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EMCP 3.2 Controller

The EMCP 3.2 is a generator-set controller. It is used on generator sets from Caterpillar, including the C3.3 Rental Generator Set, C4.4 Rental Generator Set, DM9073 and DM9628.

7
Generator sets
Caterpillar
Brand
484–800 kW
Power range
Diesel
Fuel

Specifications

DisplayLCD Display with adjustable contrast and backlight with auto power off, English, French or Spanish
CommunicationsModbus RTU over RS485, CAN
ProtectionsFail to start shutdown, Low oil pressure shutdown, High engine temperature, Approaching high coolant temperature alarm, Approaching low oil pressure alarm, Not in auto mode alarm, Underspeed / Overspeed, Loss of Engine Speed Detection, Low / High battery voltage, Battery charger failure (if fitted), Under volts, Over volts, Under frequency, Over frequency, Overcurrent

Troubleshooting

13

Symptoms & remedies

Symptom
Fail to start shutdown
Low oil pressure shutdown
High engine temperature
Approaching high coolant temperature alarm
Approaching low oil pressure alarm
Not in auto mode alarm
Underspeed / Overspeed
Loss of Engine Speed Detection
Low / High battery voltage
Battery charger failure (if fitted)
Under volts, Over volts
Under frequency, Over frequency
Overcurrent

Fault codes and symptom→remedy steps extracted from this controller’s service/owner documentation; verify against the official manual before servicing. Extracted directly from this controller's manual.

Generator sets using this controller

7
Caterpillar C3.3 Rental Generator SetCaterpillar C4.4 Rental Generator SetCaterpillar DM9073Caterpillar DM9628Caterpillar SR4BCaterpillar SR4B Generator

Engines paired with this controller

2

Troubleshooting

22

Fault codes

CodeMeaning
21Fault shutdown
22Fault alarm
2301A ControlWhen the engine oil pressure is increased beyond the low oil pressure setpoint, the GSC will inform the governor that the engine speed should be increased from IDLE to RATED rpm.
g00604607The fault alarm indicator (3) flashes when the GSC detects an alarm fault.

Symptoms & remedies

SymptomCauseRemedy
Dirt accumulations on generator windings.Proper maintenance of electrical equipment requires periodic visual examination of the generator and periodic visual examination of the windings. Proper maintenance of electrical equipment also requires appropriate electrical checks and appropriate thermal checks. Insulation material should be examined for cracks. The insulation material should be examined for accumulations of dirt and dust. If there is an insulation resistance value that is below normal, a conductive path may be present. This conductive path may be made of one of the following materials: • Carbon • Salt • Metal dust • Dirt that is saturated with moisture These contaminants will develop a conductive path which may produce shorts. Cleaning is advisable if heavy accumulations of dirt can be seen or if heavy accumulations of dust can be seen. If excess dirt is the cause of a restriction in the ventilation, cleaning is also advisable.
Emergency Stop (GSC+) — The operator presses the emergency stop push button (ESPB) on the front panel; the emergency stop indicator FLASHES and the engine is shut down; the engine is not allowed to start until the condition is correctedThe operator presses the emergency stop push button (ESPB) on the front panelCorrect the condition; the engine is not allowed to start until the condition is corrected
Emergency Stop — The operator presses the emergency stop push button (ESPB) on the front panel; the emergency stop indicator FLASHES and the engine is shut down; the engine is not allowed to start until the condition is correctedThe operator presses the emergency stop push button (ESPB) on the front panelCorrect the condition; the engine is not allowed to start until the condition is corrected
Engine Overspeed (GSC+) — The engine speed exceeds the setpoint for engine overspeed that is programmed into the GSC+; the engine overspeed indicator FLASHES; the engine is shutdown and the engine is not allowed to start until the fault is correctedThe engine speed exceeds the setpoint for engine overspeed that is programmed into the GSC+Correct the fault; the engine is not allowed to start until the fault is corrected
Engine Overspeed — The engine speed exceeds the setpoint for engine overspeed that is programmed into the GSC; the engine overspeed indicator FLASHES; the engine is shutdown and the engine is not allowed to start until the fault is correctedThe engine speed exceeds the setpoint for engine overspeed that is programmed into the GSCCorrect the fault; the engine is not allowed to start until the fault is corrected
Generator windings are damaged due to improper cleaning.Do not use water to clean the generator. Do not use trichloroethane, perchlorethylene, trichloroethane or any alkaline products to clean the generator.
Generator windings are wet.Do not operate the generator if the windings are wet. If the generator is operated when the windings are wet, damage can occur due to insulation breakdown. When moisture is present or when moisture is suspected in a generator, the generator must be dried before being energized. If the drying procedure does not restore the insulation resistance to an acceptable value, the winding should be reconditioned.
High Water Temperature (GSC+) — The engine coolant temperature rises above the setpoint for high water temperature shutdown that is programmed into the GSC+; the high water temperature indicator FLASHES; the engine is shutdown and the engine is not allowed to start until the fault is correctedThe engine coolant temperature rises above the setpoint for high water temperature shutdown that is programmed into the GSC+Correct the fault; the engine is not allowed to start until the fault is corrected
High Water Temperature — The engine coolant temperature rises above the setpoint for high water temperature shutdown that is programmed into the GSC; the high water temperature indicator FLASHES; the engine is shutdown and the engine is not allowed to start until the fault is correctedThe engine coolant temperature rises above the setpoint for high water temperature shutdown that is programmed into the GSCCorrect the fault; the engine is not allowed to start until the fault is corrected
Low Coolant Level — The engine coolant level drops below the probe of the coolant loss sensor; the engine coolant level indicator FLASHES; the engine is shut down; the engine is not allowed to start until the fault is correctedThe engine coolant level drops below the probe of the coolant loss sensorCorrect the fault; the engine is not allowed to start until the fault is corrected
Low Oil Pressure (GSC+) — The engine oil pressure drops below the setpoints for low oil pressure shutdown that are programmed into the GSC+; the low oil pressure indicator FLASHES, and the engine is shut down; the engine is not allowed to start until the fault is correctedThe engine oil pressure drops below the setpoints for low oil pressure shutdown that are programmed into the GSC+Correct the fault; the engine is not allowed to start until the fault is corrected
Low Oil Pressure — The engine oil pressure drops below the setpoints for low oil pressure shutdown that are programmed into the GSC; the low oil pressure indicator FLASHES, and the engine is shut down; the engine is not allowed to start until the fault is correctedThe engine oil pressure drops below the setpoints for low oil pressure shutdown that are programmed into the GSCCorrect the fault; the engine is not allowed to start until the fault is corrected
Overcrank (GSC+) — The engine does not start within the setpoint for total cycle crank time that is programmed into the GSC+; the overcrank indicator FLASHES; the engine is not allowed to start until the fault is correctedThe engine does not start within the setpoint for total cycle crank time that is programmed into the GSC+Correct the fault; the engine is not allowed to start until the fault is corrected
Overcrank — The engine does not start within the setpoint for total cycle crank time that is programmed into the GSC; the overcrank indicator FLASHES; the engine is not allowed to start until the fault is correctedThe engine does not start within the setpoint for total cycle crank time that is programmed into the GSCCorrect the fault; the engine is not allowed to start until the fault is corrected
The measured insulation resistance falls below the specified amount. The cleanup procedure does not correct the discrepancy.The winding needs to be reconditioned or replaced.
The measured insulation resistance falls below the specified amount. The drying procedure does not correct the discrepancy.The winding needs to be reconditioned or replaced.
Water accumulates in fuel tanks.Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel. Fuel tanks should contain some provision for draining water and sediment from the bottom of the fuel tanks. Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the drain valve. Check the fuel daily. Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled. Allow five to ten minutes before performing this procedure. Fill the fuel tank after operating the engine in order to drive out moist air. This will help prevent condensation. Do not fill the tank to the top. The fuel expands as the fuel gets warm. The tank may overflow.
Water or sediment from storage tanks is pumped into the engine fuel tank.Drain the water and the sediment from the fuel storage tank during the following conditions: • Weekly • Oil change • Refill of the tank. This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank. A four micron(c) absolute filter for the breather vent on the fuel tank is also recommended.

Fault codes and symptom→remedy steps extracted from this controller’s service/owner documentation; verify against the official manual before servicing. Aggregated from the service documentation of generator sets built on this controller.