Installation Instructions for the New Caterpillar Digital Voltage Regulator (CDVR) In Field Retrofit Applications{4467} Caterpillar

Electric Power Generation:

3412 GENSET (S/N: 4BZ1-UP; 1EZ1-UP; 3FZ1-UP)

3512 GEN SET (S/N: ZAF1-UP)

3512B GENSET (S/N: ZAH1-UP; ZAJ1-UP)

3516B GEN SET (S/N: ZAP1-UP)

3516C GEN SET (S/N: SBK1-UP)

C175-16 GEN SET (S/N: WYB1-UP)

SR4 (S/N: 5MA1-UP; 5RA1-UP; 5SA1-UP; 5TA1-UP; 5UA1-UP; 5VA1-UP; 5YA1-UP; 5ZA1-UP; 6AA1-UP; 6FA1-UP; 6LA1-UP; 6MA1-UP; 6NA1-UP; 6PA1-UP; 6SA1-UP; 6WA1-UP; 1GD1-UP; 2ED1-UP; 5TD1-UP; 8FD1-UP; 8ZD1-UP; 3EF1-UP; 8JF1-UP; 8KF1-UP; 8LF1-UP; 9EF1-UP; 9FF1-UP; 6CG1-UP; 6DG1-UP; 6EG1-UP; 8HG1-UP; 9FG1-UP; 3KJ1-UP; 4SJ1-UP; 5NJ1-UP; 6EJ1-UP; 7AJ1-UP; 8MM1-UP; 1MS1-UP)

SR4 HV (S/N: 8HS1-UP; 8JS1-UP; 8KS1-UP; 8LS1-UP; 8MS1-UP; 5HW1-UP; 5RW1-UP; 6CW1-UP)

SR4B (S/N: ACA1-UP; AEB1-UP; AAD1-UP; ADD1-UP; ABH1-UP; AAJ1-UP; ADL1-UP; ABM1-UP; 2DM1-UP; 2GM1-UP; 3BM1-UP; 4DM1-UP; 5DM1-UP; 6GM1-UP; 7GM1-UP; 8DM1-UP; 8HM1-UP; 1BN1-UP; 1HN1-UP; 2DN1-UP; 2FN1-UP; 2GN1-UP; 2HN1-UP; 2SN1-UP; 3EN1-UP; 3FN1-UP; 3GN1-UP; 3HN1-UP; 4EN1-UP; 4FN1-UP; 4GN1-UP; 4WN1-UP; 5SN1-UP; 5WN1-UP; 6SN1-UP; 7DN1-UP; 7TN1-UP; 8NN1-UP; 9CN1-UP; 9EN1-UP; ACP1-UP; AAR1-UP; ADR1-UP; 8XS1-UP; 5JW1-UP; 6DW1-UP; 8GW1-UP; ACX1-UP; AAY1-UP; ABY1-UP; AEZ1-UP; 2GZ1-UP; 8EZ1-UP; 8LZ1-UP; 8TZ1-UP; 9AZ1-UP; 9GZ1-UP; 9MZ1-UP; 9WZ1-UP)

SR4B HV (S/N: ABA1-UP; AEA1-UP; A5A1-UP; G4A1-UP; ACB1-UP; ADB1-UP; G4B1-UP; ABE1-UP; ABG1-UP; ACG1-UP; AEG1-UP; ADJ1-UP; AAL1-UP; AEL1-UP; ACN1-UP; G3N1-UP; PCP1-UP; ACR1-UP; G3R1-UP; AES1-UP; G3S1-UP; ABT1-UP; ADT1-UP; G3T1-UP; ACW1-UP; G3W1-UP; A4X1-UP; G3X1-UP; AEY1-UP; A4Y1-UP; G3Y1-UP; ACZ1-UP; A4Z1-UP; G3Z1-UP)

SR5 (S/N: G3M1-UP)

Engine:

3306B (S/N: B8D1-UP; 8NS1-UP; LRW1-UP; 1CZ1-UP)

3408 CUSTOM T DI (S/N: 67U1-UP)

3408 TA DI (S/N: 78Z1-UP)

3408B T DI (S/N: 67U1-UP)

3408B (S/N: 78Z1-UP)

3408C (S/N: 67U1-UP; 78Z1-UP)

3412 (S/N: 2WJ1-UP)

3412 PC T DI (S/N: 38S1-UP)

3412 T DI (S/N: 81Z1-UP)

3412C (S/N: 5FL1-UP; DJN1-UP; 9EP1-UP)

3412C TA DI (S/N: RLR1-UP)

3412C (S/N: 9BR1-UP; TFT1-UP; BCW1-UP; LRY1-UP; RTY1-UP; 81Z1-UP; 3FZ1-UP)

3412E (S/N: TGC1-UP)

3508 (S/N: ZAA1-UP; ZAB1-UP; CNF1-UP; CAW1-UP; 5PW1-UP; 23Z1-UP; 70Z1-UP; 1JZ1-UP)

3508B (S/N: S2A1-UP; CNB1-UP; S2B1-UP; ZAD1-UP; 3DM1-UP; 3DW1-UP; 5KW1-UP; BGX1-UP; 1FZ1-UP)

3512 (S/N: ZAE1-UP; CMJ1-UP; FDR1-UP; 6WW1-UP; 24Z1-UP; 67Z1-UP; 1KZ1-UP)

3512B (S/N: CMC1-UP; FDE1-UP; BLF1-UP; S2G1-UP; S2H1-UP; BRK1-UP; 8EM1-UP; 1PW1-UP; 6GW1-UP; 1GZ1-UP)

3512C (S/N: SBG1-UP; SLM1-UP)

3516 (S/N: CMD1-UP; 4XF1-UP; 5SJ1-UP; ZAK1-UP; CAL1-UP; ZAL1-UP; 8TW1-UP; 25Z1-UP; 73Z1-UP; 1LZ1-UP)

3516B (S/N: CPA1-UP; BMB1-UP; CDE1-UP; BPJ1-UP; FDN1-UP; 7RN1-UP; 9AN1-UP; S2P1-UP; GAR1-UP; PBR1-UP; S2R1-UP; YAR1-UP; ZAR1-UP; GZS1-UP; 2FW1-UP; 8NW1-UP; FDX1-UP; S2Z1-UP; 1HZ1-UP)

3516C (S/N: SBJ1-UP; SBM1-UP)

3612 (S/N: 9RC1-UP)

C9 (S/N: X3R1-UP)

G3306 (S/N: JCA1-UP; 07Y1-UP)

G3406 SI (S/N: R7E1-UP; KAR1-UP)

G3408 (S/N: 6RJ1-UP)

G3412 SI (S/N: R7A1-UP; KAP1-UP)

G3412C (S/N: 6ZM1-UP)

G3512C (S/N: GNX1-UP)

G3516 (S/N: ZBA1-UP; 4EK1-UP; 25Z1-UP)

G3516B (S/N: ZBB1-UP)

G3516B SI TA (S/N: CSC1-UP)

G3516E (S/N: SLY1-UP)

G3520B SI TA (S/N: CWD1-UP)

G3520C (S/N: MAD1-UP; GZK1-UP; GZM1-UP; RLP1-UP)

G3520C SI TA (S/N: CWW1-UP; CWY1-UP)

G3532 (S/N: 8BZ1-UP)

Generator Set:

3406 GEN SET (S/N: 4ZR1-UP)

3406C GEN SET (S/N: C2G1-UP; C5G1-UP; C8G1-UP; KPS1-UP; 9ES1-UP; LRX1-UP; C2Y1-UP; 1DZ1-UP)

3406C MARINE GS TA DI (S/N: PFH1-UP)

3406E GEN SET (S/N: 8AZ1-UP)

3456 GEN SET (S/N: CCB1-UP; C1G1-UP; C3G1-UP; C4G1-UP; CAH1-UP; GHJ1-UP; CBX1-UP)

C15 GEN SET (S/N: C5E1-UP; C5H1-UP; C5L1-UP; X4R1-UP; CYY1-UP)

C18 GEN SET (S/N: G4C1-UP; N1D1-UP; STD1-UP; DKE1-UP; PEJ1-UP; STM1-UP; EKW1-UP; M1Z1-UP)

C18 MARINE GS (S/N: MGS1-UP)

C27 GEN SET (S/N: DWB1-UP)

C32 GEN SET (S/N: SXC1-UP; WDR1-UP)

C9 GEN SET (S/N: C9E1-UP)

Industrial Engine:

3412C IND (S/N: 38S1-UP)

Petroleum Engine:

3512C PETROLEUM (S/N: LLB1-UP)

3516C PETROLEUM (S/N: PES1-UP)

C15 PET GS ENG (S/N: PET1-UP)

Petroleum Power Train Package:

TH35-C13P (S/N: PBJ1-UP)

Power Module:

C32 POWER MODUL (S/N: MED1-UP; MEG1-UP)

PM3412 (S/N: CAJ1-UP)

PM3456 (S/N: B3G1-UP)

PM3508 (S/N: BLM1-UP; BPY1-UP)

PM3512 (S/N: BRF1-UP; BNR1-UP)

PM3516 (S/N: CAC1-UP; BPD1-UP; KEN1-UP)

PMG3516 TA DI (S/N: CFD1-UP)

PP3516 (S/N: PPS1-UP)

Introduction

Illustration 1	g01425620

Show/hide table

The Cat Digital Voltage Regulator presents an electrical shock/electrocution hazard. This hazard will cause serious injury or death. Service by trained personnel only. The terminals and heat sinks are live at hazardous voltages when power is applied and for up to 8 minutes after power is removed.

These instructions are provided in order to assist in replacing an existing DVR or VR6 with a new Caterpillar Digital Voltage Regulator (CDVR). Refer to the Specifications, Systems Operation, Testing and Adjusting, RENR7941-08, "Cat^® Digital Voltage Regulator " for complete information.

Parts kit 329-4513 Conversion Kit is required to complete this retrofit for both the DVR and the VR6 voltage regulators. The VR6 also requires some additional parts as called out in Table 4.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used. Ensure that the tool, procedure, work method, or operating technique is safe to use. Ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Mounting the CDVR

The CDVR, DVR, and VR6 use the same mounting holes. The parts kit includes the hardware that is required for mounting the CDVR. The following hardware is included in the kit: bracket, shorter bolts and additional hardware. The additional hardware required for the VR6 is shown in Table 4. Install the CDVR with the heat sinks on the CDVR in the same position as the display on the DVR or the heat sinks on the VR6. The CDVR may also be mounted in a remote location.

Wiring The CDVR

The CDVR requires connections that are similar to the DVR or VR6, although the harness and connectors will be different. A new wiring harness is provided with the parts kit. The part number for the harness is 243-4271 Wiring Harness . One end of the harness is terminated with connectors that mate to the CDVR. The other end of the harness has a label on each wire in order to identify the wire.

The CDVR has three multipin plug connectors. The connectors have the following markings: "P6", "P9" and "P12". Connector "P6" mates with a corresponding connector with six pins on the harness. Connector "P9" mates with a corresponding connector with nine pins on the harness. Connector "P12" mates with a corresponding connector with 12 pins on the harness. Refer to the Tables 1, 2 or 3. Each table corresponds to the connector number in order to identify the function of each pin in the connector.

Illustration 2	g03157977
Illustration of changes to VR6 wiring Part 1

Illustration 3	g03157978
Illustration of changes to VR6 wiring Part 2

Illustration 4	g01456243
Illustration of changes to DVR wiring

Illustration 5	g01015474
Illustration of a typical CDVR installation

The CDVR does not require a burden resistor. When changing from a DVR, remove the resistor in parallel with the CT for sensing droop. The CT connections are polarized. One of the terminals has a dot. Confirm that the CT connection with the dot is connected to P12-1 on the CDVR. Refer to the Illustrations 2, 3, and 4.

Note: Whereas the DVR and CDVR require 24V DC power, the VR6 does not. When converting from the VR6, two extra wires will be needed to jumper from the existing battery power terminations to the included terminal block. Refer to the Table 4 for the recommended DC wiring.

Note: If the CDVR harness wires (1A and 2A) are long enough for the installation, the recommended battery jumper wires will not be necessary.

Illustration 6	g01455440
Illustration of a terminal block with connections for RTDs

Illustration 7	g01455439
Illustration of a terminal block with connections for thermocouples

Different labels and additional terminals are provided in the parts kit. These parts are required for the terminal blocks. These terminal blocks may be located inside the generator terminal box or located in a remote location. Some labels may need to be changed on the terminal blocks or added to the terminal blocks. These labels include the following: "VAR/PF", "Enable", "Fault Reset" and "Excitation Disable". Refer to the Illustrations 4 and 5. Install the new terminals and labels that are required for your specific application. Refer to the Illustrations 6 or 7.

A new momentary switch is provided in the parts kit. The part number for the switch is 110-7884 Toggle Switch . This switch is used to adjust the voltage on the CDVR output. The common wire to the switch will replace the following connections: pin 50 to "Excitation Disable", "Fault Reset" and pin 52a enable for VAR and PF. This switch also replaces the rheostat that was used on the DVR and VR6. Refer to the Illustration 5. CAN datalink communication wires (P9-1, 2 and 3) are not included in the 243-4271 Wiring Harness . If datalink communication for the CDVR is desired, it will be necessary to install the additional 153-2707 Electrical Cable . Three 244-0452 Wire Ends will also be needed. These parts are included in Table 4, "Additional Parts Required for the VR6".

Note: When installing the CDVR on the J1939 datalink, please be aware of the terminating resistor location and adjust as necessary.

Note: When converting from a VR6 to a CDVR, an additional wire will be needed for the common wire connection from the included terminal block to the momentary switch. Refer to Table 4 for the recommended wire part number and amount needed.

In the case of the DVR, the drivers for the alarm output and the shutdown circuit will remain connected between 24V DC, pin 50 and the output contacts.

The logic for the control circuit has changed in the CDVR. The DVR supplies a signal unless a fault is present. The CDVR signals only when the fault has occurred. Refer to the Illustration 4.

Operator Interface

In order to configure the parameters of the CDVR, a PC with the CDVR PC Software is required. Software can be downloaded from the Service Information System (SIS).

Refer to the Specifications, Systems Operation, Testing and Adjusting, RENR7941-08, "Cat^® Digital Voltage Regulator ", for more thorough information on the CDVR software.

The CDVR requires a connection to a PC for configuring the settings for the generator. The PC is also used to monitor the parameters for the generator and the faults from the generator.

A nine pin RS232 cable is required to communicate with the CDVR from a PC or a laptop computer.

Note: Do not use a null modem cable.

The following CDVR settings will need to be configured in the CDVR: rated voltage, current, frequency, PT Ratio, CT ratio, setpoints for VAR and PF, mode for load compensation, voltage adjustment band, setpoints for soft start, setpoints for under frequency, protective relay functions and settings for PID. More parameters may need to be configured for your specific application.

Note: If CAN datalink communication wires are installed, Caterpillar Electronic Technician can also be used to adjust voltage regulator settings. Refer to the Specifications, Systems Operation, Testing and Adjusting, RENR7941-08, "Cat^® Digital Voltage Regulator ", for more information.