EMCP 4.

4 Simulator Manual

Author: Lucas Tolbert

CIC Engineering
345 Center Street
East Peoria, IL

Date of Origin: 11/23/2010

Overview
This document will detail the features and operation of the EMCP 4.4 simulator. The
EMCP 4.4 simulator was designed to provide a way to demonstrate some of the
capabilities of Caterpillar’s EMCP 4.4 control.

Each simulator comes with a set of prints that details the wiring and circuitry inside the
simulator. The simulator manual document will describe the functionality of the
simulator and will reference the internal wiring. This document is not intended to convey
complete details regarding the internal wiring of the simulator. Complete details are
shown in the electrical schematics.

The simulator can be configured via the UP/DOWN and ENTER/ESC toggle switches
and the simulator’s LCD display.

The simulator produces a 3-phase waveform to simulate the generator’s output voltage.
These waveforms are connected to the EMCP’s generator and bus voltage input pins.
There is a built in phase-shift circuit that allows the generator waveforms to be phase-
shifted prior to being connected to the bus voltage input pins. A separate set of 3-phase
waveforms are generated to simulate the current phases.

The simulator has the required wiring for the EMCP control to seize the dead bus using
the dead bus arbitration sequence. Toggle switches are provided that allow the user to
manually control the DBA pins to demonstrate various stages of the DBA process.

The simulator generates an engine speed sensor. The simulator will begin ramping the
engine speed when a start initiate command is issued. The RPM will ramp until 1800
RPM is reached.

The simulator has switches to allow the user to control some of the EMCP digital inputs.
The simulator has LEDs used to indicate the state of some of the EMCP digital outputs.

The simulator has connectors for the user to connect devices to the CAN1, CAN2, RS485
MODBUS, RS485 annunciator, and the Ethernet communication ports of the EMCP.

The simulator can also parallel with other simulators. This can be used to demonstrate
the operation of the sync overview screen on the EMCP.
Simulator Power
The simulator’s incoming power can range from 120VAC to 240VAC at 50 or 60Hz.
Power is connected through an AC inlet located on the top right of the simulator front
panel. Power can be switched on and off using the toggle switch located to the left of the
AC inlet. The incoming power has a 6A breaker in series with the power switch.

A 24VDC power supply is used to provide power for the simulator I/O and the EMCP
control. This power supply also powers any devices attached to the communication
ports. The 24VDC power supply has a 6A breaker in series with the output.

There is a 9VDC power supply that is used to power the internal electronics of the
simulator.

There is a +5VDC and –5VDC power supply used to provide power for the 3-phase
current and voltage waveforms.
3-Phase Voltage

Figure 1

Figure 1 shows a simplified schematic of the 3-phase wiring. The RUN contact and GEN
CB contact are relays. The 3-phase waveform generator is the large PCB in the
simulator. The phase shift circuit is a RC circuit.

The simulator PCB generates a set of 3-phase voltage waveforms. These waveforms are
approximately 70 volts RMS. The amplitude for each phase can be digitally controlled
using the simulator LCD interface. See the simulator configuration section later in the
manual for details on how to use the setup interface.

The phase shift circuit has 3 possible operating states. The operating state is selected
using the VOLTAGE switch located in the lower right above the paralleling connectors.
The up position disables the phase shift circuit and connects the bus voltage inputs to the
generated 3-phase waveform. The center position opens the phase shift circuit so no
voltage is applied to the bus voltage inputs. The down position applies a phase shift of
approximately 7 degrees using a RC circuit. The RC circuit will reduce the amplitude of
the 3-phase voltage waveform slightly so a small difference in amplitude will be seen
between the generator voltage inputs and the bus voltage inputs.

The RUN relay contact will close when the engine speed sensor is above 400 RPM. The
GEN CB relay contact will close when the simulator receives a breaker close request. A
LED is provided on the front panel that illuminates when the GEN CB is closed. The
GEN CB relay contact will open when the simulator receives a breaker open request

3-Phase Current
The simulator PCB generates a second set of 3-phase waveforms. These waveforms are
approximately 3.5 volts peak. These waveforms are connected to a 2-ohm resistor and
return to common through the EMCP current inputs. Current does not flow until the
GEN CB relay closes. See the Figure 1 for additional details.

The front panel of the simulator has a LOAD CURRENT ADJUST potentiometer that is
used to vary the amount of current being generated by varying the amplitude of the
waveforms. The waveforms have been adjusted such that the waveforms are sinusoidal
until the LOAD CURRENT ADJUST is set too high.

Once the potentiometer is adjusted high enough; the current waveforms will begin to clip.
This was done to allow for higher current readings while reducing the total amount of
heat generated. Once the current waveforms begin clipping the power factor displayed
by the EMCP control will no longer match the setting of the simulator.

Engine Speed Sensor

The engine speed sensor is simulated by generating a square wave and then passing it
through an isolation transformer. The engine speed begins ramping from 0 to 1800 RPM
at the rate configured in the simulator configuration. The rate is specified in the number
of seconds it should take the simulator to ramp from 0 to 1800 RPM.

The engine speed sensor begins ramping up when the DISCRETE OUTPUT 10 signal
goes high. The engine speed sensor begins ramping down when the DISCRETE
OUTPUT 10 signal goes low.

The current engine speed sensor rate is used to drive the RUN relay. The RUN relay
connects the generator output voltage to the EMCP generator voltage input pins. The
RUN relay turns on when the engine speed sensor reaches 400 RPM as the sensor ramps
up. The RUN relay turns off when the engine speed sensor falls below 400 RPM.

EMCP Digital Inputs

There are 4 switches wired to the EMCP digital inputs. These switches are wired to be
active low and are active when switched up (towards the descriptive text).

The E-STOP switch is connected to the DEDICATED DISCRETE INPUT #1 on the

EMCP. The REMOTE INITIATE switch is connected to the DEDICATED DISCRETE
INPUT #2 on the EMCP.

The DIGITAL INPUT 1 switch is connected to the PROGRAMMABLE DISCRETE

INPUT #1. The DIGITAL INPUT 2 switch is connected to the PROGRAMMABLE
DISCRETE INPUT #2.
The GEN BREAKER MANUAL CLOSE switch is connected to the DEDICATED
ISOLATED DISCRETE INPUT #4 on the EMCP. The GEN BREAKER MANUAL
OPEN switch is connected to DEDICATED ISOLATED DISCRETE INPUT #3 on the
EMCP. This switch is a 3-position momentary toggle switch.

The generator circuit breaker monitoring inputs are wired to the relay being used to
simulate the generator circuit breaker.

EMCP Digital Outputs

There are 4 LEDs wired to the EMCP’s DISCRETE OUTPUTS. These LED’s are wired
to output #1 through #4.

DISCRETE OUTPUT #10 is used by the simulator’s internal logic to begin simulating
the start of a generator by ramping the engine speed sensor. This output should be
configured in the EMCP to turn on with the FUEL CONTROL RELAY STATUS.

DEDICATED DISCRETE OUTPUT #2 and #3 are used by the simulator’s internal logic
to control the GEN CB relay. DEDICATED DISCRETE OUTPUT #2 is used by the
simulator to open the GEN CB relay. DEDICATED DISCRETE OUTPUT #3 is used by
the simulator to close the GEN CB relay.

EMCP Analog Inputs

The EMCP ANALOG INPUT 1 is wired to simulate the jacket water temperature sensor.
This input is tied to a 47-ohm resistor.

The EMCP ANALOG INPUT 2 is wired to simulate the engine oil pressure sensor. This
input is tied to a 10-ohm resistor when the engine is not running and a 100-ohm resistor
when the engine is running.

The EMCP ANALOG INPUT 3 is wired to a potentiometer on the front panel. The
potentiometer is connected to the EMCP +5V sensor power supply. A tip jack is
provided on the front panel to allow for easy voltage measurements of the analog signal.

EMCP Analog Outputs

The EMCP ANALOG OUTPUT 1 is wired to the front panel and tip jacks have been
provided. These jacks allow for easy measurement of the analog output signal.

EMCP PWM Outputs

The EMCP PWM OUTPUT 1 is wired to the front panel and tip jacks have been
provided. These jacks allow for easy measurement of the PWM output signal.

EMCP HWDBA Control

The simulator has been designed to allow for demonstration of the hard-wired dead bus
arbitration process.
A relay is wired to function as the DBA relay for the pre and post arbitration inputs. This
relay is driven by the EMCP HWDBA #5 pin. It is wired to allow the EMCP to detect
the voltage difference on the pre-arbitration and post-arbitration inputs.

The REQUEST switch is used to control the state of the REQUEST line. The center
position of the switch allows the REQUEST line to float and lets the EMCP drive the
REQUEST line. The down position pulls the REQUEST line to the switch reference in
order to simulate another EMCP control driving the REQUEST line. The up position
places the REQUEST line in parallel mode. Additional details about paralleling will be
described in a later section.

The CAPTURE switch functionality is identical to the REQUEST switch but controls the
CAPTURE line.

EMCP Communication
There are several connectors in the lower left of the front panel that allows access to the
various communication ports supported by the EMCP.

The CAN 1 CONNECTOR allows access to the CAN 1 communication port of the
EMCP. The connector is wired to match the standard service port wiring. +24VDC
power is supplied through pins A and B. An internal 120-ohm termination resistor is
installed inside the simulator.

There are 2 connectors provided for access to the CAN2 communication port. These
connectors are wired in parallel. The 2 connectors have been provided so that auxiliary
devices such as a DIO module can be connected to the simulator using one of the
connectors and a computer can be connected to the other connector. The connectors are
wired to match the standard service port wiring. +24VDC power is supplied through pins
A and B. An internal 120-ohm termination resistor is installed inside the simulator.

An 8-pin connector has been provided to allow for connection of a RS-485 annunciator.
An extension cable has been provided to allow the annunciator to be connected to the
simulator.

A RJ45 connector has been provided to allow for connection to the Ethernet
communication port.

A spring cage terminal strip has been provided for connection to the RS-485 MODBUS
communication port.
EMCP Simulator Paralleling
Up to 3 EMCP simulator units can be paralleled. A diagram of the required cabling is
shown in Figure 2.

The followings steps must be done to allow for multiple simulators to be paralleled.
1. The PARALLEL MODE switch, the REQUEST switch, and the CAPTURE
switch must be put in the up (PARALLEL) position.
2. The VOLTAGE control switch must be put in the center (OFF) position.
3. 1 simulator unit must be designated the first unit. This unit should have the first-
unit jumper plug connected to the PARALLEL INPUT connector. This jumper
plug is a 12-pin connector with a jumper from pin 5 to pin 8.
4. A 12-pin parallel cable must be connected from the 1st unit’s PARALLEL output
connector to the 2nd unit’s PARALLEL input connector.
5. Any additional units should have a parallel cable connected from the previous
unit’s PARALLEL OUTPUT connector to their PARALLEL INPUT connector.

Figure 2

When multiple simulator units are connected together by the parallel cable the REMOTE
INITIATE switch on any unit will cause all the simulators to begin the generator starting
sequence.

The GEN TO BUS MAX VOLT DIFFERENCE % THRESH setting should be at the
maximum allowable amount. This is required because the bus voltage seen by the units
will be lower than the internal generator voltage. Once a unit completes the paralleling
sequence that unit will disconnect it’s internal 3-phase voltage signals from the common
bus. This will cause the voltages seen on the SYNC OVERVIEW screen to be different
from unit to unit.

The simulator that wins access to the dead bus will continue to drive the bus lines on the
parallel cables.

The exact details of how the paralleling functionality was implemented are shown in the
electrical schematics and on the paralleling overview page of the schematics.
Simulator Configuration
The simulator has settings that can be configured using the simulator LCD display.
There are 2 switches provided that allow for LCD menu navigation. The UP/DOWN
switch allows the cursor to be moved or a value to incremented or decremented. The
ENTER/ESC switch has 2 positions. The ENTER switch allows for a menu entry to be
selected or a configured value to be saved. The ESC switch allows for a menu or prompt
to be exited.

The MAIN MENU is shown at power-up.

One of the methods used to configure the simulator is a series of prompts. This method is
used in several places and each of the instances function in a similar manner. The ESC
switch will cancel any edits to the current prompt and will return to the previous menu.
The ENTER switch will accept any edits to the current prompt and advance to the next
prompt. The display will return to the previous menu after the last prompt has been
answered.

DISPLAY MODE
This menu entry displays a screen where the current value of the ANALOG INPUT 3
signal is shown. This screen also shows the approximate amount of actual load selected
through the LOAD ADJUST CONTROL potentiometer. The screen can be exited using
the ESC switch.

RPM SETUP/INFO
This menu entry displays a screen showing details about the engine speed signal
generation.

The current engine speed signal ramp time is shown. This number is the amount of time
it will take the simulator to ramp from 0 to 1800 RPM.

The ramp rate of the engine speed signal can be configured. Use the UP/DOWN switch
to increment and decrement the value.

The screen can be exited using either the ENTER or ESC switch. The ENTER switch
will save any changes to the ramp rate. The ESC switch will cancel any changes.

LCD SETUP
This menu entry displays a sequence of prompts that allows the user to configure the
LCD contrast and brightness.

WAVEFORM FREQUENCY
This menu entry allows the user to configure the frequency of the 3-phase waveforms.

Use the UP/DOWN switch to increment and decrement the frequency.

The screen can be exited using either the ENTER or ESC switch. The ENTER switch
will save any changes to the ramp rate. The ESC switch will cancel any changes.

WAVEFORM AMPLITUDE
This menu entry displays a sequence of prompts that allows the user to configure the
amplitude percentage of each phase of the generator voltage signals. The edited value
takes effect immediately but edits can still be canceled using the ESC switch. This was
done so that phase amplitudes could be tweaked easily.

POWER FACTOR
This menu entry displays a screen that allows the power factor to be configured.

Use the UP/DOWN switch to increment and decrement the power factor percentage.

The screen can be exited using either the ENTER or ESC switch. The ENTER switch
will save any changes to the ramp rate. The ESC switch will cancel any changes.

ROTATION DIRECTION
This menu entry displays a screen that allows the rotation direction of the generation 3-
phase signals to be selected.

This screen shows the currently selected rotational direction. The UP switch can be used
to toggle between the two possibilities: ABC and CBA.

DIAGNOSTICS
This menu entry displays a sub-menu that allows the I/O of the simulator to be viewed.

DIAGNOSTICS->INPUTS
This menu entry displays a list of the digital inputs for the simulator PCB. The current
state of each input is shown. Use the UP/DOWN switch to navigate the list of inputs.
Use the ESC switch to return to the previous menu.

DIAGNOSTICS->OUTPUTS
This menu entry displays a list of the digital outputs for the simulator PCB. The current
state of each output is shown. Use the UP/DOWN switch to navigate the list of outputs.
Use the ENTER switch to toggle the state of an output. Use the ESC switch to return to
the previous menu.

Note: while this screen is being shown the automatic processing of the outputs is
suspended. When this screen is exited the automatic processing of the outputs will
resume.

DIAGNOSTICS->DAC OUTPUTS
This menu entry displays a list of the analog outputs for the simulator PCB. The 3-phase
signals are generated using these analog outputs.
The current raw value of each output is shown. Use the UP/DOWN switch to navigate
the list of outputs. Use the ESC switch to return to the previous menu. Use the ENTER
switch to begin editing an output.

Once an output is selected for editing the UP/DOWN and ENTER/ESC switches take on
a new function. The UP/DOWN switch will increment and decrement the current
output’s value. The ENTER or ESC switch accept the edit and return to the state where
the list can scrolled.

Note: while this screen is being shown the automatic processing of the analog outputs is
suspended. When this screen is exited the automatic processing of the outputs will
resume.

DIAGNOSTICS->ANALOG INPUTS
This menu entry displays a list of the analog inputs for the simulator PCB. The current
raw value of each input is shown. Use the UP/DOWN switch to navigate the list of
inputs. Use the ESC switch to return to the previous menu.