Upgrade Emcp 3.1 To Emcp 4.2

Media Search - REHS9799 - Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, E...
Page 1 of 24
Previous Screen
Welcome: j320psr
Product: NO EQUIPMENT SELECTED

Model: NO EQUIPMENT SELECTED
Configuration: NO EQUIPMENT SELECTED
Special Instruction
Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2
{4490, 7610}
Media Number -REHS9799-01 Publication Date -29/07/2015 Date Updated -05/07/2016
i06736211
Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1,

EMCP 3.2, and EMCP 3.3 to EMCP 4.2 {4490, 7610}
SMCS - 4490; 7610
Electric Power Generation

All
Introduction
Reference: Systems Operations Troubleshooting/Testing and Adjusting, UENR1209, "EMCP4.1/EMCP4.1 4.2"
Reference: Application and Installation Guide, LEBE0006, "EMCP 4.1, 4.2 Generator Set Control"
This Special Instruction contains necessary information for upgrading Electric Power Generator Set Control
mounted panels that use the EMCP Engine Status Control (ECS), EMCP1 (per 7C-1000 Control Panel Chart),
EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2.
Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you
understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools.
Failure to follow these procedures can result in personal injury. The following procedures should also be observed.
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to
perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every
possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure
that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is
safe.
Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication,
maintenance, or repair procedures used. Proper care is your responsibility.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 13/3/2018
Media Search - REHS9799 - Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, E... Page 2 of 24
Do not operate or work on this engine or generator set unless you have
read and understand the instructions and warnings in the Operation
and Maintenance Manuals.
Failure to follow the warnings and instructions could result in injury or

death. Contact any Caterpillar dealer for replacement manuals. Proper
care is your responsibility.
Overview
Applicability
This kit is intended to replace EMCP Controls by using the existing generator-mounted enclosure.
Features
As implemented, the EMCP 4.2 control offers more features and communication options than what was available
with the earlier EMCP models. Refer to Application and Installation Guide, LEBE0006, "EMCP 4.1, 4.2 Generator
Set Control" for a complete description.
Required Documents
Refer to the following documents for review prior to installation.
Table 1
Media
Systems Operations, Troubleshooting, Testing and Adjusting, UENR1209, "EMCP4.1/EMCP4.2"
LEBE0006 EMCP 4.2 Application and Installation Guide
Power Requirements
This control is designed to operate on 24 V, DC only. Current draw of the control package is less than 2.0 amps.
External solenoids, loads driven by the control's relays and connection of a Caterpillar ET communications adapter
will add to the current draw.
Safety
Lock Out / Tag Out
Accidental engine starting can cause injury or death to personnel

working on the equipment.
To avoid accidental engine starting, disconnect the battery cable from

the negative (−) battery terminal. Completely tape all metal surfaces of
the disconnected battery cable end in order to prevent contact with
other metal surfaces which could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop switch location to inform

personnel that the equipment is being worked on.
Illustration 1 g03858739
Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the battery disconnect
location before you service the equipment. The warning tags are available from your Caterpillar dealer.
Electrical Safety
Note: Do not operate or work on a generator set unless you have read and understand the instructions and
warnings in this manual and the EMCP 4.2 Application and Installation Guide. Failure to follow the instructions or
heed the warnings could result in injury or death. Contact any Cat Dealer for replacement manuals. Proper care is
your responsibility.
Electrostatic Discharge Awareness
NOTICE
The EMCP 4 control contains components that are sensitive to

electrostatic discharge (ESD). An electrostatic charge can damage the
control resulting in EMCP 4 breakdown or improper operation. Take
the following precautions while installing, removing, and handling the
control.
• Handle equipment correctly. Use ESD protective packaging and material handling containers that are anti-
static and provide discharge protection and electric field suppression.
• Use protective devices: ESD-protective workstations and/or work surfaces (grounding mat, anti-static wrist
strap and so on).
• Keep all plastic items away from the devices. Any plastic item is a potential static generator. Examples
include candy wrappers, foam cups, synthetic carpet, foam cushions, and so on.
• The anti-static bag cannot function as a static dissipating mat.
• DO NOT use an anti-static bag for any other purpose than to enclose a product.
• The 120 pin or 70-pin connector on the back of the control is the most vulnerable area to
ELECTROSTATIC DISCHARGE (ESD). While handling the EMCP 4.2, extra attention is required at the
back of the control. The control may become damaged or inoperable if extra care is not taken.
Removal of the Existing Control

Resolve Existing Issues
• Resolve any existing issues with the control, the generator set, or the wiring between them. If the existing
installation has generator set or control issues, these issues should be repaired prior to performing a control
upgrade. Troubleshooting a failure will only become more difficult after the new control is installed. If the
control has failed, it may not be possible to perform some of the following tasks.
• Use the documentation appropriate for the control. The document should be available on SIS web.
• Check the control for stored diagnostic codes and repair the issues that are causing the codes
• As much as practical, insure that the control and generator set are working without issues.
Voltage and Continuity Check

• Perform a voltage and continuity check to determine that the schematic conforms to the old control as it has
been installed. An accurate schematic of the existing installation will be required when installing the new
control.
• Using a voltmeter, connect the negative lead to ground
• Measure the voltage at every point shown on the schematic that is connected to battery (+). Check continuity
for every point on the schematic. Mark up the schematic to reflect the control as it is installed. Continuity
should be < 10 ohms. Voltage is Vbat ± 0.5 V
Determine Idle and Rated Speed Parameters

Record the generator set parameters when the generator is at idle and rated speed.
The value of the generator set parameters will be needed to verify that there are no problems after the installation
of the new sensors.
Start the generator set and force the generator to remain at idle. The governor must be disconnected or disabled.
When the coolant temperature has stabilized, record the following values listed in Table 2.
Table 2
Value Unit Recorded Value
Engine Idle Speed RPM
Engine Oil Pressure psi / kPa
Engine Coolant Temperature C/F
Enable the generator set to go to rated speed. When the coolant temperature has stabilized, record the values listed
in Table 3.
Table 3
Value Unit Recorded Value
Engine Rated Speed RPM
Engine Oil Pressure psi / kPa
Engine Coolant Temperature C/F
Baseline Generator Set Operating Parameters
Record the existing baseline operating parameters of the generator set.
Use documentation found in the service information system website to determine how to access the generator set
parameters. The parameters will be needed to program the new control. Record the data for the list of parameters
that are shown in Illustration 2.
Remove the Existing Control
Accidental engine starting can cause injury or death to personnel

working on the equipment.
To avoid accidental engine starting, disconnect the battery cable from

the negative (−) battery terminal. Completely tape all metal surfaces of
the disconnected battery cable end in order to prevent contact with
other metal surfaces which could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop switch location to inform

personnel that the equipment is being worked on.
Bodily contact with electrical potential can cause bodily injury or death.
To avoid the possibility of injury or death, ensure that the main power
supply has been disconnected before performing any maintenance or
removing any modules.
Working with electrical circuits is hazardous. Bodily contact with

electrical potential will cause personal injury or death. Ensure that
personnel are trained in proper operating procedures in order to ensure
safe operation.
1. Insure that the generator has been disconnected and isolated from the utility power and any other power
source. Ensure that proper lock out and tag out procedures are followed.
2. Disconnect the AC power from the battery charger.
3. Disconnect the battery charger from the battery.
4. Disconnect the battery from the generator set.
5. Inspect the wiring coming out of the conduit that enters the bottom of the panel. All the wires must be
labeled with the number of the terminal blocks that the wires are connected to. Ensure that the terminal
block numbers match the wire numbers. The labeling is shown on the schematic for the existing installation.
When all the wires have been labeled, disconnect the wires from the terminal blocks.
6. Disconnect the conduit and spiral wrap from the original EMCP panel. Ensure that none of the wiring is
damaged during removal of the conduit or spiral wrap.
Note: Do not remove any wiring from the conduit or spiral wrap.
7. If the governor/speed control is going to be reused in the EMCP 4.2 panel, the governor/speed control
should be removed from the original EMCP panel.
8. Remove the original EMCP panel from the generator enclosure.
Installation of the EMCP 4.2 Control

Parts List
Table 4
Contents of the 467-4168 Electronic Panel Gp
QTY Part Number Description
1 457-1582 Panel Harness As
1 467-4169 Panel Harness As
1 459-1873 Terminal Marker As
15 3S-2093 Cable Strap
9 9X-8256 Washer
6 095-0827 Lockwasher
1 103-6272 Seal
9 208-8469 Locknut
1 442-0635 Bracket As
2 3E-2286 Contact Strip
2 5C-2890 Nut
2 8T-4205 Hard Washer
1 9Y-6027 Ceramic Fuse
1 105-7543 Fuse Block
8 115-1322 Terminal
1 115-2538 End Cover
22 116-5140 Terminal
1 125-9969 Rail
1 203-9007 Nut
2 225-3322 Screw
3 264-2957 Screw
2 314-9101 End Bracket
1 355-9019 Generator Set Electronics Gp
3 448-1934 Spacer
1 499-6725 Plate
Control Module Installation
(1) EMCP Control

(2) 499-6725 Plate
Mounting 499-6725 Plate is provided to give the installer an additional option for mounting the EMCP. Refer to
Illustration 3 for measurements.
Terminal Block Installation
EMCP 4.2 Terminal Block-Rail mounting
Refer to Illustration 4 for layout of the Terminal Block Assembly.
Control Harness Installation

Once the wire 467-4169 Panel Harness As has been installed , use Table 5 for wire to Terminal Block Assembly.
Table 5
Control Harnesses
467-4169 Panel Harness As Wire Number/Color Terminal Block Number
7 196-E6 GY 404
9 185-E5 BR 403
11 183-E7 PU 402
13 180-E4 OR 401
16 P735-E35 E-CBL2 WH 306
18 101-E18 RD 104
26 R957-E42 BK 313
27 L925-E43 PU 314
31 A368-E13 BR 405
37 R952-E38 E-CBL3 BK 308
38 R951-E37 E-CBL3 RD 307
39 184-E8 BU 408
46 P734-E34 E-CBL2 BK 305
47 A367-E12 GN 406
48 R955-E41 BK 312
51 R954-E40 BK 311
52 101-E17 RD 103
55 A775-E15 BK 310
56 P733-E33 E-CBL2 RD 304
57 A364-E11 YL 407
58 101-E19 RD 105
60 200-E10 BK 201
61 101-E16 RD 104
65 200-E9 BK 201
66 G404-E30 E-CBL1 RD 303
67 G405-E31 E-CBL1 BK 302
70 A774-E14 BK 309
457-1582 Panel Harness As Wire Number/Color Terminal Block Number
A 101-G1 RD 105
B 200-G2 BK 202
457-1582 Panel Harness As Splice together 467-4169 Panel Harness As
F711-G8 GN Splice together F711-E27 GN
F712-G5 YL Splice together F711-E22 YL
The schematic for the existing installation and the schematic for the EMCP 4.2 is required to install the wiring to
the EMCP 4.2 control. Since the EMCP 4.2 can replace many different controls, the wire numbers on the existing
wiring will likely not correspond with the EMCP 4.2 terminal blocks.
The wire numbers on the existing wiring along with the schematic for the existing control will help to identify the
function for each wire. Using the schematic for the EMCP 4.2, find the corresponding function and the terminal
block number. Connect each wire to the correct terminal block. In many installations there will be wiring that is
not used. If it is certain that a wire will not be used, it can be pulled out of the conduit and discarded.
Note: All wiring connected to generator output must have an insulation rating of 600 V.
Wiring Diagrams
Media Search - REHS9799 - Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, ... Page 10 of 24
Wiring Diagram 1
Items shown as dashed lines are not included in the kit.
Note: Replacing the oil pressure sensor, engine speed sensor, and coolant temperature sensor may be necessary if
the existing sensors are not compatible with the EMCP4.2 or have failed.
Install Existing Sensors

Note: PWM Sensors will not work with the EMCP 4.2 Control. For more information refer to the section
"Recommended Sensors".
Use Wiring Schematic Illustration 5 and 6 for help in the wiring of sensors. Use the reference document
(UENR1209) for sensor configuration.
Control Parameter Configuration
Configuration Parameter Default Values
For information on configuration of various sensors, reference Application and Installation Guide, LEBE0006,
"EMCP 4.1, 4.2 Generator Set Control" which can be found on Power Net.
Winding Ratings
Potential Winding Rating
The EMCP 4.2 control can directly monitor generator voltages up to 600 V. Voltages more than 600 V must use
potential transformers or an ATB (AC Transformer Box) to scale the generator voltage to less than 600 V.
Secondary Winding Rating
Whether the generator is wired directly to the EMCP 4.2, or when potential transformers or an ATB is used, it is
recommended that fuses at the appropriate voltage rating be installed. Fuses are connected to the load bus
generator tab as shown in Illustration 6. If there is a short on one of the connections to the control (Bus Voltage L1,
L2 and L3, Neutral), a fuse will blow to protect the generator, control, and personnel. If potential transformers are
used, the voltage ratio is set in the Potential Transformer Secondary Winding Rating setting. The value of this
rating depends on the turns ratio of the potential transformer's primary winding to secondary winding.
Primary Winding Rating
The EMCP 4.2 control must use current transformers to measure generator output current. The current
transformers must scale the generator output current from, 0 to 1 or 0 to 5 amps for use by the EMCP 4.2. The
current transformer ratio is set in the EMCP 4.2 parameter settings. Use (Configuration Setup for "Generator AC
Monitor") shown above, as a path to access the current primary and secondary winding rating parameter using
CAT ET.
The recommended Transformers can be found in Table 6.
Table 6
Part Number Description Rating
122-6585 Current Transformer As 1000:5 Amps, 600 Volt, Stud terminals
365-1431 Link and Bearing As 3000:5 Amps, 600 Volt, Stud terminals
357-1219 Transformer 1500:5 Amps, 600 Volt, Stud terminals
Configuration Setup for "Generator AC Monitor"
To change the following parameters, refer to the following instructions:
1. Navigate to the EMCP 4.2 screen in Cat ET, and click "Configuration Tool".
2. Navigate to desired parameter "Generator AC Monitor", and double-click the "desired parameter line of
choice" to change "VALUE".
3. In the (Change Parameter Value) box, enter new value and click "OK".
4. Continue to the next Parameter as needed.
5. Double-Click CAT ET (Configuration Tool) Icon
Analog Inputs
There are two analog inputs from the generator set:
◦ Engine Oil Pressure
◦ Engine Coolant Temperature
High Coolant Temperature Shutdown
This can be found listed as Analog Input #2 High Shutdown Event Threshold. The range of this parameter is
95 -120 °C or 203-248°F. The default value is set at 108°C.
Low Oil Pressure Shutdown Event Threshold
This can be found listed as Analog Input #1 Low Shutdown Event Threshold. The range of this parameter is
13.4 - 880 kPa. The default value is set at 150 kPa.
6. Select the value of the parameter that is being modified. Enter the new value and click "OK" to change
7. Program the parameters into the EMCP 4.2 control using the parameter data that was obtained in 3.4
Baseline Generator Set Operating Parameters.
8. For information on how to set the time and date on the EMCP 4.2 control, refer to Systems Operations
Troubleshooting Testing and Adjusting, UENR1209, "EMCP4.1/EMCP4.2".
9. This control has not allocated inputs for battery charger fault detection. If it is necessary to monitor the
battery charger status and the battery charger provides status outputs, refer to Systems Operations
Troubleshooting Testing and Adjusting, UENR1209, "EMCP4.1/EMCP4.2" for instruction on how to
implement digital inputs.
Validation
Electrical Validation
Power Off Tests
The battery should not be connected.
Check for continuity between the following points (TB designates the terminal blocks in the EMCP 4.2 control):
Table 7
From PIN To PIN
Battery (+) lug TB 101
Battery (-) lug TB 201
Remote Initiate Contact 1 (IC) TB 310 (Optional Feature)
Remote Shutdown Contact 1 (PSS) TB 309 (Optional Feature)
Air Shut Off Relay coil 2 TB 312 (Optional Feature)
Fuel Solenoid coil 2 TB 312
Fuse T1 protected terminal TB 401
Generator Enclosure TB 50 TB 408

Note: To check the continuity of the wiring from the generator output to the EMCP 4.2, remove the three fuses
(F10, F11, F12 in Illustration 6) to isolate the wiring from the generator. Replace the fuses after the continuity
checks have been completed.
Note: This validation assumes that potential transformers or an ATB is not being used.
Power On Test
Perform the following procedure for power-on test :
1. Connect the battery terminals to the battery. Connect the battery charger to the battery and insure the battery
charger is connected to an AC source.
2. Using terminal block 201 as (-) Battery, check that there is (+) Battery voltage on the following points: (See
Illustration 4 Schematic for fuse terminal block identification)
3. Fuse 1 terminal 2.
4. Verify that the EMCP 4.2 control is powered up
Operational Validation
Cranking Cycle, E-Stop Test
This test will verify that the generator set cranking cycle can be stopped with the E-Stop button. To prevent the
engine from starting, disconnect wire from TB312. Make sure to isolate wire, to prevent short to ground.
1. Push the "RUN" button and allow the generator set to go through the first crank/rest cycle. When the second
crank cycle begins, press the E-Stop button to verify that the generator set can be stopped
2. Acknowledge the cranking cycle faults and reset the EMCP 4.2 control.
3. Connect wire to TB312 to allow the Fuel Control Relay (FCR) to function.
Idle Speed Tests
Disconnect or disable any speed governor to prevent the generator set from running at rated speed
Idle Speed, E-Stop Test
This test will verify that the generator set can be stopped at idle speed with the E-Stop button.
1. Press the "RUN" button and allow the generator set to start and run at idle speed.
2. Press the E-Stop button to verify that the generator set will come to a controlled stop.
Idle Speed Parameter Validation
Perform the following procedure for idle speed parameter validation:
1. Push the "RUN" button on the EMCP 4.2 control panel. The generator set should start and run at idle speed.
2. Check the coolant temperature as the generator set starts and verify that it is close to the block temperature
of the generator set. This check is done to determine if the coolant temperature sensor and related wiring is
functional.
3. Allow the coolant temperature to stabilize, then read the following parameters from the ECM display:
Engine speed - RPM
Battery Voltage - Volts
Engine oil pressure - kPa or psi (circle which)
Engine coolant Temperature - °C / °F (circle which)
4. Any parameter that is not the same as the original data value data will need to be investigated and resolved
before proceeding.
5. Press the "Stop" button on the EMCP 4.2. The generator set should come to a controlled stop.
6. Correct any issues that prevented the generator set from starting, idling, or verification of the idle speed
parameters.
Engine Speed Sensor Loss Test
The engine speed sensor loss test will verify that the generator set will stop if the engine speed sensor fails.
1. Push the "RUN" button and allow the generator set to start and run at idle speed.
2. Jumper terminal 302 to terminal 303. The generator set should shutdown immediately. Loss of engine speed
results in an "Unexpected Engine Shutdown" fault. To recover from this fault, remove power from the
EMCP 4.2 control by removing Fuse 1 to remove power from the control, and then reinstall the fuse.
3. Restart the generator set and allow it to run at idle speed.
4. Disconnect the engine speed sensor from either terminal 302 or 303. The generator set should shutdown
immediately. Reconnect the engine speed sensor and cycle the power on the EMCP 4.2 by removing Fuse 1
to remove power from the control, and then reinstall the fuse.
5. Reconnect or enable the governor to allow the generator set to run at rated speed.
Engine Set point Verification
The engine set point verification procedure verifies that the EMCP 4.2 operates correctly when a Low Oil Pressure
or High Coolant Temperature event occurs. The engine set point verification procedure also verifies that the
EMCP 4.2 operates correctly when an Engine Overspeed event occurs.
Low Oil Pressure and High Coolant Temperature each have two events, Warning and Shutdown. The EMCP 4.2
will issue a warning whenever the warning threshold is reached and a shutdown whenever the shutdown threshold
is reached. This verification procedure will modify configuration set points used in normal operation. The steps
below outline how to perform the Low Oil Pressure Shutdown and High Coolant Temperature shutdown
procedures. A similar process can be used for Low Oil Pressure Warning and High Coolant Temperature Warning,
along with Low Idle Low Oil Pressure.
During this procedure, each configuration set point should be recorded prior to adjustment then returned back to
the original setting after the set point has been verified.
The following conditions are required before the Engine Set points are verified:
• The set points must be correct for the generator set application.
• No shutdown events should be present. If necessary, troubleshoot, correct, and reset any shutdown events
Low Oil Pressure Verification
Note: Low Oil Pressure Shutdown is disabled during start-up and while the generator set is not running by the
Fault Protection Timer (FPT). The fault protection timer starts timing when crank terminate RPM is reached
during the starting sequence. The fault protection timer will then run for a programmed time which is determined
by the Engine Start Fault Protection Activation Delay Time set point. Make sure that the fault protection timer has
elapsed before starting the Low Oil Pressure Verification.
1. Start the generator set and run the generator set at rated speed.
2. Adjust the set point value for Analog Input #1 Low Shutdown Event Threshold to a value that is above the
oil pressure at which the generator set is operating. The shutdown event will occur after the programmable
time delay (Analog Input #1 Low Shut down Event Delay Time set point)
3. View the event by going to the EMCP 4.2 event log.
4. Reset the event
5. Return the set point value for Analog Input #1 Low Shutdown Event Threshold to the original value.
Overspeed Verification
Perform the following procedure on overspeed verification:
2. Adjust the set point value for Engine Overspeed Set point to a value that is below the speed that the
generator set is running at. An Engine Overspeed Set point event will occur immediately after the set point is
changed, and the generator set will shut down.
3. View the event by going to the EMCP 4.2 Control event log.
4. Reset the event.
5. Return the set point value for the Engine Overspeed Set point to the original value.
Overspeed Verification
Perform the following procedure on overspeed verification:
2. Adjust the set point value for Engine Overspeed Set point to a value that is below the speed that the
generator set is running at. An Engine Overspeed Set point event will occur immediately after the set point is
changed, and the generator set will shut down.
3. View the event by going to the EMCP 4.2 Control event log.
4. Reset the event.
5. Return the set point value for the engine overspeed set point to the original value.
Analog Inputs
There are two (2) Analog inputs from the generator set:
• Engine Oil Pressure
• Engine Coolant Temperature.
High Coolant Temperature Shutdown - This can be found listed as Analog Input #2 High Shutdown Event
Threshold. The range of this parameter is 95 - 120°C or 203 - 248°F. The default value is set at 108°C.
Low Oil Pressure Shutdown Event Threshold - This can be found listed as Analog Input #1 Low Shutdown
Event Threshold. The range of this parameter is 13.4 -880 kPa. The default value is set at 150 kPa.
Automatic Start/Stop
Configuration of the Automatic Start/Stop parameters is done in ET via the parameters shown below.
Cycle Crank Configuration
This can be found listed as Crank Duration. The range of this parameter is 1 - 60 seconds. The default value is set
at 10 sec.
Cycle Crank Rest Interval
The range of this parameter is 1 - 60 seconds. The default value is set at 5 sec.
Maximum Number of Crank Cycles
The range of this parameter is 1 - 99. The default is set to 1.
Cool down Configuration
This can be found listed as Cool down Duration.
The range of this parameter is 0 - 30 minutes. The default value is set at 5 minutes.
Crank Termination Speed Configuration
This can be found listed as Crank Terminate RPM.
The range of this parameter is 100 - 1000 RPM. The default value is set at 300 RPM. Battery Voltage Monitor
Idle Speed Oil Pressure Shutdown
This is listed as Low Idle Low Engine Oil Pressure Shutdown Event Threshold. The range of this parameter is 20 -
420 kPa. The default value is set at 200kPa.
Low Idle Low Engine Speed Oil Pressure Warning Event Threshold
The range of this parameter is 22 - 462 kPa. The default value is set at 2. The value of this parameter should be set
at least 110% of the value of the Idle Speed Oil Pressure Shutdown parameter.
Oil Step Speed
This is listed as Low Engine Oil Pressure Step Speed. The range of this parameter is 400 - 1800 RPM. The default
value is set at 400 RPM.
Overspeed
This can be found listed as Engine Overspeed Set point. The default value is set at 1540 RPM. This value is
generator set specific
Software Requirements
Flashing the EMCP 4.2 requires the following hardware and software:
• The Caterpillar ® Service Tool software installed and licensed on a PC.
• A Caterpillar Communication Adapter.
• A 9-pin round Deutsch connector service connection to the Primary Data link (CAN 1).
Use the following files when flashing or configuring:
EMCP 4.2 ECM Flash File: Can be found on SIS web, ELEK GP-A6001 PN: 355-9019 Generator Set Electronics
Gp
Recommended Sensors
The recommended sensors for the EMCP4.2 upgrade are listed below:
• Coolant temperature sensor
• Oil pressure (Gauge) sensor
• Oil temperature sensor
Coolant Temperature Sensor

The physical and electrical connections of 7X-1043 Temperature Sensor Gp are listed below:
Physical Connection - #6 STOR (9/16-18) male thread and use 214-7568 O-Ring Seal.
Electrical Connection - Use mating connector 8T-8731 Connector Plug.
The configuration parameters of coolant temperature sensor (Analog Input #2) for the EMCP4.2 are listed below:
• Signal type is voltage output.
• Supply voltage given is 5 Volt.
• Signal range is between 0.5 to 4.5 Volts.
• Data identification through engine coolant temperature.
• Minimum data range is −3.442° C (25.80440° F).
• Maximum data range is 238.982° C (462.16760° F).
Note: All configuration parameter values are in metric (SI) units (degrees Centigrade, kPa) even though the user
display may be in English units.
The connections of sensor wire for EMCP4.2 are listed below:
• Signal (White) wire is connected to terminal block 307.
• Ground (Black) wire is connected to terminal block 308.
• Supply (Orange) wire is connected to terminal block 306.
Note: Terminal block 308 (Sensor Ground) must be tied to Battery Ground (terminal block 204) in order for the
EMCP4.2 to properly read the sensor.
Oil Pressure (Gauge) sensor

The physical and electrical connections of 246-8150 Pressure Sensor are listed below:
Physical Connection - Use 1/8-27 NPT (National Pipe Thread) male thread
Electrical Connection - Use M4 studs and 2L-8065 Ring Terminal (12-10 AWG), 2L-8075 Ring Terminal (16 -
14 AWG), 7N-9194 Terminal Ring (22 - 18 AWG)
The configuration parameters of oil pressure sensor (Analog Input #1) for the EMCP4.2 are listed below:
• Signal type is resistive sender.
• Configuration code is map #2.
• Data identification through engine oil pressure.
The electrical connection for a resistive sensor on Analog Input #1 is given as follows:
• Terminal block 304 is connected to either terminal of temperature sensor (resistance sensors do not have a
polarity).
• Terminal block 305 is connected to remaining terminal.
Note: Terminal block 305 (Sensor Ground) must be tied to Battery Ground (terminal block 204) in order for the
EMCP4.2 to properly read the temperature sensor.
Oil Temperature Sensor

The physical and electrical connections of 106-0735 Temperature Sensor Gp are listed below:
Physical Connection - #8 STOR (3/4-16) male thread and use 3K-0360 O-Ring Seal.
Electrical Connection - Use 155-2260 Connecting Plug Kit (deutsch connector 3 pin).
The configuration parameters of oil temperature sensor (Analog Input #3) for EMCP4.2 are listed below:
• Signal type is voltage output.
• Supply voltage given is 5 Volt.
• Signal range is between 0.5 to 4.5 Volts.
• Data identification through engine oil temperature.
• Minimum data range is −23.671° C (−10.60780° F).
• Maximum data range is 118.926° C (246.06680° F).
Note: All configuration parameter values are in metric (SI) units (degrees Centigrade, kPa) even though the user
display may be in English units.
On the EMCP4.2 kit, Analog Input #3 has not been brought out to terminal blocks. The pins on the 70-pin
connector are given as below:
• Analog Input #3 (+) - 30
• Analog Input #3 (-) - 29
Note: Analog Input #3 (-) must be tied to Battery Ground (terminal block 204) in order for the EMCP4.2 to
properly read the sensor.
Available Hardware Add-ons

Annunciator
Front EMCP 4.2 Panel
The EMCP Annunciator serves to display generator set system alarm conditions and status indications. The
annunciator can be mounted with the generator control or in a desired remote location.
Table 8
Annunciator Parts List
1 422-1193 Film
1 303-5893 Alarm Module Gp
4 9x-8256 Washer
4 5C-2890 Nut
1 244-9613 Gasket
1 265-4123 Connector Receptacle As
1 203-9007 Nut
2 155-2267 Connector Plug As
2 134-2540 Resistor As
Optional 130-4676 Electrical Wire
Optional 130-4673 Electrical Wire
Optional 206-3985 Wire
Optional 206-3986 Wire
4 9X-3401 Connector Pin
2 9X-3401 Connector Pin
1 8T-8737 Seal Plug
E-STOP
E-STOP Connection
The E-STOP is used to perform a hard shutdown of the engine in the event of an Emergency. Use the
recommended Parts listed in Table 9, for replacement.
Table 9
E-STOP Parts List
1 442-6212 Stop Switch
1 442-6215 Contact Block
1 442-6217 Holder
1 442-6219 Shroud
1 443-2546 Adapter
Starter Motor Magnetic Solenoid (SMMS)
Starter Motor Magnetic Solenoid mounting location
Starter Motor Magnetic Solenoid Connection
The Starter Motor Magnetic Solenoid acts as a switch control from the EMCP , to allow the engine to crank. The
recommend replacement is listed in Table 10.
Table 10
Starter Motor Magnetic Solenoid Parts List
1 125-1302 Magnetic Switch Gp
1 5C-2890 Nut
1 8T-4205 Hard Washer
Potentiometer
Wiring diagram for connecting the potentiometer
The Potentiometer can be used to adjust the Engine Speed manually. Use the recommended parts list in Table 11.
Table 11
Potentiometer Parts List
1 122-9458 Potentiometer
1 4W-5972 Knob
1 7C-4550 Seal
Copyright 1993 - 2018 Caterpillar Inc. Tue Mar 13 14:54:30 UTC+0800 2018
All Rights Reserved. j320psr
Private Network For SIS Licensees.

Upgrade Emcp 3.1 To Emcp 4.2

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Upgrade Emcp 3.1 To Emcp 4.2

Hochgeladen von

Copyright:

Verfügbare Formate

Media Search - REHS9799 - Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, E...

Product: NO EQUIPMENT SELECTED

Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1,

Electric Power Generation

Important Safety Information

Failure to follow the warnings and instructions could result in injury or

Accidental engine starting can cause injury or death to personnel

To avoid accidental engine starting, disconnect the battery cable from

Place a Do Not Operate tag at the Start/Stop switch location to inform

Electrostatic Discharge Awareness

The EMCP 4 control contains components that are sensitive to

• The anti-static bag cannot function as a static dissipating mat.

Removal of the Existing Control

Voltage and Continuity Check

• Using a voltmeter, connect the negative lead to ground

Determine Idle and Rated Speed Parameters

Baseline Generator Set Operating Parameters

Record the existing baseline operating parameters of the generator set.

Remove the Existing Control

Accidental engine starting can cause injury or death to personnel

To avoid accidental engine starting, disconnect the battery cable from

Place a Do Not Operate tag at the Start/Stop switch location to inform

Working with electrical circuits is hazardous. Bodily contact with

2. Disconnect the AC power from the battery charger.

3. Disconnect the battery charger from the battery.

4. Disconnect the battery from the generator set.

8. Remove the original EMCP panel from the generator enclosure.

Installation of the EMCP 4.2 Control

Control Module Installation

(1) EMCP Control

Terminal Block Installation

Refer to Illustration 4 for layout of the Terminal Block Assembly.

Control Harness Installation

Items shown as dashed lines are not included in the kit.

Install Existing Sensors

Control Parameter Configuration

Configuration Parameter Default Values

Potential Winding Rating

Secondary Winding Rating

Primary Winding Rating

The recommended Transformers can be found in Table 6.

Configuration Setup for "Generator AC Monitor"

To change the following parameters, refer to the following instructions:

4. Continue to the next Parameter as needed.

5. Double-Click CAT ET (Configuration Tool) Icon

There are two analog inputs from the generator set:

◦ Engine Oil Pressure

◦ Engine Coolant Temperature

High Coolant Temperature Shutdown

Low Oil Pressure Shutdown Event Threshold

Power Off Tests

The battery should not be connected.

Generator Enclosure TB 50 TB 408

Perform the following procedure for power-on test :

4. Verify that the EMCP 4.2 control is powered up

Cranking Cycle, E-Stop Test

Idle Speed Tests

Idle Speed, E-Stop Test

Idle Speed Parameter Validation

Perform the following procedure for idle speed parameter validation:

Engine speed - RPM

Battery Voltage - Volts

Engine oil pressure - kPa or psi (circle which)