EPIC Training Schedule: Electric Power Division

electric power division
one powerful future.
EPIC Training Schedule
Day One Day Two Day Three

 ISO Introduction PPT  Sequence Of  Hands On EPIC
 Product Basics Operations Operation Training
 EPIC Product and  HMI Design  HMI Upload
Application  Screens Procedure
 BREAK - Lunch  BREAK - Lunch  BREAK - Lunch
 Components  Documentation  Node Changing
 System Examples  Questions and Procedure (Mod
Open Discussion Scan)
 Hardware Design
 Software Design
 Optional Features
 Questions and Open
Discussion
Confidential Yellow Page 1

Product Basics
Product Basics
• Caterpillar Diesel Generators (C9 – C32)*
• Expandable from 2-10 Generators
• EGP or XLM systems
• Low Voltage (208V - 480V) 50/60 Hz screen selectable
• Low Voltage (600V) for Canadian market
– If PTs and 120V terminals are used, EMCP 3.S Controller can be configured for 600V use
• Medium Voltage (up to 35kV)
– PT’s (120V secondary) are required by dealer
• UL, cUL Listed & IEC rating
• Single 12” Color Touchscreen Panel per EPIC system
* 3500 series supported outside of US market

Product Basics (cont)
• Fast Delivery Time – built to inventory at factory (6-8 wks)

• Designed for flexibility, modularity, and easy installation and
operation
• Modular Design (three standard units)
– Master Control Panel (MCP)
– Generator Control Panel (GCP)
– Utility Control Panel (UCP)

EPIC product and application
(WHAT IS IT?)
The Product Family

• Basics:
– Off-package control system
• 2-10 Diesel Generator Sets (C9-C175)
• 0-1 Utility
• <15kV
– Parallels across on-package or remote gen
& utility breakers
– Designed for flexibility, modularity & ease of
use
– Intended as value-rich alternative
– Faster delivery time

Three Core Components:

•Master Control Panel (MCP)
•Synchronization and control of first 2 engine gensets
•Scalable Human Machine Interface (HMI) displays
system and individual genset data
•Dual EMCP 3.S Controls (Provide master controller
redundancy for Gensets 1 & 2)
•Industrial Grade Protective relaying functions:
•15/25, 27/59, 81O/U, 32, 40, 90, 65, 67
•Monitoring functions:
•VM, AM, PF, kVAR, kW, FM, kWHr, KVA


•Generator Control Panel (GCP):
•Synchronization and control of incremental engines
•Communicates engine data to MCP
•Wall Mount
•15/25, 27/59, 81O/U, 32, 40, 90, 65, 67


•Utility Control Panel (UCP):
•Synchronizes system (closed transition and extended
paralleling) with utility source
•Provides base loading and import control
•Communicates Utility data to MCP
•Wall Mount
•15/25, 27/59, 81O/U, 32, 40, 90, 65, 67
•UTILITY GRADE PROTECTIVE RELAY NOT PROVIDED
3 EPIC Options:
• Hardware 25 Sync Check Relay

– (redundant to standard synch check embedded in EPIC software)
• Data Table Interface

– Communication of system/genset parameters for remote systems
• Generator Demand
– Controls number of gensets on the bus based on actual load

Systems Integration Requirements

(Note = to be supplied by dealer or customer):
• Governor:
– Speed Brick (ADEM III, IV, PEEC), 1724, 2301A, Woodward LSM
• Voltage Regulators:
– CDVR, DVR, VR3, VR6, R23/R448
• Fused Genset and Utility phase voltage wiring interconnect
• Current Transformers with local CT shorting Block
• Electrically Operated package mounted or remote Genset circuit
breaker furnished with the following:
– Integral short circuit trip protection
– Control Power fusing and wiring for charging and closing the circuit breaker
– Circuit breaker close circuit.
– Shunt trip circuit or UV release
– Auxiliary Contacts 1A, 1B
Modular Application
Building Block approach allows for a system that
grows with your customer’s needs

Components
Master Control Panel (MCP)
• Controls 2 Generators
• Horn & Horn Silence Push Button
• Touchscreen Panel
– Current Supported Languages (English, Spanish,
French Canadian, Simple Chinese – Arabic by 4Q11)
• Generator CBCS (for each generator)
• Circuit Breaker Status Open/Closed Status
Lamps (for each generator)

Generator Control Panel (GCP) (optional)

• Controls 1 Generator
• Generator CBCS
• Circuit Breaker Status Open/Closed
Status Lamps
• Up to eight (8) additional GCPs
supported

Utility Control Panel (UCP) (optional)
• Controls 1 Utility Source

• One Utility CBCS
• Circuit Breaker Status Open/Closed
Status Lamps
• Utility CBCLS

System Examples
Example of EGP2

Example of EGP4

Example of XLM4

Unsupported Systems
• Does not support XLMT

• Does not support Generator Ties (or split generator bus)
• Does not support MTM
• Does not support Ties in series

Hardware Design
Design Goals
• Modular hardware design
– Allow easy expansion on existing systems
– Keep hardware as uniform as possible between the three components
• Minimal wiring between control units
• Standard speed and voltage interfaces
• Based upon Caterpillar EMCP 3.S technology

System Integration Requirements
• Supports standard governors (Speed Brick – ADEM III, IV, PEEC,

1724, 2301A, Woodward LSM)
• Supports standard regulators (CDVR, DVR, VR6, VR3,
R230/R448)
• Generator/Utility 3 Phase Voltage Reference
• Single Phase Bus Voltage Reference
• CT Transformers w/ local CT Shorting Block

System Integration Requirements (cont)
• Electrically-operated Circuit Breaker:

– 5-Cycle Open/Close
– Integrated Short Circuit Trip Protection
– Control Power Fusing and Wiring (for charging and closing circuit breaker)
– Circuit Breaker Close Circuit
– Shunt Trip Circuit
– Aux Contacts

Network Layout (Between Components)

Network Layout (In MCP) Node 1

192.168.0.1
EMCP 3.S
Magelis 12”
192.168.0.100 G1
Touchscreen
Controller
Ethernet
Switch
Node 2
192.168.0.2
Node 61
EMCP 3.S
EMCP 3.S G2
192.168.0.61
DTI Controller
Controller
Optional
Network Layout (In GCP & UCP) Node X

192.168.0.X
To MCP
EMCP 3.S
GX
Controller
Node 33
192.168.0.33
To MCP
EMCP 3.S
N1
Controller

MCP Hardware Design
• MCP contains control hardware for two generators

• MCP design is similar to GCP
• MCP contains dual redundant Master controllers (based
upon moving master technology)
• Floor Mount Cabinet

Modular Design

MCP Drawings (DC Best Source) – S02

MCP Drawings (Stickers & Labels) – A06 – A09

GCP Hardware Design
• GCP contains hardware for single

generator
• Requires MCP to operate (single
Ethernet cable connects the two)
• Wall Mount Cabinet



















UCP Hardware Design
• UCP contains hardware for single

utility breaker
• Wall Mount Cabinet






Software Design
Software Design
• EPIC Product based upon EMCP 3.S Technology
• Almost Identical Functionality to a Caterpillar Switchgear
EGP/XLM system
• Designed for easy setup, operation, and expansion of system with
minimal software impact
• Modular design allows for expansion of system with minimal
software impact

Software Differences
• Moving Master limited to first two generators only (this is done

internally in the moving master function block)
• No Engine Data communications
• Weak Crank Battery Voltage Monitoring
• Battery Voltage alarms run off of voltage present at input 65
• Load Shed Relay logic differs from standard load shed relay logic
• Software Version Type differs from switchgear application
• Relay Contacts for Engine Running, Engine Alarm, and Engine
Fault

Software Version Types
• GenMaster (CCLG) – Applies to all generator controllers in both

the MCP and GCP cabinets
• UtilEmerTie_1 (CCLU) – Applies to utility controller in the UCP

cabinet
• DataTableInterface (CCLD) – Applies to DTI controller in the MCP

cabinet

EPIC Alarm Configuration
• The EMCP 3.S platform allows for user settable alarm class
modifications from the HMI for many of the alarms
• The configurable settings vary for all alarms
• Alarm Class, Time Delay, On/Off, Active/Deactive, Setpoint, Delay
By Engine are the common configurable settings

Alarm Classes
• Allow user to change functionality of protective alarms without

needing to reprogram the controller
• Supported Alarm Classes
0 – Annunciated
1 – Annunciated + Horn Active
2 – Annunciated + Horn Active + Soft Unload + Cooldown + Shutdown
3 – Annunciated + Horn Active + Cooldown + Shutdown
4 – Annunciated + Horn Active + Soft Unload + Shutdown
5 – Annunciated + Horn Active + Shutdown

Sequence of Operations
Sequence
• Sequence is Identical to standard Caterpillar Switchgear
EGP/XLM Sequences
– Load Shed Relays are more flexible than our standard Load Shed Relays in
our switchgear product
– Both Conditional & Load Sensitive Load Shed operations are supported
– Generator Demand is an optional purchase (unlockable from the HMI)

Load Shed Relay
• EPIC contains no Master I/O, so control of the LS Relays was

spread between each generator. Each generator controls a load
shed relay, but the state of the relay is determined by the system
as a whole.
• The relay can be assigned any level from the HMI (including
essential and non-essential)
• The relay operates at the level assigned, regardless of the state of
the generator controlling it.
• The number of generators determine the total number of levels.

Load Shed Controls
To test load shed relay operation

touch areas Shed or Add to verify relay
operation
 For Essential, enter a value of 0 will
cause your relay to remain in its
normal state.
Always remember to place your
switch in auto before leaving this
screen or use INSTANT AUTO
Load Shed priority assignment can be
placed in any order, depending on the
configured number of Gens
Load Shed has two mode of
operation: Conditional or Load
Sensitive selectable from this screen.
(Not shown)

LS Relay Example (EGP-3)
SYSTEM LEVEL: 0
G1 G2 G3
AVAILABLE AVAILABLE AVAILABLE
LVL 1 LVL 2 LVL 3

SHED SHED SHED

SYSTEM LEVEL: 0
G1 G2 G3
RUNNING FAULT RUNNING
LVL 1 LVL 2 LVL 3

SHED SHED SHED

SYSTEM LEVEL: 1
G1 G2 G3
LVL 1 LVL 2 LVL 3

ADD SHED SHED

SYSTEM LEVEL: 2
G1 G2 G3
LVL 1 LVL 2 LVL 3

ADD ADD SHED

Optional Features
Optional Features
• Data Table Interface
– Data can be read for all “available” EPIC related system information
– Customer can interface with DTI via ModbusRTU over RS-485 (port B) or
ModbusTCP via Ethernet (port B)
– Commands to system from DTI are NOT supported as standard
– Panels pre-drilled and wired for field installation
• Generator Demand
• Sync Check Relay
– Panels pre-drilled and wired for field installation

HMI Design
Magelis Software & Hardware
• Uses VijeoDesigner 4.6.0d (Patch D)

• Magelis XBTGT 6330 12” Color TFT (standard 12” Magelis touch
screen)

Node Setup
• Each EMCP 3.S controller requires

three separate nodes
– LO: Node used for all 16-bit
modbus addresses less than
50000 (settings, switches)
– HI: Node used for all 16-bit modbus
addresses greater than 50000
(alarming, metering, status)
– LO_AN: Node used for all 32-but
modbus addresses less than
50000 (settings)

Node Setup (cont)
• Frame Length
– Determines maximum size of
modbus query
• Double Word Order
– Sets the order of words for 32-bit
values
• Byte Order
– Sets the order of bytes for ASCII
strings
• Scan Rate
– Determines the speed at which the
data for the node is queried

Dynamic Overview Screen
• Multiple overview screens have

been created to reflect all possible
system sizes and types from EGP2
to XLM10
• A single blank screen (OVERVIEW)
serves as the master overview
screen, and a panel script is
triggered to navigate to one of two
other overview screens, depending
on the system size:
– OVERVIEW_MAIN
– OVERVIEW_PLANT1

Screens HMI
Setup From HMI
• HMI powers up to setup screens by default.

• Setup screens serve to configure entire system.
• All selections made in setup screen are stored and saved in non-
volatile memory.
• If system changes, setup screens can be re-entered to reconfigure
system.

System Setup Screen

Generator Setup Screen

Utility Setup Screen

Overview Screen (EGP4)

Overview Screen (XLM6)

Overview Screen (EGP10)

Generator Control Screen
• Similar to ISO standard Generator

Control Screen
• Current and Power scales on right
side no longer reference other gens
(too many possible gens)

Generator Meter Screen
• Exactly same as ISO Standard Gen

Meter screen

Generator Annunciation Screen
• Similar to standard ISO Gen

Annunciator screen

Generator Rated Settings Screen
• Rated Settings
• Unit Specific Timer Settings
• Available & Deadbus Settings
• Droop Settings

Generator VT/CT Ratio Settings Screen
• All settings pertaining to accurate

measurement of Gen and Bus
voltage

Generator Circuit Breaker Settings Screen
• All settings pertaining to the

Generator Circuit Breaker

Generator Under/Over Volt/Freq Alarm Settings Screen
• All settings pertaining voltage and

frequency alarms (Alarm Class,
On/Off, Self Ack, Setpoint, Time
Delay)

Generator Under/Over Excitation & Reverse Power Alarm

Screen
• All settings for Under/Over
Excitation and Reverse Power
Alarms

Generator Fuel Alarm Settings Screen
• All settings for Fuel Alarms (High,

Low, and Tank Malfunction)

Generator Battery Alarm Settings Screen
• All settings pertaining to Battery

Alarms

Generator Tune Sync Settings Screen
• Similar to standard Generator Tune

Sync Screens

Generator Tune Load Settings Screen
• Similar to standard Generator Tune

Load Screens

Utility Metering
• Similar to standard Utility Metering

Screens

Utility Control
• Similar to standard Utility Control

Screens

Utility Annunciation
• Similar to standard Utility

Annunciation Screens (save for a
few different alarms)

Utility Rated Settings
• Similar to Generator Rated Settings

(minus droop settings and timers)

Utility VT/CT Ratio Settings
• Similar to Generator VT/CT Ratio

Settings Screen

Utility Circuit Breaker Settings Screen
• Same as Generator Circuit Breaker

screen

Utility Under/Over Voltage/Frequency Alarm Settings

Screen
• Similar to Generator Under/Over
Voltage/Frequency Alarm Settings
Screen

Utility Reverse Power / Voltage Asymmetry Alarm Settings
• Contains all Reverse Power Alarm

Settings
• Contains all Voltage Assymetry
Alarm Settings

Alarm Summary Screen

System Control Screen

Load Shed Control Screen

Generator Demand Control Screen

Load Shed Setting Screen

Generator Demand Setting Screen

DTI Settings Screen

Optional Features Configuration Screen

Software Versions Screen

Improved Lower Menu
• Settings now appears on lower menu

• Lower menu now consistent across most screens
• Most screens now accessible from any other screen

Password Entry
• Settings sub-menu now contains password entry (no longer

necessary to go to main menu to enter password)
• ALL settings screens are now represented

Documentation
Documentation
• Installation Manual – Describes installation of EPIC product
• Operation Manual – Describes operation of EPIC product
• Parts Manual – Contains information for all EPIC parts and
components
• DTI Manual – Instructions on how to connect and use the DTI
controller
• Genset & Utility Interconnection Manual – Genset and utility
requirements for connection to EPIC panel

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electric power division

one powerful future.

EPIC Training Schedule

Day One Day Two Day Three

Confidential Yellow Page 1

Confidential Yellow Page 3

Product Basics (cont)

• Fast Delivery Time – built to inventory at factory (6-8 wks)

Confidential Yellow Page 4

The Product Family

Confidential Yellow Page 6

Three Core Components:

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Three Core Components:

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Three Core Components:

• Hardware 25 Sync Check Relay

• Data Table Interface

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Systems Integration Requirements

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Master Control Panel (MCP)

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Generator Control Panel (GCP) (optional)

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Utility Control Panel (UCP) (optional)

• Controls 1 Utility Source

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• Does not support XLMT

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System Integration Requirements

• Supports standard governors (Speed Brick – ADEM III, IV, PEEC,

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System Integration Requirements (cont)

• Electrically-operated Circuit Breaker:

Confidential Yellow Page 25

Network Layout (Between Components)

Confidential Yellow Page 26

Network Layout (In MCP) Node 1

Network Layout (In GCP & UCP) Node X

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MCP Hardware Design

• MCP contains control hardware for two generators

Confidential Yellow Page 29

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MCP Drawings (DC Best Source) – S02

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MCP Drawings (Stickers & Labels) – A06 – A09

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GCP Hardware Design

• GCP contains hardware for single

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