Units Description
Name Default
Relay Output
Relay Output #1 is always configured
#1 Active State N/A N/A N/A 1
as the “Starter Motor Relay”
Configuration
Relay Output
Relay #2 is always configured as
#2 Active State N/A N/A N/A 1
the “Fuel Control Relay”
Configuration
Relay Output #3 is controlled by
Relay Output
Digital Selector #1
#3 Active State N/A N/A N/A 1
The output can be set to “Active
Configuration
High” or“ Active Low”
Relay Output #4 is controlled by
Relay Output
Digital Selector #2
#4 Active State N/A N/A N/A 1
The output can be set to “Active
Configuration
High” or“ Active Low”
Relay Output #5 is controlled by
Relay Output
Digital Selector #3
#5 Active State N/A N/A N/A 1
The output can be set to “Active
Configuration
High” or“ Active Low”
Relay Output #6 is controlled by
Relay Output
Digital Selector #4
#6 Active State N/A N/A N/A 1
The output can be set to “Active
Configuration
High” or“ Active Low”
Relay Output #7 is controlled by
Relay Output
Digital Selector #5
#7 Active State N/A N/A N/A 1
The output can be set to “Active
Configuration
High” or“ Active Low”
Relay Output #8 is controlled by
Relay Output
Digital Selector #6
#8 Active State N/A N/A N/A 1
The output can be set to “Active
Configuration
High” or“ Active Low”
(29) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Table 60
Setpoints - Spare Analog Input(29)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Spare Analog
Input Enable N/A N/A N/A Enabled
Status
Spare Analog
Can be set to Temperature,
Input Type N/A N/A N/A Temperature
Pressure, or Level .
Configuration
Spare Analog
Input Suspect
N/A N/A N/A 107
Parameter
Number(SPN)
Spare Analog
Input High Level
0 100 % 0
Warning Event
Threshold
Spare Analog
Input High
Deg.
Temperature -273 1,735 -273
C
Warning Event
Threshold
Spare Analog
Input High
-250 10,000 kPa -250
Pressure Warning
Event Threshold
Spare Analog
Input High
Warning Event 0 60 sec. 0
Notification Delay
Time
Spare Analog
Input High Level
0 100 % 0
Shutdown Event
Threshold
Spare Analog
Input High
Deg.
Temperature -273 1,735 -273
C
Shutdown Event
Threshold
Spare Analog
Input High
Pressure -250 10,000 kPa -250
Shutdown Event
Threshold
Spare Analog
Input High
Shutdown Event 0 60 sec. 0
Notification Delay
Time
Spare Analog
Input Low Level
0 100 % 0
Warning Event
Threshold
(continued)
136 RENR7902
Testing and Adjusting Section
NETWORK
Data Link - SCADA
Table 61
Setpoints - Data Link - SCADA(4)
Setpoint Max
Min Value Units Factory Default Description
Name Value
SCADA Data Link
N/A N/A N/A 2
Baud Rate
SCADA Data Link Parity N/A N/A N/A 0
SCADA Data Link
1 247 N/A 1
Slave Address
SCADA Data Link
0 0xfffff N/A 0
Access Password
SCADA Data Link
Connection Time-out 0.1 3600.0 sec. 30
Interval
RS485 Bias Resistor
N/A N/A N/A 0
Enable Status
(4) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
OTHER
Digital Selectors
Table 62
Setpoints - Digital Selectors(8)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Digital Selector #1 controls
Relay Output #3
Config Options are:
Disabled
Digital Selector
Use Input #1
#1 Source Use Input #1
Use Input #2
Configuration
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
Digital Selector #2 controls
Relay Output #4
Config Options are:
Disabled
Digital Selector
Use Input #1
#2 Source Use Input #4
Use Input #2
Configuration
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
(continued)
138 RENR7902
Testing and Adjusting Section
Table 63
Setpoints - Electronic Control Module Reduced Power Mode(9)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Electronic Control
Module Reduced Allows control to go into reduced
N/A N/A N/A Enabled
Power Mode Enable power mode
Status
Electronic Control
Module Reduced
0 120 min. 30
Power Mode Delay
Time
(9) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
Remote Callback
Table 64
Setpoints - Remote Callback(30)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Remote Dial Enable Setpoints for relay Outputs
N/A N/A N/A 1
Status #1 - #8
Remote Dial
Setpoints for relay Outputs
Command N/A N/A N/A 1
#1 - #8
Configuration
(30) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
ASSV – Air Start Solenoid Valve EFCR – Emergency Fuel Control Relay
GSM – Governor Synchronizing Motor PPPS – Prelube Pump Oil Pressure Switch
KWR – Kilowatt Level Relay PWM – Electrical Converter (Pulse Width Modulated)
LFLAS – Low Fuel Level Alarm Switch RPR – Reverse Power Relay
LFS – Latching Fuel Control Solenoid RPSR – Reverse Power Slave Relay
LWLAS – Low Water Level Alarm Switch SASV – Start Aid Solenoid Valve
LWTL – Low Water Temperature Light SATS – Start Aid Temperature Switch
SL – Synchronizing Light
SM – Starting Motor
SR – Slave Relay
SS – Synchronizing Switch
V – AC Voltmeter
VR – Voltage Regulator
WT – Water Temperature
XDUCER – Transducer
Z – Zener Diode
i02148840
ECM Connections
SMCS Code: 4490; 7566
g01090088
Illustration 19
144 RENR7902
Testing and Adjusting Section
g01090992
Illustration 20
RENR7902 145
Testing and Adjusting Section
g01090993
Illustration 21
146 RENR7902
Index Section
Index
A Electronic Control Module (Generator Set) -
Configure ............................................................. 89
Analog Input Circuit Fault ...................................... 74 Initial Setup ........................................................ 89
Annunciator Module............................................... 21 Programming the Display Preferences .............. 91
Adding Optional Remote Annunciator................ 25 Programming The Setpoints .............................. 92
Basic Operation ................................................. 22 SETPOINT TABLES .......................................... 92
Configuration...................................................... 22 Setpoints ............................................................ 90
General Information ........................................... 21 Electronic Control Module (Generator Set) - Flash
Program ............................................................... 89
Electronic Control Module (Generator Set) -
C Replace................................................................ 89
Replacement Procedure .................................... 89
Charging System ................................................... 75 Engine Cooldown Warning .................................... 54
Component Location ............................................... 6 Engine Overcrank Warning ................................... 54
Engine Overspeed Warning .................................. 56
Engine Speed Circuit Fault.................................... 80
D Engine Speed Warning.......................................... 56
Engine Underspeed Warning ................................ 59
Data Link ............................................................... 26 Event Resetting ..................................................... 31
Accessory Data Link - J1939 (CAN 2) ............... 27 Event Viewing........................................................ 30
Data Links .......................................................... 26 External Potential Transformer Connections ......... 86
Primary Data Link - J1939 (CAN 1) ................... 26
System Control and Data Acquisition (SCADA)
Data Link - Modbus RS-485............................. 27 G
Data Link Circuit Fault ........................................... 77
Diagnostic Capabilities .......................................... 42 General Information........................................... 4, 40
The Caterpillar Electronic Technician (ET)......... 42 Generator Control Not in Automatic Warning ........ 61
Diagnostic System Procedures ............................. 54 Generator Output Sensing Circuit Fault ................ 61
Diagnostic Trouble Code List ................................ 43 Generator Overcurrent Warning ............................ 61
Digital Input Circuit Fault ....................................... 78 Generator Overfrequency Warning ....................... 62
Digital Input Programming ..................................... 33 Generator Overvoltage Warning............................ 65
Programming the Active State of the Digital Generator Reverse Power Warning ...................... 66
Input ................................................................. 33 Generator Underfrequency Warning ..................... 68
Programming the Event Input Functions............ 33 Generator Undervoltage Warning.......................... 71
Digital Output Circuit Fault..................................... 79
Digital Output Programming .................................. 34
Programming the Active State of the Digital I
Output .............................................................. 34
Programming the Digital Selectors .................... 34 Important Safety Information ................................... 2
Discrete Input/Output Module................................ 14 Introduction............................................................ 40
Configurability .................................................... 17
General Information ........................................... 14
Inputs ................................................................. 14 P
Outputs .............................................................. 16
Specifications..................................................... 17 Password Entry ..................................................... 28
Change level 1 or level 2 password ................... 30
Drop to Minimum Security Level ........................ 29
E Enter Level 1 or 2 Password.............................. 29
Enter level 3 password....................................... 29
ECM Connections................................................ 142
Electrical Connector - Inspect................................ 85
Electronic Control Module (Engine) (EUI Engines R
Only) .................................................................... 27
Electronic Control Module (Generator Set) ............. 8 Real Time Clock Programming.............................. 38
Alarm Indicators ................................................... 9 Relay Output Programming ................................... 36
Digital Inputs ........................................................ 9 Programming the Active State of the Relay
Navigation Keys ................................................... 8 Output .............................................................. 36
Programming the Digital Selectors .................... 37
RENR7902 147
Index Section
Table of Contents..................................................... 3
Testing and Adjusting ............................................ 85
Testing and Adjusting Section ............................... 85
Thermocouple Module........................................... 10
Configurability .................................................... 13
Diagnostics ........................................................ 10
General Information ........................................... 10
Monitoring Features ............................................ 11
Specifications..................................................... 14
Troubleshooting Section........................................ 40
Typical Generator Abbreviations ......................... 140