CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 1

FACILITATOR GUIDE

Slide 1 Say:
 Hello, my name is______

Do:
 Introductions
 Safety
 Instructions and general information. There is Continuing Education Credit
available for those who desire to receive it. Please make sure you check the
box on the Sign in sheet and make sure your e-mail address is correct. The
CEU Certificate will be e-mailed to you from Bradley University

Do: (next slide)

Facilitator’s Notes

Page 1 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 2
FACILITATOR GUIDE

Slide 2 Say:
 Caterpillar has been manufacturing complete generator set packages since
the late 1930s. Over the years, diesel technology has evolved in many areas:
basic engine design, engine electronics, air systems and fuel systems.
Similarly, the generator set control system has progressed from basic
mechanical designs to electro-mechanical to electronic, and now the high
functionality digital control designs used today.

 In the early 1970’s, the first generation of generator set control panels was
introduced – the Electro-Mechanical Control Panel. The Electro-
Mechanical Control Panel provided a complete generator set monitoring
system that met the needs for most installations in a rugged, generator-
mounted enclosure. This was the first time engine mechanical and generator
electrical monitoring and protection was combined with generator set control
into a single panel.

 This was followed in the early 80’s by the Electronic Modular Control Panel
(EMCP). It moved the control panel from an electro-mechanical control to
a microprocessor based control panel, with digital monitoring and protection
that set the industry standard for accuracy and reliability. The original
EMCP was the first unit to offer improved reliability and durability using
environmentally sealed, solid state, microprocessor-based modules. These
units offered the precision of a digital LCD display and the advantage of
diagnostic codes. EMCP also had user-friendly outputs to which an
annunciator could easily be connected to remotely sound or display system
faults.

 Building on the success of the EMCP I, the EMCP II was introduced in the
early 90’s, and integrated the engine control module and AC meter module
into a single unit, eliminating the guesswork in generator set monitoring.
EMCP II also added the ability for a customer to access analog information
using the Cat Customer Communication Module (CCM).

Page 2 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 3
FACILITATOR GUIDE

Facilitator’s Notes
Slide 2 Say:
Cont’d. (SAME SLIDE - TEXT CONTINUES)  For mechanical unit injection (MUI) engines, the EMCP II controlled start/stop, monitored
engine and package parameters, and protected the engine for low oil pressure, high water
temperature, and over-speed. External controls were used to govern the engine. With the
advent of electronic engines, the engine monitoring, protection, and governing was moved
to an ADEM engine controller. Critical engine data was communicated to the EMCP II via a
Cat Datalink.
 The next evolution of the EMCP family came in the mid 90’s with the introduction of the
EMCP II+. EMCP II+ offered additional three-phase power metering - data could be
displayed in kW, kVAR, kVA, pf, % of rated power, kWhr, and kVARhr. This unit also had
programmable protective relay functions, power metering and improved diagnostics.
 In the late 90’s, the EMCP II+P was introduced. The EMCP II+P incorporated the
functionality of an external synchronizer with breaker control, dead bus detection, and built
in synchroscope to allow for paralleling with multiple generator sets.
 In 2004, the next generation of EMCP controls was introduced – the EMCP 3 series of
controls. EMCP 3 was a complete controller re-design, which introduced expanded
functionality such as a totally menu-driven interface. The EMCP 3 series is available in
three models – 3.1, 3.2, and 3.3 – designed to match features with specific customer
requirements. Higher levels offer expanded options with the introduction of Modbus
communications and expansion modules.
 As technology continues to advance at an ever increasing pace, the generation gap between
controllers is shrinking. The EMCP II platform served Cat Electric Power for almost 15
years. But only 6 years separates the EMCP 3 from its successor – the EMCP 4. Further
development of the EMCP 4 platform continues with the more recent upgrades including the
EMCP 4.4 Master Control Panel, the Supervisory Control Panel (SCP) and features such as
thermal damage overcurrent protection.

Say:
 Next, we will examine the details on each controller level.

Do: (next slide)

Facilitator’s Notes

Page 3 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 4
FACILITATOR GUIDE

Slide 3
Say:
 In discussing Genset Controls technology, we will walk you through the various
options available to you from Caterpillar, ranging from the most basic of controls to
sophisticated paralleling systems and available accessories.
 A breakdown of the EMCP 4 Product Family:
o The EMCP 4.1 is the most basic Generator Set Controller
o The EMCP 4.2 / 4.2B adds KW Metering as well as the ability to add
accessory devices
o The EMCP 4.3 adds Ethernet communication capability along with an
Enhanced monitoring Screen (5 1/2 “)
o And the EMCP 4.4 adds generator Paralleling capability
 We also have a number of controls accessories that we will talk about

 Next, we will examine the details on each controller level.

Do: (next slide)

Facilitator’s Notes

Page 4 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 5
FACILITATOR GUIDE

Slide 4 Say:
 Our most basic genset controller, the EMCP 4.1, is a reliable and cost
effective controller for basic generator set operation, and is the entry level
controller for monitoring and control of a single generator set. The
controller provides basic engine controls – stop/run/auto push button
controls, cycle crank, and cooldown timer. The display is a 3.8 inch
graphical display that supports multiple languages, including character
languages such as Chinese, Arabic, Russian, and Japanese. The EMCP 4.2
provides monitoring of generator electrical output, including AC voltage,
current, and frequency. For the AC metering, the EMCP 4.1 provides ±2%
metering accuracy. From an engine standpoint, the EMCP 4.1 monitors
mechanical information such as oil pressure, oil temperature, coolant
temperature, engine speed, and battery voltage.

 Monitoring of mechanical information such as oil pressure, oil temperature,

coolant temperature, engine speed, and battery voltage, and monitoring of
generator electrical output, including AC voltage, current, and frequency.
For the AC metering, this controller provides ±2% metering accuracy.

Do: (Next Slide)

Facilitator’s Notes

Page 5 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 6
FACILITATOR GUIDE

Slide 5 Say:

 At this level of controller, a number of protective functions are available.

For generator AC protection, the EMCP 4.1 provides warnings and
shutdowns for over/under voltage, over/under frequency, and generator
phase sequence. Engine protection includes warnings and shutdowns for
low oil pressure, high coolant temperature, low coolant level, failure to start,
and overspeed.

 In addition to the generator and engine protection, this control level provides
programmable security levels that can be set in the field to prevent un-
authorized access to operate the generator set. The EMCP 4 is equipped
with five security levels: Level 0 (accessible by anyone), Level 1 & 2
(password protected at the controller), level 3 (requires a factory password),
and service tool accessible (via Cat Electronic Technician (ET).

 EMCP 4 also includes a reduced power mode function, which places the
controller into a state where power consumption is reduced to extend battery
charge during times when the generator set is sitting between run times.

(Slide Continues)

Facilitator’s Notes

Page 6 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 7
FACILITATOR GUIDE

Slide 5 Same Slide Say:

 The EMCP 4 provides a number of programmable input and outputs as standard

on the controller for customer use. There are six relay outputs that can be
programmed for various operating conditions including: Air shut-off, Pre-glow or
pre-lube, Common Alarm, Common Shutdown, Common Warning, Engine
Running, & Crank Alert. The EMCP 4.1 controller also includes three analog
inputs. Two of the inputs are dedicated to monitoring oil pressure and water
temperature, with the third available for customer use. The analog inputs are
configurable for either a 0-5V, 1-5V, or 0.5-4.5V sensor or 0-2000 ohm resistive
sender, and can be programmed for a number of customer specified monitoring
parameters, including oil temperature, fuel level of a remote fuel tank, or user
specified parameter.

 This controller includes six digital inputs that can be programmed for various
alarm, shutdown, & status conditions including: Low Fuel Level, High Fuel
Level, Fuel Leak Detected, High Oil Temperature, High Exhaust Temperature,
Circuit Breaker status, Low Starting Air Pressure, Low/High Ambient Air
Temperature. Inputs can be programmed for either high or low activation using
programmable Normally Open or Normally Closed contacts.

 One additional feature with the EMCP 4 controller is the ability to program the
digital inputs to accept a physical switch input to control the generator set mode
of operation. In some installations, there is a requirement for a physical switch,
often a key switch, to place the generator set controller into a specific mode of
operation, such as AUTO. By programming a digital input for a specific mode of
operation (STOP-RUN-AUTO), a physical key switch can easily be added in the
field.

Do: (Next Slide)

Facilitator’s Notes

Page 7 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 8
FACILITATOR GUIDE

Slide 6 Say:

 You see here the basic generator set communication diagram showing the
EMCP 4.1 when connected to an electronic engine with a Cat digital voltage
regulator (CDVR). The EMCP 4.1 communicates to the engine ADEM
controller and the CDVR over the primary CAN data link (CAN1). The CAN1
data link allows the EMCP 4.1 controller to display basic engine information
(oil pressure, water temperature, RPM), basic generator data (excitation voltage
and current), and provide control of the engine speed and generator voltage.

 For mechanical engines, the data link communication to the engine is replaced
with dedicated analog sensors for oil pressure, water temperature, and engine
speed. The EMCP 4.1 will monitor this engine information and provide engine
protection. Speed control will be provided separately from the EMCP 4
controller. For generator sets not equipped with the CDVR, voltage control is
provided separately from the EMPC 4 controller.

 Are there any questions on the EMCP 4.1 Basic Genset controller?

Do: (Next Slide)

Facilitator’s Notes

Page 8 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 9
FACILITATOR GUIDE

Slide 7 Say:
 The EMCP 4.2 offers all of the features of the EMCP 4.1, plus the additional
features highlighted in blue. The first major enhancement to the EMCP 4.2
is the addition of a real time clock with data/time stamping of events. With
the real time clock, a programmable cycle timer function has been added to
EMCP 4.2. The programmable cycle timer allows the customer to program
up to seven independent times a week when the generator set will run for a
pre-determined length of time to exercise/operate the generator set.

 The second major addition is the inclusion of power metering (kW, kVA,
kVAR, power factor) and hour meters (kW-hour, kVAr-hour). In addition to
the power metering, general AC metering accuracy is improved to ±1%.

 The final enhancements focus around the additional data links available on
the EMCP 4.2. The first data link that is added is the accessory module
CAN data link (CAN2). This data link allows the addition of local and
remote annunciator modules, generator temperature monitoring, and
additional I/O capability. This includes a link for remote annunciators which
provides a long distance solution for remote annunciation, allowing remote
annunciators to be easily installed up to 4000 feet (1220 meter) from the
generator set. The final data link is the RS-485 SCADA data link to allow
customers to access data on the EMCP 4.2 remotely via Modbus RTU
protocol.

 One final note. EMCP 4.2 is the lowest level of EMCP 4 controllers that can
be used to meet the annunciator requirements of the NFPA 110 requirements.

(Same Slide)
Facilitator’s Notes

Page 9 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 10
FACILITATOR GUIDE

Slide 7 Same slide Say:

 From a generator protection standpoint, EMCP 4.2 adds overcurrent

protection (timed & inverse) and reverse power protection (real – kW,
reactive – kVA).

 In addition to the protection features, EMCP 4.2 offers two further

enhancements. The first is a programmable kW relay which can be
programmed to activate when the power output of the generator set exceeds
a certain threshold. The second is integration with the Tier 4 generator sets,
which provides detailed information of the status of the additional systems
required to meet Tier 4, including SCR status and urea levels.

 Like the EMCP 4.1, the EMCP 4.2 includes a number of programmable
inputs and outputs as standard on the controller for customer use. The
EMCP 4.2 expands the number of relay outputs from six (on the EMCP 4.1)
to eight. The EMCP 4.2 also includes two digital outputs which can be
programmed for various operating conditions including: generator set mode
of operation (auto/run/stop), not in auto, crank alert, engine started, common
warning, common shutdown, and programmable kW trip point. Discrete
outputs can sink up to 300 mA and are suitable for driving relay coils or
incandescent lamps.

 Do: (Next Slide)

Facilitator’s Notes

Page 10 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 11
FACILITATOR GUIDE

Slide 8 Say:
 We also want to discuss another optional controller available
from Caterpillar. Over time, we wanted to expand the capability
of even the more basic generator set control system. We have
enhanced the EMCP 4.2 with a hardware and software upgrade.
The added features include, among others:
o Enhanced overcurrent protection / thermal damage curve
protection. This serves to provide overcurrent protection
which more closely reflects the damage curve of the
generator than does traditional circuit breaker protection.
o Real (kw) Load Histograms which allow a view of how
the generator set is being loaded, over time.
o Also, Programmable Relay Control capability has been
added to this controller. This greatly enhances the
capability of the controller allowing for greater
flexibility for accommodating specific site control
requirement.
o It should be noted that these features are also available
in our more advanced controllers.

Do: (Next Slide)

Facilitator’s Notes

Page 11 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 12
FACILITATOR GUIDE

Slide 9 Say:

 You see here a sample generator set communication diagram of the EMCP
4.2 when connected to an electronic engine with a Cat digital voltage
regulator (CDVR). Like the EMCP 4.1, the EMCP 4.2 communicates to the
engine ADEM controller and the CDVR over the primary CAN data link
(CAN1). The CAN1 data link allows the EMCP 4.2 controller to display
basic engine and generator information and provide control of the engine
speed and generator voltage.

 When used with a mechanical engine, the EMCP 4.2 acts just like the EMCP
4.1, monitoring dedicated engine oil pressure, water temperature, and engine
speed sensors.

 As mentioned earlier, EMCP 4.2 also includes the accessory CAN data link
(CAN2) for connecting local and remote optional modules, the RS-285
annunciator data link for remote annunciators, and the RS-485 data link for
customer communications.

 Are there any questions on the EMCP 4.2?

Do: (Next Slide)

Facilitator’s Notes

Page 12 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 13
FACILITATOR GUIDE

Slide 10 Say:

 The EMCP 4.3 offers all of the features of the EMCP 4.2, plus the additional features
highlighted here. The most obvious enhancement is the larger display. EMCP 4.1 and 4.2
offer a 3.2 inch graphical display. With EMCP 4.3 (and EMCP 4.4), the display is a 5.5 inch
graphical display – a much larger display that can provide more information at a glance.
Four soft keys have also been added to provide improved menu navigation.
 EMCP 4.3 also offers ±¼% metering accuracy.
 The EMCP 4.3 includes an additional Ethernet SCADA data link using the Modbus TCP
protocol in addition to the Modbus RTU data links for customer communications. This
provides high speed data communications between customer monitoring equipment and the
EMCP 4.3 controller.
 From a generator protection standpoint, EMCP 4.3 adds monitoring and protection for
current balance.
 A Status Event Log is also available, which provides a chronological listing of events to aid
in troubleshooting any faults on the system.
 A recent addition is Inducement override capability which supports Tier 4 emission
regulation requirements.
 Like the 4.1 and 4.2, the EMCP 4.3 includes a number of programmable inputs and outputs
as standard on the controller.
 The EMCP 4.3 includes five programmable analog outputs. Thee of the analog outputs are
customer configurable for either 4-20 mA or ±10V output and two are configurable for a
PWM output. The analog outputs can be used to provide an output signal based on a
number of customer selectable parameters, including oil pressure, water temperature, and
engine kW.
 And finally, the EMCP 4.3 includes one additional programmable input. The inputs also
have an increased range of sensor compatibility, and are compatible with most standard
voltage, current, PWM, or resistive senders used today.
Do: (Next Slide)
Facilitator’s Notes

Page 13 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 14
FACILITATOR GUIDE

Slide 11 Say:

 From a communication architecture standpoint, the EMCP 4.3 is

very similar to the EMCP 4.2 when used on an electronic engine
with the CDVR. The primary CAN data link (CAN1)
interconnects the EMCP 4.3 controller to the ADEM and CDVR.

 The accessory module data link (CAN2) is available for the

optional modules. The serial annunciator data link provides for
long distance annunciators. The modbus RTU data link is
available for customers to access data from the controller.

 As mentioned previously, the major feature change is the addition

of the Ethernet SCADA data link for customer communication.

 Are there any questions on the EMCP 4.3?

Do: (Next Slide)

Facilitator’s Notes

Page 14 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 15
FACILITATOR GUIDE

Slide 12 Say:

 From a basic feature set, EMCP 4.4 is identical to the EMCP 4.3.
Larger display, improved metering accuracy, improved
communications - all of the benefits of the EMCP 4.3 are
included with the EMCP 4.4.
 So what is the difference between EMCP 4.3 and 4.4?
Paralleling. The EMCP 4.4 offers fully automatic, multi-unit
paralleling.
 The EMCP 4.4 offers a Hardwired Paralleling Option, which is
backward compatible with traditional analog load sharing
systems. With this option, you can parallel up to 8 generator sets.
 The EMCP 4.4 also offers the Multiple Genset Data Link
(MGDL) option, which is Ethernet based and can Parallel up to
16 generator sets. With MGDL, a Failsafe Mode of Operation is
provided to ensure that loads remain powered in a Loss of
communication scenario.
 With this option, Bus phase sequence is provided
 A total of 17 programmable digital outputs are provided as are 2 x
±10V Analog inputs (PWM, current, or resistive) for Oil temp,
fuel level or custom

Do: (next slide)

Facilitator’s Notes

Page 15 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 16
FACILITATOR GUIDE

Slide 13 Say:
 EMCP 4.4 brings on package paralleling to Cat generator sets. The EMCP 4.4
performs all of the functions required to automatically parallel multiple
generator sets. The functions include:
 Bus Metering – The EMCP 4.4 provides bus voltage and frequency metering.
 Dead bus arbitration – the ability for the multiple EMCP 4.4 controllers to
determine which generator set can close first to a dead bus.
 Manual and automatic synchronization – In automatic mode, the EMCP 4.4
will automatically adjust the voltage and frequency of the generator set to
match that of the live bus, then close the circuit breaker. In manual
synchronization mode, the operator will adjust the frequency and voltage of
the generator set to match that of the live bus, and then manually close the
circuit breaker.
 Real and reactive load sharing – the EMCP 4.4 will communicate with other
EMCP 4.4 controllers to ensure all generator sets are sharing real load (kW)
and reactive load (kVAr).
 Load shed/load add – The EMCP 4.4 system will generate a signal that can be
used to automatically add load as additional generator sets are brought online.
As generator sets are shut down, a signal is generated that can be used to shed
(remove) load from the system to prevent overloading the generator sets.
 Load sense/load demand – The EMCP 4.4 system will automatically regulate
the number of generator sets on-line, based on total required output power. As
load increases, additional generator sets will be brought online to support the
increased demand. As load decreases, generator sets will be taken off line to
reduce the wear on the generator sets.
 Base Load paralleling control for Single Gen to Utility is also provided, which
is primarily used in Rental applications.

Facilitator’s Notes

Page 16 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 17
FACILITATOR GUIDE

Slide 13 Say:
Cont’d. (SAME SLIDE - TEXT CONTINUES)
 From a system standpoint, the EMCP 4.4 supports two basic systems. The
first is multi-unit island mode application. In this system, the operator will
initiate a system start, and the EMCP 4.4 system will automatically
synchronize the generator sets together to provide power to the load. The
second system is a multi-unit standby application. In this system, an external
device, such as an automatic transfer switch (ATS), will detect loss of utility
and send a group start signal to the EMCP 4.4 system. The EMCP 4.4 system
will automatically synchronize the generator sets together and the ATS will
transfer power to the load.

 Are there any questions on the paralleling features of the EMCP 4.4?

 If not, we will move to the EMCP 4.4 controller features...

Do: (Next Slide)

Facilitator’s Notes

Page 17 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 18
FACILITATOR GUIDE

Slide 14 Say:

 From a communication architecture standpoint, the EMCP 4.4 is identical to

the EMCP 4.3 when used on an electronic engine with the CDVR.

 The primary CAN data link (CAN1) interconnects the EMCP 4.3 controller to
the ADEM and CDVR.

 The accessory module data link (CAN2) is available for the optional modules.

 The serial annunciator data link provides for long distance annunciators.

 The modbus TCP and modbus RTU data links are available for customers to
access data from the controller.

 Are there any questions on the EMCP 4.4?

Do: (next slide)

Facilitator’s Notes

Page 18 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 19
FACILITATOR GUIDE

Slide 15 **NOTE: THIS SLIDE IS Say:

ANIMATED. ** **NOTE: THIS SLIDE IS ANIMATED. **
 A look at the user interface of the EMCP 4 products. The EMCP 4.1 and 4.2
share the same user interface.
 We will walk you through the features you should expect from a basic genset
controller

 **CLICK**

 The first item is an Alarm Acknowledge button.

 **CLICK**

 The next item is an Event Reset button, which allow all faults to be reset with
the touch of a single button. This can potentially decrease the time needed to
get your genset back online after a shutdown has occurred.

Page 19 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 20
FACILITATOR GUIDE

 **CLICK**

 We also have an Event Log navigation button. Pressing this button will take
the operator to the Event Log, where a complete list of all active and up to
100 past alarms and shutdowns can be individually viewed.

 **CLICK**

 Also, there are selection buttons and indicating led’s for Run, Auto and Stop
control of the generator set.

 You will also note in each case, that text is included under these functions to
further improve operator usability.

 **CLICK**

Page 20 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 21
FACILITATOR GUIDE

 Next are the Display navigation buttons which allow the operator to progress
through the display, up/down, left/right; to “select” using the OK button, and
the “backup” or “undue” button

 **CLICK**

 Next is the Main Menu navigation button that will take you to the top menu
screen.

 **CLICK**

Page 21 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 22
FACILITATOR GUIDE

 We also have an Engine Overview button which takes you directly to the
Engine parameters

 **CLICK**

 In similar fashion, we have a Generator Overview Button which takes you

directly to the Generator parameters

Do: (Next Slide)

Facilitator’s Notes

Page 22 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 23
FACILITATOR GUIDE

Slide 16 **NOTE: THIS SLIDE IS **NOTE: THIS SLIDE IS ANIMATED. ** (ARROWS AND
ANIMATED. ** TITLES APPEAR WITHOUT CLICKING THROUGH.)

Say:

 Next, is the more advanced Genset controller set, which includes the EMCP
4.3 and 4.4 interface. The same features on EMCP 4.1 and 4.2 are present on
the 4.3 and 4.4. Additionally, at this level, we add

 A Control Navigation button that takes the operator directly to the Control
screen.

 Dynamic soft keys for context specific functions that can change based on
what is on the display.

 **CLICK**

Page 23 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 24
FACILITATOR GUIDE

 And, finally, the larger, graphical display. A 5.5” graphical display which
improves operator readability, but serves as the basis of system level
monitoring with paralleled systems.

 Before we look at the optional modules, are there any questions on the EMCP
4 user interface or EMCP 4 features & functions?

Do: (next slide)

Facilitator’s Notes

Page 24 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 25
FACILITATOR GUIDE

Slide 17 Say:

 The CAN Annunciator connects to the accessory CAN network, and, other
than the data link and battery voltage, requires no discrete wiring. It provides
annunciation for 16 different parameters with two indicating levels for each
parameter – i.e. for oil pressure, there is both an amber alarm light and a red
shutdown light for the single parameter.

 The CAN annunciator ships standard configured for the standard NFPA99/110
alarms, but is fully configurable for any event monitored by the EMCP 4
controller. A custom label kit is available.

 The CAN annunciator is available both locally installed at the generator set or
for remote installation up to 800 feet (244m) on the accessory CAN data link.
The CAN annunciator is compatible with the EMCP 4.2, 4.3, and 4.4, and up
to four CAN annunciators can be installed per generator set package.

Do: (next slide)

Facilitator’s Notes

Page 25 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 26
FACILITATOR GUIDE

Slide 18 Say:
 New to the EMCP 4 is the RS-485 annunciator. Like the CAN annunciator, it
provides annunciation for 16 different parameters with two indicating levels
for each parameter – i.e. for oil pressure, there is both an amber alarm light
and a red shutdown light for the single parameter.

 The RS-485 annunciator ships standard configured for the standard

NFPA99/110 alarms, but is customizable in the field for various monitoring
combinations.

 The RS-485 annunciator is available for remote installation up to 4000 feet

(1220m) on the dedicated RS-485 annunciator data link, and works with the
EMCP 4.2, 4.3, and 4.4. There is no limit to the number of annunciators that
can be installed per generator set package.

 One other note. The RS-485 does not require CAN cabling to interconnect it
to the EMCP controller. The annunciator requirement is a shielded twisted
pair – similar to what would be run for any Modbus RTU network. This
should result in a significant saving in installation cost over the CAN cable.
And if there are requirements to extend the distance beyond 4000 feet, there
are a number of third party devices available to boost the RS-485 data link.

Do: (next slide)

Facilitator’s Notes

Page 26 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 27
FACILITATOR GUIDE

Slide 19 Say:

 The digital I/O module is available on the EMCP 4.2, 4.3,

and 4.4 controllers to provide additional input and output
capability. The digital I/O module can be configured to
monitor or annunciate any event monitored by the EMCP 4
controller, and can be either mounted locally on the
generator set package, or installed remotely up to 800 feet
(244 meters) from the generator set on the accessory CAN
data link.

 Up to four digital I/O modules can be installed per

generator set, each one expanding the I/O capability by 12
inputs and 8 outputs.

 The optional RTD and Thermocouple Modules allow for monitoring of

Generator Stator and Bearing temperatures. The module provides
temperature monitoring from the EMCP 4.2/4.3/4.4 controller and
adjustable high temperature warning and shutdown protection.

Do: (next slide)

Facilitator’s Notes

Page 27 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 28
FACILITATOR GUIDE

Slide 20 Say:

 The final option available for the EMCP 4 system is the EMCP 4
monitoring software. The EMCP 4 monitoring software can
monitor and control up to eight EMCP 4.2 / 4.3 / 4.4 generator set
controllers.

 In addition to the EMCP 4 controllers, the monitoring software

can monitor and control multiple Cat ATS and Cat UPS.

 The software also allows the user to perform basic data trending
and graphing of critical information on system performance.

Do: (next slide)

Facilitator’s Notes

Page 28 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 29
FACILITATOR GUIDE

Slide 21 Say:

 Beginning with Production Software version 4.3, an embedded

Web Server feature was added to the EMCP 4.3 and 4.4.

 This feature allows the operator to view basic event status, as

well as engine and generator overviews over Ethernet (to a
local/remote viewing station or pc for example via a local area
network.

 This slide shows information available by using the EMCP 4.3

(and 4.4) embedded webserver.

Do: (next slide)

Facilitators Notes

Page 29 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 30
FACILITATOR GUIDE

Slide 22 Say:

 With the on board paralleling solution, Caterpillar also offers a

couple of options which serve to extend the functionality of
EMCP 4.4 based solutions. Those options include:

 Supervisory Control Panel – which provides System level

Display & Control. It adds the capability of complex 16 stage
load add/ shed functionality to an EMCP 4.4 island mode system
(for non-utility paralleling)
 Master Control Panel – which adds a 15” Graphical User
Interface for System Level Monitoring / Control / Setup. It also
provides an option for Multi-unit utility paralleling to a single
utility. That options includes Utility CB Control as well as
Import/Export/Base Load Control.
 In both cases, scope of supply includes an Ethernet Switch and a
Best Battery Diode system to ensure continuity of power to the
control power as well as a location for centralized wiring for
Load Shed / Load Add.

Do: (next slide)

Facilitators Notes

Page 30 of 31
CATERPILLAR EPD SALES TRAINING EMCP 4 CONTROLS 31
FACILITATOR GUIDE

Slide 23 Say:

 This concludes the Generator Controls Technology presentation.

 Are there any additional questions on controls technologies or the

EMCP 4 controller and optional devices?

Do: Make sure everyone has signed the registration sheet and
indicated if they wanted CEUs or not.

If you haven’t already, distribute surveys and ask them to fill out
and leave for you.

Facilitators Notes

Page 31 of 31