Functional Spec

EPIC Functional Specification – 208-480V (ROW Region)
Engine Paralleling Integration Controls

(EPIC)
EMCP3.S Controls Only

208 to 480V 50/60Hz systems
Rest of World Region

(ROW)
Functional Specification
DCN0025 Rev 1.0
Page 1 of 35
Table of Contents
SECTION 1 OVERVIEW ..............................................................................................5

1.1 Intent.......................................................................................................................................... 5
1.2 Scope......................................................................................................................................... 5
1.2.1 Scope ............................................................................................................................. 5
1.3 Specification Control/Changes............................................................................................... 6
1.4 Product Approval ..................................................................................................................... 6
SECTION 2 HARDWARE REQUIREMENTS ....................................................................7
2.1 Control System Configuration................................................................................................ 7
2.1.1 Master Control Panel..................................................................................................... 7
2.1.1.1 Generator Protection..............................................................................................................8
2.2 Add-On Utility Control Panel (UCP) ....................................................................................... 8
2.2.1 Utility Protection ........................................................................................................................9
2.3 Add-On Genset Control Panel .............................................................................................. 10
2.1.1.1 Generator Protection............................................................................................................11
2.4 Control System Connections................................................................................................ 11
2.4.1 Control Panel Interconnection ...................................................................................... 11
2.4.2 Genset Interconnection ................................................................................................ 11
2.4.2.1 Required Hardware..............................................................................................................12
2.4.2.2 Required Genset Interconnection Wiring .............................................................................12
2.4.2.3 Optional Load Shed/Add Wiring...........................................................................................13
2.4.2.3 GenSet Status contacts .......................................................................................................13
2.4.3 Utility Interconnection .................................................................................................. 13
2.4.3.1 Required Hardware..............................................................................................................13
2.4.2.2 Required Utility Interconnection Wiring ...............................................................................14
2.5 System Power Supply Requirements .................................................................................. 14
2.6 AC Sensing Requirements.................................................................................................... 14
2.6.1 Voltage Sensing ........................................................................................................... 14
2.6.2 Current Sensing ........................................................................................................... 15
2.6.2.1 Current Transformer Ratios .................................................................................................15
2.7 Environmental Requirements ............................................................................................... 15
2.8 HMI Graphic Display .............................................................................................................. 15
2.8.1 Additional Support languages ...................................................................................... 15
2.8.2 Menu system ................................................................................................................ 15
2.8.3 Screens ........................................................................................................................ 15
2.8.3.1 System.................................................................................................................................16
2.8.3.1 GenSet (Each Generator) ....................................................................................................16
2.8.4.1 Utility (Requires UCP option) ...............................................................................................16
2.8.4 Annuniciators................................................................................................................ 16
2.8.4.1 System.................................................................................................................................16
2.8.4.2 GenSet (Each Generator) ....................................................................................................17
2.8.4.3 Utility (requires UCP option) ................................................................................................18
2.9 Standard I/O Requirements................................................................................................... 18
2.9.1 Voltage Sensing ........................................................................................................... 18
2.9.1.1 Voltage Sensing ........................................................................................................ 18
2.9.1.2 Voltage Sensing – Additional for Utility Option.......................................................... 18
2.9.2 Current Sensing ........................................................................................................... 18
2.9.2.1 Current Sensing ........................................................................................................ 18
2.9.2.2 Current Sensing – Additional for Utility Option.......................................................... 18
Page 2 of 35
2.9.3 Analog Outputs............................................................................................................ 18

SECTION 3 OPERATIONAL FUNCTIONALITY ..............................................................20
3.1 Control System Capabilities ................................................................................................. 20
3.1.1 Control System configurations .................................................................................... 20
3.1.2 Sequences of Operation – Standard EGP ................................................................... 20
3.1.2.1 Sequences of Operation (XLM)................................................................................. 22
SECTION 4 SYSTEM CONFIGURATION ......................................................................29
4.1 Overview ................................................................................................................................. 29
4.1.1 System Configuration Parameters (standard).............................................................. 29
4.1.1 Individual GenSet Configuration Parameters (standard) ............................................. 29
4.1.2 Utility Configuration Parameters – (Optional) requires UCP........................................ 30
SECTION 5 DOCUMENTATION ..................................................................................31
5.1 Overview ................................................................................................................................. 31
5.1.1 Drawing Packages ....................................................................................................... 31
5.1.2 Manuals ........................................................................................................................ 32
5.1.2.1 Installation manual ...............................................................................................................32
5.1.2.2 Operations manual...............................................................................................................32
5.1.2.3 Replacement parts manual ..................................................................................................32
5.1.2.4 Data Table Interface manual................................................................................................32
SECTION 6 OPTIONAL FEATURES ............................................................................33

6.1 Hardware 25............................................................................................................................ 33
6.2 Data Table Interface ............................................................................................................... 33
6.3 Add-On GenSet Control Panel.............................................................................................. 33
6.4 Add-On Utility Control Panel ................................................................................................ 33
6.5 ISO Factory Startup ............................................................................................................... 33
SECTION 7 SYSTEM PLATFORM CONFIGURATION .....................................................34
Page 3 of 35
Revision History
Rev. Date Editor Changes

1.0 10.07.09 MR Initial release
1.1 06.02.10 MR Revisions to spec
Page 4 of 35
Section 1
Overview
1.1 Intent
The intent of this specification is to define the product requirements for the Engine
Paralleling Integration Controls (EPIC) product line (208-480volt) for the Rest of World
(ROW) region. In the following document this will be referred to as EPIC
1.2 Scope
The EPIC System will be furnished to Caterpillar Dealers as an alternative to
Switchgear mounted controls. It will be furnished as a kit for Caterpillar Dealer
installation and start-up. It will support EGP type functionality for 2 GenSets with the
Master Control Panel (MCP) in the base offering. Optionally the system will support up
to 8 additional GenSets for total of 10 GenSets by adding the optional individual
Generator Control Panels (GCP). In addition, the system will support XLM type
functionality for 1 utility with the addition of an Optional Utility Control Panel. This
product will support 208-480V 50/60 hertz applications. Additional scope & options
listed below.
The Caterpillar Dealer will be responsible for providing all supporting hardware and
wiring required by the system to interface with the generators. This document points out
the dealer provided hardware and wiring.
1.2.1 Scope
• Engine Size supported:
o C9 – 3500 series
• Engine types supported:
o Diesel
• Frequencies / Voltages supported:
o 50Hz / 60Hz
o 208-480 volts
Page 5 of 35
• Voltage regulators supported:

o (V1) CDVR
o (V2) R230 / R440
o (V3) VR3
o (V4) VR6
o (V5) DVR
• Governor systems supported:
o (G1) Caterpillar speed control (speed brick)
o (G2) Woodward 1724 speed control
o (G3) Woodward 2301A
o (G4) Adem III speed control
o (G5) Woodward Load share Module
• Optional ISO Startup
1.3 Specification Control/Changes

The final product shall be in accordance with this specification. If changes to the product
are identified by either Caterpillar Switchgear Marketing or the chosen supplier, they
must be agreed by both parties. This specification shall then be updated and re-issued
prior to making the agreed changes. This specification shall remain the property of
Caterpillar Switchgear who will be solely responsible for its maintenance.
1.4 Product Approval

The product resulting from this specification must be reviewed and approved by
Caterpillar Switchgear Marketing for compliance to this specification prior to introduction
into the marketplace.
Page 6 of 35
Section 2
Hardware Requirements
2.1 Control System Configuration

The control system shall be of modular construction. No customization of modular
components will be possible. The system will support 2 to 10 GenSets and one utility.
Three basic products will be produced. GenSets 1 and 2 will be connected to the
Master Control Panel (MCP). Optionally, up to 8 additional GenSet Control Panels
(GCP) may be added to the system. Optionally, 1 Utility Control Panel (UCP) may be
added to the system.
2.1.1 Master Control Panel

The Master Control Panel shall be a free standing enclosure, supporting (2)
GenSets. It will be approximately 72”H x 30”W x 18”D. Mounted inside the
Master Control Panel will be all necessary hardware for 2 GenSets, including:
1. 2 - EMCP 3.S Controllers
2. 2 - sets of current transformer shorting blocks
3. 1 – 16 port Ethernet switch
4. 2 – Sets GenSet Circuit Breaker open/close relays
5. 2 – Engine Run Contacts (EMCP3S outputs)
6. 2 – Engine Common Alarm (EMCP3S outputs)
7. 2 – Engine Common Fault (EMCP3S outputs)
8. 2 – 4PDT Load Shed/Add relays (dry contacts)(1 per gen)
9. 2 – Sets Best Source DC Hardware
10. 1 – Wide Range DC/DC Power Supply
11. Other Relays and Hardware as required
12. 1 – Set control interconnection terminal blocks
13. 1 – Set Field Connection terminal blocks
14. 2 – Voltage Adjust Switch/Potentiometer
15. 2 – Speed Adjust Potentiometer
16. 1 – Instant Auto Switch
Page 7 of 35
Mounted on the door of the Master Control Panel will be all necessary controls
for 2 GenSets, including:
1. 1 – 12” (diagonal) color touchscreen Operator Interface.
2. 1 – Horn Silence Pushbutton
3. 1 – Horn
4. 2 – Sets of GenSet Circuit Breaker Control Hardware. Included in
each set shall be:
a. 1 – Oiltight Circuit Breaker Control Switch
b. 1 – Circuit Breaker Closed Light
c. 1 – Circuit Breaker Open Light
NOTE
The Circuit Breaker Tripped Indicator is displayed on the HMI.
2.1.1.1 Generator Protection

Each Generator shall have the following required protection available to
protect the generator during fault conditions. Each function will have the
ability to adjust setpoints and time delays to coordinate the system operation.
The following is a minimum required list of Generator protective functions:
1. (27) Under voltage
2. (59) Over voltage
3. (32) Reverse Power
4. (25) Synchronizing Check
5. (15) Auto synchronizer
6. (40) Loss Of Excitation
7. (81U) Under Frequency
8. (81O) Over frequency
9. (65) Governor Load Sharing, Soft loading control
10. (90) Var/PF and Cross current Compensation Controller
11. (50) Instantaneous Overcurrent (part of the Circuit Breaker)
12. (51) Time Overcurrent (part of the Circuit Breaker)
2.2 Add-On Utility Control Panel (UCP)

The Utility Control Panel shall be a wall mounted enclosure, supporting (1) Utility
breaker. It will be approximately 24”H x 30”W x 8”D. Mounted inside the Utility
Control Panel will be all necessary hardware for 1 Utility breaker, including:
Page 8 of 35
1. 1 - EMCP 3.S Controller

2. 1 - sets of current transformer shorting blocks
3. 1 – Set Utility Circuit Breaker open/close relays
4. Other Relays and Hardware as required
Mounted on the door of the Utility Control Panel will be all necessary controls for
1 Utility, including:
1. 1 – Set of Utility Circuit Breaker Control Hardware. Included in
each set shall be:
d. 1- Utility Close Lockout Switch (UCLOS)
NOTE
2.2.1 Utility Protection

The Utility will have the required protection available to protect the system
during fault conditions. Each function will have the ability to adjust setpoints
and time delays to coordinate the system operation. The utility EMCP3S
controls are designed to coordinate with a Customer supplied external Utility
Multifunction relay for Utility protection. The EMCP3S controls have protective
relays that can serve as backup to the external Customer relay or as primary
protection when the Customer Utility Multifunction relay is not required by the
applicable utility company.
The following is a minimum required list of Utility protective functions:
Page 9 of 35
2.3 Add-On Genset Control Panel

The GenSet Control Panel shall be a wall mounted enclosure, supporting (1)
(see scope list under 1.2.1) GenSet. It will be approximately 24”H x 30”W x 8”D.
Mounted inside the GenSet Control Panel will be all necessary hardware for 1
GenSet, including:
1. 1 - EMCP 3.S Controller
2. 1 - set of current transformer shorting blocks
3. 1 – Set GenSet Circuit Breaker open/close relay
4. 1 – Engine Run Contact (EMCP3S output)
5. 1 – Engine Common Alarm (EMCP3S output)
6. 1 – Engine Common Fault (EMCP3S output)
7. 1 – 4PDT Load Shed/Add relays (dry contacts)
8. 1 – Set Best Source DC Hardware
Other Relays and Hardware as required
11. 1 – Voltage Adjust Switch/Potentiometer
12. 1 – Speed Adjust Potentiometer
Mounted on the door of the Generator Control Panel will be all necessary
controls for 1 GenSet, including:
13. 1 - set of GenSet Circuit Breaker Control Hardware:
NOTE
Page 10 of 35
2.1.1.1 Generator Protection

Each Generator shall have the following required protection available to
protect the generator during fault conditions. Each function will have the
ability to adjust setpoints and time delays to coordinate the system operation.
The following is a minimum required list of Generator protective functions:
6. (40) Loss Of Excitation
2.4 Control System Connections

The control system shall be designed to be installed, connected and commissioned
by the Caterpillar Dealer in the field. Control System Connections shall be as
follows: Provision of necessary support hardware and wiring shall be the
responsibility of the Caterpillar Dealer:
2.4.1 Control Panel Interconnection

The Caterpillar Dealer shall provide the following hardware and interconnect wiring
for each system GenSet:
For ease of installation, Control Panel Interconnections will be kept to a minimum.

Control Panel Interconnection wiring shall include:
1. 1 – Ethernet Cat 6 cable (limited to a maximum 100 meters length)
2. 2 – System “Hot Bus” wires
3. 2 – Best Source wires
4. 1– Emergency Start Request wire ( supplied by others)
2.4.2 Genset Interconnection

Provision of necessary support hardware and wiring shall be the responsibility of the
Caterpillar Dealer:
Page 11 of 35
2.4.2.1 Required Hardware

1. Primary fusing for GenSet and Bus phase voltages
2. Current Transformers with local CT shorting Block
3. Electrically Operated package mounted or remote GenSet circuit
breaker furnished with the following:
a. Integral short circuit trip protection
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 Release (See Note 1
below)
e. Auxiliary Contacts 1A, and 1B
f. Bell Alarm Contacts (overcurrent trip)
g. Maximum 12 cycle breaker open/close time (EGP operation)
h. Maximum 5 cycle breaker open/close time (XLM operation)
NOTE 1
Circuit breaker Trip/Close signals are rated 40A up to 300vac, 5A
@300-600vac, 10A @110vdc, and 4A@ 225vdc.
2.4.2.2 Required Genset Interconnection Wiring

The Caterpillar Dealer shall provide the following control system
interconnection wiring for each system GenSet and/or remote mounted
GenSet circuit breaker:
1. Circuit Breaker Wiring
a) 2 – Circuit Breaker Close wires
b) 2 – Circuit Breaker Open wires
c) 4 – Auxiliary Contact sensing wires(a & b contacts)
d) 2 – Bell Alarm Contact sensing wires
2. GenSet Wiring
a) 4 – Engine Battery Best Source DC wires (#10 awg)
b) 2 – Engine Run Request wires
c) 1 – Crank Terminate signal wire
d) 1 – Engine Summary Shutdown Fault signal wire
3. Sensing Alarm Contacts
a) 1– Engine Battery Charger Failure (Optional)
Page 12 of 35
b) 1– Low Fuel Level (Optional)

c) 1– High Level (Optional)
d) 1– Fuel Tank Rupture (Optional)
Note: (Common 24Vdc supply wire for items (2c) thru (3d)
above)
2.4.2.3 Optional Load Shed/Add Wiring

The Caterpillar Dealer may optionally utilize the provided Load Shed/Add
relays for System Load Shed/Add functions. Conditional 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” form “C” Contacts
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.
2.4.2.3 GenSet Status contacts

The Caterpillar Dealer may optionally utilize the provided GenSet status
contacts provided for each generator from the EMCP3.S controller.
• GenSet running
• GenSet common alarm
• GenSet common shutdown
2.4.3 Utility Interconnection

Provision of necessary support hardware and wiring shall be the responsibility of the
Caterpillar Dealer:
2.4.3.1 Required Hardware

1. Primary fusing for Utility and Bus phase voltages
2. Current Transformers with local CT shorting Block
3. Electrically Operated circuit breaker furnished with the following:
a. Integral short circuit trip protection
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 Release (See Note 1
below)
e. Auxiliary Contacts 1A, and 1B
f. Bell Alarm Contacts (overcurrent trip)
g. Maximum 5 cycle open/close time
Page 13 of 35
NOTE 1
Circuit breaker Trip/Close signals are rated 40A up to 300vac, 5A
@300-600vac, 10A @110vdc, and 4A@ 225vdc.
2.4.2.2 Required Utility Interconnection Wiring

The Caterpillar Dealer shall provide the following control system
interconnection wiring for a single Utility remote mounted circuit breaker:
1. Circuit Breaker Wiring
a. 2 – Circuit Breaker Close wires
b. 2 – Circuit Breaker Open wires
c. 4 – Auxiliary Contact sensing wires(a & b contacts)
d. 2 – Bell Alarm Contact sensing wires
2. (Optional) Utility Multifunction Relay (MFR) or individual protective
relays providing the same functionality. - Owner Furnished
3. (Standard) Utility protection provided by the EMCP 3.S Utility
Controller
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 Furnished Utility protection
2.5 System Power Supply Requirements

All system controls shall be designed to operate from nominal 24vdc best source power.
This power source will be derived from all associated engine batteries. All system
components shall be design for continuous operation within a system voltage range of
18 – 40vdc.
2.6 AC Sensing Requirements

The control system shall employ 3 phase, true RMS sensing. Metering accuracy will be
Class 1. The requirements listed below will apply to each system GenSet and the
Utility.
2.6.1 Voltage Sensing

208-480v systems shall be connected directly to dedicated potential sensing
terminals in the control panel(s). The dealer shall furnish 1 each protective 3 amp
fuses per phase, mounted in close proximity to the source of the voltage for phase
A, B, and C generator output sensing and 1 each protective 3 amp fuses per phase
mounted on the load side of the generator breaker for phase A and B sensing.
Page 14 of 35
2.6.2 Current Sensing

The dealer shall provide and install 3 current transformers with 5 amp secondary.
These current transformers 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:
2.6.2.1 Current Transformer Ratios

Current transformer ratios are fully configurable on the touchscreen by the
operator to meet the specific installation.
• Primary selection between 50 and 4000 amps
a. Recommend minimum C20 Relay Class with 600v
insulation class
2.7 Environmental Requirements

• Control System operating temperature 0oC to 55oC
• Storage temperature: –20oC to 60oC
• Humidity: 95% non-condensing 30oC to 60oC
• Sealing: Type 12
• Vibration and Shock: 5Hz to 9Hz single amplitude 3.5mm, 9Hz to 150Hz fixed
acceleration 9.8m/s2
• Operational Altitude: 2000 meters
2.8 HMI Graphic Display

The control system HMI shall be a 12 inch, graphical, color touchscreen display. The
display shall have a resolution of 800 x 600 pixels and be provided with a back light. It
shall communicate to the control system via 100MHz Ethernet, via ModBus TCP
protocol. Operator and configuration screens shall be contained within the HMI in non-
volatile memory and displayed in English language as the default.
2.8.1 Additional Support languages

• Spanish
• Chinese (simplified)
2.8.2 Menu system

The operator interface shall be provided with a menu system which allows
easy and intuitive movement through the associated screens.
2.8.3 Screens
All screens shall be developed so that an operator in the field can select
the appropriate areas without having to use a stylus or pointer type device.
Page 15 of 35
Appropriate touch area shall be allocated for active areas to prevent

overlap and improper movement to screens. Data displayed on the
screens shall be readable in an outdoor environment. Typical minimum
screens as follows:
2.8.3.1 System
1. System Initialization screens
2. Overview Screen - graphical mimic one line
3. Main Menu Screen
4. System Control Screen
5. System Metering Screen
6. System Settings Screen
7. System Alarm Annunciator Screen
2.8.3.1 GenSet (Each Generator)

1. Generator Metering Screen
2. Generator Control Screen
3. Generator Ratings Screen
4. Generator Circuit Breaker settings Screen
5. Generator Volt/Freq Protective settings Screen
6. Generator VT/CT ratio screen
7. Generator Power Protective settings Screen
8. Generator Battery under/over volt alarm settings Screen
9. Generator Fuel Alarm settings Screen
10. Generator Tuning Synch/Load settings Screen
11. Generator Alarm Annunciator Screen
2.8.4.1 Utility (Requires UCP option)

1. Utility Metering Screen
2. Utility Control Screen
3. Utility Ratings Screen
4. Utility Circuit Breaker settings Screen
5. Utility Volt/Freq Protective settings Screen
6. Utility VT/CT ratio screen
7. Utility Power Protective settings Screen
2.8.4 Annuniciators
Annunciation of alarms, shutdowns, and status conditions will be display
on the Touchscreen interface meeting standard NFPA 99 and 110
requirements. Annunciation shall be provided that includes the following
minimum information:
2.8.4.1 System
2.8.4.1.1 Status, Light only (non-latching)
1. Utility Fail Test (on-off)(requires UCP option)
2. Master Mode switch (on – off)
3. Gen No load switch (on-off)
Page 16 of 35
4. Load Shed switch (on-off)

5. Utility Re-Xfer switch (on-off) (requires UCP option)
6. Xfer select switch (open-closed) (requires UCP option)
7. Load shed active
8. System Operating Mode setup Screen
2.8.4.1.2 Alarm, Light and Horn (non-latching)

1. System In emergency
2. System not in auto
3. Load shed override
4. Master Shutdown
5. Bus Underfrequency
6. Known node not found
7. Unknown node found
2.8.4.2 GenSet (Each Generator)

1. Sync switch status
2. Swgr ECS status
3. Circuit breaker status (open – closed)
2.8.4.2.2 Alarm, Light and Horn (non-latching)

1. Low battery voltage
2. High battery voltage
3. Battery charger failed (requires customer input)
4. Fail to synch
5. Low Fuel Level (requires customer input)
6. Synch switch not in auto
7. ECS not in auto
8. Fuel rupture basin (requires customer input)
9. High fuel level (requires customer input)
10. CB failed to close
11. CB failed to open
12. Remove Deny
2.8.4.2.3 Shutdown, Light and Horn (latching)

1. Underfrequency
2. Over frequency
3. Under voltage
4. Over voltage
5. Reverse Power
6. Loss of Field
7. Over Excitation
8. CB trip
9. Loss of crank terminate signal
10. EMCP Fault shutdown
Page 17 of 35
2.8.4.3 Utility (requires UCP option)

1. Sync switch status
2. Circuit breaker status (open – closed)
2.8.4.2.2 Alarms, Light and Horn

1. Utility circuit breaker tripped
2. CB failed to close
3. CB failed to open
4. Utility failed to synch
5. Protective relay fault (requires customer input)
6. Utility fault
7. External relay reverse power (requires customer input)
8. Synch not in auto
9. Close Lockout switch status
10. 86 lockout relay tripped (requires customer input)
11. Underfrequency
12. Over frequency
13. Under voltage
14. Over voltage
15. Reverse Power
2.9 Standard I/O Requirements

The control system shall be furnished with the following I/O, as a minimum
2.9.1 Voltage Sensing

2.9.1.1 Voltage Sensing
GenSet – 3 phase, 480vac RMS maximum, Class 1 accuracy.
Bus – 1 phase, 480vac RMS maximum, Class 1 accuracy.
2.9.1.2 Voltage Sensing – Additional for Utility Option

Utility – 3 phase, 480vac RMS maximum, Class 1 accuracy.
Bus – 3 phase, 480vac RMS maximum, Class 1 accuracy.
2.9.2 Current Sensing

2.9.2.1 Current Sensing
GenSet – 3 phase, 0-5 amp secondary input, Class 1 accuracy.
2.9.2.2 Current Sensing – Additional for Utility Option
Utility – 3 phase, 0-5 amp secondary input, Class 1 accuracy.
2.9.3 Analog Outputs

2 – Voltage outputs, +/- 10 volts (speed and voltage control)
Page 18 of 35
Page 19 of 35
Section 3
Operational Functionality
3.1 Control System Capabilities

The control system shall be capable of Standard EGP functionality for 2 to 10 GenSets.
Modular program and commercial considerations will limit EGP functionality.
3.1.1 Control System configurations

The control system will diverge from Standard EGP offering in the following
areas:
• Limited Master – Modified Moving Master functionality will be provided.
The default master shall be GenSet 1. Generator 2 will automatically
become the Master is generator 1 fails.
• Single Ethernet Supervisory Network – Redundant Ethernet shall not
be supported.
• Load Shed/Add – Load Sensitive Load Shed/Add and Conditional Load
Shed/Add functionality will be provided through 1 - 4PDT relay for each
GenSet.
• Generator Demand Priority – Generator Demand Priority functionality
shall be provided as an option.
• Test with Load – Test with Load functionality shall not be provided.
3.1.2 Sequences of Operation – Standard EGP

The following Sequences of Operation will be provided as standard with the
Master Control Panel (MCP) and the Utility Control Panel (UCP) option is not
provided:
Automatic/Standby Mode
1. The automatic transfer switches are in the normal position serving utility
power to the loads.
2. The generator mains are open.
3. The automation is standing by to act in response to a run request from
associated Automatic Transfer Switches.
Page 20 of 35
Emergency Mode
1. Automatic Transfer Switch Run Request
Automatic transfer switches send system a run request.
All available generators are started.
The first generator up to voltage and frequency is closed to the bus.
The remaining generators are synchronized and paralleled to the

bus as they come up to voltage and frequency.
As each GenSet closes to the emergency bus, Load Shed levels

are added, powering their associated loads.
The system is now in Emergency Mode.
2. Exit from Emergency Mode

Automatic transfer switches sense the utility source is within
acceptable operational tolerances for a time duration set at the
automatic transfer switch.
As each automatic transfer switch transfers back to utility power, it

removes its’ run request from the generator plant.
When the last automatic transfer switch has retransferred to the

utility and all run requests have been removed from the generator
plant, all generator main circuit breakers shall open.
The generators are allowed to run for their programmed cool down
period.
The system is now in Automatic/Standby Mode.
Page 21 of 35
No Load Test Mode

1. Entrance into No Load Test Mode
The No Load Test Switch is placed in the ON position.
NOTE
The No Load Test Switch is a software switch located on the HMI
display.
All available generators are started.
The first generator up to voltage and frequency is closed to the bus.
The remaining generators are synchronized and paralleled to the

bus as they come up to voltage and frequency.
The system is now in No Load Test Mode.
2. Exit from No Load Test Mode

The No Load Test Switch is placed in the OFF position.
All generator breakers are opened.
The generators are allowed to run for their programmed cool down
period.
The system is now in Automatic/Standby Mode.
3.1.2.1 Sequences of Operation (XLM)

The following Sequences of Operation will be provided when the optional Utility
Control Panel (UCP) is added to the system:
Automatic/Standby Mode
a. The utility main breaker is closed serving utility power to the generator/load
bus.
b. The generator main breakers are open.
c. The automation is standing by to act in response to a utility failure.
Emergency Mode
Utility Sensing
1. By Utility MFR provided by Others
2. By EMCP 3.S Utility controller
Page 22 of 35
Utility Failure – (MFR furnished by Owner/Others)

1. Utility protective relaying senses utility voltage or frequency out of
tolerance.
a. Contacts provided by others signal Utility Failure.
2. The utility main breaker is opened.
3. A run request is sent to the generator plant.
4. The first generator up to voltage and frequency is closed to the bus.
5. The remaining generators are synchronized and paralleled to the bus
as they come up to voltage and frequency. As each generator closes
to the emergency bus, Load Shed levels are added, powering their
associated loads.
6. The system is now in Emergency Mode.
Utility Failure – (EMCP 3.S Utility Controller functioning as MFR)

1. EMCP3.S senses utility voltage or frequency out of tolerance.
2. The utility main breaker is opened.
4. The first generator up to voltage and frequency is closed to the bus.
5. The remaining generators are synchronized and paralleled to the bus
as they come up to voltage and frequency.
Utility Restoration and Exit from Emergency Mode (Closed Transition)

1. Utility protective relaying senses utility voltage and frequency within
tolerance.
2. The system starts an adjustable time delay (which can be abbreviated
by the operator) to assure that the utility power source is stable. If the
system is set for Manual Retransfer (user settable), the system will
remain in Emergency Mode until the user allows the retransfer to utility
by either pressing the Immediate Transfer push button, or moving the
Retransfer switch back to Auto.
3. The generator plant is passively synchronized and paralleled to the
utility source by closing the utility main breaker.
4. The generator plant is soft ramp unloaded until the utility source is
nominally serving the entire system load.
5. The generator breakers are opened.
6. The generators are allowed to run for their programmed cool down
period.
7. The system is now in Automatic/Standby Mode.
Page 23 of 35
Utility Restoration and Exit from Emergency Mode (Open Transition)

1. Utility protective relaying senses utility voltage and frequency within
tolerance.
remain in Emergency Mode until the user allows the retransfer to utility
by either pressing the Immediate Transfer push button, or moving the
Retransfer switch back to Auto.
4. The utility main breaker is closed.
5. The generators are allowed to run for their adjustable cool down
period.
Transfer to Emergency Mode

Entry
1. The operator places the Master Mode Selector Switch into the Transfer
to Emergency position.
3. The generators are allowed to run for an adjustable warm-up time
(which can be abbreviated by the operator).
4. The generators are synchronized and paralleled to the bus at no load
as they come up to voltage and frequency.
5. When the generators are on the bus, they are soft ramp loaded until
the generator plant is serving nominally the entire load on the bus and
the utility main breaker is opened.
Exit (Closed Transition)

1. The operator removes the Master Mode Selector Switch from Transfer
to Emergency position and returns it to the Auto position.
remain in Emergency Mode until the user allows the retransfer to utility.
3. The generator plant is passively synchronized and paralleled to the
utility source by closing the utility main breaker.
nominally serving the entire system load.
period.
Page 24 of 35
7. The system is now back in Automatic/Standby Mode.
Exit (Open Transition)

1. The operator removes the Master Mode Selector Switch from Transfer
to Emergency position and returns it to the Auto position.
remain in Emergency Mode until the user allows the retransfer to utility.
4. The utility main breaker is closed.
period.
Load Management Mode

Entry
1. Select one of the modes of operation:
a. Utility Track Import - The user places the Peaking Mode Selector
Switch in the Utility Track Import. The user sets the Utility Import
Limit set point to the desired amount of kW that they want to import
through the Utility Circuit Breaker during Load Management Mode.
b. Utility Track Export - The user places the Peaking Mode Selector
Switch in the Utility Track Export. The user sets the Utility Export
Limit set point to the desired amount of kW that they want to export
through the Utility Circuit Breaker during Load Management Mode.
c. Base Load Import - The user places the Peaking Mode Selector
Switch in the Base Load Import position. The user sets the Base
Load Set point to the desired amount of kW that they want the
generator plant to assume during Load Management Mode. The
controls will not allow the generator plant to export kW through the
Utility Circuit Breaker and will always maintain a nominal amount of
Utility kW imported through the Utility Circuit Breaker equal to or
greater than the amount set by the Utility Import Limit set point.
d. Base Load - The user places the Peaking Mode Selector Switch in
the Base Load position. The user sets the Base Load Set point to
the desired amount of kW that they want the generator plant to
assume during Load Management Mode. The controls will allow the
generator plant to export kW through the Utility Circuit Breaker.
2. The user places the Master Mode Selector Switch in the Load
Management position.
Page 25 of 35
4. The generators are allowed to run for an adjustable warm-up time

(which can be abbreviated by the operator by pressing the Immediate
Transfer push button).
5. The generators are synchronized and paralleled to the bus at no load
after completion of the warm-up time.
6. When all generators are on the bus they are soft ramp loaded until the
generator plant is serving nominally the required amount of the load on
the bus to meet the mode of operation selected.
7. The generator output is dynamically adjusted to maintain the set point
to meet the mode of operation selected.
8. Should the utility fail at any time during Load Management operation,
the utility protective relay or the internal EMCP 3.S utility protective
shall cause the utility main to open, placing the system in Emergency
Mode. When utility is restored, the system will exit as described in
Emergency Mode exit).
Exit
1. The operator removes the Master Mode Selector Switch from Load
Management position and returns it to the Auto position.
nominally serving the entire system load and the generator main
breakers are opened.
period.
No Load Test Mode

Entry
1. The No Load Test Switch is placed in the ON position.
2. All available generators are started.
3. All generators come up to voltage and frequency and remain running
disconnected from the bus.
4. The system is now in No Load Test Mode.
Exit
1. The No Load Test Switch is placed in the OFF position.
period.
Page 26 of 35
Utility Fail Test Mode

Entry
1. The Utility Fail Test Switch is placed in the ON position.
2. Voltage sensing at the utility protective relay and the EMCP 3.S
controller is opened, which simulates a loss of utility.
3. The system enters into Emergency Mode as described in the
“Emergency Mode” sequence above.
Exit
1. The Utility Fail Test Switch is placed in the OFF position.
2. Voltage sensing at the utility protective relay and the EMCP 3.S
controller is restored, which simulates the return of utility power.
3. The system exits from Emergency Mode as described in the
“Emergency Mode” sequence above.
Generator Demand Control – (Requires Optional Upgrade)

The System Controls shall include a Generator Demand Priority Control
function to automatically match the on-line generator capacity to the loads to
avoid unnecessary operation of all the generators when the loads are low.
The following controls shall be provided for each generator:

• User-settable Generator Priority Selector
• Status indicator for the Generator Priority Selected
• Status indicator for generator On-line or Off-line
The Generator Demand Priority Control shall have the following controls:
• Generator Demand Priority Control Switch (On/Off)
• User-settable Online Reserve (in kW)
• User-settable Generator Add Delay (in seconds)
• User-settable Remove Differential (in kW)
• User-settable Generator Remove Delay (in minutes)
• User-settable Immediate Add Reserve (in kW)
• User-settable Load Stabilization Delay
• User-settable Minimum Number of Online Generators
Upon entrance into Emergency or Load Management modes, all generators

shall be started and paralleled to the bus. After the Load Stabilization Delay
time has elapsed, Generator Demand will become active.
If the bus power drops below the plant capacity minus the sum of the size of
the highest priority online generator, the Online Reserve set point, and the
Remove Differential set point, then following a remove delay, the highest
priority generator is removed from the bus. If the statement below is true, the
plant enters a remove state:
Page 27 of 35
Bus kW < Plant Capacity – (Gen Size + Online Reserve + Remove Diff)
If the bus power rises above the plant capacity minus the Online Reserve set
point, the Add Delay time elapses, and the lowest priority available offline
generator is added to the bus. If the statement below is true, the plant enters
an add state:
Bus kW > Plant Capacity – Online Reserve
If the bus power rises above the plant capacity minus the Immediate Add
Reserve set point, the lowest priority available generator is added to the bus
without delay. If the statement below is true, the plant enters an immediate
add state:
Bus kW > Plant capacity – Immediate Add Reserve
The Minimum Number of Online Generators set point will specify the number
of generators to keep on the bus regardless of excess capacity.
Page 28 of 35
Section 4
System Configuration
4.1 Overview
The control system shall be capable of complete configuration in the field by the
Caterpillar Dealer. No controller program access will be provided. All configurations will
be accomplished through the system HMI
4.1.1 System Configuration Parameters (standard)

The system will allow HMI configuration of the following parameters:
1. System nominal voltage (based on potential transformer ratio)

2. System frequency
3. Number of GenSets in the system
4. System Type (EGP or XLM) (UCP option required for XLM)
5. Data Table Interface (DTI) (Note: DTI option must be present)
6. System kW/kVar meter scaling
7. System Voltmeter maximum scale
8. System Ammeter maximum scale
4.1.1 Individual GenSet Configuration Parameters (standard)

1. Individual GenSet nominal voltage.

2. Individual GenSet rated frequency.
3. Individual GenSet rated kW output.
4. Individual GenSet rated current.
5. Individual GenSet rated kVar.
6. Individual GenSet Current transformer primary.
7. Individual GenSet Load Shed/Add relay priority setting.
8. Individual GenSet Protective relay setpoints.
9. Individual GenSet kW/kVar meter scaling
10. Individual GenSet Voltmeter maximum scale
11. Individual GenSet Ammeter maximum scale
Page 29 of 35
4.1.2 Utility Configuration Parameters – (Optional) requires UCP

1. Utility nominal voltage.

2. Utility rated frequency.
3. Utility rated kW output.
4. Utility rated current.
5. Utility rated kVar.
6. Utility Current transformer primary.
7. Utility Load Shed/Add relay priority setting.
8. Utility Protective relay setpoints.
9. Utility kW/kVar meter scaling
10. Utility Voltmeter maximum scale
11. Utility Ammeter maximum scale
Page 30 of 35
Section 5
Documentation
5.1 Overview
Provided with each system will be all documentation required by a Level 1 Caterpillar
Dealer to allow for complete system assembly and operation in the field. No
participation by ISO engineers or technicians will be necessary.
The EPIC EMCP 3.S Controls Only Installation manual will provide all of the pertinent
information required to install, setup and operate the system. The manual will contain
major sections including the following.
5.1.1 Drawing Packages

The following drawings packages will be available:
1. Master Control Panel Installation diagrams.

2. Master Control Panel Production diagrams.
3. GenSet Control Panel Installation diagrams.
4. GenSet Control Panel Production diagrams
5. Utility Control Panel Installation diagrams.
6. Utility Control Panel Production diagrams
The following minimum information will be included:

1. Control Panel interconnection diagrams.
2. Run Request example wiring diagrams.
3. GenSet interconnection diagrams.
4. Owner provided Utility protective relay interface
5. Load Shed/Add contacts
6. Assembly drawings for each panel design
7. Bills of materials for detailing all components
Page 31 of 35
5.1.2 Manuals
5.1.2.1 Installation manual

A comprehensive manual defining how to install the equipment will be provided.
This manual will allow a general contractor the ability to understand the
requirements for installing each panel, the number of conduits, the number of
wires in each conduit, and routing of each conduit.
5.1.2.2 Operations manual

A comprehensive manual defining how to set up the system will be provided. All
GenSet, system, and protective configuration points shall be available through
the HMI. Each configuration point will include default settings and limits.
The manual will provide comprehensive detail on running the system. All
operational modes will be described and illustrated in detail. All HMI screens will
be documented, with instructions on their navigation and operation.
5.1.2.3 Replacement parts manual

A comprehensive manual listing all the parts used with a detailed specification
sheet for each replaceable part shall be provided.
5.1.2.4 Data Table Interface manual

A comprehensive manual listing all the available data table points, data register
locations, and instructions for wiring interface connections shall be provided.
Page 32 of 35
Section 6
Optional Features
6.1 Hardware 25
An optional hardware 25 relay may be included to provide an additional level of
synchronization protection for the circuit breaker.
This device is typically located in the associated control panel on the subpanel. This
option is selected individually for each circuit breaker. Refer to the drawings
provided with the system for location details when this option is provided. This option
can be added at a latter date in the field if required.
6.2 Data Table Interface
The optional Data Table Interface allows the customer to monitor system metering
and examine engine status and operational parameters. This information is
available through the selection of the following interface connections:
1. ModBus RS-422/485
2. ModBus TCP/IP Ethernet
This device is located within the Master Cabinet. Refer to the drawings provided
with the system for location details when this option is provided. This option can be
added at a latter date in the field if required.
6.3 Add-On GenSet Control Panel
An optional GenSet control panel (GCP) (described in paragraph 2.3) may be
included to provide synchronization and control for additional generators, up to 8
more units Refer to the drawings provided with the system for detailed assembly and
wiring drawings when this option is provided. This option can be added at a latter
date in the field if required.
6.4 Add-On Utility Control Panel
An optional Utility control panel (UCP) (described in paragraph 2.2) may be included
to provide closed transition transfer and utility control for one remote utility breaker.
Refer to the drawings provided with the system for detailed assembly and wiring
drawings when this option is provided. This option can be added at a latter date in
the field if required
6.5 ISO Factory Startup
Optional Factory Startup packages can be purchased.
Page 33 of 35
Section 7
System Platform Configuration
EPIC Solution (Standard)
12" T/S Display
12"
ES
3S 3S 3S 3S 3S
Data Table Interface

(DTI)
(Optional)
Bldg Management System
(BMS)
Analog
Analog
Analog
EMCP EMCP EMCP
VR VR VR
Governor Governor Governor

Sysem Sysem Sysem
Master Control Panel Add-On Generators Add-On Utility

Controls (2) Gensets Control Panels Control Panels
(Maximum 8) (Maximum 1)
Page 34 of 35
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 35 of 35

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EPIC Functional Specification – 208-480V (ROW Region)

Engine Paralleling Integration Controls

EMCP3.S Controls Only

Rest of World Region

DCN0025 Rev 1.0

SECTION 1 OVERVIEW ..............................................................................................5

2.9.3 Analog Outputs............................................................................................................ 18

SECTION 6 OPTIONAL FEATURES ............................................................................33

Rev. Date Editor Changes

• Voltage regulators supported:

1.3 Specification Control/Changes

1.4 Product Approval

2.1 Control System Configuration

2.1.1 Master Control Panel

2.1.1.1 Generator Protection

2.2 Add-On Utility Control Panel (UCP)

1. 1 - EMCP 3.S Controller

2.2.1 Utility Protection

2.3 Add-On Genset Control Panel

2.1.1.1 Generator Protection

2.4 Control System Connections

2.4.1 Control Panel Interconnection

For ease of installation, Control Panel Interconnections will be kept to a minimum.

2.4.2 Genset Interconnection

2.4.2.1 Required Hardware

2.4.2.2 Required Genset Interconnection Wiring

b) 1– Low Fuel Level (Optional)

2.4.2.3 Optional Load Shed/Add Wiring

2.4.2.3 GenSet Status contacts

2.4.3 Utility Interconnection

2.4.3.1 Required Hardware

2.4.2.2 Required Utility Interconnection Wiring

2.5 System Power Supply Requirements

2.6 AC Sensing Requirements

2.6.1 Voltage Sensing

2.6.2 Current Sensing

2.6.2.1 Current Transformer Ratios

2.7 Environmental Requirements

2.8 HMI Graphic Display

2.8.1 Additional Support languages

2.8.2 Menu system

Appropriate touch area shall be allocated for active areas to prevent

2.8.3.1 GenSet (Each Generator)

2.8.4.1 Utility (Requires UCP option)

4. Load Shed switch (on-off)

2.8.4.1.2 Alarm, Light and Horn (non-latching)

2.8.4.2 GenSet (Each Generator)

2.8.4.2.2 Alarm, Light and Horn (non-latching)

2.8.4.2.3 Shutdown, Light and Horn (latching)

2.8.4.3 Utility (requires UCP option)

2.8.4.2.2 Alarms, Light and Horn

2.9 Standard I/O Requirements

2.9.1 Voltage Sensing

2.9.1.2 Voltage Sensing – Additional for Utility Option

2.9.2 Current Sensing

2.9.3 Analog Outputs

3.1 Control System Capabilities

3.1.1 Control System configurations

3.1.2 Sequences of Operation – Standard EGP

The first generator up to voltage and frequency is closed to the bus.

The remaining generators are synchronized and paralleled to the

As each GenSet closes to the emergency bus, Load Shed levels

The system is now in Emergency Mode.

2. Exit from Emergency Mode