14A Star Crescent, Hallam, Victoria, Australia, 3803. Ph: (+61 3) 9796-4002 Fax: (+61 3) 9796-4003 Web: www.systemsinsight.com.

au

Standard Generator Control Systems Synchronising Unit for Caterpillar Gen. Sets

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Product Bulletin PSTD0005 June 2002

CAT Generator Paralleling Unit

14A Star Crescent, Hallam, Victoria, Australia, 3803. Ph: (+61 3) 9796-4002 Fax: (+61 3) 9796-4003 Web: www.systemsinsight.com.au

Standard Generator Control Systems Synchronising Unit for Caterpillar Generator Sets
_____________________________________________________________________
Systems Insight has designed a range of standard generator control systems to provide ready made, pre-engineered solutions to address frequently requested customer requirements. A new add-on paralleling control panel has been designed, for installation to Caterpillar generators fitted with an EMCP II+ control unit. The control panel features a manufactured cubicle which attaches to the rear of the EMCP II+ via lift-off hinges. The cubicle profiles the exact dimensions of the EMCP II+ and swings via the hinges to provide access to the rear compartment. A control switch and push buttons are supplied, installed to the front of the EMCP II+ to provide operator control of paralleling operations. The standard paralleling unit is designed to incorporate a Woodward DSLC (Digital Synchroniser & Load Control). The DSLC is connected via a Lonworks communications network to other paralleled generators. Labelled terminals are provided for installation of network cabling by the site installer. The DSLC is interfaced to the voltage regulator and engine speed control as part of the installation provided by Systems Insight. LED indicator lights are also fitted to the fascia of the EMCP II+, to provide indication of Open and Closed status of the synchronising circuit breaker. Operation: The control selector and push buttons fitted to the front fascia of the EMCP II+ provide the operator with two paralleling control options: Auto Paralleling control is automatic when the generator is started via the remote start input on the EMCP II+. The DSLC is called to synchronise the generator with an external bus voltage reference as soon as the generator is started and nominal frequency is achieved. When in synchronism, the DSLC activates a close pulse to call the external synchronising circuit breaker to close. When the circuit breaker is closed, the DSLC automatically ramps the generator onto the connected load. When the remote start call signal is removed, the DSLC unloads the generator from the bus and activates an open signal to call the external synchronising circuit breaker to open. Manual Paralleling control is manually initiated by an operator, when the generator is started either (a) via the local EMCP II+ control selector, or (b) via the remote start input on the EMCP II+. A Sync. & Close push button is fitted to the fascia of the EMCP II+. When the generator is started and nominal frequency is achieved the Sync. & Close button may be held pressed to call the DSLC to synchronise the generator with an external bus voltage reference.

CAT Generator Paralleling Unit

Standard Generator Control Systems CAT Paralleling Control __________________________________________________________

When in synchronism, the DSLC activates a close pulse to call the external synchronising circuit breaker to close. The Sync & Close button can be released once the circuit breaker is closed. When the circuit breaker is closed, the DSLC automatically ramps the generator onto the connected load. An Unload & Open push button is also fitted to the fascia of the EMCP II+. When the Unload & Open button is held pressed, the DSLC unloads the generator from the bus and activates an open signal to call the external synchronising circuit breaker to open. The Unload & Open button can be released once the circuit breaker is open. For both Automatic and Manual control modes, a maintained open command is signalled to the synchronising circuit breaker when the generator is stopped. The open command is issued as soon as the run signal to the engine is removed. A synchroniser alarm is generated by the DSLC on detection of a synchronising fault. This alarm is connected to a spare fault input on the EMCP II+ and programmed to indicate a synchroniser fault on the LCD display. The paralleling system is designed to be adaptable for use with either air or motor operated synchronising circuit breakers, or with latching contactors. Where motor operated circuit breakers are used, the control circuit to open the circuit breaker includes both a 24V shunt trip and a maintained, AC voltage pulse of 4 seconds duration, to motor the circuit breaker from the trip to the off position.

Mains Paralleling Option:

A variant to the standard CAT DSLC paralleling control panel is available, featuring facility to parallel the generator with the supply authority mains. This facility enables the operator to provide a no-break transfer between normal mains and generator supply, dispensing with inconvenient and disruptive power interruptions. This feature is particularly useful on critical, interruption sensitive sites when returning to mains after operating on generator (as a result of an earlier mains outage). The facility can also be used to load test the generator, to soft load and unload the generator to the building load without interrupting supply. The mains paralleling version of this system includes the following additional items: v Mains supply voltage sensing relay (3 phase). v Micro PLC with 8 digital inputs, 4 analogue inputs and 6 relay outputs. v Mains import power (kilowatts) sensing transducer with output to analogue PLC input. (Provides an analogue process control reference to the PLC) Note: Voltage and current references are derived from existing external CTs and VTs v Additional labour allowance for commissioning of the installed system, extended to maximum 32 labour hours (local Melbourne Metro. Area P.O.A. for other areas).

CAT Generator Paralleling Unit

Standard Generator Control Systems CAT Paralleling Control __________________________________________________________

Standard CAT Generator Paralleling Control Panel:

Wiring Schematics:
1 2 3 4 5 6 7 8 9 1 0 1 1 A
0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 A T A SO MR CRNF R E B X E MN L O T R I AS I EC N MP CAT CURRENT TRANSFORMERS IN ALTERNATOR ENCLOSURE R W B N N W T R I AS E E MN L A D DT E C DE O MP CT2 2 T51A 51A (E) RD T52A 52A CT3 T53A 53A GEN COMMON BUS VOLTAGEREFERENCE (LC) BA K (E) RD ( HE WI ) T T50 (L E BU ) T51 51 T52 52 T53 53 (E) RD (LC) BA K ( HE WI ) T (LC) BA K (L E BU ) (LC) BA K DSLC-CB CLOSERELAY "C " SR 03 00 09 00 00 00 00 00 00 00 00 00 03 00 09 00 DSLC-CB OPENRELAY "DOR" C1 DL -C S B C OE RLY P N EA SR O FN E 5 . 40 7 I D R 53 . 0 0 DL -C S B C COEEA L SRLY SR C FN E 5 . 40 7 I D R 53 . 0 0 2 C1 S21 S22 51A 51 52A 52 53A 53 (LC) BA K B-P1 CBF 20/6 (LC) BA K (E) RD C1 GENERATOR 24VDC SUPPLY FROM ENGINE BATTERIES ALTERNATOR & EMCP EQUIPMENT & TERMINALS EMCP TERMINALS T2 2 RMB+ 1 1 CF1 20/6 C1 WOODWARD DSLC DIGITAL SYNCHRONISER AND LOAD CONTROL PWRUP O ESPL Y 9 OTUT UPTO 2 NU 14VC IPT 80D O R UTRG 3 E VLAE 0 GA T LO +/-9V 3 1 BSAPAE U HS OD P6NI TAS. O6 z A TSUPT 3 OE U 2 PT E 4 -ETLRNF 5TH OPL T R 3 OCNOU (R OOL T ) P MUA WOINT 3 T P 4 4mO1D 2 ARVC - 5 0 A E LAST 5 N T REFDCSG 3 IP OMORCT URREPOEI M EEN REN S RE 6 3 B GETR ERO NA 7 3 P TNA O I 41V 25 0 TAEOMR R 6 TL O-mD R-A C 3 4 -NFRES 56Sz H 8 P CS RT L OS E C CNOU OR T 3 N IP 9 0 4 LNOS O R WK NT OKO 4 EWGT 1 LR GNLNRL EA DIO C TAS 4 O ITL 2 3 1 A 4 1 5 1 GET EE NN A CRTR R URO B TRS RES RNF M AO 6 1 0A P - MS 7 7 1 DPL1EPT 4 SRTID I 8 SCY4NU 3 UPE-VC 0 C 8 1 CC 4 HK E PRSIE 4 EMV 5 IS -1 9 R 4 U 6 N RA LNU EY R E SLDDIR U V +2 0 10PYPT 8VCI 4P C ACRO) B D NC A A OE FROXDOT 4 (PNO LU OT P 7 1 RAEC E 2 BEKRLS O RIE VLAE 4 A OG 8 S T 2 BEKR PN RAEOE LWROAE 4 O EVL G 9 T 3 OTGRS 2 V LA EAE I BSL A 5 AEOD 0 4 OAEW 2 VLGO E TL R LAULA 5 ODN D 1 / O 5 ODW 2 L AS TH IC LARMPUE 5 ODA PAS 2 6 I HI I 2 HG LMT R LA 5 AO 3 S D I E 7 O LI 2 L WI T M LWROD 5 O ELA 4 8 LM 2 AR A POECNO 5 RCSOT L S R 2

- 1 + 2 3 4 5 6 7 109 8 9 1 1 0 0 1 1 101 1 2 S3 S5 108

HP I M L M OIP C O M +/-3V C O M

S29 S31 S32 S33 OUTPUTTO V LA E R G L T R OT G E UA O OUTPUTTOENGINE SPEEDCONTROLLER

CT1

L IK + N L IK + N + -

S40 S41 ERTDLNT OR CBE A T AC EW LK ALS H L N OY L S A S ED N G

+ -

B L E 90 ED N27 N T O K C BE EW R A L L K DT A L I E O L N GENERATORDSLC's ANDMSLC

C
0011 0012 T1 0013 2AMP 0014 T2 0015 CLF 2AMP 109 T12 109 ( HE WI ) T A T A SO MR CRNF R E BOXFUSES&TERMINALS I EC N MP CLF 108 T11 108 (E) RD

a 03 03 02 09 b 00 00 00 00 a 00 00 00 00 b 03 03 00 07

S46 S47 N L IK N L IK S50

11

R M V LN (FP E E T O A LD L s E O E I KI R S N ) N L S C ' ECPLSDL (N ONT O K X E T A T S CE D F E W R ) SYNC. CONTROL SWITCH AT UO MAN HS Z1 CBR-1 14 2 1 01 03 01 02 02 02 SYNC & CLOSE 01 04 4 3 C1 CBR-1 PRESS&HOLDBUTTON UNTILSYNC.CBCLOSES 02 02 PRESS&HOLDBUTTON UNTILSYNC.CBOPENS UNLOAD &OPEN 01 05 8 07 7 01

0016 0017 0018 0019

T3

CLF 2AMP

110

T13

110

(L E BU )

a 00 00 00 00 b 04 04 02 02

00 03 00 02 00 00 00 00 DSLC ALARMRELAY "A " SR

DL SC AA M EA LR RLY C1 S A R FN E 5 . 40 7 I D R 53 . 0 0

S28

DS51 L T1 02 03

SR-1 01 05 02 06 01 06

C1

H21 101 101 (LC) BA K BASELOADSWITCH(OPTIONAL) NR A OML BSL A AEOD S50 K C1 0013 0022 0023 OUTPUT TO RL 0012 C1 OUTPUT TO RL 0000 SYNC. CIRCUIT BREAKER COM N/O SYNC. CB AUXILIARY N/C 02 02 02 02 C SST C BA TYU . E Y ANS L R C B R 2 SYNCCB SAU R L Y T T S EA "B" CR a 01 03 03 04 00 06 b 01 00 03 02 00 07 2 a 01 06 b 00 00 2 1 C1

GEN BUS FREQUENCY RELAY "HZS" CROMPTON 252-PHUW 0020 0021 0022 0023 0024 0025 0026 (LC) BA K 101 21 22 24 GENERATOR PARELLELING CIRCUIT BREAKER (L E BU ) 110 L S46 11 12 14

E
00 00 02 08

D EA FN E 5 . 40 7 L AID L Y I D R 53 . 0 0 OTM R E P E E =S C L R S T1 E D T

R OUTPUT TO LOAD W B N

CLF 62 35 /

CBF BR1 20/6 COMMON GENERATOR BUSREFERENCETODSLC (RL0004) B N 30

REMOTESTARTCONTACT IC 57

SRC E &C U P E HRS H H R7F AS 2 2- E 1 U2 57 SA T R L Y T R EA "R S" a 01 06 b 00 00 CB O E TM R / PN I E I0 E . /TMN &F.D( 401 ) COER 9N 3246C BIPE 9 1 RV D " O" CT P E E = S C C T 101 a 02 R S T4 E O 09 b 00 00 SRC E &C U P E HRS H H R7F AS 2 2- E 1 U2 COT-1 02 09 02 07 S R RLY TT E A A SR ( E AV G D N G TE N ) I / CBR-2 02 02 SCR-1 03 02 01 03 (LC) BA K 101 CB CHARGE MOTOR CBF 1 1 0 2 A 4 C 0 V 03 01 2V C 4D SYNC. CB CLOSECOIL EMCP TERMINALS E C R NR L Y M P U EA RR

DSLCLOAD DLY T E EA I R M "D " LT

EMCP TERMINALS C1

RM8

RM24

R N CL U AL RLY EA RR 2 C FN E 5 . 40 7 I D R 53 . 0 0

F
0027 0028 0029 0030 0031 UTILITY/MAINS CIRCUIT BREAKER

E GN R N NIE U CL RLY AL EA "RCR" a 01 00 00 04 00 00 b 00 02 00 00 09 00

00 00 00 00

110

CBR-4 02 02 RCR-2

(L E BU )

SYNC. CIRCUIT BREAKER SYNC. CB MOTOR OFF (MOULDED CASE C/B ONLY) C N E T N M N F CU E S E F O N CO S A UA T R R P CC I II 2 A 4 C 0 V SYNC. CB SHUNT TRIP COIL LINK 2

C1 02 06 LINK 02 08 SOR-1 01 04 SR A4 03 00

110 ( L E BU )

0032 01 06 0033 CLF 0034 0035 0036 0037 INCOMING NORMAL MAINS SUPPLY 0038 0039 0040 0041 0042 03 09 VOLT FREE CONTACT FOR CUSTOMER CONNECTION - SYNC. CB CLOSE (240VWIRING) SCR-2 01 03 04 00 04 00 VOLT FREE CONTACT FOR CUSTOMER CONNECTION - SYNC. CB OPEN ( L WRN ) EV I I G 62 35 / MBF 20/6 NORMAL MAINS BUSREFERENCE C1 N N NR1

20/6

M
2 A 4 C 0 V CBR-3 03 05 02 02 SYNCH CB CLOSED 2 R SYNCH CB OE PN 03 06 G 2

03 07

SOR-2 01 04

03 08

CBR-3 02 02

03 08

0039A VOLT FREE CONTACT FOR CUSTOMER CONNECTION - SYNC. CB CLOSE ( L WRN ) EV I I G

SCR-3 01 03

0040A

0040A

TERMINALLEGEND ELV TERMINAL

30 INDICATION TO EMCP "SP1"(SPAREINPUTNo.1) -DSLCALARM 23

SR A1 01 06

SP1 VOLT FREE CONTACT FOR CUSTOMER CONNECTION -DSLCALARM

0041

SR A2 01 06

04 02

415/240V AC TERMINAL

SP1 EMCP TERMINALS

04 02

COPYRIGHT - SYSTEMS INSIGHT PTY LTD 2001

REPRODUCTION OF THIS DESIGN ONLY BY PERMISSION

J H G F E D C B A RV E:

DA N M.COLLINS RW : DATE: 2/2001 SCALE: NTS CHECK:

DRAWING "FOR MANUFACTURE"

SIGNED: SYSTEMS DESIGN ENGINEER

M.COLLINS __ REVISION DETAILS MC REV BY: __ RV D T: E AE

CATERPILLAR GENERATOR SYNCHRONISING CONTROL SYSTEM

5 6 7 8 9

CAT SYNCHRONISING PANEL WIRING SCHEMATIC

DRG. No.

SYSTEMS INSIGHT PTY LTD 14A Star Crescent, Hallam, Victoria, Australia, 3803. Ph: (+613) 9796-4002 Fax: (+613) 9796-4003 Email: insight@one.net.au ACN 074 284 343 REV

DSTD0020M
1 0 1 1

An electronically drafted wiring schematic (as shown above) is supplied with the standard Cat generator paralleling control system. All field installed cables interfacing to CAT terminals and new components are clearly highlighted, to assist with easy installation.

CAT Generator Paralleling Unit

Standard Generator Control Systems CAT Paralleling Control __________________________________________________________

Notes: v Each system is inclusive of one complete synchronising control package per generator. v Each system includes supply and installation of all equipment to a Cat generator set with EMCP II+ and maximum of 8 hours labour for load testing and commissioning. (32 hours for mains paralleling option) v All installation and commissioning inclusions are based on works within the Melbourne Metropolitan area. Travel and other associated costs apply for interstate and overseas works. v Where the mains paralleling option is employed, the local electrical supply authority may specify additional protection to operate during parallel operation of the generator with the mains. This additional protection is not included and would be priced and supplied separately.

Exclusions: The following items are normally excluded from our standard package but are available as options: v Provision of engine speed controller and voltage regulator (by generator supplier or customer) v Provision and set-up of load banks for testing v Local supply authority charges (in cases of mains parallel operation) are not included. v Supply of electrical protection relays.

CAT Generator Paralleling Unit