C32
C32
C32
CATERPILLAR 1000 kVA POWER MODULE C32 ACERT TECHNOLOGY 50 / 60 Hz CONVERTIBLE SOUND ATTENUATED ISO 20 ft. CSC CERTIFIED 400 V, 50 Hz, 1000 kVA (800 EKW) 480 V, 60 Hz, 910 EKW
Page 1
TABLE OF CONTENTS
Item Page #
1. OVERVIEW ...................................................................................................................... 4 2. CATERPILLAR C32 4-STROKE-DIESEL ENGINE ............................................................ 4 2.1. Specifications ................................................................................................................ 4 2.2. ADEM IV Engine Controller ......................................................................................... 5 2.2.1. Introduction............................................................................................................. 5 2.2.2. Features ................................................................................................................. 5 2.2.3. Description.............................................................................................................. 6 2.2.4. ADEM IV Specifications ........................................................................................ 7 3. CATERPILLAR SR4B 693 FRAME GENERATOR........................................................... 8 3.1. Specifications ................................................................................................................ 8 3.3. Random Wound Stator Winding before Impregnation................................................... 9 3.4. Rotor construction ......................................................................................................... 9 3.5. Caterpillar Digital Voltage Regulator (CDVR)......................................................... 10 3.5.1. CDVR Description .............................................................................................. 10 3.5.2. CDVR Features .................................................................................................. 10 3.5.3. CDVR Specifications.......................................................................................... 11 3.5.4. CDVR Regulation Characteristic........................................................................ 12 3.6.2 60 Hz Technical Data - Caterpillar SR4B Generator 2628094 .......................... 17 4. EMCP 3.3 GENERATOR SET CONTROLLER.................................................................. 22 4.1. EMCP 3.3 General Description ................................................................................... 22 4.2. EMCP 3.3 Operator Interface ...................................................................................... 22 4.3. EMCP 3.3 Features & Benefits.................................................................................... 22 4.4. EMCP 3.3 Environmental specifications...................................................................... 23 4.5. EMCP 3.3 Standards................................................................................................... 23 4.6. EMCP 3.3 Standard features....................................................................................... 24 4.6.1. Controls ................................................................................................................24 4.6.2. Digital (LCD) Indication......................................................................................... 24 4.6.3. Warning/Shutdown indication ............................................................................... 25 4.6.4. Digital inputs (8 Total)........................................................................................... 25 4.6.5. Protective relaying ................................................................................................ 25 4.6.6. Relay outputs (8 Total) ......................................................................................... 26 4.6.7. Discrete outputs (2 Total) ..................................................................................... 26 4.6.8. Sensor inputs........................................................................................................ 26 4.7. EMCP 3.3 Available local display languages .............................................................. 27 5. CONTAINER ...................................................................................................................... 28 5.1. General description ..................................................................................................... 28 5.2. Features ...................................................................................................................... 28 5.3. Drawings, Dimensions & Weight ................................................................................. 29 5.3.1. Container dimensions & weight ............................................................................ 29 5.3.2. Container views: ................................................................................................... 29 6. Switchgear & Controls ........................................................................................................ 33
Technical Description Revision 1.2 CATERPILLAR 1000 kVA UTILITY POWER MODULE 15 October 2006 Page 2
AVAILABLE OPTIONAL CONTROL EQUIPMENT ........................................................ 36 6.2. Controls Power organizer ......................................................................................... 37 6.3. Monitoring................................................................................................................... 43 6.4. Protection .................................................................................................................... 44 6.4.1. Power assembly ................................................................................................... 44 6.4.2. Generator circuit breaker...................................................................................... 44 7. Testing................................................................................................................................ 45 7.1. Prototype Testing ........................................................................................................ 45 7.2. Standard Power Module Test ...................................................................................... 45 7.3. Documentation ............................................................................................................ 46
Page 3
1. OVERVIEW
This specification describes the Caterpillar Utility Power Module. This module is rated for 400 V at 50 Hz producing 1000 kVA (800 EkW) or 480 V at 60 Hz producing 910 ekW. Included are: the Caterpillar C32 engine, the Caterpillar SR4B 693 frame generator, the Utility paralleling switchgear, a industry standard 20 foot (6 m) high-cube sound attenuated CSC certified container and a cooling system for 50C ambient. The complete solution is fully tested at 60 and 50 Hz and delivered ready to operate. Its modes of operation are field configurable and include single or multiple island mode (up to 18 units) and single unit utility paralleling mode.
Page 4
2.2.2. Features
1 - General features RELIABLE, DURABLE - All ADEM IV controllers are designed to survive the harshest environments. Environmentally sealed, die-cast aluminum housing isolates and protects electronic components from moisture and dirt contamination. Rigorous vibration testing ensures product reliability and durability. Accuracy maintained from -40 C to +85 C. Electrical noise immunity to 100 volts/meter. Internal circuits are designed to withstand shorts to +battery and battery. SIMPLE SERVICING
SIMPLE SERVICING - Each ADEM IV system works in combination with the Caterpillar ET service tool software to keep the engine operating at peak performance. _ Displays measured parameters _ Retrieves active and logged event codes documenting abnormal system operation
Performs calibrations and diagnostic tests. Supports flash programming of new software into the ADEM IV ECM.
SELF-DIAGNOSTICS Each ADEM IV ECM has a full compliment of self-diagnostics. The ECM can detect faults in the electrical system and report those faults to the service technician for quick repair. Selfdiagnostic capability pinpoints operational problems in need of attention.
Page 5
2 - Advanced features Isochronous or droop speed control. Enhanced performance from fuel injection timing and limiting. J1939 Communications. Adjustable monitoring of vital engine parameters. Idle/rated speed setting. Programmable speed acceleration ramp rate. Adjustable cool down duration. Data link interfaces.
2.2.3. Description
The ECM is housed in an environmentally sealed casting. All wiring connections to the ECM are made at the two sealed seventy-pin connectors. ENGINE SPEED GOVERNING - Desired engine speed is calculated by the ECM and held within 0.2 Hz for isochronous and droop mode. The ECM accounts for droop that is requested. The proper amount of fuel is sent to the injectors due to these calculations. The ECM also employs cool down/shutdown strategies, acceleration delays on startup, acceleration ramp times, speed reference and a low/high idle switch is also available via communications to the EMCP 3.3 generator mounted local control panel. FUEL LIMITING - Warm and cold fuel-air ratio control limits are controlled by the ECM. Electronic monitoring system derates, torque limit, and cranking limit, programmable torque scaling, and cold cylinder cutout mode are standard features. FUEL INJECTION TIMING - Master timing for injection is controlled by the ECM control. Temperature dependencies are accounted for in the fuel injection calculations. ELECTRONIC MONITORING - Electronic monitoring of vital engine parameters can be programmed. Warning, derate and shutdown event conditions may be customized by the user. INFORMATION MANAGEMENT -The ECM stores information to assist with electronic troubleshooting. Active and logged diagnostic codes, active events, logged events, fuel consumption, engine hours, and instantaneous totals aid service technicians when diagnosing electronic faults and scheduling preventive maintenance. CALIBRATIONS - Engine performance is optimized through injection timing. Auto/manual sensor calibrations are standard features. ON-BOARD SYSTEM TESTS - System tests are available to assist in electronic troubleshooting. These tests include: injector activation, injector cutout, and override of control outputs.
Page 6
ELECTRONIC SENSORS - The following sensing is available on the ADEM IV controller: oil pressure, fuel pressure, fuel temperature, atmospheric pressure, air inlet temperature, turbo outlet pressure, engine coolant temperature, engine speed, throttle speed, droop position, exhaust temperature, engine control switch position, oil filter pressure differential, fuel filter pressure differential, air filter pressure differential, crankcase pressure, and remote e-stop switch position. ELECTRONIC ACTUATORS - Electronic Unit Injectors are driven by the ECM. Actuators to control ether are optional.
Page 7
Insulation: Enclosure: Overspeed capability: 150%. Waveform: Less than 5% deviation. Paralleling capability: Standard with adjustable voltage droop. Voltage regulator: 3-phase true RMS sensing with adjustable Volts-per-Hertz response. Voltage regulation: Less than 0.5%. Voltage gain: Adjustable to compensate for engine speed droop and line loss. THD: Less than 3%. TIF: Less than 50. Number of leads: 6 Excitation: Permanent magnet.
Page 8
3.2. Features The Caterpillar Series generators are the worldwide industry leaders. Features include: Superior harsh environment performance. Class H rotor and stator insulation. Suitable for continuing or prime power operation in harsh environments. Random wound/VPI stators provide superior handling of high switching loads & harmonics. Built-in paralleling capability with adjustable voltage droop. 4-Pole terminal strip for convenient customer load connection. Least total harmonic distortion 0.7222 winding pitch. Standard voltages: 480V, 60Hz, 380V to 415V at 50 Hz. Standards: meets or exceeds the requirements of IEC 34-1, NEMA MG 1-22, BS4999, BS5000, VDE0530, UTE5100, CSA22.2, ISO8528-3 Permanent Magnet Excited Generator: The Caterpillar SR4B Permanent magnet exciter provides power isolation to voltage regulator, which eliminates the need for series boost. The permanent magnet provides circuit current sustaining for 300% rated current for 10 seconds. An additional feature is improved performance with non-linear loads. Marine certified by ABS, LR, DNV, BV, and others. Radio frequency noise suppression meets 82/449/EEC, VDE875/10.84. industry standards MIL-STD-461,
Page 10
Programmable Variables
Voltage vs. Frequency Characteristic Fine Voltage Level Droop Adjustment Overvoltage Setpoint Overvoltage Time Delay Undervoltage Setpoint Undervoltage Time Delay Gain Single Phase or Three Phase Sensing Under Frequency Point Knee Frequency Minimum Voltage Setpoint Var Operating Mode PF Operating Mode Line Drop (IR) Compensation Loss of Excitation Loss of Excitation Time Delay Over Excitation Time Delay Fixed Time Option Loss of Sensing Time Delay Diode Fault Monitor Soft Start Function
Adjustment
Two slope ranges adjustable from 1 to 10 PU in 0.1 increments 10% to +10% in 0.1% increment 0 to 10% in 0.1% increment 105 to 135% of rated voltage in 1.0% increment 2 to 30 seconds in 1 second increments 60 to 95% of rated voltage in 1.0% increment 10 to 120 seconds in 1 second increments 1 to 20% in 0.1% increments 20 to 40 Hz 45 to 65 Hz in 0.1 Hz increments 50 to 100% of rated voltage 100% to 100% in 0.001 increments 0.6 lead to 0.6 lag in 0.01 increments 0 to 10% in 0.1% increment 0.1 to 1.0 PU leading vars 0.1 to 9.9 seconds in 0.1 second increments 0 to 12 Adc in 0.1 Adc increments 0 to 10 sec in 0.1 sec increments 0 to 25 sec in 1 sec increments 1 to 10A rms field ripple current 1 to 120 sec
Page 11
Page 12
I.
Efficiency Data
II.
Page 13
III.
IV.
Mechanical Data
Page 14
V. Motor Starting 50 Hz
Page 15
IX.
X.
Page 16
Reactive chart
Page 17
I.
Efficiency Data
II.
Reactance Data
III.
Page 18
V. Motor Starting 60 Hz
Page 19
VI
Page 20
IX Reactive curve
Page 21
duplex) protocol using RS-485, which easily interfaces with existing plant systems and equipment. Simultaneous viewing of all AC L-L voltages, all AC L-N voltages, or all AC line currents. User-friendly, convenient, customer programmability directs the customer to logical parameter groups (Ex. AC metering, protective relaying, engine monitoring) for quick keypad access. Set points and software are stored in nonvolatile memory, preventing loss during a power outage. Compatibility with both mechanical and electronic engines makes it versatile. True RMS sensing ensures AC metering accuracy of 1% for AC voltage (L-L and LN) and current. kW and kVA metering accuracy of 5%. Three levels of security allow for configurable operator privileges. Single, standard 70-pin connector Communication, assured by J1939 (Primary Data Link), J1939 #2 (Secondary Data Link) and MODBUS RTU (1/2 duplex) and RS-485 (Customer Communication).
Page 23
Notes: 1. Temperature indications are viewable in either C or F (operator selectable). 2. Pressure indications are viewable in psi, kPa, or bar. 3. Fuel Consumption viewable in US/Imperial gal/hr or Liters/hr.
Relay outputs can be programmed for various operating conditions including: Air Shut-off, or Pre-lube, Common Alarm, Common Shutdown, Common Warning, Engine Running, Crank Alert, and Idle/Rated. Relays are rated for 2A at 30 VDC and consist of 6 Form A (Normally Open) contacts. Two of the programmable outputs are Form C (Normally Open and Normally Closed) contacts.
Page 26
Page 27
5. CONTAINER
5.1. General description
The module is contained in an industry standard 20 foot (6 m) high-cube container. The container is sound attenuated to meet 85 dB (A) at 7 m prime power. Its Lloyds CSC (Convention for Safe Containers) certified for convenient transport and stackable up to 3 high for transport and storage.
5.2. Features
New container with checkered steel deck on floor. Interior walls and ceiling are insulated with 50 mm (2 in) of acoustic glass and covered with perforated galvanzed steel for a durable interior wall surface. Three personnel doors provided with sound attenuation and double sealed. One door located on each side of the engine and one in control room. Includes stainless steel hardware and hinges and panic release. External access door provided for bus bars and auxiliary connections (jacket water heaters, battery charger, space heater in generator and optional interior loads). Two 24 VDC interior lights with 60 min. timer in switchgear room and 3 in engine room. AC / DC Distribution and Motor Control Assembly includes the following distribution IEC rated breakers for Power Module accessories: o 1 # 10A, two (2) pole # Battery Charger input o 1 # 15A, single pole - AC Lighting Controls. o 3 # 15A, two pole # Generator Space Heater, Receptacles and Lighting. o 1 # 20A, single pole # Switchgear DC Control Power. o 2 # 30A, two pole # Jacket Water Heater #1 & #2. Duct Silencers for engine room and radiator room
Page 28
Page 29
Top View
(Roof removed to show interior components, dimensions in inch)
Page 30
Page 31
Front view
Rear view
Legend
Page 32 Reference:
Page 33
Benefits MODES of OPERATION Utility paralleling switchgear is included for automatic paralleling with a utility power source as a load management system, with provisions for standby operation feeding in an isolated load network. Modes of operation are field configurable and include: - Single Unit Island Mode - Multiple Unit Island Mode (up to 18 modules per site) with ramp loading Includes Load Sense / Load Demand control Each module displays system summary power level and summary alarms. Load sharing capability is provided via CAN network communication - Single Unit Utility Parallel Mode. Automatic paralleling Selectable for Import / Export control If Import control is selected a 4-20mA or 0 - 10 V signal is required and will be provided by others that is scalable to the utility contribution. Provision for Manual Paralleling 50 - 60 Hz selectable controls. AUTOMATIC LOAD DEMAND: Load demand operation includes sequencing of multiple units, with configurable start stops levels and timers. Although the modules are intended for prime power rental applications, they can also be configured for various stand-by scenarios as well. This includes strategies where the first module up to speed becomes the master and can close on a dead bus with the remaining packaging automatically paralleling to it. AUTOMATIC SYNCHRONIZING: The control system provides soft loading and unloading for bumpless transfer in parallel operation. The control system also works together with EMCP 3.3 to provide automatic cooldown feature. The control system provides data communication for 1 to 18 modules in a network. Communication is provided with a robust high speed CAN network. The CAN data link was selected for robust high speed deterministic data transfer. Modules are connected in series with a 15 m long high speed CAN cabes (provided with each module). Parallel operation includes both real kW and reactive KVAR load sharing and control.
Page 34
Switchgear Protection
Page 35
Benefits SHORE POWER CONNECTION The module is provided with shore power connection for lighting, generator space heater, and battery charger. The control system provides a 20 Amp internal transfer switch that automatically transfers internal loads to the genset for autonomous operation. POWER OUTPUT CONNECTION The electrical power output connections are provided through a convenient door on the right hand side of the module. The paralleling circuit breaker is rated for 65 kA interrupt capability. The module features robust well braced busbars with easy customer access. These busbars are three phase plus full rated neutral. They include IEC standard hole pattern, fully rated for 0.8 power factor.
Site Controller
Page 36
Functional description The power organiser is a measuring device that in cooperates 3 phase measuring, combined with complete automatic synchronising capabilities. The module is typical suitable for generator application, but it can also be used for power measuring applications like outgoing load feeders or mains incomer load control. Electrical information can be used for diagnostics, control and protection. Variables required for control and protection can be retrieved at high sample rate, such that high performance can be achieved. Current inputs are used both for measurements and for over current protections. Different selectable inverse time characteristics over current protections are applicable: IEC Normal inverse IEC Very inverse IEC Extremely inverse IEC Short inverse ANSI Normal inverse ANSI Very inverse ANSI Extremely inverse ANSI Short inverse Active synchronisation is integrated. Synchronisation is only activated if: Frequency from both generator and busbar side are above threshold. Phase sequence from both generator and busbar are equal All 3 line voltages are above threshold value Synchronisation is activated
Technical Description Revision 1.2 CATERPILLAR 1000 kVA UTILITY POWER MODULE 15 October 2006 Page 37
Synchronisation pulse is given if Frequency is within given window Phase difference is corresponding the given circuit breaker time delay Power organiser will send raise and lower pulses to the engine control panel in order to change generator frequency. Because both generator and mains voltage are available, engine control will be able to match generator voltage with busbar voltage Available variables at 4 wire WYE: Generator side Frequency Phase voltages Measured on any available line voltage V L1-L2 V L2-L3 V L3-L1 V L-L average Active Power Current kW L1 I L1 kW L2 I L2 kW L3 I L3 kW total I L average Apparent Power Reactive power kVA L1 kVAr L1 kVA L2 kVAr L2 kVA L3 kVAr L3 kVA total kVAr total Energy Powerfactor kWh total Pf L1 Pf L2 Pf L3 Pf average Mains side Frequency Phase Voltage Measured on any available line voltage V L1-L2 V L2-L3 V L3-L1 Protections Overcurrent protection I L1 I L2 I L3 Synchroniser Phase difference Between generator and Frequency difference
Page 38
Available variables at 3 wire open delta: Generator side Frequency Phase voltages Measured on any available line voltage V L1-L2 V L2-L3 V L3-L1 V L-L average Active Power Current kW total I L1 I L2 I L3 I L average Reactive power Apparent Power kVAr total kVA total Powerfactor Energy Pf average kWh total kVarh total Mains side Frequency Phase Voltage Measured on any available line voltage V L1-L2 V L2-L3 V L3-L1 Protections Overcurrent protection I L1 I L2 I L3 Synchroniser Phase difference Between generator and Frequency difference
Page 39
7 8 9
10
11
12
13
14
15
16
17
18
19
20
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Dipswitch for CAN 1 Bitrate (125,250, 500 Kbit). Dipswitches for card address CAN 1. Barrier strip connector for generator voltages. Serial communication (standalone or monitor). Connector for Tacho (0..10V). Connector for Pickup with LED indication. Connector for CAN 1. Connector for CAN 2. End of bus dipswitch for CAN 1 and 2. Barrier strip connector for mains voltages. Dipswitch for CAN 2 Bitrate (125,250, 500 Kbit). Dipswitches for card address CAN 2. LED indication for Power, Run, Low Battery, CAN 1 and CAN 2. Barrier strip connector for generator currents. Drawing reference code. Logo and description 4 Digital outputs with LED indication. Supply voltage. Barrier strip connector for mains current. Chassis ground connection (4 connection points; one in each corner).
CATERPILLAR 1000 kVA UTILITY POWER MODULE 15 October 2006 Page 40
Listing of available monitoring and protective functions - Generator over current - Neutral earth current - Generator current imbalance - Generator under voltage - Generator over voltage - Generator voltage imbalance - Generator leading power factor - Generator lagging power factor - Generator under frequency - Generator over frequency - Generator reverse power - Generator overload - Busbar under voltage - Busbar over voltage - Busbar voltage imbalance - Busbar under frequency - Busbar over frequency - Loss of mains ANSI 50/51 ANSI 50/51 * Subjected to optional CT ANSI 46G ANSI 27G ANSI 59 G ANSI 18 G ANSI 81 U/G ANSI 81 O/G ANSI 32 G ANSI 32 O/G ANSI 27 ANSI 59 ANSI 18 ANSI 81 U ANSI 81 O Vector shift, Rate of Change Of Frequency (ROCOF)
Technical description CAN NETWORK 2 CAN connections can be used to retrieve data. CAN 1 is used to get data at high sample rate. CAN2 is used to get all other data. The bit rate at CAN1 needs to be the same as the bit rate from all I/O modules (default 500kBit) The bit rate at CAN2 needs to be the same as setup for CAN-COM interface cards (by default 500kBit). CAN1 address is 1 for the first Power organiser that is connected to the network. Address is 2 if a second Power organiser is added. This is similar as used when setting up addresses for I/O card. First digital input card will have address 1, second digital input card will have address 2 etc. CAN2 address is by default 1, (please check drawing to confirm). It is important that all nodes connected at CAN2 network do have a unique node address. All current measuring is implemented via internal CTs. Current sensing Nominal measuring current 5 Maximal current (< 0,1 sec) 100 Input impedance < 0,1 Power consumption 5 Voltage sensing (AC) Barrier strip connector rated to 600V Line to Line Nominal voltage 420 Maximal voltage continuous 500
Technical Description Revision 1.2 CATERPILLAR 1000 kVA UTILITY POWER MODULE 15 October 2006
A A Ohm VA
Volt Volt
Page 41
Maximum voltage < 0,1sec Burst voltage test (20usec) Input impedance Power supply (DC) Nominal voltage Minimal voltage Maximal voltage continuous Input current Digital Outputs Maximum forward current Output voltage Power Run LED indication On if 24V powersupply is connected Flashing if device is in operation. Starts automatically after powerup Flashing if backup battery voltage is low Flashing once per second if not connected to sbc
4000 Volt 15000 Volt 1200 kOhm 24 18 30 500 200 24 Volt Volt Volt mA mA Volt
On if battery is low low Flashing fast (more than twice per second) if communicating with sbc
Measurements (@ 50Hz or @60Hz at full range) Parameter Accuracy +/Display Voltage 0,4% 0V Frequency 0,01% 0,00Hz Current 0,4% 0 Amp kVA 0,5% 0 kVa kVAr 0,8% 0 kVar kWatts(1) 0,5% 0 kWatts
(1)
Page 42
6.3. Monitoring
A 5,7 color touch screen provides the following a overview of the power module status. The three pushbuttons provide easy start/stop control and alarm reset. The alarm button also provides alarm status indication. The system consist no moving parts. It is well protected by 9 password levels. The system provides for instance the following screens: - general overview - All electrical values (voltage current, power factor, KWH, KW, KVA. KVAr) - Alarm and event history - Start and stop information - Running hours information - Site configuration settings - Process settings - Load control modes and settings - Los of mains settings - Installation overview (general status and electrical values up to 18 power modules)
Page 43
6.4. Protection
6.4.1. Power assembly
Power Module switchgear lineup is 480V rated for indoor use with one C32 generator set.
Page 44
7. Testing
7.1. Prototype Testing
The Caterpillar Utility Power Module has extensive prototype testing and validations. This includes both 50 Hz and 60 Hz load testing with the following parameters being recorded: Fuel rate and specific fuel consumption Frequency and speed Real and reactive power Power factor Jacket water temperature Oil pressure Fuel pressure Phase voltages and currents Sound level measurements Alarms / shutdowns functional tests settings Multiple units paralleling
Page 45
7.3. Documentation
Caterpillar Utility Power Module documentation includes: As built electrical schematics Container package drawings Caterpillar sheets Repair parts lists.
Reference: DCQ123-9
Page 46