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Power System – Fast Training

Program

Inst. Ahmed M.
A/Hafeez

PSD-FTP 1
PSD-FTP 2
EMCP
The EMCP uses a similar type of logic but a microprocessor GSC
performs the functions of all the relays and timers used before.
They are : EMCP I , EMCPII, EMCPII +, EMCPII +P

GSC

PSD-FTP 3
Engine monitoring :
System DC voltage
Engine RPM
Oil pressure
EMCP Features
Engine hour meter
Coolant temperature Cooldown timer

Optional: System diagnostics


Coolant loss
Exhaust temperature Diesel and gas engine functionality

Start/Stop control Various system fault codes

Cycle cranking Engine set point programming

AC monitoring Engine set point verification


AC voltage
AC current
Frequency

PSD-FTP 4
Sensor:
• The GSC monitors the following engine sensors that
are listed below:
– Pressure Sensor (Engine Oil)
– Temperature Sensor (Engine Coolant)
– Optional Liquid Level Sensor (Engine Coolant)
– Speed Sensor (Engine) for all engines

PSD-FTP 5
Wiring MEUI , PEEC

Coolant Temp

Coolant level
Oil Press
ECM MP

Boost Press
E
Oil Press
generator M
Coolant Temp Engine
C
Atmos. Pressure
P
PEEC Actuator

MP

PSD-FTP 6
Wiring EUI
CAT Data link

ECM MP

Boost Press
E
Oil Press
generator M
Coolant Temp Engine
C
Atmos. Pressure
P
Fuel TEMP

MP

PSD-FTP 7
Speed control
MEUI
For EUI engines the analog signal from the speed
potentiometer need to be converted in a PWM for the
ECM to recognized it

LSM PWM converter

3 2 1

-B S D +B

PSD-FTP 8
PSD-FTP 9
4

1
5

6
2
3 13

7 8 9 10 11 12
PSD-FTP 10
1) Dedicated shutdown indicator.
2) Fault shutdown indicator.
3) Fault alarm indicator.
4) Upper display.
5) Lower display.
6) Keypad.
7) Scroll right key.
8) Phase select key and scroll up key.
9) Engine meter key and scroll down key.
10) Lamp test key and select key.
11) Alarm codes key and enter key.
12) Exit key.
13) Service mode key.
PSD-FTP 11
• Note:

To rapidly scroll through a large range of information


pres and hold the appropriate scroll key.

PSD-FTP 12
Relay Module
• The relays are located in the
relay module on the rear of
the GSC.

PSD-FTP 13
• The relays are permanently
attached within the relay
module and the relays are
not removable.

PSD-FTP 14
Relays on the Relay Module
• K1 Electronic Governor Relay (EGR)
This signals the engine ECM to begin injection
• K2 Generator Fault Relay (GFR)
This trips the optional circuit breaker when a shutdown fault occurs.
• K3 Crank Termination Relay (CTR)
The CTR indicates that the engine is running without cranking.
• K4 Starting Motor Relay (SMR)
This activates the starting motor magnetic switch.
• K5 Run Relay (RR)
This provides power to the optional start aid switch.
• K6 Air Shutoff Relay (ASR)
This activates an optional air shutoff solenoid during fault shutdowns.
• K7 Fuel Control Relay (FCR)
This activates the fuel solenoid during starting and running.

PSD-FTP 15
Alarm Module
1) Amber Indicator.
2) Red Indicator.
3) Lamp Test Switch.
4) Alarm Silence Switch.
5) Horn.

• The ALM is an attachment.


• The ALM is located on the
instrument panel.

PSD-FTP 16
Fault Description
• A fault is any condition that does not conform to the rules that the GSC
operates.

• A fault can be active or a fault can be inactive.


– An active fault is a fault that is occurring now.
– An inactive fault is a fault that has previously occurred.

• Some examples of faults:


– Engine speed is 4500 rpm. This is an engine overspeed condition.
– There is a broken wire in the engine harness. This is a diagnostic fault.

PSD-FTP 17
• Faults are either alarm faults or shutdown faults.
– Alarm faults are not critical.
– Shutdown faults are critical.

• Most faults have a code.


• There are three types of fault codes.
– AL Fault Codes
Shown as AL1-AL4 Include specific engine conditions & protective relaying
functions.
– SP Fault Codes
Shown as SP1 through SP3 on the upper display.
– Diagnostic Codes
Diagnostic codes are identified by the illumination of "CID FMI" on the upper display.

PSD-FTP 18
Diagnostic Codes
• Diagnostic codes are associated with failed electrical components or circuits.
• Each diagnostic fault consists of two identifiers and an indicator.
• Component Identifier (CID):
– Is a three digit code. The code that is indicated corresponds to a faulty component.

• Control System Identifier:


– Is a single digit. If an "E" is showing on the display, the engine ECM has generated the
diagnostic code. If there is no "E", the GSC has generated the diagnostic code.
• Failure Mode Identifier (FMI):
– Is a two digit code. The FMI tells the type of failure that has occurred. The FMI is shown
on the upper display at the same time as the CID.

PSD-FTP 19
• The GSC has four modes of
operation:

• Normal Mode:
For normal operation of the generator.
Dedicated shutdown indicators –off.
Fault shutdown indicator –off.
Fault alarm indicator –off.
“SERV” is not showing on the upper
display.

PSD-FTP 20
• Alarm Mode:
To alert the operator.
Fault alarm indicator is FLASHING.
Diagnostic code will appear when the
alarm codes key is pressed.

PSD-FTP 21
• Shutdown Mode:
AL4
To alert the operator.
Fault code shown in the upper display
Dedicated shutdown indicator is
FLASHING.
OR
Shutdown indicator is FLASHING.

PSD-FTP 22
– Service Mode:
When the “service mode” key on the keypad pressed.
Can be used for the following purposes:

• Assist with troubleshooting diagnostic codes.

• Verify the generator set functions.

• Calibrate the generator set functions.

• Adjust the generator set functions.

• Satisfy special applications.

• Satisfy the needs of the customer.

PSD-FTP 23
Note:

Service mode can not be entered when the ECS is in the auto
position.

When in service mode, “SERV” is showing on the upper


display.

PSD-FTP 24
Programming the EMCPII
• There are ten options in EMCPII service mode.

PSD-FTP 25
– OP1 – Fault log viewing.
– OP2 – Setpoint viewing.
– OP3 – Password entry.
– OP4 –Fault log clearing.
– OP5 – Setpoint programming.
– OP6 – Spare input/output programming.
– OP7 – hourmeter programming.
– OP8 – Voltmeter/Ammeter programming.
– OP9 – Engine setpoint verification.
– OP10 – AC calibration.

PSD-FTP 26
– The keypad and the display of the GSC are used
for activating service mode and selecting the
desired option.

– When in the service mode the keys of the keypad


have a different meaning than usual.

– A film (label) on the vandal door of the control


panel identifies each key when in service mode.

PSD-FTP 27
– Procedure to enter service mode:

• Press the service mode key on the keypad of the GSC,


the “SERV” indicator flashes on the upper display.

• The desired option can now be selected.

• To return to normal mode, press the exit key a few times


until the “SERV” indicator is not showing.

PSD-FTP 28
• Note:

– Any active fault must be made inactive in order to access


service mode.

– To enter service mode options OP4 through OP8, the engine


must be shutdown.

PSD-FTP 29
– OP1 – Fault log viewing.

• Only inactive diagnostic codes are stored in fault log.

• An active codes programmed as alarm fault becomes


inactive when the problem no longer occurring.

• An active codes programmed as shutdown fault becomes


inactive when the problem no longer occurring AND the
ECS is turned to the OFF/RESET position.

PSD-FTP 30
– OP4 –Fault log clearing.
• Option for clearing an inactive fault logged in OP1.

– OP5 – Setpoint programming.


• Option for programming the generator setpoints.
• Example: fuel solenoid type, unit shown, number of ring
gear teeth and engine over speed.
– OP6 – Spare input/output programming.
• option for programming spare I/O.
• Provided to satisfy customer needs.

PSD-FTP 31
– OP7 – hourmeter programming.
• Used to program the hours that are on the hourmeter.
• It can be increased but not decreased.

– OP8 – Voltmeter/Ammeter programming.


• Used when the GSC or ATB has been replaced for
programming the calibration value of the voltmeter and
ammeter.
• Ensure accurate voltage and current value.

PSD-FTP 32
– OP9 – Engine setpoint verification.
• Option for verification that EMCP operates correctly when
a fault occur with low oil press., high coolant temp. or
engine overspeed.

– OP10 – AC calibration.
• Option for adjusting the voltmeter reading of the GSC.
• Necessary when operated in parallel.

PSD-FTP 33
OP1 PHASE ENGINE LAMP ALARM SERVICE
EXIT MODE
SELECT METER TEST CODE

SCROLL SCROLL SCROLL SELECT ENTER


RIGHT UP DOWN

OP1 FAULT LOG VIEWING


Service mode
OP4 Fault log programming
OP2 SETPOINT VIEWING
OP5 Set point programming
OP3 PASSWORD ENTRY
OP6 Spare Input/Output programming

OP7 Hourmeter programming

PE: - - - - OP8 Voltmeter/Ammeter programming

OP9 Engine setpoint verification

OP10 AC calibration
PSD-FTP 34
P001 fuel solenoid type 0=ETR, 1=ETS
P002 Units shown 0=Eng, 1=metric
P003
P004
P005
OP5 Setpoint
Shutdown override for Engine fault
Shutdown override for for Sensor fault
Coolant loss sensor installed
0=Shutdown, 1=Alarm
0=Alarm, 1=Shutdown
0=w/o sensor, 1=w/sensor
P006 Shutdown override for coolant loss fault 0= shutdown, 1= alarm
P007 System voltage 24 volts or 32 volts
P008 Not used NA
P009 Number of ring gear teeth95 to 350 teeth
P010 Engine overspeed 500 to 4330 rpm
P011 Crank terminate speed 100 to 1000 rpm
P012 Oil step speed 400 to 1800 rpm
P013 Low oil pressure shutdown at Rated speed 34 to 240 kPa (5 to 61 psi)
psi)
P014 Low oil pressure shutdown at Idle speed 20 to 336 kPa (3 to 49 psi)
psi)
P015 High water temperature shutdown85 to 123 C (185o to 253oF)
P016 Low water temperature alarm 0 to 36oC (32 to 97oF)
P017 Total cycle crank time 5 to 360 seconds
P018 Cycle crank time 5 to 300 seconds
P019 Cooldown time 0 to 30 minutes
P020 AC voltage 150V to 30.0 kV
P021 AC current full scale 75A to 4000A
P022 GSC Engine Number 01 to 08
P023 Engine type 0=MUI, 1=Gas, 2=EUI
P024 Crank time delay (only for gas) 0 to 20 seconds
P025 Oil temperature sensor installed 0=w/o sensor, 1=w/sensor
P026 High oil temperature shutdown 85 to 123oC (185 to 253oF)
P027 Shutdown enable for high oil temperature 0=alarm, 1=shutdown
P028 Name plate voltage 100 to 25kV
P029 Name plate Current 0 to 4000A
P030 Name plate power 0 to 10MW
P031 Rated frequency 50, 60 or 400 Hz
P032 Connection configuration of generator 0=wye, 1=delta
P033 Number of generator poles PSD-FTP 0 to 254 35
Speed Sensor (Engine ) - Adjust

150 to 250 
Adjustable gap 1.0Vrms mini When connected @ rated speed
0.56 to 0.85mm or 10 to 20 Vrms disconnected @ rated speed

Common
Signal
Flywheel
Shield

Permanent magnet

PSD-FTP 36
Relay Module - Replace

(1) Relay Module


(2) Screws
(3) Tape
(4) Desiccant Package
(5) O-Ring Seal
(6) Cable connector

PSD-FTP 37
1. Remove the positive lead wire from the battery.
2. Remove all wires from the terminals and posts of the relay module.
3. Remove the screws that fasten the relay module to the GSC.
4. Be aware that the O-ring seal exists. Partially separate the relay module
from the GSC. Carefully disconnect cable clamp and cable connector from the
relay module.
5. Replace desiccant package with the new desiccant package and tape.
6. Install new O-ring seal in the groove of relay module.
7. Place relay module (1) on the GSC.
8. Reconnect all the wires to the terminals of the relay module that were
removed. Reconnect the positive lead wire to the battery.

PSD-FTP 38
EMCP Electronic Control (Generator Set) - Replace

If the GSC that is being replaced is functional,


then make a note of the following items:
Hourmeter, all engine setpoints and any spare
inputs or outputs that are programmed.
"Engine/Generator Setpoint Viewing OP2".

1.Shut down the engine. Remove the positive lead wire from the battery.
2. Remove the harness connector from the GSC.
3. Remove all wires from the terminals and from the posts of the relay module.
4. Remove the six nuts that fasten the GSC to the front panel. Remove the GSC.
5.Place the new GSC in the front panel.
6. Reconnect the harness connector to the GSC.
Reconnect the positive lead wire to the battery.
7. Reprogram the setpoints,
PSD-FTP 39
A Case Study
GSC CID 0190 - FMI 03

PSD-FTP 40
PSD-FTP 42