Installation Manual

Engine Paralleling Integration Controls
(EPIC)
208-480 Installation Manual
EPIC 208-480 Installation Manual

DCN0010 Rev 1.2.1
DCN0010 EPIC Installation Manual
Important Definitions
The following are standard notifications that may appear through the document. Be sure to pay special at-
tention to the notifications below.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment.
NOTE
Provides other helpful information that does not fall under the warning or caution categories.
Important Information
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging device, make
sure the charging device is turned off before disconnecting the battery from the system.
Electronic controls contain static-sensitive parts. Observe the following precautions to prevent
damage to these parts.
• Discharge body static before handling the control (with power to the control turned off, con-
tact a grounded surface and maintain contact while handling the control).
• Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit
boards.
WARNING
Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property damage.
Any unauthorized modifications to or use of this equipment outside its specified mechanical, elec-
trical, or other operating limits may cause personal injury and/or property damage, including dam-
age to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negli-
gence" within the meaning of the product warranty thereby excluding warranty coverage for any
resulting damage, and (ii) invalidate product certifications or listings.
DOCUMENTATION
This publication may have been revised or updated since this copy was produced. To verify that
you have the latest revision, be sure to contact Intelligent Switchgear Organization, LLC.
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at Intelligent Switchgear Organization, LLC.
ISO Company reserves the right to update any portion of this publication at any time.
Intelligent Switchgear Organization, LLC

All Rights Reserved.
DCN0010 EPIC 208-480 Installation Manual
Revision History
Rev. Date Editor Changes

NEW 05/18/09 DL Draft
0.2 10/22/09 DL Front rear mod
0.3 01/19/10 DL Edits
1.0 01/21/10 DL Released
1.1 02/10/10 DL update wiring required
1.2 06/02/10 DL Corrected Gen Main voltage Sense E1TB Terminals
1.2.1 7/22/10 DL Added 208-480 to title
Page 3 of 60
Content
INSTALLATION MANUAL ............................................................................................................. 1

Revision History ....................................................................................................................................... 3
Content..................................................................................................................................................... 4
Figures ..................................................................................................................................................... 6
Tables....................................................................................................................................................... 7
SECTION 1. QUICK START GUIDE ............................................................................................... 8
SECTION 2. GENERAL INFORMATION .......................................................................................... 9
INTRODUCTION...................................................................................................................................... 9
Operational Functionality ......................................................................................................................... 9
EGP Control System Capabilities ............................................................................................................ 9
EGP Control System Features................................................................................................................. 9
EGP Control System Configuration ....................................................................................................... 10
Master Control Panel ................................................................................................................... 10
Add-On Genset Control Panel ..................................................................................................... 11
XLM Control System Capabilities .......................................................................................................... 12
XLM Control System provides ............................................................................................................... 12
XLM Control System Configuration........................................................................................................ 12
Add-On Utility Control Panel........................................................................................................ 12
SECTION 3. DIMENSIONS .......................................................................................................... 14
Master Panel Outline Dimensions.......................................................................................................... 14
Optional Add-On Genset / Add-On Utility Control Panel Dimensions ................................................... 15
EGP Cabling and Wiring detail .............................................................................................................. 16
Conduit Size and Conduit Wiring ........................................................................................................... 16
XLM Cabling and Wiring Detail .............................................................................................................. 18
Conduit Size and Conduit Wiring ........................................................................................................... 18
Master Panel Terminal Locations .......................................................................................................... 19
Add-on Gen Panel Terminal Locations.................................................................................................. 20
Add-On Utility Panel Terminal Locations ............................................................................................... 21
Dealer Provided Control System Connections ...................................................................................... 22
Control System Connections ................................................................................................................. 22
Master Control Cabinet Interconnection ...................................................................................... 22
Genset Interconnection................................................................................................................ 22
Genset Required Hardware ......................................................................................................... 22
Required Genset Interconnection Wiring..................................................................................... 23
AAdd-On Genset Control Panel Interconnection......................................................................... 24
Add-On Genset Interconnection ..................................................................................................24
Add-On Genset Required Hardware ........................................................................................... 24
Required Add-On Genset Interconnection Wiring ....................................................................... 25
Optional Load Shed/Add Wiring ..................................................................................................26
Utility Interconnection .................................................................................................................. 27
Utility Control Panel Interconnection ........................................................................................... 27
Required Utility Hardware............................................................................................................ 27
Required Utility Interconnection Wiring ....................................................................................... 27
Utility Circuit Breaker Wiring ........................................................................................................ 28
Additional Utility Wiring ................................................................................................................ 28
Optional Load Shed/Add Wiring............................................................................................................. 29
System Power Supply ............................................................................................................................ 29
AC Sensing ............................................................................................................................................ 29
480 Volt Sensing.......................................................................................................................... 29
Current Sensing ........................................................................................................................... 29
Environmental ........................................................................................................................................ 30
Page 4 of 60
SECTION 4. STANDARD I/O SPECIFICATIONS............................................................................. 31

Voltage Sensing........................................................................................................................... 31
Current Sensing ........................................................................................................................... 31
Analog Inputs ............................................................................................................................... 31
Analog Outputs ............................................................................................................................ 31
Communications Ports................................................................................................................. 31
SECTION 5. CONNECTIONS ....................................................................................................... 32
Power Supply ......................................................................................................................................... 32
Engine Battery Connections .................................................................................................................. 33
Best Source Wiring ................................................................................................................................ 34
Hot Bus Connections ............................................................................................................................. 35
Voltage Measuring ................................................................................................................................. 36
Voltage Measuring: Generator Mains, 3 Phase .......................................................................... 36
Generator Current Measuring ................................................................................................................ 37
Digital Inputs .......................................................................................................................................... 38
Engine Run Digital Outputs.................................................................................................................... 39
Engine Circuit Breaker Wiring................................................................................................................ 40
Speed Control and Voltage Regulator Wiring (Analog Outputs) ........................................................... 41
Speed Control Wiring................................................................................................................... 41
Voltage Regulator wiring.............................................................................................................. 41
Emergency Start Wiring ......................................................................................................................... 43
Utility Mains Voltage Measuring............................................................................................................. 44
Utility Circuit Breaker Wiring .................................................................................................................. 45
Utility Mains Current Measuring............................................................................................................. 46
Mains Current (multi-unit only)..................................................................................................... 46
DATA TABLE INTERFACE.................................................................................................................... 47
SECTION 6. ENGINE / CIRCUIT BREAKER CHECKOUT ................................................................ 48
Startup Procedures (Level 1) ................................................................................................................. 48
Step 1 Engine / Generator Inspection ......................................................................................... 48
Step 2 Power Cable Inspection ................................................................................................... 49
System Start Procedures Level 2 .......................................................................................................... 50
Verify Best Source DC Voltages To Master panel .....................................................................50
Master Panel Application setup ............................................................................................................. 51
SECTION 7. SYSTEM STARTUP ................................................................................................. 52
Initial System Setup Procedures............................................................................................................ 52
Initial Setup steps................................................................................................................................... 52
System Startup Procedures ................................................................................................................... 56
Functional Startup steps ........................................................................................................................ 56
SECTION 8. OPERATIONAL FUNCTIONALITY .............................................................................. 57
Control System Capabilities................................................................................................................... 57
SECTION 9. DRAWINGS ............................................................................................................ 58
Page 5 of 60
Figures
Figure 2-2: EGP Control System – System Overview with optional Genset Controllers ........................................ 10
Figure 2-3: XLM Controller System – System Overview with optional Genset & Utility Add-On Controllers ........... 13
Figure 3-1: EPIC Master Panel – Outline Drawing ................................................................................................ 14
Figure 3-2: Optional Add-On Genset / Utility Control Panel Dimensions ................................................................ 15
Figure 3-3: Basic EGP system conduit diagram ..................................................................................................... 16
Figure 3-4: EGP system expanded up to 10 Gensets c.......................................................................................... 17
Figure 3-6: EPIC Master Panel - Terminal Locations ............................................................................................ 19
Figure 3-7: Add On Gen Controller - Terminal Locations ....................................................................................... 20
Figure 3-8: Add On Utility Controller - Terminal Locations...................................................................................... 21
Figure 5-1: Power Supply – EMCP 3.S Safe Operating Range, Voltage 24Vdc Cranking...................................... 32
Figure 5-2: 24Vdc Engine Battery inputs ................................................................................................................ 33
Figure 5-3: Best Source Wiring............................................................................................................................... 34
Figure 5-4: Hot Bus Connections............................................................................................................................ 35
Figure 5-5: Voltage Measuring – Generator Mains 3 Phase................................................................................... 36
Figure 5-6: Current Measuring – Generator Mains ................................................................................................. 37
Figure 5-7: Digital Inputs - alarm/control inputs - operation logic............................................................................ 38
Figure 5-8: Engine Run Digital Output .................................................................................................................... 39
Figure 5-9: Engine Circuit Breaker – Wiring ........................................................................................................... 40
Figure 5-10: Analog Voltage and Speed Output – Wiring ....................................................................................... 41
Figure 5-11: Emergency Start – Wiring .................................................................................................................. 43
Figure 5-12: Voltage Measuring – Utility Mains ...................................................................................................... 44
Figure 5-13: Utility Circuit Breaker – Wiring............................................................................................................ 45
Figure 5-14: Current Measuring – Utility Mains ...................................................................................................... 46
Page 6 of 60
Tables
Table 2-1: Applicable Manuals ................................................................................................................................. 9

Table 3-1: Master Panel – Detail Outline................................................................................................................ 14
Table 3-2: Optional Add-On Genset / Utility Control Panel Dimensions ................................................................. 15
Table 5-1: 24Vdc Engine Battery input - terminal assignment ................................................................................ 33
Table 5-2: Terminal Assignment Current Measuring - - Generator Current ............................................................ 37
Table 5-3: Terminal Assignment -- Current Measuring - - Utility Current ................................................................ 46
Page 7 of 60
Section 1.
Quick Start Guide
Complete mounting of cabinets
Complete all of the interconnection wiring

Refer to drawings
1. Master Control Panel
To Gens 1 & 2
To other Add-On Gens
To Utility Control Panels if applicable
2. Add-On Control Panels

To Gensets
To Master Control Panel
3. Add-On Utility Control Panel

To Utility
To Master Control Panel
Complete Check and setup of the system settings
1. Step through the INITIAL screens and setup the system settings.
See Section 7
2. Step through the System settings.
See Section 7
3. Step through the Generator settings for each generator.
See Section 7
4. Step through the Utility settings for each generator.
See Section 7
5. On the Overview screen set the Engine Control Switch to the desired position. Verify that the
ECS switch is set to OFF.
Perform startup test as describe in Section 6

1. Each of the engine must be checked for proper interconnection wiring and phasing.
Circuit Breaker control
Run, stop cooldown control
2. Check the sync scope on each control screen for proper rotation direction
3. Each engine must be checked for it ability to synchronize with each of the other engines
Page 8 of 60
Section 2.
General Information
Type
EPIC 208-480V Installation Manual this manual DCN0010

EPIC – Operation Manual DCN0011
EPIC – Parts Manual DCN0012
Table 2-1: Applicable Manuals
INTRODUCTION
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
The Engine Paralleling Integrated Control (EPIC) system is a rugged, industrially hardened, microproces-
sor based Genset controller designed to work exclusively with Caterpillar engine-generator sets. The
EPIC Control system eliminates the need for traditional synchronizers, power factor controllers, load
share modules, protective relays, cross-current compensation devices, annunciators’, switches and me-
ters by replacing them with a single Caterpillar controller.
The EPIC control system product line is furnished to Caterpillar Dealers as an alternative to Switchgear. It
is furnished as a modular controls only product for Caterpillar Dealer installation and start-up. The EPIC
control system supports EGP functionality for 2 to 10 Generator systems. Optionally, up to 8 additional
individual Genset Control Panels may be added to the system. Optionally, an ADD-ON Utility Control
Panel may be added to the system. Only low voltage applications are supported.
Operational Functionality
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
EGP Control System Capabilities
The control system provides the Standard ISO EGP functionality for 2 to 10 Gensets.
EGP Control System Features
• Moving Master functionality is provided. The default master is Genset 1. In the event
that Genset 1 fails, the master functions transfer to Genset 2 .
• Single Ethernet Supervisory Network.
• Conditional Load Shed/Add – Load Sensitive Load Shed/Add is supported. Conditional
Load Shed/Add functionality will be provided through 1 - 4PDT relay for each Genset.
• Generator Demand Priority – Generator Demand Priority functionality is provided.
• Test with No Load – Test with No Load functionality is provided.
Page 9 of 60
EGP Control System Configuration

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
The control system is modular construction. No customization of modular components is possible. The
system will support 2 to 10 Gensets. Two basic modules will be produced. Gensets 1 and 2 will be con-
nected to the Master Control Panel. Optionally, up to 8 additional Genset Control Panels may be added
to the system.
Gen 1 Gen 2 Gen 3 Gen 10
Master Add-On Add-On

Controller
Remote Gen Remote Gen
Controller Controller
Ethernet Gen 1 Gen 2
Switch
1
2
3
4
5
6
7
8 PowerLynx Ethernet Cable
(Optional) Touchscreen 300 ft max
Data Table
Interface
Interface Type
RS 422 / 485 – 2000ft
Ethernet – 300 ft
Building Denotes Customer Provided

Management
System
Figure 2-2: EGP Control System – System Overview with optional Genset Controllers
Master Control Panel

The Master Control Panel is a free standing enclosure, supporting 2 Gensets. It is approximately
72”H x 30”W x 18”D (182.8cm H x 76.2cm W x 45.7cm D). Mounted inside the Master Control
Panel is all necessary hardware for 2 Gensets, including:
• 2 EMCP 3.S Controllers

• 2 sets of current transformer shorting blocks
• 1 Ethernet switch
• 2 sets Genset Circuit Breaker open/close relays
• 2 Engine Run Contacts (EMCP3S Outputs)
• 2 Engine Common Alarm Contacts (EMCP3S Outputs)
• 2 Engine Common Shutdown Fault Contacts (EMCP3S Outputs)
Page 10 of 60
• 2 4PDT Load Shed/Add relays (dry contacts)(1 per gen)

• 2 sets Best Source DC Hardware
• 1 Wide Range DC/DC Power Supply
Other Relays and Hardware as required
• 1 set control interconnection terminal blocks
• 1 set Field Connection terminal blocks
• 2 Voltage Adjust Switch/Potentiometer
• 2 Speed Adjust Potentiometer Controls
• 1 Instant Auto Switch
Mounted on the door of the Master Control Panel are all the necessary controls for 2 Gensets
plus system controls, including:
• 1 12” (diagonal) color touchscreen Operator interface.

• 1 Horn Silence Pushbutton
• 1 Horn
• 2 sets of Genset Circuit Breaker Control Hardware. Included in each set shall
be:
1 Oiltight Circuit Breaker Control Switch
1 Circuit Breaker Closed Light
1 Circuit Breaker Open Light
NOTE
The Circuit Breaker Tripped Indicator is displayed on the HMI.
Add-On Genset Control Panel

The Genset Control Panel is a wall mounted enclosure, supporting 1 Genset. It will be approxi-
mately 24”H x 30”W x 8”D (60.9cm H x 76.2cm W x 20.3cm D). Mounted inside the Genset Con-
trol Panel will be all necessary hardware for 1 Genset, including:
• 1 set of current transformer shorting blocks
• 1 set Genset Circuit Breaker open/close relay
• 1 Engine Run Contact (EMCP3S output)
• 1 Engine Common Alarm (EMCP3S output)
• 1 Engine Common Shutdown Fault (EMCP3S output)
• 1 4PDT Load Shed/Add relay
• 1 set Best Source DC Hardware
• 1 Voltage Adjust Switch/Potentiometer
• 1 Speed Adjust Potentiometer
Page 11 of 60
Mounted on the door of the Generator Control Panel, are all necessary controls for 1 Genset,
including:
1 set of Genset Circuit Breaker Control Hardware:
a) 1 Oiltight Circuit Breaker Control Switch
b) 1 Circuit Breaker Closed Light
c) 1 Circuit Breaker Open Light
NOTE
XLM Control System Capabilities

The XLM control system provides the Standard ISO XLM functionality for 2 to 10 Gensets and 1 Utility
controller. Modular program and commercial considerations limit XLM functionality.
XLM Control System provides:

• Genset Master – Moving Master functionality is provided between Gensets 1 and 2 . The
default master shall be Genset 1. Only Genset 1 or Genset 2 can act as master, and co-
ordination between the two is handled automatically.
• Single Ethernet Supervisory Network.
• Conditional Load Shed/Add – Load Sensitive Load Shed/Add are supported. Conditional
Load Shed/Add functionality is provided through 1 - 4PDT relay for each Genset.
XLM Control System Configuration

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
The XLM control system is modular construction. No customization of modular components is possible.
The system will support 2 to 10 Gensets. Two basic modules are produced. Gensets 1 and 2 are con-
nected to the Master Control Panel. Optionally, up to 8 additional Genset Control Panels may be added
to the system. An Add-on Utility Control panel is provided with the XLM control system.
Add-On Utility Control Panel

The Utility Control Panel is a wall mounted enclosure, supporting 1 Utility controller. It is approximately
24”H x 30”W x 8”D 24”H x 30”W x 8”D (60.9cm H x 76.2cm W x 20.3cm D).. Mounted inside the Utility
Control Panel will be all necessary hardware for 1 Utility, including:

• 1 set of current transformer shorting blocks
• 1 set Utility Circuit Breaker open/close relay
• 1 set utility multifunction relay interface
Page 12 of 60
Mounted on the door of the Utility Control Panel are all necessary controls for 1 Utility, including:
1 set of Utility Circuit Breaker Control Hardware:
a) 1 Oiltight Circuit Breaker Control Switch
b) 1 Circuit Breaker Closed Light
c) 1 Circuit Breaker Open Light
d) 1 Close Lockout control switch
NOTE
Gen1 Gen2 Gen (N) Utility
Master Add-On Add-On

Control Panel Gen Control Utility Control
( MCP) Panel Panel
Gen 1 Gen 2
Ethernet ( GCP)
Switch ( UCP)
1
2
3
4
5
6
7
8 PowerLynx Ethernet Cable
(Optional) Touchscreen 300 ft max
Data Table
Interface
Interface Type
RS 422/ 485– 2000ft
Ethernet– 300ft
Building
Management Denotes Customer Provided
System
Figure 2-3: XLM Controller System – System Overview with optional Genset & Utility Add-On Controllers
Page 13 of 60
Section 3.
Dimensions
Master Panel Outline Dimensions

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Figure 3-1: EPIC Master Panel – Outline Drawing
Description Inch Metric cm

Housing
HxWxD 72 x 30 x 18 182.8cm x 76.2cm x 45.7cm
dimension
Top cutout WxD 4 x 10
Bottom Cutout WxD 4 x 10
Table 3-1: Master Panel – Detail Outline
NOTE
Refer to EPIC Master Installation Drawing EPIC-MCP-I01 for precise detailed dimensions
Page 14 of 60
Optional Add-On Genset / Add-On Utility Control Panel Dimensions

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
G R
24
3
30 8
4
2
10 10
Figure 3-2: Optional Add-On Genset / Utility Control Panel Dimensions
Description Inch Metric cm

Housing
HxWxD 24 x 30 x 8 60.9cm x 76.2cm x 20.3cm
dimension
Top cutout WxD NA
Bottom Cutout WxD 10 x 4
Table 3-2: Optional Add-On Genset / Utility Control Panel Dimensions
NOTE
Refer to the EPIC-GCP Installation drawings for precise detailed dimensions.
Page 15 of 60
EGP Cabling and Wiring detail
Conduit Size and Conduit Wiring

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Master Panel and two generators
Figure 3-3: Basic EGP system conduit diagram
Figure 3-3: Illustrates the basic EGP conduit connections to two generators and a typical conduit to an
ATS unit.
NOTE
For conduit sizes and detailed wiring information, refer to the EPIC-MCP Installation drawings.
Page 16 of 60
Master Panel and Add-On Gensets
Master Panel (and two generators) can be expanded to a total of up to 10 generators with the addition of
Add-On Genset Control Panels. The first two generators are connected as shown in Figure 3-3.
Figure 3-4: EGP system expanded up to 10 Gensets conduit diagram
NOTE
For conduit sizes and detailed wiring information, refer to the EPIC-MCP and EPIC-GCP Instal-
lation drawings.
.
Page 17 of 60
XLM Cabling and Wiring Detail
Conduit Size and Conduit Wiring

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Master Panel and Add-On Gensets and Add-On Utility Panel
An XLM system may be configured with up to 10 gensets and a Add-On Utility control Panel. A Master
Panel (and two generators) can be expanded to a total of up to 10 generators and the addition of Add-On
Genset Control Panel. The first two generators are connected as shown in Figure 3-3.
MASTER CONTROL
PANEL
(MCP)
G R G R
Optional
Optional Add-On
Add-On Utility
Control Panel Control Panel
(GCP) (UCP)
G R G R
GEN1 GEN 2 GEN 3 GEN 4
Denotes Dealer
Supplied
Figure 3-5: XLM Conduit Diagram
NOTE
For conduit sizes and detailed wiring information, refer to EPIC Installations drawings
Page 18 of 60
Master Panel Terminal Locations

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Figure 3-6: EPIC Master Panel - Terminal Locations
NOTE
Refer to Assembly Drawing EPIC-MCP_A03 for detailed identification and location of
parts.
Page 19 of 60
Add-on Gen Panel Terminal Locations

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Figure 3-7: Add On Gen Controller - Terminal Locations

NOTE
Refer to Assembly Drawing EPIC-GCP-A03 for detailed identification and location of
parts.
Page 20 of 60
Add-On Utility Panel Terminal Locations

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Figure 3-8: Add On Utility Controller - Terminal Locations

NOTE
Refer to Assembly Drawing EPIC-UCP-A03 for detailed identification and location of
parts.
Page 21 of 60
Dealer Provided Control System Connections

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Control System Connections
The control system is designed to be installed, connected and commissioned by the Caterpillar
Dealer in the field. Control System Connections shall be as follows:
Master Control Cabinet Interconnection

For ease of installation, Control Panel Interconnections will be kept to a minimum. Control Cabi-
net Interconnection wiring include:
• 1 Ethernet Cat 6 cable (limited to 100 meters length)

• 2 System “Hot Bus” wires
• 2 Best Source wires
• 1 Emergency Start Request wire
Genset Interconnection
Provision of necessary support hardware and wiring shall be the responsibility of the Caterpillar
Dealer:
Genset Required Hardware

The Caterpillar Dealer will provide the following hardware for each system Genset.
1. Primary fusing for Genset phase voltages signals (3 phase, 4 wire)

2. Primary fusing for Bus phase voltage signals (A & B phase)
3. Current Transformers with local CT shorting Block
4. Electrically Operated package mounted or remote Genset circuit breaker fur-
nished with the following:
a. Integral short circuit trip protection (ANSI 50/51)
b. Control Power fusing and wiring for charging and closing the circuit
breaker ( see Note:1)
c. Circuit breaker close circuit. ( see Note:1)
d. Shunt trip circuit or UV release (see Note:1)
e. Auxiliary Contacts 1A, 1B (Can be Form C)
f. Bell Alarm Contacts (overcurrent trip)
g. Recommend 5 cycle breaker open/close time (for systems with UCP
panel) (maximum 12 cycle)
h. Breaker (xx) kAIC will need to be addressed per instance
Page 22 of 60
Required Genset Interconnection Wiring

The Caterpillar Dealer will provide the following control system interconnection wiring for each
system Genset and/or remote mounted Genset circuit breaker:
1. Primary fusing for Genset phase voltage signals:
a. Provide 3 phase 4 wire sensing from the generator side of the circuit
breaker. Each of the three phases should be protected by minimum a
600v 3A fuse. The Neutral does not require a fuse.
b. Provide connection points for each phase and neutral. (Total of four
wires run to EPIC panel)
2. Primary fusing for Bus phase voltage signals:
a. Provide single sensing (A and B phase) from the bus side of the circuit
breaker. Each phase should be protected by minimum a 600v 3A fuse.
b. Provide connection points for phase A and B. (Total of two wires run to
EPIC panel)
3. Provide three Current Transformers with CT shorting Block
a. Current transformer should be mounted on the generator side of the cir-
cuit breaker and the (H1) polarity facing the generator.
b. Provide a shorting terminal block for landing the current transformer wir-
ing and for field interconnection. (Total of four wires run to EPIC panel)
4. Electrically Operated Genset circuit breaker furnished with the following:
b. Fusing and wiring for charging and closing the circuit breaker (See Note
1 below)
c. Circuit breaker close circuit. (See Note 1 below)
d. Circuit Breaker shunt trip circuit or UV supported Release (See Note 1
below)
e. Auxiliary Contacts 1A and 1B (Can be Form C)
g. Recommend 5 cycle breaker open/close time (maximum 12 cycle)
Genset Circuit Breaker Wiring

a. Circuit Breaker Close wires (two wires)
b. Circuit Breaker Open wires (two wires)
c. Auxiliary Contact sensing wires (a & b contacts) (three or four wires)
d. Bell Alarm Contact sensing wires (two wires)
e. Current transformer wires (A–B–C–N) (four wires)
f. Generator AC potential (Genset Breaker line side) (four wires)
g. Generator AC bus potential (Genset Breaker bus side) (two wires)
Page 23 of 60
Genset Engine Wiring

a) Engine Battery Best Source DC wires (4 wires - #10 awg minimum)
b) Engine Run Request wires (two wires)
c) Crank Terminate signal wire (one wire)
d) Engine Summary Shutdown Fault signal wire (one wire)
Sensing Alarm Contacts
a) Engine Battery Charger Failure (Optional) (one wire)
b) Low Fuel Level (Optional) (one wire)
c) High Level (Optional) (one wire)
d) Fuel Tank Rupture (Optional) (one wire)
e) Common 24Vdc supply wire for items (2c) thru (3d) above ( one wire)
Voltage regulator interface
a) Reference Caterpillar Switchgear Voltage Regulator interface drawing for
exact wiring information
Governor interface
b) Reference Caterpillar Switchgear Governor interface drawing for exact
wiring information
NOTE 1
Circuit breaker Trip/Close signals are rated 40A up to 120vac, 3A @300-600vac,
10A @110vdc, and 4A @ 225vdc.
AAdd-On Genset Control Panel Interconnection
The Caterpillar Dealer shall provide the following hardware and interconnect wiring for each sys-
tem Genset:
For ease of installation, Control Panel Interconnections will be kept to a minimum. Control Panel
Interconnection wiring shall include:
• 1 Ethernet Cat 6 cable (limited to 100 meters length between the Master Control Panel
and any Add-on panels).
• 2 System “Hot Bus” wires
• 2 Best Source wires
• 1 Emergency Start Request wire ( supplied by others)
Add-On Genset Interconnection

Dealer:
Add-On Genset Required Hardware
1. Primary fusing for Genset phase voltage signals (3 phase, 4 wire)

2. Primary fusing for Bus phase voltage signals: (A & B phase)
a. Recommend minimum C20 Relay Class with 600v insulation class
4. Electrically Operated Genset circuit breaker furnished with the following:
Page 24 of 60
2 below)
below)
e. Auxiliary Contacts 1A, and 1B (Can be Form C)
g. Recommend 5 cycle breaker open/close time (for systems with UCP
panel) (maximum 12 cycle)
Required Add-On Genset Interconnection Wiring
Add-On Genset Circuit Breaker Wiring

f. Generator AC potential (Genset Breaker line side) (four wires)
g. Generator AC bus potential (Genset Breaker bus side) (two wires)
Add-On Genset Engine Wiring

a. Engine Battery Best Source DC wires (4 wires - #10 awg minimum)
b. Engine Run Request wires (two wires)
c. Crank Terminate signal wire (one wire)
d. Engine Summary Shutdown Fault signal wire (one wire)
Sensing Alarm Contacts
a. Engine Battery Charger Failure (Optional) (one wire)
b. Low Fuel Level (Optional) (one wire)
c. High Level (Optional) (one wire)
d. Fuel Tank Rupture (Optional) (one wire)
e. Common 24Vdc supply wire for items (2c) thru (3d) above ( one wire)
Voltage regulator interface
a. Reference Caterpillar Switchgear Voltage Regulator interface drawing for
exact wiring information
Governor interface
a. Reference Caterpillar Switchgear Governor interface drawing for exact
wiring information
NOTE 2
10A @110vdc, and 4A @ 225vdc.
Page 25 of 60
Optional Load Shed/Add Wiring

The Caterpillar Dealer may optionally utilize the provided Load Shed/Add relays for System Load
Shed/Add functions. Conditional or Load Sensitive Load Shed functionality shall be provided,
with 1 - 4PDT relay per system Genset. For user Load Shed interface, such as transfer switches
or distribution breakers, relay contacts are limited to 10 amps. “Dry” Contacts only are provided
for Load Shed/ Load Add operations. The Caterpillar Dealer must provide all other hardware and
wiring to interface with devices to be added or shed.
Page 26 of 60
Utility Interconnection
Dealer:
Utility Control Panel Interconnection

Utility Control Panel Interconnection wiring includes:
1 Ethernet Cat 6 cable (limited to 100 meters length)

2 System “Hot Bus” wires
Required Utility Hardware

1. Primary fusing for Utility incoming phase voltage signals: (3 phase,3 wire)
2. Primary fusing for Bus phase voltage signals: (3 phase,4 wire)
3. Electrically Operated package mounted or remote Genset circuit breaker fur-
nished with the following:
a. Current transformer should be mounted on load side of the Utility circuit
breaker and the (H1) polarity facing the Utility.
b. Recommend minimum C20 Relay Class with 600v insulation class
5. Electrically Operated circuit breaker furnished with the following:
3 below)
d. Circuit Breaker shunt trip circuit or UV Release (See Note 3 below)
g. Recommend 5 cycle open/close time (maximum 12 cycle)
h. Breaker (xx) kAIC will need to be addressed per instance. Typical utility
requirement is 100kAIC.
Required Utility Interconnection Wiring

The Caterpillar Dealer shall provide the following control system interconnection wiring for a sin-
gle Utility remote mounted circuit breaker:
1- Primary fusing for Utility incoming phase voltage signals:

a. Provide 3 phase 4 wire sensing from the Utility side of the Utility circuit
600v 3A fuse. The Neutral does not require a fuse.
b. Provide connection points for each phase. (Total of four wires run to
EPIC UCP panel).
2- Primary fusing for Bus phase voltage signals:
Page 27 of 60
a. Provide 3 phase 3 wire sensing from the Load side of the Utility circuit
600v 3A fuse.
b. Provide connection points for each phase and neutral. (Total of three
wires run to EPIC UCP panel)
3- Provide three Current Transformers with CT shorting Block
c. Current transformer should be mounted on load side of the Utility circuit
breaker and the (H1) polarity facing the Utility.
d. Provide a shorting terminal block for landing the current transformer wir-
ing and for field interconnection. (Total of four wires run to EPIC UCP
panel)
4- Electrically Operated Utility circuit breaker furnished with the following:
3 below)
below)
g. Recommend 5 cycle breaker open/close time (maximum 12 cycle)
h. Breaker (xx) kAIC will need to be addressed per instance. Typical utility
requirement is 100kAIC.
Utility Circuit Breaker Wiring

f. Utility AC potential (Utility Breaker line side) (four wires)
g. Utility AC bus potential (Utility Breaker bus side) (three wires)
Additional Utility Wiring

a. 86 Lockout Relay Tripped wire (one wire)
b. Utility Failed signal from Customer provided relaying (one wire)
c. Utility Reverse Power Relay signal (one wire)
d. Utility Multifunction relay malfunction (one wire)
e. Reverse Power Inhibit signal (two wires)
f. Common 24Vdc supply wire for items (6a) thru (6d) above ( one wire)
Page 28 of 60
(Optional) Utility Multifunction Relay (MFR) or individual protective relays providing the
same functionality. - Owner Furnished (See 2.3.1)
a. The Utility EMCP 3.S controller has built in utility protection that can
serve as the primary utility protection or backup protection to Owner Fur-
nished Utility protection. 50/51 Overcurrent protection shall be provided
by owner
NOTE 3
10A @110vdc, and 4A @ 225vdc.
Optional Load Shed/Add Wiring

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
The Caterpillar Dealer may optionally utilize the provided Load Shed/Add relays for System Load
Shed/Add functions. Conditional or Load Sensitive Load Shed functionality is provided, with 1 - 4PDT re-
lay per system Genset. Relay contacts are limited to 10 amps. Each set of Load Shed/Add relays can
support up to 2 distribution breakers. Distribution Circuit Breaker position sensing is not supported. “Dry”
Contacts only are provided for open and close operations. The Caterpillar Dealer must provide all other
hardware and wiring.
System Power Supply

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
All system controls are designed to operate from nominal 24vdc best source power. This power source
should be derived from all associated engine batteries. All system components should be design for con-
tinuous operation within a system voltage range of 18 – 40vdc.
AC Sensing
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
The control system employs 3 wires, true RMS sensing. Metering accuracy is Class 1. The require-
ments listed below apply to each system Genset.
480 Volt Sensing

480 volts systems may be connected directly to dedicated potential sensing terminals in the control
Panel(s). The dealer shall furnish 3 protective 3 amp fuses, mounted in close proximity to the source of
the voltage for phase A, B and C sensing.
Current Sensing
The dealer shall provide and install 3 current transformers with 5 amp secondaries. These current trans-
formers shall be wired to a dealer installed current transformer shorting block, mounted in close proximity
to the current transformers. The following configurable current transformer sizes are supported by the
control system:
Range of CT primary 1 to 32000
Page 29 of 60
Environmental
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
• Control System operating temperature 0oC to 50oC
• Storage temperature: –20oC to 60oC
• Humidity: 95% non-condensing 30oC to 60oC
• Sealing: NEMA Type 12
Page 30 of 60
Section 4.
Standard I/O Specifications
The EMCP3.S controller is furnished with the following I/O, as a minimum
Voltage Sensing
Genset – 3 phase, 0 – 480 volt line to line max, 480 Vac RMS, Class 1 accuracy.
Bus – 1 phase, 0 – 480 volt line to line max, 480 Vac RMS, Class 1 accuracy.
Current Sensing
Genset – 3 phase, 0 – 5 amp secondary input, Class 1 accuracy.
Analog Inputs
2 –Switchable 0/4-20ma or 0-10 volts
3– 0/4-20ma or 0-10 volts
Analog Outputs
2 – Isolated and switchable, +/- 10 volts, 0/4 to 20ma, PWM
2 – Non-isolated and switchable, +/- 10 volts, 0/4 to 20ma
Communications Ports
2 100 MHz Ethernet
2 – RS-485
Page 31 of 60
Section 5.
Connections
Power Supply
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
NOTE
Safety ground –Use the ground stud located between terminals 60 and 61 on the controller
40 v
Continuous Voltage Range = 8.0 Vdc to 40 Vdc
24 v
Volts DC
12 v
9.6 v
8.0 v
Graph Not
to Scale
Time
0ms 30 sec
50 ms 100 sec
5 ms
10 ms
Safe Operating area

Typical Cranking Waveform
EMCP3.S can recover from 0.0 Vdc for 10 ms
Figure 5-1: Power Supply – EMCP 3.S Safe Operating Range, Voltage 24Vdc Cranking
This chart shows the safe operating range for a 24 Vdc Engine. The minimum cranking voltage is 21 Vdc
and the EMCP 3.S can sustain a loss of DC for 10ms and can operate continuously at 8 Vdc.
Page 32 of 60
Engine Battery Connections

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Figure 5-2: 24Vdc Engine Battery inputs
Terminal Description AWG

E1TB 1,2 Gen 1 Battery B+ 12/24 Vdc 14
E1TB 3,4 Gen 1 Battery B- 0 Vdc 14
E2TB 1,2 Gen 2 Battery B+ 12/24 Vdc 14
E2TB 3,4 Gen 2 Battery B- 0 Vdc 14
Add On Gens
ETB 1,2 Gen 3 Battery B+ 12/24 Vdc 14
ETB 3,4 Gen 3 Battery B- 0 Vdc 14
ETB 1,2 Gen 4 Battery B+ 12/24 Vdc 14
ETB 3,4 Gen 4 Battery B- 0 Vdc 14
Table 5-1: 24Vdc Engine Battery input - terminal assignment
NOTE
Refer to drawing EPIC-MCP-F01 for details
Page 33 of 60
Best Source Wiring

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Figure 5-3: Best Source Wiring

NOTE
Refer to drawing EPIC-MCP-F01 for details
.
NOTE
The dashed wiring in figure 6-4 is required to be installed by the dealer when the add-on generators are
supplied. Recommended wire size is # 10 AWG.
Page 34 of 60
Hot Bus Connections

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Figure 5-4: Hot Bus Connections
NOTE
Refer to the drawings EPIC-MCP-S01 for precise details. Recommended wiring #14
AWG.
Page 35 of 60
Voltage Measuring
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
NOTE
ISO requires protecting the voltage measuring inputs with slow-acting fuses rated for 2 to 6 A.
Voltage Measuring: Generator Mains, 3 Phase
Gen M a in s
Vo ltage
Bus Vo ltage
Figure 5-5: Voltage Measuring – Generator Mains 3 Phase
NOTE
For details refer to drawing- EPIC-MCP-E01, E05 and - E01.
NOTE
Recommended wiring is #14 AWG.
Page 36 of 60
Generator Current Measuring

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
NOTE
For details refer to drawing EPIC-MCP- E01, E05 and EPIC-GCP- E01.
CAUTION
Before disconnecting the device, ensure that the current transformer/CT is short-circuited.
Generator Current
52G Generator
H2 H1
L1 x2 x1
L2
H2
x2
H1
x1 H2 H1 G
L3 x2 x1
N
E-( )
GND A Generator
B Current
C Measuring
GND (Gen Mains)
Denotes 1-CTB or 2-CTB or Addon CTB

Figure 5-6: Current Measuring – Generator Mains
NOTE
CT shorting blocks not shown for clarity. CT shorting blocks must be installed.
Recommended CT wiring is #14 AWG.
Description AWG
Terminal
A phase Generator current - phase L1- transformer terminal x1 14
B phase Generator current - phase L2 - transformer terminal x1 14
C phase Generator current - phase L3 - transformer terminal x1 14
Table 5-2: Terminal Assignment Current Measuring - - Generator Current
Page 37 of 60
Digital Inputs
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Digital inputs are configured to be normally open (N.O.). In the state N.O., no potential is present during
normal operation; if an alarm is issued or control operation is performed, the input is energized. Refer to
drawing EPIC-MCP -F01 for details.
Figure 5-7: Digital Inputs - alarm/control inputs - operation logic

NOTE
The figure 5-7 shows source wiring.
NOTE
Page 38 of 60
Engine Run Digital Outputs

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Figure 5-8: Engine Run Digital Output
NOTE
Refer to drawings EPIC-MCP-F01, F02 for details.
Page 39 of 60
Engine Circuit Breaker Wiring

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
E1TB
E2TB
ETB
Figure 5-9: Engine Circuit Breaker – Wiring

NOTE
NOTE
Page 40 of 60
Speed Control and Voltage Regulator Wiring (Analog Outputs)

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
E1- TB
E2- TB
ETB
37
SPEED
38
16 AWG SHIELDED CONTROLLER
39
TWISTED TRIAD Selected from Dwg
40
MCP-GOV
41
42
43 16 AWG SHIELDED
VOLTAGE
44 TWISTED TRIAD REGULATOR
45 Selected from Dwg
MCP-VR
46 RAISE
47 COM
48 LOWER
Refer to the MCP, GCP GOV and VR drawings

for specific wiring details
Figure 5-10: Analog Voltage and Speed Output – Wiring
Speed Control Wiring

Speed control wiring details are provided on EPIC-MCP-GOV drawing. Five possible speed control op-
tions are illustrated.
Option “G1” Caterpillar Speed Control
Option “G2” Woodward 1724 Governor
Option “G3” Woodward 2301A Speed Control
Option “G4” ADEM III Speed Control
Option “G5” Woodward LSM Control
All output wiring connections are made through E-TB terminals 37 thru terminal 42. Depending on the se-
lected speed control, the wiring to these terminals must be adapted to the specific speed control with the
location of the wires and the addition of jumpers as required. In addition the speed control potiometer
must be selected for the specific control as described on the drawing.
Voltage Regulator wiring

Voltage control wiring details are provided on EPIC-MCP-VR drawing. Five possible voltage control op-
tions are illustrated.
Option “V1” Caterpillar Voltage Regulator
Option “V2” Caterpillar R230/R448 Voltage Regulator
Option “V3” Caterpillar VR3 Voltage Regulator
Option “V4” Caterpillar VR6 Voltage Regulator
Option “V5” Caterpillar DVR Voltage Regulator
All output wiring connections are made through E-TB terminals 43 thru terminal 48. Depending on the se-
lected voltage control, the wiring to these terminals must be adapted to the specific voltage control with
the location of the wires and the addition of jumpers as required. In addition, the voltage control potenti-
Page 41 of 60
ometer /switch must be selected for the specific control as described on the drawing.
Page 42 of 60
Emergency Start Wiring

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Figure 5-11: Emergency Start – Wiring
NOTE
Refer to drawing EPIC-MCP-S01 for details.
Page 43 of 60
Utility Mains Voltage Measuring

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Utility
N TB
N L1 L2 L3
480 Vac 33 480 Vac L 1 / V a
Line Side
Voltage sense 480 Vac 34 480 Vac L 2 / Vb
( Utility Mains)
480 Vac 35 480 Vac L 3 / Vc
480 Vac 36 480 Vac N / Vcom
52 N
480 Vac 30 480 Vac L 1 / V a

Load Side
Voltage Sense 480 Vac 31 480 Vac L 2 / Vb
( Bus Mains)
32 480 Vac L 3 / Vc
480 Vac
N L1 L2 L3
To Generator Note 1 : Voltage sensing configurations need to

Common Bus
be of the same wiring option
Figure 5-12: Voltage Measuring – Utility Mains
Page 44 of 60
Utility Circuit Breaker Wiring

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Figure 5-13: Utility Circuit Breaker – Wiring

NOTE
NOTE
Page 45 of 60
Utility Mains Current Measuring

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
CAUTION
Before disconnecting the device, ensure that the current transformer CT is short-circuited.
Mains Current (multi-unit only)
52N Utility
H2 H1
L1 x2 x1 H2 H1
L2 x2 x1 H2 H1
L3 x2 x1
N
N- CTB
A Utility
B Current
C Measuring
GND
GND
Figure 5-14: Current Measuring – Utility Mains

NOTE
CT shorting blocks and x2 grounding have been omitted for clarity. CT shorting blocks must
be installed.
Terminal Description AWG

A phase Current - phase L1- transformer terminal x1 14
B phase Current - phase L2 - transformer terminal x1 14
C phase Current - phase L3 - transformer terminal x1 14
Table 5-3: Terminal Assignment -- Current Measuring - - Utility Current
Page 46 of 60
DATA TABLE INTERFACE

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Refer to the Data Table Interface manual, which is provided with the system, to obtain connection details.
Page 47 of 60
Section 6.
Engine / Circuit Breaker Checkout
The following steps are to be performed after the operation of the engine/generators have bee thoroughly
checked for operational readiness. The following items must have been inspected and checked.
All wiring to and from the generator sets and the EPIC panels
All wiring to and from the circuit breakers
Each circuit breaker checked and verified for manual switch control.
Each engine/generator has been tested for operational warning and shutdown controls.
All fuses and circuit breakers in the Master Panel and each Genset panel are installed .
Startup Procedures (Level 1)

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
These procedures provide a detailed description of the steps required to accomplish the check-
list activities.
The following inspections must be performed on each of the engine/generators making up the
system.
Step 1 Engine / Generator Inspection
Ensure battery chargers are operational and engine-cranking batteries are charging. Insure
1
Engine Battery negative is grounded.
2 Generator Power Cables installation complete
3 Fuel System completely installed and filled.
4 Cooling System completely installed and filled.
5 Lube Oil system completely installed and filled.
6 Exhaust System installation complete
7 Engine jacket water heaters complete, energized and functioning.
8 Louvers and exhaust fans connected, powered, and or unobstructed.
9 Battery charger installation complete and energized on each generator
10 Batteries for ISO switchgear mounted and wiring completed per field wiring drawings.
11 Set each engine cool down time to (0 min) Set point
Gen 1 Gen 2 Gen 3 Gen 4 Gen 5 Gen 6 Gen 7 Gen 8 Gen 9 Gen
10
Step 1
Com-
plete
Page 48 of 60
Step 2 Power Cable Inspection
Visually inspect power cables connected at each generator to verify there are no prob-
1 lems such as nicks in the insulation or cables lying against sharp edges. Note the color-
coding on the cables.
Visually inspect power cables connected at the switchboard coming from each generator
to verify there are no problems such as nicks in the insulation or cables lying against sharp
edges. Verify that the cables are landed at the proper generator breaker stabs. The breaker
2
stabs are labeled and indicate which generator should connect to them and which phase
should connect to them. When facing the rear of the cubicle the phases are A-B-C right to
left. Also, verify the color-coding on the cables is the same as that at the generator.
Field wiring complete from generators to switchgear.
3
All best source DC cabling installed and connected.
4
Rotation certified to be A-B-C clockwise for each generators
5
Gen 1 Gen 2 Gen 3 Gen 4 Gen 5 Gen 6 Gen 7 Gen 8 Gen 9 Gen
10
Step 2
Com-
plete
Page 49 of 60
System Start Procedures Level 2

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Verify Best Source DC Voltages To Master panel
NOTE:
Refer to EPIC Master Control Panel Drawings Generator 52G1 E01 and EPIC Mas-
ter Control Panel Drawings Generator 52G2 E06
All fuses should NOTot be installed at this point.
Step Procedure Verified

1 Verify Best Source Gen 1 engine battery voltage between E1-TB 1and 2
(+24Vdc) to 3,4(Gnd)
2 Verify Best Source Gen 2 engine battery voltage between E2-TB 1 and 2
(+24Vdc) to 3,4(Gnd)
3 Close Gen 1 FD-E202 and verify 24Vdc E1-BS+ 1 to E1-BS-
4
Open Gen 1 FD-E202 (see parts Location on Assembly drawing A03)
5
Close Gen 2 FD-E602 and verify 24Vdc E2-BS+ 1 to E2-BS-
6
Open Gen2 FD-E602 (see parts Location on Assembly drawing A03 )
Install DC power fuses as follows

1 Install fuses FU-S210A.
2 Close Gen 1 FD-E202 and verify 24Vdc 1DST-P
3 Open Gen 1 FD-E202
4 Close Gen 2 FD-E602 and verify 24Vdc 2DST-P
5 Close Gen 1 FD-E602
6 Install fuses FU-E209 and FU-E210
7 Close Gen 1 FD-E202 and verify 24Vdc at G1 EMCP Terminals 65 to 63
8 Install fuses FU-E609 and FU-E610
9 Close Gen 2 FD-E602 and verify 24Vdc at G2 EMCP Terminals 65 to 63
Touchscreen DC Voltage and DTI Controller

1 Install fuses FU-S210A and FU-S210B
2 Power is applied to the Touchscreen
3 Open Gen 1 FD-E202 and Gen 2 FD-E602 to remove DC Voltage
4 Install fuse FU-E216
5 Close Gen 1 FD-E202 and Gen 2 FD-E602 to supply DC Voltage
6 Verify 24Vdc at DTI EMCP Terminals 65 to 63
Page 50 of 60
Master Panel Application setup
The application will take a few seconds to load and then the SYSTEM SETUP screen will appear.
Proceed to perform the initial system setup described in the following section
Page 51 of 60
Section 7.
System Startup
Initial System Setup Procedures

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Initial Setup steps.

Enter the system voltage and frequency.
Enter the number of generators
Select the system type, EGP or XLM
Denotes a touch control and

touch areas.
1. Enter the System Voltage and System Frequency
2. Enter the Number of Generators.
3. Select the System Type
Set the metering scaling for kW kVAR
2. Touch the System kW/kVAR Scale Max display and enter a maximum meter scale.
The meter scale will change to indicate the selected scaling.
Typically the max scale should be the combined rated kW of all generators
When the scale is correct proceed to the set the System Current Scale Max.
3. Touch the System Current Scale Max display and enter a maximum meter scale.
Page 52 of 60
The meter scale will change to indicate the selected scaling.

Typically the max scale should be the combined maximum rated AMPS of all generators.
4. When the system current scale is correct then continue to the Setup Generator screens.
Touch the CONTINUE button located at lower left hand corner of the screen to continue.
Page 53 of 60
Setup each generator as follows:

Select each touch area and enter the correct value.
1. Enter Rated kW. Use the Rated kW as found on the CAT Engine/Generator rating plate mounted on
the Eng/Gen.
2. Enter Rated kVAR. Use the Rated kVAR as found on the CAT Engine/Generator rating plate
mounted on the Eng/Gen.
3. Adjust the kW/kVAR metering scaling. Press the System kW/kVAR Scale Max and enter the maxi-
mum meter scaling (typically 125% of rated kW)..
4 Enter the CT primary size. This must match the current transformers ratio. (That is, for a 300/5 CT ra-
tio, enter 300.)
5. Adjust the current metering scaling. Press the System Current Scale Max and enter the maximum
meter scaling. This should be the primary CT rating. (That is, for a 300/5 CT ratio, enter 300.)
6. Set the Voltage Control type . The setting is determined by the Voltage Control module provided with
the Eng/Gen set.
7. Set the Speed Control type. The setting is determined by the Speed Control module provided with the
Eng/Gen set.
Touch the CONTINUE button located at the lower left hand corner of the screen to continue entering the
information for each generator.
8. Repeat for each generator in the system, pressing the CONTINUE button should then take you to the
OVERVIEW screen. The next section guides you through the remaining system setup steps.
Continue to the next screen
Page 54 of 60
If an XLM system was selected then enter the Utility setup values and select the meter scaling.
1. Enter Rated Voltage.
2. Enter Frequency.
3. Enter Current.
4. Enter Rated kW.
5. Enter Rated kVAR.
6. Enter Ct Primary
7. . Adjust the kW/kVAR metering scaling. Press the Utilility kW/kVAR Scale Max and enter the maxi-
mum meter scaling (typically 125% of rated kW)..
8. Adjust the voltage metering scaling. Press the Utility Voltage Scale Max and enter the maximum me-
ter scaling scaling (typically 125% of rated voltage)..
9. Adjust the current metering scaling. Press the Utility Current Scale Max and enter the maximum me-
ter scaling scaling (typically 125% of rated current)..
Touch the CONTINUE button located at the lower left hand corner of the screen to continue entering the
information for each generator.
From the Main Menu or the Overview screen proceed to perform the startup steps in the following sec-
tion.
Page 55 of 60
System Startup Procedures

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Functional Startup steps

The following steps complete the startup and the system will be placed on line and Standby Mode for an
emergency situation to arise. The system may be tested with the NO-Load test procedures .
1. Place the Master Mode selector switch in AUTO. (System Control screen)
Insure the Generator No Load Test Switch is OFF.
If the system is an XLM and has a Utility breaker insure that the Utility breaker Sync Mode switch is in
AUTO.
(Utility Control screen)
Close the Utility breaker.
Loads will be power from the Utility source.
2. Place all generator Engine Control Switches (ECS) in AUTO. (Gen Control screen)
3. Place all generator Sync Mode Switches in AUTO. (Gen Control screen)
4. Check Annunicator Alarms.

Ack current alarms and address any situations that are resulting in an Alarm.
System is now in a Standby mode.
Page 56 of 60
Section 8.
Operational Functionality
Control System Capabilities

The EPIC Control System is capable of standard ISO EGP or XLM functionality for 2 to 10 Gensets.
Modular program and commercial considerations will limit EGP functionality. Detailed operational se-
quences for both EGP and XLM system are provided in the Operation Manual.
Page 57 of 60
Section 9.
Drawings
The following installation drawing sets are provided, as required, for the Master Control Panel, an Add-On
Generator Control Panel and the Add-On Utility Control Panel.
Master Control Panel Installation Drawings
DESCRIPTION SHEET
Front Elevation and Details EPIC—MCP—I01
Control Conduit Schedule EPIC—MCP—I02
Field Interconnect – Gen 1 EPIC—MCP—I05
Field Interconnect – Gen 2 EPIC—MCP—I06
Governor Options EPIC—MCP—I07
Voltage Regulator Options EPIC—MCP—I08
Add-On Generator Control Panel Installation Drawings
DESCRIPTION SHEET
Front Elevation and Details EPIC—GCP—I01
Control Conduit Schedule EPIC—GCP—I02
Field Interconnect – Gen 3 EPIC—GCP—I05
Field Interconnect – Gen 4 to EPIC—GCP—I06
10 typical
Governor Options EPIC—GCP—I07
Voltage Regulator Options EPIC—GCP—I08
Add-On Utility Control Panel Installation Drawings
DESCRIPTION SHEET
Front Elevation and Details EPIC—UCP—I01
Control Conduit Schedule EPIC—UCP—I02
Control Conduit Schedule EPIC—UCP—I03
Field Interconnect – Utility EPIC—UCP—I04
Page 58 of 60
Page 59 of 60
Intelligent Switchgear Organization, LLC is a Caterpillar Electric Power Business
Intelligent Switchgear Organization, LLC

4955 Marconi Drive
Alpharetta, Georgia 30005
Disclaimer:
Information contained in this publication may be considered confidential. Discretion is recommended

when distributing. Materials and specifications are subject to change without notice.
Ownership:
© 2009 Intelligent Switchgear Organization

All rights reserved.
Page 60 of 60

Installation Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Installation Manual

Uploaded by

Copyright:

Available Formats

Engine Paralleling Integration Controls

EPIC 208-480 Installation Manual

Intelligent Switchgear Organization, LLC

Rev. Date Editor Changes

INSTALLATION MANUAL ............................................................................................................. 1

SECTION 4. STANDARD I/O SPECIFICATIONS............................................................................. 31

Table 2-1: Applicable Manuals ................................................................................................................................. 9

Complete mounting of cabinets

Complete all of the interconnection wiring

2. Add-On Control Panels

3. Add-On Utility Control Panel

Complete Check and setup of the system settings

Perform startup test as describe in Section 6

EPIC 208-480V Installation Manual this manual DCN0010

Table 2-1: Applicable Manuals

EGP Control System Features

EGP Control System Configuration

Gen 1 Gen 2 Gen 3 Gen 10

Master Add-On Add-On

Building Denotes Customer Provided

Master Control Panel

• 2 EMCP 3.S Controllers

• 2 4PDT Load Shed/Add relays (dry contacts)(1 per gen)

• 1 12” (diagonal) color touchscreen Operator interface.

Add-On Genset Control Panel

XLM Control System Capabilities

XLM Control System provides:

XLM Control System Configuration

Add-On Utility Control Panel

• 1 EMCP 3.S Controllers

Gen1 Gen2 Gen (N) Utility

Master Add-On Add-On

Master Panel Outline Dimensions

Figure 3-1: EPIC Master Panel – Outline Drawing

Description Inch Metric cm

Optional Add-On Genset / Add-On Utility Control Panel Dimensions

Figure 3-2: Optional Add-On Genset / Utility Control Panel Dimensions

Description Inch Metric cm

EGP Cabling and Wiring detail

Conduit Size and Conduit Wiring

Figure 3-3: Basic EGP system conduit diagram

Master Panel and Add-On Gensets

Figure 3-4: EGP system expanded up to 10 Gensets conduit diagram

XLM Cabling and Wiring Detail

Conduit Size and Conduit Wiring

GEN1 GEN 2 GEN 3 GEN 4

Figure 3-5: XLM Conduit Diagram

Master Panel Terminal Locations

Figure 3-6: EPIC Master Panel - Terminal Locations

Add-on Gen Panel Terminal Locations

Figure 3-7: Add On Gen Controller - Terminal Locations

Add-On Utility Panel Terminal Locations

Figure 3-8: Add On Utility Controller - Terminal Locations

Dealer Provided Control System Connections

Master Control Cabinet Interconnection

• 1 Ethernet Cat 6 cable (limited to 100 meters length)

Genset Required Hardware

1. Primary fusing for Genset phase voltages signals (3 phase, 4 wire)

Required Genset Interconnection Wiring

Genset Circuit Breaker Wiring

Genset Engine Wiring

Add-On Genset Interconnection

Add-On Genset Required Hardware

1. Primary fusing for Genset phase voltage signals (3 phase, 4 wire)