Power System – Fast Training

Program

Inst. Ahmed M.
A/Hafeez

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SDLC PSD-FTP 2
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 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)
· Optional Temperature Sensor (Engine Oil)
· Speed Sensor (Engine)

SDLC PSD-FTP 4
Wiring MEUI , PEEC

Coolant Temp

Coolant level
Oil Press
Oil Temp
ECM MP

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

SDLC PSD-FTP 5
 Wiring EUI
CAT Data link

ECM MP

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

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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

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The main component of the EMCP II+ system is the generator set control +
(GSC+).
GSC+ is powered by 24 DCV.

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Engine monitoring :
System DC voltage
Engine RPM EMCP Features
Oil pressure
Engine hour meter
Coolant temperature
Optional:
Coolant loss Power metering:
Exhaust temperature Total real power
Total reactive power
Start/Stop control Percentage of rated power
Power factor (average)
Cycle cranking Total energy output

AC monitoring
AC voltage
AC current
Frequency

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GSC+ Part Number & GSC+ Serial Number

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Keypad

OP1 Power PHASE ENGINE LAMP ALARM SERVICE

EXIT MODE
METER SELECT METER TEST CODE

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 Upper Display

The primary function of the upper display is showing the following

information of the generator output: AC voltage, current and frequency.

These options can be viewed

one at a time by pressing the
AC Meter key on the keypad.

· Voltage (average), generator frequency, current (total)

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 · Voltage (line-line), generator frequency, current (line) for any one phase

· Voltage (line-line) for all three phases at once

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· Current (line) for all three phases at once

Note: When total current increases above

"9999A", the GSC+ will show current in "kA" units.

· Voltage (line-neutral) for all three phases at once

Note:
Line to neutral voltages are not shown when the
setpoint P032 is set to 1 for delta generator sets.
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 Lower Display

Shows values for power metering, engine parameters and the relay status.
The left side of the lower display serves as a power meter

The following functions will scroll automatically.

· Total real power (kW)

· Total reactive power (KVAR)
· Percentage of rated power (%kW)
· Power factor (average)
· Total energy output (kW/h)

The display will stop scrolling when the operator presses

the power meter key for less than five seconds.
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 If the power meter key is held for more than five seconds and
then released. The additional functions are shown below.

· Total real power (kW)

· Real power phase A (kW)
· Real power phase B (kW)
· Real power phase C (kW)

· Total apparent power (kVA)

· Total reactive power (KVAR)
· Percentage of rated power (%kW)
· Power factor (average) Note: All real power values are
· Power factor phase A signed with a "+" or a "-". A negative
· Power factor phase B value indicates reverse power.
· Power factor phase C
· Total energy output (kW/h)
· Total reactive energy output (kVARHr)
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The right side of lower display shows the value of certain engine
parameters. The parameters are listed below.

· Left side exhaust temperature (optional)

· Right side exhaust temperature (optional)
· Engine oil temperature (optional)
· System battery voltage
· Engine hours
· Engine speed
· Engine oil pressure
· Engine coolant temperature

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 Note:
If the GSC+ displays dashes (---) for oil pressure, coolant
temperature, or engine oil temperature, this indicates that the GSC+
is receiving invalid data from the sensor.

The upper display will be showing a corresponding diagnostic

code for the sensor.

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Fault Indicators
The fault indicators are divided into four groups.

alarm indicator

The yellow fault alarm indicator FLASHES when the GSC+ detects a fault
that is an alarm fault.

The engine is able to start.

OR
The engine will continue operating.

Accompanied by an alarm fault code that is shown on upper display when

the alarm codes key is pressed.

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The red fault shutdown indicator FLASHES when the GSC+ detects a fault
that is a shutdown fault.

fault shutdown indicator

The engine is shutdown if the engine is running and the engine is

not allowed to start.

Accompanied by a fault code that is immediately shown on the upper display

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 The yellow spare fault indicators FLASH when the conditions that are
associated with that spare fault are active.

Spare faults can be programmed to

show coolant loss, oil temperature,

The yellow fault alarm indicator or spare fault indicators

the red fault shutdown indicator will
accompany the spare fault indicators

The spare fault condition may be a customer generated switch input.

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The red dedicated shutdown indicators (1) represent the following shutdown
faults:

When the GSC+ detects a fault in one of

these areas, the dedicated shutdown
indicator FLASHES

dedicated shutdown indicators

The engine is shutdown if the engine is

running, and the engine is not allowed to start.

No fault codes are associated with

the dedicated shutdown indicators

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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.

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 Faults are either:
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-AL15 (AL18 on EMCP II+P) Include specific engine
conditions & protective relaying functions. (underfrequency fault)

SP Fault Codes
Shown as SP1 through SP4 on
the upper display.
Diagnostic Codes
Diagnostic codes are identified
by the illumination of "CID FMI" on
the upper display.

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 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):

Control System Identifier:
Is a three digit code indicated
If an "E" is showing on the
corresponds to a faulty
display, the engine ECM has
component.
generated the diagnostic code.
Failure Mode Identifier (FMI): If not "E", the GSC
Is a two digit code tells the type
of failure that has occurred &
shown on the upper display at the
same time as the CID.

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Alarm Module (Optional)

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.

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• 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.

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• Alarm Mode:
To alert the operator of a non-
critical fault.
Fault alarm indicator is
FLASHING.
Diagnostic code will appear when
the alarm codes key is pressed.

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• Shutdown Mode:
To alert the operator of a critical
AL4
fault.
Fault code shown in the upper
display
Dedicated shutdown indicator is
FLASHING.
OR
Shutdown indicator is FLASHING.

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• Service Mode:
When the “service mode” key on the keypad pressed.
Can be used for the following purposes:

– Assist with troubleshooting diagnostic faults.

– Verify, calibrate or adjust the generator set functions.
– Satisfy special applications.
– Satisfy the needs of the customer.

OP1

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 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.

Note:
The GSC+P has an additional mode of operation. The fifth mode of
operation is "Parallel Mode".

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 Parallel Mode:

uses to synchronize the generator sets to other generator sets or to

a utility bus.

The GSC+P is in Parallel Mode whenever the Parallel Mode Switch is

in AUTO, Semi-Auto, or Manual positions.

Parallel Mode is enabled in Normal Mode or Alarm Mode.

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Programming the EMCPII+

• There are 11 options in EMCPII+ service mode.

SDLC PSD-FTP 33
 PHASE ENGINE LAMP ALARM SERVICE
EXIT MODE
SELECT METER TEST CODE
OP1 SCROLL SCROLL SCROLL SELECT ENTER
RIGHT UP DOWN

Service mode
OP4 Fault Log Clearing
OP1 FAULT LOG VIEWING OP5-0 Engine/Generator Programming

OP2-0 Engine/Generator Setpoint Viewing OP5-1 Protective Relay Programming

OP2-1 Protective Relaying Setpoint Viewing OP5-2 AC Factory Calibration Setpoint Programming

OP2-2 AC Factory Calibration Setpoint Viewing OP5-3 Parallel Setpoint Programming

OP6 Spare Input/Output Programming

OP2-3 Parallel Setpoint Viewing
OP7 Hourmeter Programming
OP3 PASSWORD ENTRY
OP8 Voltmeter/Ammeter Programming

OP9 Engine Setpoint Verification

OP10 AC Offset Adjustment

PE: 13231
OP11 Parallel Setpoint Tuning

SDLC PSD-FTP 34
 OP4 Fault Log Clearing

1. Turn the ECS to the STOP position. Enter service mode and enter
the password. "OP 4" is showing on the lower display.
2. Press "SELECT" key.
3. Press "SELECT" key. The CID FMI fault code, hourmeter value,
and fault count will flash.
4. Press and hold the "ENTER" key for two seconds.
5. Press the "EXIT" key. "OP 1" is showing on the lower display.
6. Press the "EXIT" key. The display is now in normal mode.

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 OP5-0 Engine/Generator Programming P001 to P033
Affect the proper operation and serviceability of the engine, and
the accuracy of information shown on the display.

OP5-1 Protective Relay Programming P101 to P142

Reduce the possibility of damage to the generator, and in order to reduce
the possibility of damage to the customer equipment.

OP5-2 AC Factory Calibration Setpoint Programming

The AC Factory Calibration Setpoints are only used in the factory. The
setpoints are read only and the setpoints are not accessible by the user.

OP5-3 Parallel Setpoint Programming P301 to P314

The Synchronization setpoints within the GSC+P define various parameters

that allow precise frequency and phase matching.

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 OP11 Parallel Setpoint Tuning P305, P306, P307, P308, and P309

Programming some of the Synchronization setpoints (P305, P306, P307,

P308, and P309) are the setpoints that are affected by this procedure.

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EMCP Electronic Control (AC Transformer Box) - Replace
1. Shut down the engine. Remove the positive lead wire from the
battery.

2. Remove all external wires from the terminal strip.

3. Disconnect the ATB+ connector from the harness connector.
4. Remove the ATB+.
5. Place the new ATB+ in the subpanel.
6. Reconnect the harness connector to the ATB+. Reconnect the
positive lead wire to the battery.
7. Program the bar code (calibration value) for the
voltmeter/ammeter into the GSC+.
8. If the generator set is operating in parallel with another
generator set and the voltmeter values must match, then
reprogram the AC offset.

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EMCP Electronic Control (Generator Set) - Flash Program

(1) Relay Module

(2) AUX terminal strip.
(3) 152-7143 GSC Data Cable
(4) Personal Computer.
(5) 160-0140 PC/COMM Adapter Cable
(6) 160-0133 Data Link Cable
(7) 171-4401 Communication Adapter

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1. Turn OFF the power to the EMCP II+ panel

2. Connect the communication adapter to the PC

3. Connect the Data Link Cable to the "Data Link" port on the communication
adapter

4. Connect GSC Data Cable to the opposite end of the Data Link Cable

5. Connect the "Data+" and "Data-" spade terminals of the cable to the
appropriate terminals in the AUX terminal strip. Connect the "Power+“
spade terminal to "RM1“, and "Power-" to "RM28“.

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6. Set the engine control switch (ECS) to OFF/RESET. Connect the battery,
then, turn the ECS to the COOL/STOP position.

7. Verify that the GSC+ and the communication adapter are receiving power.

8. Turn on the PC. The operating system on the computer must finish loading.

Flash Update Procedure

Note: Before starting this procedure, record setpoints P015, P016, and P026.
1. Obtain a flash file copy.
2. Open ET.
3. Start "WinFlash"

4. The "WinFlash" program will display the serial numbers of any modules that
are found on the data link.
5. Select the serial number of the unit that needs the software update.

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 6. Click on the "Select File" button Select the appropriate ".fls" file.

7. Click on the "Begin" button.

8. The display of the GSC+ will be blank and the "Fault Shutdown"
indicator will be blinking while the software update is in progress.
9. Once the process is finished, the GSC+ will automatically start
working again. Exit the "WinFlash" software.
10. The GSC+ should now have the new software. In order to verify
the version of the software, go to the display at OP2-2.

Check setpoints P015, P016, and P026. Reprogram if necessary.

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A Case Study
GSC CID 0110 - FMI 03

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SDLC PSD-FTP 45