Procedure for Installation of VR6 Voltage Regulator{4467} Caterpillar

Engine:

C15 (S/N: ZKA1-UP)

C18 (S/N: ZKB1-UP)

Generator Set:

3406 GEN SET (S/N: NKM1-UP)

3406C GEN SET (S/N: ZKC1-UP; C2G1-UP; C5G1-UP; C8G1-UP; C2Y1-UP)

3456 GEN SET (S/N: C1G1-UP; C3G1-UP; C4G1-UP; C2T1-UP)

C15 GEN SET (S/N: C5E1-UP; STG1-UP; C5H1-UP; C5L1-UP; NKL1-UP; CYY1-UP)

C18 GEN SET (S/N: C6C1-UP; G4C1-UP; N1C1-UP; N1D1-UP; STD1-UP; DKE1-UP; NKK1-UP; NKM1-UP; STM1-UP; EKW1-UP; M1Y1-UP; M1Z1-UP)

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

Introduction

ReferenceTesting and Adjusting, RENR2480, "Voltage - Adjust"

This instruction will guide the user on the replacement of the existing R448 voltage regulator with the new VR6 voltage regulator.

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. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

Show/hide table

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

Show/hide table

The Cat VR6 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.

Show/hide table

Electrocution Hazard! Keep the machine and attachments a safe distance from electrical power. Stay clear 3 m (10 ft) plus twice the line insulator length. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions and warnings will cause serious injury or death

Installation Procedure

Removal of Existing R448 Voltage Regulator

1. Remove the generator top cover to gain access to the generator terminal box.

2. Remove the access cover panel to gain access to the voltage regulator.

3. Disconnect the remote voltage adjust potentiometer - and the exciter wires from the R448.

   Note: On some generators, the exciter wires are labeled "+"and "-".

4. Disconnect two sensing wires connected to the R448 terminals 0 and 110, 220 or 380.

5. If you have a Permanent Magnet Generator (PMG), disconnect wires labeled 14, 15, and 16 from the R448. If you have an Auxiliary (Winding) Regulation Excitation Principle (AREP), disconnect wires labeled 9, 10, 11, and 12 from the R448. If you have neither option, remove shunt excitation wires labeled 9 and 10 from the R448.

6. If droop Current Transformers (CT) is present, disconnect wires labeled S1 and S2 from the R448.

7. Remove the R448 with the mounting bracket.

8. Disconnect and remove the sensing harness, wires labeled 2 and 3, and the shunt excitation harness if present, wire 9 and 10 from the generator terminal bars.

Installation Location for Replacement VR6 Regulator

1. Determine an optimal location for the replacement VR6 kit making sure the VR6 adjustment potentiometers can be accessed via existing access cut-outs. Utilize existing holes in the generator terminal box when possible. This location will vary depending on your generator model.

2. On LC6100 generators, it is recommended to have the VR6 installed on the left side panel of the generator terminal box in a vertical position. Refer to Illustration 6.

3. On LC5000 generators, it is recommended to have the VR6 installed on the left side panel of the generator terminal box in a horizontal position. Refer to Illustration 2.

4. On LC7000 generators, it is recommended to have the VR6 installed on the front panel of the generator terminal box. Refer to Illustration 1.

Preparation of VR6 kit for mounting on the LC7000 and LC5000 Generators

Illustration 1	g02395121
LC7000 generator (1) Voltage regulator kit location

Illustration 2	g02411141
LC5000 generator (2) Voltage regulator kit location

1. Refer to Illustration 1 for the VR6 kit installation location on the LC7000 generators. Refer to Illustration 2 for the VR6 kit installation location on LC5000 generators.

Show/hide table



Illustration 3	g02411717
(3) 19 mm (3/4 inch) diameter holes

2. The left side kit bracket supplied with the VR6 regulator kit may need to be modified by enlarging (drill) the existing holes (3) to 19 mm (3/4 inch) diameter. Refer to Illustration 3.

Show/hide table



Illustration 4	g02411756
Example of marking holes

3. Hold the VR6 kit assembly behind the existing opening in the terminal box at the installation location. Make sure the drilled holes fit over the existing cage nuts on the inside of the cover. Use the existing holes in the cover as a template to mark the mounting holes in the left bracket that will need to be drilled. Refer to Illustration 4.

Show/hide table



Illustration 5	g02411776
(4) Temporarily reinstalled bolts

4. Temporarily reinstall two of the cover bolts (4) and hold the kit in place on the outside of the generator terminal box using the bolts to locate the left side VR6 bracket. Mark the holes for the right side bracket using the existing bracket holes as a template. Refer to Illustration 5.

5. Remove the VR6 kit and drill two 5.5 mm (7/32 inch) diameter holes in the left bracket where the marked holes are.

6. Drill two 8 mm (5/16 inch) diameter holes in the marked locations in the generator terminal box.

7. Use the existing 6V-8931 Washer Head Screw that were used to hold the existing R448 bracket to tap the 5.5 mm (7/32 inch) holes in the left bracket and retain the screws for the kit mounting later.

8. The VR6 kit is now ready for installation. Refer to installation chapter below to proceed.

Preparation for Mounting of the VR6 Kit on LC6100 Generators

Illustration 6	g02411816
LC6100 generator (5) Voltage regulator kit location

1. Refer to Illustration 6 for the VR6 kit installation location on the LC6100 Generators.

Show/hide table



Illustration 7	g02411839
Example of clearance check with regulator kit

2. Hold the VR6 kit assembly behind the existing opening in the terminal box at the installation location. Place and hold the kit inside the cover and assure the selected location will not intervene with any existing parts. For optimal fit in a typical generator, it is recommended that the bottom bracket is aligned with the cover opening. Refer to Illustrations 7 and 8.

Show/hide table



Illustration 8	g02411880
VR6 kit assembly (6) Alignment of the bottom bracket with the cover opening

3. Hold the VR6 kit assembly on the outside of the panel and use the existing holes in the brackets as a template to mark the mounting holes in the left side panel that will need to be drilled. Ensure that the bottom bracket is aligned with the cover opening (6). Refer to illustration 8.

4. Drill four 8 mm (5/16 inch) diameter holes in the marked locations in the generator terminal box.

5. The VR6 kit is now ready for installation.

VR6 Kit Installation and Wiring Common to All Applications

1. Inspect the wiring harness shipped with the VR6 kit and assure tight terminal connections. Install harness per wire markup. All wires are labeled with termination points, however, review the wiring diagrams, Illustrations 9, 10, and 11 at the end of this special instruction if required.

2. Determine the VR6 configuration and any optional wiring. For self/shunt excited (SE) generators refer to ""SE Generators Wiring" " below and wiring diagram Illustration 9. For PMG excited generators refer to ""PMG Excited Generators Wiring" " below and the wiring diagram Illustration 10. For AREP excited generators refer to ""AREP Excited Generators Wiring" "below and the wiring diagram Illustration 11

3. Identify the exciter wires labeled 5 and 6 or on some generators the exciter wires are labeled "+"and "-" and cut off the existing terminals. Be aware not to drop these terminals in the generator. Install two new 125-9997 Fork Terminals (2) onto these wires.

4. Cut off the existing terminals from the voltage adjust potentiometer, these are wires 80 and 82. Strip both wires and land wire labeled 80 onto terminal block labeled "4". Land wire 82 onto the terminal block labeled "5". This terminal block is installed on the right side bracket of the VR6 kit. To activate remote voltage adjustments, remove the jumper between VR6 terminals "4" and "7".

5. If you have a droop CT option, cut off existing terminals from the droop CT harness wires. Install 125-9997 Fork Terminals (2) on both wires, and land the wires on the VR6 terminals "5" and "6".

   Note: VR6 Terminal "5" is used for 1 Amp CT which was utilized on R448 regulators.

SE Generators Wiring

Show/hide table



Illustration 9	g02411925

Note: (C) These jumpers are installed standard on the VR6, remove these jumpers if the PMG and AREP options listed below are present.

1. On SE generators retain/ install wire jumpers between VR6 terminals 20 and 28, 22 and 30, 24 and 26.

PMG Excited Generators Wiring

Illustration 10	g02411996

1. On PMG excited generator, identify the existing PMG wire harness labeled "14","15","16" and cut off the existing terminals. Install new fork terminal (2) on wire 16 and install 239-8548 Blade Terminal on the other two wires.

2. Land PMG wire 16 on the VR6 terminal "28". Refer to Illustration 10.

3. Land the other two wires in the terminal block fuses. This terminal block is installed on the right side bracket of the VR6 kit. Land PMG wire 14 on the fuse which has wire 30 on opposing end and land PMG wire 15 on the fuse which has wire 26 on opposing end.

AREP Excited Generators Wiring

Illustration 11	g02412016

1. On AREP excited generators identify the existing four AREP wires labeled "9", "10", "11", "12". Then, cut off the existing terminals. Install new fork terminal (2) on wire 12 and install 239-8548 Blade Terminal on the other three wires.

2. Land wire 12 on the VR6 terminal "28". Refer to Illustration 11.

3. Land the other three wires in the terminal block fuses. This terminal block is installed on the right side bracket of the VR6 kit. Land AREP wire 9 on the fuse which has wire 26 on opposing end. Land the other two wires 10 and 11 on fuse which has wire 30 on opposing end.

VR6 Kit Mounting and Final Wiring Common to All Applications

1. Install the VR6 retrofit kit in the mounting holes drilled per the above instructions using the hardware provided in the kit.

   Note: On LC5000 and LC7000 generators you will need to reuse two 6V-8931 Washer Head Screw M6 bolts that previously held the R448 bracket.

2. Lay out harness in the generator terminal box to determine optimal routing for the harness considering all connection points.

3. Attach the voltage sensing wires on the generator bus bars. If the voltage of your generator is 240 V or less, install these wires on phase T1 (U), T2 (V), and T3 (W). If the voltage of your generator is more than 240 V, install these wires on center taps of the 12 lead generators T4, T5, and T6. Refer to Illustrations 9, 10, and 11.

4. Install ground wire on the VR6 "GND" terminal and ground (earth) bar in the generator terminal box.

5. Use 3S-2093 Cable Straps provided in the kit to secure the harness avoiding any contact with sharp edges.

6. Perform a final inspection of the generator terminal box for any unsecured wires, loose connections, or wires rubbing on sharp edges. Ensure that the generator terminal box is free from any debris left over from the rework.

7. Install previously removed covers.

Remote Voltage Adjust Potentiometer Retrofit

1. The R448 2 kOhm potentiometer is not compatible with the VR6. Install new 10 kOhm potentiometer.

2. Remove the voltage adjust knob in the control panel.

3. Disconnect the existing remote voltage adjust potentiometer by cutting off the minimal length of wires 80 and 82.

4. Remove the potentiometer but retain the seal and rubber hex cap on the current potentiometer for use with the new potentiometer.

5. Strip wires 80 and 82 from control panel harness and install two new 207-5432 Blade Terminals .

6. Connect wire 80 onto terminal "1" of potentiometer and wire 82 onto terminal "2" of the potentiometer.

7. Install the previously removed voltage adjust knob, seal, and rubber cap.