3145, 3150 & 3160 ELECTRIC SET ENGINES Caterpillar


Testing And Adjusting

Usage:



Pre-Operation Check

After the generator is installed and before operating the first time, perform a check of the equipment as follows:

1. If the generator has been exposed to excessive dampness it may be necessary to dry out the windings before operating. If the generator has been exposed to extremely low temperatures it should be slowly warmed up to prevent condensation.

2. Check all interconnecting wiring against the wiring diagrams.

3. Make certain no foreign objects are lodged in the generator. Remove all tools and shop cloths from the vicinity of the equipment.

4. Ensure that all covers and guards are installed correctly.

Initial Start Procedures

After installation and the above checks have been completed, make an initial start and checkout of the equipment as follows:

1. Open the main circuit breaker to the load.

2. Turn the AUTO VOLTAGE ADJUST rheostat to the minimum (full clockwise). Turn the RANGE ADJUST rheostat slowly clockwise to obtain maximum voltage setting.

NOTE: Never set voltage more than 10% higher than that desired. Turn the VOLTAGE ADJUST rheostat to the desired voltage.

Indicator Lights


CONTROL PANEL
1-Amber lamps. 2-Red lamp. 3-Voltage adjust rheostat (R18). 4-Indicator lamp legend.

The generator mounted control panel contains two amber (1) and one red (2) indicator lamps. The two amber lamps are labelled "Overspeed" and "Underspeed", and the red lamp is marked "Overvoltage". A decal, with the indicator legend is mounted on the control panel.


FREQUENCY/VOLTAGE SENSING ASSEMBLY

5 R6

6 SW1

7 R2

8 R4

9 R1

10 C1

11 Overspeed tap

12 139 volt tap

13 Common tap

14 Underspeed tap

15 120 volt tap

16 Overvoltage tap

17 100 volt tap

18 Common tap

19 R3

20 R5

21 T1

Assume the generator is connected for 3 phase 120/208 volts operation. At 120 VAC and 60 hertz, both speed indicating lamps will be moderately and evenly lit. The brilliance of the lamps are an indication of voltage. The lamps will go out at 115 VAC. At 130 VAC, either or both lights will glow at maximum brilliance, depending on the frequency, and the over-voltage lamp will light. The speed lights also indicate frequency. At exactly 60 hertz, both will be equally lit. As the frequency increases, the overspeed light becomes brighter while the underspeed lamp will go out. Decreasing frequency will have the opposite effect.

The recommended procedure for setting voltage and frequency is to accelerate engine to an estimated 1800 RPM. This is a generator frequency of 60 hertz. At least one of the speed lights should be lit. If not, increase the VOLTAGE ADJUST rheostat until at least one of the lamps comes on. Adjust the engine speed until both lights are evenly lit, then fine adjust the VOLTAGE ADJUST rheostat until both lamps glow dimly. The voltage at which the lamps begin to glow is 115 volts, so adjust for a moderately low brilliance.


INDICATOR LAMP SYSTEM SCHEMATIC

Calibration Procedure

A voltmeter and a frequency meter, accurate within 2%, are required to calibrate the indicator lamps.

1. Make sure that switch (6) is in the correct position (50 or 60 cycle), and that the voltage is on the correct voltage tap (100, 120, 139 volts).

2. Start the engine and adjust the RPM until generator speed (on the frequency meter) is as rated. Adjust the generator voltage (with the voltmeter) until it is as rated.

NOTE: All adjustments are made with no load on the generator.

3. Adjust R1 (9) until both amber lamps glow. Adjust R2 (7) until the lamps glow at the same brilliance. Readjust R1 (9) so that the amber lamps both glow dimly and appear to oscillate off and on evenly. Readjust R2 (7) if necessary.

4. Increase generator voltage approximately 5% above rated. Adjust R3 (19) until the red lamp just begins to glow.

5. Reduce the frequency and voltage to below rated and readjust to rated using the lamps. After proper operation is attained, recheck with the voltmeter and frequency meter. Both voltage and frequency should be within a few percent of rated.

6. Start and stop the generator several times. Observe any unusual conditions such as excessive noise or vibration. Allow sufficient time between stops and starts for cooling.

7. Start the generator, close the main circuit breaker and apply a light load. Adjust AUTO VOLTAGE ADJUST rheostat to desired output voltage. Slowly increase the load to the generator's full load rated capacity. Adjust the AUTO VOLTAGE ADJUST rheostat, as necessary, until the desired output voltage is obtained.

8. Check voltage regulation. This can be done by varying the load. If the voltage is unstable, adjustment of the STABILITY ADJUST rheostat may be necessary. Refer to topic STABILITY ADJUSTMENT.

9. During operation, observe the generator at regular intervals to ensure that abnormal operating conditions can be corrected before serious damage occurs.

10. With a steady rated load applied, check the current on each line. A clamp-on ammeter may be used for this purpose if a regular ammeter is not installed in the system.

NOTE: The current in each line should be as equal as possible.

11. Check line-to-line and line-to-neutral voltages.

12. Open the circuit breaker and shut down the unit.

Stability Adjustment

STABILITY ADJUST resistor, R8 (1) is located on the pre-amplifier printed circuit board.


PRE-AMPLIFIER PRINTED CIRCUIT BOARD
1-Stability adjust resistor.

Adjust the STABILITY ADJUST resistor, R8 (1) only if, during operation, instability or slow response occurs. Turning STABILITY ADJUST resistor clockwise increases the negative feedback, thus increasing stability and response time. STABILITY ADJUST should be set so that the output voltage is stable at both no-load and full-load conditions allowing for the fastest regulator response possible.

NOTE: Be sure the unit is operating at rated speed when making voltage and stability adjustments (50 or 60 Hertz, whichever is being used).

Caterpillar Information System:

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