This power module is intended for use in generating electrical power. The power module is a complete self-contained unit that can be towed to any location for the generation of electrical power. The power module can be utilized for prime power generation or standby power generation.
Cat 3516C HD Engines provide the following features:
- Four-cycle
- Direct fuel injection
- Mechanical Electronic Unit Injector (MEUI)
- Turbocharged
The lube oil makeup system is located to the right of the forward personnel access door on the right side of the power module. The lube oil makeup system consists of the following:
- two sight glasses (1/3 full, and 2/3 full)
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113.6 L (30 US gal) capacity - low-level sensor outputs to controller (used to give low-level warning alarm)
Cat 3516C HD Engines are designed with electronic controls. The integral on board computer controls the operation of the engine. Current operating conditions are monitored. The Electronic Control Module (ECM) controls the response of the engine to these conditions and to the demands of the operator. These conditions and operator demands determine the precise control of fuel injection by the ECM. The electronic engine control system provides the following features:
- Engine and auxiliary monitoring
- Engine speed governing
- Cold start strategy
- Automatic air/fuel ratio control
- Torque rise shaping
- Automatic altitude compensation
- Injection timing control
- System diagnostics
For more information on electronic engine features, refer to the Operation and Maintenance Manual, "Features and Controls" topic (Operation Section).
The SR5 brushless generator can be used with the following loads: mixed loads of motors and lights, SCR-controlled equipment, computer centers, installations of communications and petroleum drilling applications.
SR5 generators are utilized in three-phase full-wave excitation and regulation. The generator is a wye configuration intended for nominal voltages of 400V or 480V, and produces electrical power in 50 Hz or 60 Hz applications.
The enclosure for the power module is a shipping container. The container meets the following standards and regulations:
- ISO/TC 104 Requirements for cargo containers
- ANSI/ MH5.1 Basic requirements for cargo containers
- ANSI/MH5.1.1 Requirements for closed van containers
- UIC Code 592-1 International union of railway
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| Illustration 1 | g03642248 |
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Load cable access door | |
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| Illustration 2 | g03594125 |
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Bus bar with connected load leads | |
The load cable access door is located on the side of the power module. The door has a lock handle that requires a Cat key to unlock, for access into the bus bar area.
The load cable access door shall remain closed and locked during normal operation. During extended run time, a qualified service technician may be necessary in order to open this door occasionally, to take temperature scans on the bus bars, for example.
A transparent shield is located in front of the bus bars to protect personnel against accidental contact with energized parts. This shield is held secure by four captive fasteners. The shield must be in place before the generator circuit breaker is allowed to close. If the shield is removed while the unit is powering the load, the generator breaker will be tripped open. There are two limit switches that detect when the shield is installed. One is used to trip the generator breaker. The other is entirely for customer use, and is wired to nearby terminal blocks.
Bus bars are provided for customer load cable connections, and earth ground. Bus bars are (from left to right), T1, T2, T3, N and ground (mounted to the side wall). The bus bars will accept either single or double lug type cable ends.
The neutral is ungrounded as shipped from the factory. Certain applications may require the neutral to be grounded. In those cases, the dealer is responsible for grounding the neutral.
All the customer cables exit underneath the round bar and rubber flap. The bar prevents cables from pressing against the door. The rubber flap helps keep water and debris from entering the load cable access areas.
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| Illustration 3 | g03594136 |
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(1) louvers
(2) awnings | |
Louvers are installed in the power module in order to receive fresh air. The louvers are sized in order to meet the inlet air supply that is required for the power module. The louvers allow fresh air to enter the power module that is needed for the engine air inlet and for radiator cooling during full load.
The intake louvers for the cooling system (front of power module) are hinged to facilitate cleaning of the radiator cores.
The intake louvers to the engine compartment have awnings. The awnings must be open prior to starting the power module.
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| Illustration 4 | g03653024 |
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Fuel tank assembly | |
A
Fuel tanks are plumbed via external connection to customer fuel connection. The external connection provides short-term storage in a disruption to the site fuel storage and delivery system.
Connection to the site fuel storage and delivery system is provided via a 1 inch BSPP fitting (Max. 100 PSI).
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| Illustration 5 | g03642225 |
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Fuel/water separators | |
Three fuel/water separators are mounted on the fuel tank. The fuel/water separators are connected in parallel. The fuel/water separators provide primary filtration for the fuel for the engine.
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| Illustration 6 | g03592699 |
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Batteries | |
The engine starting batteries are located next to the generator set. These batteries also provide the 24V DC power source for the entire control system and overhead lights.
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| Illustration 7 | g03592697 |
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(3) engine DC distribution box
(4) battery disconnect switch | |
The DC power distribution begins at the battery disconnect switch bracket seen in illustration 7. The battery disconnect switch (4) is used to interrupt DC "-" to the starter, and engine distribution box. When switched to the OFF position, the switch prevents the engine from being started, and minimizes battery drain while the power module is not being used. The switch can be locked in the OFF position with a padlock.
Two circuits bypass the battery disconnect switch and are connected directly to the batteries via the DC positive "+" and DC negative "-" studs on the back of this bracket. The first circuit goes to the battery charger located on the container wall. The circuit is protected by the 60A breaker located next to the battery disconnect switch. The second circuit goes to the generator terminal box in order to power the overhead DC lights, and ethernet switch (located in the operator panel). This circuit is protected by the 20A breaker located next to the battery disconnect switch and by breakers in the generator terminal box. If either the 20A or 60A breakers trip, push in on the circuit breaker in order to reset.
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| Illustration 8 | g03592701 |
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Engine DC distribution box AUX circuits (5) AUX1 (6) AUX2 (7) AUX3 | |
The engine DC distribution box (illustration 8) contains several breakers for branch circuit protection. Most are for on-engine equipment but three are provided to power "AUX" circuits off-engine. The three breakers are referred to as "AUX1", "AUX2", and "AUX3". The three breakers are used in distributing DC power to the genset and package controls.
The battery charger is the only means by which the batteries are charged and maintain charge since the engine does not have a charging alternator. The charger receives 400/480VAC (3-phase) typically from the load side of the generator and outputs 50A maximum at 24VDC to the engine starting batteries. This charger is an automatic, high efficiency battery charger/rectifier and has built-in protection against short circuit, overload, and high temperatures.
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| Illustration 9 | g03592703 |
The battery charger is equipped with a 3-stage charging characteristic consisting of modes "Bulk", "Absorption", and "Float" (illustration 9) as marked by the indicators on the front right-hand side of the charger. Battery charge indicators are just above the "ON/OFF" switch.
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| Illustration 10 | g03592705 |
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(8) green indicators (status OK)
(9) select button (10) audible alarm (11) mute button (12) LCD display (13) red indicators (status alarm) | |
An alarm interface module (illustration 10) is included as standard on the battery charger. A screen on the battery charger displays the charging voltage and current as well as alarms. The batter charger also has indicators to provide the status of the incoming AC power, the charger, and outgoing DC power. Normal state is indicated by green, and alarm state is indicated by red.
There are two buttons on the interface module, a "Select" button and a "Mute" button. Press the "Select" button momentarily in order to scroll through screens of measured parameters. The "Mute" button is used to silence the audible alarm. However, the audible alarm is disabled by factory default.
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| Illustration 11 | g03592716 |
Factory wiring configuration allows for two different AC sources to the battery charger. The AC sources are either the load side of the generator breaker (the common bus), or directly from the generator. Source is selectable by turning on either breaker CB2 (common bus), or CB5 (generator) to deliver AC power to the charger. A mechanical interlock between the breakers prevents the user from accidentally connecting both sources simultaneously.
The breaker CB2 should almost always be selected. If the common bus is dead, or the engine will be run with the generator breaker open for an extended time, CB5 may be selected.
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| Illustration 12 | g03596479 |
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Interior lighting | |
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| Illustration 13 | g03596487 |
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Switch for interior lights | |
There are 24 V interior lights that are mounted in the engine area and in the operator control area inside the power module. The lights are wired to a 0-60 minute timer switch. The timer switch is mounted to the wall beside the entrance door. These lights are powered from the batteries.
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| Illustration 14 | g03642196 |
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Electrical outlet receptacle (Universal type - 3 amps) | |
One electrical outlet receptacle (120VAC/ 60 Hz, 110VAC/ 50 Hz) is included as a convenience, for the service technician in powering a laptop computer or similar device. The universal style receptacle is to accommodate the many different types of plugs used in different geographical regions.
The power distribution panel has two compartments: one for the generator breaker on the left-hand side, and one for the controls on the right-hand side. Each section has a sealed access door having a lock handle which requires a CAT key to unlock.
The generator breaker compartment contains the generator breaker, current transformers, and fuses (used in AC voltage). The fuses are KTK type 2A, and are easily accessible with six bayonet style fuse holders. Three are used in sensing generator voltage, and the other three are used in sensing bus voltage. The breaker compartment is sealed from dust entering from the lower bus bar area, in order to keep the breaker as clean as possible
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, short circuits, and equipment ground faults. The circuit breaker is designed to open and close a circuit electrically. The circuit breaker is designed to open the circuit automatically at a predetermined over current setting.
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.
Note: Breaker closing and opening operations are initiated by electrical signals from the AGC controller. Use operator controls on the AGC controller to close and open the breaker. Do not use the open and close buttons on the front of the breaker for operation.
Note: During maintenance, it may be necessary to lock out the breaker. A mechanism is provided just above the red "OFF" button on the breaker, to prevent the breaker from closing.
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| Illustration 15 | g03653128 |
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Lock mechanism | |
To lock out the breaker from being able to close, first pull out the lock mechanism, and then apply the padlock. There is no need to press the red "OFF" button.
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| Illustration 16 | g03582622 |
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(14) Cradle rejection kit
(15) Lifting tab (16) Trip unit connection to over current trip switch (17) Auxiliary control connection (18) Shunt trip (MX2) or under voltage trip device (MN) (19) Arc chamber (20) Shunt trip (MX1) (21) Auxiliary contact connection (22) Additional switches (OF) or combined connected/closed switches (EF) (23) Auxiliary form "C" contacts (24) Shunt close (XF) (25) Ready-to-close contact (PF) (26) Charging handle (27) Spring charging motor (MCH) (28) Close breaker push button (29) Open breaker push button (30) Operation counter (31) Trip unit (32) Over current trip switch (SDE1) (33) Circuit breaker communication module (34) Over current trip switch (SDE2) or electric reset (35) Face plate (36) Charge/discharged indicator (37) Open/close indicator (38) Push-to-reset fault trip button | |
Over Current Fault Trip Indicator
If the generator circuit breaker experiences an overcurrent event, the circuit breaker will automatically open and the reset button (39) will extend. The circuit breaker will not be operational until the reset button (39) is pushed into the normal operating position.
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| Illustration 17 | g03582651 |
| (39) reset button | |
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.
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| Illustration 18 | g03582637 |
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(40) Test lamp, and reset
(41) Trip cause indicator (42) Digital display (43) Three-phase bar graph and ammeter (44) Navigation buttons (45) Overload signal (46) Long-time rating screw (47) Long-time current setting and tripping delay (48) Short-time pickup and tripping delay (49) Instantaneous pickup (50) Electronic push-to-trip (51) Ground fault pickup and tripping delay (52) Test connector | |
The variable frequency drive (VFD) receives AC power input from the generator and automatically controls the cooling system fan motor speed. The VFD saves energy by regulating the fan speed based on cooling system demand. The AGC controller monitors the cooling system parameters, sending signals to the VFD to speed up, slow down, or maintain the fan motors speed. The three phase AC input to the VFD is protected by a circuit breaker and a line reactor. The line reactor serves to reduce harmonics being exported from the VFD back onto the common bus. The line reactor also serves to protect the VFD from surges or spikes from the incoming AC lines.
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| Illustration 19 | g03593383 |
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(53) VFD
(54) Circuit breaker (RCB) (55) Line reactor (LR) | |
AC Power Distribution and Shore Power
The power distribution panel provides AC power distribution to on-board equipment such as a cooling fan, motors, jacket water heater, battery charger, service receptacle and generator space heater.
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| Illustration 20 | g03586996 |
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(56) Breaker CB4 for incoming power from common bus (50A)
(57) Connection point AUX for optional customer shore power wiring installation (58) Wiring gland for use in optional customer shore power wiring installation (59) Breaker CB1 for jacket water heater heating elements (20A) (60) Breaker CB3 for generator space heater and transformer (15A) (61) Breaker CB2 for battery charger (from AUX as source)(15A) (62) Breaker CB5 for battery charger (from generator as source)(15A) (63) Breaker CB6 for panel interior air circulation fans (3A), breaker CB7 for service receptacle (5A), breaker CB8 for jacket water heater circulation pump (10A) (64) Forward, and reversing contactors LVC and HVC, used with voltage selector switch to changeover transformer primary taps (65) Fan motor overload. Each provides overload protection for a single fan motor (66) Voltage selector switch VSS used to configure system to match incoming shore power voltage | |
AC power distribution is factory-configured to use power from the common bus to power the on-board equipment such as jacket water heater and generator space heater. However, if the user desires to power this equipment from an external source (Shore Power), then provisions have been made to accept this external source.
In cases where the user brings in external power to power the on-board equipment mentioned above, the user will do the following:
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| Illustration 21 | g03586960 |
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breaker (CB4) | |
- Choose a source to provide either 400VAC, 50Hz, 3-phase, 50A OR 480VAC, 60Hz, 3-phase, 50A.
- Include ground from the external source.
- Turn off breaker "CB4".
- Remove the three short wires between "CB4" and "AUX" distribution block and store.
- Route the ground and phase cables from the external source under the rubber flap, and the round bar in the load cable connection area.
- Connect the ground cable from the external source to the ground bar located beside the neutral bus bar.
- Route the three phase cables from the external source through the rubber wiring gland located underneath the "AUX" distribution block.
- Connect the three phase cables from the external source to the "AUX" distribution block in place of the wires that were previously removed.
The onboard equipment can now be powered from the external source. Refer to the film located on the back side of the VFD compartment door for a simple diagram of the AC distribution system.
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| Illustration 22 | g03614977 |
This diagram shows the entire AC power distribution. Most of the components in this diagram are located within the Power Distribution Panel.
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| Illustration 23 | g03632837 |
| (67) Voltage selector switch | |
The voltage selector switch (67) is used to control the forward/reverse contactors which change the primary taps on the 2 kVA transformer in order to match the incoming shore power voltage. Normally the switch remains in the center, AUTO position.
The AUTO position allows the AGC controller to control the low voltage contactor (LVC), and high voltage contactor (HVC) contactors automatically. For example, when the AGC is programmed to 400V/50Hz nominal setting, LVC is selected. When programmed to 480V/60Hz nominal setting, HVC is selected.
If manually selecting 400V or 480V is desired, the manual selection can be made using the voltage selector switch.