C1.5 and C2.2 Generator Caterpillar

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Personal injury or death can result from high voltage. When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made. When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE. Remove all fuses. Make sure the generator engine is stopped. Make sure all batteries are disconnected. Make sure all capacitors are discharged. Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (-) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Illustration 1	g00992028

The generator should be connected with the terminal lugs on top of each other. See illustration 1.

Grounding the Frame

In any generator set installation, the frame of the generator must be positively connected to an earth ground or to the hull of a vessel. This connection is the first connection that is made at the installation. This connection is the last connection that should be removed. If the generator set is on flexible mounting pads, the ground connection must be flexible in order to avoid possible breakage in later operation.

Ground connection cable or straps should have at least the current carrying capacity of the largest line lead to the connected load. Joints in cables or straps must be clean, free of electrical resistance, and protected from possible oxidation. Bolted ground connection joints eventually oxidize. The joints are frequent sources of radio frequency interference (RFI). Joints that are silver soldered and bolted are preferred.

Neutral Connections

The generators with a Wye Configuration usually have the neutral ground when the generator is installed. Grounding the neutral is for preventing damage to equipment.

If the neutral wire is grounded and one of the phase leads becomes grounded, the excessive current will open a load circuit breaker. Also, the excessive current will cause the generator voltage to collapse. The result depends on the following items: electrical characteristics of the generator, type of fault and trip rating of the circuit breaker. An undervoltage device may be required in order to provide an adequate short circuit protection.

There are some cases when the neutral wire is not grounded. An ungrounded generator neutral lead is acceptable when the possibility of grounds to the phase leads has been eliminated. An example of such measures are ground fault protective circuits. Ground fault protection requires the entire group of distribution circuits to be treated as a system. The owner should contact a certified consultant if a new distribution system is being developed. The owner should also contact a certified consultant if an existing system should be modified for the ground fault protection.

In a three-phase, four-wire system, the neutral wire should be grounded according to local wiring codes.

Be sure to check your local wiring codes.

Connection Diagrams

The connections are located in the electrical box that is mounted on top of the generator.

Change the position of the wire terminals in order to modify the connection. The code for the winding is specified on the nameplate.

Wiring Code A for Three-Phase Configuration

Illustration 2	g00996508

Illustration 3	g00996511
Factory connection for "A" wiring code

R 230 voltage sensing - 0 => (T8) / 110 V => (T11)

R 438 LS voltage sensing - 0 => (T3) / 220 V => (T2)

Wiring Code B for Single-Phase Configuration or Three-Phase Configuration

Illustration 4	g00996512

Illustration 5	g00996514
Factory connection for "B" wiring code

R 230 voltage sensing - 0 => (T8) / 110 V => (T11)

R 438 LS voltage sensing - 0 => (T3) / 110 V => (T2)

Wiring Code D for Three-Phase Configuration

Illustration 6	g00996517

Illustration 7	g00996519
Factory connection for "D" wiring code

R 230 voltage sensing - 0 => (T8) / 110 V => (T11)

R 438 LS voltage sensing - 0 => (T3) / 380 V => (T2)

Wiring Code F for Single-Phase Configuration or Three-Phase Configuration

Illustration 8	g00996520
Voltage LM equals one half of voltage LL.

Illustration 9	g00996522
Factory connection for "F" wiring code

R 230 voltage sensing - 0 => (T8) / 110 V => (T11)

R 438 LS voltage sensing - 0 => (T3) / 220 V => (T2)

Wiring Code FF for Single-Phase Configuration

Illustration 10	g00996524
Voltage LM equals one half of voltage LL.

Illustration 11	g00996526
Factory connection for "FF" wiring code

R 230 voltage sensing - 0 => (T1) / 110 V => (T4)

R 438 LS voltage sensing - 0 => (T10) / 220 V => (T1)

Single Phase with 4 Leads, Winding Dedicated Type M or Type M1

Illustration 12	g00996527
Wiring diagram for a connection in series

R 230 voltage sensing - 0 => (T1) / 110 V => (T2)

Illustration 13	g00996528
Wiring diagram for a parallel connection

R 230 voltage sensing - 0 => (T1) / 110 V => (T2)

R 791 T Interference Suppression

Illustration 14	g00996531
Connect the interference suppression, as shown. The letters in the circles represent the wiring codes for the generators. (BLK) Black (BLU) Blue (WHT) White (A) Wiring code "A" (B) Wiring code "B" (D) Wiring code "D" (F) Wiring code "F" (FF) Wiring code "FF"