Dual Frequency Conversion for the 3516C Power Module{1000, 4450} Caterpillar

Engine:

3516C (S/N: NAM100-UP; KEN100-UP)

Introduction

This Special Instruction provides the information in order to adjust the 3516C Power Module for either 50 Hz operation or 60 Hz operation.

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.

Reference Information

The following publications can be used for reference.

ReferenceSee EMCP3 Systems Operation Troubleshooting Testing and Adjusting, RENR7902 for more information.

ReferenceSee Caterpillar Digital Voltage Regulator (CDVR) Systems Operation, RENR7941 for more information.

ReferenceSee Systems Operation Testing & Adjusting, RENR4928 for more information.

ReferenceSee Troubleshooting, RENR4929 for more information.

Glossary

Cat Datalink (CDL) - The Cat Datalink (CDL) is a serial communications system that is used for communication with other microprocessor based devices. The CDL is a proprietary data link that is used for Caterpillar equipment. The panel for the electronic monitoring system utilizes the CDL for communication. The CDL is also used for communication with ET.

Caterpillar Electronic Technician (ET) - Cat ET is a service tool that uses a software program in order to run on a personal computer (PC).

Electronic Control Module (ECM) - The ECM is the engine's control computer. The ECM provides power to the electronics. The ECM monitors data that is input from the engine's sensors. The ECM acts as a governor in order to control engine speed.

J1939 CAN Data Link - This data link is an SAE diagnostic communications data link that is used to communicate between the electronic engine and the instrument clusters.

Configure the Control

Connect Cat ET

1. Turn the key switch to the ON position. The 24 VDC power should be applied in order to power up the Electronic Modular Control Panel (EMCP) .

2. Caterpillar Electronic Technician (Cat ET) must be used in order to communicate with the EMCP3. Connect the Cat ET communications cable to the EMCP3.3 communications port.

3. Open the Cat ET application on the personal computer. The service tool will search for any components that are connected to the primary J1939 network. The components can be an EMCP3, a CDVR or an ECM that is used for an engine that is part of a generator set. The service tool will search for any components that are connected to the Cat Datalink network. The components can be an ADEM IV controller (engine control module) or a CDVR.

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Illustration 1	g01949514

4. The service tool will connect to an EMCP3, a CDVR or an ECM.

   Note: Cat ET will connect to only one electronic module at a time. Cat ET will connect to either the EMCP3, the voltage regulator or the engine control module (ECM).

5. In order to select the EMCP3 or the ADEM IV controller, navigate to the "Switch Data Link" dialog.

   1. Click "File" at the "ECM Summary" dialog.

   2. Select "Switch Data Link" from the drop down menu. Refer to Illustration 2.

Illustration 2	g01949743

Configure the EMCP3

1. Click on the configuration button in order to access the configuration dialog. Refer to Illustration 14.

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Illustration 3	g01950012
Configuration Button

2. Click the plus sign that is next to the EMCP3.3 in order to view the EMCP parameters. Refer to Illustration 4.

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Illustration 4	g01950033
(1) Engine Over Speed Set Point RPM (2) Engine Under Speed Warning Event Threshold RPM (3) Engine Under Speed Shutdown Event Threshold RPM

3. Change the following list of parameters.
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   Table 1

   EMCP3.3 Parameters
   Parameter	50 Hz	60 Hz
   Engine Over Speed Set Point RAM (1)	1770	2124
   Engine Under Speed Warning Event Threshold rpm (2)	1290	1548
   Engine Under Speed Shutdown Event Threshold rpm (3)	1230	1476

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   ( 1 )	This is the speed above the rated speed that the EMCP will sisue a shutdown of the gererator set. The speed should be 118% of the rated speed.
   ( 2 )	This is the speed below the rated speed that the EMCP will issue a warning to the operator. The speed should be 86% of the rated speed.
   ( 3 )	This is the speed below the rated speed that the EMCP will initiate a shutdown of the generator set. The speed should be 82% of the rated speed.

4. Next, click on "Generator AC Monitor". Change the following list of parameters. Refer to Table 2, Illustration 5 and Illustration 6.
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   Table 2

   EMCP3.3 Parameters
   Parameter	50 Hz	60 Hz
   Generator Rated Frequency	Set to the desired Frequency of 50 Hz or 60 Hz
   Generator Rated Voltage	400 V	480 V
   Generator Rated Power (kW)	Prime - 1310 kW	Prime - 1825 kW
   	Standby - 1440 kW	Standby - 2000 kW
   Generator Rated Apparent Power (kVA) (1)	Prime - (1310kW) 1635 kVA (2)	Prime - (1825 kW) 2250 kVA (2)
   	Standby - (1440 kW) 1800 kVA (2)	Standby - (2000 kW) 2500 kVA (2)

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   ( 1 )	Refer to the calculation in Illustration 5.
   ( 2 )	0.8 PF used for Calculation

   Note: The "Generator Rated Power" (kW) is in parenthesis.

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Illustration 5	g01950118
Calculation for the Apparent Power Using the Generator Rated Power and the Power Factor

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Illustration 6	g01950134
(6) Generator Rated Frequency (7) Generator Rated Voltage (9) Generator Rated Power (kW) (10) Generator Rated Apparent Power (kVA)

5. Set the desired nominal output voltage. Navigate to the "AVR Desired Voltage Request". Enter the desired generator nominal output voltage (11). Refer to Table 3 and Illustration 7.

   Note: "AVR" is the acronym for "Automatic Voltage Regulator".

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   Table 3

   EMCP3.3 Parameter
   Parameter	50 Hz	60 Hz
   Generator Nominal Output Voltage	400 V	480 V

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Illustration 7	g01950149
(11) Nominal Output Voltage

6. Set the desired nominal output frequency. Navigate to the "Governor Desired Engine Speed Request" (12). Click on the "Governor Desired Engine Speed Request". Enter the desired frequency (13). Refer to Table 4 and Illustration 8.
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   Table 4

   EMCP3.3 Parameter
   Parameter	50 Hz	60 Hz
   Generator Nominal Output Frequency	Set to the desired Frequency of 50 Hz or 60 Hz

Illustration 8	g01952884
(12) Governor Desired Engine Speed Request (13) Frequency

Configure the CDVR

1. Set the desired the voltage regulator power input frequency. Navigate to the "Digital Voltage Regulator" that is shown in the list of "Available ECM(s)".

2. Click the plus sign that is next to the "Digital Voltage Regulator" in order to view the CDVR parameters.

3. Click on "Monitor". Refer to Illustration 9.

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Illustration 9	g01950214

4. Change the setting for the "Voltage Regulator Power Input Frequency Configuration" (14) to the desired value.

   Note: The "Voltage Regulator Power Input Frequency Configuration" value must be equal to four times the generator frequency for permanent magnet generators (PMG). The value should be equal to one times the generator frequency for "Self Excited" or "Internal Excitation/AREP" generators.

   Note: Do not change the values for the potential transformers or the current transformers unless those components are changed.

5. Navigate to "Protection" that is shown in the list of selections under the "Digital Voltage Regulator". Change the values for the "Generator Rated Frequency" (16) and "Generator Rated Voltage" (17) and the "Generator Rated Current" (18). Refer to Table 5 and Illustration 11.
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   Table 5

   CDVR Parameter
   Parameter	50 Hz	60 Hz
   Generator Rated Frequency	Set to the desired Frequency of 50 Hz or 60 Hz
   Generator Rated Voltage	400 V	480 V
   Generator Rated Current	Prime - 400 V 1310 kW = 2366 Amps (1)	Prime - 480 V 1825 kW = 2747 Amps (1)
   	Standby - 400 V 1440 kW = 2601 Amps (1)	Standby - 480 V 2000 kW = 3007 Amps (1)

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   ( 1 )

   0.8 PF

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Illustration 10	g01950480
Calculation for the Generator Rated Current

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Illustration 11	g01950486
(16) Generator Rated Frequency (17) Generator Rated Voltage (18) Generator Rated Current

6. Set the knee frequency. Click on "Voltage Regulator Control Parameters" in order to access the knee frequency parameters. Change the generator nominal output voltage (20) to the desired value. Change the voltage regulator corner (knee) frequency (21) to the desired value. Refer to Table 6 and Illustration 12.

   Note: The knee frequency must be set to 0.2 Hz less than the desired frequency as shown in Table 6.

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   Table 6

   CDVR Parameter
   Parameter	50 Hz	60 Hz
   Generator Nominal Output Voltage	400 V	480 V
   Voltage Regulator Corner (Knee) Frequency	49.8 Hz	59.8 Hz

Illustration 12	g01950578
(20) Generator Nominal Output Voltage (21) Corner (Knee) Frequency

Configure the ADEM III

Note: The EMCP3 control or the engine ECM can be accessed. Go to the tool bar of the "ECM Summary" dialog. Click on "File". Select "Switch Data Link" (22) from the drop down menu. Refer to Illustration 13.

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Illustration 13	g01950589

1. Click on the configuration button in order to access the configuration dialog. Refer to Illustration 14.

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Illustration 14	g01950012
Configuration Button

2. Cursor down to the "Selected Engine Rating" (25). Click on the plus sign that is next to the "Selected Engine Rating" in order to access the parameters. Refer to Illustration 15.

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Illustration 15	g01950619
(25) Selected Engine Rating

3. Double click on the rating number. The "Change Engine Power Rating" dialog will open.

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Illustration 16	g01950795
(27) Rating Number that can be Changed

4. The rating number must be changed to 2 for 50 Hz operation or to 3 for 60 Hz operation. After the rating number has been selected, then the rating information will change.
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   Table 7

   ADEM III Parameter
   Parameter	50 Hz	60 Hz
   Engine Power Rating	2	3

5. Click "OK" in order to accept the change.

   Note: Caterpillar power modules use either a 2 rating and a 3 rating. Caterpillar generator sets use a 1 rating. A change from 1 to 2 or 1 to 3 is a change from one interlock to another which requires a factory password. Only the power modules that begin with engine serial number prefixes "MHB" will be granted a factory password. Once access is granted to interlock 26, the change from rating 2 to 3 or 3 to 2 will not require a factory password.

6. Click "YES" in order to confirm the rating that is to be changed. Reset any faults that are displayed on the EMCP3, ECM or CDVR.

Configure the Paralleling Controls

Enter Set Point Values for Auto Paralleling Control

1. Enter set point programming mode by simultaneously pressing the two "arrow keys". Refer to Illustration 17.

   Note: The "Active" lamp with go off after entering the set point programming mode.

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Illustration 17	g01950817

2. Press the "DISPLAY/SELECT" button to advance through the set point parameters.

3. After the "DISPLAY/SELECT" button is pressed twice, you will be prompted to enter the password. At first, a random number will appear. Enter the password number in place of the random number. The correct password is 5712.

4. The two "arrow keys" must be used in order to enter the password. The "right arrow" key moves the cursor. The "up arrow" key increases the value of the selected digit. Once all four digits are entered, press the "DISPLAY/SELECT" button again in order to accept the correct password number. Press the "DISPLAY/SELECT" button again in order to advance to the set point parameters.

5. Enter the value for each "bold" parameter that is listed below.

   Note: Use the same procedure that is listed in Step 4 in order to change each parameter.

6. Once all of the set point parameters have been entered and once all of the set point parameters have been accepted, exit the set point programming mode. Simultaneously press the two "arrow keys" in order to exit the set point programming mode.

   Note: The "Active" lamp will come on after exiting the set point programming mode.

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   Table 8

   Parameter Values of the Parallel Control For 400 V, 50 Hz Operation
   Parameter	Value
   Rated frequency fn	50 Hz
   Generator frequency set point	50 Hz
   Generator voltage secondary	100 V
   Mains voltage secondary	100 V
   Generator voltage primary	0.400 kV
   Mains voltage primary	0.400 kV
   Rated voltage Vn	100 V
   Generator voltage set point	100 V
   Current transformer generator	3000/5
   Connection type generator	1W2
   Angle adjustment generator current	000
   Rated power generator	1440 kW
   Power controller	On
   Power controller P max	92%
   Power controller P min	5%
   Warm up load set point	5%
   Warm up load time	000 s
   Download and open GCB	ON
   Power controller P set1 =	1440 kW
   Power controller P set2 =	N/A
   Power set point External	On
   Analog input	4 - 20 mA
   External setp. 0mA, 4mA	0 kW
   External setp. 20mA	1440 kW
   Power controller ramp	10 kW/s
   Power controller gain Kp	7
   Power controller reset Tn	2.5 s
   Power controller derivat. Tv	0.02 s

Test the Power Module

1. Rotate the circuit breaker handle to the left and then pull it straight out.

2. Press "Auto" on the EMCP3.3 in order to run the generator set.

3. Turn the local "Start" switch to the ON position.

4. Check for proper generator operation. Ensure that the generator is running at the proper speed. Ensure that the generator output voltage is correct. If no faults or errors are present, then the conversion procedure was properly completed. If any faults or errors are present, review the steps that are listed in the conversion procedure in order to troubleshoot. Also, use the publications that are listed in the "Reference" section of this publication for possible assistance.

Switchgear Controls

Original "Human Machine Interface" (HMI) Version 4.0 June2006-April2009

This information applies to switchgear controls that possess "Human Machine Interface" (HMI) Version 4.0 June2006-April2009 software. The following list of software is the minimum software revision that is required.

• ProFace_XQ2007

• GXQ2004

• UXQ2003

1. Access the "System Setup" screen on the HMI. Select "400V/50Hz" for 50Hz operation. Select "480V/60Hz" for 60Hz operation.

   Note: A light colored background and dark letters means the feature is selected. Refer to Illustration 18.

Illustration 18	g01950853
(29) Shows 50 Hz Operation is Not Selected (30) Shows that 60 Hz Operation Is Selected

Note: When the operation mode is changed, the system voltage, the frequency and the protective settings will change.

Enhanced HMI Version 5.0 May2009-Present

This information applies to switchgear controls that possess HMI Version 5.0 May2009-Present software. The following list of software is the minimum software revision that is required.

• T2XQ201

• G739901

• U739901

The "Enhanced HMI" allows the user to save single unit sittings for quick setup after a control power interruption to the Programmable Logic Control (PLC). If control power were lost with the "Original HMI" software, then the user would have to go through the process once again in order to select the voltage and the frequency setting on the system setup screen. In order to save a configuration, the unit must be setup for single unit operation and a "Compact Flash" (CF) card must be installed in the PLC in order to store the configuration data.

1. Access the "System Setup" screen on the HMI. Select "400V/50Hz" for 50Hz operation. Select "480V/60Hz" for 60Hz operation.

   Note: A light colored background and dark letters means the feature is selected. Refer to Illustration 18.

2. Press the "Save Settings" soft key (), that is shown on the main menu, in order to save any data changes that were made. Refer to Illustration 19.

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Illustration 19	g01951134
(34) Save Settings Button

3. The data for the "Settings" can be retrieved with the use of the "Load Last Settings" button. The screen that contains the "Load Last Settings" button will appear only during the power up initialization process. Once the dialog appear, press the "Load Last Settings" button in order to retrieve that last settings that were saved. Refer to Illustration 20.

Illustration 20	g01951182
(35) Load Last Settings

Test the Power Module

1. Turn the switchgear "Engine Control Switch" (ECS) switch to the OFF position. Reset any faults.

2. Place the "Sync" switch in the OFF position.

3. Place the generator set EMCP control panel to "AUTO" mode. Start the switchgear unit in "MANUAL" mode. Place the ECS switch to the ON position. Start the generator set and then check for the desired output voltage and output frequency.

4. Ensure that the generator is running at the proper speed. Ensure that the generator has the correct output voltage. If there are no active faults or errors, then the conversion procedure was successfully completed. If there are active faults or errors, then review the steps that are in conversion procedure in order to troubleshoot the fault or error. Also, reference above publications for assistance. Also, use the publications that are listed in the "Reference" section of this publication for possible assistance.

Parameter Changes Summary