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New Digital Controls

The document introduces new digital control systems for generator sets in 4 levels, with increasing functionality from Level 1 to Level 4. Level 1 provides basic controls while Level 4 adds advanced controls like auto-sync and load sharing. Optional devices include annunciators, I/O modules, and monitoring software. The controls will be supported by service tools and introduced on new Perkins and Caterpillar generator sets through 2005.

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80 views20 pages

New Digital Controls

The document introduces new digital control systems for generator sets in 4 levels, with increasing functionality from Level 1 to Level 4. Level 1 provides basic controls while Level 4 adds advanced controls like auto-sync and load sharing. Optional devices include annunciators, I/O modules, and monitoring software. The controls will be supported by service tools and introduced on new Perkins and Caterpillar generator sets through 2005.

Uploaded by

AliHabes
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Introduction of New

Digital Controls
David Marrs
Product Comparison – Olympian
PowerPort1 PowerPort2 PowerPort3 PowerPort4
Current
Proposal Product

ns
t io
lu
So
Future

Caterpillar: Confidential Green


Product Comparison - Caterpillar
Current

on
Product

ri s
pa
m
co
ct
re
di

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


No
Proposal
Future

EMCP 3.1 EMCP 3.2 EMCP 3.3 EMCP 3.4

Caterpillar: Confidential Green


Level 1 Control System
• Digital control system targeted
as Olympian 2001 and 4001
panel replacement
• Basic Auto Start controls,
protection and metering
• Fault log
• Limited options
• No remote comms.

Caterpillar: Confidential Green


Level 1 Features
• Basic Auto Start Digital Control with LCD display
• Fault Log
• AC Metering – Volts, Amps, Frequency
• DC Metering – Battery Volts, Hours Run, Engine Jacket Water
Temperature, Lube Oil Pressure, Engine Speed
• Engine Protection
o Fail to Start
o Low Oil Pressure
o High Engine Temperature
o Overspeed
o Loss of Speed detection via Magnetic Pick-up
• 2 spare fault channels

Caterpillar: Confidential Green


Control Architecture - L1

Hardwired senders on mechanical


engines

J1939 on electronic engines

Caterpillar: Confidential Green


Level 2 Control System
• Replaces Olympian 4001E, Access 4000 and 6100
• Replaces Caterpillar EMCPII
• Modbus remote communications
• Increased engine & AC protection
• Power metering as standard
• Options on Can 2.0b expansion network
– Additional I/O
– Annunciator (NFPA 99/110)
– Modem communications

Caterpillar: Confidential Green


Level 2 Features
• Auto Start Digital Control with LCD Display
• Fault Log
• AC Metering – Volts, Amps, Frequency, kW, kVA, kVar, Power Factor, kW
hours, kVar hours
• DC Metering – Battery Volts, Hours Run, Engine Jacket Water Temperature,
Lube Oil Pressure, Engine Speed, Crank Attempt counter, Start counter
• Engine & Generator Protection
o Fail to Start, Low Oil pressure, High Eng temperature,
o Underspeed, Overspeed
o Loss of Speed detection via Magnetic Pick-up
o High Battery Voltage, Low Battery Voltage
o Under Volts, Over Volts
o Under Frequency, Over Frequency
o Overcurrent
• 4 spare fault channels
• Remote communications – Modbus (option)
• Expansion modules available – Remote annunciator, additional I/O module

Caterpillar: Confidential Green


Control Architecture - L2 & L3

I/O etc

Can 2.0b expansion


network

J1939 Modbus

Caterpillar: Confidential Green


Level 3 Control System
• Replaces Caterpillar EMCPII+
• Additional functionality over Level 2
– Loss of Excitation protection
– Reverse Power protection
– Improved monitoring for electronic engines via J1939 communications
– Upgraded graphical display

• Options
– Additional I/O
– Annunciator
– Modem communications
– RTD Module
– TC module
– DVR

Caterpillar: Confidential Green


Level 4 Control System
• Replaces Olympian 6201, 6301 & 6401
• Replaces Caterpillar EMCPII+P
• Additional functionality over Level 2
• Auto-sync & load sharing control system
• Advanced control, metering and protection
• RS485 proprietary add’l comms. link for
inter-genset & supervisory comms
• Compatible with all optional expansion
modules
• Class leading graphic display
• Available Q4 2004

Caterpillar: Confidential Green


Control Architecture
L4 - 2 x Unit (Island Mode)

I/O etc I/O etc

Can 2.0b expansion network Can 2.0b expansion network

Modbus

RS485 MGDL (Proprietary)

J1939 J1939

Caterpillar: Confidential Green


Control Architecture
L4 - 2 x Unit (Utility Sync)

I/O etc I/O etc

Can 2.0b expansion network


Can 2.0b expansion network

Modbus

RS485 MGDL (Proprietary)

J1939 Switchgear J1939

Caterpillar: Confidential Green


Optional Devices (1)
(Olympian L2 – L4 & EMCP 3.2 – EMCP 3.4)
• Annunciators (Local & Remote)
– 16 Multi-Light LED’s, NFPA99-110
– Optional Custom Annunciator and Film
• I/O Module
– 8 Digital Inputs
– 8 Form-C Relays Outputs
• Customer Monitoring Software
– Remote Dial-up Modem (RS485 –
RS232)
– Remote Monitoring Software

Caterpillar: Confidential Green


Optional Devices (2)
(Olympian L3 – L4 & EMCP 3.3 – EMCP 3.4)
• Thermocouple Input Module
– 20 Point, Type J or K
• RTD Input Module
– 8 Point, 3 or 4 wire 100 Ohm
• Digital AVR
– Communicates on J1939

Caterpillar: Confidential Green


Panel Configuration
• The control module is software configured
• Set points can be adjusted by the operator or service
engineer from the front of the module or by using the service
tool.
• Set points are password protected
• Display language is controlled by the flash file. Each file
contains a customer language and technician English
• The service tool can be used to download new flash files to
the module e.g. to change display language

Caterpillar: Confidential Green


Service Tool
• The new control modules will be supported by CAT ET and
COM ADAPTOR 2.

Caterpillar: Confidential Green


Olympian Introduction

• Perkins 400 Jun 04


• PEP Aug 04
• Gas inc. K Series Sep 04
• Perkins 1300,2300,2800 Nov 04

Caterpillar: Confidential Green


CAT Introduction

• C18/3456/3406 Sept 04
• 3508/3512 GD Sept 04
• 3516 GD Dec 04
• ACERT packages C9, C13, C15 through 2005

Caterpillar: Confidential Green


Summary
Quality, Increased Functionality and Growth
• Competitively priced, 21 st century product
• Increased feature bundling
• Consistent direction – common electronics on Olympian and
CAT product
• Increased quality and reliability
• Industry leading family of control systems

Caterpillar: Confidential Green

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