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| Illustration 1 | g03645228 |
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(1) Display screen
(2) F4 Soft key (3) F3 Soft key (4) F2 Soft key (5) F1 Soft key (6) Control key (7) AC overview key (8) Engine overview key (9) Main menu (10) Warning Indicator lamp (yellow) (11) Alarms acknowledge key and silence key (12) Shutdown Indicator lamp (red) (13) Event reset key (14) Event log key (15) Run key (16) Auto key (17) Stop key (18) Escape key (19) Up key (20) Right key (21) OK key (22) Down key (23) Left key | |
The EMCP 4 performs generator voltage regulation, generator temperature monitoring, generator AC metering, and engine monitoring.
The main component of the Electronic Modular Control Panel 4.3/4.4 ( EMCP 4.3/4.4) is the electronic control module (ECM). This section discusses the display, keys, and indicators on the control system panel of the ECM. The EMCP 4.3/4.4 panel is used for monitoring and controlling many of the generator set functions. Some of the functions include:
- Sending start and stop signals to the engine
- Providing visual and audible indications when warning or shutdown events occur
- Displaying engine information and AC generator set information
- Displaying Suspect Parameter Number (SPN) and Failure Mode Identifier (FMI) information for events
- Programming set points for the standard EMCP 4.3/4.4 (The set points for optional modules are set with the use of Cat ET.)
- Annunciator configuration is done within the EMCP 4.3/4.4
The following components can be found on the front panel of the ECM:
- Information Display
- Alarm Indicators
- Alarm Acknowledge/Silence Key
- Event Reset Key
- Function Keys
- Navigation Keys
- System Overview Keys
(1) Display Screen - Information from the EMCP 4 is displayed on the display screen. This screen is used for the following programming and display functions.
- Displaying AC parameter information of the generator set
- Displaying engine parameter information of the generator set
- Programming set points for the generator
- Displaying engine event information
- Displaying event codes from other modules
- Programming the display preferences of the EMCP 4.3/4.4
- Changing password levels of the EMCP 4.3/4.4
(11) Alarm Acknowledge/Silence Key - Pressing the alarm acknowledge/silence key will cause the horn relay output to turn off and silence the horn. Pressing the key will also make yellow or red flashing lights turn off or become solid depending on the active status of the alarms. The alarm acknowledge/silence key may also be configured to send out a global alarm silence on the J1939 Data Link to silence horns on annunciators. However, other modules must be configured in order to listen to the global acknowledge.
(13) Event Reset Key - The event reset button will clear all inactive fault conditions.
Yellow Warning Light - The yellow warning light (10) is located directly above the alarm acknowledge/silence key (11). A flashing yellow light indicates that there are unacknowledged active warnings. A solid yellow light indicates that there are acknowledged warnings active. If there are any active warnings, the yellow light will change from flashing yellow to solid yellow after the alarm acknowledge/silence key is pressed. If there are no longer any active warnings, the yellow light will turn off after the alarm acknowledge/silence key is pressed.
Red Shutdown Light - The red shutdown (12) light is located directly above the event reset key (13). A flashing red light indicates that there are unacknowledged active shutdown events. A solid red light indicates that there are acknowledged shutdown events active. If there are any active shutdown events, the red light will change from flashing red to solid red after the alarm acknowledge/silence key is pressed. Any condition that has caused a shutdown event must be manually reset. If there are no longer any active shutdown events, the red light will turn off.
(2) F4 - Pressing the F4 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.
(3) F3 - Pressing the F3 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.
(4) F2 - Pressing the F2 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.
(5) F1 - Pressing the F1 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.
(15) RUN - Pressing the "RUN" key causes the EMCP 4.3/4.4 to enter the run mode.
(16) AUTO - Pressing the "AUTO" key causes the EMCP 4.3/4.4 to enter the auto mode.
(17) STOP - Pressing the "STOP" key causes the EMCP 4.3/4.4 to enter the stop mode or the cool down mode.
(18) Escape Key - The escape key is used during menu navigation in order to navigate up through the menu/submenu structure. Each key press causes the user to move backward (upward) through the menus. The escape key is also used in order to cancel of data entry screens during set point programming. If the escape key is pressed during set point programming, then none of the changes displayed on the screen will be saved to memory.
(21) OK Key - The OK key is used during menu navigation in order to move forward (downward) through the menu/submenu structure. The key is also used during set point programming in order to save set points changes. Pressing the OK key during set point programming causes set point changes to be saved to memory.
(6) Control Key - The control key will navigate the display to the screen that allows the user to monitor and/or adjust various special control features.
(9) Main Menu Key - The main menu will navigate the display to the main menu directly without having to navigate out of menus.
(14) Event Log - The event log button will navigate the display to the event log.
(19) Up Key - The up key is used in order to navigate up through the various menus or monitoring screens. The key is also used during set point entry. During numeric data entry, the key is used in order to increment the digits (0-9). If the set point requires selection from a list, then the key is used to navigate up through the list.
(20) Right Key - The right key is used during set point adjustment. During numeric data entry, the key is used in order to choose which digit is being edited. The key is also used during certain set point adjustments in order to select a check box or to deselect a check box. If a box has a check mark inside, then pressing the key will cause the check mark to disappear. If the box does not have a check mark inside, then pressing the key will cause a check mark to appear inside.
(22) Down Key - The down key is used in order to navigate down through the various menus or monitoring screens. The key is also used during set point entry. During numeric data entry, the key is used in order to decrement the digits (0-9). If the set point requires selection from a list, then the key is used to navigate down through the list.
(23) Left Key - The left key is used during set point adjustment. During numeric data entry, the key is used in order to choose which digit is being edited. The key is also used during certain set point adjustments in order to select a check box or to deselect a check box. If a box has a check mark inside, then pressing the key will cause the check mark to disappear. If the box does not have a check mark inside, then pressing the key will cause a check mark to appear inside.
(7) AC Overview - Pressing the AC overview key displays the first screen of AC information for the generator set. This initial information page contains various AC parameters that summarize the electrical operation of the generator set. Additional AC parameters can be viewed by pressing the down key multiple times.
(8) Engine Overview - Pressing the engine overview key displays the first screen of engine information. This initial information page contains various engine parameters that summarize the operation of the engine. Additional engine parameters can be viewed by pressing the down key multiple times.
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| Illustration 2 | g03645301 |
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(24) Emergency stop button
(25) CAN 1 Connector | |
Emergency stop button (24) - The emergency stop button is used to shut down the engine during an emergency situation.
CAN1 Connector (25) - Connection for Cat service tool on the CAN1 network (used for the Engine ECM and EMCP).
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| Illustration 3 | g03645187 |
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Inside of control panel (26) Idle/Rated speed switch (27) Automatic generator set controller (AGC) controller (28) Ethernet switch module (eight ports) (29) Control relays (30) Breaker CBF for the fuel solenoid valve (15A) (31) CAN2 service connector | |
Idle/Rated Speed Switch (26) - Controls the engine speed. Switch in the UP position commands the engine to run at rated speed. Switch in the DOWN position commands the engine to run at idle speed.
AGC Controller (27) - Performs paralleling and load control, fuel tank level monitoring and control, rated voltage and frequency selection, generator and bus AC metering, VFD start/stop and speed control and integrates with IPP plant control system.
Ethernet Switch Module (28) - Interface point for integrating with IPP plant SCADA system. Two ports are factory connected to the EMCP, and AGC controllers to provide access to TCP/IP network data. The remaining six ports are for customer use.
Control Relays (29) - Relays for the controls.
CBF (30) - Breaker for the fuel solenoid valve (15A).
CAN2 Service Connector (31) - Connection for Cat service tool on the CAN2 network (used for RTD module).
The AGC is the primary means of starting and operating the unit. If started via the EMCP, the variable frequency drive (VFD) will not run in Remote/Auto mode. The VFD must be turned ON in local mode to operate the cooling fans if the unit is started via EMCP.
The AGC has two displays. The upper display is for primary operator control to start/stop the engine and open/close the generator breaker. The lower display is for secondary operator control buttons, and status indicators.
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| Illustration 4 | g03607851 |
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(32) Alarm lamp
(33) View button (34) Yellow alarm indicator (35) Red alarm indicator (36) Log button (37) Power indicator (38) Self check OK indicator (39) PM CAN indicator (40) Select/arrow buttons (41) Back button (42) Local button/indicator (43) Remote button/indicator (44) Bus voltage indicator (45) Close generator circuit breaker button (46) Breaker closed indicator (47) Generator voltage indicator (48) Generator running indicator (49) Stop button (50) Start button (51) Jump button (52) Info button | |
Alarm lamp (32) - this indicator is illuminated when any active alarms are present. The indicator flashes for new alarms.
View button (33) - this button allows the user to select views on the display screen.
Yellow alarm indicator (34) - this indicator will illuminate when the engine ECM has transmitted an alarm condition over the J1939 CAN1 bus.
Red alarm indicator (35) - this indicator will illuminate when the engine ECM has transmitted a shutdown condition over the J1939 CAN1 bus.
Log button (36) - this button displays the events that have occurred and recorded in the history.
Power indicator (37) - this indicator will illuminate when the AGC4 power supply input is within tolerance.
Self check OK indicator (38) - this indicator will illuminate when AGC4 hardware and software are functioning correctly.
PM CAN indicator (39) - this indicator will illuminate when the AGC4 is connected to plant management CAN bus.
Select/arrow buttons (40) - these buttons are used to navigate through the user menus and screens.
Back button (41) - this button returns the screen to the previous selection.
Local button/indicator (42) - this button initiates the "LOCAL" mode of the controller. The indicator is lit when "LOCAL" mode is selected.
Remote button/indicator (43) - this button initiates the "REMOTE" mode of the controller. The indicator is lit when "REMOTE" mode is selected.
Bus voltage indicator (44) - this indicator will illuminate when bus voltage, and frequency are within limits.
Close generator circuit breaker button (45) - this button closes the generator circuit breaker when pressed. A second press on this button will open the generator circuit breaker.
Breaker closed indicator (46) - this indicator will illuminate when the generator breaker is closed.
Generator voltage indicator (47) - this indicator will illuminate when the generator voltage, and frequency are within limits.
Generator running indicator (48) - this indicator will illuminate when the generator is running.
Stop button (49) - this button stops the generator set when the EMCP is in AUTO.
Start button (50) - this button starts the generator set when the EMCP is in AUTO.
Jump button (51) - this button allows the user to scroll to specific parameters with the use of the scroll buttons.
Info button (52) - this button gives the user a more detailed description of alarms that are present.
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| Illustration 5 | g03615779 |
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(53) "GEN AVAILABLE" lamp
(54) "OVERCURRENT" lamp (55) "EXT FAULT" lamp (56) "BATT ALARM" lamp (57) "DELTA AIR FILTER" lamp (58) "DELTA FUEL FILTER" lamp (59) "DELTA OIL FILTER" lamp (60) "OIL ALARM" lamp (61) "EMCP NOT AUTO" lamp (62) "EMCP ALARM" lamp (63) "NO FUEL" lamp (64) "FUEL VALVE ON" lamp (65) "RDTR ALARM" lamp (66) "COOLANT ALARM" lamp (67) "FIXED POWER" lamp (68) "MANUAL" lamp (69) "RESET" button (70) "DATA VIEW" button (71) "RPM UP" button (72) "RPM DOWN" button (73) "VOLTAGE UP" button (74) "VOLTAGE DOWN" button (75) "FIXED POWER ON/OFF" button (76) "MANUAL ON/OFF" button | |
"GEN AVAILABLE" lamp (53) - If the lamp is illuminated green, the generator is ready to run.
"OVERCURRENT" lamp (54) - If illuminated, there is a generator trip on overcurrent.
"EXT FAULT" lamp (55) - If illuminated, there is a plant trip, or remote emergency stop trip.
"BATT ALARM" lamp (56) - If illuminated, there is a battery charger alarm/fault.
"DELTA AIR FILTER" lamp (57) - Delta pressure across the generator terminal box air filter is high.
"DELTA FUEL FILTER" lamp (58) - Delta pressure across the primary fuel water separator filter on the fuel tank.
"DELTA OIL FILTER" lamp (59) - Delta pressure across the oil filter in the engine. Not configured at this time.
"OIL ALARM" lamp (60) - Make-up oil tank low-level alarm.
"EMCP NOT AUTO" lamp (61) - If illuminated, the EMCP is not in "AUTO" mode.
"EMCP ALARM" lamp (62) - If illuminated, the EMCP has an alarm/fault.
"NO FUEL" lamp (63) - If illuminated, the fuel is low, and shutdown will occur.
"FUEL VALVE ON" lamp (64) - If illuminated, the fuel valve is open, and will allow fuel to come into the fuel tank.
"RDTR ALARM" lamp (65) - Activates in the event one of the following occurs: radiator breaker trip, auto lube pump failure and VFD failure.
"COOLANT ALARM" lamp (66) - Activates in the event one of the following occurs: coolant level is low and coolant temperature is high.
"FIXED POWER" lamp (67) - If illuminated, the unit is in "FIXED POWER" mode. Speed/KW, and voltage/KVar can be manually controlled by the operator.
"MANUAL" lamp (68) - If illuminated, the unit is in "MANUAL" control mode. Speed/KW, and voltage/KVar can be manually controlled by the operator.
"RESET" button (69) - Press to acknowledge AGC4 alarms/shutdown, or to reset VFD fault.
"DATA VIEW" button (70) - Press to jump to "VIEW 1".
"RPM UP" button (71) - Press to increase generator speed when breaker is open, and "MANUAL" mode is on. Push to increase KW when breaker is closed, and "MANUAL" mode is on.
"RPM DOWN" button (72) - Press to decrease generator speed when breaker is open, and "MANUAL" mode is on. Push to decrease KW when breaker is closed, and "MANUAL" mode is on.
"VOLTAGE UP" button (73) - Press to increase generator voltage when breaker is open, and "MANUAL" mode is on. Push to increase KVar when breaker is closed, and "MANUAL" mode is on.
"VOLTAGE DOWN" button (74) - Press to decrease generator voltage when breaker is open, and "MANUAL" mode is on. Push to decrease KVar when breaker is closed, and "MANUAL" mode is on.
"FIXED POWER ON/OFF" button (75) - Press to turn "FIXED POWER" mode on or off.
"MANUAL ON/OFF" button (76) - Press to turn "MANUAL" mode on or off.
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| Illustration 6 | g03790614 |
To go to a menu, press the "JUMP" button on the AGC upper display, and then enter the desired menu number using the arrow keys, and "ENTER" key. When prompted, enter the password "2002".
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| Illustration 7 | g03635404 |
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AGC display screen showing "Menu group number 1000" (77) SP (menu 1001) set point (78) DEL (menu 1002) delay (79) OA (menu 1003) output A (80) OB (menu 1004) output B (81) ENA (menu 1005) enable (82) FC (menu 1006) fail class | |
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| Illustration 8 | g03635428 |
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(83) Minimum setting
(84) Actual setting (85) Maximum setting | |
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| Illustration 9 | g03635446 |
| (86) Cursor (underlined text) | |
The left and right arrow keys change the cursor position. The "SEL" key is used to make a selection, and the up and down arrow keys are used to change settings.
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| Illustration 10 | g03634476 |
The AGC can be set for the operator to control the unit manually ("LOCAL" mode). The AGC can alternately be set for the plant control system to control the unit automatically ("REMOTE" mode). The mode can be selected by pressing either the "LOCAL", or "REMOTE" buttons on the AGC display. Mode indicators located next to the buttons illuminate depending on which mode is active.
In "LOCAL" mode, the following operations are affected:
- Engine can be started/stopped by pressing the "START" button on the upper AGC display, if the EMCP is in "AUTO" mode
- Generator breaker can be opened/closed by pressing the breaker symbol on the upper AGC display
- Engine start/stop and generator breaker operation by remote means, such as digital inputs, or commands via communications, are disabled.
In "REMOTE" mode, the following operations are affected:
- Engine cannot be started/stopped using the upper AGC display
- Generator breaker cannot be opened/closed using the upper AGC display
- Engine start/stop and generator breaker operation by remote means, such as digital inputs, or commands via communications, are enabled. The EMCP must be in "AUTO" mode for remote means to work.
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| Illustration 11 | g03635092 |
A button is provided on the lower AGC display to enable/disable certain local operator functions, in "MANUAL" mode.
When "MANUAL" mode is activated, the generator set can be controlled from the display and with digital inputs. The following operations are affected:
- Engine speed can be adjusted up/down using the lower AGC display
- Generator Kw output can be adjusted up/down using the lower AGC display (when paralleled to the utility)
- Generator voltage can be adjusted up/down using the lower AGC display
- Generator Kvar output can be adjusted up/down using the lower AGC display
- Synchronization failure alarm is disabled
To enter and exit "MANUAL" mode, use the following procedure:
- Ensure that the unit is in power management mode.
- Press fixed power button (the unit will go into fixed power mode).
- Press manual button (the unit will go into manual mode in fixed power mode).
- Use up/down buttons to control generator output manually.
- Press manual button to exit manual mode.
- Press fixed power button to exit fixed power mode (the unit will return to power management mode).
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| Illustration 12 | g03634838 |
Fixed power mode is used when a single unit is base loading to the utility in which the generator output is controlled by setpoints contained within the controller and nothing controlled over CAN communications.
A button is provided on the lower AGC display to enable/disable fixed power (or base load) mode.
In fixed power/base load (remote mode), the user starts the unit and synchronizes to the utility when the remote "auto start"/"auto stop" signal is activated. After the generator breaker closure, the unit ramps up the load to the setpoint level. When the signal is deactivated, the unit is unloaded and stopped after the cooling period.
When the generator breaker is closed, the generator power output continues to rise in ramp up steps, determined by the number of steps in menu 2615. For example, if the delay point is set to 20%, and the number of load steps is set to 3, the unit will ramp to 20%, wait the configured delay time, ramp to 40%, ramp to 60%, wait, and then ramp to the present power setpoint.
Note: For the load steps to be active, menu 2614 ENABLE must be set to "ON".
Island mode is used when paralleling multiple units on a common bus, powering an isolated load, or for a single unit powering an isolated load. In this mode, load sharing is performed via analog signals shared among all units and nothing controlled over CAN communications.
In island mode (manual mode), ensure that each unit is set to "LOCAL" mode. Start one unit, and close the breaker for that unit to the dead bus. If paralleling multiple units, go to each of the other units. Start the units, and parallel the units to the live bus. As load is applied, the real and reactive power is automatically shared proportionally among all paralleled units via analog load share signals, shared among all paralleled units.
Power management mode is used when two or more units communicate to each other or to a plant control system over CAN communications.
In island applications, power management mode enables CAN communications among other units. In utility applications, power management mode enables CAN communications with the plant control system.
Engine Speed Control (Idle or Rated)
A two position toggle switch is located inside the operator panel that allows the user to run the engine at either idle, or rated speed. The operator may desire to select idle speed (down position) when starting a cold engine or the initial startup after engine maintenance has been performed. The generator breaker cannot be closed, nor the engine batteries charged/maintained by the battery charger while running in idle speed. The normal position is rated speed (UP position).
Nominal Voltage and Frequency Selection
The unit can quickly be configured to run at either 400V/50Hz, or 480V/60Hz by changing a setting in the AGC controller. Using the AGC upper display, go to menu 6006. Select "1" to cause the nominal ratings to be 400V/50Hz. Select "2" to cause the nominal ratings to be 480V/60Hz. Whenever changing the selection, a relay output from the AGC will cause the EMCP, engine ECM, and shore power 2kVA transformer to be properly reconfigured.
Note: The transformer voltage selector switch must be set to AUTO to allow the transformer to change automatically.
After changing the AGC setting, the entire package control system is ready to run at the new rating, with no further user intervention.
There are four rating groups within the engine ECM:
- Low Best Fuel Efficiency (BSFC), 60Hz/1800RPM
- Low Best Fuel Efficiency (BSFC), 50Hz/1500RPM
- Low emissions, 60Hz/1800RPM
- Low emissions, 50Hz/1500RPM
The Cat service tool is required to switch from any low BSFC group to any low emissions group. The Cat service tool is also required to switch from any low emissions group to any low BSFC group. Factory passwords are not required to change activation of any of the four ratings groups.
Decide which is preferred for a given site, best fuel, or best emissions. Use the Cat service tool to activate one of the two groups in the preferred category. The 50Hz or 60Hz rating within the category is selected automatically by the AGC controller using a digital input to the engine ECM.
The following describes how to start the unit, control the generator breaker, paralleling, and generator load control based on different operation scenarios.
The following table contains the relevant settings that must be made prior to startup depending on application:
| Application | AGC Configurations | |||
| Menu 9160 | Menu 6070 | Menu 7531 | Menu 7051 and 7052 | |
| Island Mode/Single Unit | A1 | Island Mode | N/A | N/A |
| Island Mode/Multi- Units | A2 | Power Management Mode | Assign unique number to each unit | N/A |
| Utility Mode/Base Load | A3 | Fixed Power Mode | N/A | Set desired % load (7051) and power factor (7052) |
A1 (menu 9160) used for any of the following applications:
- Single unit, prime power
- Multiple units paralleling in island mode using analog load share lines
- Commissioned unit in a typical IPP plant system (AGC software must be customized as per the plant configuration)
A2 (menu 9160) used for the following application:
- Two units (max) paralleling in island mode with CAN communications from AGC-to-AGC
Note: The unit is configured for two generator sets (ID1 and ID2). For more than two generator sets, the AGC software must be customized.
A3 (menu 9160) used for the following application:
- Single unit, base load (fixed power). Non-typical plant application.
Manual Control Startup Procedure
- Press the "AUTO" button (16) on the EMCP to put the EMCP into auto mode.
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Illustration 14 g03643840 - Verify "LOCAL" mode is active. If "LOCAL" mode is inactive, press the "LOCAL" button (42) on the AGC upper display. The unit is now ready to start.
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Illustration 15 g03643848 - Press the "START" button (50) on the AGC upper display to start the engine.
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Illustration 16 g03643808 - Press the breaker symbol (45) on the AGC upper display in order to close the generator breaker after the two indicators, (47) and (48) illuminate.
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Illustration 17 g03643853 - When the generator breaker closes, indicators (44) and (46) will illuminate. The unit is now powering the load.
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| Illustration 13 | g03643830 |
Manual Control Shutdown Procedure
- Press the "STOP" button (49) on the AGC upper display to open the generator breaker immediately, and put the engine in cooldown/stop mode.
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| Illustration 18 | g03643948 |
Note: Always use the AGC upper display to start/stop the engine when using manual control. Using the EMCP for startup or shutdown will result in improper equipment operation.
Automatic Control Startup Procedure
- Press the "AUTO" button (16) on the EMCP to put the EMCP into auto mode.
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Illustration 20 g03643818 - Verify "REMOTE" mode is active. If "REMOTE" mode is inactive, press the "REMOTE" button on the AGC upper display. The unit is now ready to start.
- Close the remote start contact to activate the AGC digital input. The engine will start, the generator will build up voltage, and the generator breaker will close automatically.
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Illustration 21 g03643853 - When the generator breaker closes, indicators (44) and (46) will illuminate. The unit is now powering the load.
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| Illustration 19 | g03643830 |
Automatic Control Shutdown Procedure
- Open the remote start contact to open the generator breaker immediately, and put the engine in cooldown/stop mode.
Manual Control Startup Procedure
- On each unit, press the "AUTO" button (16) on the EMCP to put the EMCP into auto mode.
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Illustration 23 g03643840 - On each unit, verify "LOCAL" mode is active. If "LOCAL" mode is inactive, press the "LOCAL" button (42) on the AGC upper display. The units are now ready to start.
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Illustration 24 g03643848 - On the lead unit, press the "START" button (50) on the AGC upper display to start the engine.
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Illustration 25 g03643808 - On the lead unit, close the generator breaker (45) to a dead bus by pressing the breaker symbol on the AGC upper display after the two indicators, (47) and (48) illuminate.
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Illustration 26 g03643939 - Parallel all other units to the common bus using the same sequence. On those units, the AGC will automatically synchronize, and parallel to the live bus when the breaker symbol is pressed to close the generator breaker.
Note: The indicator (44) illuminates when a live bus is present.
- Verify that all units are sharing real and reactive load proportionally via the kW and kVAR values on the AGC upper display of each unit.
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| Illustration 22 | g03643830 |
Manual Control Shutdown Procedure
- On each unit, press the "STOP" button (49) on the AGC upper display to open the generator breaker immediately, and put the engine in cooldown/stop mode. Alternately, the breaker symbol can be pressed first to unload the generator, and open the generator breaker before pressing the "STOP" button.
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| Illustration 27 | g03643948 |
Note: Always use the AGC upper display to start/stop the engine when using manual control. Using the EMCP for startup or shutdown will result in improper equipment operation.
Automatic Control Startup Procedure
- On each unit, press the "AUTO" button (16) on the EMCP to put the EMCP into auto mode.
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Illustration 29 g03643818 - On each unit, verify "REMOTE" mode is active. If "REMOTE" mode is inactive, press the "REMOTE" button (43) on the AGC upper display. The units are now ready to start.
- Close the remote start contact to activate the AGC digital input on all units. The engine will start, the generator will build up voltage, and the generator breaker will close automatically.
Note: The remote start signal can be sent to all units simultaneously.
- The first unit to come up to speed will close the generator breaker of that unit to the dead bus automatically. The remaining units will synchronize, and parallel to the live bus automatically.
Note: The indicator (44) illuminates when a live bus is present.
Note: The AGC will only use first up discrimination to allow one unit to close its breaker first if power management (application A2) is used. If using application A1 (paralleling with analog load sharing), and the remote start signal is sent to multiple units simultaneously, two breakers can be closed onto a dead bus simulaneously. For this reason, power management is preferred.
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Illustration 30 g03643939 - Verify that all units are sharing real and reactive load proportionally by viewing the kW and kVAR values on the AGC upper display of each.
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| Illustration 28 | g03643830 |
Automatic Control Shutdown Procedure
- Open the remote start contact to all units. Each unit will soft unload, then open the generator breaker, and put the engine in cooldown/stop mode.
Manual Control Startup Procedure
- Press the "AUTO" button (16) on the EMCP to put the EMCP into auto mode.
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Illustration 32 g03643840 - Verify "LOCAL" mode is active. If "LOCAL" mode is inactive, press the "LOCAL" button (42) on the AGC upper display. The unit is now ready to start.
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Illustration 33 g03643939 - Verify live utility source. The indicator (44) will illuminate when a live source is detected. The unit is now ready to start.
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Illustration 34 g03643848 - Press the "START" button (50) on the AGC upper display to start the engine.
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Illustration 35 g03643808 - Press the breaker symbol (45) on the AGC upper display to close the generator breaker after the two indicators, (47) and (48) illuminate.
Note: Pressing the breaker symbol causes the AGC to automatically synchronize, and parallel to the utility.
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Illustration 36 g03643853 - When the generator breaker closes, the two indicators, (46) and (44) will illuminate. The unit is now parallel to the utility.
- The generator output power will steadily increase up to the preprogrammed level.
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| Illustration 31 | g03643830 |
Manual Control Shutdown Procedure
- Press the "STOP" button (49) on the AGC upper display to open the generator breaker immediately, and put the engine in cooldown/stop mode. Alternately, the breaker symbol can be pressed first to unload the generator, and open the generator breaker before pressing the "STOP" button (49) .
Note: Always use the AGC upper display to start/stop the engine when using manual control. Using the EMCP for startup or shutdown will result in improper equipment operation.
Automatic Control Startup Procedure
- Press the "AUTO" button (16) on the EMCP to put the EMCP into auto mode.
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Illustration 38 g03643818 - Verify "REMOTE" mode is active. If "REMOTE" mode is inactive, press the "REMOTE" button (43) on the AGC upper display.
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Illustration 39 g03643939 - Verify live utility source. The indicator (44) will illuminate when a live source is detected. The unit is now ready to start.
- Close the remote start contact to activate the AGC digital input on all units. The engine will start, the generator will build up voltage, and the generator breaker will close automatically.
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Illustration 40 g03643853 - When the generator breaker closes, the two indicators, (46) and (44) will illuminate. The unit is now parallel to the utility.
- The generator output power will steadily increase up to the preprogrammed level.
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| Illustration 37 | g03643830 |
Automatic Control Shutdown Procedure
- Open the remote start contact. The unit will soft unload the generator, open the generator breaker, and put the engine in cooldown/stop mode.
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| Illustration 41 | g03790608 |
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(77) Display status
(78) Menu line (79) Submenus (80) Status line (81) Function buttons (82) Stop/Reset button (83) Run button (84) Navigation button/dial (85) FWD/REV button (86) ESC button (87) Scroll boxes | |
Display status (77) - displays the default settings the state of the drive, active control channels, frequency reference and LOC/REM (T/K key status). The "Display Status" content can be configured.
Menu line (78) - displays the name of the current menu or submenu.
Submenus (79) - lists the submenus of the current menu.
Status line (80) - displays the functions assigned to function buttons "F1-F4: Code (F1)""<<(F2)"">>(F3)""T/K (F4)".
Function buttons (81) - F1: displays the code of the selected parameter, or contextual help, F2: navigates to the left, or returns to the previous menu or submenu, F3: navigates to the right, or advances to the next menu or submenu and F4: command and reference via the terminal or keypad.
Stop/Reset button (82) - stops the drive controller and resets the faults when in HMI command mode.
Run button (83) - runs the motor with the current setting. Starts the drive controller if in HMI command mode.
Navigation button/dial (84) - pressing the button saves a value, or enters a menu or parameter. Turning the dial clockwise increases a value or advances to the next menu item or line. Turning the dial counterclockwise decreases a value or backs up to the previous menu item or line. In HMI mode, the dial acts as a speed reference control.
FWD/REV button (85) - reverses the rotation direction of the motor (if configured to allow reverse for HMI command mode).
ESC button (86) - exits a menu or parameter, or cancels a value to return to the previous value in the memory.
Scroll boxes (87) - indicates (by arrow direction) whether there are additional submenus or levels to access. A blank box indicates that there are no additional submenus or levels to access.
The VFD is controlled automatically from the AGC controller when the indicator on the display status reads "REM". The VFD is controlled manually, using the dial, when the indicator on the display status reads "LOC". This automatic or manual mode selection is made by pressing the "T/K" button (F4).
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| Illustration 42 | g03593416 |
After using the "F4" button to change to "LOC" mode, navigate to "HMI Frequency Ref." and use the dial to adjust the speed of the fan motor.
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| Illustration 43 | g03593419 |
Navigate to "Current Fault List" or "Fault History" to view alarms. To reset faults, press the "STOP/RESET" button on the VFD. Disconnect the drive power supply in the event of a non-resettable fault. Wait for the display to disappear completely. Find the cause of the fault in order for the fault to be corrected.
The Altivar 61 does not require any preventive maintenance. Performing the following regularly is advisable:
- Check the condition and tightness of the connections
- Ensure that the temperature around the unit remains at an acceptable level, and that ventilation is effective (average service life of fans: 3 to 5 years depending on the operating conditions)
- Remove any dust from the VFD heat sink fans on the back of the breaker box
Note: Do not run "Auto Tune" as this function will not work properly with multiple motors controlled by a single VFD.