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CAT EMCP 4 - User Manual

CAT EMCP 4
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APPLICATION AND INSTALLATION GUIDE
EMCP 4
SCADA DATA LINKS
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Summary

1 GENERAL INFORMATION

1.1 INTRODUCTION

Overview of the EMCP 4 generator set control panel and its SCADA data links.

1.2 OVERVIEW OF EMCP 4 SCADA DATA LINKS

Details the RS-485 and TCP/IP SCADA data links supported by EMCP 4.

2 RS-485 SCADA DATA LINK - WIRING AND CONFIGURATION

2.1 NETWORK TOPOLOGY

Describes the multi-drop bus topology used for RS-485 communication.

2.2 WIRING

Details the physical connections and pinouts for RS-485 SCADA data links.

2.3 SOFTWARE CONFIGURATION

Covers baud rate, parity, slave address, and stop bits for RS-485 SCADA.

BAUD RATE

Configuration of communication speed for RS-485 SCADA, must match across devices.

PARITY

Configuration of parity settings (ODD, EVEN, NONE) for RS-485 SCADA.

SLAVE ADDRESS

Unique identifier for each RTU on the Modbus network for RS-485 SCADA.

STOP BITS

Configuration of stop bits for devices on the RS-485 SCADA network.

BIAS RESISTORS

Use of bias resistors to maintain network voltage levels and prevent communication failure.

2.4 ERROR CHECKING

Explains the Cyclic Redundancy Check (CRC) used for error detection in RS-485 SCADA.

3 TCP;IP SCADA DATA LINK - WIRING AND CONFIGURATION

3.1 NETWORK TOPOLOGY

Discusses Ethernet network topologies supported by TCP/IP SCADA links.

3.2 WIRING (INCLUDING SWITCHES, ROUTERS, ETC)

Details wiring requirements for TCP/IP SCADA using 10BaseT Ethernet connections.

CROSSOVER CABLES

Information on when crossover cables are needed for direct device connections in TCP/IP networks.

3.3 SOFTWARE CONFIGURATION

Covers IP address, network mask, and default gateway for TCP/IP SCADA setup.

IP ADDRESS

Unique identifier for each device on an Ethernet network for TCP/IP SCADA.

NETWORK MASK

Property of each Ethernet network used in TCP/IP configuration.

DEFAULT GATEWAY

IP address of a gateway device on the network for TCP/IP SCADA.

3.4 ERROR CHECKING

Explains TCP/IP error checking handled by the TCP wrapper, not CRC.

4 EMCP 4 SCADA COMMUNICATION

4.1 ADDRESSING

Explains Modbus addresses and Holding Registers used for EMCP 4 communication.

4.2 SUPPORTED FUNCTION CODES

Lists Modbus Function Codes supported by EMCP 4 for data communication.

4.3 DATA INTERPRETATION

Describes how to interpret numerical, state-based, and complex data from EMCP 4.

NUMERICAL DATA

Explains how to convert raw data bits into real-world measurement values.

STATE-BASED DATA

Describes data represented by fixed states and their corresponding values or bits.

COMPLEX DATA

Covers aggregate data made up of multiple pieces of other data types.

4.4 SECURITY

Details SCADA access levels, passwords, and security features for EMCP 4.

5 EMCP 4 SCADA DATA POINTS

5.1 GENERATOR AC MONITORING

Lists all AC data available via Modbus, varying by wiring configuration.

VOLTAGE DATA

Specific AC voltage parameters available for generator monitoring.

CURRENT (AMPS) DATA

AC current parameters available for generator monitoring.

FREQUENCY DATA

AC frequency parameters available for generator monitoring.

5.2 GENERATOR POWER MONITORING

Provides details on real, apparent, reactive power, and power factor data.

REAL POWER DATA

Lists real power parameters for generator monitoring.

APPARENT POWER DATA

Lists apparent power parameters for generator monitoring.

REACTIVE POWER DATA

Lists reactive power parameters for generator monitoring.

POWER FACTOR DATA

Lists power factor parameters for generator monitoring.

5.3 GENERATOR OTHER MONITORING

Covers other monitoring parameters like bearing temps, excitation voltage/current.

5.4 BUS AC MONITORING

Details bus voltage and frequency monitoring, available on EMCP 4.4.

VOLTAGE DATA

Bus voltage parameters available for monitoring.

FREQUENCY DATA

Bus frequency parameters available for monitoring.

5.5 GENERATOR SET STATE MONITORING AND CONTROL

Parameters related to generator set operating state and basic control commands.

START; STOP CONTROL

Parameters for starting, stopping, and controlling the generator set.

ENGINE SPEED CONTROL

Parameters for reading and controlling engine speed and speed bias.

GENERATOR VOLTAGE CONTROL

Parameters for reading and controlling the generator output voltage.

FUEL TRANSFER MONITORING

Status of fuel unload and load pumps.

DEAD BUS ARBITRATION (EMCP 4.4 ONLY)

Parameters related to dead bus arbitration for EMCP 4.4.

GENERATOR TO BUS SYNCHRONIZING (EMCP 4.4 ONLY)

Parameters for generator to bus synchronization on EMCP 4.4.

GENERATOR CIRCUIT BREAKER MONITORING AND CONTROL

Parameters for monitoring and controlling the generator circuit breaker.

5.6 ENGINE MONITORING

Comprehensive engine monitoring parameters including speed, fuel, oil, coolant, and exhaust.

SPEED

Engine speed monitoring parameters.

FUEL

Engine fuel system monitoring parameters.

OIL

Engine oil system monitoring parameters.

COOLANT

Engine coolant system monitoring parameters.

EXHAUST

Engine exhaust port and manifold temperature monitoring.

INTAKE

Engine intake manifold temperature monitoring.

TURBOCHARGERS

Turbocharger parameters including inlet/outlet temperatures and boost pressure.

FILTERS

Monitoring of differential pressure for oil, fuel, and air filters.

AFTERTREATMENT

Parameters related to the aftertreatment system, including DEF and SCR.

GAS

Engine knock level and ignition timing parameters for gas engines.

5.7 EVENT MONITORING

Monitoring of system events, including bitwise and legacy log data.

BITWISE EVENT DATA

Event statuses represented as individual bits for quick status checks.

LEGACY EVENT LOG DATA

Event log data for legacy applications.

MODULE EVENT LOG DATA

Detailed event log data accessible via SCADA from EMCP 4 modules.

OTHER EVENT-RELATED DATA AND CONTROL

Additional event data and control commands like acknowledging events.

5.8 TIMERS, COUNTERS, TOTALS, AND ENERGY

Parameters for timers, counters, totals, and energy measurements.

ENERGY DATA

Real and reactive energy exported by the generator set.

REAL TIME CLOCK

Access to the system's real-time clock data.

SERVICE METERING

Service interval countdown and reset parameters.

5.9 PROGRAMMABLE CYCLE TIMERS

Status of programmable cycle timers for outputs.

5.10 SYSTEM INFORMATION

Information about installed modules and network status.

MODULE INSTALLATION INFO

Status of EMCP 4 GSC, ECM, I/O modules, AVR, RTD, and Thermocouple modules.

NETWORK STATUS

Indicates the fault status of associated communication networks.

5.11 EMCP 4 GSC INPUTS AND OUTPUTS

Details analog and digital inputs and outputs available on the EMCP 4 GSC.

ANALOG INPUTS

Parameters for reading analog sensor values and converted data.

ANALOG OUTPUTS (EMCP 4.3 AND 4.4)

Parameters for reading and writing analog output values.

DIGITAL INPUTS

Parameters indicating the active status of digital input pins.

DIGITAL OUTPUTS

Parameters indicating the active status and commands for digital outputs.

PWM OUTPUTS (EMCP 4.3 AND 4.4)

PWM output data and command parameters for EMCP 4.3/4.4.

RELAY OUTPUTS (EMCP 4.2 ONLY)

Relay output status and command parameters for EMCP 4.2.

5.12 LOAD SHED COMMAND (EMCP 4.3 AND 4.4)

Parameters for controlling and resetting load shedding commands.

6 TROUBLESHOOTING

6.1 INTERMITTENT OR NO COMMUNICATION

Troubleshooting steps for communication issues on RS-485 and TCP/IP SCADA links.

6.2 MODBUS ERRORS: EXCEPTION RESPONSES

Explains Modbus exception responses and their meaning.

6.3 DATA INVALID - OUTSIDE OF DATA RANGES

Troubleshooting steps when invalid data is suspected or observed.

7 SCADA PROGRAMMING EXAMPLES

7.1 SIMPLE REGISTER READS

Examples of reading single registers, including battery voltage and power factor.

BATTERY VOLTAGE

Example of reading battery voltage via Modbus.

GENERATOR OVERALL POWER FACTOR

Example of reading generator overall power factor via Modbus.

7.2 TWO-REGISTER DATA READS

Example of reading two-register data, such as engine operating hours.

7.3 READING INVALID DATA

Demonstrates reading data and receiving an invalid response, with troubleshooting.

7.4 SECURITY - READING AND GAINING ACCESS

Example of setting and entering passwords to gain SCADA security access.

7.5 REAL TIME CLOCK

Details on interpreting real-time clock data from registers.

7.6 READING ASCII DATA

Example of reading ASCII data, such as the control serial number.

7.7 READING AND SETTING VOLTAGE BIAS

Demonstrates reading and setting voltage bias parameters.

7.8 READING ANALOG INPUTS

Procedure for reading analog input sensor values and converted data.

7.9 READING EVENT DATA

Steps to read event information via SCADA from EMCP 4 modules.

READING THE GENSET CONTROL EVENT LOG

Steps to read the genset control event log entries from EMCP 4 modules.

7.10 READING AND INTERPRETING ALARM GROUP DATA

How to read and interpret alarm group data from RS-485 Annunciator modules.

CONFIGURING AND READING CONFIGURABLE ALARM GROUP DATA

Example of configuring and reading alarm group data for Annunciator modules.

APPENDIX A MODBUS REGISTER DATA

APPENDIX B INDEX OF MODBUS REGISTERS - ALPHABETICAL

APPENDIX C INDEX OF MODBUS REGISTERS - NUMERICAL

CAT EMCP 4 Specifications

General IconGeneral
BrandCAT
ModelEMCP 4
CategoryController
LanguageEnglish