emcp ii operation manual
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emcp ii operation manualIf you continue browsing the site, you agree to the use of cookies on this website. See our User Agreement and Privacy Policy.If you continue browsing the site, you agree to the use of cookies on this website. See our Privacy Policy and User Agreement for details.If you wish to opt out, please close your SlideShare account. Learn more. You can change your ad preferences anytime. The team of writers operates very quickly. It's called ? www.HelpWriting.net ? Hope this helps!Systems Operation. Troubleshooting. Testing and Adjusting. SXC1-Up (Generator Set). For C32 Generator Set Packaged in Grif?n, GAImportant Safety Information. Most accidents that involve product operation, maintenance and repair are caused by failure to observeAn accident can often be avoided by recognizing potentially hazardousA person must be alert to potential hazards. This person should alsoImproper operation, lubrication, maintenance or repair of this product can be dangerous andDo not operate or perform any lubrication, maintenance or repair on this product, until you haveSafety precautions and warnings are provided in this manual and on the product. If these hazard warningsThe hazards are identi?ed by the “Safety Alert Symbol” and followed by a “Signal Word” such asThe Safety Alert “WARNING” label is shown below. The meaning of this safety alert symbol is as follows. Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictoriallyOperations that may cause product damage are identi?ed by “NOTICE” labels on the product and inCaterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,You should also ensure thatThe information, speci?cations, and illustrations in this publication are on the basis of information thatThe speci?http://4cmedica.com/ficheiros_upload/delonghi-pdf-manuals.xml
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cations, torques, pressures,These changes canObtain the complete and most current information before youWhen replacement parts are required for thisFailure to heed this warning can lead to prema-Table of Contents. Systems Operation Section. General Information. 5. Component Location. 6. EMCP Electronic Control (Generator Set). 9. Instrument Panel. 17. Data Link. 18. Sensors. 18. Modes Of Operation. 20. Normal Mode. 21. Alarm Mode. 23. Shutdown Mode. 24. Paralleling Mode. 25. Service Mode. 31. Fault Log Viewing OP1. 33. Protective Relaying Setpoint Viewing OP2-1. 34. AC Factory Calibration Setpoint Viewing OP2-2. 34. Parallel Setpoint Viewing OP2-3. 35. Password Entry OP3. 35. Fault Log Clearing OP4. 36. Protective Relaying Programming OP5-1. 40. AC Factory Calibration Setpoint ProgrammingHourmeter Programming OP7. 50. Engine Setpoint Veri?cation OP9. 52. AC Offset Adjustment OP10. 54. Parallel Setpoint Tuning OP-11. 55. Fault Description. 56. AL Fault Codes. 56. SP Fault Codes. 61. Diagnostic Codes. 61. Programmable Spare Relay Outputs. 62. Programmable Spare Output. 63. Programmable Kilowatt Level Output. 63. Alarm Modules. 64. Alarm Module Control (Custom). 67. Customer Interface Module. 68. System Communication Module (Customer). 69. Troubleshooting Section. Introduction. General Information. 71. Service Tools. 71. Fault Identi?cation. 72. Symptom Procedures. Engine Does Not Shutdown. 74. Display of Voltage or Current Is Zero. 76. Display of Voltage or Current or Power Is. Inaccurate. 81. Indicators of Alarm Module or Remote Annunciator. Are Constantly Flashing. 87. Diagnostic Code Procedures. Troubleshooting Diagnostic Codes. 90AL Fault Code. 156. SP Fault Code. 157. Troubleshooting Dedicated Shutdown. Indicators. 159. Indicator for Emergency Stop. 159. Indicator for High Water Temperature. 160. Indicator for Low Coolant Level. 160. Indicator for Low Oil Pressure. 161. Indicator for Overcrank. 161. Testing and Adjusting Section. Electrical Connector - Inspect.http://au-coeur-du-temps.com/userfiles/delonghi-pinguino-pac-l30-manual.xml 162. Alarm Module Control - Adjust. 166. Speed Sensor (Engine) - Adjust. 167. EMCP Electronic Control (AC Transformer Box) -. Replace. 168. EMCP Electronic Control (Bus Transformer Box) -. Replace. 168Relay Module - Replace. 170. EMCP Electronic Control (Generator Set) -. Replace. 171. EMCP Electronic Control (Generator Set) - Flash. Program. 172. Typical Generator Abbreviations. 176. Symbols. 178. Block Diagram of Generator Set Control. 180. Connector Contact Identi?cation of Generator Set. Control. 181. Schematics and Wiring Diagrams. 182. Service Record. 185. Index Section. Index. 195Systems Operation SectionGeneral Information. SMCS Code: 4490Illustration 1Component Location. SMCS Code: 4490Illustration 2. Control PanelIllustration 3. Relay panelIllustration 4. Caterpillar Digital Voltage Regulator (CDVR) panelEMCP Electronic ControlSMCS Code: 4490Illustration 5Note: The pictographs shown to the left of the Spare. Fault Indicators (2) are present only in parallelingThe displaysThe programmable featuresNote: Setting P023 to 0 ensures proper operationP023 to 2 for EUI engines. Failure to set setpoint. P023 can result in improper engine operation,Illustration 6. The part number is stamped into the rear housing ofIllustration 7Calibration Setpoint Viewing OP2-2”. Fault Indicators. The ten fault indicators are used in order to showThe ten fault indicators areThe yellow fault alarm indicator (4) FLASHES when. The alarm fault does not cause the engine status toThe engine willFault alarm indicator (4)The red fault shutdown indicator (3) FLASHES when. The engine is shutdown if the engine is running andFault shutdownThe yellow spare fault indicators (2) FLASH when theThe spare fault conditionThe spare fault indicatorsThe “Spare Fault” indicators have alternate functions. Spare 1 becomes the voltage indicator. This indicatorSpare 2 becomes theThis indicator illuminates when the phase differenceProgramming OP6”. The red dedicated shutdown indicators (1) representFLASHES.http://gbb.global/blog/boss-gt-6b-manual-pdf The engine is shutdown if the engineNo fault codes are associated with the dedicatedMany of the dedicated shutdown faults depend on. Operation, “Setpoint Programming OP5” for moreThe conditions that are required to activate theOne setpoint is used whenThe other setpoint is usedWhen a low oilFLASHES, and the engine is shut down. The engineEmergency Sop Push Button (ESPB) on the frontFLASHES. The engine is shutdown and the engine isThe engine is shutdown and the engine is not allowedThe engine is notCONTINUOUSLY. The corresponding dedicatedWhen the dedicatedThe operator or the service technician must decideIf desired, theUpper DisplayIllustration 8. Upper Display (5) With All Segments. The primary function of the upper display (5) isNote: When total current increases above “9999A”. Note: Line-neutral voltages are not shown whenUpper display (5) is also used to show the variousFor more informationDescription”.Illustration 9. Upper Display Showing:Illustration 10. Upper Display Showing:Illustration 11. Upper Display Is Showing:Illustration 12. Upper Display Is Showing:Illustration 13. Upper Display Is Showing:Note: Line to neutral voltages are not shown whenLower DisplayIllustration 14. Lower Display (6) With All Segments. The lower display (6) shows values for powerThe left side of the lower display serves as a powerThe following functionsThe display will stop scrolling when the operatorThe additionalNote: Real power phase A, B, and C as well asIllustration 15. Lower Display Showing:Illustration 16. Lower Display Showing:Note: Phase B and phase C can be viewed in aIllustration 17. Lower Display Showing:Illustration 18. Lower Display Showing:Illustration 19. Lower Display Showing:Illustration 20. Lower Display Showing:Note: You may view the power factor for theIllustration 21. Lower Display Showing. Note: Total energy output that is greater than 999,999Illustration 22.https://fjdeboer.com/images/97-geo-metro-service-manual-pdf.pdf Lower Display Showing:The right side of lower display (6) shows the valueThe parameters areDiagnostic Codes”. The value for one of these conditions is shown onThe display then scrollsA small pointerWhen the engine meterThe lower display continuously shows one particularIllustration 23. K1, K3 and K5 are active. K2, K4, K6, K7 and K8 are not active. The relay status indicators are on the bottom of theKeypadIllustration 24. Keypad (7) is used to control the information that isThe seven keys have two sets of functions, normalRefer to the topic. Systems Operation, “Service Mode” for a descriptionThis information is shownPressing the key for at least ?vePressing the key causes the display to show aThe scrolling of the engineCONTINUOUSLY. Every segment of upper displayOn the optionalFLASHING, pressing this key causes upper displayPressing this key again will resume the showing ofRefer to Systems. Operation, “Service Mode” for more information. RelaysIllustration 25Illustration 26. Relays In Relay ModuleThe relays are located in the relay module on theThe relays areFor more information, refer to. Schematics And Wiring Diagrams, “Generator Set. Wiring Diagram”. Some of the contacts of the relays are internallyNote: Jumper block (1) is used to select the voltageThe relay moduleRange Selection”.Table 1. Relay Module Terminal. Number. Rating For. Resistive. Loads. Inductive. LoadsThe relays and the functions are listed below. For the C32 package, this contact sends a runThe circuit breakerThe CTR is used to indicate that the engine isRPM reaches 0.AC Control Power Relay (AC-CR2). The K5 relayOn non-paralleling panels, this relay is for customerFor more information, refer to Systems Operation,Instrument Panel. SMCS Code: 4490; 7451Illustration 27. Instrument Panel SwitchesThe Engine Control Switch (ECS) (1) determines theIn the AUTO position (1b),A cooldown period for the engine is programmableAlso, any fault indicatorsIf the red ESTOP (2) is pressed, the power isThe operator mustThe CBCPB will illuminate when the circuit breakerThe Circuit Breaker Open Push button (CBOPB) (4)CBOPB is also an illuminated button. The CBCPBThe Paralleling Control Switch (PCS) (5) controlsThe Panel Light Switch (PLS) (6) turns ON the panelThe Speed Adjust Potentiometer (SAP) (8) is usedThe SAP is also used toThe Voltage Adjust Switch (VAS) (9) is used to raiseThe VAS switch is also usedData Link. SMCS Code: 4490Illustration 28. The Connection Points For The CAT Data Link.Modules” for more information about the ALM Data. Link. Also, refer to Systems Operation, “Customer. Interface Module”for more information on the ALM. Data Link. The data link has two functions. This data link is usedThe CAT Data Link uses a shielded twisted pair cableECM. For more information, refer to the Systems. Operation, “Customer Communication Module”.Communication Module (CCM). The Data Link usesOperation, “Customer Communication Module”.Sensors. SMCS Code: 4490Note: On C32 controlled engines, all of the listed. C32 engines the oil pressure sensor and coolantTemperature Sensor (Engine Oil). Note: This description applies to EUI,MUI and PEECIllustration 29. Engine Oil Temperature Sensor. The engine oil temperature sensor is optional andThe engine oil temperatureThe exact location depends onThe engine oil temperature sensor is a pulse widthThe sensor continuouslyThe duty cycle of the. PWM signal continuously varies from 10 to 95 inThe base frequency of theThe sensor is supplied operating power (8 DCV) atThere are ?ve setpoints that are related to engine oilP025, P026 and P027. Refer to Systems Operation. Fluid Level Sensor (Engine. Coolant)Illustration 30. Engine Coolant Loss Sensor. The engine coolant loss sensor is optional andThe engine coolant loss sensor is usually mountedThe exact locationThe engine coolant loss sensor sends a negative. The signal wireThe sensor is supplied operating power (8 DCV) atThere are three setpoints that are related to the lossP005 and P006. Refer to Systems Operation. Speed Sensor (Engine)Illustration 31. Engine Magnetic Speed Sensor. The engine magnetic speed sensor is an input of theThe sensor creates a sine wave signal from passingThe frequency is measured at one pulse per gearThere are four setpoints that are related to theP010, P011 and P012. Refer to Systems Operation,Modes Of Operation. SMCS Code: 4490. Table 2. Display Area Functions When In Normal Mode, Alarm Mode Or Shutdown Mode(1). Item Of Display Area Normal Mode(2) Alarm Mode(2) Shutdown Mode. Upper Display AC Data Shown AC Data Shown(3) Fault Code Shown. Lower Display AC Power Data, Engine Data. And Relay Status Shown. AC Power Data, Engine Data. Shutdown Indicator(s) All Off All Off Flashing. Fault Alarm Indicator Off Flashing(3) Off. Key Function Normal Mode Alarm Mode Shutdown Mode. Power Meter Key Starts And Stops The. Scrolling Of Power Meter. Data On Lower Display. Selects All Power Meter Data. To Be Shown. Starts And Stops The. AC Select Key Selects The AC Data That. Is Shown On The Upper. Display. Selects The AC Data That. No Function. Engine Meter Key Starts And Stops The. Scrolling Of Engine. Conditions On Lower Display. Lamp Test Key Performs A Lamp Test Performs A Lamp Test Performs A Lamp Test. Alarms Code Key No Function Shows The Alarm Fault Code. On The Upper Display. Exit Key(4) No Function No Function No Function. Service Mode(4). Service Mode(5). No FunctionFor a description of theIllustration 32Refer to the individual topics for more detailedThe fault shutdown indicator is OFF. The fault alarmThe operator canThe fault code will beThe operator can identify the shutdown mode byThe operator canThe operator can identify service mode by observingMode, “SERV” is SHOWN on the upper display. Note: Service Mode cannot be entered when the. ECS is in the AUTO position.Semi-Auto, or Permissive positions. Parallel Mode isFor more information, refer to Systems Operation,Normal Mode. Normal mode is used in order to monitor theThe operator can identify normal mode by observingSHOWING on the upper display.Note: The optional Customer Communication. Module (CCM) can remotely control certain generatorAUTO position. Refer to Systems Operation, “System. Communication Module (Customer)” for moreEngine Starting SequenceNote: Shutdown faults are removed by turning the. Electronic Governor Relay (EGR). The EGRControl Module (ECM) located on the engine.Factory default for crankP011 is 400 rpm.Engine Stopping Procedure. The signal will be one of two.The factoryThe spare output is activated only if the spareThe circuitBefore the engine speed reaches 0 rpm, a restartRelay (SMR) does not activate until the CTR isNote: The engines can be shut down immediately by. The cooldownAlarm Mode. The alarm mode alerts the operator when an alarmAn alarm faultThe operator is alerted by the. FLASHING fault alarm indicator. Press the “ALARM. CODES” key in order to identify the alarm fault. ASP fault code or a diagnostic fault code. “Spare 1”Diagnostic fault codes areNote: When the operator overrides a shutdown faultWhen the fault shutdownThe dedicated shutdown indicator remains ON. CONTINUOUSLY until the fault is corrected andThe dedicated shutdownRefer toSystems. Operation, “Setpoint Programming OP5 (P03)”. For more information, refer to System Operation,Alarm faults do not have an immediate adverse effectHowever, the operator shouldIf the operation of theAlarm Mode SequenceRefer to Testing And. Adjusting, “Fault Identi?cation”.Shutdown Mode. Shutdown mode prevents damage to the generatorThe name of theShutdown IndicatorsIf the fault shutdown indicator is the only indicator. FLASHING, additional information is available. ARefer to System Operation, “Fault Description” forShutdown Mode SequenceRelay (EGR).Note: The spare output may also be programmed toThis output canRefer to SystemDescription”.FLASHING, additional information is available. AK6 (ASR) will alsoEngine Start Sequence (After. Shutdown)Refer to the System. Operation, “Fault Identi?cation”.Paralleling Mode. SMCS Code: 4490Illustration 33. Parallel Control SwitchControl Switch (PCS) is in the AUTO position, or the. Permissive position. There are several parallelingThese functions areControl Switch (ECS).Illustration 34These subjects are beyondConsult your Caterpillar. Dealer for more information. WIRED GENERATORS. If setpoint P032 is set to 1An “AL17” diagnostic codeTable 3. Parallel Function Bus Status ECS Position Parallel Control. Switch Position. Frequency. Control. Close Breaker. Output. Automatic. Synchronization. Live Start or Auto(1) Auto Controls frequency,SYNC with bus. WhenDead Bus Paralleling Dead Start or Auto(1) Auto Does not controlActivates forPermissive. Paralleling. Live Start or Auto(1) Permissive Does not controlWhenEnables manualStart, Stop. Off Does not controlNot activated.GlossaryThe individual sineIf the generatorIf the generatorRPM “down” indicator is shown. These indicators areThe inactiveSynchroscopeA square symbolTable 4. Phase Angle Relationship. Pointer Position Indication. Rotating Clockwise Frequency of the incomingRotating counterclockwise Frequency of the incomingStopped in any positionFrequency of the incomingStopped at top center Frequency of the incomingThe upper display toggles between the incomingPressing the AC meter keypad will stop the togglingWhen the toggling isIllustration 35. The Bus Voltage and the frequency are shown on the Upper. Display.Illustration 36. The Generator Voltage And Frequency are shown on the Upper. Display.Illustration 37. The Lower Display (synchroscope) is showing the Bus AndThe Phase Angle Relationship is alsoThe Generator And the Bus are not synchronized.Illustration 38. The Lower Display (synchroscope) is Showing that the Generator. And the Bus are Synchronized. Note: The “RPM” indicators are shown only in. Permissive Mode. Spare Fault Indicators. The “Spare Fault” indicators have alternate functionsThis indicator illuminates when the phase differenceFault indicators retain their normal functions as. Programming OP6”.Synchronizing Tuning Procedure. Due to the variance in the characteristics of theAdjust 1 output. The response is tuned for optimumThe adjustmentChanges to theSpeed Adjust 1 output. Refer to the appropriateDO NOT proceed withNote: For optimum performance, synchronizationThis requirement can be enabled or disabled withThe acceptable range isThe dwell time forAfter all synchronization conditions are withinTuning ProcedureP301 is set to 1 to enable synchronization. P307 is set to 2.5. P308 is set to 0. P309 is set to 0. Ensure that the other setpoints are programmedExit Service Mode.Engine Control Switch (ECS) in the COOLDOWNRefer to Service Mode, “Synchronization Setpoint. Tuning - OP11”.ECS in the AUTO position.If the synchroscope pointerStep 6. If the synchroscope pointer is oscillating,Place the ECS in the. COOLDOWN position. Enter the service modeCalculate 60P307 by 0.6. Reset Setpoint P307 to the newFor example, when the engine oscillates for 20Multiplying 80 by 0.6Enter Service Mode andOP11 P307 remains set to the value that wasThen, the synchroscopeSYNCH” symbol is ON. Wait 20 seconds, if “IN. SYNCH” is ON proceed to Step 11. Otherwise,Place the ECSEnter Service ModeAdjust P308 upwardSYNCH” indicator does not come ON within 20When this happens, adjustPlace the ECSEnter Service ModeSet P309 to 2.5.ECS in the AUTO position.Place the ECSEnter Service ModeSynchronization Sequence Of. Operation. Note: Before attempting to execute these functions,Automatic Synchronization Mode. Dead Bus CloseThe followingChanging either of theseIf the ?rst generator sets circuit breaker does notIf the secondThe dead bus circuit con?rms the bus is deadPermissive Timer (DBPT) will close its contact,The contact from this relay is fed into theShutdown Relay (SDR) is not energized.Relay (CBR).Breaker Permissive Relay (CBPR).Close Relay (CBCR).Live Bus CloseThe followingChanging either of theseManual Synchronization Mode. Dead Bus CloseChanging the switch position will interrupt theCBCPB, activating the CBPR.Live Bus CloseChanging the switch position will interrupt theA CBPR contact will energize the CBCR.Service Mode. SMCS Code: 4490Illustration 39Service Mode is used for the following purposes:Service Mode has options that can be selected. Service personnel use the options to obtainTable 5. OP1, Fault log viewing. OP2-1, Protective relaying setpoint viewing. OP2-2, AC factory calibration setpoint viewing. OP2-3, Synchronization setpoints(1). OP3, Password entry. OP4, Fault log clearing. OP5-1, Protective relaying programming. OP5-2, For factory use, not accessible by the user. OP5-3, Synchronization setpoint programming(1). OP7, Hour meter programming. OP9, Engine setpoint veri?cation. OP10, AC offset adjustment. OP11, Synchronization setpoint tuning(1)Also, thereWhen you areWhen you are entering theNote: The appropriate “Scroll” Key should be heldTo change an option, use the Select Key. To start theThe display now returns to Normal Mode. The “SERV”Service Mode. The “SERV” indicator on the upper. Mode. The “SERV” indicator on the upper display. FLASHES when the keypad performs functions inProcedure To Enter Service Mode. Note: Any active shutdown fault must be madeFLASHING shutdown indicator means that aTo temporarily change aAlso, the ECS must be. If the jumper fromNote: Service Mode cannot be entered when the. ECS is in the AUTO position.Service Mode.Note: To enter options OP4 through OP8 of the. Service Mode, the engine must be shut down. TurnOptions OP4 through OP11 of the Service ModeRefer to Systems. Operation, “Password Entry OP3”. Option OP1Option OP1 and option OP2 are not protected withFault Log Viewing OP1. Refer to the appropriateDO NOT proceed withNote: For optimum performance, synchronizationThis requirement can be enabled or disabled withThe acceptable range isThe dwell time forAfter all synchronization conditions are withinTuning ProcedureP301 is set to 1 to enable synchronization. P307 is set to 2.5. P308 is set to 0. P309 is set to 0. Ensure that the other setpoints are programmedExit Service Mode.Engine Control Switch (ECS) in the COOLDOWNRefer to Service Mode, “Synchronization Setpoint. Tuning - OP11”.ECS in the AUTO position.If the synchroscope pointerStep 6. If the synchroscope pointer is oscillating,Place the ECS in the. COOLDOWN position. Enter the service modeCalculate 60P307 by 0.6. Reset Setpoint P307 to the newFor example, when the engine oscillates for 20Multiplying 80 by 0.6Enter Service Mode andOP11 P307 remains set to the value that wasThen, the synchroscopeSYNCH” symbol is ON. Wait 20 seconds, if “IN. SYNCH” is ON proceed to Step 11. Otherwise,Place the ECSEnter Service ModeAdjust P308 upwardSYNCH” indicator does not come ON within 20When this happens, adjustPlace the ECSEnter Service ModeSet P309 to 2.5.ECS in the AUTO position.Place the ECSEnter Service ModeSynchronization Sequence Of. Operation. Note: Before attempting to execute these functions,Automatic Synchronization Mode. Dead Bus CloseThe followingChanging either of theseIf the ?rst generator sets circuit breaker does notIf the secondThe dead bus circuit con?rms the bus is deadPermissive Timer (DBPT) will close its contact,The contact from this relay is fed into theShutdown Relay (SDR) is not energized.Relay (CBR).Breaker Permissive Relay (CBPR).Close Relay (CBCR).Live Bus CloseThe followingChanging either of theseManual Synchronization Mode. Dead Bus CloseChanging the switch position will interrupt theCBCPB, activating the CBPR.Live Bus CloseChanging the switch position will interrupt theA CBPR contact will energize the CBCR.Service Mode. SMCS Code: 4490Illustration 39Service Mode is used for the following purposes:Service Mode has options that can be selected.11 SHIELDED AND COMMUNICATION WIRING Shielded twisted pair cable is required for the magnetic speed sensor. CAN cable is required for Primary and Accessory CAN Data Links. This cable is used for maximum protection against inductive noise, electromagnetic interference, and radio frequency interference. The shield greatly reduces the amplitude of any unwanted voltages on the signal wire. The shields should not be connected to the sheet metal. If the shields are connected to sheet metal, the connections are susceptible to loose bolts, corrosion, etc. The faulty connections increase the resistance of the shield. Faulty connections also reduce the effectiveness of the shield. When the cable terminates at junction boxes, the shields must be connected to each other in order to maintain a continuous path. A continuous path must be maintained in the shield wire for sensors, whenever possible. Wire exposed beyond the shield should be as short as possible. The shield must be connected to battery negative as close to the controller as possible. Shields should be drained at one point only. When possible, this should be done at, or close to, the EMCP 4. To avoid electromagnetic interference, do not run shielded signal wires near other wires carrying large currents. In installations with unavoidable risk of electromagnetic interference (EMI), shielded wire run in conduit, extra shielding, or other precautions may be necessary. Page 14 All rights reserved. 23 Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control 4 INITIAL OPERATION AND USER ORIENTATION 4.1 TYPES OF EMCP 4 EVENTS The EMCP 4 has two lamps to annunciate events. The amber lamp indicates warningtype events, while the red lamp indicates shutdown-type events. The amber lamp also lights if a Protect lamp is being sent by a different module. ET2013B and later can be used to help identify what modules are sending different lamp statuses.