Application &

Installation Guide

Cat® EMCP 4.4

Supervisory Control

LEBE0040-00
 Table of Contents

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.0 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.0 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.1 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Electrostatic Discharge Awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Operating Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 EMCP 4.4 Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.7 Shielded and Communication Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.0 Initial Operation and User Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.1 Types of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Using the Cat® Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Viewing System Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3.1 Supported Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3.2 Genset Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3.3 AC Bus Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Viewing and Adjusting Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4.1 Setting the Preferences Using the EMCP 4 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4.2 Changing the EMCP 4 Contrast When the Display is Unreadable . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4.3 Changing the EMCP 4 Display to Technician English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.4 Changing the EMCP 4 Display to the Primary Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.5 Setting the Preferences Using the Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5 Configuring Time/Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5.1 Changing the Time/Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.6 Starting and Stopping the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6.1 Starting the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6.2 EMCP 4 Group Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6.3 Stopping the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6.4 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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5.0 Handling Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.1 Configuring Event Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Resetting Individual Active Events for the EMCP 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3 Troubleshooting Resetting Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3.1 Gen Not Ready to Auto Parallel Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4 Using Status Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.0 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7.0 Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1 Configuring Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2 Setpoint Sub-menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3 Setpoints on the Cat Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3.1 Setpoint Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8.0 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8.1 Programming Digital Inputs Using the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1.1 Viewing the Current Digital Input Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1.2 Configuring Digital Inputs for Status Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1.3 Digital Input Status Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1.4 Configuring Digital Inputs for System Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1.5 Configuring Digital Inputs for SCADA Data link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1.6 Disabling Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1.7 Programming Digital Inputs Using the Cat Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9.0 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

9.1 Programming Analog Inputs Using the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.1.1 Viewing the Current Analog Input Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.1.2 Configuring Analog Inputs for Resistive Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.1.3 Configuring Analog Inputs for PWM Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.1.4 Configuring Analog Inputs for Current Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.1.5 Configuring Analog Inputs for Voltage Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.1.6 Disabling Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.2 Programming Analog Inputs Using the Cat Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.3 Analog Input Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.3.1 Warnings and Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.3.2 Unsupported Analog Input Sensor Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.3.3 Sensor Range is Smaller than Setpoint Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.3.4 Sensor Range is Larger than Setpoint Options, but Usable Range is Not . . . . . . . . . . . . . . . . . . . 57
9.3.5 S
 ensor Range is Larger than Setpoint Options, and Usable Range is Larger
than Setpoint Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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10.0 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

10.1 Programming Digital Outputs Using the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.1.1 Viewing the Current Digital Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.1.2 Configuring Digital Outputs for Status Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.1.3 Digital/Relay Output Status Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10.1.4 Configuring Digital Outputs for System Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10.1.5 Digital/Relay Output System Event Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.1.6 Configuring Digital Outputs for SCADA Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.1.7 Disabling Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

11.0 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

11.1 Programming Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.1.1 Viewing the Current Analog Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.1.2 Configuring Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

12.0 PWM Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

12.1 Programming PWM Outputs Using the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
12.1.1 Viewing the Current PWM Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
12.1.2 Configuring PWM Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

13.0 Load Add and Load Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

13.1 Supervisory Load Add . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
13.1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
13.1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
13.2 Supervisory Load Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
13.2.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
13.2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

14.0 Modifiable Text Strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

14.1 Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
14.2 Programming Modifiable Text Strings Using the Cat Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

15.0 Saving and Restoring Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

16.0 Programmable Cycle Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

16.1 Configuring the Programmable Cycle Timer Using the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
16.2 Configuring the Programmable Cycle Timer Using the Cat Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

17.0 CAN Data Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

17.1 Primary CAN Data Link (CAN 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
17.1.1 Network Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
17.2 Accessory CAN Data Link (CAN 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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18.0 Optional Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

19.0 SCADA (Modbus) RS-485 Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

19.1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
19.2 Line Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
19.3 Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
19.3.1 Configuring the SCADA Data Link Using the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
19.3.2 Configuring the SCADA Data Link Using the Cat Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

20.0 SCADA (Modbus) TCP/IP Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

21.0 Multiple Genset Data Link (MGDL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

21.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
21.2 MGDL Hardware Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
21.2.1 EMCP 4.4 MGDL Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
21.2.2 MGDL Network Topologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
21.2.3 Ethernet Switch/Hub/Repeater Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
21.2.4 MGDL and TCP./IP SCADA Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
21.3 MGDL Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
21.3.1 MGDL System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
21.3.2 MGDL Load Sense Load Sense Load Demand Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
21.3.3 MGDL Event Response Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
21.4 MGDL Paralleling Features Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
21.4.1 Supervisory Control Panel MGDL Group Start Command Operation . . . . . . . . . . . . . . . . . . . . . . 104
21.4.2 MGDL Network Configuration Reset (Expected Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
21.5 MGDL Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
21.5.1 MGDL Overview Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
21.5.2 MGDL Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
21.5.3 MGDL Load Sense Load Demand Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
21.5.4 MGDL Network Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
21.5.5 MGDL Status Event Log Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
21.5.6 MGDL Genset Event Log Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
21.6 MGDL Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
21.6.1 MGDL Configuration Error Event (SPN-FMI: 625-14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
21.6.2 MGDL Control is Offline Event (SPN-FMI: 625-31) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
21.6.3 MGDL Communications Failure Event (SPN-FMI: 625-19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
21.6.4 MGDL Software Version (Protocol) Mismatch Event (SPN-FMI: 234-31) . . . . . . . . . . . . . . . . . . . 122
21.6.5 Ethernet Port Abnormal Update Rate (SPN-FMI: 625-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

6 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Table of Contents

22.0 Installing and Upgrading Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

23.0 Appendix A – Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

24.0 Appendix B – EMCP 4 Front View and Navigation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

25.0 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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Foreword

Foreword
This Application and Installation Guide describes the EMCP 4.4 electric power Supervisory Control Panel (SCP).

Some data used in this guide is generalized and is provided only for the purpose of comparison or illustration.
Also, PC application screenshots and EMCP 4 screen images may be actual screens or simulated and are shown
for illustrative purposes only. These images may not be identical to those seen by the user. Screen images of
the EMCP 4 may differ from the actual screens depending on flash file language, flash file version, and setpoint
configuration.

In various places throughout this document, reference is made to the release date of the EMCP 4 software.
This information can be found by connecting to the subject module using the Cat Service Tool, and viewing the
ECM Summary (this is the default startup screen). The release date is found in the field entitled Software Group
Release Date.

See Figure 1, showing the release date for an EMCP 4.4 SCP flash file.

Figure 1 – EMCP Software Release Date

Other product specific information and data is available from a variety of sources. For more information, contact
the Cat dealer or dealer Technical Communicator (TC) nearest you.

The information in this document is the property of Caterpillar Inc. and/or its subsidiaries. Any copying,
distribution, transmission to others, and any use except that for which it is loaned is prohibited without written
permission.

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, the “Power Edge” trade dress as well as
corporate and product identity used herein, are trademarks of Caterpillar and may not be used without
permission.

8 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 General Information

1.0 General Information

1.1 Introduction
Caterpillar has developed a product line of Generator Set Controls for use in the Electronic Modular Control
Panel 4 (EMCP 4). They are available in four versions based on Generator Set Control feature sets.

The EMCP 4 Generator Set Control, or GSC, is the primary controller within the Generator Set Control system.
The EMCP 4 line of Generator Set Controllers includes EMCP 4.1, 4.2, 4.3, and 4.4. Appendix B shows a front view
of the 4.4.

This Application and Installation Guide is intended to cover the EMCP 4.4 Supervisory Control Panel and its
application in generator set systems. The intended audience for this guide includes Cat generator set system
designers, Caterpillar service support personnel, Cat dealers and service technicians, contractors, and customers.

1.2 Applications
The EMCP 4 product line of generator set controllers is designed for use in a wide range of applications. They can
be used on standby and prime Cat brand power generator sets. The configurability of the controllers allows them
to be used, in some cases, on other applications such as Marine auxiliary generators, switchgear applications,
and industrial engines and generator sets.

Most of the information in this document applies to all applications. However, the document was written with
Cat brand generator sets in mind. Please contact your Caterpillar support representative for questions regarding
different applications.

Note: Proper application of EMCP 4.4 paralleling controllers is critical; along with the technical requirements
outlined elsewhere in this guide, please consider the following commercial requirements applicable to
ANSI certified areas of the world:

1. The EMCP 4.4 is primarily intended for applications whose aggregate current of paralleled units is 6000A
or less.

2. Applications whose aggregate current for paralleled units is between 6000A and 10,000A are acceptable;
however, review/approval of the application by Caterpillar A&I Engineering (via the ASC) is required prior
to installation. Applications whose aggregate current for paralleled units exceeds 10,000A are not generally
recommended. Dealers wishing consideration/support for such opportunities must contact the ASC to secure
written approval from the Systems Product Team prior to sale. Cat floor-standing paralleling switchgear better
suits large-scale, complex applications such as these.

3. EMCP 4.4 paralleling is commercially intended for low voltage generator set applications only (less than 1000V).
Cat floor-standing control or switchgear should be used for medium and high voltage applications in these
ANSI certified areas.

1.3 References
The EMCP 4.3 & EMCP 4.4 Application & Installation Guide (LEBE0007) along with the SCADA A&I Guide
(LEBE0010) are available to gain a better understanding of how the EMCP 4 Supervisory Control Panel (SCP) can
be integrated into a system.

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Safety Information

2.0 Safety Information

2.1 Electrical Safety
DO NOT operate or work on a generator set unless you have read and
understand the instructions and warnings in the Operation and Maintenance
Manual. 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.

2.2 Electrostatic Discharge Awareness

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/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, etc.).
• Keep all plastic items away from the devices. Any plastic item is a potential static generator. This includes
candy wrappers, foam cups, synthetic carpet, foam cushions, etc.
• 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.

Caution: The 120-pin connector and 70-pin connector for EMCP 4.4 on the back of the control is the most
vulnerable area to ESD. While handling the EMCP 4, extra attention is required to the back of the control.
The control may become damaged or inoperable if extra care is not taken.

Consult the Electrostatic Discharge Association for proper procedure during particular situations:
http://www.esda.org.

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 Installation

3.0 Installation
3.1 Mounting Location
When selecting a mounting location for the EMCP 4 Supervisory Control Panel, consider the following:
• Protection from high-voltage and high-current devices.
• Protection from devices which may produce electromagnetic interference.
• Protection from excessive vibration.
• Protection from direct exposure to water. Once installed with gasket, the EMCP 4 controllers are sealed to a
level of IP Level 56 for resistance to moisture.

3.2 Operating Temperature Range

EMCP 4 has a continuous operating temperature range of -20°C (-4°F) to +70°C (158°F) ambient. The EMCP 4
controller will continue to operate down to temperatures of -40°C (-40°F) but the display will become unusable.

3.3 Power Requirements

The EMCP 4.4 requires a nominal voltage of 24VDC. If batteries are used for operating power, a charging source
such as an alternator or dual-mode battery charger is necessary to maintain a stable supply voltage. The
maximum power consumption of the EMCP 4.4 SCP with all I/O at maximum power drain will not exceed 10A at
24VDC. Any customer load connections are not included in this amount.

Regional electrical codes must be followed. In the case of standby operation, follow the regional requirements
for installing standby power systems. An example of this is the National Fire Protection Association (NFPA)
guidelines for emergency power systems.

When connecting the EMCP 4 to the DC power source, make sure that there is only one common connection
to the negative potential of the power source. Make extra effort to avoid any ground loops in the DC electrical
system. A single-point common ground for sensitive electronics is recommended at the negative battery terminal
or Power Distribution Box.

Avoid daisy-chaining power supply connections from one device to another. This builds resistance from one
Battery (-) point to the next, effectively building a potential difference between two different reference points.
Each electronics subsystem and major engine subsystem should have its own DC network so that they do not
interfere with each other.

The PANEL GROUND should be bonded separately to the customer ground connection and not be used as the
electronics reference.

The sensitive electronics, such as sensors and control modules, have isolated power source paths. High current
loads such as starters and solenoids can cause interference and possibly damage to low current loads, such as
controllers and sensors.

Caution: Extra effort must be made to keep the high current and low current loads electrically separated.

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3.4 Electrical Connections

The EMCP 4.4 used in the supervisory control has a 120-pin connector (not all of the 120 pins are used) on the
back of the control and an additional 70-pin connector (not all of the 70 pins are used). The 70-pin connector on
the EMCP 4.4 is not keyed or configured the same as the 70-pin connector on the EMCP 4.1 and 4.2.

Figure 3.1 and 3.2 show:

• All possible connections
• What pins are used for connections
• How each pin is connected for each control version

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 Installation

3.5 EMCP 4.4 Electrical Diagram

Figure 3.1 – EMCP 4.4 120-pin Connector Electrical Diagram

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Installation

Figure 3.2 – EMCP 4.4 70-pin Connector Electrical Diagram

3.6 Wiring Requirements

When selecting the type of wire to use, consideration must be given to the wire voltage drop (line loss), accuracy,
communication error, and other requirements. See Table 3.1.

Component Wire Size (AWG) Type of Wire Connections (1)

Shielded twisted triad cable is recommended. For
Three-wire
conduits inside facilities, use Belden 8618. For the
Sensors
engine harness, use the 4G-2556 Shielded Cable. Deutsch DT type of connectors
(When applicable. 16
The cable must be resistant to fuel and oil. The are recommended. If spring
Not used on most
cable must have a temperature range from spade or ring terminals are
systems)
-40ºC (-40ºF) to plus 125ºC (257ºF). used, the connection between
Part number 153-2707 is available for lengths of the terminals and the wire
up to 200 ft. The cable has a temperature range of should be crimped and
Primary Data
16 or 18 -40ºC (-40ºF) to plus 125ºC (257ºF). soldered.
Link Cable
For longer runs, select a cable that meets
SAE J1939-11 requirements.
Stranded wire normally used on engine harnesses.
Power and Other The cable must be resistant to fuel and oil. The
Multiple 14-18
Connections cable must have a temperature range of
-40ºC (-40ºF) to plus 125ºC (257ºF).
Cat 5, Cat 5e, or Cat 6. Dual twisted pair wire
may be used to wire from the EMCP. Cat part
numbers 143-2454 (20 AWG), 9X-8922 (18 AWG),
Ethernet or quantity of 2 of 143-5018 (18 AWG) may be
18 or 20 RJ-45 male connector
Connector suitable for this purpose.
The cable must be resistant to fuel and oil. The
cable must have a temperature range of
-40ºC (-40ºF) to plus 125ºC (257ºF).
(1)
The number of connections must be kept to a minimum.

Table 3.1: Wiring Requirements

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 Installation

3.7 Shielded and Communication Wiring

Sensor shields should be brought to the EMCP if pins are allocated on the controller for that purpose. When the
cable terminates at junction boxes, the shields must be connected to each other in order to maintain a continuous
path. A continuous path must be maintained in the shield wire for sensors, whenever possible. Wire exposed
beyond the shield should be as short as possible. When no provisions exist to incorporate the draining of the
shield wire internal to the controller, the shield must be connected to battery negative as close to the controller
as possible. Shields should be drained at one point only. When possible, this should be done at, or close to, the
EMCP 4.

To avoid electromagnetic interference, do not run shielded signal wires near other wires carrying large currents.
In installations with unavoidable risk of electromagnetic interference (EMI), shielded wire run in conduit, extra
shielding, or other precautions may be necessary.

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Initial Operation and User Orientation

4.0 Initial Operation and User Orientation

4.1 Types of Events
The EMCP 4 has two lamps to annunciate events. The amber lamp indicates warning-type events, while the red
lamp indicates shutdown-type events. The amber lamp also lights if a “Protect” lamp state is being sent by a
different module. ET 2012B and later can be used to help identify what modules are sending different lamp statuses.
The lamps flash when new events arrive, and remain flashing (often accompanied by an audible horn) until
acknowledged by pressing the acknowledge button locally or remotely. Shutdown-type events do not clear until the
user fixes the condition(s) that caused the shut down and “resets” the events. The EMCP 4 supports a very large
number of events, and most events generated by the EMCP can be configured based on application needs. For
information on viewing, resetting, and configuring events, see Chapter 5.

4.2 Using the Cat Service Tool

Many of the features of the EMCP 4 system can be accessed via the Cat Service Tool. These features include
viewing status data, monitoring optional modules, viewing and resetting events, and configuring setpoints.

Note: A minimum of the Cat ET Service Tool version 2015B is required to communicate properly with the EMCP 4. If
an earlier version is used, the EMCP 4 will be grayed out or improper choices may be shown. In order to have
access to the latest setpoints, the latest version of the Cat ET service tool should always be used.

Throughout this document, instructions for accessing a feature both via the EMCP 4 display and via the Cat
Service Tool will be given. However, the Cat Service Tool also offers other unique features that are useful for
site commissioning, ECM retrofitting, or troubleshooting, such as the ability to log data to a file or graph data in
real-time. Such features are not in the scope of this document. For more information on the Cat Service Tool,
refer to the Cat Service Tool documentation and training.

Figure 4.1 outlines the EMCP 4 features that are available within the Cat Electronic Technician software.

1. Status Tool
2. Active Diagnostic Codes
3. Logged Diagnostic Codes
4. Active Event Codes
5. Logged Event Codes
6. ECM Summary
7. Configuration Tool
8. Connect/Disconnect
9. WinFlash

Figure 4.1 – Electronic Technician EMCP 4 Features

When in the Status tool, buttons to Active Codes and Events are provided at the bottom of the screen.

16 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Initial Operation and User Orientation

Connecting to the EMCP 4 to Configure Setpoints

In order to use the Cat Service Tool with the EMCP and configure setpoints, do the following:

1. Connect the Service Tool to the PC and configure the port settings as appropriate.

2. Ensure the Service Tool is connected to the Primary Data Link (CAN 1).

3. Start the Cat Electronic Technician software. The software will search the data links.

4. When the software finds the EMCP and connects to it, The ECM Summary screen will appear. If multiple
devices are detected, always select the EMCP before continuing to be able to access special EMCP features
with ET such as annunciator configuration and device lamp status.

5. To view configurable parameters within the EMCP 4, press the Configuration button.

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Initial Operation and User Orientation

6. The parameter groups will appear.

7. Selecting a group in the left pane will show all the parameters within that group in the right pane.

4.3 Viewing System Parameters

Many generator and engine parameters are viewable in real time from both the Cat Service Tool, and the
EMCP 4 display.

From the Cat Service Tool

Parameters are accessed by selecting Information > Status from the menu, or by clicking on the STATUS
TOOL icon in the toolbar. Only the EMCP 4.4 SCP battery voltage parameter is available in the ET Status
Tool. Refer to the Cat Service Tool help from the Help > Contents menu for more information on the Status Tool.

From the EMCP 4 Display

Parameters are accessed (irrespective of the current screen position) by pressing the AC OVERVIEW ,

ENGINE GENERATOR SET OVERVIEW , Main Menu , or Control buttons located below the

screen. Detailed screens provide even more information by pressing the SCROLL DOWN button from
each of the overview screens. Alternately, this additional information may be accessed by pressing Page Down
from the soft keys. For a description of the front view and navigation keys, refer to Appendix B.

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 Initial Operation and User Orientation

The EMCP 4 parameters are organized with different levels of users in mind. These levels are as follows: View,
Control, and Configure. Some of the parameters are accessible from multiple paths. For a complete menu
structure, refer to Appendix A.

4.3.1 Supported Parameters

Different revisions of the EMCP 4 software support different numbers of parameters. Some parameters are only
available in certain configurations. The sections below list most of the parameters available.

Parameters are displayed with units, some of which are configurable. For changing units or setting other user
preferences see Section 4.4, Viewing and Adjusting Preferences.

Parameters that are not available to the EMCP 4 are shown as **** (four asterisks). This may indicate an
incorrect software configuration, a wiring problem, or a problem with the sensor.

4.3.2 Genset Overview

The Genset Overview screens display the status of the networked EMCP 4.4 controllers. A maximum of six
generator sets along with the supervisory controller is shown on each page. Additional units are available
via Page Right Soft Key. Each engine generator set and the supervisory controller can be selected using the
navigation keys for additional information.

Note: Page Down soft key will bring up the MGDL Overview Display Screen.

Genset Overview Screen

• Online Units
• Engine Control Switch Position
• Count of Warnings
• Count of Shutdowns

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Initial Operation and User Orientation

4.3.3 AC Bus Overview

The AC Bus Overview screens display various bus frequency and bus average L-L voltage parameters. Soft keys
provide a quick link to the Load Bus Overview screens. The following parameters are displayed on the
AC Overview screens:

AC Bus Overview Screen

• AC Bus Frequency
• Average Bus Line-Line AC Voltage

4.4 Viewing and Adjusting Preferences

The EMCP 4 display can be used for monitoring the generator status, viewing and resetting events, and
configuring setpoints. There are several preferences to alter how you view the data on the display. These include:
display contrast, units used to display pressure, units used to display temperature, units used to display volume,
circuit breaker symbol, and displayed language (to select between the customer language and technician
English).
Note: These preferences do not affect operation of the EMCP 4, the values in the SCADA Communications
(Modbus) or the data as viewed in the Cat Service Tool. They only affect how the text and data is
converted and displayed on the EMCP 4 display.

4.4.1 Setting the Preferences Using the EMCP 4 Display

MENU/PREFERENCES. For additional detail on how to navigate through these preferences, please refer to LEBE0007.

Preferences:
Contrast
This determines the darkness of the pixels on the display. A minimum contrast setting (reached by pressing
and holding the down or left arrow) effectively blanks the screen, and a maximum contrast setting (reached by
pressing and holding the up or right arrow) effectively darkens the entire screen. To change the contrast if the
screen is unreadable due to a misconfiguration or ambient conditions, see 4.4.2 Changing the EMCP 4 Contrast
When the Display is Unreadable.

Pressure
This allows pressure parameters and setpoints to be shown in either kPa, psi, or bar. Select the desired unit with
the up or down arrows, or the function keys.

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 Initial Operation and User Orientation

Temperature
This allows temperature parameters and setpoints (to be shown in either Celsius (Centigrade) or degrees
Fahrenheit. Select the desired unit with the up or down arrows, or the function keys.

Volume
This allows volume parameters (such as fuel volume) to be shown in liters, imperial gallons, or U.S. gallons. Select
the desired unit with the up or down arrows, or the function keys.

Circuit Breaker Symbol

This allows the graphic for the circuit breaker to be either the ISO symbol, or the U.S. symbol. Select the desired
symbol with the left or right arrows.

Lamp Test
When this selection is highlighted, pressing and holding the OK KEY will darken all pixels on the screen
and illuminate all LEDs on the face of the controller.

Language
This allows the display to be switched between technician English (always listed first) and the customer language
(always listed second, and written in the font of the customer language). The below example shows the language
selection in the German language flash file. Select the desired language with the up or down arrows. To change
the language to technician English, regardless of the current screen, and without needing to read the text, see
4.4.3 Changing the EMCP 4 Display to Technician English.

The LANGUAGE setting has been conveniently located at the bottom of the Preferences menu, which is at the
bottom of the Main Menu.

4.4.2 Changing the EMCP 4 Contrast When the Display is Unreadable

1. Press the MAIN MENU key.

2. Scroll DOWN until scrolling stops. If the display is unreadable such that scrolling can’t be seen, press
down a minimum of 10 times.

3. Press the OK KEY (this will take you into the Preferences Menu).

4. Press the OK KEY again (this will take you into the Contrast selection).

5. Press and hold either LEFT ARROW or RIGHT ARROW until the text and graphics become visible.

6. Press the OK KEY to accept the adjustment.

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Initial Operation and User Orientation

4.4.3 Changing the EMCP 4 Display to Technician English

1. Press the MAIN MENU key.

2. SCROLL DOWN until the scrolling stops.

3. Press the OK KEY (this will take you into the Preferences Menu).

4. SCROLL DOWN until the scrolling stops.

5. Press the OK KEY (this will take you into the Language selection).

6. Press the UP ARROW key until the scrolling stops.

7. Press the OK KEY to select TECHNICIAN ENGLISH.

The EMCP 4 language setting is changed back to TECHNICIAN ENGLISH. Similar steps can be followed by a
customer who is unfamiliar with English, to change the language setting back to their primary language.

4.4.4 Changing the EMCP 4 Display to the Primary Language

1. Press the MAIN MENU key.

2. SCROLL DOWN until the scrolling stops.

3. Press the OK KEY (this will take you into the Preferences Menu).

4. SCROLL DOWN until the scrolling stops.

5. Press the OK KEY (this will take you into the language selection).

6. Press the SCROLL DOWN arrow to select the customer language.

7. Press the OK KEY to change to the customer language.

The EMCP 4 language setting is changed back to the customer language.

22 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Initial Operation and User Orientation

4.4.5 Setting the Preferences Using the Service Tool

Only the preferences for units can be configured using the Cat Service Tool. They are located in the Configuration
Tool. Select Display Preferences from the left panel.

Figure 4.2 – EMCP 4 Display Preferences

The display units can be changed the same way other setpoints are changed with the Service Tool.

Pressure
This allows pressure parameters (such as Engine Oil Pressure) and some setpoints (such as Low Engine Oil
Pressure Event Threshold via Data Link) to be shown in either kPa, psi, or bar.

Temperature
This allows temperature parameters (such as Engine Coolant Temperature) and setpoints (such High Engine
Coolant Temperature Event Threshold) to be shown in either Celsius (Centigrade) or degrees Fahrenheit.

Volume
This allows volume parameters (such as Fuel Volume) to be shown in liters, imperial gallons, or U.S. gallons.

Circuit Breaker Symbol (EMCP 4.4 only)

This allows a choice of graphics for the circuit breaker symbol for various display screens.

4.5 Configuring Time/Date

The EMCP 4.4 had an internal Real Time clock that is used for time-stamping events, Programmable Cycle Timer
(Chapter 16), and the Status Event Log (Chapter 5). The timestamps for the last date and time an event has
occurred and the first date and time the event has occurred are viewed by selecting a module in the Event Log
and pressing the OK key.

4.5.1 Changing the Time/Date

The EMCP 4 clock allows the time/date to be modified. Changing the time/date will change the timestamp on all
future events, but not for existing events. (For example, an event that has occurred previously will still show the
same FIRST time/date, but if it occurs again after the time/date has been adjusted, the LAST time/date will reflect
the change.)

This procedure must be performed on the EMCP 4 display; it cannot be done using the Cat Service Tool. In
order to update time/date, LEVEL 1 ACCESS is required. Refer to Chapter 6, Security for information on obtaining
LEVEL 1 ACCESS.

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Initial Operation and User Orientation

To Change the Time/Date

1. At MAIN MENU scroll DOWN to CONFIGURE.

2. Press the OK KEY .

3. Scroll DOWN to TIME/DATE.

4. Press the OK KEY .

5. To begin editing the time, press the OK KEY while the
current time is selected.

6. Select a digit using the LEFT ARROW or

RIGHT ARROW .

7. To change the selected digit use the UP ARROW or

DOWN ARROW .

8. To accept changes, press the OK KEY . To reject changes,

press the ESCAPE KEY .

24 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Initial Operation and User Orientation

To Change the Date From This Point

1. To begin editing the date, press the OK KEY while the current date is selected.

2. Select a digit using the LEFT ARROW or RIGHT ARROW .

3. To change the selected digit use the UP ARROW or

DOWN ARROW .

4. To accept changes, press the OK KEY . To reject changes,

press the ESCAPE KEY .

The date format can be set to either display in the form Month/Day/Year or the form Day/Month/Year. This
procedure must be performed on the EMCP 4 display; it cannot be done using the Cat Service Tool.

Note: This preference does not affect operation of the EMCP 4 or the data as viewed in the Cat Service Tool. It only
affects how the date is displayed on the EMCP 4 display and the format of the event time stamps.

To Change the Date Format

Select the format using the LEFT ARROW or RIGHT ARROW or soft keys, then press the the OK KEY

to accept, or the ESCAPE KEY to reject, the change.

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Initial Operation and User Orientation

4.6 Starting and Stopping the System

4.6.1 Starting the System
Once the control is configured correctly, the control panel is powered up, and the supervisory control panel is
ready to be operated, the generator set can be started. While the normal way will be to start the system via the
group start input, there are several ways the generator set can be started from the control panel.

To Start the Engine

1. In MANUAL OPERATION, press the RUN KEY or Activate a Digital Input programmed for ECS in Run or
place the control in AUTO mode. Then the engine can be started THREE DIFFERENT WAYS:
a. Activate DEDICATED DISCRETE INPUT #2, which is the REMOTE START INPUT OR DEDICATED ISOLATED
DISCRETE INPUT #1 which is the GROUP START INPUT(PREFERRED).
b. Activate a REMOTE INITIATE over the MODBUS data link.
c. Configure a PROGRAMMABLE CYCLE TIMER. See Chapter 16.

If there are no shutdown events that are active or present, the EMCP 4 SCP will send a start signal to the
connected generator sets and start any generator sets that are in AUTO.

Note: If a Digital Input is programmed for ECS in Auto, or Run, or Stop, and a maintaining switch latches that input
to make it active, the front panel buttons will not have any effect.

4.6.2 EMCP 4 Group Start

The EMCP 4 has the ability to accept a remote start signal. If this signal is activated, the EMCP 4.4 SCP will begin
its operation and will send an Engine Start request to the attached generator sets. A momentary signal will not
keep the system running.

4.6.3 Stopping the System

Once the engine is started, the engine can be stopped by pressing the STOP KEY on the control panel, or
activating a Digital Input programmed for ECS in Stop. If the control is in AUTO, the engine can also be stopped by
DEACTIVATING all of the remote initiate commands. There are three possible sources for this command:
1. The REMOTE START INPUT
2. The REMOTE START COMMAND over the Modbus data link.
3. The PROGRAMMABLE CYCLE TIMER. See Chapter 16.

Once the STOP command is issued, the supervisory control will remove the group start signal that was sent to the
connected generator sets.
Note: The ECS will automatically return to AUTO.
Note: If a Digital Input is programmed for ECS in Auto, or Run, or Stop, and a maintaining switch latches that input
to make it active, the front panel buttons will not have any effect.

4.6.4 Emergency Stop

The EMCP 4 Emergency Stop input is configurable as Active High, or Active Low. The active state may be
configured within the EMCP 4 display or within Cat ET under System Settings. Emergency STOP also has an Event
Response Configuration (ERC) and is shipped from the factory configured as a warning. The ERC can be changed,
but the communication link to the generator sets should not be used in a safety situation.

26 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Handling Events

5.0 Handling Events

The EMCP 4 shows previous and current events from both the EMCP and external modules. These events are
organized into logs for each physical module the EMCP 4 is receiving EVENT messages from.

The logs include:

STATUS EVENTS Recent operational event history (See section 5.8)
SUPERVISORY CONTROL Events for the EMCP 4 Supervisory Control

The Supervisory Control Log stores events generated by the EMCP 4.

Each log is visible only if the module is connected to the appropriate data link, either the Primary data link or the
Accessory data link, and is communicating with the EMCP 4.

The list of Event Logs can be viewed by pressing the Event Log key or via the View Submenu. Select the
log you wish to view and press OK to view the events.

An event in the EMCP 4 Genset Control Log can be in one of three states; PRESENT, ACTIVE, or INACTIVE.

Present
This state is only applicable to the Supervisory Control Log. PRESENT means that the condition that caused the
event is still present. The condition needs to be addressed before the event can be reset.

Active
The event was previously in a “Present” state, but it is no longer present. It has been latched by the event system
and needs to be reset before the engine can be restarted.

Within the Supervisory Control Log, the condition that caused the event is still affecting the system, but may
be reset. (See Sections 5.3 to 5.6 on how to Reset Events). Warning type events automatically reset when the
condition that caused the event is resolved and will never be Active.

Inactive
The event has happened at some time in the past but is no longer affecting the system. Inactive events are stored
for historical purposes only.

5.1 Configuring Event Responses

The category of event, as well as other behavior when an event occurs, can be configured via a group of EMCP
4 setpoints called EVENT RESPONSE CONFIGURATIONS. An example of an event response configuration is BUS
UNDERFREQUENCY WARNING EVENT RESPONSE CONFIGURATION. This setpoint determines what actions the
EMCP 4 takes when it receives an event.

Each EVENT RESPONSE CONFIGURATION type setpoint can either be viewed or edited. By default, VIEW is
highlighted.

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Handling Events

The following is a list of all the possible options for an event response configuration:

Warning
Creates a Warning event in the event log and lights the amber LED. The engine will not shut down. A Warning
event will reset by itself (i.e. it will go from the “Present” state to the “Inactive” state) as soon as the condition
that caused it goes away.

Audible Alert
Determines whether this event will also trigger an audible horn. If so, the event activates any relays that are
programmed for Horn Control (see Chapter 10). If no relay is programmed for Horn Control, no action will be
taken; the EMCP 4 does not have an internal horn. Audible Alert can only be programmed if either a Warning or
Shutdown is also programmed.

Soft Shutdown
Creates a shutdown event in the Supervisory Control event log, lights the red LED, and sends a signal for a soft
shutdown of the connected engine generator sets with a System Event Shutdown in the EMCP 4.4 genset control
event log (after cooldown period has expired). Note: Communication to the engine generator set is based on
having a valid communication link.

Hard Shutdown
Creates a Shutdown event in the Supervisory Control event log, lights the red LED, and sends a signal for a soft
shutdown of the connected engine generator sets with a System Event Shutdown in the EMCP 4.4 genset control
event log (after cooldown period has expired).

Note: Since the hard shutdown ERC acts like the soft shutdown, a soft shutdown should be used if a shutdown
is required.

Breaker #1 Trip
Activates a Breaker #1 Trip, which can be programmed for a Relay Output or Digital Output for external use.

Active Only
Creates an active only event in the event log. Active only events are for informational purposes only. They
typically do not light the amber LED or behave like a warning (although many events can be configured to do so).
When the condition goes away, the event disappears from the event log.

Note: Not all options are available for all setpoints. For example, the Bus Underfrequency Warning event cannot
be configured as a shutdown.

Changing an Event Response Configuration

To change an event response configuration (ERC), navigate to Main Menu/Configure/All Setpoints/Event
Response Configuration or use Caterpillar ET. Unlike an EMCP 4.4 generator set control, ERC can be configured in
all modes. For step by step configuration example, refer to LEBE00006. Keep in mind that an ERC of shutdown will
cause a soft shutdown of the engine generator sets communicating to the EMCP 4.4 SCP.

The group name should help find the setpoint. However, a list of setpoints in each group, or submenu is given in
Table 5.1

28 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Handling Events

Diagnostics Protect Response Bus Response Custom Event Other System

Configuration Configuration Configuration Configuration Configuration
• Accessory Data • Ext Fuel Tank • Bus Under • Digital Input • Battery Voltage
Link Level Frequency Custom Events • Battery Charging
• Primary Data • Remote • Bus Under • Analog Input System Voltage
Link Emergency Stop Voltage Custom Events • Earth Leakage
• Battery Charger • Earth Fault • EPS Supplying
Fail • Gen Not Ready Load
• RS-485 SCADA to Auto Parallel • Battery Cranking
Data Link • Fuel Level Voltage
• TCP/IP SCADA
Data Link
• RS485-
Annunciator
Data Link
• Analog Inputs
• MGDL Comms
Failure
• MGDL Unit Not
Detected
Table 5.1: Event Response Configuration Setpoints

5.2 Resetting Individual Active Events for the EMCP 4

There are two ways to reset events. One way, described in this section, which applies to the EMCP 4.4 SCP only
(the “Supervisory Control” log), is to reset individual Active events by navigating to the desired event in the event
log. The second way is to use the Reset All button. For information on performing the Reset All Events Command
via Modbus, refer to the EMCP 4 SCADA Data Links, Application and Installation Guide (LEBE0010). If desired, a
Programmable Digital Output can be set to activate during a reset.

The amount of time the Digital Output configured for ECU Fault Reset is active is configurable in the EMCP 4 via
the ECU Fault Reset Active Time setpoint. This setpoint is found in the SYSTEM SETTINGS setpoint group in ET or
EMCP 4 display menu.

5.3 Troubleshooting Resetting Events

There are common reasons for the EMCP 4 not allowing events to be reset. First of all, in order to reset any
event, the event must no longer be Present. GEN NOT READY TO AUTO PARALLEL WARNING is explained more
fully below.

5.3.1 Gen Not Ready to Auto Parallel Warning

This event is Present whenever the EMCP 4.4 SCP or any networked EMCP 4.4 Generator Set controls are not
in AUTO. This includes any unit in RUN rather than AUTO. This event can be disabled by modifying the GEN
NOT READY TO AUTO PARALLEL WARNING EVENT RESPONSE CONFIGURATION setpoint. See Chapter 5.2 for
instructions on editing that setpoint.

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Handling Events

5.4 Using Status Events

Status events are useful troubleshooting information that can help determine or understand the sequence of
operation that led up to a failure or specific system condition. Status events differ from normal event log events
in that they do not generate a red shutdown or amber warning lamp on the EMCP and are not necessarily
indicative of a failure mode. Status events can be triggered as a result of user configuration changes or normal
system operation.

Each status event in the status event log has a short description and an associated time/date stamp. The Status
Event Log holds the last 500 status events that occurred in the system. Once the Status Event Log is filled, old
status events are lost and are replaced by the most recent status events. The time and date are not synchronized
in the system, so when comparing generator times to SCP times, adjustments may be required.

The first page of the Status Event Log shows the current time/date as configured on the EMCP 4 controller for
reference.
Note: If the time/date setting on the EMCP 4 is updated, already logged status event time/date stamps are NOT
updated and will retain the previous time/date stamp. However, all future triggered status events will use
the updated time/date setting.

A list of the possible EMCP 4.4 SCP status events and the corresponding trigger conditions are provided below in
Table 5.2.

Status Event Trigger Conditions

The EMCP 4 control has completed a power up transition
POWER UP COMPLETE
from OFF to ON.
EMERGENCY STOP RECEIVED An Emergency Stop input or command has been activated.
LSLD UNIT OFFLINE A unit is commanded off as a result of LSLD
LSLD UNIT ONLINE A unit is online and under LSLD control
PACKAGE NOT IN AUTO ECS is Not in Auto
REMOTE INITIATE RECEIVED Remote Initiate or Group Start input is activated.
REMOTE INITIATE REMOVED Remote Initiate input or Group Start is deactivated.
RESET EVENTS COMMAND ISSUED Command to Reset All Events has been received.
PCT OUTPUT #1 REMOVED Programmable Cycle Timer Output #1 was active but has been removed.
PCT OUTPUT #1 ACTIVATED Programmable Cycle Timer Output #1 has become active.
PCT OUTPUT #2 REMOVED Programmable Cycle Timer Output #2 was active but has been removed.
PCT OUTPUT #2 ACTIVATED Programmable Cycle Timer Output #2 has become active.
Engine Control Switch placed in RUN mode by receiving the command
MODBUS ECS IN RUN
via Modbus RS-485 or TCP/IP Data Link.
Engine Control Switch placed in STOP mode by receiving the command
MODBUS ECS IN STOP
via Modbus RS-485 or TCP/IP Data Link.
Engine Control Switch placed in AUTO mode by receiving the command
MODBUS ECS IN AUTO
via Modbus RS-485 or TCP/IP Data Link.
MODBUS REMOTE INITIATE RECVD Remote Initiate activated from Modbus RS-485 or TCP/IP Data Link.
MODBUS REMOTE INITIATE REMVD Remote Initiate deactivated from Modbus RS-485 or TCP/IP Data Link.
PACKAGE IN AUTO ECS is in Auto
Indicates when SCADA control (Modbus Write parameters)
REMOTE COMMS CONTROL ENABLED
is configured to enable.

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 Handling Events
Status Event Trigger Conditions
Indicates when SCADA control (Modbus Write parameters)
REMOTE COMMS CONTROL DISABLED
is configured to disabled.
Expected number of controls is non-zero, actual number of
NO MGDL UNITS DETECTED controls is one. The unit detects only itself and
no other MGDL units on the network.
Expected number of controls is non-zero, actual number of
controls is non-zero and not equal to expected number of
MGDL UNIT(S) NOT DETECTED
controls. The unit no longer detects one or more
MGDL units on the network.
Expected number of controls equals actual number of controls.
ALL MGDL UNITS DETECTED
The unit detects all expected MGDL units on the network.
GROUP START INPUT ACTIVE Group Start input is activated.
GROUP START INPUT INACTIVE Group Start input is deactivated.
MGDL GROUP START RCVD Group Start command was received via the MGDL network.
MGDL GROUP START RMVD Group Start command was removed via the MGDL network.
Group Start command was latched due to the group start
MGDL GROUP START LATCHED
command being lost from the MGDL network.
Group Start command was unlatched by the return of the lost
MGDL GROUP START UNLATCHED MGDL group start command, the assertion of a new group start
command or the controller being taken out of auto mode.
Multiple units on the MGDL network were detected with the same
DUPLICATE UNIT NUMBER DETECTED
MGDL unit number.
Engine Control Switch is placed in RUN mode
ECS IN RUN
from the EMCP fascia.
Engine Control Switch is placed in AUTO mode
ECS IN AUTO
from the EMCP fascia.
Engine Control Switch is placed in STOP mode
ECS IN STOP
from the EMCP fascia.
Engine Control Switch is placed in RUN mode by
ECS IN RUN INPUT
receiving the command via digital input.
Engine Control Switch is placed in AUTO mode by
ECS IN AUTO INPUT
receiving the command via digital input.
Engine Control Switch is placed in STOP mode by
ECS IN STOP INPUT
receiving the command via digital input.
ECM TIME/DATE MODIFIED The controller time/date settings were modified.
Load Sense Load Demand is unable to drop a unit even though it
LSLD DROP DENIED KVAR
is not required for real power due to reactive power requirements.
TEST WITH LOAD INPUT ACTIVE The digital input for Test with Load has been activated.
TEST WITH LOAD INPUT INACTIVE The digital input for Test with Load has been deactivated.
NO LOAD TEST I/P ACTIVE The digital input for Test with No Load has been activated.
NO LOAD TEST I/P INACTIVE The digital input for Test with No Load has been deactivated.
CONDITIONAL LOAD ADD ACTIVE The EMCP 4.4 SCP is operating in Conditional Load Add.

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Handling Events

Status Event Trigger Conditions

LOAD SENSITIVE LOAD ACTIVE The EMCP 4.4 SCP is operating Load Sensitive Load Add.
ADD PRIORITY 1 LOAD Priority 1 Load has been added.
ADD PRIORITY 2 LOAD Priority 2 Load has been added.
ADD PRIORITY 3 LOAD Priority 3 Load has been added.
ADD PRIORITY 4 LOAD Priority 4 Load has been added.
ADD PRIORITY 5 LOAD Priority 5 Load has been added.
ADD PRIORITY 6 LOAD Priority 6 Load has been added.
ADD PRIORITY 7 LOAD Priority 7 Load has been added.
ADD PRIORITY 8 LOAD Priority 8 Load has been added.
ADD PRIORITY 9 LOAD Priority 9 Load has been added.
ADD PRIORITY 10 LOAD Priority 10 Load has been added.
ADD PRIORITY 11 LOAD Priority 11 Load has been added.
ADD PRIORITY 12 LOAD Priority 12 Load has been added.
ADD PRIORITY 13 LOAD Priority 13 Load has been added.
ADD PRIORITY 14 LOAD Priority 14 Load has been added.
ADD PRIORITY 15 LOAD Priority 15 Load has been added.
ADD PRIORITY 16 LOAD Priority 16 Load has been added.
SHED PRIORITY 1 LOAD Priority 1 Load has been shed.
SHED PRIORITY 2 LOAD Priority 2 Load has been shed.
SHED PRIORITY 3 LOAD Priority 3 Load has been shed.
SHED PRIORITY 4 LOAD Priority 4 Load has been shed.
SHED PRIORITY 5 LOAD Priority 5 Load has been shed.
SHED PRIORITY 6 LOAD Priority 6 Load has been shed.
SHED PRIORITY 7 LOAD Priority 7 Load has been shed.
SHED PRIORITY 8 LOAD Priority 8 Load has been shed.
SHED PRIORITY 9 LOAD Priority 9 Load has been shed.
SHED PRIORITY 10 LOAD Priority 10 Load has been shed.
SHED PRIORITY 11 LOAD Priority 11 Load has been shed.
SHED PRIORITY 12 LOAD Priority 12 Load has been shed.
SHED PRIORITY 13 LOAD Priority 13 Load has been shed.
SHED PRIORITY 14 LOAD Priority 14 Load has been shed.
SHED PRIORITY 15 LOAD Priority 15 Load has been shed.
SHED PRIORITY 16 LOAD Priority 16 Load has been shed.
LATCH PRIORITY 1 LOAD Priority 1 Load has been shed and latched.
LATCH PRIORITY 2 LOAD Priority 2 Load has been shed and latched.
LATCH PRIORITY 3 LOAD Priority 3 Load has been shed and latched.
LATCH PRIORITY 4 LOAD Priority 4 Load has been shed and latched.
LATCH PRIORITY 5 LOAD Priority 5 Load has been shed and latched.

32 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Handling Events

Status Event Trigger Conditions

LATCH PRIORITY 6 LOAD Priority 6 Load has been shed and latched.
LATCH PRIORITY 7 LOAD Priority 7 Load has been shed and latched.
LATCH PRIORITY 8 LOAD Priority 8 Load has been shed and latched.
LATCH PRIORITY 9 LOAD Priority 9 Load has been shed and latched.
LATCH PRIORITY 10 LOAD Priority 10 Load has been shed and latched.
LATCH PRIORITY 11 LOAD Priority 11 Load has been shed and latched.
LATCH PRIORITY 12 LOAD Priority 12 Load has been shed and latched.
LATCH PRIORITY 13 LOAD Priority 13 Load has been shed and latched.
LATCH PRIORITY 14 LOAD Priority 14 Load has been shed and latched.
LATCH PRIORITY 15 LOAD Priority 15 Load has been shed and latched.
LATCH PRIORITY 16 LOAD Priority 16 Load has been shed and latched.
The system is able to meet the desired number of units
N+X STRATEGY MET
under Load Sense Load Demand.
The system is unable to meet the desired number of units
N+X STRATEGY NOT MET
under Load Sense Load Demand
Loss of communications or MGDL protocol mismatch has
FAILSAFE MODE ACTIVATED occurred and the unit is attempting to load add while
operating in failsafe mode.
LOAD SHED OVER ACTIVATED Load Shed System Overload Activated
LOAD SHED OVER DEACTIVATED Load Shed System Overload Deactivated
LOSS OF UTILITY INPUT RECEIVED The Group Start signal on the EMCP 4.4 SCP has been received.
The output from the EMCP 4.4 SCP has been activated
FAILSAFE HW START ACTIVATED since communications have been loss and the
EMCP 4.4 Group Start Input is active.
The output from the EMCP 4.4 SCP has been deactivated since
FAILSAFE HW START DEACTIVATED communications have been restored or the EMCP 4.4
Group Start Input is no longer active.
Supervisory controller detected generator set controllers
GEN SOFTWARE NEED UPDATE
not having suggested software versions.

Table 5.2 – EMCP 4.4 SCP Status Events and Trigger Conditions

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Security

6.0 Security
There are five levels of security access on EMCP 4: Level 0, Level 1, Level 2, Level 3, And Service Tool. Any
configurable parameter or function that is set to Level 0 can be accessed by anyone at any time, and there will
never be any security information on the display screen.

Level 1 Access And Level 2 Access represent increasing levels of access to the setpoints and functions of the
controller. Both Levels 1 and 2 can be password protected with separate user-defined passwords.

Note: These are optional levels of security; by default these passwords are disabled, and the default access level
is Level 2 from Parts Service.

Level 3 Access is password protected at the factory, and requires contacting the Cat dealer TC to obtain a
password.

• If the present security level of the controller is below the level needed to perform a desired function, a padlock
and a number will be displayed at the bottom right hand corner of the display. The number represents the level
of security that is required in order to perform the desired function; 1, 2, or 3.

• If there is a padlock but no number, the Cat Service Tool is required in order to perform the desired function; or
the setpoint may be read only and cannot be changed.

All of the adjustable parameters are associated with a specific level of security required to make an adjustment
to the parameter. Certain functions are also associated with a specific level of security. The passwords only
affect actions taken at the EMCP 4. Access of the EMCP 4 remotely via the Cat Service Tool or via the SCADA
data link is not affected by the security level on the EMCP 4 display.

Changing parameters with the Cat Service Tool does not require passwords, since the service tool already has
the highest level of access.

When connecting via the SCADA DATA LINK, passwords can also be used. The levels of access granted via
SCADA are identical to the levels of access granted at the EMCP 4. However, the passwords themselves may
differ. Furthermore, the EMCP 4 and the SCADA data link may be at different levels of access at any given time.
For more information about SCADA security see Chapter 6.

Level 1 and Level 2 passwords are usually DISABLED when shipped from the factory. Level 1 and Level 2
passwords can be user defined if desired. If the Level 1 and Level 2 passwords are not user defined, the
Level 2 will be the MINIMUM LEVEL. All parameters that require Level 0, Level 1, or Level 2 security will be able
to be changed by anyone at any time.

Note: The EMCP 4 will always move up in security level to the highest level of access that is not password
protected when a certain level of access is requested. For example, if a Level 1 password has been
defined, but a Level 2 password has not, the EMCP 4 will start at Level 0 on power up. When the Level 1
password is entered, the EMCP 4 will move up to Level 2 access.

If neither a Level 1, nor a Level 2 password has been defined, the EMCP 4 will always be at least at a
Level 2 access.

34 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Security

The Security Menu

1. To get to the security menu, press MAIN MENU/CONFIGURE/SECURITY.

There are six options on the security menu:

DROP TO MINIMUM LEVEL CHANGE LEVEL 1 PASSWORD
ENTER LEVEL 1 OR 2 CHANGE LEVEL 2 PASSWORD
ENTER LEVEL 3 CHANGE SCADA PASSWORD

2. Selecting DROP TO MIN LEVEL will make the control go to the minimum level of security. As previously
discussed, if the Level 1 and Level 2 passwords are not defined by the user, the minimum level of security will be
Level 2. If a Level 2 password is defined by the user, but not a Level 1 password, the minimum level of security
will be Level 1.

In contrast, if a Level 1 password is defined by the user, but not a Level 2 password, the minimum level of
security will be Level 0.

The password entry screen will have 4 spaces. In each space, a number from 0 through 9 can be entered. The
password can be from 1 to 4 digits and is entirely user defined. Enter the password for either Level 1 or Level 2

if either of those passwords have been defined. Use the UP ARROW or DOWN ARROW to

change the value of any highlighted digit. Use the LEFT ARROW or RIGHT ARROW to navigate
between digits.

3. Selecting ENTER LEVEL 3 will cause the display to say “PHONE IN WITH” and a 16-digit number will be
displayed. Under that, ENTER RESPONSE will be highlighted with a password entry field. Record the 16-digit
number and call the Cat dealer TC with this number.

Note: Level 3 seed key and response will change based on various pieces of information. It is valid only when
generated, and will be different in the future for that specific controller. The TC will reply with another
16-digit number. Enter the password that was supplied by the TC in the same manner as the other types of
passwords.

4. Press the OK KEY to confirm, or ESCAPE KEY to reject the change. Pressing the OK KEY
after entering the number will set the current level to 3. The control will remain in Level 3 security level until
no key presses have been made for 10 minutes. After 10 minutes of inactivity the control will revert back to the
minimum level of security.

Note: To change a Level 3 parameter requires either a Level 3 password from the TC or a PC connection using
a Service Tool. Therefore, if you have a Service Tool, try to change the parameter using the Service Tool
rather than calling the TC.

A P P L IC A T I O N & I N ST A LLATI ON GUI DE 35

Security

5. Selecting CHANGE LVL 1 PSWD will allow for the Level 1 password to be changed. The control must be at
Level 1 security in order to select CHANGE LVL 1 PSWD. The CHANGE LVL 1 PSWD screen looks just like the
password entry screen. It has 4 blank spaces that can each be set to a number from 0 to 9. The password can
use as few as one digit and as many as 4 digits. It is entirely up to the user. If a password has been set but, it
is now desired to not have Level 1 password protection, the Level 1 password can be disabled by setting the
password to be a single 0.

6. Once the desired password is entered, press the OK KEY and the control will go back to the security
screen and the Level 1 password will be set.

7. Selecting CHANGE LVL 2 PSWD will allow for the Level 2 password to be changed. The control must be at
Level 2 security in order to select CHANGE LVL 2 PSWD. The CHANGE LVL 2 PSWD screen looks just like the
password entry screen. It has 4 blank spaces that can each be set to a number from 0 to 9. Selecting a password
is entirely up to the user and can use as few as one digit or as many as 4 digits.

The Level 2 password can be disabled by setting the password to be a single 0.

8. Once the desired password is entered, press the OK KEY and the control will go back to the SECURITY
SCREEN and the Level 2 password will be set.

9. Selecting CHANGE SCADA PSWD will allow for the SCADA password to be changed.

This password, if ENABLED, will require a SCADA system to first enter the password into the WRITE ACCESS
PASSWORD register prior to conducting any other reads and writes. The control must be at Level 2 security in
order to select CHANGE SCADA PSWD. The CHANGE SCADA PSWD screen looks just like the password entry
screen. It has 8 blank spaces that can each be set to a number from 0 to 9. The password can use as few as one
digit and can use as many as 8 digits. Keep in mind that most control and changes over SCADA also require the
SCADA Remote Control to be Enabled under CONTROL/SYSTEM SETTINGS.

Just as with Level 1 and Level 2 passwords, entering a single 0 will DISABLE the SCADA password.

36 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Setpoints

7.0 Setpoints
The EMCP 4.4 has a variety of setpoints that can be programmed or adjusted. These setpoints can be adjusted
via the display, or via the Cat Service Tool. In order to program the setpoints via the display, go through the menu
options of MAIN MENU/CONFIGURE.

All of the setpoints on EMCP 4.4 SCP can be accessed through the ALL SETPOINTS menu. However, setpoints
related to some items can also be accessed under CONFIGURE. It is recommended to use the latter to configure
these items.

7.1 Configuring Setpoints

Setpoints can be one of three different types: NUMERICAL ENTRY, SELECTION, or EVENT RESPONSE. Each type
is configured differently. For configuring any setpoint via the display, the user must first have the proper security
access. See Chapter 6 for more information on security.

NUMERICAL ENTRY setpoints are parameters like time delays, thresholds, etc. For these setpoints the display will
show the current value.

To change the value of a NUMERICAL ENTRY type setpoint:

1. Press the OK KEY when the setpoint is highlighted. The current value of the setpoint will be shown with
the rightmost digit highlighted.

2. Use the UP and DOWN arrow keys to adjust that digit to the desired value. Digits will wrap
around. Therefore, pressing up when 9 is shown will change it to 0, or pressing down when 0 is shown will
change it to 9.

3. Once that digit is set to the desired value, use the LEFT arrow key to move the cursor to the next digit.

4. Then use the UP and DOWN arrow keys to adjust that digit to the desired value.

5. Continue this process until the desired value for the setpoint is set.

6. Then press the OK KEY to save the value.

Tip: You can quickly select the largest possible value for the setpoint by pressing the LEFT arrow key until

the leftmost digit is shown, and then pressing the UP arrow key until the value stops changing.

A P P L IC A T I O N & I N ST A LLATI ON GUI DE 37

Setpoints

Similarly you can select the smallest possible value by pressing the LEFT arrow key until the leftmost digit is

shown, and then pressing and holding DOWN arrow key until the value stops changing.

SELECTION type setpoints, such as Units, or Active State, have options that are not numerical. For these
setpoints, the display will show the current setting.

To change the value of a SELECTION type setpoint:

1. Press the OK KEY when the setpoint is highlighted. The current setting of the setpoint will be shown.

2. Use the UP or DOWN arrow keys to scroll through the options that are available for that
setpoint. Scroll quickly by holding the key.

3. When the desired option is displayed, press the OK KEY to save the setting.

EVENT RESPONSE CONFIGURATION type setpoints are a little different from the previously discussed setpoints.
Each setpoint configures one or more actions that occur when the event occurs. See Section 5.1 for more
information.

7.2 Setpoint Sub-menus

The setpoints in the EMCP 4 are organized into multiple submenus. See Appendix A and the appropriate sections
of this document for more information.

7.3 Setpoints on the Cat Service Tool

EMCP 4 setpoints can also be configured using the Cat Service Tool (ET). To access setpoints, see Section 4.2.

If a value is changed from the EMCP display, Cat ET may not refresh the setpoint automatically. Press the “Config
Tool” icon to refresh the list.

Categories of setpoints are listed along the left pane, and clicking on one of them will bring up that list in the
right pane.

The family of EMCP 4 controllers will have various setpoints based on hardware version, software version, and
ET version. The categories shown here match those for EMCP 4.4 SCP in ET version 2015B and Prod v.4.6.1. Other
versions may have different choices. ET versions earlier than 2015B will show setpoints that are not available.

Note: Any setpoint with a value given as ”Unavailable” is not applicable to that level of EMCP 4.

38 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Setpoints

7.3.1 Setpoint Categories

Here are the categories of setpoints as found in the left pane of the ET Configuration Tool:

Analog Inputs
Setpoints related to Analog Inputs. See Chapter 9.

Analog Outputs
Setpoints related to Analog Outputs. See Chapter 11.

Analog PWM Outputs

Setpoints related to Analog PWM Outputs. See Chapter 12.

System Settings
Setpoints related to EMCP 4.4 SCP system under the Control Menu such as ECU fault reset time, SCADA Data Link
Control, and Emergency Stop Active state.

Battery Voltage Monitor

Setpoints related to monitoring battery voltage from the battery power input to the EMCP 4.

Data Link: RS-485 SCADA

Setpoints related to SCADA (Modbus) data link communications. See Chapter 19.

Data Link: TCP/IP SCADA

Setpoints related to Ethernet communications. See Chapter 20.

Digital Inputs
Setpoints related to Digital Inputs. See Chapter 8.

Digital Outputs
Setpoints related to Digital Outputs. See Chapter 10.

Event Response Configuration – Diagnostic Events

Setpoints used to configure the EMCP 4 response to diagnostic events. See Chapter 5.

Event Response Configuration – Bus Events

Setpoints used to configure the EMCP 4 response to Bus events. See Chapter 5.

Event Response Configuration – Protection Events

Setpoints used to configure the EMCP 4 response to protection events. See Chapter 5.

Event Response Configuration – Other System Events

Setpoints used to configure the EMCP 4 response to events that do not fit into the category of diagnostics, engine
protection, or generator protection. See Chapter 5.

Event Response Configuration – Custom Events

Setpoints used to configure the EMCP 4 response to custom events. See Chapter 5.

Fuel Transfer
Setpoints related to fuel transfer feature.

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Setpoints

AC Monitor
Setpoints related to generator configuration (for EMCP 4 calculation and reporting).

Over/Under Frequency
Setpoints related to bus overfrequency and underfrequency monitoring.

Load Add
Setpoints related to Load Add. See Chapter 13.

Load Shed
Setpoints related to Load Shed. See Chapter 13.

Load Sense/Load Demand

Setpoints related to MGDL Load Sense Load Demand. See Section 21.3.

Programmable Cycle Timer

Setpoints related to configuring Programmable Cycle Timers. See Chapter 16.

Display Preferences
Setpoints determining the units used on the EMCP 4 display. Note that this does not affect the data as viewed on
the Cat Service Tool. See Section 4.4.

40 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Digital Inputs

8.0 Digital Inputs

The EMCP 4.4 SCP has eight programmable Digital Inputs and four isolated programmable Digital Inputs, however,
only the first 4 programmable digital inputs are wired to terminal blocks. The user programmable Digital Inputs
are referenced to Battery (-) and will see a change in state at ~3VDC with a 1VDC hysteresis. The isolated user
programmable Digital Inputs are all also referenced to the isolated references of the connected generator sets
for use with the “Group Start” signal.

In addition to the user programmable Digital Inputs, the EMCP 4.4 has dedicated Digital Inputs, both isolated and
non-isolated. The dedicated isolated Digital Inputs are all referenced to a common signal that is user supplied and
is the same as the user supplied reference wired to pin 118 on the 120-pin connector of the EMCP 4.4.

Table 8.1 outlines which functions are assigned to each of the dedicated inputs. The Group Start input is the only
input wired out to Terminal Blocks.

Input Onscreen Label Dedicated Function

Dedicated Non-Isolated Digital #1 A Emergency Stop
Dedicated Non-Isolated Digital #2 B Remote Initiate
Dedicated Isolated Digital #1 A Group Start

Table 8.1 – Dedicated Input Assignments

The other inputs are linked to functions that are called STATUS OR SYSTEM EVENTS and can be configured to
trigger warnings or shutdowns in the EMCP 4. System Event configurations determine the EMCP 4 response to
any supported event. For more information on Event Response Configurations, see Chapter 5.1.

The programming of the Digital Inputs starts by selecting a “Usage Type.“ The rest of the programming is
dependent upon what Usage Type is selected. Programming Digital Inputs from the EMCP display requires Level 2
security access. Figure 8 summarizes the paths possible for Programming a Digital Input.

Usage Type
Disabled
Status Status Parameter List of Choices
System Event Active State
SCADA Data Link

Event Parameter List of Choices

Failure Type
Event Delay List of Choices
Active State

Figure 8.1: Digital Input Programming Paths

A P P L IC A T I O N & I N ST A LLATI ON GUI DE 41

Digital Inputs

The Usage Type of DISABLED is used to completely disable the input. No status will be shown, and no action will
be taken by the EMCP 4.

The Usage Type of STATUS is used to make certain system conditions be known by the EMCP 4.

The Usage Type of SYSTEM EVENT is used to inform the EMCP 4 of system conditions that require the EMCP 4 to
trigger an event.

The Usage Type of SCADA DATA LINK is used to bring in data to the EMCP 4 specifically for use by the SCADA
data link. EMCP 4 will not take any action or trigger any events on such an input.

The Digital Inputs of the EMCP 4 are tied to an internal pull-up resistor inside the controller. Therefore, if a Digital
Input is UNCONNECTED, the Digital Input will sit at a PHYSICAL HIGH state. See Figure 8.2. Note that a Digital
Input wired to battery positive will always remain Active if programmed for Active High, and will always remain
Inactive if programmed for Active Low.

A battery negative input should be switched to each EMCP 4 Digital Input for proper operation. Isolated Digital
inputs must be switched to Isolated Reference.

• If an ACTIVE HIGH configuration is desired, the reference or battery negative input should be wired through a
normally-closed switch.

• If an ACTIVE LOW configuration is desired, the reference or battery negative input should be wired through a
normally-open switch.

Figure 8.2 – Valid States of Digital Input Wiring and Configuration

Note: Improper configuration of these inputs can cause a false event to be triggered, or cause an event to not be
triggered when desired.

Note: If more than one Digital Input is configured for the same physical quantity (i.e. the setpoint Digital Input
Data Identification matches between two Digital Inputs), the higher numbered Digital Input value will have
priority. For example, if both Digital Input #4 and Digital Input #5 are configured for ECS in Run but Digital
Input #4 is activated with Digital Input #5 left inactive, Digital Input #4 will be ignored and ECS in Run will
be inactive.

42 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Digital Inputs

8.1 Programming Digital Inputs Using the Display

The steps to configure the Digital Inputs for each of the Usage Types are described below.

8.1.1 Viewing the Current Digital Input Status

To view the current status of a Digital Input, go through the following menu options: Main Menu/VIEW/”I/O
STATUS”/DIGITAL INPUTS. For detailed information about each input, use the arrow keys to select an input. For a
step by step procedure, refer to LEBE0007.

8.1.2 Configuring Digital Inputs for Status Parameters

Command or Status parameters are used to control specific functions within the control system or to make
certain conditions within the system be known. To configure a Digital Input as a Command or Status Parameter,
go through the following menu options: MAIN MENU/CONFIGURE/INPUTS and OUTPUTS/DIGITAL INPUTS. Each
digital input can be configured for STATUS, along with ACTIVE STATE. For a step by step procedure

Any Digital Input can be configured for any one of the Status parameters in Table 8.1:

Status Parameter Status Parameter

ECS in Run* Auto Load Fuel
ECS in Auto* Auto Unload Fuel
ECS in Stop* Load Shed Reset Command
Inhibit Generator Breaker Closure (4.4) Test without Load

Table 8.1– Digital Input Command/Status Options

*If a Digital Input is programmed for ECS in Auto, or Run, or Stop, and a maintained switch latches that input to
make it active, the front panel buttons will not have any effect.

8.1.3 Digital Input Status Descriptions

Below is a brief description of the purpose of each command/status digital input option:

ECS in Run
• When activated, has the same effect as pressing the “Run” button (puts the EMCP 4.4 SCP in RUN mode and
sends a group start signal to the connected generator sets. This functionality is not backed up with a failsafe
mode. While this input is Logically Active, the ECS can’t be changed from RUN.

ECS in Auto
• When activated, has the same effect as pressing the “Auto” button (puts the EMCP in AUTO mode). While this
input is Logically Active, the ECS can’t be changed from AUTO.

ECS in Stop
• When activated, has the same effect as pressing the “Stop” button (puts the EMCP in STOP mode). While this
input is Logically Active, the ECS can’t be changed from STOP.

Auto Load Fuel

• When activated, initiates the automatic fuel transfer in feature (if enabled). Typically used in conjunction with
programmable digital outputs and analog input to control loading fuel. The use of this feature will require
additional wiring and a decrease in the number of supported load steps.

A P P L IC A T I O N & I N ST A LLATI ON GUI DE 43

Digital Inputs

Auto Unload Fuel

• When activated, initiates the automatic fuel transfer out feature (if enabled). Typically used in conjunction with
programmable digital outputs and analog input to control unloading fuel. The use of this feature will require
additional wiring and a decrease in the number of supported load steps.
Load Shed Reset Command (Load Shed Reset)
• When activated, an EMCP 4.4 supervisory control will reset ALL latched load shed outputs.

Test With Load

• When activated, the EMCP 4.4 SCP will start and proceed as normal with adding load similar to a
“Group Start.”

Test Without Load

• When activated, the EMCP 4.4 SCP will start, but will NOT add any load steps. It will remove all load steps. If a
Group Start comes during this process, it will override this functionality.

8.1.4 Configuring Digital Inputs for System Events

System Events are used to know when specific conditions are reached and to alert the control system of warning
or shutdown conditions. To configure a Digital Input as a System Event Input, go through the following menu
options: MAIN MENU/CONFIGURE/INPUTS and OUTPUTS/DIGITAL INPUTS. Each digital input can be configured
for a specific system event, along with time delay, active state, and the event response configuration (ERC). Refer
to LEBE0007 for step by step instructions.

Any Digital Input can be configured for any one of the System Event parameters in Table 8.2:

Levels Others
Engine Coolant Level Custom Event
Battery Charger Failure
Earth Fault
Earth Leakage
Battery Charging System Voltage
EPS Supply Load (EMCP 4.2 only)
Emergency Stop Switch (Remote)

Table 8.2 – Digital Input System Events

8.1.5 Configuring Digital Inputs for SCADA Data Link

When a Digital Input is configured for SCADA Data Link, the state of the input will be placed into the appropriate
MODBUS register only. No alarms or warnings will be generated by the EMCP. Refer to LEBE0007 if detailed
instructions are desired.

For information on reading the status of Digital Inputs via MODBUS, please refer to the SCADA documentation.

44 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Digital Inputs

8.1.6 Disabling Digital Inputs

Digital Inputs can also be disabled. Refer to LEBE0007 if detailed instructions are desired.

Note: If a Digital Input is set to Disabled, any faults or events on that input will not be broadcast or annunciated
on the network.

8.1.7 Programming Digital Inputs Using the Cat Service Tool

The EMCP 4 Digital Inputs can be configured using the Cat Service Tool. The key to programming them is to
program the setpoints related to each input in order from top to bottom. Detailed instructions are available
in LEBE0007.

The display will only show valid SPN-FMI combinations, but ET will show invalid combinations that will be
rejected. Valid SPN-FMI combinations are listed below.

Failure Mode Identifier Valid Options

Category Suspect Parameter Number High Low High Low
Status
Shutdown Shutdown Warning Warning
Levels External Tank Fuel Level Y Y Y Y
Battery Charging System Voltage Y Y Y Y
Battery Charger Failure Y Y Y Y Y
Custom Event (see note below) Y Y Y Y Y
Others Earth Fault Y Y Y Y Y
Earth Leakage Y Y Y Y Y
Emergency Stop Switch Y Y Y Y Y*
EPS Supply Load Y Y Y Y Y

Table 8.3 – Event Input Function SPN and FMI Options

*This status is FMI 14 (Special Instruction), not FMI 31 (Condition Exists). This gives a means to differentiate
between a Remote Emergency Stop and Emergency Stop.

Note: For Custom Events, each input can only trigger the custom event number that matches the Digital Input
number (Digital Input #1 can only activate Custom Event #1, etc.).

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Analog Inputs

9.0 Analog Inputs

The EMCP 4.4 supports four 2-wire (plus shield) individually-isolated Analog Inputs. None of these inputs are
dedicated to specific functions. These are individually selectable +/- 10V bipolar, PWM, Resistive Sender or
current (0-20 mA) inputs for interface to senders, customer signals, etc. For resistive senders, the negative signal
is tied to the negative pin on the controller for that sender. The modes of operation are described below:
• Voltage Mode: The input impedance is a minimum of 1 M Ohms (see Table 10 for ranges).
• PWM Mode: approximately 500 Hz, non-synchronized, 5 VDC peak, 0.5% accuracy or better with software
selectable sub-ranges.
• Current Mode: The input impedance is a minimum of 50 Ohms and maximum of 250 Ohms with software
selectable sub-ranges.
• Resistive Sender (VDO type) Mode: 5-2000 Ohms, with 1% accuracy or 0.5 Ohms, whichever is worse.

For the EMCP 4.4, each of these Analog Inputs have an individual isolated power supply capable of supplying up
to 50 mA, are software configurable as 5 V or 8 V, and have overload protection. These supplies are to be used
to provide power to sensors if required by the source power pin and Analog Input negative. These supplies are
isolated from battery negative.

See Electrical Connections Section 3.4 for illustrations on how to connect the sensors to the control.

Analog Inputs programmed to monitor pressures should be wired to sensors that read gauge, not absolute
pressure, unless absolute pressure is desired.

For Analog Inputs, the data range can be positive or negative, but Event thresholds are only positive. Therefore, to
prevent nuisance alarms for low warnings, disable the Event Response Configuration if data is acceptable to be
negative (see Chapter 5).

All four Analog Inputs are protected at Level 2 security. For details on security, see Chapter 6, Security.
Alternately, the Cat Service Tool can be used to program these setpoints.

Note: If the Analog Inputs are set to DISABLED, then any sensor faults or events will not be broadcast or
annunciated on the network.

Note: If more than one Analog Input is configured for the same physical quantity (i.e. the setpoint Analog Input
Data Identification matches between two Analog Inputs), then the lowest numbered Analog Input value will
be displayed. Warnings and Shutdowns will be monitored for both Analog Inputs. When troubleshooting
inputs, always make sure to check for configuration conflicts!

The programming of the Analog Inputs starts by selecting a “Usage Type.“ The rest of the programming is
dependent upon what Usage Type is selected. Figure 9.1 summarizes the paths possible for Programming an
Analog Input.

46 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Analog Inputs

Usage Type Data Identification List of Choices

Disabled Map Selection Number
Resistive Isolated Voltage
PWM
Current Signal Range List of Choices
Voltage Data Identification
Min Data List of Choices
Max Data
Isolated Voltage

Signal Range List of Choices

Data Identification
Min Data List of Choices
Max Data
Isolated Voltage

Signal Range List of Choices

Data Identification
Min Data List of Choices
Max Data
Isolated Voltage

Figure 9.1 – Analog Input Programming Paths

9.1 Programming Analog Inputs Using the Display

The steps to configure the Analog Inputs for each of the Usage Types are described below. Level 2 security is
required for all Analog Inputs.

9.1.1 Viewing the Current Analog Input Status

To view the current status of an Analog Input, go through the following menu options: Main Menu/View/”I/O
Status”/Analog Inputs.

9.1.2 Configuring Analog Inputs for Resistive Mode

To configure an Analog Input for Resistive Mode, go through the following menu options: Main Menu/Inputs and
Outputs/Analog Inputs.

The Data Identification will remain the same when switching between Resistive and Voltage.

A P P L IC A T I O N & I N ST A LLATI ON GUI DE 47

Analog Inputs

Any Analog Input can be configured for any one of the Data Identification parameters in Table 9.1:

Data Identification Parameters

Custom Parameters #N AMBIENT TEMPERATURE
Data Link - SCADA ENGINE FUEL LEVEL
External Tank Fuel Level MAIN TANK UREA LEVEL
Table 9.1 – Analog Input Data Identifications

The Sensor Codes correspond to sensor maps as defined in Chapter 9.3.

9.1.3 Configuring Analog Inputs for PWM Mode

To configure an Analog Input for PWM Mode, configure for the data identification, the PWM range and the
associated engineering values. For detailed instructions, refer to LEBE0007.

9.1.4 Configuring Analog Inputs for Current Mode

To configure an Analog Input for Current Mode configure for the data identification, the current range and the
associated engineering values. For detailed instructions, refer to LEBE0007.

9.1.5 Configuring Analog Inputs for Voltage Mode

To configure an Analog Input for Voltage Mode configure for the data identification, the voltage range and the
associated engineering values. For detailed instructions, refer to LEBE0007.

The Data Identification list is the same whether Signal Type is Resistive, PWM, or Voltage.

Any Analog Input can be configured for any one of the Data Identification parameters in Table 8.

9.1.6 Disabling Analog Inputs

To disable an Analog Input, select DISABLED. For detailed instructions, refer to LEBE0007.

48 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Analog Inputs

9.2 Programming Analog Inputs Using the Cat Service Tool

The EMCP 4 Analog Inputs can be configured using the Cat Service Tool. The key to programming them is
to program the setpoints related to each input in order from top to bottom. For detailed instructions, refer to
LEBE0007. Table 9.2 lists the FMI options for Analog Input data identifications.

Failure Mode Identifier Valid Options

Suspect Parameter Number
High Shutdown Low Shutdown High Warning Low Warning
External Tank Fuel Level Y Y Y Y
Engine Fuel Level Y Y Y Y
AI #N Custom Parameter (see note below) Y Y Y Y
Data Link – SCADA*
Urea Level*
Ambient Temperature*
*Information only.
Table 9.2 – Event Input Function SPN and FMI Options

Note: For Custom Events, each input can only trigger the custom event number that matches the Analog Input
number (Analog Input #1 can only activate Custom Event #1, etc.).

9.3 Analog Input Maps

Resistive senders can use nonlinear sensor maps. These maps are not available for Voltage or Current modes.
Maps are predefined in the software flash file, and can be selected by the customer. The Analog Inputs are
capable of reading resistance from ~5 Ohms up to 2000 Ohms.

The following maps are predefined:

Analog Input Map #1

Engine Oil Pressure Map #1 Engine Oil Pressure
Ohms kPa Ohms kPa
1000
5.1 0 107.3 500
10.2 0 115.9 550 800
20.9 50 124.3 600
31.3 100 132.5 650 600
kPa

41.6 150 140.5 700

51.6 200 148.2 750 400

61.3 250 155.8 800

200
70.9 300 163.1 850
80.4 350 170.2 900 0
89.5 400 177.2 950 0 50 100 150 200

98.6 450 183.9 1000 Ohms

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Analog Inputs

Analog Input Map #2

Engine Oil Pressure Map #2 Engine Oil Pressure
Ohms kPa
1000
0 0
8 0 800

9 45
9.8 50 600

kPa
97.5 1000
400

200

0
0 25 50 75 100
Ohms

Analog Input Map #3

Engine Coolant Temperature Map #1 Engine Coolant Temp
Ohms °C Ohms °C
11.0 150 103.6 68
130
12.8 143 129. 6 61
15.0 136 168.0 54 105

17.9 129 221.9 47

Degrees C

80
20.8 123 291.5 40
55
24.2 117 387.5 33
28.4 111 520.6 26 30

33.4 105 677.0 20 5

39.6 99 890.6 14 0 500 1000 1500 2000
-20
46.9 93 1182.9 8 Ohms
56.1 87 1575.6 2
67.9 81 2249.4 -5
82.4 75

50 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Analog Inputs

Analog Input Map #4

Engine Coolant Temperature Map #2 Engine Coolant Temp
Ohms °C Ohms °C
150
2442 -48 31 62
130
1518 -39 24.8 70 110
968.9 -30 20 78 90

633.6 -21 16.3 86 70

Degrees C
50
423.9 -12 13.3 94
30
289.7 -3 11.0 102
10
201.9 6 9.18 110 -10 0 500 1000 1500 2000 2500
148.8 14 7.7 118 -30

111.2 22 6.5 126 -50

Ohms
84.2 30 5.5 134
64.5 38 4.7 142
50 46 4.1 150
39.2 54

Analog Input Map #5

Oil Temperature Oil Temp
Ohms °C Ohms °C
200
10.2 180 93.6 86
180
11.9 172 115.6 79
160
13.9 164 145.2 72 140
16. 4 156 184.7 65 120
Degrees C

100
19.0 149 238.0 58
80
22.0 142 309.9 51
60
25.7 135 408.7 44 40
30.2 128 546.6 37 20

35.6 121 773.7 29 0

0 500 1000 1500 2000 2500
42.5 114 1114.9 21 Ohms
51.2 107 1640.3 13
61.9 100 2473.6 5
75.8 93

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Analog Inputs

Analog Input Map #6

Engine Coolant Temperature Map #3 Lean2B Temp
Ohms °C Ohms °C
6.9 150 68.5 64 140

8.2 142 87.1 57 120

9.8 134 111.8 50 100

11.6 127 145.1 43

Degrees C
80

13.8 120 190.5 36 60

16.3 113 253.4 29 40

19.6 106 341.5 22 20

23.8 99 467.0 15 0
0 500 1000 1500 2000
-20
28.8 92 648.8 8
Ohms
35.4 85 916.6 1
43.7 78 1318.5 -6
54.5 71 2046.6 -14

Analog Input Map #7

Fozmula Fuel Level Fozmula Fuel Level
Ohms %
100
9.0 0
10.5 0
75
35.6 25
% Fuel Level

60.2 50
50
85.2 75
103.2 100
25
110.0 100

0
0 25 50 75 100
Ohms

52 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Analog Inputs

Analog Input Map #8

Linear Level Linear Level
Ohms %
100
0 0
2000 1000
75

% Level
50

25

0
0 500 1000 1500 2000
Ohms

Analog Input Map #9

Power Module Tank Level #1 Power Module Tank Level #1
Ohms %
100
10. 5 0
35.6 25
75
60.2 50
85.2 75
% Level

50
103.2 100

25

0
0 20 40 60 80 100
Ohms

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Analog Inputs

Analog Input Map #10

Power Module Tank Level #2 Power Module Tank Level #2
Ohms %
120
10 100
135 100 100

348.2 0
80
500 0

% Level
60

40

20

0
0 100 200 300 400 500
Ohms

Analog Input Map #11

Fuel Level Fuel Level
Ohms % 100
255 0
240 0 80

30 100
% Fuel Level

60
15 100
40

20

0
255 240 30 15
Ohms

54 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Analog Inputs

Analog Input Map #12

Useful for temperatures based on Cat
sensor part number 256-6453. (EMCP only
supports down to 10°C).

Temperature Temperature
Ohms °C Ohms °C
140
2541.5 5 148.1 75
120
1991.4 10 125.7 80
100
1249.5 20 107.2 85

Degrees C
80
1000 25 91.7 90
805.5 30 78.8 95 60

652.8 35 68 100 40

532.3 40 58.9 105 20

436.6 45 51.2 110 0

2541.5 652.8 248.7 107.2 51.2 18.6
360 50 44.6 115
Ohms
298.4 55 39 120
248.7 60 30.1 130
208.2 65 23.6 140
175.2 70 18.6 150

For EMCP 4.4, PWM, voltage, and current senders can be configured within the ranges in Table 9.3:

PWM Sender Ranges Current Sender Ranges Voltage Sender Ranges

0 to 100% 0 to 20mA 0 to 5V
5 to 95% 4 to 20mA 1 to 5V
0 to 10mA 0 to 10V
-3 to +3V
-2.5 to +2.5V
-5 to +5V
-10 to +10V
0.5 to 4.5V
-1 to +1V

Table 9.3 – Analog Input Ranges

Analog Input data ranges can be defined with positive and negative values, but Event thresholds are only
programmable as positive values. Therefore, to prevent nuisance alarms for low warnings when using negative
numbers for data ranges, the Event Response Config can be disabled if input data is acceptable to be negative.

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Analog Inputs

9.3.1 Warnings and Shutdowns

Each of these inputs can be configured to have HIGH WARNINGS, LOW WARNINGS, HIGH SHUTDOWNS, and
LOW SHUTDOWNS with configurable thresholds. Any value below the bottom point on the map or above the
highest point on the map will raise a corresponding diagnostic event. Also, all of the events associated with the
Analog Inputs have programmable time delays. Low Idle Oil Pressure setpoints are also available under the Engine
Oil Monitor area. Information on how to program these thresholds and time delays can be found in Chapter 7,
Setpoints.

9.3.2 Unsupported Analog Input Sensor Ranges

There may be voltage sensors available that use ranges not explicitly supported by the EMCP 4. Depending on the
situation, there may be different ways to handle this. The following sections give options on how to handle these
situations.

9.3.3 Sensor Range is Smaller than Setpoint Options

If the desired sensor range is smaller than one of the available setpoint options, extrapolation may be used to
support the desired sensor. For example, for a 0-3V temperature sensor reads -30°C to 120°C, the only range that
includes all of 0-3V is 0-5V. The 0-5V range should be used. The range between 3V and 5V will simply never be
used. To make the data accurate, set the Minimum Data Range to -30°C, and determine the Maximum Data Range
mathematically. See Figure 9.2.

Figure 9.2 – Mathematical Extrapolation of Maximum Data Range

The Maximum Data Range can be found graphically or algebraically. In this example, the Maximum Data Range
would be defined by the equation of the line after the slope is determined. Since the data rises by 50 degrees for
every volt, increasing two volts above the three volt limit requires the maximum range to be 100 degrees above the
sensor limit of 120 degrees, or 220 degrees total. See Figure 9.3.

Figure 9.3 – Example Calculation for Extrapolation of Maximum Data Range

56 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Analog Inputs

9.3.4 Sensor Range is Larger than Setpoint Options, but Usable Range is Not
If the desired sensor range is larger than one of the available setpoint options, but the useful range for the sensor
is within the supported ranges, then interpolation may be used to support the desired sensor. For example, for a
0-6V temperature sensor that reads -40°C to 500°C, the EMCP 4 will not support the analog voltages higher than
5V. However, as long as the sensor will not exceed 5V, the 0-5V range may be used. To make the data accurate,
set the Minimum Data Range to -40°C, and determine the Maximum Data Range mathematically. See Figure 9.4.

Figure 9.4 – Mathematical Interpolation of Maximum Data Range

The Maximum Data Range can be found graphically or algebraically. In this example, the Maximum Data Range
would be defined by the equation of the line after the slope is determined. Since the data rises by 90 degrees for
every volt, decreasing one volt below the six volt limit requires the maximum range to be 90 degrees below the
sensor limit of 500 degrees, or 410 degrees total. See Figure 9.5.

Figure 9.5 – Example Calculation for Interpolation of Maximum Data Range

9.3.5 Sensor Range is Larger than Setpoint Options, and Usable Range is Larger than
Setpoint Options
If the desired sensor range is larger than one of the available setpoint options, and the useful range for the sensor
is outside of the supported ranges, a third party device is required to convert the signal range into a supported
range. See Figure 9.6.

Figure 9.6 – Signal Conversion of Sensor Range

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Digital Outputs

10.0 Digital Outputs

The EMCP 4.4 supports 17 programmable discrete sourcing outputs capable of driving 200mA per channel. The
voltage of these outputs will be the source voltage to the EMCP 4 plus a voltage drop of ~1 VDC. The common
signal is Battery (-). Each of these outputs are wired to a slimline relay.

The EMCP 4.4 SCP additionally supports two dedicated discrete outputs used for the failsafe starting signal. One
of these outputs is sourcing (FMR), while the other output is sinking (PRR).

Outputs can be configured by using the EMCP 4 display or using Cat ET. The programming of the Digital Outputs
starts by selecting a “Usage Type.“ The rest of the programming is dependent upon what Usage Type is selected.
Figure 10.1 summarizes the paths possible for Programming a Digital Output.

Note: If the Engine Operating State is configured as Hardwired, Digital Output #1 must be programmed to Starter
Motor Relay.

Usage Type
Disabled
Command/Status Status Type List of Values
System Event
SCADA Data Link Event Parameter List of Values
Event Trigger
List of Values

Figure 10.1 – Digital Output Programming Paths

10.1 Programming Digital Outputs Using the Display

10.1.1 Viewing the Current Digital Output Status
To view the current status of an Output, go through the following menu options: Main Menu/View/”I/O Status”/
Digital Outputs.

10.1.2 Configuring Digital Outputs for Status Parameters

Command or Status parameters are used to control specific functions within the control system or to make certain
conditions within the system be known.

To configure a Digital Output as a Status Parameter, go through the following menu options:

58 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Digital Outputs

Any Output can be configured for any one of the COMMAND/Status parameters in Table 10.1:

COMMAND/Status Parameters
Add Load Step # 1 Add Load Step # 16
Add Load Step # 2 Common Alarm
Add Load Step # 3 Run Mode
Add Load Step # 4 Auto Mode
Add Load Step # 5 Stop Mode
Add Load Step # 6 Transfer Fuel In
Add Load Step # 7 Transfer Fuel Out
Add Load Step # 8 Common Warning
Add Load Step # 9 Common Shutdown
Add Load Step # 10 Programmable Cycle Timer Output #2
Add Load Step # 11 Horn Control
Add Load Step # 12 ECU Fault Reset
Add Load Step # 13 Breaker #1 Trip*
Add Load Step # 14 Package Not In Auto
Add Load Step # 15

Table 10.1 – Output Command/Status List

*This output does not control a circuit breaker unless the user makes the connections to do so. This output type
should be viewed as having a generic name because the name does not necessarily imply the action that is
performed.

10.1.3 Digital/Relay Output Status Descriptions

Below is a brief description of the purpose of each command/status digital/relay output option:
Add Load Step #N
• Activates when the EMCP 4.4 SCP activates Load Step #N.
Run Mode
• Activates when the EMCP is placed in RUN mode (such as when the ‘Run’ button is pressed). Matches the state
of ECS LED on the EMCP.
Auto Mode
• Activates when the EMCP is placed in AUTO mode (such as when the ‘Auto’ button is pressed). Matches the
state of ECS LED on the EMCP.

Stop Mode
• Activates when the EMCP is placed in STOP mode (such as when the ‘Stop’ button is pressed). Matches the
state of ECS LED on the EMCP.
Package Not In Auto
• Activates when conditions are present that prevent the EMCP from operating in AUTO mode (such as engine
control switch not in auto, engine not in Rated mode, shutdown red lamp is active).

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Horn Control
• Activates when a horn alert is sounding. Typically occurs when any event configured with an audible alert
event response is PRESENT or ACTIVE and unacknowledged.
Common Warning
• Activates when any warning is PRESENT in the event log (regardless of source).
Common Shutdown
• Activates when any shutdown is PRESENT or ACTIVE in the event log (regardless of source).
ECU Fault Reset
• Activates for a configurable period of time when a Reset All Events command is issued. Typically only used to
interface to legacy engines.
Programmable Cycle Timer Output #2
• Activates for the duration of the Programmable Cycle Timer #N Active Time as configured in the Programmable
Cycle Timer feature (refer to Chapter 16).
Common Alarm
• Activates when any shutdown is PRESENT or ACTIVE in the event log or any warning is PRESENT in the event
log (regardless of source).
Breaker #1 Trip
• Activates when any event configured with a Breaker #1 Trip event response is PRESENT or ACTIVE. Note:
EMCP 4.4 uses Breaker #1 for the Generator Set Breaker.
Reduced Power Off
• Activates when the EMCP is NOT in reduced power mode (Useful for placing other controls in a reduced power
mode when the EMCP is in Reduced Power Mode).
Transfer Fuel In
• Activates when manual or automatic fuel loading is initiated.
Transfer Fuel Out
• Activates when manual or automatic fuel unloading is initiated. (Not available on standard software)

10.1.4 Digital Outputs for System Events

System Events are used to know when specific conditions are reached and to alert the control system of warning
or shutdown conditions. For detailed instructions on the process of configuring a digital output as a system event,
refer to LEBE0007.

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 Digital Outputs

Any Output can be configured for any one of the System Events in Table 10.2:
System Events
Levels Others
Fuel Level Any Suspect Parameter Number Digital Input #1 Custom Event
External Tank Fuel Level Accessory Data Link Digital Input #2 Custom Event
Battery Charging System Voltage Digital Input #3 Custom Event
Battery Voltage Digital Input #4 Custom Event
Emergency Stop Switch Digital Input #5 Custom Event
Generator Control Not in Automatic Digital Input #6 Custom Event
Primary Data Link Digital Input #7 Custom Event
SCADA Data Link Digital Input #8 Custom Event
Battery Charger Failure Isolated Dig Input #1 Custom
Isolated Dig Input #2 Custom
Isolated Dig Input #3 Custom
Isolated Dig Input #4 Custom
Analog Input #1 Custom Event
Analog Input #2 Custom Event
Analog Input #3 Custom Event
Analog Input #4 Custom Event
Table 10.2 – Output System Events
Care must be taken in configuring the correct triggers. Only some of these parameters can be configured for a
specific System Event and even if it can be configured, it may not be representative of the system requirements.
Output system event trigger conditions are listed in Table 10.3 below.
Category SPN Suspect Parameter Supported FMI Trigger Conditions
96 Fuel Level 0, 1, 15, 17
Levels
38 External Tank Fuel Level 0, 1, 15, 17
n/a Any Suspect Parameter Number n/a
1231 Accessory Data Link 11
167 Battery Charging System Voltage 17
168 Battery Voltage 0, 15, 17
Others
4007 Control Not in Automatic 31
639 Primary Data Link 11
3581 SCADA Data Link 11
4003 Battery Charger Failure 31
701 Digital Input #1 Custom Event 31
702 Digital Input #2 Custom Event 31
703 Digital Input #3 Custom Event 31
704 Digital Input #4 Custom Event 31
705 Digital Input #5 Custom Event 31
706 Digital Input #6 Custom Event 31
707 Digital Input #7 Custom Event 31
708 Digital Input #8 Custom Event 31
709 Isolated Digital Input #1 Custom Event 31
710 Isolated Digital Input #1 Custom Event 31
711 Isolated Digital Input #1 Custom Event 31
712 Isolated Digital Input #1 Custom Event 31
1083 Analog Input #1 Custom Parameter 0, 1, 6, 15, 17
1084 Analog Input #2 Custom Parameter 0, 1, 6, 15, 17
4158 Analog Input #3 Custom Parameter 0, 1, 6, 15, 17
4157 Analog Input #4 Custom Parameter 0, 1, 6, 15, 17
Table 10.3 – Supported Output System Event SPN and FMI Trigger Conditions

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Digital Outputs

10.1.5 Digital/Relay Output System Event Descriptions

Below is a brief description of the purpose of each system event digital/relay output option:

Engine Fuel Level

• Activates when an engine fuel level event (SPN 96) is triggered in the EMCP event log.
External Fuel Level
• Activates when an external fuel level event (SPN 38) is triggered in the EMCP event log.
Any Suspect Parameter Number
• Activates when any suspect parameter number is triggered in the EMCP event log.
Battery Charging System Voltage
• Activates when a battery charging system voltage event (SPN-FMI: 167-17) is triggered in the EMCP event log.
Battery Voltage
• Activates when a battery voltage event (SPN 168) is triggered in the EMCP event log.
Control Not In Automatic
• Activates when a control not in auto event (SPN 4007) is triggered in the EMCP event log.
Primary Data Link
• Activates when a primary data link diagnostic (SPN 639) is triggered in the EMCP event log.
Accessory Data Link
• Activates when an accessory data link diagnostic (SPN 1231) is triggered in the EMCP event log. This is not
used with a Supervisory Control Panel.
SCADA Data Link
• Activates when a SCADA data link diagnostic (SPN 3581) is triggered in the EMCP event log.
Emergency Stop (Auxiliary Engine Shutdown Switch)
• Activates when an emergency stop event (SPN 970) is triggered in the EMCP event log.
Battery Charger Failure
• Activates when a battery charger failure event (SPN 4003) is triggered in the EMCP event log.
Digital Input #N Custom Event
• Activates when a digital input #N custom event (SPN 701 to 712) is triggered in the EMCP event log.
Analog Input #N Custom Event
• Activates when an analog input #N custom event (SPN 1083, 1084, 4158, 4157) is triggered in the EMCP event log.

10.1.6 Configuring Digital Outputs for SCADA Data Link

When a Digital Output is configured for SCADA Data Link, an active state will be sent to the output over MODBUS
communications. No alarms or warnings will be generated by the EMCP. For further detail, see LEBE0007.

10.1.7 Disabling Digital Outputs

Each Digital Output can be disabled via the service tool or the display. When an output is disabled, the I/O
Status screen will reflect a “X” symbol. This allows easy identification of unused digital outputs. For further detail,
see LEBE0007.

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 Analog Outputs

11.0 Analog Outputs

The EMCP 4.4 supports three 2-wire (plus shield) fully individually isolated Analog Output channels (individually
switchable for 0 to 20mA current) or analog voltage -10 to 0 to +10VDC. These outputs are NOT wired out as part
of the Supervisory Control Panel design.
Full resolution, with a minimum of 8 bits (256 points) of data, is supported -10 to +10VDC, -3 to +3VDC, 0-5VDC,
along with equivalent current ranges (0 to 20mA).
Configurable Analog Outputs can be configured to two different types: voltage or current. The hardware
limitations are: -10V to +10V for voltage, 0 to 20mA for current. Refer to Table 11.1 for the valid configuration
ranges.

Current Sender Ranges Voltage Sender Ranges

0 to 20mA 0 to 5V
4 to 20mA 1 to 5V
0 to 10mA 0 to 10V
-3 to +3V
-2.5 to +2.5V
-5 to +5V
-10 to +10V
0.5 to 4.5V
-1 to +1V

Table 11.1 – Analog Output Configuration Ranges

11.1 Programming Analog Outputs

11.1.1 Viewing the Current Analog Output Status
To view the current status of an Analog Output, go through the following menu options:
MAIN MENU/VIEW/”I/O STATUS”/ANALOG OUTPUTS

11.1.2 Configuring Analog Outputs

Each analog output can be configured for voltage, current, or disabled. For further details on how to configure each
analog output, refer to LEBE0007.
Any Analog Output can be configured for any one of the Data Identifications in Table 11.2:

Data Identifications
CUSTOM PARAMETER #1 OUTPUT FROM SCADA
CUSTOM PARAMETER #2 ENGINE FUEL LEVEL
CUSTOM PARAMETER #3 EXTERNAL TANK FUEL LEVEL
CUSTOM PARAMETER #4
Table 11.2 – Analog Output Data Identifications List

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PWM Outputs

12.0 PWM Outputs

The EMCP 4.4 supports two 2-wire (plus shield) fully individually isolated analog PWM output channels.

The PWM outputs can be configured for one of two different ranges: 0 to 100%, or 5 to 95%. The data range is
configurable and should be set to the generator voltage. The output signal is ~6V peak.

12.1 Programming PWM Outputs Using the Display

12.1.1 Viewing the Current PWM Output Status
To view the current status of a PWM Output, go through the following menu options:
MAIN MENU/VIEW/”I/O STATUS”/PWM OUTPUTS:

12.1.2 Configuring PWM Outputs

Each PWM output can be configured for PWM, or disabled. For further details on how to configure each PWM
output, refer to LEBE0007.

Any PWM Output can be configured for any one of the Data Identifications in Table 12.1.

Data Identifications
CUSTOM PARAMETER #1 OUTPUT FROM SCADA
CUSTOM PARAMETER #2 ENGINE FUEL LEVEL
CUSTOM PARAMETER #3 EXTERNAL TANK FUEL LEVEL
CUSTOM PARAMETER #4

Table 12.1 – PWM Output Data Identifications List

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 Load Add and Load Shed

13.0 Load Add and Load Shed

Load Add and Load Shed are complementary features that work together to add and shed loads while the
EMCP 4.4 Supervisory Control Panel is running.

13.1 Supervisory Load Add

13.1.1 Purpose
The Load Add feature on the EMCP 4.4 SCP will automatically add loads in a priority-based manner (up to 16 levels
via digital outputs) when the generating capacity of the system is sufficient to power all connected loads.

13.1.2 Function
The Load Add feature consists of an initial Conditional Load Add period follow by a Load Sensitive Load Add period
when the Conditional Load Add Timer expires. The Supervisory Control Panel can be configured to add or remove
all loads when the SCP does NOT have a RUN signal.

13.1.2.1 Conditional Load Add

Conditional Load Add Timer = (Load Sense Load Demand Enable Minimum Delay Time (setpoint) – (1 Minute)

The conditional load add timer starts when a unit detects bus voltage (same as with the LSLD settling timer). The
conditional load add timer is still used even if load sense load demand is disabled on the generator sets based on
the last setting of the timer.

Note: This is a system level setpoint, so when changed on any individual control, it is sent to all controls on the
network. Load adding is expected to occur along-side LSLD. While we expect to sequence on all available
(and required) generator sets fairly quickly, the EMCP 4.4 Supervisory Control Panel does not need to wait
for all available generator sets to have synchronized onto the bus before it start to add loads.

Priority
All load steps are added based on priority with the highest priority (first to add) being the lowest number. Priorities
are assigned using load add priority for load step N (setpoint). If multiple load add steps are programmed to the
same priority, the lower number load step has priority over the higher number load step. While it is NOT required,
it is recommended that each step be programmed for the matching priority. The following calculations are based
on both the priority and load step, such that the required available genset kW is based on a single step even if
multiple steps have the same priority.

Load add generator supplied maximum load step priority number (setpoint) – priority numbers beyond the
programmed value will only be activated if utility return transition load configuration is set to ADD ALL and the SCP
does not have a RUN signal. The standard load add/shed functionality will only use the priorities based on this
number and numerically below.

Calculations for both kW and kVAr

Discussion below only describes the algorithm for kW. However both kW and kVAr capacity requirements must be
met before we attempt to add a load step.
• Available Genset kW = [Sum of all rated generator sets on common bus (this is all generator sets on MGDL)] *
[Load Add Maximum Generator System Percentage (setpoint)]
• C
 apacity Headroom (kW) = [Available Genset kW] – [Sum of applied Load Add kW Load Steps (Load Add Rated
Real Power for Load Step N, N+1, N+2…(setpoint)] OR
• Capacity Headroom (kW) = [Available Genset kW] – [Actual Load on the bus], whichever value is LESS

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Load Add and Load Shed

Adding a Load Step

A load step is added if all the following is TRUE:
1. Capacity headroom is greater than the load step rating of the load step (both kW and kVAr)
2. The load add minimum generator load step time delay (setpoint) (triggered for the previous load step added) has
expired
3. The load shed latch enable for load step N (setpoint) is not enabled for that load step (see Supervisory Control
Load Shed doc).
4. Load add priority for load step n (setpoint) number <= load add generator supplied maximum load step priority
number

Load Step Time Delay

The load add minimum generator load step time delay starts to time as soon as any load step is added. Even if
capacity is such that two or more load steps can be applied at the same time, this minimum delay is still enforced
between successive non-zero load add steps. If the load step is defined as rated 0 kW and 0 kVAr, this time is not
applied and the load step may be added immediately after the previous.

Note: For load steps above load add generator supplied maximum load step priority number (setpoint), there is a
load add minimum utility load step time delay (setpoint) that should be used instead.

Once the load add minimum generator load step time delay starts to time, a timer starts against the load add
duration for load step N (setpoint) time in order to keep track of its expiration when conditional load add is ended
and we transition to load sensitive load add. The load add duration for load step N time is not used to space out
loads during the conditional load add.

Note: Anytime the load shed timers are timing, all Load Add timers are paused. Anytime a Load Step is shed, all
load add timers are reset.

13.1.2.2 Load Sensitive Load Add

Load sensitive load add is active when the conditional load add timer expires and when a load add duration for
load step N time (that started while the conditional load add period was still active) expires.

Priority
(Same as mentioned above in the conditional load add.)

Calculations for both kW and kVAr

Discussion below only describes the algorithm for kW. However, both kW and kVAr capacity requirements must be
met before we attempt to add a load step.
• (Same as mentioned above in the Conditional Load Add)
Available Genset kW = [Sum of all rated generator sets on common bus] * [Load add maximum generator
system percentage (setpoint)]
• (Different than mentioned above in the conditional load add)
Capacity headroom (kw) = [available genset kw] – [actual load on the bus] – [any load add rated real power for
load step N (setpoint)] with its load add duration for load step N timer running.

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 Load Add and Load Shed

Adding a Load Step

(Same as mentioned in the conditional load add.)

Load Step Time Delay

(Same as mentioned in the conditional load add.)

Manual Load Control

Manual load control is done via display only. The display has a screen that allows users to manually select
(inactive/not added) load steps to be added, and (active/already added) load steps to be shed. A user can select to
add load steps beyond the current available system capacity. However, when a load step is added (automatically
or manually) and the load shed threshold conditions are satisfied, EMCP 4.4 SCP will still shed that load step. Load
steps will be latched or unlatched based on each steps setpoint. Any step that is latched stays inactive unless
unlatched by one of the methods specified below.

Methods for unlatching/ reset of a latched load step:

1. That latched load step is manually reset via the soft key on the “Manual Control” display screen.
A single-key press of the reset latch soft key will only reset the lowest latched priority number, i.e. one key
press/latched load priority.
2. That latched load step is manually add via the soft key on the “Manual Control” display screen.
A single key press of the Add Load Step soft key will only add the next priority number, i.e. one key press /
latched load priority.
3. Activation of a digital input programmed for “Load Shed Reset Command.”
4. Removal of RUN signal.
5. User configures the load step latch enable for load step “N” to disable and then back to enabled.
6. Power cycle of the EMCP 4.4 Supervisory controller.

Failure Modes
Upon loss of all MGDL communication, load levels shall be automatically added based upon the generator sets that
met “MGLD Package in Auto” status before loss of communications.

A generator set is considered to have “MGDL Package in Auto” status if the following conditions are TRUE:
1. Engine Control Switch Status (global) = AUTO and
2. Sync Mode Switch (global) = AUTO and
3. Idle/Rated (global) = RATED and
4. No active Shutdown Events and
5. Following Warnings Events = FALSE:
a. Not Ready to Automatically Parallel Warning (event)
b. Generator to Bus Synchronization Failure Warning (event)

Of the units that meet “MGDL Package in Auto” status AND have not closed to the bus, the supervisory control
assumes that the order in which the units close to the bus will be from smallest rated unit to the largest rated unit.

Loads will be added based on assuming the first non-viewable generator set reaches the bus 10 seconds after the
start signal or loss of utility is received. Each additional non-viewable generator set will be assumed to reach the
bus 10 seconds after the previous generator set.

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Load Add and Load Shed

Load steps are added (still based on priority) with the load add minimum generator load step delay time, up to
the assumed capacity headroom (see below). Additional loads can be added manually via display. Loads added
manually may go beyond the calculated assumed capacity headroom.

Supervisory Control Loses all MGDL Communication:

Load steps are added based upon the generator sets that met “Package in Auto” status before loss of
communications. Conditions under load sensitive load add will no longer be applied.
• Assumed Available Genset kW = [Sum of all rated generator sets (assumed to be online already and ones that
will be online (this logic needs to take into consideration of generator sets becoming available every 10s)] – [the
largest non-viewable rated unit]
• Assumed Capacity Headroom = [Sum of all rated generator sets (assumed to be online)]

Supervisory Control Loses Partial MGDL Communication

1. I f the supervisory control is still communicating with at least one unit from the majority group, loads are added
based on the load sensitive load add calculations (below) and on the information being communicated by the
generator sets that are still online. The supervisory control assumes that the units that are not online, but have
“MGDL Package in Auto” status prior to loss of communication, are added in the order of smallest rating to
largest rating with a 10 second delay between generator sets (excluding the largest non-viewable unit). (When
calculating the available genset and capacity headroom, the EMCP 4.4 SCP include all generator sets prior to
loosing communications and add load steps up to that capacity (prior to loosing communications). The 10s for
assumed generator sets in our calculations can also be started as soon as loss of communications occurs.)
• A
 ssumed available genset kW = [Sum of all rated generator sets (includes those assumed online)] * [Load add
maximum generator system percentage (setpoint)]
• A
 ssumed capacity headroom (kw) = [available genset kw (includes those assumed online)] – [Actual Load on
the bus] – [any load add rated real power for load step N (setpoint)] with its load add duration for load step N
timer running.
2. If the supervisory control is communication with unit(s) from the minority group, loads are added based on the
following:
• A
 ssumed available genset kW = [Sum of all rated generator sets (online and assumed to be online)] – [the
largest non-viewable rated unit] OR
• [ Sum of all rated generator sets (online and assumed to be online)] * [Load Add Maximum Generator System
Percentage (setpoint)]
Whichever has the LARGER value.
• A
 ssumed Capacity Headroom = [Sum of all rated generator sets (that are online and assumed to be online)
that have closed to the bus]. Conditional Load add will be based on the timer and the assumed units that are
coming. Load sensitive load add needs to continue to add load based on communicated headroom, but does
not assume there is headroom on the units that aren’t being communicated to.

Loss of Group Go/Run

If the EMCP 4.4 SCP run or group go signal becomes inactive, the EMCP 4.4 SCP will transition back to non running
mode and will add or shed all load steps based on the selection from the load add/load shed utility only mode
configuration (utility return transition load configuration) (setpoint).
• Add all load steps
• Shed all load steps

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 Load Add and Load Shed

Load steps are still added and shed based on priority number. When the setpoint is configured for “Add All Load
Steps,” the load add minimum utility load step time delay will be used to add successive load steps. When the
setpoint is configured for “Shed All Load Steps,” all loads are shed at once.

Setpoints
Digital Output #NN Command/Status Parameter Data Identification

Load Add Rated Real Power for Load Step #N

Min = 0, Max = 65503
Resolution = 1 kW

Load Add Rated Reactive Power for Load Step <index>

Min = 0, Max = 65503
Resolution = 1 kVAr

Load Add Priority for Load Step <Index>

Min = 0, Max = 16
Resolution = 1
It is recommended that priority and Load Step match for easier understanding.

Load Add Duration for Load Step <Index>

Min = 0, Max = 6550
Resolution = 1 sec

Load Add Generator Supplied Maximum load Step Priority Number

Min = 0, Max = 16
Resolution = 1

Load Add Maximum Generator System Percentage

Min = 50%, Max = 110%
Resolution = 1%

Load Add Minimum Generator Load Step Time Delay

Min = 0.0, Max = 60.0
Resolution = 0.1 sec

Load Add Minimum Utility Load Step Time Delay

Min = 0.0, Max = 60.0
Resolution = 0.1 sec

Utility Return Transition Load Configuration

Add all load steps
Shed all load steps

Load Shed Latch Enable

If the Load Shed Latch Enable for Load Step N is set to Enabled, then once that Load step is shed, that load step
along with subsequent load step will not be allow to be re-added until it is reset.

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Status Events
The following status events are supported by the Load Add feature.

Load Sensitive Load Active

Conditional Load Active
Add Priority 1 Load
Add Priority 2 Load
Add Priority 3 Load
Add Priority 4 Load
Add Priority 5 Load
Add Priority 6 Load
Add Priority 7 Load
Add Priority 8 Load
Add Priority 9 Load
Add Priority 10 Load
Add Priority 11 Load
Add Priority 12 Load
Add Priority 13 Load
Add Priority 14 Load
Add Priority 15 Load
Add Priority 16 Load

Display Screens

“Page Right” – shows the next set of 8 units and “Page Left” would be shown in F3 of that screen.

(Deep Dive into Load Priority Detail)

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 Load Add and Load Shed

[Load Bus Control Screen]

[Manual Load Control Screens]

A padlock indicates a latched load step priority.
• (Line 1) Padlock shall appear on the load bus graphic for any load step that is latched.

A reset latched load step will be shown as an inactive load step. A single button press of the reset latch will reset
the current lowest priority numbered latched step. Therefore holding the reset latch button will not reset more than
a single latched load step. User can manually shed a load step currently being added and manually add a load step
that is currently being shed.

Custom Text Strings

Custom text associated with each load step will provide a short one line description of each load step on the
display. This is helpful both in seeing which load step is about to come on and when assigning priority to each load
step. Custom text strings shall use the same modifiable text strings feature structure used today for digital/analog
input custom text strings.

The Custom text string (if programmed) will appear on the “Load Bus Overview-> Load Step Priority #NN” deep
dive screen (Line 1) centered on the screen as shown in previous screen mock up. If user did not provide a custom
text string, the text that appears on Line 1 of the deep dive screen should be “Load Step #xx” where xx = the load
step number on Line 5

13.2 Supervisory Load Shed

13.2.1 Purpose
The load shed feature on the EMCP 4.4 SCP will automatically take loads offline based on priority if the available
generator sets capacity is not sufficient to power all connected loads. This feature works in conjunction with the
Load Add feature.

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13.2.2 Function
When the generator sets system percent kW or percent kVAr load exceeds the appropriate Load Shed threshold
setpoint, the associated Load Shed timer will begin to time. If the generator sets system percentage drops below
the threshold, the timer is not immediately reset, but it will count backwards towards zero. If the Load Shed timer
expires we shed the last load step that was added. If the rated real or reactive power of a particular Load Step
was defined as 0% kW and 0% kVAr, the Supervisory Control should shed the next load until a non-zero defined
load is shed.

Load Shed Timers

Anytime the load shed timers are timing, all load add timers are paused. Anytime a load step is shed, all load
add and load shed timers are reset. The load shed timers begin timing as long as they meet their appropriate
threshold (setpoints) and conditions as specified below.

Load Shed Delay Time (setpoint)

There are separate timers (with same setpoint value) for load shed real power percentage threshold (setpoint)
and for load shed reactive power percentage threshold (setpoint).

Load Shed Fast Shed Delay Time (setpoint)

There are separate timers (with same setpoint value) for load shed fast shed real power percentage threshold
(setpoint) and for load shed fats shed reactive power percentage threshold (setpoint).

Load Shed System Overload Load Shed Delay Time (setpoint)

If a bus under frequency warning OR a bus under voltage warning event is triggered, then the last (non-zero load
step) that was added is instantly shed (without time delay).

If either warning is still present after shedding the load step, and the “rate of change of bus voltage” shows
that bus voltage is not increasing, or if the “rate of change of bus frequency” shows that bus frequency is not
increasing, the EMCP 4.4 SCP sheds an additional load step every load shed system overload load shed delay
time (setpoint).

Note: Any load steps shed during load shed system overload conditions will be latched regardless of load step
latch enable for load step N setpoint configuration.

Example:
Loads that are shed as a result of bus under voltage or bus under frequency are not independent.

If Load Shed System Overload Load Shed Delay Time = 0.5s

• T = 0 A bus under voltage warning is present and shed a load step
• T = 0.2 seconds we have a bus under frequency (we will not shed another load step until T = 0.5)
• T = 0.5 If ( [(bus under frequency warning is present) AND (rate of change of frequency is NOT moving in a
positive direction)] OR [(bus under voltage warning is present) AND (rate of change of voltage is NOT moving in
a positive direction)] ), we shed another load step
• T = 1.0 If the previous condition is still true we shed another load step.

In the previous example, we assume that the Load Shed Delay Time (setpoint) and the Load Shed Fast Shed Delay
Time (setpoint) values are set larger than the Load Shed System Overload Load Shed Delay Time (setpoint).

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 Load Add and Load Shed

A bus under frequency warning event or bus under voltage warning event is triggered when the appropriate
threshold and delay times are met:
• Bus under frequency warning event percentage threshold
• Bus under frequency warning event delay time
• Bus under voltage warning event percentage threshold
• Bus under voltage warning event delay time

These are based on the nominal and warning setpoints programmed in the EMCP 4.4 SCP.

Load Step Latch

A latched load priority (step) is represented by a padlock, instead of an arrow, on display.

The Load Step Latch Enable for Load Step N (setpoint) is used to latch out a load step (and subsequent higher
priority numbered load steps) that has been shed. This means that if the setpoint is enabled for a load step, the
load step can be added one time onto the bus but if the load step is shed, then it cannot be re-added onto the bus.
Any load steps shed on the display manual Control screen or during a failsafe or system overload condition will
also be latched and cannot be re-added until the system recovers back to normal and unlatched by one of the
following methods.

Methods for unlatching/reset of a latched load step:

1. That latched load step is manually reset via the soft key on the “Manual Control” display screen.
A single key press of the reset latch soft key will only reset the lowest latched priority number, i.e. one key
press/latched load priority.
2. That latched load step is manually add via the soft key on the “Manual Control” display screen.
A single key press of the add load step soft key will only add the next priority number, i.e. one key press/
latched load priority.
3. Activation of a digital input programmed for “Load Shed Reset Command.”
4. Removal of RUN signal.
5. User Configures the load step latch enable for load step “N” to disable and then back to enabled.
6. Power cycle of the EMCP 4.4 supervisory controller.

Manual Load Control

Manual load control is done via display only. The display has a screen that allows users to manually select
(inactive/not added) load steps to be added, and (active/already added) load steps to be shed. A user can
select to add load steps beyond the current available system capacity. However, when a load step is added
(automatically or manually) and the load shed threshold conditions are satisfied, EMCP 4.4 SCP will still shed that
load step.

As stated under the load step latch conditions, a latched load can be reset via a “Reset” selection on the manual
load control display screen, or by user selecting to add the latched load step.

Load add and shed timers should continue to run (count down if displayed) while user is on the manual load
control screen.

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Failure Mode
Upon loss of all MGDL communication, load shed will NOT be functional.

Upon partial loss of MGDL communications while sustaining communication with at least one online majority
group generator set, kW and kVAr based load shed will continue to function based on the information being
communicated by online generator sets and units assumed to be online. Frequency and voltage based load shed
will be based at 1.5 * Z, the amount of voltage and frequency droop (“Z” = 3% droop for kW and 6% droop for
kVAr). Any load step that is shed will be latched regardless of its load shed latch enable for load step <Index>
setpoint configuration.

Loads that are shed during failsafe will remain latched until the supervisory control no longer detects failsafe
mode (i.e. system is back to normal mode). Shed loads that are latched during failsafe can be re-added if any of
the above conditions for unlatching latched loads are met.

Loss of Group Go/Run

If the EMCP 4.4 SCP run or group go signal becomes inactive, the EMCP 4.4 SCP will transition back to utility only
mode and will (continue to) add or shed all load steps based on the selection from the (utility return transition
load configuration) (setpoint).
• Add all load steps
• Shed all load steps

Setpoints
Number of available load steps
Min = 0, Max = 16
Resolution = 1

Load Shed Real Power Percentage Threshold

Min = 50%, Max = 125%
Resolution = 0.1 % kW

Load Shed Reactive Power Percentage Threshold

Min = 50%, Max = 125%
Resolution = 0.1 % kVAr

Load Shed Delay Time

Min = 0, Max = 6550
Resolution = 1 sec

Load Shed Fast Shed Real Power Percentage Threshold

Min = 60%, Max = 150%
Resolution = 0.1 % kW

Load Shed Fast Shed Reactive Power Percentage Threshold

Min = 60%, Max = 150%
Resolution = 0.1 % kVAr

Load Shed Fast Shed Delay Time

Min = 0.0, Max = 300.0
Resolution = 0.1 sec

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 Load Add and Load Shed

Load Shed System Overload Load Shed Time Delay

Min = 0.0, Max = 10.0
Resolution = 0.1 sec

Status Events
The following status events are supported by the load shed feature.
Shed Priority 1 Load
Shed Priority 2 Load
Shed Priority 3 Load
Shed Priority 4 Load
Shed Priority 5 Load
Shed Priority 6 Load
Shed Priority 7 Load
Shed Priority 8 Load
Shed Priority 9 Load
Shed Priority 10 Load
Shed Priority 11 Load
Shed Priority 12 Load
Shed Priority 13 Load
Shed Priority 14 Load
Shed Priority 15 Load
Shed Priority 16 Load

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Modifiable Text Strings

14.0 Modifiable Text Strings

The EMCP 4.4 support the renaming of digital input custom events for the event log and analog input custom
parameters for monitoring the event log, along with naming of each individual load step. This feature is called
MODIFIABLE TEXT STRINGS. This is useful when an existing SPN and text string do not exist for the required
event or parameter. These events/parameters can be configured and triggered similar to other events/
parameters. However, these events/parameters are unique in that their displayed text strings can be customized
via the Cat Service Tool using any character in the supported character set of the EMCP 4 software flash
file. Furthermore, the Cat Service Tool has the capability to upload a modifiable text strings configuration file
(containing previously saved custom event text strings) from the computer, or download a configuration from the
EMCP 4 to the computer.
In order to display a custom text string for an event, the following steps must be taken:
1. One of the digital inputs must be configured as a custom event with a failure mode identifier of status (or
condition exists). For more information on configuring Digital Inputs, see Section 8.1.7.
2. A custom string must be entered, using the modifiable text strings tool in the Cat Service Tool, as described in
Chapter 14.
3. The language must be set to the customer language, not to Technician English.

An example of entering a modifiable text string for Digital Input Custom Event #1 is given in Figure 14.1.

Figure 14.1 – Customizing a Text String With the Cat Service Tool

The MCP 4.4 supports one modifiable text string per custom event on each programmable digital input and a
modifiable text string per custom parameter and one per custom units on each programmable
analog input.

14.1 Language Support

The primary language for the EMCP 4 control will always be Technician English. The user will always be able to
revert back to Technician English from the selected language that is supported by the flash file. However, when
the EMCP 4 display is viewed in Technician English, the user will not be able to view the custom text strings and
will only be able to view the default strings (Custom Event #N) for a given input.

The EMCP 4 has the capability of supporting one flash file containing one secondary language at any particular
time. If the user is interested in having a new secondary language, a new flash file to configure the new language
must be installed. Therefore, the user is not able to install multiple flash files supporting different languages
simultaneously.

The EMCP 4 supports unicode characters from the English character set, as well as the character set from the
local language supported by the file. It is the user’s responsibility to install the preferred flash file with the correct
language support that will allow the modification of text strings.

76 EMC P 4.4 GEN ER ATOR S ET C ONTROL

 Modifiable Text Strings
The user is also responsible for choosing the appropriate operating system or unicode text entry system for the
chosen language. The Cat Service Tool software accepts input from the PC keyboard settings. If, for example, the
PC keyboard setting is for U.S. English, it may be difficult to enter Russian (or other non-English) characters.

Different language software supports different sets of characters. Therefore, modifiable text string configuration
files created in one language will not become translated if new language software is flashed into the
EMCP 4. The original text string will still show as originally entered, or it may not show correctly if the new
software language does not support all the characters in the original language.

14.2 Programming Modifiable Text Strings Using the Cat Service Tool
To configure a modifiable text string using the Cat Service Tool, go through the following menu options:

1. Connect the EMCP to the Cat Electronic Technician as described in Section 4.2.
Note: The service tool must be connected to CAN 1 and the EMCP must be selected during the connection if
multiple ECMs are present.

2. Select “Modifiable Strings” under “Service” from the choices at the top of the software screen.
Note: The modifiable text string parameter value’s field is initially blank until it is replaced with a custom text
string parameter value. The custom text string parameter value entered will replace the default strings.

3. Load the file from the ECM.

4. Modify the file as desired.

5. Save the file to the ECM.

6. If desired, also save an offline copy.

The user’s custom text strings are displayed in the user’s preferred language. If the service tool doesn’t support
the user’s preferred language, U.S. English will be used.

It is advisable to split the text across both lines if present even if it can fit on a single line since the default terms
will show if text has not been entered.

Note: The user must save any offline changes before attempting to connect the service tool to the EMCP 4, or the
changes will not be saved

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Saving and Restoring Setpoints

15.0 Saving and Restoring Setpoints

The EMCP 4 supports the saving and uploading of the EMCP 4 setpoints through a setpoint configuration file. This
file, called the ECM replacement file, or fleet replacement file, is accessible via the ECM replacement tool of the
Cat Service Tool software. The file contains information specific to the EMCP 4, and includes the setpoint values
that are specific to a given EMCP 4 module. The user has the option of saving the data to an ECM replacement
file from an EMCP 4 module or uploading the data from the ECM replacement file to another EMCP 4 module. The
user also has the option of uploading general configuration data to several EMCP 4 modules by means of a similar
tool called fleet configuration. Both of these options are accomplished through the Cat Service Tool software.
Note: This chapter only addresses setpoints residing in the EMCP 4. To save and restore setpoints for other
(optional) modules on the EMCP 4 CAN data links, a similar procedure must be followed for each individual
module.

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 Programmable Cycle Timer

16.0 Programmable Cycle Timer

The Programmable Cycle Timer (PCT) feature allows the operator to program seven independent times, when
tasks (called PCT Outputs), will be activated or deactivated automatically during the week. This is useful for
exercising generator sets, or cases where two or more generators are required to automatically share the duty of
supplying a load throughout the week.
Using the PCT, each generator set can be programmed to start and stop at pre-set times. The PCT is capable
of handling a seven day sequence with seven independent starts happening one or more times each week. The
timing of these start/stop cycles may be programmed in advance, either locally or via the service tool.
For example, if a standby set does not have access to a utility supply to power a trickle charger, the PCT can be
set for an hour a week to run the generator set to have the charging alternator help keep the battery charged.

Caution: External equipment such as a transfer switch is required to ensure that the generator sets are not
stopped on load.

The PCT FEATURE consists of seven independent timers; each timer has the following setpoints (setpoints shown
are for PCT #1):

PROGRAMMABLE CYCLE TIMER #1: Activation Day of the Week:

This permits independent selection of each day (Sun -> Sat) that the timer will activate. All seven days can be
selected, if desired.

PROGRAMMABLE CYCLE TIMER #1: Activation Start Time

The time of day (in hours and minutes) that the timer will activate. The time must be programmed using a
24-hour clock.

PROGRAMMABLE CYCLE TIMER #1: Active Time

The duration (in hours and minutes) for which the timer will be active (up to 24 hours).

PROGRAMMABLE CYCLE TIMER #1: Output #1 Activation Configuration

The Programmable Cycle Timer’s first output will be activated when this timer is active and will allow the
generator set to start if in Auto. This will not close the generator breaker.

PROGRAMMABLE CYCLE TIMER #1: Output #2 Activation Configuration

The Programmable Cycle Timer’s second output will be activated when this timer is active. Output # 2 can be
assigned to a programmable output for connection to an external device. This external device can be used to
control a load bank, transfer switch or other device.

PROGRAMMABLE CYCLE TIMER #1: Output #3 Activation Configuration (EMCP 4.4 only)
The Programmable Cycle Timer’s third output will be activated when this timer is active. The EMCP 4 will not
close the generator circuit breaker unless Output # 3 is configured and all other required conditions are met.
Output # 3 will signal the EMCP 4 controller to synchronize and close the generator circuit breaker if the Sync
Mode Switch (SMS) is in Auto, ECS is in Auto, and Hardwired Dead Bus Arbitration (HWDBA) is enabled (if a live
bus does not exist).

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Programmable Cycle Timer

The PCT has two internal outputs (three for EMCP 4.4); these should not be confused with the physical outputs
of the control. The outputs are connected internally to the control module. In the standard configuration, PCT
OUTPUT #1 is connected to an internal Remote Initiate command. OUTPUT #2 is customer configurable via a
discrete output. OUTPUT #3 is connected to breaker control. This allows the operator to configure a timed relay,
for external connectivity.

Note: The outputs of all seven timers are tied together in an “OR” fashion. This means that if any one, or more,
timer is activated, then any output will activate (depending on programming).

The status of each output is indicated by a 1, 0, or – in the PROG CYCLE column under #1 through #7.
See Figure 16.1.

A – Programmed to be TRUE at another time.

A DASH (–) means that this PCT is NOT programmed to activate this output.

Figure 16.1 – PCT Main Screen

• In Figure 16.1, PCT #1 is INACTIVE on Output #1. Outputs #2 and #3 are NOT enabled and will never activate, as
programmed.

• PCT #3 is ACTIVE on Output #1, and NOT enabled on Output #2. Output #3 is NOT enabled and will never
activate, as programmed.

• PCT #5 is NOT enabled and will never activate, as programmed, on Outputs #1 and #3. Output #2 is ACTIVE.

• PCT #2, PCT #4, PCT #6, and PCT #7 are DISABLED. They NEVER activate Output #1, Output #2, or Output #3, as
programmed.

• To select a specific Programmable Cycle Timer, use the LEFT and RIGHT buttons until the desired

PCT is within the selection box and then press the OK KEY .

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 Programmable Cycle Timer

16.1 Configuring the Programmable Cycle Timer Using the Display

To configure a Programmable Cycle Timer with the display, go through the following menu options:

1. At MAIN MENU, scroll down to CONTROL.

2. Press the OK KEY .

3. Scroll DOWN to PROG CYCLE TIMER.

4. Press the OK KEY .

5. The box surrounding the first column outlines the first of

seven timers.

6. Press the OK KEY to program this timer.

7. The box surrounding the first row outlines the day selection.

8. Press the OK KEY to select the day(s) for this timer.

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Programmable Cycle Timer

9. Use the UP and DOWN arrow keys along

with the LEFT and RIGHT arrow keys to select the

days that this timer will activate.

10. Press the OK KEY when done. To program Saturday,

continue scrolling down past Friday.

11. Scroll DOWN to select the START TIME.

12. Press the OK KEY .

13. Use the arrow keys to enter the START TIME.

14. Press the OK KEY when done.

15. Scroll DOWN to select the RUN FOR time.

16. Press the OK KEY .

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 Programmable Cycle Timer

17. Use the arrow keys to enter the RUN FOR time.

18. Press the OK KEY when done.

19. S
 croll DOWN to select the OUTPUT STATE for
Output #1.

20. Press the OK KEY .

21. Select the OUTPUT STATE that you want to program.

22. Press the OK KEY when done.

23. S
 croll DOWN to select the OUTPUT STATE for Output #2 and #3 to program with the same steps as
Output #1.

24. P
 ress the ESCAPE KEY to return to the Programmable

 ycle Timer main screen. Use the LEFT

C and RIGHT buttons to select the other timers and repeat the
above steps.

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Programmable Cycle Timer

16.2 C
 onfiguring the Programmable Cycle Timer Using the
Cat Service Tool
To configure a programmable cycle timer with the Cat Service Tool, go through the following menu options:

1. Connect to the EMCP 4 using the Cat Service Tool as stated in Section 4.2.

2. Select Programmable Cycle Timer on the left.

3. Double click the Programmable Cycle Timer #N Activation Day setpoint for a given day to change this value
from the drop down menu. Click the OK button to program.

4. Double click the Programmable Cycle Timer #N Activation Start Time setpoint to change this value. Click the OK
button to program.

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 Programmable Cycle Timer

5. Double click the Programmable Cycle Timer #N Active Time setpoint to change this value. Click the OK button
to program.

6. Double click the Programmable Cycle Timer #N Output #1 Active Configuration setpoint to change this value
from the drop down menu. Click the OK button to program.

7 .Double click the Programmable Cycle Timer #N Output #2 Active Configuration setpoint to change this value
from the drop down menu. Click the OK button to program.

8. Repeat the above steps to program additional timers.

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CAN Data Links

17.0 CAN Data Links

17.1 Primary CAN Data Link (CAN 1)
The Primary CAN data link is supported by all levels of the EMCP 4.

The Primary CAN data link for the EMCP 4 Supervisory Control Panel is used for programming and flashing of the
EMCP 4.4 control panel. Primary CAN wiring

The primary CAN communication wires are brought out of the EMCP 4 as part of the 120-pin connector. The pins,
as designated on the EMCP 4 connector, are shown in Table 17.1.

Primary CAN Communication Wires

Pin # Name Description
43 CAN 1 - Differential (-) for CAN
30 CAN 1 SH Shield for CAN
32 CAN 1 + Differential (+) for CAN

Table 17.1 – Primary CAN Data Link on the 120-pin EMCP 4 Connector

17.1.1 Network Topology

The physical topology of the CAN network used in the primary CAN data link is a bus topology, consisting of a
main trunk and small drops.

• The maximum allowable trunk length is 130 ft (40 m), and the maximum drop length is 3 ft (1 m).

• The CAN network requires a 120 Ohm termination resistor on the extreme ends of the main trunk.

17.2 Accessory CAN Data Link (CAN 2)

The accessory CAN data link is not used by the EMCP 4.4 Supervisory Control Panel.

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 Optional Modules

18.0 Optional Modules

The EMCP 4 Supervisor Control Panel does NOT support any optional modules.

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SCADA (Modbus) RS-485 Data Link

19.0 SCADA (Modbus) RS-485 Data Link

The SCADA Data Link or Modbus is supported on the EMCP 4.4.

The EMCP 4.4 have a SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) communications link between
the controller and a host device using the MODBUS protocol. The host device is able to remotely monitor or
control the genset package equipped with the EMCP 4 in much the same way an operator does from the panel.
• The host device connects to the EMCP GSC through an RS-485 SCADA data link (Modbus RTU, half duplex).
• The data is transmitted in a binary format over the serial connection.
• The host device acts as Modbus master, and the EMCP 4 acts as the Modbus slave, also called a REMOTE
TRANSMITTER UNIT (RTU).
• The host device initiates all communication, sending commands or requests for information to the EMCP 4.
• The EMCP 4 then takes action based on the query and/or sends a response to the query over Modbus.

Baud rates can be configured on the EMCP 4. Various data rates between 9600 bits/second (baud) and 57,600
bits/second are available. See the 19.2 Section for instructions.

Note: This port may be required to be used to communicate to BMS or other monitoring device. Only a single
device can be used with this port.

19.1 Wiring
SCADA COMMUNICATION wires are NOT brought out of the EMCP 4 SCP as part of the 120-pin connector since
Modbus TCP is available over Ethernet. The pins, as designated on the EMCP connector, are shown in Table 19.1

SCADA Pins on EMCP 120-pin Connector

Pin # Name Description
90 MODBUS – Optically isolated half-duplex differential (-) for Modbus
101 MODBUS Reference Half-duplex RS-485 Reference for Modbus
100 MODBUS + Optically isolated half-duplex differential (+) for Modbus

Table 19.1 – SCADA Pins on EMCP 70-pin Connector

MODBUS DATA TRANSMISSION over RS-485 is accomplished over a single-shielded twisted pair for differential
signaling with transmit and receive alternating over the same wire pair (MODBUS+ and MODBUS-). The
Reference (MODBUS REF) should be connected to the shield, to prevent ground loop currents.

• Figure 17.1 shows a possible wiring configuration to a RS-485 device.

• Figure 17.2 shows a possible wiring configuration to a RS-485 to RS-232 converter.

Note: See documentation of connected device to verify wiring configuration.

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 SCADA (Modbus) RS-485 Data Link

Figure 19.1 – Possible Wiring Configuration To An RS-485 Device

Figure 19.2 – Possible Wiring Configuration to an RS-485 to RS-232 Converter

19.2 Line Termination

Both ends of the Modbus lines (or the extreme ends of the trunk, for a multipoint network) should have
termination between MODBUS+ (B) and MODBUS- (A).

A 0.5W 150 Ohm resistor may be adequate.

If line polarization is implemented (see Software Configuration Section), a better choice is a 10 μF capacitor
(10V minimum) in series with a 0.25W 120 Ohm resistor.

A bias resistor may be used for line polarization. Line polarization is used to keep the network voltages at
well-defined levels during silent times to prevent potential false diagnostics and communication failures. This
bias resistor is different than a termination resistor. There should only be one device on the network with bias
resistors enabled to polarize the network.

Note: For more details on setting up a Modbus network over a serial line, please refer to RS-485 specifications
or Modbus specifications. See the Software Configuration Section for instructions on enabling line
polarization.

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19.3 Software Configuration

19.3.1 Configuring the SCADA Data Link Using the Display
The SCADA DATA LINK may require software configuration. The configuration parameters are accessible on the
EMCP 4 via the following menu options:

1. At MAIN MENU, scroll DOWN to CONFIGURE.

2. Press the OK KEY .

3. Scroll DOWN to ALL SETPOINTS.

4. Press the OK KEY .

5. Scroll DOWN to NETWORK.

6. Press the OK KEY .

7. Scroll DOWN to RS-485 SCADA DATA LINK.

8. Press the OK KEY .

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9. Press the OK KEY to edit the current SCADA DATA LINK

BAUD RATE.

Select the SCADA DATA LINK BAUD RATE that you want to program.

1. Press the OK KEY .

2. Scroll DOWN to SCADA DATA LINK PARITY.

3. Press the OK KEY to edit the current SCADA DATA LINK

PARITY.

4. Select the SCADA DATA LINK PARITY that you want to program.

5. Press the OK KEY .

6. Scroll DOWN to SCADA DATA LINK SLAVE ADDRESS.

7. Press the OK KEY to highlight the current SCADA DATA

LINK SLAVE ADDRESS.

8. Select the SCADA DATA LINK SLAVE ADDRESS that you want.

9. Press the OK KEY .

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SCADA (Modbus) RS-485 Data Link

10. Scroll DOWN to RS-485 BIAS RESISTOR ENABLE

STATUS.

11. Press the OK KEY to edit the current RS-485 BIAS

RESISTOR ENABLE STATUS.

12. Select the RS-485 BIAS RESISTOR ENABLE STATUS that you
want to program.

13. Press the OK KEY .

19.3.2 Configuring the SCADA Data Link Using the Cat Service Tool
The EMCP 4 SCADA data link can be configured using the Cat Service Tool. To program this data link, do the
following steps:
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Section 4.2.
2. Select RS-485 SCADA Data Link on the left.

3. Double click SCADA Data Link Baud Rate to change this to the desired value from the drop down menu. Click
the OK button to program.

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4. Double click SCADA Data Link Parity to change this value from the drop down menu. Click the OK button
to program.

5. Double click SCADA Data Link Slave Address. Change this value by typing a new value. Click the OK button to
program.

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SCADA (Modbus) RS-485 Data Link

6. Double click SCADA Data Link Access Password. Change this value by typing a new value. Click the OK button
to program.

7. Double click RS-485 Bias Resistor Enable Status to change this value from the drop down menu. Click the OK
button to program.

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20.0 SCADA (Modbus) TCP/IP Data Link

The EMCP 4.4 has a modbus TCP/IP data link for customer monitoring and control. This data link allows for remote
monitoring of all parameter data visible on the display and the service tool. It also allows for data link based
control of outputs. The modbus TCP/IP functionality is similar to the modbus RTU data link, but with much higher
speed capability. All ethernet UDP messages used for the multiple genset data link are automatically filtered out.

In addition, this data link can be used for interfacing with Cat Switchgear.

The modbus TCP/IP Data Link can be configured with the service tool or from the EMCP 4 GSC. To program this
data link with the service tool, do the following steps:

1. Connect to the EMCP 4 using the Cat Service Tool as stated in Section 4.2.

2. Select TCP/IP Data Link on the left.

3. Double click Internet Protocol Address to change this to the desired value. Click the OK button to program.

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4. Double click Internet Protocol Network Mask to change this to the desired value. Click the OK button to
program.

5. Double click Network Default Gateway Internet Protocol Address to change this to the desired value. Click the
OK button to program.

These setpoints will need to be changed prior to first use and can’t be changed back to 0.0.0.0.

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21.0 Multiple Genset Data Link (MGDL)

21.1 Introduction
The EMCP 4.4 Multiple Genset Data Link (MGDL) feature is an ethernet data link used between engine-generator
sets for on-package paralleling and control. The EMCP 4.4 MGDL feature does NOT employ a master controller
strategy for paralleling operation. While the EMCP 4.4 Supervisory Control Panel does allow for a single point
of connection for load add and load shed, the generator sets will continue to operate without it. The EMCP 4.4
controller uses a proprietary protocol to communicate information between generator sets and the supervisory
control panel to control paralleling features like dead bus arbitration, synchronizing, load sharing and load
sequencing. The EMCP 4.4 is not designed or intended to connect to third-party products over this data link.

The MGDL feature requires EMCP 4.4 controllers with at least v4.3 PROD software installed. MGDL capability does
NOT exist in EMCP 4.4 controller software versions prior to v4.3 PROD. Up to sixteen (16) EMCP 4.4 controllers and
one (1) EMCP 4.4 supervisory controller can be networked together in a single system via MGDL. MGDL provides
a view of the entire system as well as visibility to all other units in the system from a single EMCP 4.4 display
(Figure 21.1).

MGDL
Ethernet Switch Ethernet Switch

Figure 21.1 – Multiple Genset Data Link (MGDL)

The “Multiple Genset” load topology example shown in Figure 21.1 is a representation of a system application
in which the EMCP 4.4 MGDL feature can be used. A degree of flexibility is built into the MGDL control system
to allow for additional topology support (such as feeder breaker control). The EMCP 4.4 MGDL feature does not
support utility paralleling or intelligent automatic transfer switch capabilities with the initial version of Prod v4.3
software.

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Multiple Genset Data Link (MGDL)

Ethernet Switch

MGDL

EMCP 4.4 EMCP 4.4 EMCP 4.4

UNIT 01 UNIT 02 UNIT 03

G G G

GCB GCB GCB

Load

Figure 21.2 – Multiple Genset, Topology Example

The following guide describes the installation, configuration, and operation of the EMCP 4.4 MGDL feature.

21.2 MGDL Hardware Installation

21.2.1 EMCP 4.4 MGDL Connections
The MGDL uses a 10BaseT connection to an ethernet network. It requires a minimum of Category-5 (Cat5) cable,
but Category-5e or Category-6 are also permitted and preferred. It uses four-wire communications. It requires two
twisted pairs of conductors (Rx+ and Rx-, Tx+ and Tx-) and may be terminated in a connection such as RJ-45 jack.
See Table 22.1 for the Ethernet pins on the EMCP 4.4.

Pin # Name Description

87 ETH1-3 Ethernet differential non-inverting transmit line (Tx+)

88 ETH1-1 Ethernet differential non-inverting receive line (Rx+)

97 ETH1-2 Ethernet differential inverting receive line (Rx-)

98 ETH1-4 Ethernet differential inverting transmit line (Tx-)

Table 22.1 – EMCP 4.4 MGDL (Ethernet) Connections

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 Multiple Genset Data Link (MGDL)

The MGDL connection is the same connection as the modbus TCP/IP connection. While the same connection
is used, the protocols are different and do not interfere with each other under normal conditions. Because the
receiving lines on one device need to be connected to the sending lines on another, it is possible that a crossover
cable will be required. Fortunately, many ethernet adapters automatically detect and internally crossover;
the EMCP 4 also automatically detects and does an internal crossover. See Figure 21.3 for an illustration of
connecting the EMCP 4.4 to a typical RJ-45 connector or device.

EMCP 4.4 Typical

ETHERNET RJ-45
(MGDL) Connector

Tx+ (87) Tx+ (1)

Tx- (98) Tx- (2)

Rx+ (88) Rx+ (3)

Rx- (97) Rx- (6)

Figure 21.3 – EMCP 4.4 Wiring to RJ-45 Connector/Device

21.2.2 MGDL Network Topologies

The MGDL is ethernet-based and supports the 10BT topologies. The recommended topologies for MGDL are the
star or tree topology using a hub, switch, or repeater ethernet device. See Figure 21.4 for an illustration of a star
network topology and a tree network topology.

hub / switch /
repeater
hub / switch /
repeater

(a) (b)

Figure 21.4 – Recommended MGDL Ethernet Network Topologies

a) Star Network and (b) Tree Network

For maximum redundancy, using the dual connections available on some EMCP 4.4 hardware to daisy
chain connections is NOT recommended for an MGDL network since a single wire break can cause loss of
communications between large portions of the network. See Figure 21.5 for an illustration of a daisy-chained
network topology.

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Multiple Genset Data Link (MGDL)

(a)

Figure 21.5 – Non-recommended MGDL Ethernet Network Topologies

(a) Daisy-chain Network Between Internal EMCP 4.4 Hubs

The limits on the length are 330 ft (100 m) between each device (controller, computer, hub, or switch). Fiber optic
converters are recommended for any network section length greater than 330 ft (100 m), but may be worthwhile in
order to give greater electrical immunity for all connections.

21.2.3 Ethernet Switch/Hub/Repeater Considerations

The EMCP 4.4 Supervisory Control Panel comes complete with supplied ethernet switches. If additional switches
are required for any reason, certain characteristics should be considered when choosing an ethernet hub,
switch, or repeater to install with an MGDL network. Switches are always preferable over hubs in order to
minimize communication conflicts. In addition, if the MGDL network is being connected to any other network, a
switch is strongly recommended. The hub/switch/repeater characteristics to consider for a specific application
include:
• Power supply requirements
• Availability of power supply with and without utility power
• Environmental specifications (temperature, humidity, pressure, EMC, etc.)
• Transmission speed/length requirements
• Maximum number of ports required
• Troubleshooting signal LEDs

21.2.4 MGDL and TCP/IP SCADA Monitoring

It should be noted that the EMCP 4.4 ethernet MGDL connection points are the same as the ethernet TCP
connection points used for SCADA monitoring. The EMCP 4.4 dual purpose ethernet port lends itself to convenient
wiring and reduced connection points. However, MGDL and TCP/IP SCADA data links are separate in their
operation and function.
Note: The same ethernet network used for MGDL can also be used for TCP/IP SCADA monitoring.
In order to perform TCP/IP SCADA monitoring of all EMCP 4.4 controllers that are connected to an MGDL network,
connect to the existing ethernet network and follow standard TCP/IP SCADA monitoring setup procedures.
Figure 21.6 illustrates an example of a TCP/IP SCADA network connected to an EMCP 4.4 MGDL network.

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 Multiple Genset Data Link (MGDL)

SCADA Monitoring
System
TCP/IP SCADA
Data Link

Ethernet Switch
MGDL

EMCP 4.4 Controller EMCP 4.4 Controller EMCP 4.4 Controller

UNIT 02 UNIT 03
UNIT 01

G G G

GCB GCB GCB

Load

Figure 21.6 – Concurrent MGDL and TCP/IP Network Overview

Separate IP addresses exist for EMCP 4.4 controllers on the MGDL network and on a TCP/IP SCADA network. The
EMCP 4.4 TCP IP address, subnet and gateway used for SCADA monitoring are configurable by the user whereas
the EMCP 4.4 MGDL IP address is NOT configurable. The EMCP 4.4 MGDL IP address is dynamically assigned at
the time the unit connects to an MGDL network. Therefore, the EMCP 4.4 MGDL IP address MAY change based
on existing MGDL network nodes. The EMCP 4.4 MGDL IP address is provided on the EMCP 4.4 display screen for
reference only and is described in the MGDL network status screens section of this manual (Section 21.5.4). Due
to the criticality of the MGDL communications, care should be taken in the routing of the signals to be sure other
network traffic does not interfere in the transmission of these critical control parameters.

For more information on EMCP 4 SCADA data links including TCP/IP SCADA monitoring refer to the EMCP 4
SCADA Data Links, Application and Installation Guide (LEBE0010).

21.3 MGDL Software Configuration

The EMCP 4.4 Supervisory Control software has very limited MGDL feature setpoints. It only supports
configuration of load sense load demand and resetting of the expected number of units from the display. Please
note that ET Service Tool version 2015B or later is recommended for accessing and adjusting MGDL load sense
load demand setpoints.

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21.3.1 MGDL System Configuration

To access the MGDL Load Sense Load Demand system configuration setpoints using the ET Service Tool,
connect to the EMCP 4.4 Supervisory Control and click on the ‘Configuration Tool’ button (alternatively press
F5) to enter the configuration menu.

To reset the expected number of MGDL units from the display, navigate to the following sub-menu:

MAIN MENU

→ CONFIGURE

→ PARALLELING

→ MGDL CONTROL

The EMCP 4.4 Supervisory Control Panel has a fixed MGDL unit number and only 1 (one) supervisory control
panel can be on each MGDL network. It contains logic that does not allow two units to be configured to the same
MGDL unit number. If the EMCP 4.4 detects duplicate MGDL unit numbers on the MGDL network a MULTIPLE
GENSET DATA LINK CONFIGURATION ERROR (SPN-FMI: 625-14) event is triggered and the two units will be
shutdown. For more details on troubleshooting the MULTIPLE GENSET DATA LINK CONFIGURATION ERROR
(SPN-FMI: 625-14) event refer to Section 21.6.1.

The following subsections provide setpoint configuration details on each of the MGDL paralleling features.

21.3.2 MGDL Load Sense Load Sense Load Demand Configuration

While the EMCP 4.4 Supervisory Control Panel does NOT participate in load sense load demand, it does allow
configuration of the system wide load sense load demand setpoints. Refer to LEBE0007 for further details.

21.3.3 MGDL Event Response Configurations

The EMCP 4.4 response to an event being triggered can be configured in the EMCP 4.4 via setpoints called event
response configurations. These setpoints determine the actions the EMCP 4.4 takes when the event occurs.
To access the MGDL related event response configuration setpoints in ET, select one of the ‘Event Response
Configuration’ groups from the menu on the left to display the setpoints.
To access the Event Response Configuration setpoints through the EMCP display, navigate to the following
sub-menu:
MAIN MENU

→ CONFIGURE

→ ALL SETPOINTS

→ EVENT RESPONSE CONFIG

→ DIAGNOSTICS RESP CONFIG

Each setpoint used for configuring MGDL related event response configurations is described below.

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MGDL Network Diagnostic Response Configurations

Name Min Max Default Value Access
Warning,
Audible Alert,
Soft Shutdown,
Multiple Genset Control
Hard Shutdown, ET Service Tool
Data Link Communication Audible Alert,
Disabled Breaker#1 Trip, or
Failure Diagnostic Response Hard Shutdown
Breaker #2 Trip, EMCP Display
Configuration
Fault Protection
Timer Enabled,
Active Only
Warning,
Audible Alert,
Soft Shutdown,
Control is Offline Multiple
Hard Shutdown, Audible Alert,
Genset Control Data Link
Disabled Breaker#1 Trip, Warning,
Diagnostic Response
Breaker #2 Trip, Active Only
Configuration
Fault Protection
Timer Enabled,
Active Only
Table 22.2: MGDL Network Diagnostic Response Configurations

The MGDL communication failure diagnostic response configuration (setpoint) determines how the EMCP 4.4
responds to an MGDL COMMUNICATION FAILURE (SPN-FMI: 625-19) event. See section 21.6.3 for further details
on this event.

The control is offline MGDL diagnostic response configuration (setpoint) determines how the EMCP 4.4 responds
to the loss of a communications with an expected unit on the MGDL network that triggers an MGDL CONTROL IS
OFFLINE (SPN-FMI: 625-31) event. See section 21.6.2 for further details on this event.

21.4 MGDL Paralleling Features Operation

The EMCP 4.4 with MGDL has several paralleling functions including dead bus arbitration, synchronizing, load
sharing, load shed, and load sense/load demand. The EMCP 4.4 with MGDL also provides for multiple modes of
operation, including automatic synchronizing, manual synchronizing, and sync check mode. More details on the
failsafe modes are available in LEBE0007.

Load Shed
The EMCP 4 genset controller also provides a configurable signal to aid in the removal of load from a generator
set. With the addition of MGDL network feature, the load shed functionality on the EMCP 4.4 has not changed.
Please refer to LEBE0007 for detailed information on the EMCP 4.4 load shed feature.

MGDL Group Start Command

The EMCP 4.4 provides the ability to command all units to start and run via MGDL from a single unit’s dedicated
isolated group start digital input. See Section 21.4.1 and LEBE0007 for more information.

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Load Sense/Load Demand

The EMCP 4.4 includes logic to sequence generator sets based on the total load requirement of the system.
If the site load exceeds a minimum reserve kW threshold, additional generator sets will automatically start,
synchronize, and close the generator breaker. If the site load falls below a reserve kW threshold, a generator set
will automatically unload, open the generator circuit breaker, and shut down. Generator sets can be configured
to sequence on and off in order to balance engine hours (with an optional offset) or priority assignment. See
Section 21.4.2 and LEBE0007 for more details.

Feeder Breaker Control (Load Add)

The EMCP 4.4 generator set control includes limited feeder (tie) breaker close and trip control for connecting a
generator bus and a load bus in an automatic mains failure (AMF) or utility dead bus condition. See LEBE0007
for more details.

MGDL Loss of Communications Strategy

The EMCP 4.4 includes logic that provides redundancy to the MGDL paralleled system in the case of a unit being
lost from the MGDL network. The loss of communications strategy groups units and alters modes in failure
scenarios in order to maximize the load capability of the MGDL paralleled system but also to minimize the risk of
loss of load or damage to equipment. See Section 21.4.3 and LEBE0007 for more details.

MGDL Network Configuration (Expected Units) Reset

The EMCP 4.4 provides the ability for updating or re-configuring the MGDL network configuration (topology)
by resetting the number of expected units on the MGDL network. This capability is typically only necessary for
re-defining the MGDL network node count and should be done with caution. See Section 21.4.4 and LEBE0007
for more details.

MGDL Failsafe Load Sharing/Droop

The EMCP 4.4 provides a patented failsafe strategy for load sharing in loss of MGDL communication scenarios.
In these failure mode scenarios, this strategy adaptively adjusts generator set operating conditions in order to
maximize the amount of load the MGDL paralleled system can provide while introducing minimal disruption or
instability into the system.

21.4.1 Supervisory Control Panel MGDL Group Start Command Operation

Group Start Command Assertion Purpose
MGDL Load Sense Load Demand (LSLD) is the control system used in EMCP 4.4 controllers to automatically bring
generator sets on the bus or take generator sets off the bus in order to serve facility loads while maintaining
fuel efficiency and adequate reserve. The LSLD control algorithm analyzes system load levels, sequence priority
assignments and generator status communicated via MGDL. This information is used to compare load levels with
programmable thresholds and time delays before deciding to drop under loaded generator sets or add additional
available generator sets in order to efficiently match load demand. While the Supervisory Control Panel does
allow for adjustment of the system wide setpoints, refer to LEBE0007 for more details.

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21.4.2 MGDL Network Configuration Reset (Expected Units)

As described the MGDL network configuration is determined by the number of actual controls detected
(communicating) and the number of expected controls on the MGDL network. These values allow each unit to
determine network topology information such as the total number of nodes in the MGDL network as well as
assign the appropriate failsafe modes during loss of communications. The MGDL network configuration and each
unit’s understanding of the network is reliant on the accuracy of these values.
The actual number of controls detected is dynamically sensed and therefore is not user adjustable. However,
the number of expected controls on the MGDL network is the critical parameter used by each unit and is user
resettable. Expected number of controls is defined as the maximum number of unique MGDL unit numbers
broadcasting on the MGDL network over a given period of time. The expected number of controls on the MGDL
network ONLY increments and can only be reset or decremented in the following ways:
1. Forced to reset from display (MGDL Control Screen – Section 21.5.1 of this manual). A reset expected command
from display is communicated to ALL units on the MGDL network. In order for all controls to agree on the
network configuration, if one unit is commanded to reset expected number of controls all other units will reset
expected number of controls.

2. After certain period of time being powered down the EMCP 4.4 controller will “clear” internal memory of the
number of expected controls. This is done in order to benefit generator sets that are commonly relocated and
are frequently powered up into new MGDL network topologies (such as rental units). The logic for this resetting
of expected number of controls is after my control is powered down for >12 hours:
a. If all other controllers on the network with mature communications agree on the expected number of
controls online,
– Reset expected number of controls to the agreed upon expected number of controls online.
b. If all controllers on the network with mature communications do NOT agree on the expected number of
controls online,
– Reset expected number of controls online to zero and recalculate the units.
c. If all controllers on the network have immature communications,
– Reset expected number of controls online to zero and recalculate the units.

Note: The actual detected number of controls online and the expected number of controls online is indicated on
display on the MGDL control screen described in Section 21.5.1 of this manual.

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Resetting expected number of controls via display should only be done as a result of proper troubleshooting or
only when intentional MGDL network node adjustments are desired. It is NOT recommended to reset expected
number of controls while generator sets are running and providing load. Resetting expected number of controls
results in the definition of new MGDL network nodes connected to the same electrical bus that may or may not
communicate with each other. Therefore resetting expected number of controls inappropriately creates a risk of
system instability and/or a crash-parallel.

21.5 MGDL Display Screens

The EMCP 4.4 MGDL display screens provide information on the individual unit’s paralleling operations. The
display screens also provide the ability to monitor key information from ANY EMCP 4.4 controllers communicating
on the MGDL network. The EMCP 4.4 MGDL display screens also provide additional control and configurability
that is NOT available through ET. Each MGDL display screen is described in more detail below.

21.5.1 MGDL System Overview Screens

The MGDL system Overview and MGDL unit details screens can be accessed directly through the EMCP 4.4
display. To access the MGDL overview and MGDL unit details through the display, navigate to the following
sub-menus:

MAIN MENU

→ VIEW

→ PARALLELING

→ MGDL OVERVIEW

The MGDL Overview screen displays key information for all MGDL units from a single EMCP 4.4 controller’s
display. The MGDL Overview screen information is described in Figures 21.7 through Figure 21.10.

Note: These screens are hidden from display until Multiple Genset Control Data Link Unit Number (setpoint) is
configured to a non-zero value.

“My Unit” Indicator

Unit % Real Power

Unit Communication
Status

Generator-Breaker-Bus System Bus Status

Status

System Status

Figure 21.7 – MGDL Overview Screen with Less Than 8 MGDL Units

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 Multiple Genset Data Link (MGDL)

The unit communication status information of all MGDL units is provided in the top section of the MGDL
Overview screen.
• The unit number of any MGDL unit that is broadcasting information on the network will automatically appear in
a solid block text.
• A unit number that is reverse videoed indicates immature communications. The immature communications
indicator is active for the first 60 seconds after a unit begins broadcasting on the MGDL network.
• A unit number is replaced with a question mark if communications have been lost with that unit. Scrolling to
and selecting the question mark on the MGDL Overview screen displays a message indicating the unit number
of the lost unit (Figure 21.12).
• To avoid confusion and improve troubleshooting, an asterisk next to a unit number indicates “my unit” and
refers to the unit number assigned to the controller whose display is being viewed.
The percent of rated real power of each individual MGDL unit is displayed just below the unit number
identification. This provides an indication of the real power loading of each MGDL unit at a given point in time.
Volts & Hz Within
Limits status

Breaker status

Bus status

Figure 21.8 – Generator-Breaker-Bus Status Symbol

The generator-breaker-bus status symbol (Figure 21.8) provides an indication of the generator operating state and
consists of three separate indicators:
1. Generator Volts/Hz Within Limits Status
2. Generator Breaker Status
3. Bus Voltage Status
If communications are lost, the generator-breaker-bus symbol disappears since the information is unknown.
The generator volts/hz within limits status provides an indication to the generator sets readiness. The generator
circle is populated with a sinusoidal wave symbol when the generator voltage and generator frequency are
greater than 90% of their rated values. The generator circle is left blank when either generator voltage or
generator frequency are less than or equal to 90% of their rated values.
The generator breaker status provides an indication of the generator breaker state. Table 22.3 shows the possible
generator breaker states and corresponding symbols on display.
Open Closed Locked Out Unknown

U.S.

International

Table 22.3 – Generator Breaker Status Symbols

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The generator breaker status symbol can be switched between U.S. and international symbols under the EMCP
display preferences.
The bus voltage status detected by each MGDL unit is indicated by the bottom row of the generator-breaker-bus
symbol. The unit bus bar symbol is filled in to indicate a live bus is detected and is left empty to indicate a dead
bus is detected by the individual unit.
The system bus status indication considers the dead bus detection of all MGDL units on the network. The system
bus status reads LIVE BUS when any MGDL unit detects a live bus and reads DEAD BUS when all MGDL units
detect a dead bus.
The system kW value is the total real power provided by all MGDL units on the network. The system % kW is the
real power provided by all the MGDL units on the network as a percentage of all the rated power of all the MGDL
units on the network regardless of their operating state.

Indicates > 8 units

Unit %kW
(of Rated Real Power)
Solid – Mature communication
Reverse Video – Immature communication
Volts & Hz Question Mark – Loss of communication
Within Limits

Circuit Breaker Status:

Live Bus (fill) Open, Closed, Locked Out, Unknown (FID)
Dead bus (blank) (US and International Symbols)

System kW Hot key to view

(Real Power) additional units
( > 8 units)
System %kW (Real Power)

Figure 21.9 – MGDL Overview Screen with Greater Than 8 MGDL Units (Screen 1 of 2)

When more than 8 units are connected to the MGDL network an arrow appears indicating an additional MGDL
Overview screen is available. Pressing the PAGE RIGHT (F4 hot key) navigates to the second MGDL Overview
screen (Figure 21.10).

Figure 21.10 – MGDL Overview Screen with Greater Than 8 MGDL Units (Screen 2 of 2)
Scrolling left and right on the MGDL Overview screen with the left and right arrow keys allows the user to select

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 Multiple Genset Data Link (MGDL)

a particular MGDL unit. Pressing the OK key provides more detailed information (Figure 28.38) on the operation of
the selected MGDL unit.

MGDL Unit Overview

The MGDL Unit Overview screen displays detailed information of the selected MGDL unit from a single EMCP 4.4
controller’s display. The MGDL Unit Overview screen information is described in Figure 21.11 and Figure 21.12.

Unit kW/kVAr %
Volts & Hz Within
Unit number (Rated)
Limits
Breaker status

Unit kW/kVAr
level Bus status

Shutdown count
Engine Hrs
Warning count

Unit Load Engine Control

Sharing State Switch State

Unit LSLD state

Hot key returning to

MGDL Overview Screen

Figure 21.11 – MGDL Unit Overview Screen

• The unit number of the MGDL unit details being viewed is listed in the title bar of the MGDL Unit Overview
Screen.

• The actual kW and kVAr totals as well as % kW and % kVAr of the unit is listed in the top left of this screen.

• The generator-breaker-bus status (described in Figure 28.35) is also replicated on this screen from the MGDL
Overview screen.

• In the middle of the screen, the number of active warnings and active shutdowns on the MGDL unit are
displayed. If the number of warnings or shutdowns is greater than 9, the number is replaced by a “+” symbol.

• The engine control switch symbols (RUN, AUTO, and STOP) visible on the EMCP fascia are replicated on this
screen representing the current operating state of the MGDL unit’s engine control switch. As the engine control
switch is changed from the unit’s RUN, AUTO, and STOP keys, the symbol is updated on display.

• The total operating hours of the unit is listed to the right of the engine control switch status.

• The unit’s load sharing and LSLD state is listed on the final two rows of this screen. If communications are
lost with a unit, the unit details are not available and the Unit Overview screen is replaced with a message
indicating a loss of communications as shown in Figure 21.12.

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Figure 21.12 – MGDL Unit Overview Screen of Unit with Loss of Communications

21.5.2 MGDL Control Screen

The EMCP 4.4 maintains a list of expected controls on the MGDL network and actual controls on the MGDL
network. Under normal operation, the expected controls equal actual controls. However, in the case of network
topology updates or loss of communications, expected controls may NOT equal actual controls. The ability to
view and reset the number of expected controls to the number of actual controls for ALL units on the MGDL
network is provided through the MGDL Control screen.

Note: RESET EXPECTED is a system-wide reset where resetting the expected number of MGDL units from
“my unit” sends a system-wide command to ALL units on the MGDL network to reset expected number of
MGDL units.

Further details and implications of resetting expected controls on the MGDL network are provided in MGDL
Network Configuration (Expected Units) Reset section 21.4.4 and Troubleshooting section of this manual
Section 21.6.

To access the MGDL Control screens through the EMCP display, navigate to the following sub-menus:

MAIN MENU

→ CONTROL

→ PARALLELING

→ MGDL CONTROL

Note: Pressing the CONTROL key on the face of the EMCP 4.4 provides a shortcut to the control menu.

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Expected #
MGDL Units

Actual #
Unit #’s MGDL Units

Hot key to Reset Expected

Number of Controls

Figure 21.13 – MGDL Control Screen for Viewing/Resetting Expected Number of Units on the MGDL Network

Pressing the RESET EXPECTED (F1 hot key) populates an additional verification screen that requires an OK button
press to reset the expected number of MGDL units.

21.5.3 MGDL Load Sense Load Demand Screens

The MGDL Load Sense Load Demand (LSLD) screens can be accessed directly through the EMCP 4.4 display.
To access the MGDL Load Sense Load Demand view screens through the display, navigate to the following sub-
menus:

MAIN MENU

→ VIEW

→ PARALLELING

→ LOAD SENSE LOAD DEMAND

The MGDL load sense load demand view screen displays load sense load demand information of the individual
EMCP 4.4 controller as well as the overall MGDL system. The MGDL Load Sense Load Demand view screen
information is described in Figure 21.14 below.

Note: These screens are hidden from display until the LSLD input configuration setpoint is configured to
“ethernet (MGDL).”

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My Unit Number

Unit LSLD State System

LSLD State

System %kW
Unit %kW (Rated Real Power
(Rated Real Power) of units participating
in LSLD)
Sequencing Order
LSLD Priority
Sequence Strategy

Hot keys to Paralleling View

Screens

Figure 21.14 – MGDL Load Sense Load Demand View Screen

The unit LSLD state reflects the state of the unit’s LSLD operating mode as seen by the rest of the system. These
states take into account the configured LSLD mode, generator breaker status, and soft load/unload status. The
possible unit LSLD states are listed in Table 22.4 below.

Unit LSLD State Description

Unit Operating Under LSLD Control
Unit is running with the generator breaker closed and soft loading complete under LSLD
GOING
control. This unit could sequence off as required based on load demand.
Unit is running with the generator breaker closed and soft loading complete with the
SETTLING LSLD Enable Delay Timer active. No units will sequence off until the LSLD Enable Delay
(Settling) Timer has expired.
UNLOADING Unit is stopping and soft unloading under LSLD control.
LOADING Unit is starting, synchronizing, and soft loading under LSLD control.
Unit is stopped with the generator breaker open under LSLD control and is available to
AVAILABLE
come on the bus.
Unit Unable to Participate Under LSLD Control
Unit is running and the generator breaker is closed, but the unit is unable to participate in
GOING LSLD OFF LSLD control due to failure to meet certain conditions (such as by the result of manually
starting and synchronizing or a failure to open breaker condition).
Unit is stopping or stopped and the generator breaker is open, but the unit is unable to
UNAVAILABLE participate in LSLD control due to certain conditions (such as by the result of pressing the
STOP key or an active shutdown).
Table 22.4 – LSLD Unit Operating State

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The system LSLD State reflects the state of LSLD at an overall system level. This state takes into account
the individual LSLD state of all units on the MGDL network. The possible system LSLD states are listed in
Table 22.5 below.

System LSLD State Description

GOING All LSLD units are in the GOING state then the system is GOING.
SETTLING Any LSLD unit is in the SETTLING state then the system is SETTLING.
UNLOADING Any LSLD unit is in the UNLOADING state then the system is UNLOADING.
LOADING Any LSLD unit is in the LOADING state then the system is LOADING.
Any LSLD unit is in the AVAILABLE state then the system is AVAILABLE implying that
AVAILABLE
the system is not operating at full capacity.
At least one LSLD unit is in the GOING LSLD OFF state and all units are either GOING
GOING LSLD OFF
LSLD OFF or UNAVAILABLE.
UNAVAILABLE All LSLD units are in the UNAVAILABLE state then the system is UNAVAILABLE.
Table 22.5 – LSLD System Operating State

The generator-breaker-bus status (described in Figure 21.8) is also replicated on this screen from the MGDL
Overview screen. This screen also provides the generator voltage, frequency and percent real power measurements
as well as bus voltage, frequency and system percent real power measurements.

The individual unit’s order for sequencing on or off the bus under LSLD is indicated by the “NEXT TO LOAD” or
“NEXT TO UNLOAD” status in the bottom left corner of this screen. If the unit is going under LSLD and it is prioritized
such that it is 1st unit to unload, this status reads “NEXT TO UNLOAD.” If the unit is prioritized such that it is 2nd unit
to unload, this status reads “NEXT TO UNLOAD + 1.”

Similarly, if the unit is available for loading under LSLD and it is prioritized such that it is the 1st unit to load this
status reads “NEXT TO LOAD.” If the unit is prioritized such that it is the 2nd unit to load this status reads “NEXT TO
LOAD + 1.”

The currently active LSLD sequence strategy as configured in the LSLD setpoints is listed in the bottom right corner
of this screen.

MGDL Load Sense Load Demand control screen (Figure 21.15) is similar to the view screen except it provides
easy access to the LSLD configuration setpoints as well as access to the LSLD Priority Assignment screen. To
access the MGDL Load Sense Load Demand control screens through the EMCP 4.4 display, navigate to the following
sub-menus:

MAIN MENU

→ CONTROL

→ PARALLELING

→ LOAD SENSE LOAD DEMAND

Note: Pressing the CONTROL key on the face of the EMCP 4.4 provides a shortcut to the control menu.

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Hot key to LSLD Priority Hot key to LSLD Configuration

Assignment Screen Screens

Figure 21.15 – MGDL Load Sense Load Demand Control Screen

The MGDL LSLD Priority Assignment screen displays the LSLD priority assigned to each controller in the MGDL
network. This priority is only used when operating in the “PRIORITY NUMBER” sequence strategy. The LSLD
priority can also be edited from this screen by selecting the “EDIT” F1 hot key. When editing is complete, save the
changes by pressing the “ASSIGN ALL PRIORITY” F1 hot key. The LSLD priority assignment screens are shown in
Figure 21.16 and Figure 21.17.

Unit #’s

Unit Priority #

Hot key to Edit Priority

Assignment

Figure 21.16 – MGDL LSLD Priority Assignment View Screen

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Unit #’s

Unit Priority #

Edit Unit
Priority #

Hot key to Assign

All Priority

Figure 21.17 – MGDL LSLD Priority Assignment Edit Screen

21.5.4 MGDL Network Status Screens

The MGDL network status screens can be accessed directly through the EMCP 4.4 display. To access the MGDL
network status screens through the display, navigate to the following sub-menus:

MAIN MENU

→ VIEW

→ NETWORK STATUS

→ MULTIPLE GENSET DATA LINK

Note: This screen is hidden from display until Multiple Genset Control Data Link Unit Number (setpoint) is
configured to a non-zero value.

Data Link Status:

OK, FAULT

My Unit’s MGDL
IP Address

Figure 21.18 – MGDL Network Status Screen

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The MGDL network status screen provides an indication of the status of the MGDL network. If the MGDL network
status displays “FAULT,” there is a problem with the MGDL network and the event log should be consulted for
troubleshooting. Otherwise, the MGDL network status displays “OK.”

The MGDL network IP address listed on the MGDL network status screen is specific to the MGDL network node
and is NOT related to the TCP/IP network IP address. The MGDL network IP address is dynamically assigned at
power-up and is NOT configurable by the user. The MGDL network IP address may change based on network
topology and is provided on this screen for reference purposes only.

21.5.5 MGDL Status Event Log Screens

The Status Events log screens can be accessed directly through the EMCP 4.4 display. To access the Status
Events log screens through the display, navigate to the following sub-menus:

MAIN MENU

→ VIEW

→ EVENT LOGS

→ STATUS EVENTS

Note: Pressing the EVENT LOG key on the face of the EMCP 4.4 provides a shortcut to the event logs menu.

Event

Date Time

Figure 21.19 – Status Events Screen

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The Status Events log is meant to provide a record of recent generator set events or conditions with time stamps
to assist in troubleshooting. Many status events exist and are triggered for the EMCP 4.4. Only the MGDL network
related status events and their trigger conditions are listed in Table 22.6.

Status Event Trigger Conditions

Expected number of controls is non-zero, actual number of controls is one. The
NO MGDL UNITS DETECTED
unit detects only itself and no other MGDL units on the network.
Expected number of controls is non-zero, actual number of controls is non-zero
MGDL UNIT(S) NOT
and not equal to expected number of controls. The unit no longer detects one or
DETECTED
more MGDL units on the network.
ALL MGDL UNITS Expected number of controls equals actual number of controls. The unit detects
DETECTED all expected MGDL units on the network.
DBA CAUTION MODE Unit is attempting to dead bus close while operating under a failure mode caused
ACTIVATED by a loss of communications or MGDL protocol mismatch.
Loss of communications or MGDL protocol mismatch has occurred and the unit
FAILSAFE DROOP
is attempting to load share while grouped in the Proceed with Caution failsafe
ACTIVATED
group.
FAILSAFE DROOP Unit is no longer in the Proceed with Caution failsafe group because of either loss
DEACTIVATED of communications recovery or exiting of load sharing.
FAILSAFE ISOCH Loss of communications has occurred and the unit is attempting to load share
ACTIVATED while grouped in the Proceed as Normal failsafe group.
FAILSAFE ISOCH Unit is no longer in the Proceed as Normal failsafe group because of either loss
DEACTIVATED of communications recovery or exiting of load sharing.

Table 22.6 – MGDL-related Status Events

21.5.6 MGDL Genset Event Log Screen

The genset event log screens can be accessed directly through the EMCP 4.4 display. To access the genset event
log screens through the display, navigate to the following sub-menus:

MAIN MENU

→ VIEW

→ EVENT LOGS

→ GENSET EVENTS

Note: Pressing the EVENT LOG key  on the face of the EMCP 4.4 provides a shortcut to the event logs menu.

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Event Status: Event

Present,
Active, Occurence
Inactive Count

SPN:FMI Date/Time
Stamp

Engine Hrs
Stamp

Figure 21.20 – Genset Event Log Entry

The genset event log is meant to provide a detailed log of current and past generator set events including
information such as event status, SPN: FMI, occurrence count, and date/time stamps of the last and first time
that particular event occurred to assist in troubleshooting. The MGDL-related generator set events are explained
further as well as troubleshooting assistance in Section 21.6.

21.6 MGDL Troubleshooting

The EMCP 4.4 is designed to provide diagnostics or events to alert the operator to problems with the MGDL
network configuration or operation of paralleled generator sets over the MGDL network. Some of the most
common MGDL-related events are listed and described here along with general troubleshooting steps. All of
these MGDL-related events appear in the EMCP (genset control) event log when triggered. For further details on
troubleshooting EMCP events refer to the EMCP 4.3/4.4 Systems Operation and Troubleshooting and Adjusting
(SOTA) Guide – UENR1210 and LEBE0031-EMCP 4.4 Multiple Genset Data Link.

21.6.1 MGDL Configuration Error Event (SPN-FMI: 625-14)

The MULTIPLE GENSET CONTROL DATA LINK CONFIGURATION ERROR DIAGNOSTIC (SPN-FMI: 625-14) is used
to identify when a misconfiguration of the MGDL network is present. This event response is a fixed shutdown and
is not configurable. This shutdown event must be cleared before an MGDL unit will operate and is used to confirm
that the EMCP 4.4 is configured appropriately.

For operating in full HARDWIRED paralleling mode, configure the EMCP 4.4 based on Table 22.7.

EMCP 4.4 Setpoint Setpoint Value

Multiple Genset Control Data Link Unit Number ZERO
Breaker Close to Dead Bus Input Configuration HARDWIRED INPUT
Generator Real Load Sharing Input Configuration 0 TO 10 V or 0 TO 3 V
Generator Reactive Load Sharing Input Configuration 0 TO 10 V
Load Sense Load Demand Input Configuration HARDWIRED INPUT

Table 22.7 – EMCP 4.4 Hardwired Paralleling Configuration

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For operating in full MGDL paralleling mode, configure the EMCP 4.4 based on Table 22.8.

EMCP 4.4 Setpoint Setpoint Value

Multiple Genset Control Data Link Unit Number NON-ZERO
Breaker Close to Dead Bus Input Configuration ETHERNET (MGDL)
Generator Real Load Sharing Input Configuration ETHERNET (MGDL)
Generator Reactive Load Sharing Input Configuration ETHERNET (MGDL)
Load Sense Load Demand Input Configuration ETHERNET (MGDL)

Table 22.8 – EMCP 4.4 MGDL Paralleling Configuration

If load sense load demand or dead bus arbitration features are not desired, they may be configured to
“DISABLED.” The EMCP 4.4 must be configured either for HARDWIRED paralleling operation or MGDL paralleling
operation. No mixture of HARDWIRED and MGDL modes is permitted. If a configuration mixture of these two
modes is detected the MULTIPLE GENSET CONTROL DATA LINK CONFIGURATION ERROR DIAGNOSTIC (SPN-
FMI: 625-14) is triggered. With that in mind, the MULTIPLE GENSET CONTROL DATA LINK CONFIGURATION
ERROR DIAGNOSTIC trigger conditions are summarized in Table 22.9.

EMCP 4.4 Setpoint Setpoint Value

Multiple Genset Control Data Zero Non-zero — Non-zero Zero
Link Unit Number (0) (1 to 64) (don’t care) (1 to 64) (0)
Breaker Close to Dead Bus
Input Configuration
ANY mixture ALL ALL
Generator Real Load Sharing ANY ANY
of Ethernet configured configured
Input Configuration configured configured
(MGDL) AND to Ethernet to Hardwired
Generator Reactive Load to Ethernet to Hardwired
Hardwired (MGDL) or Input or
Sharing Input Configuration (MGDL) Input
Input Disabled Disabled
Load Sense Load Demand
Input Configuration
MGDL Configuration Error
Event (SPN-FMI: 625-14)
√ √

Table 22.9 MGDL Configuration Error Conditions

Note: The MULTIPLE GENSET CONTROL DATA LINK CONFIGURATION ERROR DIAGNOSTIC can also be triggered
as a result of two other conditions:
• If the EMCP 4.4 detects duplicate MGDL unit numbers on the MGDL network the two units with the same unit
number will shutdown with this event.
• The MGDL feature is NOT intended to operate with single-phase genset applications. Therefore, the MULTIPLE
GENSET CONTROL DATA LINK CONFIGURATION ERROR DIAGNOSTIC will be triggered if the EMCP 4.4 is
configured for MGDL and any one of the following single-phase generator AC connection configurations:
– Single-phase (2-Wire L1-L2) Connection
– Single-phase (3-Wire L1-N-L2) Connection
– Single-phase (2-Wire L2-L3) Connection
– Single-phase (3-Wire L2-N-L3) Connection

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Troubleshooting Steps:
If the MULTIPLE GENSET CONTROL DATA LINK CONFIGURATION ERROR DIAGNOSTIC is PRESENT in the genset
events log on EMCP 4.4 display:

1. Review all setpoints listed in Table 22.9 to verify there is no mixture of HARDWIRED and MGDL setpoint
configurations.

2. Review the generator connection configuration setpoint to verify the genset is not configured for single-phase
operation.

3. If all setpoints are configured appropriately for one of the modes, verify there are not multiple units on the
MGDL network configured to the same unit number.

4. If multiple units are configured for the same MGDL unit number, reassign unique unit numbers to those units.

5. Event will transition to ACTIVE once the MGDL configuration is correct, event can now be reset.

It is common for the MULTIPLE GENSET CONTROL DATA LINK CONFIGURATION ERROR DIAGNOSTIC to be
triggered during commissioning while individual paralleling features (DBA, LSLD, load sharing) are being
configured for the first time. Once MGDL and paralleling configuration is complete, the event should be capable
of being reset.

21.6.2 MGDL Control is Offline Event (SPN-FMI: 625-31)

The CONTROL IS OFFLINE MULTIPLE GENSET CONTROL DATA LINK DIAGNOSTIC (SPN-FMI: 625-31) is used to
identify when a unit that is expected to be on the MGDL network is no longer communicating. The event response
for this event is a warning by default, but is configurable via the Control is Offline Multiple Genset Control Data
Link Diagnostic Response Configuration (setpoint) and is described in Section 21.3.3.

This event is triggered as a result of no MGDL messages being received from one or more of expected controls
online over a specified period of time. This can occur as a result of conditions such as broken or unplugged
ethernet cables, mis-configuration, power loss to ethernet router/switch/hub devices, or power loss to EMCP 4.4.
The EMCP 4.4 strategy for handling loss of communications is detailed in Section 13 and LEBE0007.

Troubleshooting Steps:
If the CONTROL IS OFFLINE MULTIPLE GENSET CONTROL DATA LINK DIAGNOSTIC is PRESENT in the genset
events log on EMCP 4.4 display:
1. Navigate to the MGDL system overview screen described in section 21.5.1. Identify any question mark symbols
(?) that are displayed. A unit number is replaced with a question mark symbol (?) if the MGDL unit has lost
communications. Scrolling to and selecting the question mark (?) on the MGDL Overview screen displays a
message indicating the unit number of the lost node (Figure 21.12).
a. A single lost node may indicate a broken wire or misconfiguration. Refer to step 2.
b. Multiple lost nodes may indicate several broken wires or a possible power loss to ethernet router/switch/hub
devices. Refer to step 3.
2. On the MGDL system overview screen, use the “my unit” indicator (*) to determine this controller’s perspective
of the MGDL network. If the MGDL system overview screen displays only one question mark (?) then there is
only one other EMCP 4.4 that has lost communications.
a. Check the STATUS EVENTS log for “MGDL Unit(s) Not Detected” status event, this triggers if some, but not
all units are lost.

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b. Check if the unit with a loss of communications has lost power to the EMCP 4.4.
c. Check if the unit with a loss of communications has the ethernet cable unplugged from the ethernet router/
switch/hub device that it was connected to.
d. Check if the unit with a loss of communications has lost power to the ethernet router/switch/hub device that
it was connected to.
e. Check if the unit with a loss of communications has a broken ethernet wire. On the EMCP 4.4 120-pin J1
connector, verify wiring to pin 87, 88, 97, and 98. These are the ethernet connections and could cause loss of
communications, if broken or poorly connected. These connections are explained further in Section 21.2.1.
f. Check if the unit with a loss of communications is properly configured for MGDL operation. Refer to
Section 21.6.1.
3. On the MGDL system overview screen, use the “my unit” indicator (*) to determine this controller’s perspective
of the MGDL network. If the MGDL system overview screen displays multiple question marks (?), there are
multiple other EMCP 4.4 controllers that have lost communications.
a. Check the STATUS EVENTS log for “No MGDL Units Detected” status event, this triggers if ALL units are lost.
– Check if this unit’s ethernet cable is unplugged from the ethernet router/switch/hub device that it was
connected to.
– Check if this unit has lost power to the ethernet router/switch/hub device it was connected to.
b. Check if this unit has a broken ethernet wire. On the EMCP 4.4 120-pin J1 connector, verify wiring to pin 87,
88, 97, and 98. These are the ethernet connections and could cause loss of communications, if broken or
poorly connected. These connections are explained further in Section 21.2.1.
c. Check the STATUS EVENTS log for “MGDL Unit(s) Not Detected” status event, this triggers if some, but not
all units are lost.
– Check if the units with a loss of communications have the ethernet cable unplugged from the ethernet
router/switch/hub device that it was connected to.
– Check if the units with a loss of communications have lost power to the EMCP 4.4.
– Check if the units with a loss of communications have lost power to the ethernet router/switch/hub device
they were connected to.
d. Check if the units with a loss of communications have a broken ethernet wire. On the EMCP 4.4 120-pin J1
connector, verify wiring to pin 87, 88, 97, and 98. These are the ethernet connections and could cause loss of
communications if broken or poorly connected. These connections are explained further in Section 21.2.1.
4. Once proper troubleshooting steps have been completed and MGDL communications are re-established:
a . CONTROL IS OFFLINE MULTIPLE GENSET CONTROL DATA LINK DIAGNOSTIC should transition from
PRESENT to INACTIVE in the genset events log on EMCP 4.4 display.
b. “All MGDL Units Detected” status event should appear in the status events log.

If it is desired to intentionally disconnect unit(s) from the network for maintenance or permanently removing from
the site then “RESET EXPECTED” should be considered. This will keep the system from operating in a failsafe
mode during these situations, but must be done with understanding of the effect on the generator system. Refer
to Section 21.4.2 for an explanation of the “RESET EXPECTED” operation as well as implications that could result
from this action.

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21.6.3 MGDL Communications Failure Event (SPN-FMI: 625-19)

The MULTIPLE GENSET CONTROL DATA LINK COMMUNICATION FAILURE DIAGNOSTIC (SPN-FMI: 625-19) is
used to identify when EMCP 4.4 receives unexpected data over the data link. The event response for this event is
a hard shutdown by default, but is configurable via the Multiple Genset Control Data Link Communication Failure
Diagnostic Response Configuration (setpoint) and is described in Section 21.3.3.

If the EMCP 4.4 receives an unexpected data packet over the data link the MULTIPLE GENSET CONTROL DATA LINK
COMMUNICATION FAILURE DIAGNOSTIC will be displayed in the genset events log and the unit will shutdown. This
event may be triggered due to mismatched software versions installed on the EMCP 4.4s in your network topology.
While this event is present, the unit can no longer participate in load sense load demand.

Troubleshooting Steps:
If the MULTIPLE GENSET CONTROL DATA LINK COMMUNICATION FAILURE DIAGNOSTIC is PRESENT in the
genset events log on EMCP 4.4 display:
1. Check the software version installed on the EMCP 4.4. To access this information through the EMCP 4.4 display,
navigate to the following sub-menus:

MAIN MENU

→ SOFTWARE INFO

a. If mismatched software versions are installed on the network a SOFTWARE VERSION (PROTOCOL)
MISMATCH (SPN-FMI: 243-31) event may also be present in the genset events log. This event as well as
further troubleshooting is explained in Section 21.6.4.

21.6.4 Software Version (Protocol) Mismatch Event (SPN-FMI: 234-31)

The SOFTWARE VERSION MISMATCH (SPN-FMI: 234-31) event is used to identify when mismatched EMCP 4.4
MGDL communication software is detected between units on the MGDL network. Units attempting to operate
with mismatched software may have mismatched MGDL communication protocols and have the potential for
unsafe operating conditions. Therefore, this scenario should be identified and avoided. Each EMCP 4.4 contains
logic to ensure that all units on the MGDL network have matched MGDL communication protocols.

If any mismatch in the MGDL communication protocol is detected the SOFTWARE VERSION MISMATCH warning
event (SPN-FMI: 234-31) is triggered and the unit enters the proceed with caution failsafe modes. The event
response to this event is a fixed warning and is not configurable. The unit will remain in failsafe mode and the
warning event will remain active until the software mismatch is no longer detected.

Troubleshooting Steps:
If the SOFTWARE VERSION MISMATCH event is PRESENT in the genset events log on EMCP 4.4 display:
1. Check the software version installed on the EMCP 4.4 controllers and identify any mismatches. To access this
information through the EMCP 4.4 display, navigate to the following sub-menus:

MAIN MENU

→ SOFTWARE INFO

2. Resolve any mismatch in software version by updating the software in MGDL units as necessary. As soon as
ALL units connected to the MGDL network have the same software version without any protocol violations, the
SOFTWARE VERSION MISMATCH (SPN-FMI: 234-31) event should be set to INACTIVE.

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21.6.5 Ethernet Port Abnormal Update Rate (SPN-FMI: 625-9)

The ETHERNET PORT ABNORMAL UPDATE RATE (SPN-FMI: 625-9) warning event is used to detect a scenario
when the ethernet port is overloaded due to improper network traffic or miswiring (such as a ring topology). This
event uses the EMCP 4 ethernet statistics to detect an abnormal increase in the rate of incoming packets.

If the rate of incoming packages is too high the ethernet port is disabled to self protect the EMCP 4 and the event
is triggered. The ethernet port is re-activated any time the warning event is acknowledged (if the abnormal rate
of incoming packets still exists the warning will trigger again). If the warning event is not acknowledged the
ethernet port is re-activated once per hour in an attempt to return to normal operations (if the abnormal rate of
incoming packets still exists the warning event remains present).

Troubleshooting Steps:
If the ETHERNET PORT ABNORMAL UPDATE RATE warning event is ACTIVE in the generator set events log on
EMCP 4 display:
1. Check ethernet wiring of the network to verify a ring topology is NOT present. Two examples of ring topology
networks are shown below:

hub / switch /
repeater

(a) (b)

Figure 22.21 – Ring Topology Network Examples

2. Investigate all nodes connected to the ethernet network and audit the network traffic using a network analyzer
(such as Wireshark). Determine if any or which device or service is abusing the network with excess traffic.

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22.0 Installing and Upgrading Software

The EMCP 4 supports field-programming (called flashing) of software for all of the modules. This is done by
using the Cat Service Tool software and a Cat communication adapter. The primary data link (CAN 1) service
connector must be used for modules connected to the primary data link. The accessory data link (CAN 2) service
connector must be used for modules connected to the accessory data link. Refer to your generator set package
documentation for the location of the service connectors.

Note: Mismatched MGDL software versions will cause units to shutdown.

To flash the EMCP 4 requires the following hardware and software:

Software and Hardware Required

• The Cat Service Tool software installed and licensed on a PC
• A Cat communication adapter
• A 9-pin Deutsch service connection to the primary data link (CAN 1)
• The new application software flash file for the EMCP 4

In order to install software into the EMCP 4, the generator set must be stopped. If upgrading software, it may be
important to back up the current configuration (see Chapter 15). Flashing application software does not affect
the setpoints. However, if a problem occurs during flashing, this backup can be used to quickly configure a
replacement module.

Record the current software version information. This is seen in the ECM summary screen of ET (see Figure 22.1)
or the Device Info Screen on the EMCP (see Figure 22.2). This information is useful to obtain the correct flash file
if it is desired to return to the previous version of software after flashing.

Figure 22.1 – ECM Summary Information in ET

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 Installing and Upgrading Software

MAIN MENU DEVICE INFO

VIEW HARDWARE PART NUMBER:
CONTROL 3507076-01 CAT
CONFIGURE SERIAL NUMBER:
DEVICE INFO 2510E023TV
PREFERENCES

PAGE PAGE
UP DOWN

DEVICE INFO DEVICE INFO

SOFTWARE PART NUMBER: FPGA FIRMWARE VERSION:
4340346-00 4.1
SOFTWARE VERSION: MAC ADDRESS:
EMCP 4.4 English 01:23:45:67:89:AB
v4.3.2c PROD MGDL PROTOCOL VERSION:
02 April 2013 01
PAGE PAGE
DOWN UP

Figure 22.2 – Device Info Summary in EMCP

Flashing of modules other than the EMCP 4 follow similar steps as the ones outlined below.

In order to flash an EMCP 4 module, do the following steps:

1. Connect to the EMCP 4 using the Cat Service Tool as stated in Section 4.2.

2. Enter the WinFlash utility by selecting Utilities > WinFlash,

or by clicking the WinFlash Icon.

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Installing and Upgrading Software

3. The WinFlash screen will appear.

Note: If WinFlash does not find all of the modules on the J1939 data link to which it is connected, rescan the data
link by pressing F8 (or selecting File > Update ECM List).

4. Select the genset control if multiple modules are listed, then click the “Browse for a File” button on the right
hand side.

5. Browse to the appropriate file and click “Open.”

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 Installing and Upgrading Software

6. The new file information will be displayed.

7. Click “Begin Flash” in the lower left corner.

8. A confirmation screen will appear. Click “OK.”

9. A progress meter will show the status of the flash and the EMCP display will show that software installation is
occurring.

10. When the flashing process is complete, the ECM that was flashed will reboot. Also, WinFlash will bring up a
window giving options for what to do next. This indicates that the software has finished flashing, and is ready
to use.

11. On startup, the EMCP 4 shows the software part number. Verify the software part number matches the new
application software that was flashed.

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Installing and Upgrading Software

23.0 Appendix A – Menu Structures

For details on the setpoints available within each submenu, refer to the appropriate section above.

Figure – A1

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 Appendix A – Menu Structures

24.0 A
 ppendix B – EMCP 4 Front View and Navigation
Keys

EMCP 4.3 and 4.4

1. Display Screen 12. Scroll Up Key
2. AC Overview Key 13. Scroll Right Key
3. Engine Overview Key 14. OK Key
4. Main Menu Key 15. Scroll Down Key
5. Alarm Acknowledge/Silence Key with Yellow Warning Lamp 16. Scroll Left Key
6. Event Reset Key with Red Shutdown Lamp 17. Control Key
7. Event Log Key 18. F1 Soft Key
8. Run System Key 19. F2 Soft Key
9. Auto Key 20. F3 Soft Key
10. Stop System Key (Momentary) 21. F4 Soft Key
11. Escape Key

1. SCREEN
Displays various generator set information and parameters.
2. AC OVERVIEW
The AC Overview Key will navigate the display to the screen of AC bus information. The AC Overview Key
information contains a F1 soft key link to load bus overview.
3. ENGINE OVERVIEW
The Engine Generator Set Overview Key will navigate the display to the first screen of generator set engine
information. The engine overview information contains ECS position along with the number of warnings and
events. The second page gives MGDL information including generator set running information, along with
generator circuit breaker position and bus status.

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Appendix B – EMCP 4 Front View and Navigation Keys

4. MAIN MENU
The main menu key will navigate the display to the main menu directly without having to navigate out of menus.
5. ALARM ACKNOWLEDGE/SILENCE
Pressing the alarm acknowledge/silence key will cause the horn relay output to turn off and silence the horn.
Pressing the key will also cause any amber or red flashing lights to turn off or to become solid depending on
the active status of the alarms.
6. EVENT RESET
The event reset button will clear all inactive fault conditions.
7. EVENT LOG
The event log button will navigate the display to the list of event logs.
8. RUN
Pressing the RUN Key will cause the EMCP to enter the RUN system mode (send a group start over MGDL).
Note: If a digital input is programmed for ECS in Auto, or Stop, and a maintained switch latches that input to
make it active, the front panel RUN key will not have any effect.
9. AUTO
Pressing the AUTO Key will cause the EMCP to enter the AUTO mode.
Note: If a digital input is programmed for ECS in RUN, or Stop, and a maintained switch latches that input to
make it active, the front panel AUTO key will not have any effect.
10. STOP
Pressing the STOP key will cause the EMCP to enter the STOP mode and remove an ECS generated group
start. This key is momentary and the system will change back to ECS in Auto unless a digital input is active.
Note: If a digital input is programmed for ECS in Auto, or RUN, and a maintained switch latches that input to
make it active, the front panel STOP key will not have any effect.
11. ESCAPE
The escape key is used during menu navigation in order to navigate up through the menu/sub-menu structure.
Each key press causes the user to move backwards/upwards through the navigation menus. The escape key
is also used to cancel out of data entry screens during setpoint programming. If the escape key is pressed
during setpoint programming, none of the changes made on screen will be saved to memory. Pressing this key
will bring the user back one menu/submenu.
12. SCROLL UP
The scroll up key is used to navigate up through the various menus or monitoring screens. The scroll up key is
also used during setpoint entry. During numeric data entry the scroll up key is used in order to increment the
digits (0-9). If the setpoint requires selection from a list, the scroll up key is used to navigate through the list.

13. SCROLL RIGHT

The scroll right key is used during setpoint adjustment. During numeric data 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 or deselect a check box. If a box has a check mark inside the box, pressing the scroll right key will
cause the check mark to disappear, disabling the function. If the box does not have a check mark inside the
box, pressing the scroll right key will cause a check mark to appear, enabling the function.

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 Appendix B – EMCP 4 Front View and Navigation Keys

14. OK
The OK key is used during menu navigation to select menu items in order to navigate forward/downward in
the menu/sub-menu structure. The OK key is also used during setpoint programming in order to save setpoints
changes. Pressing the OK key during setpoint programming causes setpoint changes to be saved to memory.
15. SCROLL DOWN
The down key is used to navigate down through the various menus or monitoring screens. The down key is also
used during setpoint entry. During numeric data entry the down key is used in order to decrement the digits
(0-9). If the setpoint requires selection from a list, the down key is used to navigate down through the list.
16. SCROLL LEFT
The scroll left key is used during setpoint adjustment. During numeric data entry, the scroll left key is used
to choose which digit is being edited. The scroll left key is also used during certain setpoint adjustments to
select or deselect a check box. If a box has a check mark inside the box, pressing the scroll left key will cause
the check 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.
17. CONTROL
The control key will navigate the display to the screen that allows the user to monitor and/or adjust various
special control features.
18. F1
Pressing the F1 key will enable the function that is described on the screen directly above this key. When this
key is defined on screen to scroll the screen up or down, the scroll up and scroll down keys will also function
in that same capacity.
19. F2
Pressing the F2 key will enable the function that is described on the screen directly above this key. When this
key is defined on screen to scroll the screen up or down, the scroll up and scroll down keys will also function
in that same capacity.
20. F3
Pressing the F3 key will enable the function that is described on the screen directly above this key. When this
key is defined on screen to scroll the screen up or down, the scroll up and scroll down keys will also function
in that same capacity.
21. F4
Pressing the F4 key will enable the function that is described on the screen directly above this key. When this
key is defined on screen to scroll the screen up or down, the scroll up and scroll down keys will also function
in that same capacity.

Alarm Indicators
AMBER WARNING LIGHT
The amber warning light is located directly above the alarm acknowledge/silence key (5). A flashing amber
light indicates that there are unacknowledged active warnings. A solid amber light indicates that there are
acknowledged warnings active. If there are any active warnings, the amber light will change from flashing amber
to solid amber after the alarm acknowledge/silence key (5) is pressed. If there are no longer any active warnings,
the amber light will turn off after the alarm acknowledge/silence key (5) is pressed.

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25.0 Glossary of Terms

ACK – Acknowledge
CAN – Controller Area Network. This will often refer to our CAN J1939 Communications between ECMs.
DIO – Discrete Input/Output Module
EMCP 4 – Electronic Modular Control Panel 4. This is the Cat generator set control panel, consisting of a
generator set control (GSC).
ECM – Engine Control Module. This is a general term and can refer to any microprocessor-based module that is
part of a control system. The engine ECM is an ECM dedicated to the task of engine timing and air/fuel
control.
ECS – Engine Control Switch
ECU – Engine Control Unit. Another name for an ECM (Electronic Control Module).
EUI – Electronic Unit Injector. A type of Fuel Injector.
FMI – Failure Mode Indicator. The CAN term for a failure code associated with a particular Suspect Parameter
Number. For a complete list of FMI codes, refer to the Systems Operation Troubleshooting Testing and
Adjusting guide.
GSC – Generator Set Controller. This is the module responsible for the overall generator protection and control
functions. It is the master module on the generator set, interfacing with the user as well as the engine ECM
and any other accessory modules.
MGDL – Multiple Genset Data Link. A proprietary ethernet based data link network between EMCP 4.4 controllers
used for paralleling operations.
PCT – Programmable Cycle Timer. A timer which supports starting a generator set for exercise on a 7 day basis.
rpm – Revolutions per minute
RS-232 – Recommended Standard 232, maintained by the Electronics Industries Alliance (EIA). Also known as
EIA-232.
RS-485 – Recommended Standard 485, maintained by the Electronics Industries Alliance (EIA). Also known as
EIA-485.
RTU – Remote Transmitter Unit. This term refers to a Slave device in a MODBUS network that merely responds
to requests from the Master. The EMCP 4.2 can function as an RTU on a SCADA system via the RS-485
SCADA port.
SCADA – Supervisory Control And Data Acquisition. This term represents any computing system designed to
perform high-level control and monitoring over various subsystems. On the EMCP 4, we provide a
MODBUS interface to allow any SCADA systems to connect and collect data about the operations of
the control and the generator set(s).
SPN – Suspect Parameter Number. The CAN term for any parameter whose data is transmitted over a CAN
network, such as the EMCP 4 primary or accessory data link. For a complete list of SPNs supported by the
EMCP 4, refer to the Diagnostic Trouble Code List in the Systems Operation Troubleshooting Testing and
Adjusting guide.

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Notes

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