Attachment

EMCP 4.4
GENERATOR SET
CONTROLLER

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GENERAL DESCRIPTION

The Cat® EMCP 4.4 offers fully featured power metering, protective relaying and engine and generator
control and monitoring. Engine and generator controls, diagnostics, and operating information are accessible
via the control panel keypads; diagnostics from the EMCP 4 optional modules can be viewed and reset
through the EMCP 4.4.

FEATURES

Full range of attachments

 Wide range of system expansion attachments, designed specifically to work with the EMCP 4.
 Flexible packaging options for easy and cost effective installation.

World wide product support

 Cat dealers provide extensive pre and post sale support.
 Cat dealers have over 1,600 dealer branch stores operating in 200 countries

Features
 A 480 x 320 pixel, 5.5 inch, white backlit graphical display denotes text alarm/event descriptions, set
points, engine and generator monitoring, and is visible in all lighting conditions.
 Textual display with support for 16 languages, including character languages such as Arabic, Chinese,
and Japanese.
 Paralleling functions, including automatic and manual synchronizing, dead bus arbitration, load sharing,
and load sense/load demand.
 Advanced engine monitoring is available on systems with an ADEM™ controller.
 Integration with the CDVR and IVR provides enhanced system performance.
 Fully featured power metering, protective relaying, engine and generator parameter viewing, and
expanded AC metering are all integrated into this controller.
 Real-time clock allows for date and time stamping of diagnostics and events in the control’s logs as well
as service maintenance reminders based on engine operating hours or calendar days. Up to 40
diagnostic events are stored in the non-volatile memory.
 Real-time clock also allows for the creation of a status event log. This log holds the last 500 control
events such as ECS Position, Circuit Breaker Closure, LSLD Operations, etc.

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FEATURES

 Ability to view and reset diagnostics on EMCP 4 optional modules via the control panel removes the
need for a separate service tool for troubleshooting.
 Set points and software stored in non-volatile memory, preventing loss during a power outage.
 Five levels of security allow for configurable operator privileges
 Programmable security levels for groups of setpoints.
 Programmable kW Relays (3)
 Programmable weekly exerciser timer
 Dealer configurable resistive maps
 Default overview screen
 Load hstogram
 Auto main failure
 Programmable logic functionality
 Selectable units
o Temperature: °C or °F
o Pressure: psi, kPa, bar
o Fuel Consumption: Liter/hr or Gal/hr (U.S. or U.K.)

STANDARD FEATURES

Generator Monitoring Engine Monitoring

 Voltage (L-L, L-N)  Coolant temperature
 Current (Phase)  Oil pressure
 Average Volt, Amp, Frequency  Engine speed (RPM)
 kW, kVAr, kVA (Average, Phase, %)  Battery voltage
 Power Factor (Average, Phase)  Run hours
 kW-hr, kVAr-hr (total)  Crank attempt and successful start
 Excitation voltage and current (with counter
CDVR)  Enhanced engine monitoring (with
 Desired Voltage, Excitation Command, electronic engines)
Operating Mode (with IVR)
Engine Protection
 Generator stator and bearing temp (with
 Control switch not in auto (alarm)
optional module)
 High coolant temp (alarm and shutdown)
 kW load histogram
 Low coolant temp (alarm)
Generator Protection  Low coolant level (alarm)
 Generator phase sequence  High engine oil temp (alarm and
 Over/Under voltage (27/59) shutdown)
 Over/Under frequency (81 O/U)  Low, high, and weak battery voltage
 Reverse Power (kW) (32)  Overspeed
 Reverse Reactive Power (kVAr) (32RV)  Overcrank
 Overcurrent (50/51)
 Current Balance (46)

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STANDARD FEATURES (Continued)

Control Language Support
 Run / Auto / Stop control Arabic, Chinese, Danish, Dutch, English, Finnish,
 Speed and voltage adjust French, German, Greek, Italian, Japanese,
 Local and remote emergency stop Portuguese, Russian, Spanish, Swedish, Turkish
 Remote start/stop
Environmental
 Cycle crank
 Control module operating temperature:
Inputs & Outputs -40°C to 70°C
 Eight dedicated digital inputs  Display operating temperature: -20°C to
 Four analog inputs 70°C
 Twelve programmable digital inputs  Humidity: 100% condensing 30°C to 60°C
 Seventeen programmable digital outputs  Storage temperature: -40°C to 85°C
 Vibration: Random profile, 24-1000 Hz,
Communications 6.0G rms
 Primary and accessory CAN data links
 RS-485 annunciator data link Bus monitoring
 Modbus TCP (10BT Ethernet)  Voltage (L–L, L–N)
 Modbus RTU (RS-485 Half duplex)  Average Voltage (L–L, L–N)
 Webserver  Frequency

PARALLELING FUNCTIONS

Dead bus arbitration

The EMCP 4.4 incorporates true dead bus arbitration to determine and select the primary generator set to
close to a dead bus, allowing only one unit to close to the dead bus. The dead bus arbitration control
minimizes the time for the first generator set to close to the dead bus. This feature is available with Hard
Wired or MGDL paralleling.

Synchronizing
The EMCP 4.4 monitors all three phases of the generator and main bus. The proprietary synchronizing
algorithms drive the generator output frequency, voltage, and phase to match another source, and close the
generator circuit breaker when conditions have been met. This feature is available with hardwired or MGDL
paralleling.

Load shed/load add

The EMCP 4.4 provides a configurable load add signal as generator set capacity becomes available. In the
event of generator capacity becoming unavailable during operation, a configurable load shed signal is
provided. Enhanced Load Shed/Add capability is available with the Feeder Breaker Control option as part of
the MGDL operation feature sets enhancements.
Methods of parallel operation
The EMCP 4.4 affords two methods of conducting parallel operation. One of these two methods must be
selected during operation and serve to provide the site application with different operating advantages:
Hard Wired: In this configuration, separate hard wired lines are run between paralleled generator sets for
each of the featured synchronizing and paralleling functions: Dead Bus Arbitration, Load Sharing and Load
Sense Demand. This mode allows for gen to gen paralleling for similarly configured EMCP 4.4 units as well
as paralleling controls utilizing either 0-10VDC or 0-3VDC real (kW) load sharing lines.
Multiple Genset Data Link (MGDL): This configuration utilizes an Ethernet based communication protocol to
accomplish the synchronizing and paralleling functions of the EMCP 4.4. This advanced communication
methodology provides enhanced feature sets of the installed paralleling system, including Feeder Breaker
Control and advanced system monitoring and increased Load sense Demand features.

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PARALLELING FUNCTIONS (Continued)

Load sharing
The EMCP 4.4 actively monitors the real (kW) and reactive (kVAr) load requirement of all paralleled generator
sets, and adjusts output of the generator set to maintain a balanced loading of all generator sets.

Soft Load/Unload
When load sharing, soft loading and soft unloading reduces instability and risk to equipment by increasing or
decreasing load in a controlled manner before closing or opening the generator breaker.
Load sense/load demand
When load sharing, soft loading and soft unloading reduces instability and risk to equipment by increasing or
decreasing load in a controlled manner before closing or opening the generator breaker. This feature is
priority based for Hard Wired Load Sense/Load Demand, but can also be Engine Hour based for MGDL Load
Sense Load Demand. Additional features available with MGDL LSLD include engine hour offset and N+X
redundant units.

MODES OF OPERATION
Automatic paralleling
In the automatic paralleling mode, the EMCP 4.4 controller automatically adjusts the voltage and frequency of
the generator set. When the generator output is synchronized with the second source, the EMCP 4.4
controller closes the generator circuit breaker.
Manual paralleling
In the manual paralleling mode, the operator will manually adjust the voltage and frequency of the generator
set. When the generator set is synchronized with the second source, the operator will initiate a generator
circuit breaker close command. A 3 phase sync check function is also included to prevent out of phase
paralleling.
Sync check mode
In the sync check mode, the EMCP 4.4 controller automatically adjusts the voltage and frequency of the
generator set without closing the generator circuit breaker. When the generator set is synchronized with the
second source, the operator will initiate a generator circuit breaker close command. A 3 phase sync check
function is also included to prevent out of phase paralleling.

OPTIONAL MODULES
CAN annunciator

The EMCP 4 CAN Annunciator serves to display generator set system alarm conditions
and status indications.
The annunciator has been designed for use on the accessory communication network and
may be used in either local (package mounted) or remote (up to 800 feet) application. A
maximum of four annunciators may be used with a single EMCP 4.4

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OPTIONAL MODULES (continued)

RS-485 annunciator
The EMCP 4 RS-485 Annunciator serves to display generator set system alarm conditions
and status indications. The annunciator has been designed for use on the long distance
annunciator datalink and is used for remote (up to 4000 feet) application.

Remote monitoring software

The EMCP remote monitoring software package is a PC based
program which allows the user to monitor and control a generator
set, and is capable of running on a Windows based operating
system. The remote monitoring software allows the user to
configure data monitoring and data acquisition processes for
monitoring, graphing, and logging of generator set data.

Digital input/output module

The Digital Input/Output (DI/O) module serves to provide expandable Input and
Output event capability of the EMCP 4 and is capable of reading 12 digital inputs
and setting 8 relay outputs.
The DI/O module has been designed for use on the accessory Communication
Network and may be used in either local (package mounted) or remote (up to
800 feet) application.

RTD module
The RTD module serves to provide expandable generator temperature monitoring capability of the EMCP 4
and is capable of reading up to eight type 2-wire, 3-wire and 4-wire RTD inputs. The RTD Module has been
designed for use on the Accessory Communication Network and may be used in either local (package
mounted) or remote (up to 800 feet) application. A maximum of one RTD Module may be used with a single
EMCP 4.4.

Thermocouple module
The thermocouple module serves to provide expandable engine and generator temperature monitoring
capability of the EMCP 4 and is capable of reading up to twenty Type J or K thermocouple inputs. The
thermocouple module has been designed for use on the primary communication network for engine
information and the accessory communication Network for generator information. It may be used in either
local (package mounted) or remote (up to 800 feet) application. A maximum of one thermocouple modules
may be used with a single EMCP 4.4 on each datalink.

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OPTIONAL CONTROL PANELS

EMCP 4.4 Supervisory Control Panel (SCP)

The EMCP 4.4 SCP is a wall-mountable control panel which adds 16-stage load add
and load shed functionality to an EMCP 4.4 island mode system (non-utility
paralleling). Based on the proven reliability and serviceability of the EMCP 4, the SCP
controller is fully integrated with each generator set mounted EMCP 4.4 via the MGDL
paralleling network.

EMCP 4.4 Master Control Panel (MCP)

The EMCP 4.4 MCP is a wall-mountable system that monitors and controls EMCP 4.4
equipped generator sets, providing centralized controls and communications through an
intuitive graphical interface. Featuring a 15” color touch screen, the MCP is available for
both Emergency Standby (EGP) and Parallel with Utility (XLM) applications.

Materials and specifications are subject to change without notice.

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and
product identity used herein, are trademarks of Caterpillar and may not be used without permission.
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©2017 Caterpillar
LEHE0135-02 (12/17) All rights reserved.