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Conversion Procedure for Frequency on the C32 Power Module{1901, 4490, 7002} Caterpillar


Conversion Procedure for Frequency on the C32 Power Module{1901, 4490, 7002}

Usage:

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

Introduction

This Special Instruction provides instruction for converting the C32 Power Module for either 50 Hertz operation or for 60 Hertz operation.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

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

ReferenceSystems Operation Troubleshooting Testing and Adjusting, RENR7902, "EMCP3"

ReferenceSystems Operation Troubleshooting Testing and Adjusting, RENR7941, "Caterpillar Digital Voltage Regulator (CDVR)"

ReferenceSystems Operation Testing and Adjusting, RENR4928, "3500 Engines for Caterpillar Built Power Modules"

Glossary

ECS - Engine Control Switch: This is the switch that is used in order to send the following signals to the engine: STOP, AUTO, OFF/RESET and MANUAL START.

ADEM - Advanced Diesel Engine Management: This is an ECM that uses sensors for monitoring and regulating the delivery of fuel and other systems in order to manage the load and performance of the engine.

AREP - Auxiliary (Winding) Regulation Excitation Principle: This is a system that is used in a generator that provides excitation power that is independent of the load.

Cat ET - Caterpillar Electronic Technician: This is a service tool that uses a computer program in order to communicate with an ECM and configure an ECM.

CDL - Cat Data Link: This is a communication protocol that is used by Caterpillar engines. The ADEM IV uses CDL in order to configure the settings by using a service tool.

CDVR - Caterpillar Digital Voltage Regulator: This component regulates the output voltage of a generator that is used with an engine generator set.

ECM - Electronic Control Module: This component is a module within a control system that uses a microprocessor in order to control a function. For example, the engine ECM is dedicated to controlling the timing and the air to fuel ratio of the engine.

EMCP - Electronic Modular Control Panel: This is a panel that is used for controlling and monitoring many of the functions of the generator set.

HMI - Human Machine Interface: This is the user interface that provides a graphics-based visualization of the monitoring system.

J1939 - This is a communication protocol that is used within the transportation and power generation industry. The EMCP3.1 supports a J1939 data link. This is the Primary Data Link. The EMCP3.2 and later versions support the Primary Data Link as well as a second J1939 data link. This secondary data link is the Accessory Data Link.

PMG - Permanent Magnet Generator: This is a brushless excitation system that is used in an alternator.

Self Excited - This is a system in an alternator that allows the automatic voltage regulator to take power directly from the output terminals of the generator.

Configuring the Control

Connect the Service Tool

  1. Turn the key switch to the ON position.

    The 24 Volt DC power will be applied in order to start the EMCP3.3.

  1. Connect the communication cable of the Cat ET service tool to the communications port of the EMCP3.3.
    Show/hide table

    Illustration 1g02120793

    The Cat ET application is searching for components.

  1. Open the Cat ET application on the computer that is connected to the network. The service tool will search for the following components:

    • EMCP3.3 on the primary J1939 network

    • CDVR generator ECM on the primary J1939 network

    • ADEM IV engine ECM on the CDL network

    The service tool will connect to one of the listed components.

Configure the EMCP3.3

    Show/hide table

    Illustration 2g02121413

    "Switch Data Link" is selected.

  1. Connect to the ECMP3.3. Click "Switch Data Link", if needed.

    Note: The EMCP3.3 and CDVR are accessible via the J1939 data link. The ADEM IV is accessible via the Cat Data Link.

    Show/hide table

    Illustration 3g02121419

    Exploded view of the configuration button

  1. Click the configuration button in order to access the "Configuration" dialog.

  1. Select the plus sign that is to the left of the "EMCP3.3" selection in order to open the submenu and change the parameters.
    Show/hide table

    Illustration 4g02121473

    Parameters for the "Engine Speed Monitor" dialog

    (1) "Engine Overspeed Setpoint"

    (2) "Engine Underspeed Warning Event Threshold"

    (3) "Engine Underspeed Shutdown Event Threshold"

  1. Select "Engine Speed Monitor". Refer to Illustration 4.

  1. Modify the parameters that are listed in Table 1, as needed.

    Show/hide table
    Table 1
    "Engine Speed Monitor"    
    Parameter     50 Hertz     60 Hertz     Unit    
    "Engine Overspeed Setpoint"     1779     2124     RPM    
    "Engine Underspeed Warning Event Threshold" (1)     1290     1548    
    "Engine Underspeed Shutdown Event Threshold" (2)     1230     1476    
    Show/hide table
    ( 1 ) This is the speed below the rated speed that the EMCP3.3 will issue a warning to the operator. The value should be 86 percent of the rated speed.
    ( 2 ) This is the speed below the rated speed that the EMCP3.3 will initiate a shutdown of the generator set. The value should be 82 percent of the rated speed.
    Show/hide table

    Illustration 5g02121516

    Parameters for the "Generator AC Monitor" dialog

    (4) "Generator Rated Frequency"

    (5) "Generator Rated Voltage"

    (6) "Generator Rated Power"

    (7) "Generator Rated Apparent Power"

  1. Select "Generator AC Monitor". Refer to Illustration 5.

  1. Modify the parameters that are listed in Table 2, as needed.

    Show/hide table
    Table 2
    "Generator AC Monitor"    
    Parameter     50 Hertz     60 Hertz     Unit    
    "Generator Rated Frequency"     50     60     Hertz    
    "Generator Rated Voltage"     400     480     Volts    
    "Generator Rated Power"
    (Prime)        		 800     910     kW    
    "Generator Rated Power"
    (Standby)        		 880     1000    
    "Generator Rated Apparent Power"
    (Prime)        		 1000     1138     kVA    
    "Generator Rated Apparent Power"
    (Standby)        		 1110     1250    
    Show/hide table

    Illustration 6g02121993

  1. Refer to the formula in Illustration 6 in order to calculate the generator rated apparent power.
    Show/hide table

    Illustration 7g02121553

    "Generator Nominal Output Voltage" (8) parameter of the "AVR Desired Voltage Request" dialog

  1. Select "AVR Desired Voltage Request". Refer to Illustration 7.

  1. Modify the "Generator Nominal Output Voltage" parameter, as needed.

    50 Hertz - 400 Volts

    60 Hertz - 480 Volts

    Show/hide table

    Illustration 8g02121577

    "Generator Nominal Output Frequency" (9) parameter of the "Governor Desired Engine Speed Request" dialog

  1. Select "Governor Desired Engine Speed Request". Refer to Illustration 8.

  1. Modify the "Generator Nominal Output Frequency" parameter, as needed.

    50 Hertz - 50 Hz

    60 Hertz - 60 Hz

Configure the CDVR

    Show/hide table

    Illustration 9g02121413

    "Switch Data Link" is selected.

  1. Connect to the CDVR. Click "Switch Data Link", if needed.

    Note: The EMCP3.3 and CDVR are accessible via the J1939 data link. The ADEM IV is accessible via the Cat Data Link.

    Show/hide table

    Illustration 10g02121419

    Exploded view of the configuration button

  1. Click the configuration button in order to access the "Configuration" dialog.
    Show/hide table

    Illustration 11g02121594

    "Voltage Regulator Power Input Frequency Configuration" (10) parameter of the "Monitor" dialog

  1. Select the plus sign that is to the left of the "Digital Voltage Regulator" selection in order to open the submenu and change the parameters.

  1. Select "Monitor". Refer to Illustration 11.

  1. Modify the "Voltage Regulator Power Input Frequency Configuration" parameter (10), as needed.

    The value to enter is based on the method that is used for excitation.

    AREP - Equal to the frequency of the generator

    PMG - Equal to four times the frequency of the generator

    Self Excited - Equal to the frequency of the generator

    Note: Unless the "Potential Transformers" and the "Current Transformers" in the generator are changed, do not change this value.

    Show/hide table

    Illustration 12g02121813

    Parameters for the "Protection" dialog

    (11) "Generator Rated Frequency"

    (12) "Generator Rated Voltage"

    (13) "Generator Rated Current"

  1. Select "Protection". Refer to Illustration 12.

  1. Modify the parameters that are listed in Table 3, as needed.

    Show/hide table
    Table 3
    "Protection"    
    Parameter     50 Hertz     60 Hertz     Unit    
    "Generator Rated Frequency"     50     60     Hertz    
    "Generator Rated Voltage"     400     480     Volts    
    "Generator Rated Current"
    Prime        		 1445     1370     Amps    
    "Generator Rated Current"
    Standby        		 1590     1505    
    Show/hide table

    Illustration 13g02121994

  1. Refer to Illustration 13 in order to calculate the "Generator Rated Current".
    Show/hide table

    Illustration 14g02121835

    Parameters for the "Voltage Regulator Control Parameters" dialog

    (14) "Generator Nominal Output Voltage"

    (15) "Voltage Regulator Corner <knee> Frequency"

  1. Select "Voltage Regulator Control Parameters".

  1. Modify the parameters that are listed in Table 4.

    Show/hide table
    Table 4
    "Voltage Regulator Control Parameters"    
    Parameter     50 Hertz     60 Hertz     Unit    
    "Generator Nominal Output Voltage"     400     480     Volts    
    "Voltage Regulator Corner <knee> Frequency" (1)     49.8     59.8     Hertz    
    Show/hide table
    ( 1 ) Equal to the frequency that is desired minus 0.2 Hz

Configure the C32 Generator Set Engine

    Show/hide table

    Illustration 15g02121413

    "Switch Data Link" is selected.

  1. Connect to the ADEM IV. Click "Switch Data Link", if needed.

    Note: The EMCP3.3 and CDVR are accessible via the J1939 data link. The ADEM IV is accessible via the Cat Data Link.

    Show/hide table

    Illustration 16g02121419

    Exploded view of the configuration button

  1. Click the configuration button in order to access the "Configuration" dialog.
    Show/hide table

    Illustration 17g02121844

    "C32 Genset Engine" dialog

    (16) "Selected Engine Rating"

    (17) "Rating Number"

  1. Select the plus sign that is to the left of the "C32 Genset Engine" selection in order to open the submenu and change the parameters.

  1. Select the plus sign that is to the left of "Selected Engine Rating" (16) in order to select the parameters. Refer to Illustration 17.
    Show/hide table

    Illustration 18g02121916

    "Change Engine Power Rating" dialog

    (18) "Rating Numbers"

    (19) "OK" button

  1. Double click "Rating Number" (17). Refer to Illustration 17.

    The "Change Engine Power Rating" dialog opens.

  1. Select the correct frequency for your application from the "Rating Numbers" (18) that are listed. Refer to Illustration 18.

    The "Rating Information" will change according to your selection.

    50 Hertz - 2

    60 Hertz - 3

    Prime and Standby - See Note

    Note: Caterpillar Power Modules use ratings 2 and 3.Caterpillar generator sets use rating 1. A change from 1 to 2 or from 1 to 3 is a change from one interlock to another. This change requires a factory password. Only Power Module engine serial number prefixes will be granted a factory password. Once inside interlock 26, the change from rating 2 to 3 or from 3 to 2 will not require a factory password.

  1. Click the "OK" button (19) in order to accept the change. A confirmation dialog opens.

  1. Click "Yes" in order to confirm the change.

  1. Reset any faults that are displayed on the EMCP3.3, ECM, or CDVR.

Configure the Switchgear

The method to change the parameters of the switchgear depends on the panel arrangement. Either the Human Machine Interface (HMI) is used or else jumpers are configured. Refer to Table 5 for the correct method for your panel arrangement.

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Table 5
Panel Arrangement     Method    
298-2714     Use the HMI    
316-2483    
326-7735     Configure the jumpers.    
329-6007    

  1. Use the HMI on the Switchgear panel.

    1. Select "Main Menu".
      Show/hide table

      Illustration 19g02121933

      The "System Setup" screen of the HMI with 60 hertz operation (20) selected

    1. Select "System Setup".

    1. Select the correct frequency for your application.

      50 Hertz - "400V/50Hz"

      60 Hertz - "480V/60Hz"

      Note: A light background with dark letters indicates that the feature is selected. Refer to Illustration 19.

  1. Configure the jumpers.

    1. Set the desired frequency by configuring the jumper that is called out in Table 6.

      Show/hide table
      Table 6
      Frequency     Jumper 50 - 53    
      50 Hertz     X    
      60 Hertz     0    

    1. Set the desired voltage by configuring the jumpers that are called out in Table 7.

      Show/hide table
      Table 7
      Voltage     Jumper    
      50 -51 50-52
      Generator
      Link Board
      Signal = Low
      (Open Input)          		 208 V     X     X    
      220 V 0     X    
      230 V X     0    
      240 V 0     0    
      Generator
      Link Board
      Signal = Low
      (Closed Input)          		 380 V     X     X    
      400 V X     0    
      415 V 0     X    
      480 V 0     0    

Test the Power Module

    Show/hide table

    Illustration 20g02121953

    "GEN 1 CONTROL" screen of the HMI

    (21) Engine Control Switch

    (22) "Sync Control" switch

  1. Set the Engine Control Switch (ECS) (21) to the OFF position.

  1. Reset any faults that may occur.

  1. Set the "Sync Control" switch (22) to the OFF position.

  1. On the EMCP3.3 panel on the generator set, place the EMCP control panel to AUTO mode.

  1. On the switchgear, use the ECS switch in order to start the unit in MANUAL mode.

  1. Ensure that the generator is running at the proper speed.

  1. Ensure that the generator set has the correct output voltage and the correct frequency.

    If no faults or no errors are present, then the conversion procedure is complete. If errors or faults are present, then review the steps that are in the conversion procedure in order to troubleshoot the problem.

    Refer to the publications that are in the ""Reference Information" " section for assistance in troubleshooting the problem.

Summary of Changes to Parameters

Show/hide table

Illustration 21g02130520

Frequency Conversion Chart for 50 Hz and 60 Hz operation

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