Conversion Procedure for Voltage on the C32 Power Module{4467, 4490, 7002} Caterpillar

Conversion Procedure for Voltage on the C32 Power Module{4467, 4490, 7002}

Usage:

C32 MED

Power Module:: C32 POWER MODULE (S/N: MED1-UP)

Introduction

These instructions are provided in order to convert the operation of the C32 Power Module from a high voltage operation to a low voltage operation. These instructions may also be used as a procedure to convert the power module from a low voltage operation to a high voltage operation. A high voltage of 480 V, 60 Hz or 400 V, 50 Hz can convert to a low voltage of 240 V, 60 Hz or 200 V, 50 Hz.

ReferenceRefer to Service Manual, RENR7902, "EMCP3", Systems Operation, RENR7941, "Caterpillar Digital Voltage Regulator (CDVR)", Service Manual, RENR4928, "3500 Engines for Caterpillar Built Power Modules", and Service Manual, RENR4929, "3500B Engines for Caterpillar Built Power Modules with the ADEM 2 Electronic Control Module" for more information.

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.

Procedure for Converting the Voltage Setting

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Only persons with training in electrical installations must carry connections to the generator.
The generator must be wired correctly. A fire or electrocution could result from wiring that is incorrect.
The generator is capable of generating high voltages. Ensure that the generator is not on while the connections are being made. Follow these two steps in order to prevent accidental starting:

Isolate the DC breaker.

Disconnect the DC supply battery.

Disconnect shore power. Turn off the 24 VDC by using the keyswitch.

Locate the 291-4928 Plate As that is inside of the housing above the generator.

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Illustration 1	g02092554

Release the four latches that are on the cover.

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Illustration 2	g02092555

Slide the cover off the housing.

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Illustration 3	g02092562
(1) 7X-2555 Bolt (2) 9X-8257 Washer (3) 291-4928 Plate As

Remove the ten large 7X-2555 Bolts (1) from the 291-4928 Plate As (3). Retain all of the hardware for use during the reinstallation.

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Illustration 4	g02092572

Slide the 291-4928 Plate As until the three contact switches are depressed.

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Illustration 5	g02092595

Align the holes of the 291-4928 Plate As . Insert the 9X-8257 Washers (2) and the 7X-2555 Bolts (1) that were removed.

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Illustration 6	g02098039

Tighten each of the bolts to 270 ± 40 N·m (199 ± 30 lb ft).

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Illustration 7	g02092674

Place the cover onto the housing.

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Illustration 8	g02092554

Secure the cover by using the four latches.

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Illustration 9	g02092676

Settings for EMCP 3 Voltage

Turn on the 24 VDC by using the keyswitch in order to power up the EMCP.

Connect the communication cable for the Caterpillar Electronic Technician (Cat ET) to the EMCP 3.3 communications port 1 in order to communicate with the control panel for the EMCP 3.

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Illustration 10	g02092793

Open Cat ET. Cat ET searches the J1939 data link for the EMCP 3 and/or the digital voltage regulator. The tool will also search for an ADEM Engine ECM on the Cat Data Link.

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Illustration 11	g02092795

The service tool connects to the EMCP 3, the Caterpillar Digital Voltage Regulator (Cat DVR) or the Engine ECM. It is not necessary to connect to the Engine ECM in order to perform this procedure. Navigate to "Switch Data Link" if it is necessary to perform a switch from the Engine ECM to the EMCP 3 or the controllers for the DVR.

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Illustration 12	g02092816
(4) "Configuration" button

Click on the "Configuration" button (4) that is located on the toolbar at the top of the service tool in order to navigate to the "Configuration" window.

Click on the "Generator AC Monitor" submenu that is located in the left hand panel in order to change the following parameter:
- High voltage setting for the "Generator Rated Voltage" of 480V or 400V
- Low voltage setting for the "Generator Rated Voltage" of 240V or 200V

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Illustration 13	g02092819

Click on the "AVR Desired Voltage Request" submenu that is located in the left hand panel in order to change the following parameter:
- High voltage setting for the "Generator Nominal Output Voltage" of 480V or 400V
- Low voltage setting for the "Generator Nominal Output Voltage" of 240V or 200V

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Illustration 14	g02092822

Click on the plus sign that is next to the Digital Voltage Regulator in order to see the submenus. Click on the "Protection" submenu in order to change the following parameters:
- High voltage setting for the "Generator Rated Voltage" of 480V or 400V
- Low voltage setting for the "Generator Rated Voltage" of 240V or 200V
"Generator Rated Current" settings for high voltage
- Prime 50Hz 400V, 800kW = 1445 Amps (0.8 PF)
- Standby 50Hz 400V, 880kW = 1590 Amps (0.8 PF)
- Prime 60Hz 480V, 910kW = 1370 Amps (0.8 PF)
- Standby 60Hz 480V, 1000kW = 1505 Amps (0.8 PF)
"Generator Rated Current" settings for low voltage
- Prime 50Hz 200V, 800kW = 2890 Amps (0.8 PF)
- Standby 50Hz 200V, 880kW = 3180 Amps (0.8 PF)
- Prime 60Hz 240V, 910kW = 2740 Amps (0.8 PF)
- Standby 60Hz 240V, 1000kW = 3010 Amps (0.8 PF)

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Illustration 15	g02092824

Click on the "Voltage Regulator Control Parameters" submenu in order to change the following parameter:
- High voltage setting for the "Generator Nominal Output Voltage" of 480V or 400V
- Low voltage setting for the "Generator Nominal Output Voltage" of 240V or 200V

The 298-2714 Control Panel AR and the 316-2483 parts for the switchgear automatically change by an input from the PLC that is connected to the relays. The voltage settings do not change automatically. You must manually set the voltage that is desired.

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Illustration 16	g02092827

The 326-7735 Control Panel AR and the 329-6007 parts for the switchgear automatically change by an input from the PLC that is connected to the relays. Set a specific voltage into the controls by using a set of jumpers. Refer to Illustration 16 for more information on the jumpers.

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Illustration 17	g02092834

Test the power module. Move the Engine Control Switch (ECS) to the "OFF" position at the switchgear and reset any of the faults.

Place the EMCP control in the "AUTO" mode on the EMCP 3 panel that is located on the genset.

Go to the switchgear and start the module in the "MAN" mode for the ECS. Check for the desired voltage and the desired frequency.

The conversion procedure is complete if faults and errors are not active. Review the steps in the conversion procedure if a fault or an error is active. Refer to the publications that are listed at the beginning of this Special Instruction for more information.