09 Lesson 04

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1
EP Basic AP Service Learning
Service Excellence &
Relentless Execution
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Today Menu:
1. CDVR
2. Introduction to Control Panels
3. System Operation/Testing and
Adjusting
EMCP I (SENR3535 via SIS)
EMCP II+ (RENR1200 via SIS)
EMCP III (RENR7902 via SIS)
4. TMI web
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Caterpillar Digital Voltage Regulator
(CDVR)
Introduction and Specifications
Prepared by Service Training
https://psmktg.cat.com/srvtrng/
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Foreword
This presentation was prepared by Caterpillar Service Training to be a
training overview of the CDVR for Caterpillar generator set service
personnel. This presentation provides comparisons to the previous
design, DVR, and includes information pertaining to the removal of a
DVR and replacement with a new CDVR. As always, the proper
service information for the regulators in SIS should be used for the
latest specific details for operation, adjustments, programming and
troubleshooting.
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5
Compatibility Products Affected
The following products standard configuration or available options will be affected.
The change will affect PMG generators that have the CDVR as standard or option.
Generators that do not have an option for the DVR will not be affected.
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Compatibility Products Affected Cont.
The following products standard configuration or available options will be affected.
The change will affect PMG generators that have the CDVR as standard or option.
Generators that do not have an option for the DVR will not be affected.
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7
Other CDVR Production Information
The CDVR will replace DVR for low and medium voltage generators
and will also replace KCR 760 & KCR 65-12B for high voltage
generators. A follow-up announcement will be sent that details product
changeover on all affected products.
The CDVR will be used in all EPG products currently available with a
standard or optional CDVR and with high voltage applications where
analog regulators are standard with current product.
3500 SE Generators will be shipped with a VR-6
3500 PM Generators will be shipped with a CDVR
8
CDVR started production January 2004
Digital Voltage Digital Voltage
Regulator or DVR Regulator or DVR
Caterpillar Digital Voltage Caterpillar Digital Voltage
Regulator or CDVR Regulator or CDVR
January January
2004 2004
Transition Transition
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9
DVR from 1994-2003
Previous design pictured
Called the DVR or Digital
Voltage Regulator
Manufactured by Magnetek-
Century
Will be discontinued
Replaced with the new
Caterpillar Digital Voltage
Regulator or CDVR
Six part numbers were used to
accommodate SE & PM, 120,
240, and 480 VAC sensing
requirements
10
New design pictured
Called the Caterpillar Digital
Voltage Regulator or abbreviated
CDVR
Made by Basler Electric
Will be used on Caterpillar
generator sets and will replace the
DVR
January 2004 Production
Only One Part Number is needed
for all applications
KVAR/PF control included
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11
CDVR Publications
Available on Service Information System (SIS)
RENR7941 Specifications System Operation
Testing & Adjusting Guide
CDVR PC Software is available on SISweb in the download
section or on the monthly SIS subscription Flash File CD ROM.
Available on Electronic Media Center
LEHE3225 Specifications Sheet
LEXE3226 November 2003 Product News
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Part Numbers
Cat Digital Voltage Regulator (CDVR) - 235-5725
Connector Part Numbers
P6 plug: 234-1856, P6 seal 246-7013.
P9 plug: 234-1857, P9 seal 246-7014.
P12 plug 234-1858, P12 seal 246-7015.
P6, P9 and P12 Pins : 244-0452.
Planned part number releases:
Crimping tool: 239-5260.
Extraction tool: 246-8636.
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13
A Brief Look
There is no touch pad or display
for programming
PC programming only
PC software is on SIS
RS-232 PC connection
No screw terminals
3 Molex connectors
Bolt pattern like the DVR
Fault LED Indicator
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Why a new Caterpillar Regulator?
DVR was designed in early 1990s
1990s technology has fewer features
Internal components are becoming obsolete
DVR designed for fewer applications
Not cost effective to improve present design
The CDVR has improved transient performance, added standard features such as VAR & PF control,
and expanded flexibility for optimizing performance to individual customer applications.
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15
Features
Microprocessor control of three standard modes
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 Under Frequency (volts/Hertz) regulation
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Features
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
Ten generator protective functions
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17
Features
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 or RS-232
UL 508 Recognized and CE certified
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Modes of Operation Defined
Automatic Voltage Regulation (AVR)
Reactive Power (VAR) Regulation
Power Factor (PF) Regulation
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Automatic Voltage Regulation Mode
AVR mode regulates the RMS generator output voltage. The
regulator senses the generator output voltage through the sensing
leads and then adjusts the dc output excitation current to the generator
exciter field. This excitation current maintains the generator terminal
voltage at the regulation setpoint.
This is the basic function of any voltage regulator on a standalone
generator set
AVR mode is the default operating mode and can be disabled by a
switch input or the J4 port with CDVR PC Software.
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VAR Control Mode
Reactive or VAR mode regulates Volt-Amps Reactive when
paralleling with an infinite bus. The CDVR calculates generator VARs
from output voltage and droop CT current quantities and adjusts the
excitation current to maintain VARs at the programmed setpoint. VAR
mode and PF mode are mutually exclusive modes that both work in
conjunction with AVR mode.
VAR mode is enabled by a switch input and the CDVR PC Software.
VAR is adjustable from 100 percent absorb to 100 percent generate.
Typically used when paralleled with utility.
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21
Power Factor Control Mode
PF mode regulates Power Factor when paralleling with an infinite bus.
The CDVR calculates PF using the sensed output voltage and current
and then adjusts the dc excitation current to maintain PF at the
programmed setpoint. Again, VAR mode and Power Factor mode are
mutually exclusive modes that both work in conjunction with AVR
mode.
PF mode is enabled by a switch input and the J4 port with CDVR PC
Software. PF setpoint is adjustable from 0.6 1.0 lag and 0.6 1.0
lead.
Typically used when paralleled with utility.
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Regulation Characteristic. Below the Knee Frequency, the generator voltage follows a
decreasing slope based on generator frequency. When generator frequency is between
the Knee Frequency and Knee Frequency minus 5 hertz, voltage follows Slope 1. When
generator frequency is between the Knee Frequency minus 5 hertz and the
Underfrequency Point, voltage follows Slope 2 down to the Minimum Voltage Setpoint.
When generator frequency is below the Minimum Frequency Point, excitation is
removed. Programming Decreasing Slope 2 is optional.
0Hz 25 45 55 60Hz
480
VAC
0
Knee Frequency (45-65Hz)
Min. Voltage Setpoint (50-100%)
5 Hz (Not Adjustable)
Decreasing Slope 1 (0-10 V/Hz)
Decreasing Slope 2 (0-10 V/Hz)
Generator Output Voltage
Minimum Frequency Point (20-40Hz)
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10 CDVR Protective Functions
Generator Overvoltage
Generator Undervoltage
Loss of Excitation
Instantaneous Field Overcurrent
Over Excitation
Loss of Sensing Voltage
Diode Fault Monitor
Internal CDVR Processor Watchdog Failure
Internal CDVR Memory Failure
Fault Reset Switch Closed Too Long
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General Specifications
Voltage Regulation:
0.25% from no load to full load with < 30% THD
Temperature Drift:
Less than 1% for a 40C (72F) change over the ambient
operating temperature range.
Regulator response time:
Maximum of 10 milliseconds.
Variable Sense Range:
90 to 600 volts.
Control Power:
24Vdc Supply (18 to 30Vdc, 5VA)
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Regulator Filtering:
THF 3% per IEC34-1
TIF of 50 NEMA MG1-22.43
Harmonic Tolerance:
0.5% Voltage regulation with up to 40% THD
Power Dissipation:
55W Maximum
Weight:
1.47 kg (3.24 lbs.)
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Regulator sensing:
True RMS 3-phase sensing is standard. Single phase sensing is
available.
Configurable Volts/Hz Regulation Characteristic
Two slope ranges adjustable from 0 to 10 V/Hz. See Regulation
Characteristic Illustrations.
Fine voltage adjust range:
15% Maximum of regulator sensing voltage.
Regulator voltage gain (line loss compensation)
Adjustable from 0 to 10%.
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Reactive droop adjustment:
Adjustable from 0 to 10%.
Fault detection and identification:
Diagnostics identify operation outside of programmed limits.
Specific fault information is available after the unit has been
powered down.
Over Excitation protection:
Shuts off generator output when excitation current exceeds normal
operating currents for 10 seconds or instantaneous shut-off if
output current exceeds approximately 28 Amperes.
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Voltage Regulation Rating
120 to 15000 VAC
Generator Excitation Type
PM Permanent Magnet
SE Self Excited
AREP Auxiliary Winding Capable
AC Input Power
Three phase, 80 to 264 VAC, 50 to 400 Hz, 1150VA
Single phase, 100 to 280 VAC, 50 to 400Hz, 1900 VA
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Output Power Maximum Continuous:
12 Amps DC @ 63VDC
10 Amps DC @ 125 VDC
Output Power Maximum Forcing (10 seconds):
AC Sensing Voltage:
True RMS three phase or single phase, 90 to 600 VAC, maximum 1 VA
per phase burden.
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Reactive Voltage Droop circuit:
5 Amp Current Transformer, maximum 1 VA
burden
Regulator has internal CT burden resistor
Exciter Field Resistance Range
3 Ohms minimum, 39 ohms maximum
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Environmental Specifications
Operating Temperature:
-40C to 70C (-40F to 158F)
Storage Temperature:
-40C to 85C (-40F to 185F)
Relative Humidity:
95% non-condensing 30C to 60C
Salt Fog:
5% for 48 hours at 38C (100F) at 115% of the nominal operating
voltage
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Environmental Specifications
Vibration:
4.5G (peak) 18-2000Hz in 3 perpendicular planes
Shock:
Withstands up to 20 gs in three mutually perpendicular planes.
Certifications:
CE Approved
UL 508 Recognized
CSA Listed
Meets MIL STD 461C
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(CDVR)
Wiring Connections
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Regulator Connectors and LED
(1) 6-pin connector P6
(2) LED Indicator
(5) 9-pin D-sub Connector J4
Note: Items 1, 3 & 4 are Molex
brand Connector plugs
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P6 connector pin numbering
P6-6 P6-5 P6-4
P6-1 P6-2 P6-3
View as looking at P6 on the regulator plug
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P6 Wiring
Pins 1, 2 & 3: AC power inputs
from either SE or PM stator
winding
Pins 4 (-) & 5 (+): DC field voltage
output to the generator exciter
stator
Pin 6 should be hard-wired to earth
ground with at least a 16AWG
copper wire
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P9-1
P9-9
View as looking at P9 on the regulator plug
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P9 Wiring
Pins 1, 2 & 3: CANbus data link
connections
Pins 4, 5 & 6: Raise and Lower
connections for voltage level
adjustments in AVR mode, KVAR
level in KVAR mode and P.F.
level adjustment in P.F. Mode
Pin 7: Excitation Disable of field
voltage to exciter stator
Pin 8: Fault Shutdown Reset
Pin 9: VAR/PF mode enable
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P12-1
P12-12
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P12 Wiring
Pins 1 & 2: droop CT input
Pins 3 & 6: +/-10 DCV in
Pin 4: Alarm output
Pin 5: Fault SD output
Pins 7 & 8: 24VDC Input
Pin 9: Alarm and Fault
Shutdown Supply Driver
Pins 10, 11, & 12: Generator
AC voltage sensing phases C,
B, and A respectively.
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J4 connector pin numbering
The digital voltage regulator has the capability to communicate with a
personal computer or programmable logic controller. The J4 connector
of the digital voltage regulator provides an RS-232 port necessary for
communication. Pin locations and numbers are shown above.
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J4 RS-232 Wiring
The J4 RS-232 port is a 9-pin connector
including a pins for Receive, Transmit,
common Signal Ground. The common
signal ground is NOT a bonding ground
and should not be grounded to the case
or frame. It is to be connected to the RS-
232 device Signal Ground connection
point. Cable length should be limited to
15 m (50 ft) maximum for the RS-232
signal wiring
Part 1U-9494 RS232 cable.
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Example PMG Diagram
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Example PMG Diagram
Required only for Var/PF control. Var/PF permitted with
52a closed, inactive with 52a open.
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Example PMG Diagram
Excitation is disabled when closed, enabled when
open.
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Example PMG Diagram
Momentary closure resets any shutdown fault.
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Example PMG Diagram
S1 (SPDT, spring-return to center-off position)
adjusts regulator setpoint or KVAR/PF
setpoint when in KVAR/PF mode
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Example PMG Diagram
Normally-off, turns on for user alarm or
trip.
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Example PMG Diagram
Analog input voltage between -10 and +10 Vdc
provides adjustment of operating voltage.
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Example PMG Diagram
External fuses should be sized to match the
PMG and protect the field. Maximum fuse size
should be limited to Bussmann type KTK-12.
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Example PMG Diagram
Three-phase PMG is shown. For single-
phase PMG, omit P6-3 connection.
52
Example PMG Diagram
Sensing potential transformer is required
if line voltage exceeds 600 Vac.
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Example PMG Diagram
Items No.10 are not
supplied by Caterpillar.
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Example PMG Diagram
When generator rotation is ACB, the connections
shown for CTB should be reversed.
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9
8
CTB
GEN
10
9
52 9
P0018-25
07-16-03
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 (-)
CAT DVR-II
GROUND
P6-6
24 Vdc
+
_
24 Vdc CONTROL
POWER
P12-8 (+) P12-7 (-)
1 52a
2 3
S1
4
9
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 CAT DVR-II 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 AREP windings and protect the field. Maximum
fuse size should be limited to Bussmann type KTK-12 or equivalent.
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.
1
2
3
4
5
6
7
8
9
10
9
7
+
Auxiliary Windings
Shunt Series
X1 X2 Z1 Z2
AREP
Wiring
Example
56
The VR-3 (not shown), VR-6, DVR and new CDVR all have the same
bolt pattern and mount in the same location in the generator enclosure.
Mounting
VR-6 DVR CDVR
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The VR-6 and CDVR both present an electrical shock risk. Terminals and heatsinks
are live at potentially lethal voltages when power is applied and for up to 8 minutes
after power is removed. This high voltage may cause electrical shock that could
result in injury or death. Service by trained personnel only.
Reminder Live Terminals and Heatsinks
VR-6 CDVR
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Wiring Comparisons to the DVR
Droop CT wiring
Fault Alarm and Shutdown Output Driver Logic
VAR/PF enable, fault reset, and excitation disable inputs
Remote voltage and VAR/PF adjustment
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DVR
60
The DVR uses an 8-ohm
resistor with a 1 Amp droop CT
or a 1-ohm resistor with a 5
Amp droop CT.
The CDVR requires a 5 Amp
droop CT and no resistor
across the CT output.
Note: CT leads which are not
connected to the regulator must
be shorted to avoid a potential
shock hazard.
DVR
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61
DVR and CDVR have the output driver
logic reversed.
The DVR low side driver outputs for
the fault alarm and shutdown are active
high (driver output floats when a fault
is active).
The CDVR low side driver outputs for
the alarm and shutdown are active low
(driver output pulls low when a fault is
active).
A CDVR output is N/O and would
energize to close the output circuit
upon an alarm or shutdown.
DVR
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The DVR VAR/PF enable, fault
reset, and excitation disable
inputs activate with +24VDC.
The CDVR VAR/PF enable,
fault reset, and excitation
disable inputs require a
normally open dry contact to
enable the function.
DVR
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63
The DVR utilizes a 10K-ohm
potentiometer for remote
voltage adjust another for
remote VAR/PF adjustments
The CDVR uses a single
momentary switch with raise
and lower contacts. The switch
adjusts voltage in AVR mode
and also adjusts VAR or PF if
operating in that mode.
DVR
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(CDVR)
PC Software Installation
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65
CDVR PC Software Download
The CDVR PC software and an IBM Compatible
Personal Computer or Laptop is required for the service
technician to program CDVR set points and parameters
and to access status indicators and regulator metering
functions.
This Presentation has detailed steps for downloading the
PC Software from SIS (Service Information System),
establishing communications and programming the
CDVR.
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Navigate to SIS at https://sis.cat.com
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67
Click on Downloads
68
Click on CDVR PC Software.exe
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69
Verify Save this file to disk is selected as shown and then click the OK button
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Select where to save the file. The example shows the file being saved as CDVR PC
Software to the computer Desktop.
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71
The CDVR PC Software file will download and a Download Complete box will
appear when the download is complete. Click Close.
This file is 6.17MB in size and may take longer with slower network or modem
connections.
This completes the software download.
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CDVR PC Software Installation
Run the file by double-clicking
on the file CDVR PC Software
If the file has not been saved to the desktop, navigate to the folder where it
was saved and open the CDVR PC Software program file as shown below.
or
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CDVR PC Software Installation CDVR PC Software Installation
Follow the installation instructions and click Next
when ready.
74
Verify the folder location and click Next.
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75
Click Next
76
Click Next
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77
Click Next
78
A window will appear with the bars showing the installation
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When the installation is complete click Finish
This completes the software Installation
80
To start the CDVR PC software
follow these four steps.
1. Click the Start button
2. Click Programs
3. Click Caterpillar Software
4. Click Cat PC Software
1
2
3
4
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81
CDVR PC Software CDVR PC Software
Startup Screen when the software is launched
82
Whats needed for communication?
1. Computer with the CDVR Software installed (the computer must meet the
minimum requirements in the CDVR Service Manual)
2. Cable to connect the computer to the CDVR RS-232 port. Newer computers
may not have an RS-232 port and may require a USB to RS-232 adapter
(237-7547). Cables are not provided.
3. 24VDC power to the CDVR input power connections. AC Sensing and/or
PMG power voltage is not needed for communication.
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83
(CDVR)
PC Software Overview
84
CDVR Programming Overview
The next few slides provide only a brief explanation of
the CDVR PC Software screens and parameters. The
CDVR Service Manual, RENR7941, should be
referenced for more detail on the parameters and
functions not covered in this overview.
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85
File pull down menu is used to Open, Save or Print CDVR program configuration
(*.DV2) files
86
Communications pull down menu is used to connect or disconnect CDVR
communication
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87
Screens pull down menu or the buttons are used to select the five configuration
screens
Both is the same
88
Upgrade pull down is for upgrading the CDVR embedded software
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89
Help pull down will display the version of PC Software being used. Also shown
here.
90
System Configuration Screen
Configuration screen has generator voltage and current output and sensing parameters.
Only fields with a
white background can
be changed. In this
case, Rated Voltage
has been selected and
is high lighted.
The bottom screen
bars show the
minimum, maximum
and step or increment
allowed for the
selected parameter.
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91
Configuration screen has generator voltage and current output and sensing parameters.
Rated voltage is changed
from 120V to 240V by
typing 240 and then the
Enter key. (Do not use
the Tab key). When 240
is entered the Rated
KVAR automatically
changes from 75 to 150.
Fields with a black
background cannot be
clicked on and changed.
92
There are two operating frequency parameters.
Power Input Freq is the
frequency of the input
power. On SE this is the
same as the generator
operating frequency which
is 50 or 60Hz only. For
PMG It is the frequency
from the PMG exciter
stator from 50-400hz.
Frequency comes from
the generator nameplate
and will be 50 or 60 Hertz.
47
93
Other sensing parameters explained
Sensing Mode can be
Three or Single Phase
PT Primary and
Secondary voltages
Droop CT is programmed
to 600 on the primary. 5
on the secondary is not
adjustable so the droop
CT ratio is 600:5
94
Get From Unit Button
Voltage regulator settings are
retrieved by clicking the Get From
Unit button. This causes the
current settings of the CDVR to be
displayed on the settings screen.
This button will be grayed out until
the communication is established.
Parameter changes are sent to the
CDVR by pressing the Enter key
on the PC or by selecting a setting
from a pull-down menu. This
causes the selected setting
displayed on the setting screen to
become the active voltage
regulator setting.
48
95
EEPROM Button
Settings are saved in the CDVR EEPROM
(nonvolatile memory). When power is
removed, the EEPROM saved settings will be
active at power-up. If the settings are
changed and sent to the voltage regulator by
hitting the enter key, they are not sent to the
EEPROM. They will be lost if the CDVR is
powered off. When closing communication
the software will prompt the user to save the
settings to the EEPROM. This question is
asked even if no changes were made to the
settings. While communicating the user can
save changes to the EEPROM anytime by
clicking the EEPROM button.
96
Information for PC Software and CDVR
PC Software version
The CDVR serial
number, internal
embedded software
version and CDVR part
number will show in
these three boxes
49
97
Setting Adjustments Screen
Setpoint Parameters
AVR Voltage is the
terminal output voltage of
the generator in the AVR
mode.
VAR percentage sets VAR
level maintained in the
VAR mode.
Power Factor sets the PF
maintained in the Power
Factor mode.
98
Setpoint Parameters
Load Compensation Mode
settings are Off, Droop, or
Line Drop. Off is no
voltage droop. Droop
allows up to 10% droop at
full load. Line Drop
allows voltage to increase
up to 10% for line loss
compensation.
The Setpoint (%) for
Droop and Line Drop is
0 to 10%.
50
99
Startup Parameters Soft Start Mode
Soft Start Bias (%)
determines the generator
voltage at startup. 0 to 90
may be entered.
Soft Start Time (sec)
establishes the length of
time for the generator
voltage to increase to the
rated level. 0 to 120 sec.
may be entered.
100
Startup Parameters Under Frequency Mode
The five programmable
Under Frequency Mode
parameters determine
the CDVR under
frequency voltage
regulation characteristic
curve.
The next slide has a
graph of the under
frequency voltage
regulation characteristic
curve and setpoints.
51
101
0Hz 25 45 55 60Hz
480
VAC
0
Minimum Frequency Point (20-40Hz)
Regulation Characteristic. Below the Knee Frequency, the generator voltage follows a
decreasing slope based on generator frequency. When generator frequency is between
the Knee Frequency and Knee Frequency minus 5 hertz, voltage follows Slope 1.
When generator frequency is between the Knee Frequency minus 5 hertz and the
Underfrequency Point, voltage follows Slope 2 down to the Minimum Voltage Setpoint.
When generator frequency is below the Minimum Frequency Point, excitation is
removed. Programming Decreasing Slope 2 is optional.
102
Control Gain Screen
Control Gain
Generators delivered with
a CDVR installed will have
these parameters set for
optimal generator
operation. These settings
may vary on different
packages.
These parameters are
covered in detail in the
Service Manual and it
should be referenced
when making changes.
52
103
Protection Settings Screen
Protection
The Shutdown Override
button can be toggled
from DISABLED to
ENABLED during set-up
or troubleshooting.
If the Fault Reset Switch is
held too long the CDVR
will take programmed
action.
104
Protection
Protective settings like
Generator Overvoltage
have the following:
1. Enable check box,
2. Fault Type (Alarm or
Shutdown)
3. Trip Value (%)
4. Time Delay (Sec.)
If output voltage exceeds
135% for 2 seconds, an
Alarm condition will
activate.
53
105
Protection
Excitation (Exciter Stator)
current is monitored and if
the programmed limits are
exceeded the excitation
current will be disabled.
Excitation current will also
be disabled if the Exciter
Diode Monitor or Loss of
Sensing limits are
exceeded.
106
Metering, Operation and Alarms Screen
Metering Password
When the Metering
button is clicked a
password prompt window
opens.
This screen has password
protection to prohibit an
untrained person from
changing parameters
which may cause damage
to the generator or force
the generator into an
unsafe operating mode.
54
107
When the password cat
is entered, full access is
granted.
If Cancel is selected the
Metering data is available
only for viewing. Fields
with white backgrounds
cannot be changed and
the soft buttons will be
inactive.
cat
108
Generator operating
parameters values are
displayed in green.
Operating Mode is AVR
and can be changed to
VAR or PF if VAR/PF
contact is closed.
Fine Adjustment acts as
the raise/lower switch and
varies the voltage setpoint
in AVR mode. This would
vary PF/VARs if in the
PF/VAR mode.
55
109
Setpoint allows the user to
change the AVR, VAR or
PF level to be maintained
while the generator is
operating.
Caution: While the
generator running, the
CDVR will immediately
change its regulation to
obey the values or buttons
changed on this screen.
Customer access is
discouraged.
1VDC change cause a 1% AVR
volt change or 10% KVAR
change or .04 PF change
110
Status will light the soft
LED modes that apply
when active.
Contact Inputs will light
when switched inputs are
activated.
Alarms will light when
the alarm is active or if a
shutdown has occurred
due to an alarm. The hard
wired reset switch will
reset.
56
111
The Alarm Signal LED
will light if there is an
active alarm condition.
When the Disabled
button is toggled to
Enabled the CDVR will
not allow normal shutdown
faults to shutdown
excitation for
troubleshooting. This
must be used carefully to
protect the generator from
unsafe conditions.
112
Summary
This concludes the training overview of the CDVR. This presentation will
be updated as needed and available on the Caterpillar Service Training
Website at: https://psmktg.cat.com/srvtrng/
Again, the proper service information for the regulators in SIS should be
used for the latest specific details for operation, adjustments, programming
and troubleshooting.
57
113
CDVR Lab
optional
114
Control Panels
58
115
The 3N8900 Type 5
This is the 3N8900 type V control panel. It's been around for a number of years and there are
still many of them in use today. This panel will be covered in detail later. The panel has AC Ammeter,
frequency meter, AC Voltmeter,; Off / Reset, Auto, Start, Stop Engine Control Switch,
Governor Speed Control, Alarm Panel, etc. Four fault lights for Low Oil Pressure,
Excessive Water Temperature, Over Crank, and Over Speed.
116
Caution VAC Caution VAC
This is the inside of the Type V control panel. Notice the tape on the back of the meters.
There is 480 volts on the meters so opening the panel during operation is not recommended.
There is a KVAR controller mounted on this particular one but Cat does not use it any longer.
59
117
Junction Box
Around 1985 Caterpillar started to standardize the control panels making this Engine Junction Box"
with all of the electromechanical inputs inside. Oil pressure switches are mounted on the rear of the box and
Water Temperature switches are mounted elsewhere on the engine. Before this box was used, wiring was done
using a schematic without a wire routing diagram or common wiring strategy. Cat developed the harness
and a Junction box to make a common wiring for all. This junction box is still being used today not only
in genset applications but also in many industrial and marine as well as other commercial applications.
118
TDR TDR
ESS ESS
Emerg Emerg. Stop . Stop
Sw. Sw.
Power Relay Power Relay
Hr. Meter Hr. Meter
Here is the internal view of the Junction Box. In it are the Engine Speed Switch (ESS), a Time Delay Relay
(TDR), an emergency stop switch, a power relay, and an hour meter. The standard harness is inside of the
corregated plastic conduit. The wires are labeled with a wire code for to make troubleshooting easier.
The box is shock mounted to absorb engine vibration to protect the components inside the junction box.
With out proper shock mounting the small relay contacts inside the ESS and TDR may chatter cause a failure
or shutdown.
60
119
The 4W8000 with auto start/stop
This electromechanical control panel 4W8000 was used with the engine mounted junction box. It has an
Automatic Stop/Start module with 4 fault lights for Oil Pressure, Water Temperature, Overspeed, and
Overcrank. There is an Emergency Stop switch. The control switch has four positions:. Auto, Manual,
Stop and Reset. The panel also has a Voltmeter, Ammeter, Frequency Meter, Oil Pressure and
Water Temperature gauges, and an optional Alarm Module that warns when some things are about to fail.
If the oil pressure is low, but not too low, it will turn on the low oil pressure alarm light.
120
EMCP I
Engine Control Engine Control
Module Module
Alarm Alarm
Module Module AC Meter AC Meter
Module Module
61
121
In 1987 the Electronic Modular Control Panel (EMCP) was put into
production. This was abbreviated as ECMP, not EMCP I. Folks
later began to call it EMCP I when the ECMP II panel was released
in the mid-90s to distinguish between the two.
The EMCP panel simplified the genset control system by eliminating a
lot of wires, senders and switches. The LCD displayed hours, Engine
Speed, Battery Voltage, Oil Pressure, and Coolant Temperature.
These controls are used in many switchgear applications also.
This panel needs only one magnetic pick-up, one oil pressure sensor,
and one coolant temperature sensor mounted on the engine. The
engine junction box was no longer needed.
122
2 2
Potentiometers Potentiometers
and Switch and Switch
Switches Switches
and Resistor and Resistor
Alarm Module Set Alarm Module Set
point Adjustment point Adjustment
62
123
EMCP Panel interior. This EMCP panel was actually cost effective too
because the enclosures are very rugged and reliable. To program, the
technician needed to remove a rear cover and use switches and a pot to
change parameters. Notice the single phase AC meter module. The
ECM and AC Meter module are installed in many switchgear
applications. The Annunciator is on the left.
Pots and switch are used to program the parameters of the ECM.
Switches and Resistor are used to program the AC Module voltage
and CT Ratios.
Alarm Module Dc Volt pot can be used to adjust the DC Alarm level
124
EMCP II
This is a picture of the EMCP II GSC. It is the brain of the EMCP II system.
The GSC (Generator Set Control) combines the AC Meter, Annunciator and ECM into one module.
Also added was a Transformer box in the back of the panel for more accurate AC metering of all
three phases. Lights for E-Stop, coolant level and fault lights were added. The EMCP II adds even more
features than the EMCP I. If there was a need to program the EMCP I ECM, the technician had to
remove a cover, push buttons and select a rotary switch to the proper position and then do the programming.
All of these switches and pots are on the back of the panel and the display is in the front. The EMCP II GSC
is programmed using the pushbuttons on the front of the panel. The programming password is 13231.
Notice the engine display (on bottom) is a little shorter in length than the generator display (on top).
EMCP II was introduced in 1994.
63
125
EMCP II+
EMCP II+. The + or Plus has large displays on the top and bottom of the GSC. In the Plus one
can read Kw, Kva, Power Factor, Kw hours, percent of load or percent Kw, etc. The AC metering can
display separate phases or totals, average voltage, average frequency and total current.
When the customer sees the total current of all three phases he may see the result of 500 Amps
per phase which will show 1500 AMPs. This usually surprises them until it is explained.
This works very much like the EMCP II. The plus also has Protective Relay functions. There is not a
typical relay but it can be programmed for alarm or shutdown parameters such as over current or over
voltage to provide industrial grade relay protection. This slide actually shows two alarm modules.
126
GSC GSC
Alarm Alarm
Module Module
Customer Customer
Alarm Alarm
Module Module
Controls Controls
64
127
EMCP 3 EMCP 3
128
EMCP I & II Control Panel
Attachments
65
ALARM MODULES
Amber Amber
Red Red
Alarm modules can be used to annunciate low fuel level, outside switch closures, air damper,
air flapper down, battery charger, not in auto, etc. The Annunciator gets information from the EMCP
or EMCP II via a serial data link from the main control panel or from external switches. Changing the
type of Annunciator or its function is a matter of sticking a new graphics film on the front and changing
the jumper wires located in on the rear terminals. There are at least six configurations for these modules.
Any one can be converted to the other usually by changing the jumpers configuration and the film on the
front. Each film has a part number listed on the lower right corner, that part number is for the film and not
the Annunciator. The Annunciator number is located on the rear of the module.
Horn and Alarm silence button are at the bottom as well as the test lamp.
GENERATOR SET
TROUBLE
GENERATOR SET
SUPPLYING LOAD
Remote Annunciators
66
131
This is a slightly different version with the same control
used as a Remote Annunciator. Shown also an NFPA 110
remote Annunciator which just has a generator trouble
light, a generator supplying load light, a horn, and a
horn silence button. An EMCP system can use as many as
three Annunciators or remote Annunciator combinations.
One can be located on the control panel, and two may be
500 feet away. 1000 feet total of wire is the limitation of
the data link because the long run of wires add capacitance
which rounds off the edges of the digital serial link pulses.
If the serial data link is corrupted or lost the Annunciator
will flash its lights at a 1/2 hertz cycle.
Remote Annunciators
Customer Interface Module (looks like the relay driver module)
67
133
This is the Customer Interface Module (CIM) and relay hardware. Instead of activating LEDs from
the serial data link like the Annunciator, it receives the data link information to activates relays. So
instead of turning LEDs on, it turns relays on. The relays can then be used to activate lamps in
various locations. A lot of switchgear builders and customers like that because they want to have the
lights instead of a single Annunciator with a set number and color of LEDs. One mis-application that
happens is that some people wire the relays to trigger a shutdown for a certain fault. It's not intended
to be a shutdown because if the generator is running and someone pushes the lamp test button, all of
the relays activate and any that can cause a shutdown will shutdown the engine. Also, if there is any
problem with the datalink, then the shutdown circuit will not work properly or possible in an unsafe
manner.
Troubleshooting Tip:
Pin 18 goes in and out on relay board (which may have electrical noise) to terminal 4 on the dark
brown terminal brick. If the CIM is shutting down, run the shielded 18 line to terminal 4 skipping the
relay board altogether. If there is a a CIM, RDM and an Annunciator all in one system and one loses
power, the un-powered unit will pull the data link down and this un-powered unit will be completely
dead and the others will have all the lights on.
134
Customer Communications Module
Customer Communications Module Customer Communications Module
68
135
The Customer Communications Module (CCM) is simply a translator box. It takes the
Cat Data Link output out of the EMCP II and translates it into an RS232 protocol that will
communicate with a computer if that computer has the CCM desktop software installed.
In the paralleling class, a CCM is used to start an engine remotely with a modem over a
phone line. It is convenient to use a CCM and Laptop PC when running an acceptance test
on a generator set. There is a data logger mode so data can be loaded into the PC and put
into a spreadsheet to show generator loading data for example. In Primary Mode a CCM
can monitor four EMCP IIs and four ADEM II ECMs. In Secondary Mode one CCM
can monitor up to eight EMCP IIs without any ADEM II ECMs. The ADEM II ECMs are
sometimes monitored because they too have the Cat Data Link and have detailed engine
sensor and operating information.
This does have an internal battery behind the display for internal memory. On the back, it
has connections for the RS-232 serial cable for connection to a PC. The Cat Data link
connection connects to the GSC Module in the EMCP.
136
EMCP II and EMCP 3 Control
Panel
Attachment
69
137
PL1000T and PL1000E
Product
138
PL1000T Package Features
M5X / M50 Protocol Support (CCM Replacement)
Cat Data Link Boost
Embedded Communications Adapter
CAN Extension Bridge
J1939 Bridge
Cat Data Link Tunnel
Sea Water Temperature and Depth Interface (NMEA-183)
Global Position System Module Interface (NMEA-183)
Engine Vision Module Interface Protocol
70
139
Embedded
Communications Adapter
CDL
Boost
EVIM GPSIM
M5X
M50
J1939
Bridge
J1939 Long
Distance Extension
CDL
Tunnel
PL1000T Cross-Functional Matrix
Modules
Previously
Required
PL1000T
Required
3
3
3
2
4
4
4
1
1
1
2
1
1
1
140
PL1000E Package Features
CDL to Modbus Parameter Translation
J1939 to Modbus Parameter Translation
Embedded Webserver
Embedded Communications Adapter
Cat Data Link Boost
Caterpillar Communications Tool Kit Configuration
CDL to Webserver Parameter Translation
J1939 to Webserver Parameter Translation
71
141
PL1000E Cross-Functional Matrix
J1939 to
Web
CDL to
Modbus
J1939 to
Modbus
Embedded
Web
Server
Embedded
Communications
Adapter
CDL Boost
CDL to
Web
142
Today Menu:
3. SIS access to System
Operation/Testing and Adjusting
EMCP I (SENR3535 via SIS)
EMCP II+ (RENR1200 via SIS)
EMCP III (RENR7902 via SIS)
4. TMI web
72
143
TMI and Web Information
144
TMI on the Web
URL: URL: http:// http://tmiweb tmiweb.cat.co .cat.com m
TMI Web pages TMI Web pages
Engine Data Engine Data
Generator Data Generator Data
73
145
146
74
147
TMI on the Web
URL: URL: http:// http://tmiweb tmiweb.cat.com .cat.com
148
75
149
150
Entry Screen
76
151
152
77
153
Test Cell Results
154
As Shipped
78
155
Flash File
156
Systems Data
79
157
Physical Data
158
Water Pump Physical Data
80
159
Gasket Kit Data
160
Re-man Parts Data
81
161
Performance Data
162
Par Dyno
82
163
Engine Test Spec.
164
Component Data
83
165
Example Component Data
166
Example Component Data
84
167
Certify Rerate
168
TMI on the Web
URL: URL: http:// http://tmiweb tmiweb.cat.com .cat.com
Generator Data Generator Data
85
5N-5078
86
Select
87
88
89
90
180
Questions ?
91
181
Other Useful Electric Power
Information available from the Web:
182
Electronic Media Center
92
Electronic Media Center
Images are not well
indexed & may not be
described correctly.
Some of the Available Document Catagories
93
185
Electric Power Quicksize software
for Olympian Generator Sets:
https://epd.cat.com/infocast/frames/ep
186
94
187
End of Slides End of Slides

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