XQ Auto Paralleling Caterpillar

The terminal box has two major compartments. The upper compartment is located behind access panel (2). The lower compartment is located behind access panel (6). Refer to Illustration 1.

Illustration 1	g02152551
(1) Upper access panel for terminal box (2) Lower access panel for the terminal box

Upper Access Panel of the Terminal Box

Illustration 2	g02150096
(15) Terminal Box (16) Cat Digital Voltage Regulator (Cat DVR) (17) Digital input/output module (DIO) (18) Gage control module (GCM) (19) Control relays and diode terminals (20) (PWM) speed control (21) 25 (synchronizing check relay) (22) Current transformer shorting block (CTSB) (24) DC/DC power supply (DCPS) (25) Circuit Breaker Switch (CBS) (26) (86) Lockout Switch (27) Service Conn2 (Attached to the Harness) (28) Permanent magnet generator (PMG) Fuses (29) Electronic modular control panel (EMCP 3) (30) Lower terminal strip (31) Idle/Rated switch (32) Paralleling control switch (PCS) (33) Annunciator

Terminal Box (15) - The terminal box houses the generator and load controls.

Cat Digital Voltage Regulator (Cat DVR) (16) - The Cat DVR automatically regulates the voltage output of the generator.

Digital Input/Output Module (DIO) (17) - The digital input/output module is an expansion I/O device that contains 12 digital inputs and 8 form "c" relay contacts. The DIO module communicates with the EMCP on the secondary CAN2 data link.

Gage Control Module (GCM) (18) - The gauge control module converts data from the primary CAN1 data link to a proprietary communications protocol for the fuel level gauge.

Relay Assembly (19) - Contains relays for various generator operations and diode terminals.

PWM Speed Control (20) - The pulse width modulated signal is used in order to control engine speed. The PWM speed control uses input from the speed potentiometer.

25 Sync Check Relay (21) - The 25 sync check relay is a protection device. The relay is intended to prevent the generator from closing, out of phase, when connecting the generator breaker to a live bus.

Current Transformer Shorting Block (CTSB) (22) - The CTSB provides connections for the "auxiliary" current transformers that are used only by the "Utility Multi-function Relay" (UMR).

DC Power Supply (24) - The DC power supply regulates power supply for the GPC and UMR devices.

Circuit Breaker Switch (CBS) (25) - Used to assist in the control of automatic and manual paralleling. functions.

(86) Lockout Switch (26) - The "86 Lockout Relay" device performs fast response fault clearance.

Service Conn2 (27) - Connection to the secondary, CAN 2, data link is attached to the harnessing behind the EMCP 3. Intended for servicing the DIO and annunciator modules.

PMG Fuses (28) - Provide fuse protection for the PMG.

Electronic Modular Control Panel (EMCP 3) (29) - Used for monitoring and controlling many of the generator set functions.

Lower Terminal Strip (30) - Provides connections for the power module electrical system inputs and outputs. Radiator coolant temperature, access doors, and fuel level are examples of inputs to the control.

Idle/Rated Switch (31) - The idle/rated switch enables engine idle running mode. If the switch is set to the idle position, then the engine will run at a reduced speed. If the switch is set to the rated position, then the engine will run at the rated speed.

Paralleling Control Switch (PCS) (32) - The PCS switch turns the GPC and UMR paralleling controls on or off. The PCS switches the engine speed bias signal reference from the PWM speed control, if the PCS is "OFF", to the GPC when the PCS in "ON".

Annunciator (33) - Provides a handy reference for viewing the status of engine and generator alarms.

Lower Access Panel of the Terminal Box

Illustration 3	g02152574
(40) Load side power transformers (41) Generator side power transformers (42) RAD circuit breaker (RCB) (43) Generator circuit breaker (GCB) (44) F16 (45) F4 (46) Fuse assembly (47) Battery negative (-) distribution block

Load Side PTs (40) - The "Load Side" potential transformers are used to step down voltage from line voltage to 120 VAC. The load side of the generator circuit breaker. The "Load Side" PTs provide sensing voltage only for the GPC, the 25 sync check relay, and the UMR.

Generator Side Potential Transformers (41) - "Generator Side" potential transformers are used to step down voltage from line voltage to 120 VAC on the line side of the generator circuit breaker. The "Gen Side" PTs provide sensing voltage only for the GPC, the 25 sync check relay, and the UMR.

RAD Circuit Breaker (RCB) (42) - The radiator circuit breaker is used to protect cables to the radiator fan motor.

GEN Circuit Breaker (GCB) (43) - The generator circuit breaker is used to disconnect the generator from the load bus. The generator circuit breaker is electrically operated and fixed mounted. The generator circuit breaker utilizes a digital trip module to monitor long time, short time, instantaneous trip and ground fault protection (LSIG).

Fuses (46) - The fuses provide protection for sensing voltage of the load side of the PTs, Generator side PTs and EMCP3.

Electrical Distribution Box

Illustration 4	g02152844
(55) Shore power terminal block (56) Ground bar (57) Jacket water heater circuit breaker (58) Jacket water pump circuit breaker (59) Generator space heater (60) Battery charger (61) Fuel transfer pump (62) AC lights (240 AC) (63) Electrical receptacle (64) Radiator motor starter with time delay (65) Unload fuel relay (66) Load fuel relay (67) Radiator motor starter overload relay (68) Radiator motor starter contactor

Motor Starter (68) (67) - The contactor and overload relay provide a means of protection for the radiator fan motor. The contactor also provides start and stop control of the radiator fan motor.

Fuel Load Relay (66) - The load relay engages the fuel transfer pump. The fuel transfer pump transfers fuel from the customer storage tank to the fuel tank of power module.

Fuel Unload Relay (65) - The unload relay engages the fuel transfer pump. The fuel transfer pump transfers fuel from the fuel tank of the power module to the customer storage tank.

Radiator Motor Starter Time Relay (64) - The radiator motor starter has a built-in time delay function. The delay allows the engine to reach rated speed before engaging the radiator fan motor starter. The default time is set at 10 seconds.

Circuit Breakers (57) through (63) - The circuit breakers provide a means of disconnect and protection for the various shore power distribution circuits. Circuit breakers provided for the circuits that are shown in Illustration 4.

Generator Paralleling Control and Utility Multifunction Relay Control

Illustration 5	g02153224
(74) GPC (75) UMR (Optional) (76) Customer interconnection junction box

Utility Multifunction Relay Control

Illustration 6	g02211135
(80) Display (81) Thumb screws

The utility multifunction relay is a protective device. The UMR prevents damage to electrical components in the event of an electrical anomaly on the bus. The UMR monitors voltage, frequency, synchronization, and other parameters. The UMR is set up specifically to protect downstream electrical components when the power module is paralleled with a utility. The UMR provides "40Z" (loss of field - dual offset MHO) protection for the generator. Protection of upstream components, such as the generator used in the power module, is provided by the EMCP 3 and the Cat DVR.

The UMR relay is a modular component that can be removed. The relay can be removed by loosening the two thumbscrews (81), then by pulling out the relay assembly.

The relay has adjustable pickup and adjustable time delay settings. The display (80) on the utility multifunction relay contains a menu for different settings. Settings for the relay can be adjusted at the discretion of the user.

The factory has programmed default settings in the unit to allow the power module to run. The settings are not intended to provide protection for any specific utility, site, or device. The user has the responsibility to check with the local utility and/or conduct a specific site study to program the UMR settings. Refer to the information that is in the "Default Settings for the Utility Multifunction Relay" section of this publication for a list of factory default set points.

Customer Connections

Illustration 7	g02153254

24 VDC - Battery positive and negative

Utility Breaker Status - The utility breaker status input provides the generator control with the open or closed status of the utility circuit breaker. The status informs the control if the system is in parallel with the utility. The input is connected to utility circuit breaker auxiliary normally open contact. The configuration is designed to close the auxiliary contact when the utility breaker is closed.

Utility Transfer Trip - The utility transfer trip provides the system with an input for a breaker trip that is commanded by the utility, opens the generator circuit breaker, places the engine in cool down, stops the engine, and activates the manually reset type "86 Lockout Relay".

Remote Start Signal - The remote start signal is connected to the "RR" and "B-" terminals. The remote start signal provides the signal to start the power module remotely. The remote start signal can originate from a SCADA or automatic transfer switch.

Standard Alarm - The standard alarm provides dry contacts that change state when any alarm or shutdown of a metered parameter is active. The temperature, pressure and level are examples of metered parameters.

Engine Running - The engine running relay provides dry contacts that change state when the engine is running.

Not in Auto - The "Not in Auto" provides dry contacts that change state when the EMCP is not in auto mode.

Fuel Alarm - The fuel alarm provides dry contacts that change state when the fuel level is above the fuel level high warning set point. The fuel alarm provides dry contacts that change state when the fuel level is below the fuel level low warning set point.

Generator Breaker Status - Provides dry contacts that change state when the generator breaker is closed.

Load Share Lines - Connect load share lines to load share modules and/or other GPC units to share the load between units.

Volts Amperes Reactive Share Lines - Connects "volts amperes reactive" (VAR) share lines to other GPC units to share VAR between all units. VAR units are not compatible with load share modules or any other system except GPC units.

First ON Logic - The jumper between 1UP-93 and 1UP-94 is used to enable the circuit breaker (Ckt Bkr) to close to a dead bus. The jumper between 1UP-95 and 1UP-94 is used as a link to the next unit. The link will enable the next unit to close to a dead bus in case first unit fails to close to the dead bus.

Battery Charger

The XQ power modules utilize a 20 A battery charger to keep the batteries at full charge. The battery charger is only required while the engine is not running. The engine has an on-board alternator that will charge the batteries as the engine runs. However, there is no circuitry that will prevent the battery charger from operating when the engine is running.

In order to maintain the charge for the batteries, the user must operate the engine at regular intervals if the user does not have enough shore power to operate the battery charger.

The battery charger has a three-digit display. The display is used to show DC volts and DC amps. The display will show both the voltage and current readings between the battery and the charger. The display will alternate the readings that are displayed. The voltage will be displayed for 3 seconds and then the current will be displayed for 6 seconds. The display will continue to repeat the voltage and current values.

Table 1 lists the battery charger indicator status lights and definitions.

Table 1

Status Light	Problem
CHGR FAIL (Red)	Battery Charger has failed
DC HIGH (Red)	Battery DC is too High
DC LOW (Red)	Battery DC is too Low
AC FAIL (Red)	AC source input is not connected or not turned on
T-COMP ACTIVE (Green)	Temperature Compensation is active
AC/ON (Green)	AC source input is connected
FLOAT MODE (Green)	Charger Output is in Float Mode
BOOST MODE (Amber)	Charger Output is in Boost Mode
BATT FAULT (Red)	Check battery

Show/hide table

NOTICE
When connecting the battery charger, make sure to connect the DC leads directly to the battery and not on the switched side of the key switch. If improperly connected, the battery charger could send a surge of current through the control system when the key switch is turned off. The surge would cause damage to electronic components.

Battery Charger Alarm

Input DI04 is used to connect the battery charger to the DIO module. If "Custom Event #4" appears on the EMCP, the battery charger fail indication is active. One of four alarms can trigger the event:

• Battery fault alarm

• Charger fail alarm

• High battery alarm

• Low battery alarm

Generator Circuit Breaker

The generator circuit breaker is a 100% rated universal power circuit breaker. The generator circuit breaker is designed to protect electrical systems from damage caused by overloads and short circuits. All Masterpact circuit breakers are designed to open and close a circuit electrically. All Masterpact circuit breakers are designed to open the circuit automatically at a predetermined over current setting.

Note: Equipment ground faults protection would require the user to install a separate CT kit which is not included in the power module.

Illustration 8	g02240433
(83) Cradel rejection kit (84) Lifting tab (85) Trip unit connection to over current trip switch (86) Auxiliary control connection (87) Shunt trip (MX2) or under voltage trip device (MN) (88) Arc chamber (89) Shunt trip (MX1) (90) Auxiliary contact connection (91) Additional switches (OF) or combined connected/closed switches (EF) (93) Auxiliary form "C" contacts (94) Shunt close (XF) (95) Ready-to-close contact (PF) (96) Charging handle (97) Sring charging motor (MCH) (98) Close breaker push button (99) Open breaker push button (100) Operation counter (101) Trip unit (102) Over current trip switch (SDE1) (103) Circuit breaker communication module (104) Over current trip switch (SDE2) or electric reset (105) Face plate (106) Charge/discharged indicator (107) Open/close indicator (108) Push-to-reset fault trip button

The generator circuit breaker is operated via a stored energy mechanism. The stored energy mechanism can be charged manually or charged by using a motor. The closing time is less than five cycles. The closing and opening operations are ideally controlled electrically, automatically, or using the circuit breaker control switch. An "Open-Close-Open" cycle is possible without recharging.

Illustration 9	g02241773
Generator circuit breaker

Remote Operation

The generator circuit breaker is designed with an anti-pumping feature. The feature causes an opening command (interrupt) to always take priority over a closing command (interrupt). If opening and closing commands occur simultaneously, the charged mechanism discharges without any movement of the main contacts. The feature keeps the circuit breaker in the open (OFF) position.

After the circuit breaker is tripped by a fault or opened intentionally, the circuit breaker cannot be closed until the power to the closing coil is removed. The circuit breaker cannot be closed again until power is applied to the closing coil.

Note: The circuit breaker can be tripped by using the manual or electrical controls while the closing coil continues to be energized.

Closing the Breaker

The generator circuit breaker can be closed automatically when running in the "AUTO" mode or manually with the circuit breaker switch in the "RUN" mode. All of the following conditions must exist to close automatically or manually:

• Engine running

• Voltage/frequency normal

• "Ckt Bkr" switch in normal position

• UMR sync check is active (if installed and the utility circuit breaker is closed)

• 86 lockout device not tripped

• Primary unit jumper installed (dead bus closing only)

• GPC sync check active (auto mode only)

• 25 Sync check active (manual mode only)

Opening the Breaker

The generator circuit breaker can be opened manually by rotating the handle of the circuit breaker switch to the left. The breaker can be held open indefinitely by rotating the handle of the circuit breaker switch to the left, then pull the switch handle toward the operator. The circuit breaker will open automatically in the event of any of the following reasons:

• Over current fault condition

• Micrologic protection setting

• Estop activated

• Any EMCP, ADEM, or Cat DVR commanded emergency shutdown (common shutdown)

• 86 Lockout activated

• DC power failure (CB2)

• Engine not running

• GPC commanded soft unload trip (If the utility circuit breaker is closed)

• "OFF" is pressed on the EMCP

• "AUTO" is pressed on the EMCP and the run request is not present

• Utility transfer trip activated

• UMR protective setting (if installed)

Note: In "AUTO" mode, the system will attempt to synchronize and close the circuit breaker automatically. If you open the breaker manually, the breaker will automatically close again in "AUTO" mode. If manual operation of the breaker is desired, operate the breaker in "Manual" mode by pressing "RUN" on the EMCP 3.

Generator Circuit Breaker Alarm

The generator circuit breaker may be connected to the DIO module. The generator circuit breaker connection to the DIO module is not made at the factory. The connection can be made in the field by the a dealer. The connection should be made to terminal block 5 (to SDE-81) and to terminal block SP3 (to SDE-82). After the connection is made, the over current trip is connected to DI03. If "Custom Event #3" appears on the EMCP, the generator circuit breaker over current fault has tripped.

Over Current Fault Trip Indicator

If the generator circuit breaker experiences an overcurrent event, the circuit breaker will automatically open and the red reset button (83) will extend. The circuit breaker will not be operational until the reset button (115) is pushed into the normal operating position.

Illustration 10	g02211573
(115) Red reset pushbutton

Micrologic Trip Unit

The Micrologic trip unit is one component of the generator circuit breaker assembly. Micrologic trip units protect power circuits and provide current measurements, overload protection and short-circuit protection.

Note: Equipment ground faults protection would require the user to install a separate CT kit which is not included in the power module.

Protection thresholds and delays are set using the rotary switches. The selected values are momentarily displayed in amperes and in seconds. A full-range of long-time settings are available via field-installable rating plug.

Illustration 11	g02211613
(116) Test lamp, and reset (117) Trip cause indicator (118) Digital display (119) Three-phase bar graph and ammeter (120) Navigation buttons (121) Overload signal (LED) (122) Long-time rating screw (123) Long-time current setting and tripping delay (124) Short-time pickup and tripping delay (125) Instantaneous pickup (126) Electronic push-to-trip (127) Ground fault pickup and tripping delay (128) Test connector

Micrologic trip unit measures the true RMS value of currents. The digital LCD screen continuously displays the most heavily loaded phase (Imax). If the navigation button is pressed, the display will show Ia, Ib, or Ic.

Illustration 12	g02242573

Radiator Fan

Generator sets that are equipped with 3516 engines require a fan for the radiator. The radiator fan is driven by a motor that can operate at 480 VAC or 600 VAC line voltage. A motor starter and circuit breaker is provided as components for the radiator fan package.

Radiator Fan Components

Illustration 13	g02234873
(130) Radiator fan motor circuit breaker

The circuit breaker (130) is for the radiator fan motor circuit. The circuit breaker is a 3-phase protective device that will open the circuit in the event of a short circuit condition.

Illustration 14	g02234933
(131) Radiator fan motor starter

The motor starter for the radiator fan consists of a 3-phase contactor and overload protection. The contactor opens and closes to complete the circuit and start the fan motor. The overload (OVL) device is a protective relay that opens if the motor draws too much current over time to prevent the motor from overheating.

Radiator Fan Operation

1. The engine begins to crank.

2. Relay 5 (R05) on the EMCP 3, triggers the "Engine Running Relay" (ERR).

3. Relay 5 (R05) on the EMCP 3, triggers the "Radiator Motor Timer" (TMR).

   Note: If the engine is in the "IDLE" mode, then the TMR will be prevented from activating as a protection against running the motor at a reduced voltage.

4. The TMR will begin timing. After the selected time has passed, the TMR will activate the motor starter coil (MS1).

   Note: The factory default time for TMR is 10 seconds.

5. MS1 will close. The MS1 contactor will complete the circuit to the fan motor. The fan will start as long as the OVL has not tripped.

Illustration 15	g02235734

Alarms for the Radiator Fan Motor

DI07

The circuit breaker for the radiator fan motor has an auxiliary contact that is connected to digital input #7 of the digital input/output (DIO) module. If the breaker is tripped, the EMCP will display the alarm "Custom Input #7". The alarm will be displayed in the "External IO" heading. The engine will initiate a shutdown if the water temperature is too hot.

Refer to Table 2.

DI08

The motor starter has an auxiliary contact that is connected to digital "Input #8" of the DIO module. If the overload element has overheated, the EMCP will display the alarm "Custom Input #8". The alarm will be displayed in the "External IO" heading. The engine will initiate a shutdown if the water temperature is too hot.

Refer to Table 2.

Table 2

Alarm Code	DIO	Problem	Description
DI07	Input #7	Radiator circuit breaker is open	Due to the tripped breaker, the radiator fan motor will not operate
DI08	Input #8	Motor starter overload element has overheated	Due to the open overload element, the radiator fan motor will not operate.

Illustration 16	g02236394

Refer to Schneider Electric publications for more information on the circuit breaker for the motor starter.

Space Heater

The generator space heater (GSH) will heat the generator and keep condensation from forming in the windings. The GSH does not have a sensor to regulate the temperature. The space heater will shut off when the engine starts.

Jacket Water Heater

The jacket water heater (JWH) will heat the engine coolant to keep the coolant above freezing temperature. The jacket water heater keeps the engine warm while the engine waits for a start command. The JWH will not operate if the circuit breaker for the jacket water pump is tripped. The JWH and jacket water pump will shut off when the engine starts.

Jacket Water Pump

The jacket water pump keeps the coolant flowing through the engine and heater elements. The JWH and jacket water pump will shut off when the engine starts.

Fuel Transfer Pump

The fuel transfer pump is used to transfer fuel to or from an external tank into the internal tank of the power module.

AC lights

The AC lights provide illumination within the power module independently of the DC lights.

Electrical Receptacle

The electrical receptacles within the power module will provide 120V, 15Amps of power to any device utilizing a standard household NEMA 5-15P connection.

Shore Power Distribution Connections

A 240V, 100A 60 Hz source is required in order to operate all devices. Some XQ models can be connected to two different 240V, 50A 60 Hz sources or a single 240V, 100A 60 Hz source. The schematics for the specific generator set must be checked to ensure the appropriate requirements.

Illustration 17	g02237158

If a 240V, 100A 60 Hz source is not available, then the installer will have to decide what devices will be operated. Refer to Table 3 for the power requirements of each device.

Table 3

	Power	Current	125% Current
Jacket Water Heater & Pump (9000W + 95W)	9095 W	37.9A	47A
Generator Space Heater	1200 W	5 A	6.3A
Battery Charger 15A AC input/20Amp DC output	3600 W	15A	15A
Fuel Transfer Pump	2000 W	8.3A	10.4A
AC LIGHTS - 32 W times 3	96 W	.40A	.50A
Elect Receptacle 15A	3600 W	15A	15A

Interconnect Box - AC Terminal Connections

Illustration 18	g02239238