Quick Start Guide for Manual Paralleling{7451} Caterpillar

Engine:

3516C (S/N: KEN1-UP)

Introduction

This Special Instruction provides information in order to clarify the functionality of the components that are used in order to perform manual paralleling.

Do not perform any procedure that is outlined in this special instruction until the entire special instruction has been read and is understood.

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 specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

Generator Breaker - Closing

The manual paralleling unit is intended for operator control of the breaker for the generator by using the "Circuit Breaker Switch" (CBS). The status of the breaker is indicated by LEDs that are located on the CBS. A "Green" LED indicates that the breaker is open. A "Red" LED indicates that the breaker is closed. Refer to Illustration 1.

Illustration 1	g01878295
Circuit Breaker Switch (CBS) (1) Breaker Status Indicator LEDs

Stand-Alone Operation

Perform the following steps in order to operate in the "Stand Alone" mode.

1. Install a jumper between terminals "1UP-93" and "1UP-94". Terminal "1UP-93" and terminal "1UP-94" are located on the terminal strip that is in the interconnect panel. The interconnect panel is local on the left side of the power module. The jumper is required in order to allow "dead bus" breaker closure.

2. Place the SYNC light module switch (2) in the ON position while attempting to close the CBS. Use the EMCP3 controller that is generator set in order to start the engine. Once the generator voltage and generator output frequency has reached the normal operating range, the operator can close the breaker by turning the CBS to the CLOSE position. Refer to Illustration 1 and Illustration 2.

   Note: Refer to the "Setup for Standby Operation with Automatic Transfer Switch" (ATS) section if needed.

Illustration 2	g01878416
SYNC Light Module (2) SYNC Light Module Switch

Multiple Units - Island Mode Operation

Perform the following steps in order to operate multiple units in the "Island" mode.

1. In only one unit, install a jumper between terminals "1UP-93" and "1UP-94". Terminal "1UP-93" and terminal "1UP-94" are located on the terminal strip that is located in the interconnect panel (3). The interconnect panel is local on the left side of the power module. The jumper is required in order to allow "dead bus" breaker closure. Refer to Illustration 3.

   Note: IMPORTANT: Only one generator set should have this jumper installed.

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Illustration 3	g01879443
(3) Location of the Interconnect Panel

2. Ensure that the cables that are used to load share are interconnected between all of the generator sets (power modules). Ensure that all of the necessary wiring is installed in order to allow primary unit selection.

3. Place the SYNC light module switch (2) in the ON position while attempting to close the CBS. Use the EMCP3 generator set controller in order to start the engine. Once the generator voltage and generator output frequency has reached the normal operating range, observe the two lamps that are on the SYNC light module. The "Speed Adjust Potentiometer" (21) and the "Voltage Adjust Switch" (22) may need to be adjusted. If the bus is dead, then the operator can close the breaker immediately. If the bus is live, then adjust the voltage and frequency so that both are slightly higher than that of the bus. The generator voltage should be 1 Volt higher than the bus. Wait for the synchronizing lights to go completely off. While the generator is in synchronism, that is "Lights Out", the operator can close the breaker by turning the CBS to the CLOSE position.

   Note: The "25 relay" (SYNC check) prevents the operator from closing the breaker out-of-phase.

Setup for Standby Operation with Automatic Transfer Switch (ATS)

The manual paralleling unit can be configured to work with an automatic transfer switch by performing the following steps.

1. Close the generator breaker.

2. Keep the generator breaker closed unless a fault condition occurs. If a fault condition occurs, then the generator breaker will automatically trip open.

Perform the following steps in order to enable the "Standby ATS" mode.

1. Place the EMCP3 control in the "STOP" mode.

2. Open the upper access panel (10) that is on the front of the terminal box. Refer to Illustration 5.

3. Remove the jumper 5 that is installed from terminal AP5 to terminal AP6. Store the jumper for future use.

4. Unplug the ERR relay (6) from the relay base. Store the relay for future use.

5. Close the generator breaker by using the push button that is on the face of the breaker.

6. Place the EMCP3 in "AUTO" mode in order to enable the auto start signal from the ATS.

   Note: The removal of the ERR relay from the relay base will disable the customer monitoring contacts that are used for "engine running". If this is not desired, then leave the relay plugged in and remove the wire from terminal number "22" of the relay base. Insulate the wire once it is removed in order to prevent a short circuit condition or a ground.

Illustration 4	g01878396
Component Location in the Terminal Box (5) Jumper from Terminal AP5 to AP6 (6) ERR Relay (ninth from top) (7) Idle/Rated Switch

Generator Breaker - Opening

The manual paralleling unit is intended for operator control of the generator breaker using the "Circuit Breaker Switch" (CBS).

At any time, the operator can open the breaker by turning the CBS to either the "TRIP" (momentary) position or to the "PULL-TO-LOCK" (maintained) position.

Note: The pull-to-lock position is obtained by rotating the handle to the left 90 degrees and then pulling the handle out approximately 12.7 mm (0.5 inch). In order to release the CBS handle from the pull-to-lock position, push the handle in and it will return to the center position.

Any shutdown event, as indicated by a "RED" lamp on the EMCP3, will cause the generator breaker to trip open.

Any time that the generator set is running, the breaker will trip open immediately when the EMCP3 is placed in "STOP" mode. Additionally, the breaker is held open in order to prevent inadvertently energizing the generator when the engine is not running.

Engine Idle and Engine Rated Speed Switch

The manual paralleling unit provides a two-position selector switch (7) in order to allow the operator to run the engine at either idle or rated speed. The option to run the engine at either idle or rated speed is intended for use in special circumstances such as cold start-ups. The engine idle and engine rated speed switch is not used normal for start-up. Therefore, the engine idle and engine rated speed switch is located on the inside of the terminal box away from the operator controls that are located on the front of the terminal box.

Refer to Illustration 4.

When "IDLE" (down) is selected, the engine ECM and the EMCP3 receive a signal that indicates that "IDLE" has been selected. Certain functions within the EMCP3 such as undervoltage and underfrequency are disabled while the engine is running in idle speed. These functions are disabled in order to prevent engine shutdown.

User Interface Panel (UIP)

The manual paralleling unit has the following standard operator controls.

Illustration 5	g01878434
User Interface Panel (10) Upper Access Panel (11) Annunciator (12) CAN1 Service Connector (13) EMCP3.3 Control (14) Circuit Breaker Switch (15) Sync Light Module (20) Emergency Stop (21) Speed Adjust (22) Voltage Adjust (23) DC Breaker Trip Indicator (24) Fuel Tank Level (25) Fuel Transfer Unload/Load Switch (26) Fuel Transfer Man/Off/Auto Switch (27) Fuel Tank Overfill Indicator

DC Breaker Trip Indicator

If the DC breaker trip indicator (23) is lit, then an investigation must be made in order to determine the root cause of the problem. Actions must be taken in order to correct any problems.

Reset CB3. CB3 is located in the terminal box behind the hinged access panel (30) that is just below UIP. CB3 is located on the left hand side of the compartment. Refer to Illustration 6.

Illustration 6	g01880197

Fuel Transfer Control

Fuel from an external fuel reservoir can be used in order to maintain the level of fuel in fuel tank of the power module. The fuel level can be automatically maintain between 50% to 85% full by pumping the fuel from the external fuel reservoir. In order to automatically maintain the fuel level, place the "Fuel Transfer Unload/Load" switch (25) in the load position and place the "Fuel Transfer Man/Off/Auto" switch (26) to the Auto position.

If the fuel level of the power module fuel tank was manually filled too high or if a malfunction in the auto transfer system occurs, a safety overfill switch activates the fuel tank overfill indicator (27). The fuel transfer pump is electrically locked in order to prevent any more fuel from being pumped into the fuel tank of the power module. Perform the following in order to reduce the amount of fuel in the fuel tank of the power module. Place the "Fuel Transfer Unload/Load" switch (25) in the Unload position and place the "Fuel Transfer Man/Off/Auto" switch (26) to the Manual position. Continue to manually pump fuel from the fuel tank of the power module into the external fuel reservoir until the "Fuel Tank Overfill Indicator" (27) goes off.

CAN1 Service Connector

The CAN1 service connector (12) provides access for Caterpillar Service Tool. The CAN1 service connector (12) provides access to the primary J1939 and to Cat Datalink. The CAN1 service connector (12) allows for configuration and/or monitoring of the engine ECM, the Caterpillar Digital Voltage Regulator (CDVR), and the EMCP3 (13) while the engine is running or while the engine is not running.

Note: The service connector for accessory modules that use CAN2 protocol, is attached to the harness that is behind the EMCP3 (13) .

Shore Power Distribution Box (Wall-Mount)

The manual paralleling unit contains a shore power distribution panel that is fed from a 230 VAC, 50 Hz or a 240 VAC, 60 Hz external supply. The shore power distribution panel is located on the wall of the power module for easy access to the:

• distribution panel

• monitor circuit breakers (CB)

• motor starter for the radiator fan

The motor starter for the radiator fan is DIN rail mounted and has a time delay relay. Refer to Illustration 7.

Illustration 7	g01878457
Shore Power Distribution Box (35) Jacket Water Heater (CB3, 50 A) (36) Jacket Water Pump (CB4, 10 A) (37) Generator Space Heater (CB5, 15 A) (38) Battery Charger (CB8, 20 A) (39) Fuel Transfer Pump (CB10, 15 A) (40) AC Overhead Lights (CB11, 5 A) (41) AC Receptacles (CB12, 15 A) (42) Radiator Fan Motor Starter (MS1) (43) Start-up Time Delay Relay for (MS1) (44) Fuel Transfer Relay-Load LR (45) Fuel Transfer Relay-Unload UR

Note: The circuit breaker (CB) for the DC overhead lights, CBL 15 A, is located in the terminal box behind the hinged access panel (30) that is just below UIP. CBL is located on the left hand side of the compartment.

Illustration 8	g01878476
Shore Power Distribution Panel Pictograph Symbols (51) Jacket Water Heater (CB3, 50 A) (52) Jacket Water Pump (CB4, 10 A) (53) Generator Space Heater (CB5, 15 A) (54) Battery Charger (CB8, 20 A) (55) Fuel Transfer Pump (CB10, 15 A) (56) AC Overhead Lights (CB11, 5 A) (57) AC Receptacles (CB12, 15 A)