Attachment-No-3-HO-PENN-Equipment-in-Storage-86-Pages.pdf

Power Systems

15 Middle Avenue • Holtsville, NY 11742 • (631) 654-4436 • FAX (631) 654-4480

Engineering submittal describing scope of work for this project: One (2) Caterpillar Model C175 diesel fueled generator set rated at 2825 kW Prime (without fan), 4160V, 3 phase, 1800 RPM, 60 hertz at 0.8 power factor.

SECTION 1: CATERPILLAR MODEL C175

AIR INLET SYSTEM

Air Cleaner; 4 x dual element air cleaners with service indicator.

CONTROL PANELS

EMCP4.2 controls including:

Emergency stop pushbutton.

EMCP4.2 controller including:

24-volt DC operation.

Environmental sealed front face.

Text alarm/event descriptions.

Warning/shutdown with common LED indication of shutdowns with indicating lights for:

Low oil pressure.

High coolant temperature.

Overspeed.

Emergency stop.

Failure to start (overcrank).

Low coolant level

Generator mounted - rear facing.

Controls:

Speed adjust.

Auto/start/stop control.

Engine cool-down timer.

Engine cycle crank.

Alarm acknowledge.

Lamp test True RMS AC metering, 3-phase, +/-2% accuracy.

Digital indication for:

-RPM.

-DC volts.

-Operating hours.

-Oil pressure (psi, kPa or bar).

-Coolant temperature.

-Volts (L-L & L-N), frequency (Hz).

-Amps (per phase & average).

CRITICAL NOTE:

ALL descriptions within this Attachment #3 are based on the prior comments of a separate VA facility. This equipment was not used at the prior facility, and all descriptions of operations included within Attachment #3 must be modified to perform as required for this location, in accordance with the emergency generator expected operational scheme.

This Attachment #3 provides the original construction details of the two (2) Generators which are not to be utilized for this project.

15 Middle Avenue • Holtsville, NY 11742 • (631) 654-4436 • FAX (631) 654-4480

-4 programmable digital inputs.

-4 programmable digital outputs.

Voltage Raise/Lower Switch – LV Raise/lower switch installed for both voltage adjust and VAR/PF adjust.

1st Local NFPA Annunciator - Provides 16 point/32 light annunciator, accessory, RS485 data link. With NFPA99-110/CSA label

Remote Annunciator Provides 2 x 16 point/32 light annunciator, RS485, shipped loose with label kit

Spare Discrete I/O Package Provides 12 digital inputs and 8 form “C” relay outputs for customer use.

COOLING SYSTEM

SCAC cooling.

JW Inlet: 6" ANSI / JW Outlet: 6" ANSI.

AC Inlet: 6" ANSI / AC Outlet: 3-1/2" ANSI.

Coolant Sensor - (2 x shipped loose: 1/4-18 and 1/2-14 NPTF).

EXHAUST SYSTEM

Dry Exhaust Manifold Bolted Flange (ANSI 6" & DIN 150) with bellow for each turbo (Qty 4)

FUEL SYSTEM

Primary Fuel Filter w/ Fuel Water Separator

10 Micron Spin On Type 3 filters, shipped loose

Secondary / tertiary fuel filters 4 Micron Spin On Type Engine Mounted - 3 Filters

GENERATORS AND GENERATOR ATTACHMENTS

3 Phase Brushless, Salient Pole.

6 lead IEC Platinum Stator RTDs (.00385 Temp coefficient) Caterpillar's Digital Voltage Regulator (CDVR).

-CDVR includes Reactive droop capability, 3-Phase voltage sensing, KVAR/PF modes, RFI suppression, min/max exciter limiter and exciter diode monitor.

1800 Frame Generators

Form Wound Permanent Magnet

NEMA Class H insulation, 125C temperature rise of 40C ambient Bus bar connections, top/center mounted, top cable entry

NEMA standard hole pattern.

Space Heater Kit

Provides heating for condensation control.

GOVERNING SYSTEM

ADEM A4

Redundant Shutdown (Overspeed protection through a duplicate speed sensing system)

LUBE SYSTEM

Lubricating oil.

Gear type lube oil pump.

Integral lube oil cooler.

Oil filter, filler and dipstick.

Oil drain lines and valve.

Fumes disposal.

Standard sump oil pan – provides oil pan for 600- hour oil change interval.

Filter Group – Primary Oil - Three-element canister filter system.

Electric Prelube pump – 24VDC, Installed.

MOUNTING SYSTEM

Rails - Engine/Generator Rubber anti-vibration mounts (shipped loose).

CRANKCASE SYSTEMS

Explosion Relief Valve

STARTING/CHARGING SYSTEM

Redundant (LH and RH Mounted) Dual 24-volt 50MT electric starting motors. Battery disconnect switch Charging Alternator, 24V, 75A Jacket Water heater – single with pump. 240V, single phase 9kw

GENERAL

- Paint: Caterpillar Yellow with high gloss black rails & radiator.

- Flywheel and flywheel housing-SAE No.00

- SAE Standard Rotation.

WARRANTY

- Caterpillar Standard 2 year warranty

SECTION 2: Axis

NEUTRAL GROUNDING RESISTOR:

- Rating: Voltage (line-to line/line-to-Neutral): 4160/2400V

- Current: 400A

- Resistance (@25C): 65

- Maximum Duty/Temperature Rise: 10 seconds / 760 degrees C

- Resistor Element: Stainless Steel Grid

- Enclosure Finish: 304 Stainless Steel

- Type: 3R, Outdoor

- Cable Entry: Neutral and Ground: Top Mounted porcelain Bushing

- 5kV (Class T100) Current Transformer

- Manufactured and tested per IEEE Std. 32

5kV BREAKER CUBICLE

Metal-Clad Switchgear per ANSI C37.20.2 1200A, 5kV, 3Ø3W, 60Hz, 60kV BIL, 350MVA, NEMA-1

Item Qty Description Type Manufacturer

1.1 1 Metal-Clad Switchgear Enclosure 1200A, 3Ø3W Copper Bus, 60kV BIL Insulated (3M BBI Heat Shrink)

NEMA-1

PCI

1.2 2 Lug Landing 600A, 3Ø3W Copper Bus, 60kV BIL Insulated (3M BBI Heat Shrink)

PCI

1.3 1 Vacuum Circuit Breaker 5kV, 1200A, 3-Pole, 25kAIC, 5-Cycle Motor: 120VAC Close: 120VAC Trip: 48VDC (or 24VDC) UL Labeled

VCP-TR Cutler-Hammer

1.4 2 Potential Transformer 4200:120V Ratio, 75kV BIL, 1500VA with (2) Primary Fuse

Type VIZ-75 ABB

1.5 1 PT Secondary Fused Disconnect with Fuses

Mersen

1.6 3 Current Transformer 600:5A Ratio, Relay Class C100

Type SCV ABB

1.7 1 Shorting Type Terminal Block 4-Point with Short Circuit Strip

Bussmann

1.8 1 Test Switch FT-1 ABB

1.9 1 Generator Management Relay

489-P5-HI-A20-E

SR-489 GE Multilin

1.10 10 Terminal Block / 12-Point Bussmann

1.11 2 Breaker Control Fused Disconnect with Fuses

Ferraz Shawmut

1.12 1 Breaker Control Switch 3-Position with Spring Return Pistol Grip Handle Escutcheon Plate with Target

Series 24 2438D

Electroswitch

1.13 1 Green Indicating Light - LED RPLH22 LEDTronic

1.14 1 Red Indicating Light - LED RPLH22 LEDTronic

1.15 1 Amber Indicating Light – LED RPLH22 LEDTronic

1.16 6 Nameplate PCI

DIESEL GENERATOR SET

Image shown may not reflect actual package

Prime 2825 ekW 3531 kVA 60 Hz 1800 rpm 4160 Volts Caterpillar® is leading the power generation market place with power solutions engineered to deliver unmatched performance, reliability, durability and cost-effectiveness.

FEATURES

EMISSIONS / FUEL STRATEGY

• EPA Tier 2

DESIGN CRITERIA

• The generator set accepts 100% rated load in one step per NFPA 110 and meets ISO 8528-5 transient response.

FULL RANGE OF ATTACHMENTS

• Wide range of bolt-on attachments, factory designed and tested

• Flexible packaging options for easy and cost effective installation

SINGLE SOURCE SUPPLIER

• Fully prototype tested with field validation

WORLDWIDE PRODUCT SUPPORT

• Caterpillar® dealers provide extensive post-sale support including maintenance and repair agreements

• Caterpillar dealers have over 1,600 dealer branch stores operating in 200 countries

• CAT SOSSM program cost effectively detects internal engine component condition, even the presence of unwanted fluids and combustion by-products

CAT C175-16 DIESEL ENGINE

• Reliable and durable

• Four-stroke diesel engine combines superior performance with excellent fuel economy

• Advanced electronic engine control

• Low installation and operating cost

CAT SR5 GENERATOR

• Designed to match performance and output characteristics of Caterpillar diesel engines

• Industry leading mechanical and electrical design

• Industry leading motor starting capabilities

• High efficiency

CAT EMCP4 CONTROL PANELS

• Simple user friendly interface and navigation

• Scalable system to meet a wide range of customer needs

• Integrated Control System and Communications Gateway

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Prime 2825 ekW 3531 kVA 60 Hz 1800 RPM 4160V

Factory Installed Standard & Optional Equipment

System Standard Optional

Air Inlet

• Air cleaner; 4 x single element canister with service indicator(s)

• Plug group for air inlet shut-off

• Air cleaner; 4 x dual element with service indicator(s)

• Air inlet adapters

Control Panel

• EMCP 4.2

• Local & remote annunciator modules

• Discrete I/O module

• Generator temperature monitoring & protection

• Remote monitoring

• Load share module

Cooling

• SCAC cooling

• Jacket water and AC inlet / outlet flanges

• Remote horizontal SCAC radiator

• Remote fuel cooler

• Low coolant level sensor (for remote radiators)

Exhaust

• Dry exhaust manifold

• Bolted flange (ANSI 6" & DIN 150) with bellow for each turbo (qty 4)

• Engine Exhaust Temperature Module

• Mufflers (15dBA, 25dBA, or 40dBA)

• 20" vertical exhaust collector

• Weld flange ANSI 20"

Fuel

• Primary fuel filter with water separator

• Secondary/ tertiary fuel filters (engine mounted)

Generator

• SR5 generator

- 3 phase brushless, salient pole

- IEC platinum stator RTDs

- Cat Digital Voltage Regulator (CDVR)

• Space heater kit

• Oversized generators

• Power connection arrangement

Governor

• ADEM™ A4 • Redundant shutdown

Lubrication

• Lubricating oil

• Oil filter, filler and dipstick

• Oil drain line with valves

• Fumes disposal

• Gear type lube oil pump

• Integral lube oil cooler

• Electric prelube pump

Mounting

• Rails-engine / generator

• Rubber anti-vibration mounts (shipped loose)

• Spring type linear vibration isolators

• IBC vibration isolators

Starting / Charging

• Dual 24 volt electric starting motors

• Batteries with rack and cables

• Battery disconnect switch

• Oversized battery set

• 75 amp charging alternator

• Battery chargers (20 amp)

• Jacket water heater

• Ether starting aid

Crankcase Systems

• Open crankcase ventilation • Crankcase explosion relief valve

Circuit Breakers

( No set mounted circuit breakers available on medium or high voltage packages)

General

• RH service (Except LH Service Oil Filter)

• SAE standard rotation

• Paint - Caterpillar yellow with high gloss black rails

• Flywheel and flywheel housing - SAE N0. 00

• Barring group- manual or air powered

• Factory test reports

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CAT C175 ENGINE

Engine C175 Number of cylinders 16 Cycle Four stroke Cooling Water Bore 175 mm 6.89 inches Stroke 220 mm 8.66 inches Displacement 84.67 L 5166.63 in3

Compression ratio 15.3:1 Aspiration TA Cooling type SCAC Fuel system Common Rail Governor type ADEMTM A4

CAT SR5 GENERATOR

Frame 1848 Insulation class (UL1446 recognized) H

125 oCTemperature rise @ 40C ambient Winding type Form Winding connection Star (wye) Winding pitch 0.6667 Excitation PM Motor starting capability @30% voltage dip and 0.4 pf (skVA) 7949 skVA Number of poles 4 Number of bearings 2 Number of leads 6 Number of phases 3 IP rating IP23 Overspeed capability - % of rated 125% Wave form deviation Less than 3% Telephone Influence Factor (TIF) Less than 50 Harmonic distortion Less than 5% Heat rejection to atmosphere 108.5 kW

CAT CDVR VOLTAGE REGULATOR

Caterpillar Digital Voltage Regulator (CDVR) Microprocessor based VAR/PF control RFI suppression Minimum / maximum excitation limiter Exciter diode monitor Direct 3 phase sensing with selectable volts/Hz Communicates with EMCP3 Programmable operating characteristics Compatible with SE, PM and IE excitation Voltage regulation steady state less than +/- 0.25%

TECHNICAL DATA

Tier 2 Generator Set Package Performance Units Generator set power rating @ 0.8 pf 3531 kVA Generator set power rating with fan * 2825 ekW Generator set rated voltage 4160 Volts Generator set rated current @0.8 pf (Amps) 490.1 Amps Air Inlet Combustion air inlet flow rate 247 m3/min 8723.9 cfm Cooling System Coolant to aftercooler temp max 48°C at 30°C ambient 118°F at 86°F ambient

Emissions (Nominal1) NOx+ HC 5.32 g/bhp-hr CO 0.73 g/bhp-hr HC 0.14 g/bhp-hr PM 0.06 g/bhp-hr Exhaust System Exhaust stack gas temperature 456.7°C 854°F Exhaust gas flow rate (Wet) 627.7 m3/min 22,165.8 cfm Exhaust system backpressure (max. allowable) 6.7 kPA 26.9 in water Exhaust flange size (internal diameter) 150 mm 6 inches Fuel Consumption 100% Load with fan 715.4 L/hr 189.0 Gal/hr 75% Load with fan 561.4 L/hr 148.3 Gal/hr 50% Load with fan 445.9 L/hr 117.8 Gal/hr Heat Rejection Heat rejection to coolant (total) 1,235.1 kW 70,299.0 Btu/min Heat rejection to exhaust (total) 2,736.2 kW 155,744.0 Btu/min

384.5 kW 21,883.0 Btu/min Heat rejection to aftercooler (Stage 2) Heat rejection to atmosphere from engine 256.9 kW 14,620.0 Btu/min

108.5 kW 6175.8 Btu/min Heat rejection to atmosphere from generator Lube System Sump refill with filter 540 L 142.6 Gal

* The generator set package is not offered with an engine driven radiator. The addition of an engine driven fan will reduce the output below the nameplate rating.

1. Emissions data measurement procedures are consistent with those described in EPA CFR 40 Part 89, Subpart D & E and ISO8178-1 for measuring HC, CO, PM, NOx. Data shown is based on steady state operating conditions of 77°F, 28.42 in HG and number 2 diesel fuel with 35° API and LHV of 18,390 btu/lb. The nominal emissions data shown is subject to instrumentation, measurement, facility and engine to engine variations.

Emissions data is based on 100% load and thus cannot be used to compare to EPA regulations which use values based on a weighted cycle.

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Weatogue, CT 06089

January 6, 2010

Subject: Prime Rating for VA Hospital

To Whom It May Concern:, The purpose of this letter is to confirm the prime power +10% rating of 2800kW with fan for the Manhattan VA Hospital.

Engine Model: C175-16 EPA Tier 2 Ambient Temperature: 40 deg C Engine Speed: 1800 rpm Compression Ratio: 15.3:1 JW Temp out: 99 deg C AC Temp in: 46 deg C Engine Prime Rating: 3047 bkW @ 1800 rpm Generator Efficiency: 96% Package w/o Fan Rating: 3047 bkW x .96 = 2925 ekW Package Prime Rating: 2800 ekW with fan (includes 125kW for fan)

Performance is based on SAE J1995 Jan90 and ISO 3046 @100kPA (99kPA dry) and 25C air.

Fuel std of 35 API, @16C having a LHV of 42,780 kj/kg used at 29C with a density of 838.9 g/L.

If you have any other questions or needs, please don’t hesitate to contact me.

Sincerely, Benjamin R. Mathews Caterpillar Electric Power (860)658-3415

Reference Number: DM8706

Systems Data October 26, 2016 For Help Desk Phone Numbers Click Here

AIR INTAKE SYSTEM

THE INSTALLED SYSTEM MUST COMPLY WITH THE SYSTEM LIMITS BELOW FOR ALL EMISSIONS CERTIFIED

ENGINES TO ASSURE REGULATORY COMPLIANCE.

MAXIMUM ALLOWABLE INTAKE RESTRICTION WITH CLEAN

ELEMENT 15 IN-H20

MAXIMUM ALLOWABLE INTAKE RESTRICTION WITH DIRTY

ELEMENT 20 IN-H20

COOLING SYSTEM

ENGINE ONLY COOLANT CAPACITY 80.2 GAL

REGULATOR LOCATION FOR JW (HT) CIRCUIT INLET

MAXIMUM UNINTERRUPTED FILL RATE 5.0 G/MIN

ENGINE SPEC SYSTEM

CYLINDER ARRANGEMENT VEE

NUMBER OF CYLINDERS 16

CYLINDER BORE DIAMETER 6.9 IN

PISTON STROKE 8.7 IN

TOTAL CYLINDER DISPLACEMENT 5167 CU IN

STANDARD CRANKSHAFT ROTATION FROM FLYWHEEL END CCW

STANDARD CYLINDER FIRING ORDER

1-2-5-6-13- 14-9-10-15- 16-11-12-3- 4-7-8

NUMBER 1 CYLINDER LOCATION RIGHT

FRONT

STROKES/COMBUSTION CYCLE 4

EXHAUST SYSTEM

THE INSTALLED SYSTEM MUST COMPLY WITH THE SYSTEM LIMITS BELOW FOR ALL EMISSIONS CERTIFIED

ENGINES TO ASSURE REGULATORY COMPLIANCE.

MAXIMUM ALLOWABLE SYSTEM BACK PRESSURE 27 IN-H20

MANIFOLD TYPE DRY

FUEL SYSTEM

MAXIMUM FUEL FLOW FROM TRANSFER PUMP TO ENGINE 570.6 G/HR

MAXIMUM ALLOWABLE FUEL SUPPLY LINE RESTRICTION 3.0 IN-HG

MAXIMUM ALLOWABLE FUEL TEMPERATURE AT TRANSFER PUMP

INLET 158 DEG F

MAXIMUM FUEL FLOW TO RETURN LINE FROM ENGINE 546.8 G/HR

MAXIMUM ALLOWABLE FUEL RETURN LINE RESTRICTION 17.7 IN-HG

NORMAL FUEL PRESSURE IN A CLEAN SYSTEM 94.3 PSI

FUEL SYSTEM TYPE CR

Page 1 of 2Systems Data

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MAXIMUM TRANSFER PUMP PRIMING LIFT WITHOUT PRIMING

PUMP 5.9 FT

MINIMUM FUEL PRESSURE TO ENGINE -1.5 PSI

MAXIMUM FUEL PRESSURE TO ENGINE (SUPPLY SIDE) 10.0 PSI

MAXIMUM HEAT REJECTION TO FUEL 125 BTU/MIN

LUBE SYSTEM

LUBE SYSTEM OIL COOLER TYPE BUNDLE

CRANKCASE VENTILATION TYPE TO ATM

MOUNTING SYSTEM

DRY WEIGHT - ENGINE ONLY (REFERENCE VALUE) 25006 LB

STARTING SYSTEM

MINIMUM CRANKING SPEED REQUIRED FOR START-RPM 100

Page 2 of 2Systems Data

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GENERATOR DATA NOVEMBER 14, 2016

For Help Desk Phone Numbers Click here

Selected Model Engine: C175-16 Generator Frame: 1848 Genset Rating (kW): 2825.0 Line Voltage: 4160 Fuel: Diesel Generator Arrangement: 3723062 Genset Rating (kVA): 3531.0 Phase Voltage: 2402 Frequency: 60 Excitation Type: Permanent Magnet Pwr. Factor: 0.8 Rated Current: 490.1 Duty: PRIME Connection: SERIES STAR Application: EPG Status: Current

Version:

41205 /40749 /40688 /9423

Spec Information Generator Specification

Frame: 1848 Type: SR5 No. of Bearings: 2 Winding Type: FORM WOUND Flywheel: 21.0 Connection: SERIES STAR Housing: 00 Phases: 3 No. of Leads: 6 Poles: 4 Wires per Lead: 1 Sync Speed: 1800 Generator Pitch: 0.6667

Generator Efficiency Per Unit Load kW Efficiency %

0.25 706.3 93.3

0.5 1412.5 95.8

0.75 2118.8 96.4

1.0 2825.0 96.5

1.1 3107.5 96.4

Reactances Per Unit Ohms SUBTRANSIENT - DIRECT AXIS X''d 0.1326 0.6499 SUBTRANSIENT - QUADRATURE AXIS X''q 0.1289 0.6316 TRANSIENT - SATURATED X'd 0.1984 0.9723 SYNCHRONOUS - DIRECT AXIS Xd 3.1234 15.3070 SYNCHRONOUS - QUADRATURE AXIS Xq 1.3848 6.7866

NEGATIVE SEQUENCE X2 0.1308 0.6408

ZERO SEQUENCE X0 0.0098 0.0479

Time Constants Seconds OPEN CIRCUIT TRANSIENT - DIRECT AXIS T'd0 5.3120 SHORT CIRCUIT TRANSIENT - DIRECT AXIS T'd 0.3374 OPEN CIRCUIT SUBSTRANSIENT - DIRECT AXIS T''d0 0.0079 SHORT CIRCUIT SUBSTRANSIENT - DIRECT AXIS T''d 0.0069 OPEN CIRCUIT SUBSTRANSIENT - QUADRATURE AXIS T''q0 0.0073 SHORT CIRCUIT SUBSTRANSIENT - QUADRATURE AXIS T''q 0.0064 EXCITER TIME CONSTANT Te 0.2230 ARMATURE SHORT CIRCUIT Ta 0.0536

Short Circuit Ratio: 0.4 Stator Resistance = 0.0547 Ohms Field Resistance = 1.106 Ohms

Voltage Regulation Voltage level adjustment: +/- 5.0% Voltage regulation, steady state: +/- 0.5% Voltage regulation with 3% speed change: +/- 0.5% Waveform deviation line - line, no load: less than 3.0% Telephone influence factor: less than 50

Generator Excitation No Load Full Load, (rated) pf

Series Parallel Excitation voltage: 10.53 Volts 53.44 Volts Volts Excitation current 0.97 Amps 4.04 Amps Amps

Page 1 of 7Caterpillar Generator Data

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Selected Model Engine: C175-16 Generator Frame: 1848 Genset Rating (kW): 2825.0 Line Voltage: 4160 Fuel: Diesel Generator Arrangement: 3723062 Genset Rating (kVA): 3531.0 Phase Voltage: 2402 Frequency: 60 Excitation Type: Permanent Magnet Pwr. Factor: 0.8 Rated Current: 490.1 Duty: PRIME Connection: SERIES STAR Application: EPG Status: Current

Version:

41205 /40749 /40688 /9423

Generator Mechanical Information Center of Gravity

Dimension X -1193.8 mm -47.0 IN.

Dimension Y 0.0 mm 0.0 IN.

Dimension Z 0.0 mm 0.0 IN.

• "X" is measured from driven end of generator and parallel to rotor.

Towards engine fan is positive. See General Information for details

• "Y" is measured vertically from rotor center line. Up is positive.

• "Z" is measured to left and right of rotor center line. To the right is positive.

Generator WT = 5593 kg * Rotor WT = 2059 kg * Stator WT = 2850 kg

12,330 LB 4,539 LB 6,283 LB

Rotor Balance = 0.0508 mm deflection PTP Overspeed Capacity = 125% of synchronous speed

Generator Torsional Data

J1 = Coupling and Fan

J2 = Rotor

TOTAL J = J1 + J2 + J3

J3 = Exciter End

K1 = Shaft Stiffness between J1 + J2 (Diameter 1)

K2 = Shaft Stiffness between J2 + J3 (Diameter 2)

J1 K1 Min Shaft Dia 1 J2 K2 Min Shaft Dia 2 J3

30.1 LB IN. s2 60.3 MLB IN./rad 5.0 IN. 651.6 LB IN. s2 57.6 MLB IN./rad 3.8 IN. 3.8 LB IN. s2

3.397 N m s2 6.81 MN m/rad 127.0 mm 73.62 N m s2 6.51 MN m/rad 96.5 mm 0.43 N m s2

Total J

685.5 LB IN. s2

77.447 N m s2

Selected Model Engine: C175-16 Generator Frame: 1848 Genset Rating (kW): 2825.0 Line Voltage: 4160 Fuel: Diesel Generator Arrangement: 3723062 Genset Rating (kVA): 3531.0 Phase Voltage: 2402 Frequency: 60 Excitation Type: Permanent Magnet Pwr. Factor: 0.8 Rated Current: 490.1 Duty: PRIME Connection: SERIES STAR Application: EPG Status: Current

Version:

41205 /40749 /40688 /9423

Page 2 of 7Caterpillar Generator Data

Generator Cooling Requirements - Temperature - Insulation Data

Cooling Requirements: Temperature Data: (Ambient 40 0C) Heat Dissipated: 102.5 kW Stator Rise: 125.0 0C Air Flow: 271.8 m3/min Rotor Rise: 125.0 0C

Insulation Class: H Insulation Reg. as shipped: 100.0 MΩ minimum at 40 0C

Thermal Limits of Generator Frequency: 60 Hz Line to Line Voltage: 4160 Volts B BR 80/40 3000.0 kVA F BR -105/40 3438.0 kVA H BR - 125/40 3750.0 kVA F PR - 130/40 3750.0 kVA H PR - 150/40 4063.0 kVA

Selected Model Engine: C175-16 Generator Frame: 1848 Genset Rating (kW): 2825.0 Line Voltage: 4160 Fuel: Diesel Generator Arrangement: 3723062 Genset Rating (kVA): 3531.0 Phase Voltage: 2402 Frequency: 60 Excitation Type: Permanent Magnet Pwr. Factor: 0.8 Rated Current: 490.1 Duty: PRIME Connection: SERIES STAR Application: EPG Status: Current

Version:

41205 /40749 /40688 /9423

Starting Capability & Current Decrement Motor Starting Capability (0.4 pf)

SKVA Percent Volt Dip

476 2.5 976 5.0

1,504 7.5 2,061 10.0 2,650 12.5 3,273 15.0 3,934 17.5 4,637 20.0 5,385 22.5 6,182 25.0 7,035 27.5 7,949 30.0 8,930 32.5 9,987 35.0

11,128 37.5 12,365 40.0

Page 3 of 7Caterpillar Generator Data

Current Decrement Data E Time Cycle AMP

0.0 3,665

1.0 2,470

2.0 2,266

3.0 2,158

4.0 2,062

5.0 1,972

7.5 1,766

10.0 1,583

12.5 1,422

15.0 1,279

20.0 1,042

25.0 1,076

30.0 1,186

35.0 1,291

40.0 1,380

45.0 1,456

Instantaneous 3 Phase Fault Current: 3665 Amps Instantaneous Line - Line Fault Current: 3196 Amps Instantaneous Line - Neutral Fault Current: 5338 Amps

Selected Model Engine: C175-16 Generator Frame: 1848 Genset Rating (kW): 2825.0 Line Voltage: 4160 Fuel: Diesel Generator Arrangement: 3723062 Genset Rating (kVA): 3531.0 Phase Voltage: 2402 Frequency: 60 Excitation Type: Permanent Magnet Pwr. Factor: 0.8 Rated Current: 490.1 Duty: PRIME Connection: SERIES STAR Application: EPG Status: Current

Version:

41205 /40749 /40688 /9423

Generator Output Characteristic Curves Open Circuit Curve

Field Current

Line - Line Volt

0.0 0

13.0 2,496

15.3 2,912

17.9 3,328

21.1 3,744

25.8 4,160

34.2 4,576

51.5 4,992

90.0 5,408

179.7 5,824

Page 4 of 7Caterpillar Generator Data

Short Circuit Curve

Field Current

Armature Current

0.0 0

38.6 294

45.1 343

51.5 392

58.0 441

64.4 490

70.8 539

77.3 588

83.7 637

90.1 686

Selected Model Engine: C175-16 Generator Frame: 1848 Genset Rating (kW): 2825.0 Line Voltage: 4160 Fuel: Diesel Generator Arrangement: 3723062 Genset Rating (kVA): 3531.0 Phase Voltage: 2402 Frequency: 60 Excitation Type: Permanent Magnet Pwr. Factor: 0.8 Rated Current: 490.1 Duty: PRIME Connection: SERIES STAR Application: EPG Status: Current

Version:

41205 /40749 /40688 /9423

Generator Output Characteristic Curves Zero Power Factor Curve

Field Current

Line - Line Volt

64.4 0

79.7 2,080

82.5 2,496

86.0 2,912

91.4 3,328

101.4 3,744

122.4 4,160

169.9 4,576

281.6 4,992

547.6 5,408

Page 5 of 7Caterpillar Generator Data

Air Gap Curve

Field Current

Line - Line Volt

0.0 0

12.8 2,496

15.0 2,912

17.1 3,328

19.2 3,744

21.4 4,160

23.5 4,576

25.7 4,992

27.8 5,408

29.9 5,824

Selected Model Engine: C175-16 Generator Frame: 1848 Genset Rating (kW): 2825.0 Line Voltage: 4160 Fuel: Diesel Generator Arrangement: 3723062 Genset Rating (kVA): 3531.0 Phase Voltage: 2402 Frequency: 60 Excitation Type: Permanent Magnet Pwr. Factor: 0.8 Rated Current: 490.1 Duty: PRIME Connection: SERIES STAR Application: EPG Status: Current

Version:

41205 /40749 /40688 /9423

Reactive Capability Curve Click to view Chart

Selected Model Engine: C175-16 Generator Frame: 1848 Genset Rating (kW): 2825.0 Line Voltage: 4160 Fuel: Diesel Generator Arrangement: 3723062 Genset Rating (kVA): 3531.0 Phase Voltage: 2402 Frequency: 60 Excitation Type: Permanent Magnet Pwr. Factor: 0.8 Rated Current: 490.1 Duty: PRIME Connection: SERIES STAR Application: EPG Status: Current

Version:

41205 /40749 /40688 /9423

Page 6 of 7Caterpillar Generator Data

Caterpillar Confidential: Green Content Owner: Commercial Processes Division Web Master(s): PSG Web Based Systems Support Current Date: 11/14/2016 11:29:05 AM © Caterpillar Inc. 2016 All Rights Reserved.

Data Privacy Statement.

General Information DM7825 Caterpillar SR5 Generators (50 Hz, 60 Hz) Data for 1400, 1600, 1700, 1800 and 1900 frames Caterpillar SR5 generators built by Leroy Somer - USA and Leroy Somer France.

Refer to DM7821 for explanation of all generator data in Technical Marketing Information (TMI) except generator efficiency for which the explanation is given below.

GENERATOR EFFICIENCY

Generator efficiency is the percentage of engine flywheel (or other prime mover) power that is converted into electrical output. The generator efficiency shown is calculated by the summation of all losses method, and is determined in accordance with the IEC Standard 60034. The efficiency considers only the generator. There is no consideration of engine or parasitic losses here.

Refer to DM7829 for low and medium voltage protective setting values a nd limits.

Page 7 of 7Caterpillar Generator Data

11/14/2016https://tmiwebclassic.cat.com/tmi/servlet/cat.edis.tmiweb.gui.GeneratorChartServlet?engi...

SR5 GENERATORS

LEHE0290-00

Image shown may not reflect actual product

1800 Frame

Standby Power

50 Hz 2500-3100 kVA 1500 rpm 60 Hz 2500-3100 ekW 1800 rpm

Prime Power

50 Hz 2275-2825 kVA 1500 rpm 60 Hz 2250-2825 ekW 1800 rpm

Continuous Power

50 Hz 2000-2600 kVA 1500 rpm 60 Hz 2050-2600 ekW 1800 rpm

FEATURES

GENERAL

• Standards: meets the requirements of NEMA, IEC, ISO, IEEE, BS, AS

• Industry leading insulation technology

• Proven mechanical and electrical design

• Reliable and durable construction

• Improved excitation system for high power quality

• Improved motor starting capability

• Radio frequency noise suppression better than industry standards

• Superior construction and testing

STANDARD

• 3 phase brushless, salient pole

• NEMA Class H insulation

• Class H temperature rise 40 ° ambient

• 2/3 winding pitch

• Form Wound

• Standard voltages:

60 Hz: 480V, 4160V 50 Hz: 400V, 3300V

• Bus bar connections 60 Hz models: NEMA standard hole pattern 50 Hz models: IEC standard hole pattern

OPTIONAL

• Space heater kit

• Bearing temperature detectors

• Optional voltages:

60 Hz: 380V, 440V, 600V 50 Hz: 380V, and 415V

• Oversized generators for Class F temperature rise

• UL Listing

Rectangle

JuliaD Rectangle

JuliaD Rectangle

KatinaH

Without Fan

SR5 GENERATORS

Information contained in this publication may be considered confidential. Discretion is recommended when distributing.

Materials and specifications are subject to change without notice.

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

www.Cat-ElectricPower.com

©2011 Caterpillar

LEHE0290-00 (03-11) All rights reserved

SPECIFICATIONS

Type……………………..…………Brushless, revolving field solid-state automatic voltage regulator Construction…………..…..……………………Two bearings three phase, series star connected Enclosure…………………………..Drip proof IP23, guarded

Over-speed capability 60 Hz…….………………..….125% of synchronous speed 50 Hz…………………...…….150% of synchronous speed Waveform deviation, line to line, no load……Less than 3% Paralleling capability……………...Standard with adjustable voltage droop sheets provides superior protection between

Voltage level adjustment………………...………….+/- 5.0% Voltage regulator ………..………...… 3-phase sensing with variable Volts-Per-Hertz response

Voltage regulation, steady state……………..……..+/- 0.5% Voltage regulation with 3% speed change……..….+/- 0.5% Voltage gain…….…………....adjustable to compensate for engine speed droop and line loss TIF………………………….………………….…Less than 50 Number of leads………...…………………………..………..6

PRODUCT SUPPORT

● Standard Caterpillar warranty

● Optional extended Caterpillar warranty

● Serviceable parts available through Cat Parts System

● Service intervals agree with recommended engine practices

SERVICEABILITY

● Stator leads exit top

● Replaceable bearing sleeve(s) for longer life and lower repair cost

● Easy access to serviceable parts

● Improved wire and terminal identification ensuring reliable connection

CABLE ENTRY

● Top cable entry on LV package

● Bottom cable entry on MV packages

MAIN STATOR CONSTRUCTION

The 1800 frame generators use Round lamination stator design.

Stator coil pitch, coil distribution designed to produce optimum waveform and minimum total harmonic distortion. Stator slots are insulated by slot liners and coil separators. Slot liners, coil separators, and top sticks provide an adequate distance from the coil to ground.

The thickness of liners, separators, and phase phases and ground.

Low voltage stator windings are given a 3000 volt “high pot” test (150% of the NEMA and IEC requirements for 460 volt generators) before the insulation is applied. The stators are then given a vacuum impregnation treatment of polyester material, followed by an application of epoxy resin. This sealed stator is then given a final 2000 volt “high pot” test.

ROTOR CONSTRUCTION

The main rotor is constructed using a precision “wet” layer winding process with epoxy painted on the bare rotor and on each layer. This ensures bonding of all the wire layers together, bonding of the coils to the rotor laminations, and a sealed insulation system. The rotor is put in the oven for curing the epoxy.

The exciter rotor is machine wound and receives a trickle coat of a fungus-resisting resin.

Numerically controlled turning and grinding machines produce rotor shafts with close repeatable tolerances. Grade-8 bolts are used wherever joints are subject to induced stresses.

A complete coating of red sealer is applied to protect the rotors and shaft from corrosion.

Every production rotor is dynamically balanced in two planes to within 0.0508 mm deflection peak-to-peak amplitude and run at rated speed before assembly into the stator.

D I G I T A L V O L T A G E R E G U L A T O R

W H E R E T H E W O R L D T U R N S F O R P O W E R

FEATURES

● Microprocessor based control featuring choice of three control modes standard:

Automatic Voltage Regulation (AVR) Power Factor Regulation (PF) Reactive Power Regulation (Var)

● Programmable stability settings

● Soft start control with an adjustable time setting in AVR control mode

● Dual Slope Underfrequency (volts/hertz) regulation

● Three-phase or single-phase generator voltage

(RMS) sensing/regulation in AVR mode

● Single-phase generator current sensing for regulation purposes

● Field current and field voltage sensing

● Five contact sensing inputs for system interface

● One common LED for visual indication of

Alarm and Shutdown fault conditions

● Fault Shutdown Driver and Alarm Output

Driver for indication of Alarm and Shutdown fault conditions

● Generator paralleling with reactive droop compensation and reactive differential compensation

● Line drop compensation

● Remote communication interface via CAN 2.0B

● Ten generator protective functions

● UL 508A Recognized and CE certified

WORLDWIDE PRODUCT SUPPORT

● Worldwide parts availability through the Caterpillar dealer network

● Over 1,800 dealer branch stores operating in 166 countries.

● 99.7% of parts orders filled within 24 hours.

The best product support record in the industry.

● Caterpillar dealer service technicians are trained to service every aspect of your electric power generation system.

COMPLETE SYSTEM INTEGRATION

Fully designed and factory tested to work seamlessly with Cat Generator using Shunt, PMG, or AREP excitation systems and EMCP controls.

Caterpillar is leading the power generation marketplace with Power Solutions engineered to deliver unmatched flexibility, expandability, reliability, and cost-effectiveness.

LEHE3225

The Cat Digital Voltage Regulator is a microprocessor based control designed to provide precise voltage control, robust transient response, and generator protection with industry leading features and versatility.

LEHE3225

SPECIFICATIONS

General Specifications

Voltage Regulation ±0.25% no load to full load

Temperature Drift ±1.0% for a 40° C change

Response Time Maximum of 10 milliseconds

Variable Sensing Range 90 to 600 Volts

Control Power 24 Vdc Supply (18 to 30 Vdc, 5VA)

Regulator Filtering THF 3% per IEC34-1 TIF of 50 NEMA MG1-22.43

Harmonic Tolerance 0.5% Voltage regulation with 40% THD

Weight 1.47 kg (3.25 lb)

Environmental

Operating Temperature –40° C to 70° C (–40° F to 158° F)

Storage Temperature –40° C to 85° C (–40° F to 185° F)

Relative Humidity 95% non-condensing 30° C to 60° C

Salt Spray 5% for 48 hrs at 38° C at 115% nominal operating voltage

Vibration 4.5G (peak) 18-2000 Hz in 3 perpendicular planes

Shock 20G

Certifications

CE Approved

UL Recognized

CSA Listed

PROTECTIVE FUNCTIONS

● Generator Overvoltage

● Generator Undervoltage

● Loss of Excitation

● Instantaneous Field Overcurrent

● Over Excitation

● Loss of Sensing

● Diode Fault Monitor

● Internal Watchdog Failure

● Internal Memory Failure

● Fault Reset Closed Too Long

LEHE3225

Programmable Variables Range of Adjustment

Voltage vs Frequency Characteristic Two slope ranges adjustable from 1 to 10 PU in 0.1 increments

Fine Voltage Level –10% to +10% in 0.1% increment

Droop Adjustment 0 to 10% in 0.1% increment

Overvoltage Setpoint 105 to 135% of rated voltage in 1.0% increment Overvoltage Time Delay 2 to 30 seconds in 1 second increments

Undervoltage Setpoint 60 to 95% of rated voltage in 1.0% increment Undervoltage Time Delay 10 to 120 seconds in 1 second increments

Gain 1 to 20% in 0.1% increments

Single Phase or Three Phase Sensing

Under Frequency Point 20 to 40 Hz

Knee Frequency 45 to 65 Hz in 0.1 Hz increments

Minimum Voltage Setpoint 50 to 100% of rated voltage

Var Operating Mode 100% to –100% in 0.001 increments

PF Operating Mode 0.6 lead to 0.6 lag in 0.01 increments

Line Drop (IR) Compensation 0 to 10% in 0.1% increment

Loss of Excitation 0.1 to 1.0 PU leading vars Loss of Excitation Time Delay 0.1 to 9.9 seconds in 0.1 second increments

Over Excitation 0 to 12 Adc in 0.1 Adc increments Time Delay — Fixed Time Option 0 to 10 sec in 0.1 sec increments

Loss of Sensing Time Delay 0 to 25 sec in 1 sec increments

Diode Fault Monitor 1 to 10A rms field ripple current

Soft Start Function 1 to 120 sec

LEHE3225

REGULATION CHARACTERISTIC — FIGURE 1

Underfrequency Point (20-40 Hz)

20 40 60 80 100

% of Nominal Frequency

Generator Output Voltage

Decreasing Slope 1 (1 – 10 V/HZ)

Decreasing Slope 2 (1 –10 V/HZ)

5 Hz (Fixed)

Minimum Voltage Setpoint (50-100%)

Knee Frequency

LEHE3225

OUTLINE DRAWING — FIGURE 2

0.16 (4.06)

0.59 (15.0)

2.81 (71.4)

2.87 (72.9)

5.50 typ.

(139.7)

6.

(1

.1

10.88 (276.4)

7.50 typ.

(190.5)

P6

P12

P9 J4

LEHE3225

EXAMPLE CONNECTION DIAGRAM — FIGURE 3

9 10

7 PMG

CTB

GEN

52 10

FIELD OUTPUT

P6-4 (F2,-) P6-5 (F1,+) P6-1

POWER INPUT

P6-2 P6-3

CURRENT

SENSING

P12-1 P12-2 P12-10

VOLTAGE

SENSING

P12-11 P12-12

P9-6

RAISE/LOWER

INPUTS

P9-4 P9-5

+/-10 VDC

CONTROL INPUT

P12-6 (+) P12-3 (-)

VAR/PF

CONTROL

P9-9

EXCITATION

DISABLE

P9-7

FAULT

RESET

P9-8 P12-4 (-)

ALARM

DRIVER

SHUTDOWN

FAULT DRIVER

P12-9 (+) P12-5 (-)

GROUND

P6-6

24 Vdc

24 Vdc CONTROL

POWER

P12-8 (+) P12-7 (-)

1 52a 2 3 S1

5 5 6

A B C

Required only for Var/PF control. Var/PF is active with 52a closed, inactive with 52a open.

Excitation is disabled when closed, enabled when open.

Momentary closure resets any shutdown fault.

S1 (SPDT, spring -return to center-off position) adjusts regulator setpoint.

Normally-off, turns on for user alarm or trip.

Analog input voltage between -10 and +10 Vdc provides adjustment of operating setpoint.

External fuses should be sized to match the PMG and protect the field. Maximum fuse size should be limited to Bussmann type KTK-12 or equivalent.

Three-phase PMG is shown. For single-phase PMG, omit P6-3 connection.

Sensing potential transformer is required if line voltage exceeds 660 Vac.

Item not supplied by Caterpillar.

When generator rotation is ACB, the connections shown for CTB should be reversed.

ATTACHMENT

Factory Installed

• Complete with hoses, circulating pump, and isolation valves

• Base frame mounting minimizes engine induced vibration

• Automatically disconnected when engine is running via the generator space heater relay

• Supplied with UL recognized components

• Thermostat is factory pre-set to 49°C (120°F)

Improved Performance

• Greater than 30% reduction in power consumption

• Uniform heating over entire cooling system

• Reduced temperature at outlet extends hose and coolant life

• Longer heating element life

JACKET WATER

HEATER

With Circulating Pump

Caterpillar offers a factory-installed jacket water heater for increased cold-starting capability. The system includes heater, isolation valves, circulation pump, hoses and generator space heater relay.

Unit specifications

Design Voltage 220 240

Rating 9 kW 9 kW Frequency 50/60 50/60 Phase 1 1 Amps 41 37 Flow Rate 32LPM 32LPM

(10GPM) (10GPM)

Circulation Pump Rating 96W 96W Control Voltage 24VDC 24VDC Adjustable Thermostat 18.3°- 60°C 65°-140°F (65°-140°F) (65°-140°F) Shipping Weight 31.8kg 31.8 lbs (70lbs) (70lbs) Optional Voltage 208 227

(with 90% heating capacity and ±5% voltage fluctuation)

Jacket Water Heater

50/60 Hz

Heater Design Description The jacket water heater package is designed to efficiently pre-heat the 3500 engine by heating and circulating the engine’s coolant. The forced coolant circulation allows the design to operate at a higher wattage and efficiency than standard thermal siphon tank heaters (tank heaters). This design results in the following benefits:

• Reduction of the maximum coolant temperatures associated with tank heater design.

• Increase life of heater hoses, engine seals, and heating elements.

• Improve heat transfer efficiency from elements to engine coolant.

• More uniform engine temperature distribution.

• Application of a thermostat with a reduced thermal differential.

• Greater than a 50% reduction of the thermostat cycle rate.

• Lower customer utility costs and increased heater reliability.

• Heater thermostat’s setpoint is preset from the factory for maximum operation efficiency.

Heater Operation / Wiring A 10-gallon per minute pump is located at the heater outlet to pull the coolant through the heater. An adjustable thermostat probe is located inside the heater tank near the inlet of the heater and responds to the temperature of the coolant entering the tank. The figure below shows the general heater design.

Overall Heater Layout

2 Page 47 of 327

E N G I N E C O N T R O L L E R

ADEM™ A4 Engine Controller

RELIABLE, DURABLE

All ADEM A4 controllers are designed to survive the harshest environments.

● Environmentally sealed, die-cast aluminum housing isolates and protects electronic components from moisture and dirt contamination.

● Rigorous vibration testing ensures product reliability and durability.

● Accuracy maintained from –40° C to 85° C

● Electrical noise immunity to 100 volts/meter

● Internal circuits are designed to withstand shorts to +battery and –battery.

● Atmosphere cooled

SIMPLE SERVICING

Each ADEM A4 system works in combination with the Caterpillar® ET service tool software to keep the engine operating at peak performance.

● Displays measured parameters

● Retrieves active and logged event code documenting abnormal system operation

● Performs calibrations and diagnostic tests

● Supports flash programming of new software into the ADEM A4 ECM

SELF DIAGNOSTICS

Each ADEM A4 ECM has a full compliment of diagnostics. The ECM can detect faults in the electrical system and report those faults to the service technician for quick repair.

● Self-diagnostic capability pinpoints operational problems in need of attention.

ADVANCED FEATURES

● Isochronous or droop speed control

● Enhanced performance from fuel injection timing and limiting

● Adjustable monitoring of vital engine parameters

● Idle/rated speed setting

● Programmable speed acceleration ramp rate

● Adjustable cooldown duration

● Data link interfaces

● Cat Data link

● CAN J1939

OPTIONAL FEATURES

● Ether control system support

● Remote monitoring and control support

LEHE5347-00

The ADEM™ A4 is the main Electronic Control Module (ECM) used on select diesel engines.

The ADEM A4 is an integral part of the innovative ACERT® Technology that provides higher degree of control over a large number of combustion variables than ever before. The ADEM A4 is designed to control/interface Electronic Unit Injector (EUI) equipped engines. The ADEM A4 engine system is composed of the ADEM A4 ECM, control software, sensors, actuators, fuel injectors, and interface to the generator system. The prime benefit of an ADEM A4 engine system is to better control and maintain the particulate emissions, both steady state and transient, while improving engine performance.

LEHE5347-00 2

DESCRIPTION

The ECM is housed in an environmentally sealed casting. All wiring connections to the ECM are made using two sealed connectors: a single seventy-pin connector and a single one hundred twenty-pin connector.

ENGINE SPEED GOVERNING

Desired engine speed is calculated by the ECM and held within ±0.2 Hz for isochronous and droop mode. The ECM accounts for droop that is requested. The proper amount of fuel is sent to the injectors due to these calculations. The ECM also employs cooldown/shutdown strategies, acceleration delays on startup, acceleration ramp times, speed reference and a low/high idle switch is also available via communications to the EMCP 3.

FUEL LIMITING

Warm and cold fuel-air ratio control limits are controlled by the ECM. Electronic monitoring system derates, torque limit, and cranking limit, programmable torque scaling, and cold cylinder cutout mode are standard features.

FUEL INJECTION TIMING

Master timing for injection is controlled by the ECM control. Temperature dependencies are accounted for in the fuel injection calculations.

ELECTRONIC MONITORING

Electronic monitoring of vital engine parameters can be programmed. Warning, derate, and shutdown event conditions may be customized by the user.

INFORMATION MANAGEMENT

The ECM stores information to assist with electronic troubleshooting. Active and logged diagnostic codes, active events, logged events, fuel consumption, engine hours, and instantaneous totals aid service technicians when diagnosing electronic faults and scheduling preventive maintenance.

CALIBRATIONS

Engine performance is optimized through injection timing. Auto/manual sensor calibrations are standard features.

ON-BOARD SYSTEM TESTS

System tests are available to assist in electronic troubleshooting. These tests include: injector activation, injector cutout, and override of control outputs.

DATA LINK INTERFACES

The ADEM A4 communicates with the EMCP 3 via the J1939 Communication network. Additionally, the ADEM A4 can communicate with the Cat ET electronic service tool and the PL1000E, PL1000T.

ELECTRONIC SENSING

The following sensing is available on the ADEM A4: oil pressure, fuel pressure, fuel temperature, atmospheric pressure, air inlet temperature, turbo outlet pressure, engine coolant temperature, engine speed, throttle, position, exhaust temperature, engine control switch position, oil filter pressure differential, fuel filter pressure differential, air filter pressure differential, crankcase pressure, and remote e-stop switch position.

LEHE5347-00 3

Humidity tolerance 0 to 90% relative humidity over operating temperature range

Impervious to:

salt spray, fuel, oil and oil additives, coolant, spray cleaners, chlorinated solvents, hydrogen sulfide and methane gas, and dust

Input and output protection all inputs and outputs are protected against short circuits to +battery and –battery

Input voltage range (24 VDC nominal) 18 to 32 VDC

Mounting engine mounted

Reverse polarity protected

Shock, withstands 20 g

Temperature range Operating: –40° C to 85° C (–40° F to 185° F) Storage: –50° C to 120° C (–58° F to 248° F)

Vibration withstands 8.0 g @ 24 to 2 kHz

Information contained in this publication may be considered confidential.

Discretion is recommended when distributing. www.cat-ElectricPower.com

Materials and specifications are subject to change without notice.

CAT, CATERPILLAR, their respective logos, ADEM, ACERT © 2005 Caterpillar

LEHE5347-00 (08-05) and “Caterpillar Yellow,” as well as corporate and produc tidentity used All Rights Reserved.

herein, are trademarks of Caterpillar and may not be used without permission. Printed in U.S.A.

This page intentionally left blank.

50/60 Hz

Adjustable Thermostat Setpoint

Due to the high amperage associated with the 9kW heater, the thermostat is wired such that it opens and closes a contactor that controls the heating elements.

To maintain uniform engine temperature while the engine is not operating, the system pump requires either a 220 or a 240 VAC supply and must run continuously independent of heater thermostat.

The pump and heating elements are de-energized whenever the engine starts. The 220V heater can run at 208V with 90% of the full heating capability, and the 240V heater can run at 227V with 90% of the full heating capability.

The figures below show the wiring diagram for the engine jacket water heater systems.

Wiring Diagram

3 Page 52 of 327

50/60 Hz

Jacket Water Heater Group General Dimension

Drawing Reference No.: 235-1224, 237-2236 www.CAT-ElectricPower.com Unless otherwise specified; all dimensions are for reference. © 2003 Caterpillar U.S. sourced All rights reserved Printed in U.S.A.

Materials and specifications are subject to change without notice.

LEHE3122-01 (7-03) The International System of Units (SI) is used in this publication.

4 Page 53 of 327

EMCP 4

LEHE0138-00

EMCP 4.2

GENERATOR SET

CONTROLLER

Caterpillar is leading the power generation market place with power solutions engineered to deliver unmatched performance, reliability, durability and cost-effectiveness.

GENERAL DESCRIPTION

The Cat® EMCP 4.2 offers fully featured power metering, protective relaying and engine and generator control and monitoring. Engine and generator controls, diagnostics, and operating information are accessible via the control panel keypads; diagnostics from the EMCP 4 optional modules can be viewed and reset through the EMCP 4.2.

FULL RANGE OF ATTACHMENTS

• Wide range of system expansion attachments, designed specifically to work with the EMCP 4.

• Flexible packaging options for easy and cost effective installation.

WORLD WIDE PRODUCT SUPPORT

• Cat dealers provide extensive pre and post sale support.

• Cat dealers have over 1,600 dealer branch stores operating in 200 countries.

FEATURES

• A 33 x 132 pixel, 3.8 inch, graphical display denotes text alarm/event descriptions, set points, engine and generator monitoring, and is visible in all lighting conditions.

• Textual display with support for 28 languages, including character languages such as Arabic, Chinese, and Japanese.

• Advanced engine monitoring is available on systems with an electronic engine control module.

• Integration with the Cat Digital Voltage Regulator (CDVR) provides enhanced system performance.

• Fully featured power metering, protective relaying, engine and generator parameter viewing, and expanded AC metering are all integrated into this controller.

• Real-time clock allows for date and time stamping of diagnostics and events in the control’s logs as well as service maintenance reminders based on engine operating hours or calendar days.

• Up to 40 diagnostic events are stored in the non-volatile memory.

Image shown may not reflect actual package

• Ability to view and reset diagnostics on EMCP 4 optional modules via the control panel removes the need for a separate service tool for troubleshooting.

• Set points and software stored in non-volatile memory, preventing loss during a power outage.

• Reduced power mode offers a low power state to minimize battery power requirements.

• Three levels of security allow for configurable operator privileges.

• Selectable units

− Temperature: °C or °F − Pressure: psi, kPa, bar − Fuel Consumption: Gal/hr or Liter/hr

STANDARDS

• UL Recognized

• CSA C22.2 No.100,14, 94

• Complies with all necessary standards for CE Certification 98/37/EC Machinery Directive

– BS EN 60204-1 Safety of Machinery 89/336/EEC EMC Directive

– BS EN 50081-1 Emissions Standard

– BS EN 50082-2 Immunity Standard 73/23/EEC Low Voltage Directive

– EN 50178 LVD Standard

• IEC529, IEC60034-5, IEC61131-3

• MIL STND 461

EMCP 4.2 GENERATOR SET CONTROLLER

LEHE0138-00 2

STANDARD FEATURES

Generator Monitoring

• Voltage (L-L, L-N)

• Current (Phase)

• Average Volt, Amp, Frequency

• kW, kVAr, kVA (Average, Phase, %)

• Power Factor (Average, Phase)

• kW-hr, kVAr-hr (total)

• Excitation voltage and current (with CDVR)

• Generator stator and bearing temp (with optional module)

Generator Protection

• Generator phase sequence

• Over/Under voltage (27/59)

• Over/Under frequency (81 O/U)

• Reverse Power (kW) (32)

• Reverse Reactive Power (kVAr) (32RV)

• Overcurrent (50/51)

Engine Monitoring

• Coolant temperature

• Oil pressure

• Engine speed (RPM)

• Battery voltage

• Run hours

• Crank attempt and successful start counter

• Enhanced engine monitoring (with electronic engines)

Engine Protection

• Control switch not in auto (alarm)

• High coolant temp (alarm and shutdown)

• Low coolant temp (alarm)

• Low coolant level (alarm)

• High engine oil temp (alarm and shutdown)

• Low, high, and weak battery voltage

• Overspeed

• Overcrank

Control

• Run / Auto / Stop control

• Speed and voltage adjust

• Local and remote emergency stop

• Remote start/stop

• Cycle crank

Inputs & Outputs

• Two dedicated digital inputs

• Six programmable digital inputs

• Six programmable form A dry contacts

• Two programmable form C dry contacts

• Two digital outputs

Communications

• Primary and accessory CAN data links

• RS-485 annunciator data link

• Modbus RTU (RS-485 Half duplex)

Language Support

Arabic, Bulgarian, Chinese, Czech, Danish, Dutch, English, Estonian, Finnish, French, German, Greek, Hungarian, Icelandic, Italian, Latvian, Lithuanian, Japanese, Norwegian, Polish, Portuguese, Romanian, Russian, Slovak, Slovene, Spanish, Swedish, Turkish

Environmental

• Control module operating temperature: -40°C to 70°C

• Display operating temperature: -20°C to 70°C

• Humidity: 100% condensing 30°C to 60°C

• Storage temperature: -40°C to 85°C

• Vibration: Random profile, 24-1000 Hz, 4.3G rms

LEHE0138-00 3

OPTIONAL MODULES

CAN ANNUNCIATOR

The EMCP 4 CAN Annunciator serves to…