Systems Operation

EMCP4.2B
Media Number -UENR7097-02 Date Updated -22/10/2018

i06293436

Electronic Control Module (Generator Set)

SMCS - 4490

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Illustration 1 g02082653
EMCP 4 Control System Panel
(1) Display screen
(2) AC overview key
(3) Engine overview key
(4) Main menu key
(5) Alarm acknowledge key
(6) Reset shut down Key
(7) Event log
(8) Run key
(9) Auto key
(10) Stop key
(11) Escape key
(12) Up key
(13) Right key
(14) "OK" key
(15) Down key
(16) Left key

General Information
The main component of the Electronic Modular Control Panel 4.2 (EMCP 4.2) is the Electronic
Control Module (ECM). This section discusses the display, keys, and indicators on the control
system panel of the ECM. The EMCP 4.2 panel is used for monitoring and controlling many of
the generator set functions. Some of the functions include:
 Sending start and stop signals to the engine
 Providing visual and audible indications when warning or shutdown events occur
 Displaying engine information and AC generator set information
 Displaying Suspect Parameter Number (SPN) and Failure Mode Identifier (FMI)
information for events
 Programming set points for the standard EMCP 4.2 (The set points for optional modules
are set with the use of Cat ET).
 RS-485 Annunciator configuration (EMCP 4.2 only)

ECM Front Panel Components

The following components can be found on the front panel of the ECM:
 Information Display
 Alarm Indicators
 Alarm Acknowledge/Silence Key
 Function Keys
 Navigation Keys
 System Overview Keys
Information Display
(1) Display Screen - Information from the EMCP 4 is displayed on the display screen. This
screen is used for the following programming and display functions.
 Displaying AC parameter information of the generator set
 Displaying engine parameter information of the generator set
 Programming set points for the generator
 Displaying engine event information
 Displaying event codes from other modules
 Programming the display preferences of the EMCP 4.2
 Changing password levels of the EMCP 4.2
Alarm Indicators
(2) Yellow Warning Lamp - A solidly illuminated yellow warning lamp indicates that there are
acknowledged warnings that are still present. A flashing yellow warning lamp indicates that
there are unacknowledged warnings that are still present. To verify the warnings, press the alarm
acknowledge/silence key (5). If there are no longer any active warnings, then the lamp will turn
off. If active warnings still exist, then the lamp will change from flashing yellow to solid yellow.
(3) Red Shutdown Lamp - A solidly illuminated red shutdown lamp indicates that there are
acknowledged shutdown events that are still active. A flashing red shutdown lamp indicates that
there are unacknowledged active shutdown events. To verify the shutdown events, press the
alarm acknowledge/silence key (5). If the condition that caused the shutdown has been cleared,
and the acknowledge/silence key (5) has been pressed, then the lamp will change from flashing
red to solid red.
Note: Any condition that has caused a shutdown event must be manually reset.
Reference: Systems Operation, "Event Resetting"
Alarm Acknowledge/Silence Key
(5) Alarm Acknowledge/Silence - Pressing the alarm acknowledge/silence key causes the horn
relay output to turn off, which silences the horn. When the alarm acknowledge key is pressed, a
global acknowledge command is transmitted on the CAN data link. Other modules may be
configured to respond to the global acknowledge signal. When the horn relay sounds, one or both
of the alarm lamps will begin to flash. Depending on the active status of the alarms when this
key is pressed, the flashing lamp(s) will either turn off or solidly illuminate. The alarm
acknowledge key always sends out a global acknowledge, however other modules must be
configured to listen to the global acknowledge.
Function Keys
(8) RUN - Pressing the "RUN" key causes the EMCP 4.2 to enter the run mode.
(9) AUTO - Pressing the "AUTO" key causes the EMCP 4.2 to enter the auto mode.
(10) STOP - Pressing the "STOP" key causes the EMCP 4.2 to enter the stop mode or cooldown
mode.
(11) Escape Key - The escape key is used during menu navigation to navigate up through the
menu/submenu structure. Each key press causes the user to move backward (upward) through the
menus. The escape key is also used to cancel out of data entry screens during set point
programming. If the escape key is pressed during set point programming, then none of the
changes displayed on the screen will be saved to memory.
(14) OK Key - The "OK" key is used during menu navigation to move forward (downward)
through the menu/submenu structure. The key is also used during set point programming to save
set points changes. Pressing the OK key during set point programming causes set point changes
to be saved to memory.
Navigation Keys
(12) Up Key - The up key is used to navigate up through the various menus or monitoring
screens. The key is also used during set point entry. During numeric data entry, the key is used to
increment the digits (0-9). If the set point requires selection from a list, then the key is used to
navigate up through the list.
(13) Right Key - The right key is used during set point adjustment. During numeric data entry,
the key is used to choose which digit is being edited. The key is also used during certain set point
adjustments to select a check box or to deselect a check box. If a box has a check mark inside the
box, then pressing the key will cause the check mark to disappear. If the box does not have a
check mark inside the box, then pressing the key will cause a check mark to appear inside the
box.
(15) Down Key - The down key is used to navigate down through the various menus or
monitoring screens. The key is also used during set point entry. During numeric data entry, the
key is used to decrement the digits (0-9). If the set point requires selection from a list, then the
key is used to navigate down through the list.
(16) Left Key - The left key is used during set point adjustment. During numeric data entry, the
key is used to choose which digit is being edited. The key is also used during certain set point
adjustments to select a check box or to deselect a check box. If a box has a check mark inside the
box, then pressing the key will cause the check mark to disappear. If the box does not have a
check mark inside the box, then pressing the key will cause a check mark to appear inside the
box.
System Overview Keys
(2) AC Overview - Pressing the AC overview key displays the first screen of AC information for
the generator set. This initial information page contains various AC parameters that summarize
the electrical operation of the generator set. More AC parameters can be viewed by pressing the
down key multiple times.
(3) Engine Overview - Pressing the engine overview key displays the first screen of engine
information. This initial information page contains various engine parameters that summarize the
operation of the engine. More engine parameters can be viewed by pressing the down key
multiple times.
Systems Operation
EMCP4.2B
Media Number -UENR7097-02 Date Updated -22/10/2018

i06293436

System Operation
SMCS - 4490

The EMCP 4 can handle all of the standard genset control functions for diesel and for gas
powered gensets.
Before putting the engine into service, verify the following:
 The desired voltage and frequency are correct at rated engine speed
 Load control devices are functioning properly and have the load isolated from the
generator when not running
 If warning events are present, that is, the yellow warning lamp is lit, then take corrective
action if necessary
 No shutdown events are active, that is, the red shutdown lamp is not lit
 For remote initiate operation, the EMCP 4 must be in AUTO mode

Engine Starting Sequence

1. The EMCP 4 receives an engine start signal under one of the following conditions:
o The operator presses the "RUN" key
o The control is in "AUTO" and the remote initiate input becomes active
o The operator presses the "AUTO" key and a start command is sent via the RS-485
SCADA Data Link (Modbus).
o Programmable cycle timer output 1 is "Active"
2. The EMCP 4 checks the following system items before beginning the cranking sequence:
o There are no shutdowns on any module
o The engine is stopped
3. The EMCP 4 begins the starting sequence.
 a. The EMCP 4 activates the pre-crank and start aid outputs, if programmed, for the
configured duration.
b. On MUI engines, the EMCP 4 activates the starting motor relay (relay output 1)
and the fuel control relay (relay output 2).
c. On EUI engines that do no utilize a common engine interface, the EMCP 4
activates the starting motor relay (SMR). The start signal is sent to the engine
ECM. This signal is sent via the primary CAN data link or through a hardwired
connection.
d. On EUI engines that utilize a common engine interface, the EMCP 4 will send a
start signal to the Engine ECM via the CAN data link or through a hardwired
connection and the ECM will be responsible for cranking the engine (step 4) and
deactivating the starting motor relay (step 5).
2. The EMCP 4 cranks the engine for the programmed crank time or until the engine starts.
If the engine does not start after the crank time has elapsed, then the starting motor relay
will de-energize for the programmed rest time. After the rest time has elapsed, then the
starting motor relay will start cranking again for the programmed crank time.
A cycle consists of a crank time and a rest time. If the engine has not started after the
programmed number of cycles, then the EMCP 4 will abort the starting process. The
EMCP 4 will then generate an "Engine Failure to Start Shutdown".
3. The EMCP 4 deactivates the starting motor relay when the engine speed reaches the
setpoint for the crank terminate speed.
Engine Stopping Sequence
1. The EMCP 4 will stop the engine under either of the following conditions:
a. The operator presses the "STOP" key.
b. If the control is in "AUTO", and no longer receives any of the following:
 the remote initiate input
 the SCADA start signal
 programmable cycle timer output 1
Note: If the control is in "AUTO", the remote initiate must be inactive, and the
Modbus data link must be requesting a stop. If either the remote initiate is active,
then the engine will not stop. Remote initiates are as follows:
 Engine run state is being requested via the Modbus
 PCT output 1 is active
2. After receiving the "Stop" signal, the EMCP 4 checks to ensure that there are no system
faults present.
3. The EMCP 4 begins the cooldown period. In order to bypass the cooldown, depress and
hold the "STOP" key. The screen displays instructions to "PRESS ENTER TO
BYPASS", and "PRESS ESCAPE TO CONTINUE". Press the "OK" key in order to
bypass the cooldown sequence or press the Escape key in order to continue the cooldown
sequence.
Note: For common engine interface applications, cooldown must be controlled by the
Engine ECM.
4. After the cooldown cycle, the EMCP 4 initiates an engine shutdown by turning off the
fuel supply.
 a. On the MUI engines, the EMCP 4 deactivates the fuel control relay, which shuts
down the engine.
b. On EUI engines, the EMCP 4 sends a shutdown signal to the engine ECM over
the primary CAN data link to shut down the engine.
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