4 - EMCP and IVR

Electric Power
EMCP 4 and Related Items
Jeff Griffin
Cat Electronics
Mossville, Illinois USA
Agenda
• EMCP Evolution and Integration
• EMCP 4.1, 4.2, 4.3, and 4.4 Descriptions and Features
• EMCP 4.4 Detailed Discussion on Paralleling
Functions, Methods, and Operation
• Complex Software
• Integrated Voltage Regulator
• EMCP 4 Resources
• Remote Monitoring
• Optional Modules
Caterpillar Confidential Yellow

2014 Power Systems TC Conference
Page 2
One powerful future.
EMCP Evolution and Integration

EMCP Evolution
Electro-Mechanical EMCP II EMCP II+P EMCP 4.x
1970 1975 1980 1985 1990 1995 2000 2005 2010
EMCP I EMCP II+ EMCP 3.x

Page 4
Controls Integration
ADEM® ADEM® II A3 A4 A5
EMCP EMCP II EMCP II+ EMCP 3 EMCP 4

1980’s 1990 1996 2004 2011
EMCP 4.3/4.4 with CDL and PANEL to replace most

EMCP/EMCP II(+) Panels
Released in ANTARES ® under kit pn 439-5044 – Available.

EMCP 3 High Level Comparison
EMCP 3.1 EMCP 3.2 EMCP 3.3

EMCP 4
EMCP 4.1 EMCP 4.2 EMCP 4.3 EMCP 4.4
Basic High Performance

Increasing Controller Functionality

EMCP 4.1, 4.2, 4.3, and 4.4 Descriptions

and Features

General EMCP 4 Enhancements
• Screen navigation
• Programming
• User interface

Page 8
EMCP 4 User Interface
New Event
EMCP 4.1 & 4.2 Reset Button
New Event Log

Navigation Button
Added Text
New Navigation Button

Layout & Style
New Main Menu

New Engine Navigation Button
Overview Button
Symbol
EMCP 3

EMCP 4 User Interface
EMCP 4.3 & 4.4
Larger
Display
Dynamic
“Soft Keys”
New Control
Navigation Button
EMCP 4.1 & 4.2

EMCP 4.1 Features
Controls
• Auto/Start/Stop
• Engine cool down timer
• Emergency stop
• Engine cycle crank
Digital (LCD) Indication

• Generator AC voltage
 3 phase (L-L&L-N)
 ± 2% Accuracy
• RPM & battery voltage
• Gen. AC current (per phase & avg)
• Generator frequency
• Engine oil pressure (psi, kPa or bar)
• Engine coolant temperature (°C or °F)
• Multiple language support
• Engine start & crank attempt counter

EMCP 4.1 Features
Engine Protection
• Low oil pressure
• High coolant temp
• Low coolant level
• Fail to start
• Overspeed
Other Features
• Programmable security levels
• Reduced power mode
Generator Protection (N/A on EMCP 3.1)

• Over/under voltage
• Over/under frequency
• Generator phase sequence/rotation

EMCP 4.1 Input/Output
Analog Inputs
• 3 programmable input
(0-5V or 5-2000 ohm resistive)
- 2 are used for oil pressure
& water temperature on
non EUI engines
- Oil temp, fuel level, custom
Digital Inputs
• Emergency stop
• Remote start
• 6 programmable inputs*
Relay Outputs
• 6 programmable relays*
* See specific package spec sheet for availability for customer
(Form A, 2A @ 30VDC) use

EMCP 4.1 Communication Diagram
DEALER
SERVICE TOOL
“ET”
CDVR
CAN1
(Max 130ft or 40m trunk)
(Max 3ft or 1m drops)
ADEM
EMCP 4.1
Local Remote

Page 15
EMCP 4.2 Features
Controls
• Auto/Start/Stop
• Emergency stop
• Programmable cycle timer
(Avail on EMCP 3, N/A to EMCP 4.1)
Digital (LCD) Indication

 ± 1% Accuracy
• Gen. AC current • Engine oil pressure
(per phase & avg) (psi, kPa or bar)
• Generator frequency • Engine oil temperature (°C or °F)
• Power metering (kW, kVA, kVAR, pf) (Avail on • Engine coolant temperature (°C or °F)
EMCP 3, N/A on EMCP 4.1) • Multiple language support
• Hour meters (kW-Hour, kVAr-Hour) (Avail on • Engine start & crank attempt counter
EMCP 3 N/A to EMCP 4.1 • Real time clock (Avail on EMCP 3, N/A on
EMCP 4.1)

Engine Protection EMCP 4.2 Features
• Fail to start
• Overspeed
Other Features
• Programmable kW relay
(Avail on EMCP 3.2/3.3, N/A on EMCP 4.1)
Generator Protection
• Over/under voltage
• Over/under frequency
• Generator phase sequence/rotation
• Over current (timed & inverse) -
• Reverse Power
– Real (Avail on EMCP 3.2, N/A on EMCP 4.1)
– Reactive (Reverse Reactive Power N/A to EMCP 3 and 4.1)

EMCP 4.2 Features
Communication
• Accessory CAN data link (Avail on EMCP
3.2/3.3 N/A to EMCP 4.1)
• **RS-485 annunciator data link (New to
EMCP 4 and N/A to EMCP 3)
• RS-485 SCADA (Modbus RTU) (Avail on
EMCP 3.2/3.3, N/A on EMCP 4.1)

Digital Outputs
• 2 programmable outputs*
Analog Inputs
• 3 programmable input
(0-5V or 5-2000 ohm resistive)
- 2 are used for oil pressure &
water temperature on non
EUI engines
Digital Inputs
• Emergency Stop
• Remote Start
• 6 programmable inputs* Relay Outputs
• 6 programmable relays*
(Form A, 2A @ 30VDC)
* See specific package spec sheet for availability for customer • 2 programmable relays*
use (Form C, 2A @ 30VDC)

4 max total
DEALER
Local CAN Remote CAN Remote RS-485
SERVICE TOOL
CDVR Annunciator Annunciator Annunciator
“ET” Generator Expansion
Engine
Temps (max of 1) I/O
Temps
(max of 4)
(max of 1)
CAN1 CAN2 (Max 800ft or 244m trunk; Max 9ft or 3m drops)

RS-485 Annunciator Data Link
(Max 4000ft or 1219m length)
ADEM
RS-485 SCADA (Modbus RTU)
EMCP 4.2 Customer
Monitoring
System
Local Remote

Page 20
Controls EMCP 4.3 Features
• Auto/Start/Stop
• Emergency stop
5.5 inch Graphical Display
 ± 0.25% Accuracy (V, I)
vs 1% for EMCP3.2/3.3 and 4.2
• Power metering (kW, kVA, kVAr, pf)
• Hour meters (kW-Hour, kVAr-Hour)
• Engine oil pressure (psi, kPa or bar)
• Multiple language support
• Real time clock

EMCP 4.3 Features
Engine Protection
• Fail to start
• Overspeed
Other Features
• Programmable kW relay Generator Protection
• Status Event log • Over/under voltage
(Fault log on EMCP 3, Event Log only on • Over/under frequency
EMCP 4.1/4.2) • Generator phase sequence
• Over current (timed & inverse)
• Reverse power (real & reactive)
• Phase Rotation
• Current balance

Digital Outputs
Analog Outputs
• 3 programmable outputs
(4-20mA or ±10V)
• 2 programmable outputs (PWM)
Digital Inputs
• Emergency Stop
• Remote Start
Analog Inputs
• 3 programmable inputs
(±10V, PWM, current, or resistive)
- 2 are used for oil pressure & water
temperature on non EUI engines
* See specific package spec sheet for availability for customer use

EMCP 4.3 Features
Communication
• Accessory CAN data link
• RS-485 annunciator data link
• RS-485 SCADA (Modbus RTU)
– May also be used instead for CDL
• **Ethernet SCADA (Modbus TCP)
(New to EMCP 4 and N/A to EMCP 3)

Ethernet Communications
• High Speed Industry Standard Interface
(Modbus TCP-IP)
– Used for Multiple Genset Data Link (MGDL) paralleling
– Connect to customer system (SCADA, BMS, Switchgear)
• Faster communication
– Use Caterpillar offered systems
• Remote Monitoring Software
• Interface with Cat Switchgear
– Webserver (separate slide)
– Create dealer system
• Product Link Possibility
• Future Possibilities

EMCP 4.3/4.4 Webserver Available today!

Page 26
4 max total
DEALER
Local CAN Remote CAN Remote RS-485
SERVICE TOOL
CDVR Annunciator Annunciator Annunciator
“ET” Generator Expansion
Engine
Temps (max of 1) I/O
Temps
(max of 4)
(max of 1)
CAN1
CAN2 (Max 800ft or 244m trunk; Max 9ft or 3m drops)
RS-485 Annunciator Data Link
(Max 4000ft or 1219m length)
ADEM
RS-485 SCADA (Modbus RTU) or CDL
Ethernet (Modbus TCP) Customer
EMCP 4.3 (Max 330ft or 100m length) Monitoring
System
Local Remote

Page 27
Caterpillar Data Link (CDL) Support
• Replaces Modbus RTU (RS-485)
– EMCP 4.3 & EMCP 4.4 Controllers only
– Software Enabled (Requires reboot when changing)
– Not available on early production hardware
• Values (if available on CDL)
– Oil Pressure, Coolant Temp, Oil Temp, Fuel Temp, Exhaust Manifold Temp
– Exhaust Cylinder Temperatures
– Additional ones being added
• Events
– Engine Event Log will support EIDs and CIDs

Page 28
Controls EMCP 4.4 Features
• Auto/Start/Stop
• Emergency stop
• Paralleling
5.5 inch Graphical Display
 ± 0.25% Accuracy (V,I)
• Power metering (kW, kVA, kVAr, pf)
• Hour meters (kW-Hour, kVAr-Hour) Communication
• Engine oil pressure (psi, kPa or bar) • Accessory CAN data link
• RS-485 annunciator data link
• Engine oil temperature (°C or °F)
• RS-485 SCADA (Modbus RTU)
• Engine coolant temperature (°C or °F) • May also be used for CDL
• Multiple language support • Ethernet SCADA (Modbus TCP)
• Real time clock

EMCP 4.4 Features
Engine Protection
• Fail to start
• Overspeed
Other Features
Generator Protection • Programmable security levels
• Over/under voltage • Reduced power mode
• Over/under frequency • Programmable kW relay
• Generator phase sequence • Status event log
• Over current (timed & inverse)
• Reverse power (real & reactive)
• Phase Rotation
• Current balance
• Bus phase sequence

EMCP 4 Electrical Protection Summary
• Phase Rotation
– Standard on all controllers. EMCP 4 must see ABC clockwise
rotation.
• Current Balance
– Standard on EMCP 4.3 & 4.4
– Looks at difference in loading of each phase.
• Overcurrent
– New software supports multiple curves
• Factory may still be shipping old software
– Separate Overcurrent Warning and Inverse Shutdown Setpoints

Page 31
EMCP 4.4 Features
Digital Outputs
(vs 16 for EMCP 4.3)
Analog Outputs
• 3 programmable outputs
(4-20mA or ±10V)
• 2 programmable outputs (PWM)
Digital Inputs
• Emergency Stop
• Remote Start
Analog Inputs
• Oil pressure & water temperature
• 4 programmable inputs
(vs 3 for EMCP 4.1/4.2/4.3)
* See specific package spec sheet for availability for customer – (±10V, PWM, current, resistive)
use – Oil temp, fuel level, custom

EMCP 4.4 Strengths and Considerations
Strengths
• Price competitive against competitor solutions
• Low install time
• Minimal complexity
Application Considerations
• No system HMI
– PC Based remote monitoring
software available
• No utility paralleling*
• Basic load shed/add
• Low voltage only (less than 700 V)
• Only interfaces to a single package mounted
electrically operated circuit breaker
• Challenging
* Covered in separate section under complex software

EMCP 4.4 Paralleling
Paralleling Features
• Multi-unit island mode
• Multi-unit standby

EMCP 4.4 is DIFFERENT
• Auto Paralleling Controller
– Generator set will start and close the circuit breaker
• Methods to disable paralleling
– Flash with EMCP 4.3 software
• Lose all functionality on 70 pin connector including AI#4 and DO#17
– Program Digital Input to Control Sync Mode Switch
– Program Digital Input to “Disable Paralleling”
• Speed and voltage adjustment held through start/stop, but not power cycling
• Breaker is still controlled
– SMS in Manual when bus is dead
» Breaker Close request must be held if automatic close is desired
– SMS in OFF when bus is live

Page 35
EMCP 4 Event Log
• STATUS EVENT LOG
– Available on EMCP 4.3 and EMCP 4.4 only
– List operational changes in a chronological order
• GENSET EVENT LOG
– This log contains events generated by the EMCP
• EMCP acts as a window into what is being sent by other devices
– Engine Events are driven by the ADEM.
• EMCP just displays what is being sent
– Voltage Regulator Events are driven by the CDVR.
• EMCP just displays what is being sent
• IVR events show up in GENSET EVENT LOG
– Other Module Events are driven by the other modules.

Page 36
EMCP 4.4 Detailed Discussion on

Paralleling Functions, Methods, and
Operation

EMCP 4.4 Methods of Paralleling
• Hardwired Paralleling (HW)
– Original Offering
– Individual Wires
• Multiple Genset Data Link (MGDL)
– Ethernet based
– Ethernet Cables and Switches

Page 38
EMCP 4.4 – Paralleling Functions
• Bus Metering
• Synchronization Discussed Independent of
• Load Shed/Load Add Paralleling Method
• Soft Load/Unload
• Dead Bus Arbitration(DBA)

• Load Sharing Discussed Separately by
– Real (kW) Paralleling Method
– Reactive (kVAr)
• Load Sense Load Demand (LSLD)

EMCP 4.4 Bus Metering

EMCP 4.4 Synchronization
Automatic Additional
Tuning
Manual
Screens

EMCP 4.4 Load Shed/Load Add
• Purpose
– Provides a method to disconnect or add loads from the system based on user
configuration.
– The EMCP 4.4 genset controller has a single defined load shed stage. More stages
can be created by correctly programming the EMCP 4.4 genset control inputs and
outputs.
– Load Add (HW) is not a separately defined feature but the control is capable of load
add using relays, contacts (particularly circuit breaker contacts), and correctly
programming the EMCP 4.4 inputs and outputs to accomplish this task.
– Load Add - related to MGDL Feeder breaker control as a separate feature (covered
later).

Page 42
EMCP 4.4 Load Shed

Page 43
EMCP 4.4 Soft Loading/Soft Unloading
• Purpose
– Reduces instability and risk to equipment by increasing or decreasing generator
output in a controlled manner before closing or opening the generator circuit
breaker.

Page 44
EMCP 4.4 Soft Loading/Soft Unloading
GEN REAL LOAD CONTROL MAX
GEN SOFT UN LOAD TIME CONFIG
30 Seconds
PAGE PAGE
UP DOWN
GEN REAL LOAD CONTROL MAX

GEN SOFT LOAD TIME CONFIG
60 Seconds
PAGE PAGE
UP DOWN
GEN REAL LOAD CONTROL SOFT

UN LOAD COMPLETE % THRESH
5%
PAGE
UP

Page 45
EMCP 4.4 Hardwired (HW) Method of Paralleling
(Dead Bus Arbitration - DBA, Load Sharing, and Load Sense Load Demand-
LSLD)

Page 46
EMCP 4.4 HW Dead Bus Arbitration(DBA)
• Purpose
– Determines if a unit is the first unit ready to close to the dead bus and allows only
one unit to close to a dead bus in such a way that minimizes the time for a dead
bus closure
• Operation
– Uses virtual token based methodology
• All units must agree that the bus is dead.
• All units allowed to request token if up to speed and voltage.
• Only one unit can possess the token.
• Unit with the token must receive permission form all other units before attempting to
close to the dead bus.
• Token is passed via the hardwired lines between the units.
• If 2 units capture token simultaneously DBA
resolves issue so only 1 unit closes.

Page 47
• If the first unit ready to close to the dead bus fails to close to
the bus and other units are or become ready to close to the
dead bus, DBA removes permission from that unit and allows a
different unit to close to the bus
• Dead Bus Arbitration is still in effect when Sync Mode Switch
(SMS) is in Manual and Check

Page 48
EMCP 4.4 Hard-Wired Paralleling Lines
for Dead Bus Arbitration(DBA)
Requesting Line
Capturing Line
Arbitration Line
Reference “A” Line
Best Battery Positive Line

EMCP 4.4 Hard-Wired Paralleling Lines
for Dead Bus Arbitration(DBA)
Gen N ( up to 8)


EMCP 4.4 Hardwired (HW) Load Sharing
• Purpose
– The purpose of Real and Reactive Load Sharing is to share the real and reactive
load proportionally among all of the online units in an island mode type
configuration. This island mode configuration can be prime power, standby, or peak
shaving (disconnected from the mains/utility).
• Operation
– When the generator breaker is closed and the load sharing is set to HW, the unit
controls load until the internally generated load (real and reactive) signal matches
the externally measured load signal (real and reactive) from another generator set.

Page 52
EMCP 4.4 HW Load Share Lines
Load Share Line (kW)
Load Share (kVAR)
Load Share Reference

EMCP 4.4 HW Load Share

EMCP 4.4 HW Load Sense Load Demand
• Purpose: To have an automatic priority sequencing function to
modulate the number of gensets online to control load
percentages per machine. This may assist with fuel efficiency
while maintaining adequate reserve capacity. It is based on:
• Priority
– ( Lowest Parallel Priority Number is the fastest unit to change for HWLSLD)
• Add/Drop % (based on individual unit capacity)
• Add/Drop time
- HWLSLD required conditions: ECS in Auto, SMS in Auto, Idle/Rated
set to Rated, No shutdown faults, HWLSLD Enable mode to HW,
Valid initiate CMD.

Page 55
EMCP 4.4 HW Paralleling Lines for Load
Sense Load Demand (LSLD)
HWLSLD – All Run
HWLSLD - Excess
HWLSLD - Overload
HWLSLD- Ramping
HWLSLD Reference “A” Line

(LSLD)

(LSLD)

EMCP 4.4 HW Method of Paralleling
10 wire Interconnection between each generator set
- Load Share line (kW, kVAR) (1 cable with 3 leads)
- Hardwire Dead Bus Arbitration (HWDBA) lines (5)
- Hardwire Load Sense Load Demand Lines (5)
kW-kVAR shielded triad
DBA-Requesting Line
DBA-Capturing Line
DBA-Arbitration Line
DBA and HWLSLD Reference “A” Line
DBA-Best Battery Positive Line
HWLSLD – All Run
HWLSLD – Excess
HWLSLD – Overload
HWLSLD – Ramping

EMCP 4.4 Multiple Genset Data Link (MGDL)
Method of Paralleling
(Dead Bus Arbitration- DBA, Load Sharing, and Load Sense Load Demand-
LSLD)

Page 60
EMCP 4.4 Multiple Genset Data Link
(MGDL)
Instead of Running 10 wires
between units, MGDL uses
low cost Ethernet
Connections between sets

Page 61
EMCP 4.4 MGDL Overview Screen
“My unit” indicator
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)

Page 62
EMCP 4.4 MGDL Unit Details Screen

Page 63
EMCP 4.4 MGDL Dead Bus Arbitration
• Purpose
– Determines if a unit is the first unit ready to close to the dead bus
and allows only one unit to close to a dead bus in such a way that
minimizes the time for a dead bus closure
• Operation
– Uses a virtual token based methodology All units must agree that
the bus is dead.
• All units are allowed to request the token if they are up to speed and voltage.
• Only one unit can possess the token.
• Unit with the token must receive permission form all other units before
attempting to close to the dead bus.
• Token is passed using the MGDL network

Page 64
• If the first unit ready to close to the dead bus fails to
close to the bus and other units are or become ready
to close to the dead bus, DBA removes permission
from that unit and allows a different unit to close to the
bus
• Dead Bus Arbitration is still in effect when Sync Mode
Switch (SMS) is in Manual and Check

Page 65
(DBA)
ETHERNET (MGDL)

EMCP 4.4 MGDL Load Sharing
• Purpose
– The purpose of Real and Reactive Load Sharing is to share the real
and reactive load proportionally among all of the online units in an
island mode type configuration. This island mode configuration can
be prime power, standby, or peak shaving (disconnected from the
mains/utility).
• Operation
– When the generator breaker is closed and the load sharing is set to
Ethernet (MGDL), the unit calculates a system load sharing target
based on information provided on the MGDL network. The unit
controls load until the individual generator load matches the system
load sharing target. As the system load sharing target changes, the
EMCP 4.4 adjusts the generator set speed or voltage control to
match the target.
Page 67
EMCP 4.4 MGDL Load Share
ETHERNET (MGDL)

EMCP 4.4 MGDL Load Sense Load
Demand (LSLD)
Purpose:
– To have an automatic priority sequencing function to modulate the
number of gensets online to control load percentages per machine.
This may assist with fuel efficiency and maintain adequate reserve
capacity.
• Supports Fast Add Setpoints
• Based on one of 2 possible strategies :
– Priority Number
» Priority - Lowest Priority Number has the highest priority
highest priority on first and off last
» Add/Drop % (based on system capacity of units in LSLD control)
» Add/Drop Time
– Total Operating Hours with optional engine hour
offset

Page 69
EMCP 4.4 MGDL Load Sense Load
Demand (LSLD)
ETHERNET (MGDL)

EMCP 4.4 Multiple Genset Data Link (MGDL)
Feeder Breaker Control

Page 71
MGDL Feeder Breaker Control
• Breaker close/trip control based on on-line capacity
• Setpoints (1 set per EMCP 4.4 controller)
– Minimum Real Power Required (kW based)
– Minimum Reactive Power Required (kVAr based)
– Programmable Digital Outputs
• Feeder Breaker Close (closes when system reaches both levels (kW and
kVAr), stays closed until FB trip)
• Feeder Breaker Trip (activates for 1 second when last unit on bus opens
CB)
• Redundancy Consideration
– Multiple Controllers
• Program and wire multiple controllers to cover loss of controller due to
maintenance?

Page 72
MGDL Feeder Breaker Control

Page 73
EMCP 4.4 Multiple Genset Data Link MGDL Loss
of Communications Strategy

Page 74
EMCP 4.4 MGDL Loss of Communications
Strategy
• Provides redundancy to the MGDL paralleled system if 1 or more
units is lost from network
• Groups units and alters modes of failure scenarios in order to
maximize load capability of the MGDL paralleled system and
minimize the risk of loss of load or damage to equipment.
• Loss of Communications is a failure mode.
– If unit is being taken offline for maintenance, reset the number of expected
controllers to allow for normal operation. System will automatically detect when
unit returns.

Page 75
EMCP 4.4 MGDL Loss of Communications
Strategy
• Load Sharing
– 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.
• Dead Bus Arbitration
– Uses knowledge of network topology and applies failsafe arbitration logic to
proceed through dead bus closure operations during an MGDL loss of
communications scenario.
• Load Sense Load Demand
– Uses knowledge of network topology and applies failsafe logic to proceed
through LSLD operations during an MGDL loss of communications scenario.

Page 76
EMCP 4.4 Multiple Genset Data Link (MGDL) and
Hard-Wired(HW) Comparisons

Page 77
EMCP 4.4 Paralleling Method General Comparisons
• Hardwired Paralleling(HW)
– Original Offering
– Individual Wires – easier to troubleshoot
– Reverse Compatibility with existing Woodward Load Sharing Lines and XQ Modules
– Parallel up to 8 Gensets
• Multiple Genset Data Link (MGDL)
– Ethernet based
– Increased capability and Information
– Decreased setup and tuning steps required
– Parallel up to 16 Gensets
– Improved Load Add (Feeder Breaker) and LSLD
– Provides Failsafe Modes of Operation for DBA, LSLD, and Load Sharing during a
loss of communications

Page 78
EMCP 4.4 MGDL: Simplified Wiring
Hardwired (HW) 10 wire MGDL Ethernet Connection
Interconnection and Switch
Switch
Ethernet Cable

EMCP 4.4 HW & MGDL Load Sense Load (LSLD)
Comparison
• Purpose: Automatically add or remove generator sets from the bus
to maintain fuel efficiency and adequate reserve capacity based on:
– Priority; Add/Drop time
– Add/Drop %
• MGDL system capacity based. HW unit capacity based
• Benefits of MGDL LSLD
– Total Operating Hour Balancing strategy option with engine hour offset
– Improved sequencing
– Fast Add Setpoints
– Setpoints are system wide (automatically duplicated through system)

Page 80
EMCP 4.4 Start Signal Comparisons
• Hardwired Paralleling
– Remote Initiate-
• Starts Single Unit in AUTO (itself),
• Load Sense Load Demand is NOT active,
– Group Start
• Starts Single Unit in AUTO,
• Load Sense Load Demand is active
• Multiple Genset Data Link
– Remote Initiate
• Starts Single Unit in AUTO (itself)
• Load Sense Load Demand is NOT active
– Group Start
• Starts ALL units that are in AUTO
– Note: For redundancy, multiple Group Start Signals should be wired
• Load Sense Load Demand is active

Page 81
Complex Software

Rental Specific Features (in Complex software)
• Switchable • Switchable ratings

ratings • Generator paralleling
• Intertie Paralleling Mode
EMCP 4.2, EMCP 4.4

EMCP 4.3
Switchable Ratings in Complex Software
• Changes rated voltage and/or rated frequency configuration using switching devices (link board
and operator switch) which supply inputs to the EMCP 4
• No need to connect a laptop or CAT service tool to make settings changes.
• Quicker site setup time
• Reliable - all necessary settings changed correctly
every time
• Simple – does not require a dealer technician to switch
ratings
Switchable Ratings(Example)
480V 400V
60Hz 50Hz
240V 208V
60Hz 60Hz

Complex Software
*Controls may be flashed with ET between Standard and Complex. No Interlock code.
• EMCP 4.1
– “Standard” software in 28 Languages
• EMCP 4.2
– “Complex” software in English*
• Contains switchable ratings
• EMCP 4.3
– “Complex” software in English
• Contains switchable ratings
• EMCP 4.4
– “Complex” software in English*
• Contains switchable ratings, Intertie paralleling functionality

Page 85
Software Releases
• EMCP 4.1/4.2 Releases
– Software Version 4.0 4Q-2010
• Initial Release
• Improved Modbus RTU communications
• Miscellaneous Improvements, New Events, Bug Fixes
• Improved Tier 4I, Gas, Rental and Solutions support
• IVR- Integrated Voltage Regulator
• Prod 4.3.2 fixed Reduced Power Mode portion of CPI project
• Improved Overcurrent Protection

Page 86
Software Releases
• EMCP 4.3/4.4 Releases
• Initial Release
• Improved Modbus RTU communications
• IVR (Integrated Voltage Regulator)
• CDL (Caterpillar Data Link, (Legacy and Gas product support))
• DGB (Dynamic Gas Blending)
• MGDL-Multiple Generator Set Data Link
• Webserver
• Prod 4.3.2 fixed portion of CPI project
• Improved Overcurrent Protection, Smart Engine Cylinder Temperature Differential, TLR (Transient Load
Relief)

Page 87
EMCP 4 Part Numbers
Replacements are fully compatible with previous versions.
– EMCP 4.1
• Original 351-8757
• Replacement 450-9596
– EMCP 4.2
• Original IVR capable 431-1966
– EMCP 4.3
– EMCP 4.4

Page 88
I/O Status
MAIN MENU/VIEW/”I/O STATUS”/
DIGITAL INPUTS, DIGITAL OUTPUTS, RELAY OUTPU

“-” I/O is NOT Logically Active
“A” or “1” I/O is Logically Active
“X” I/O is DISABLED
Move cursor (box) for details on how the I/O point works.

Page 89
Package Data Links
• CDL-Cat Data Link (Proprietary)
– EMCP II(+), ADEM 2 only has this Data Link for package communication
– CCM-Customer Communication Module
• Converts CDL to M5X (M55) (published Cat Only Data Link)
• PL1000T is the replacement
• J1939-CAN 1, CAN 2
– EMCP 3, 4, A3 and above have at least 1 port.
– Governed by SAE (Society of Automotive Engineers)
– Published by SAE-Note: Not all Cat implementation follows the standard.
– CAN 2 does NOT follow the J1939 standard
• Increased distance capabilities (800 ft) versus 40M total for CAN 1.
• ATA-Not used by EPD for Configuration

Page 90
Customer Data Links
• Modbus RTU or Modbus RS-485 or SCADA RS-485
– Physical layer is RS-485
– Modbus is communications protocol
– Master Slave Protocol
• EMCP 3.2, 3.3 and 4.2, 4.3, 4.4 are slaves.
– SCADA limited to approximately 1 16 bit word per ½ second
• Modbus TCP/IP
– Physical layer is Ethernet (10 Base T)
– Modbus is communications protocol
– Peer to Peer Network (multiple requests from different sources
– Scada limited to approximately 40 16 bit words per ½ second

Page 91
ET-Cat Electronic Technician
• Updated 3 Times each year (A, B, C)
• All licenses are now expiring licenses.
– Software may be updated while staying within license (since 2010C)
• ET may lag new software feature availability.
• Error messages on display are different than ET
– ET reflect SAE J1939 standard. Display is customized for the application.
• Product Status Report
– Gives all setpoints, current events, etc.

Page 92
ET-Cat Electronic Technician
• Configuration
– ET will try multiple data links
– CA3 supports dual Data Links (J1939 and CDL)
– Configuration can be used to speed up connections.
• Advanced Preferences-EPD does NOT use ET or Winflash over ATA.
• Error Messages
– Value out of range
• May not be a supported value
• May not be able to be written to due to current state.
– Some values are not accessible when genset is running.

Page 93
Comm Adapter
• Comm Adapter 2-CA2
• Comm Adpater 3-CA3
– Firmware-Firmware has been updated.
• Modifiable Text Strings requires the latest firmware
– Issues
• Ground Loop-Cable must have bulge in USB by adapter or sticker of USB-PC.
• Power Draw-May be powered from PC or Package.
– Plug into package first
– Run batch file to force power from package

Page 94
Integrated Voltage Regulator (IVR)

Integrated Voltage Regulator (IVR) Topics
• Key Benefits
• Technology Overview
• IVR vs Cat® DVR Comparison
• IVR Feature Specifications
• IVR Excitation Module Hardware (EM10/EM15)
• Setpoint Configuration (ET and EMCP)
• Status Information (EMCP)
• Documentation

Page 96
IVR System Key Benefits
• Simplified operation and troubleshooting
• Removes duplication of setpoints
• Configure IVR parameters directly from the EMCP screen
• Dedicated IVR status screens
• Harness simplification
• Removes duplication of voltage and current sensing
• Simplified system – fewer setpoints and less wiring
• Supports multi-rating configuration on rental products
(with complex software)
• Display screens for IVR status information
• Fully supported by Cat ET service tool
• Removes need for additional PC software

Genset Control System Overview without
IVR
EMCP 4.X or EMCP 3.X
Cat DVR
R448
R450
VR6
Automatic Voltage Regulator:

• Duplication of voltage and current sensing with Genset Control
• Duplication of setpoints with Genset Control
• Separate service tool for programming / communication

Genset Control System Overview with
IVR
EMCP 4
Key advantages of IVR system:

• Removes duplication of voltage and current sensing
• Simplified system – removes duplication of setpoints

IVR vs. Cat DVR Comparison
• Cat DVR setpoint configuration directly ports to EMCP IVR

• Matches Cat DVR feature specification
(PF Control Only offered on EMCP 4.2)
• Same transient performance as with Cat DVR
• EMCP IVR input/output capable of same functionality as Cat DVR

IVR Feature Specifications
SPECIFICATIONS
No Load to Full Load Regulation ±0.5% ±0.25% ±0.25% ±0.25%
Configurable Volts/Hz Characteristic • • • •
Configurable Knee Frequency • • • •
Regulator Response Time 10 ms 10 ms 5 ms 5 ms
Single and Three Phase Sensing • • • •
Voltage Adjustment Range (Configurable up to) ± 30% ± 30% ± 30% ± 30%
CONTROL
Dual Slope Configurable Volts/Hz Characteristic • • • •
Excitation Enable/Disable Selection • • • •
Line Loss (I2R) Compensation - • • •
Reactive Droop Compensation - • • •
Power Factor Control Mode - • • •

IVR Feature Specifications (cont’d)
PROTECTION / ALARMS
Generator Overvoltage • • • •
Generator Undervoltage • • • •
Over Excitation • • • •
Loss of Sensing • • • •
Generator Reverse VARs - • • •
Event Log • • • •
METERING
EMCP AC Metering • • • •
EMCP Power Metering - • • •
Excitation Command Percentage • • • •
Operating Mode Status Indication • • • •

IVR Feature Specifications (cont’d)
VOLTAGE ADJUSTMENT
EMCP 4 Display Voltage Bias • • • •
Digital Input (Raise/Lower) Voltage Bias1 • • • •
Potentiometer Voltage Bias1 • • • •
Analog Voltage Bias – Voltage Range1 0V to 5V 0V to 5V -10V to +10V -10V to +10V
Analog Voltage Bias – Current Range1 - - 0mA to 20mA 0mA to 20mA
Analog Voltage Bias – PWM Range1 - - 0% to 100% 0% to 100%
1Requires an available input on the controller

IVR Excitation Module Hardware
Designed to support the range of Cat generators:
EM10 EM15
Cat Part Number 398-7247 398-7248

Compatible Excitation Types Shunt / Internal Excitation (IE) / PMG
Nominal Field Current Output 6 Amps 7 Amps
Maximum (forcing) Field Current Output 10 Amps 15 Amps
Maximum AC Voltage Input 180 Vrms 240 Vrms

IVR Configuration (Using EMCP Display)
• All Voltage Regulator setpoints configurable through EMCP Display
MAIN MENU > CONFIGURE > ALL SETPOINTS > VOLTAGE REGULATOR
NOTE: Configure voltage regulator control type

through a single setpoint:
External Control (Cat DVR, R448, R450 etc.)
vs. Internal (Genset) Control (IVR)

IVR Configuration (Using 2012A ET)
Under EMCP device

IVR Status Information (Using EMCP Display)
• IVR operating mode, target voltage, excitation command and compensation type
(if configured) available from EMCP display
EMCP 4.3/4.3: MAIN MENU > VIEW > IVR OVERVIEW
EMCP 4.1/4.2: MAIN MENU > VIEW > IVR OVERVIEW

IVR Status Information (Using EMCP Display)
• Active voltage bias and excitation command PWM is available from EMCP display
• NOTE: IVR requires PWM Output #2 from EMCP 4.3/4.4
• NOTE: IVR requires Digital Output #2 / IVR CS+ from EMCP 4.1/4.2
EMCP 4.3/4.4: MAIN MENU > VIEW > IVR OVERVIEW > VOLTAGE BIAS OVERVIEW
MAIN MENU > VIEW > GENSET OVERVIEW > PWM OUTPUTS
EMCP 4.1/4.2: MAIN MENU > VIEW > IVR OVERVIEW > VOLTAGE BIAS OVERVIEW

Documentation
• Spec Sheets
• EM10-LEHE0449
• EM15-LEHE0450
• IVR-LEHE0448
• A & I Guide
– Incorporated into EMCP 4 A & I Guide
• LEBE0006-02
• Special Instruction (on SIS)

– REHS9106

EMCP 4 Resources

EMCP 3 to EMCP 4 Conversion
• EMCP 4 is more cost competitive than EMCP 3
– EMCP 4.2 can be used to replace all EMCP 3 controllers
– EMCP 4.1 can be used to replace EMCP 3.1
• Software Conversion
– ET 2013B and later
– REHS5544

EMCP 4.3 Retrofit Panel Features
• Is a complete solution for customers needing
to replace an obsolete EMCP 1 genset
controller, or upgrade from any other previous
generation EMCP
• Simply follow the procedure found in Special
Instruction REHS8842 to connect the EMCP 4.3
controller to your generator set and configure it
• Cat’s Integrated Voltage Regulator (IVR) is built
into the EMCP 4.3 genset controller
– Just add an optional excitation module
• Interfaces to external automation systems via
Ethernet, using Modbus TCP and TCP/IP
protocols

Page 114
EMCP 4.3 Retrofit Panel Benefits
• Provides an easy solution to customers with
obsolete or outdated genset controllers
• Many new or enhanced features over previous
generation controllers
• Tested and documented upgrade from Cat that
is designed to be completed within a day
• The built-in IVR with TLR (Transient Load
Reduction) technology for the very small
incremental cost of an optional excitation
module
• Modern Ethernet communications interface
provides
– Integration with upgraded switchgear
– Connection to plant/building management systems
– EMCP 4.1 and 4.2 genset controllers do not support
Ethernet communications

Page 115
EMCP 4.4 Retrofit Panel
• All the functionality of the EMCP 4.3 panel, plus generator paralleling functions
– Dead Bus Arbitration
– Synchronization
– Load Sharing
– Load Shed / Load Add
– Load Sense / Load Demand
• Available in June

Page 116
EMCP Retrofit Panel Cost and Pricing
EMCP 4.3 Upgrade Panel EMCP 4.4 Upgrade Panel
• D/N Price = $7,350 • D/N Price = $8,085
• List Price = $10,000 • List Price = $11,000
• Merchandising Program • Merchandising Program
– Runs Jan. 1 through Oct. 31 – Will add the EMCP 4.4 part
– Optional customer discount number to the PCS program once
• 10% off to the customer the upgrade panel is released by
• $500 contribution from both Cat Cat Electronics
and the dealer

EMCP 4 Retrofit Sales & Technical Literature
• EMCP 4.3
– Upgrade Data Sheet: LEXE0750-00
– Upgrade IRM: PELJ1625
– Upgrade Special Instruction: REHS8842
– A&I Guide: LEBE0007-02
– IVR Data Sheet: LEHE0448-00
• CDVR
– Data Sheet: LEHE3225
– Upgrade Special Instruction:
REHS4494-02
• Copies of this literature are stored
on POWER NET
– https://engines.cat.com/gensetelecupgra
dekits

Page 118
Sales Training (DPC (DLMS)/CLMS Courses)
• DPC Course #40941
• CLMS Course #36227
– Background Information on the EMCP 4 Controller Family
– Sales Scenarios
– CEU available

Page 119
Power Net – Your One Safe Source
https://engines.cat.com/ep/products/emcp

• Spec Sheets
– Controllers, Optional Modules, and
Monitoring Software
• Presentations
– Launch Presentation
– EMCP 4 Features and Benefits
– Paralleling Strategy
– Competitive Comparison
– Monitoring Software Overview
• Product Images

Page 121
• A&I Information
– EMCP 4.1/4.2 – LEBE0006
– EMCP 4.3/4.4 – LEBE0007
– MGDL Guide– LEBE0031
– SCADA DATA LINKs –LEBE0010
– Advanced Feature Summary
• 4.1/4.2 - LEXE0225
• 4.3/4.4 - LEXE0226
– EMCP Monitoring Software Guide –LEBE0001
– Retrofit Instructions: EMCP 3 to 4.1/4.2 (REHS5544)

Page 122
EMCP 4 Controller Demo
• Power Net
– Interactive Software: EMCP 4 Controller
– Download from EMC from Power Net Link
• Web (limited version) (share with engineers, and others)
– http://www.catelectricpowerinfo.com/emcp4/

Page 123
Support Materials
• EMCP Quick Start Guide (LEXE0186, LEXE0187)

Page 124
Knowledge Network
• Electric Power Electronics EMCP Community Issues:
– All EMCP Issues
– 22 issues related to EMCP 4
– https://kn.cat.com/cat.cfm?id=6767
• EMCP 4 Discussion Board

– Strictly EMCP 4 Issues
– 20 issues posted
– Updated P/Ns
– Notices of Software updates
– https://kn.cat.com/cat.cfm?id=16597

Page 125
White Paper on PowerNet
• Retained Speed/Frequency Biasing Methods for EMCP 4
Controllers
– LEXE0747
• Analog Input
• Complex Software
– Allows programmable rated frequency to hundredth of Hz
• Gear Ratio
• Voltage settable to individual volt (VAC)

Page 126
Remote Monitoring

EMCP 4 Monitoring Software
• EMCP 4 Remote Monitoring & Control
Software for up to 16:
– Cat Gensets
– Cat ATS (MX150/MX250 and and ATC)
– Cat UPS (UPS300 Flywheel)
• Allows the user to:
– Monitor
– Log
– Graph
– Control – EMCP Only
• Communication
– RS-485 (all devices)
– Ethernet (EMCP 4)
– Options
• Modem
• Local Area Network
• Internet

Page 128
Remote Monitoring Software
Version 3.1
• Designed to work with EMCP 4 New Features
– Quick connection with Ethernet or RS-485
• EMCP 4.3 & 4.4 only for Ethernet
• Monitor real time data from truck or building
• Offer customer monitoring capability without having
customer near Generator Set

Page 129
Remote Monitoring Software

Automatic Data Logging
• User Selectable Parameters
– Programmable update times (use Ethernet for fast updates)

Optional Modules

CAN Annunciator
• Networked device, no discrete signal wiring
required
• 16 Points, 32 LEDs
– (12) Amber and Red LEDs
– (4) Green and Red LEDs
• Standard label for NFPA 99 & 110
• All 16 points configurable to any event
– Custom Label Kit available
• Local or Remote
– up to 800ft (244m)
• Up to four (4) annunciators per EMCP 4.2,
4.3, or 4.4 on CAN 2

RS-485 Annunciator
• Networked device, no discrete
signal wiring required
• 16 Points, 32 LEDs
– (12) Amber and Red LEDs
– (4) Green and Red LEDs
• Standard label for NFPA 99 & 110
• Remote
– up to 4000ft (1220m)
• The number of annunciators per
EMCP 4.2, 4.3, or 4.4 allowed up to
network limit

Digital I/O Module
• Configure I/O for any event
• Local or remote mounted up
to 800 feet (244m)
• Up to four (4) DIO Modules
per EMCP 4.2, 4.3, or 4.4 on
CAN 2
• (12) Discrete Inputs
• (8) Relay Outputs

RTD & Thermocouple Module
• Generator Bearing & Stator
Temperature Monitoring
– EMCP 4.2, 4.3, or 4.4
controller
– Temperature Monitoring
– High Temperature
Warning/Shutdown

Questions

Page 137

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