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CATERPILLAR
UTILITY POWER MODULE
Dual Voltage
Dual Frequency
1. OVERVIEW................................................................................................................... 4
2. CAT 3516B 4-STROKE-DIESEL ENGINE.................................................................... 4
2.1. Specifications ......................................................................................................... 4
2.2. ADEM III Engine Controller .................................................................................... 5
2.2.1. Introduction ..................................................................................................... 5
2.2.2. Features .......................................................................................................... 5
2.2.3. Description ...................................................................................................... 6
2.2.4. ADEM III Specifications................................................................................... 7
3. CAT SR4B 826 FRAME GENERATOR ........................................................................ 8
3.1. Specifications ......................................................................................................... 8
3.2. Features ................................................................................................................. 9
3.3. Form Wound Stator Winding before Impregnation................................................. 9
3.4. Rotor construction .................................................................................................. 9
3.5. Caterpillar Digital Voltage Regulator (CDRV) ...................................................... 10
3.5.1. CDRV Description ......................................................................................... 10
3.5.2. CDRV Features ............................................................................................. 10
3.5.3. CDRV Specifications ..................................................................................... 11
3.5.4. CDVR Regulation Characteristic ................................................................... 12
3.6. Technical data...................................................................................................... 13
3.6.1. 50 Hz ............................................................................................................. 13
3.6.2 60 Hz Technical Data ..................................................................................... 16
4. EMCP 3.3 GENERATOR SET CONTROLLER .......................................................... 19
4.1. EMCP 3.3 General Description ............................................................................ 19
4.2. EMCP 3.3 Operator Interface............................................................................... 19
4.3. EMCP 3.3 Features & Benefits ............................................................................ 19
4.4. EMCP 3.3 Environmental specifications .............................................................. 20
4.5. EMCP 3.3 Standards ........................................................................................... 20
4.6. EMCP 3.3 Standard features ............................................................................... 21
4.6.1. Controls ......................................................................................................... 21
4.6.2. Digital (LCD) Indication ................................................................................. 21
4.6.3. Warning/Shutdown indication........................................................................ 22
4.6.4. Digital inputs (8 Total) ................................................................................... 22
4.6.5. Protective relaying......................................................................................... 23
4.6.6. Relay outputs (8 Total) .................................................................................. 23
4.6.7. Discrete outputs (2 Total) .............................................................................. 23
4.6.8. Sensor inputs ................................................................................................ 23
4.7. EMCP 3.3 Available local display languages ....................................................... 24
5. CONTAINER ............................................................................................................... 25
5.1. General description .............................................................................................. 25
5.2. Features ............................................................................................................... 25
5.3. Drawings, Dimensions & Weight.......................................................................... 26
5.3.1. Container dimensions & weight..................................................................... 26
5.3.2. Container views:............................................................................................ 26
Technical CATERPILLAR Page 2
Description UTILITY POWER MODULE
Revision 1.0 9 March 2006
6. Switchgear ..................................................................................................................29
6.1. Controls................................................................................................................ 29
6.1.1. Incoming Utility Breaker Status Circuit .......................................................... 29
6.1.2. Utility Transfer Trip Circuit............................................................................. 29
6.2. Monitoring ............................................................................................................ 29
6.3. Protection ............................................................................................................. 30
6.3.1. Power assembly ............................................................................................ 30
6.3.2. Generator circuit breaker............................................................................... 30
7. Testing ........................................................................................................................ 32
7.1. Prototype Testing ................................................................................................. 32
7.2. Standard Power Module Test............................................................................... 32
7.3. Documentation ..................................................................................................... 33
2.2.1. Introduction
The ADEM III controller is the main Electronic Control Module (ECM) used on the 3516B
diesel engines.
The ADEM III control is designed to control interface Electronic Unit Injector (EUI)
equipped engines. The ADEM III controller is composed of the ADEM III ECM, control
software, sensors, actuators, fuel injectors, and interface to the generator system.
The prime benefit of an ADEM III engine system is to better control and maintain the
particulate emissions, both steady state and transient, while improving engine
performance over the Mechanical Unit Injector (MUI) engines.
2.2.2. Features
1 - General features
RELIABLE, DURABLE - All ADEM III 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 -Each ADEM III system works in combination with the Caterpillar
ET service tool software to keep the engine operating at peak performance (not
included).
• 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 III ECM.
SELF DIAGNOSTICS - Each ADEM III 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. Self-diagnostic capability pinpoints operational problems in
need of attention.
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 cooldown/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.
General Specifications
Voltage regulation
Temeture Drift ±0.25% no load to full load
Response Time ±1.0% for a 40° C change
Variable Sensing Range Maximum of 10 milliseconds
Control Power 90 to 600 Volts 24 Vdc Supply (18 to 30 Vdc, 5VA)
Regulator Filtering THF 3% per IEC34-1 - TIF of 50 NEMA MG1-22.43
Harmonic Tolerance 0.5% Voltage regulation with 40% THD
Weight 1.47 kg (3.25 lb)
Environmental
T'do 6.929
T'd 0.484 SCR 0.47
T"do 0.008 stator (Ohms) 0.0012
T"d 0.007 field (Ohms) 1.120
T"qo 0.006 Overspeed (%) 180
T"q 0.005 BIL 3182
Ta 0.051 X/R Ratio 13.28
Te 0.223
T'do 6.929
T'd 0.484 SCR 0.45
T"do 0.008 stator (Ohms) 0.0012
field (Ohms) 1.120
T"d 0.007
Overspeed (%) 150
T"qo 0.006
BIL 3465
T"q 0.005
X/R Ratio 15.97
Ta 0.051
Te 0.223
4.6.1. Controls
x Auto/Start/Stop
x Engine Cool-Down Timer
x Emergency Stop
x Engine Cycle Cranking
x Lamp Test
x Generator Voltage (w/CDVR)
x Engine Speed/Generator Frequency (Electronic Engines Only)
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.
5.2. Features
x New container with galvanized steel deck on floor. Interior walls and ceiling are
insulated with 100 mm (4 in) of acoustic glass and covered with perforated
aluminized steel for a durable interior wall surface. Floor of container is insulated
with acoustic glass and covered with galvanized steel.
x 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.
x External access door provided for bus bars and auxiliary connections (jacket
water heaters, battery charger, space heater in generator and optional interior
loads).
x Two 24 VDC interior lights with 60 min. timer in switchgear room and 3 in engine
room.
x Separate control room with ventilation system.
x Switchgear room is separated from engine room with partitioned wall made from
2” sound panels and includes vent fan & thermostat.
x Dual ventilation fans and motorized lovers in engine room.
x The container comes with an 80 liter fuel tank with cooler and water separator, a
fuel transfer pump and a lockable External Fuel Fill.
x Two 4.5 kg (10 lb) carbon dioxide fire extinguisher bottles mounted on the wall.
x AC / DC Distribution and Motor Control Assembly includes the following
distribution IEC rated breakers for Power Module accessories:
o 2 # 10A, two (2) pole # Battery Charger input and Fuel Transfer Panel.
o 1 # 15A, single pole - AC Lighting Controls.
o 3 # 15A, two pole # Generator Space Heater, Receptacles and Lighting.
o 1 # 15A, single pole # Switchgear Space Heaters.
o 1 # 20A, single pole # Switchgear DC Control Power.
o 1 # 25A, two pole # Vent Fan and Receptacles.
o 2 # 30A, two pole # Jacket Water Heater #1 & #2.
o 1 # 40A, two pole # Switchgear Room Space Heater.
x Duct Silencers for engine room and radiator room
27 597 Kg 60 840 lb
CONTAINER VIEWS:
Top view
(Roof removed to show interior components, dimensions in inch)
Legend
6.2. Monitoring
®
PowerLynx graphical mimic shall show the Generator with its respective circuit breaker
in a one-line representation of the system. The graphics shall utilize black and white
indicators and bar graphs while actively displaying the following information:
x Utility CB Open/Closed. Input contacts provided by others.
x Utility kW. A 4-12-20mA signal required and provided by others that is scalable to
the utility contribution.
x Generator CB Open/Closed/Tripped
x Generator Volts/Amps/kW/Frequency
x Engine Stopped/Running/Cooldown/Pre-Alarm/Shutdown
x Engine ECS Position Off/Auto/Manual/Cooldown
x Utility Output kW
x System Summary Alarm
®
Standard PowerLynx System local Annunciation is also included. Status, Light Only
(Non-Latching)
Technical CATERPILLAR Page 29
Description UTILITY POWER MODULE
Revision 1.0 9 March 2006
x Single Unit Island Mode
x Multiple Unit Island Mode
x Single Unit Utility Parallel Mode
x Gen CB Open
x Gen CB Closed
x Gen Tripped
x Gen ECS Not in Auto
x Gen ECS in Auto
x Emergency Mode
x Alarm, Light and Horn (Non-Latching)
x Low Fuel Main Tank
x Gen Fail to Synch
x Fuel system alarm
x Shutdown Alarm, Light and Horn (Latching)
x Processor Fault
x Emergency Stop
x Critical Low fuel Level
x Rupture Basin
x Gen Circuit Breaker Tripped
x Gen Loss of Field
x Gen Reverse Power
x Gen Undervoltage
x Gen Overvoltage
x Gen Underfrequency
x Gen Overfrequency
x 78/81 df/dt shutdown
®
PowerLynx Generator Metering will graphically display 3f Voltage, 3f Current,
Frequency, Power Factor, KW, KVAR and a Synchroscope.
Display of EMCP3.3 faults, CDVR and ADEM3 are provided via Modbus RTU interface
from EMCP3 .3.
6.3. Protection
Because generator set engines and the generators have been pre-tested, this test is not
intended to provide a measurement of the generator set power capability.
Note: Power Module will be tested at 60hz first then tested at 50hz and will leave the
factory at 50hz.
Prior to the testing described herein, the engine and the generator and the genset
package shall be pretested by their respective manufacturer's normal production test
standards. These tests will be recorded and available for review at the Power Module
witness test.
7.3. Documentation
Caterpillar Utility Power Module documentation includes:
x As built electrical schematics
x Container package drawings
x Caterpillar sheets
x Repair parts lists.