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CAT SWITCHGEAR
TIME REQUIREMENT GUIDE (TRG)
This warranty repair time requirement guide is designed to: Provide detailed guidance on troubleshooting Determine possible solutions Guide the technician to seek assistance, based on the individuals level of qualification Establish the amount of time that will be reimbursed under warranty
PLEASE BE SURE TO SEEK ASSISTANCE APPROPIATE FOR YOUR LEVEL OF QUALIFICATION “Qualified” means that the technician not only attends classroom training, but also performs on an actual job startup, to demonstrate his expertise. “W/ Assist” means that the time will be reimbursed provided the technician calls for assistance. If the technician does not seek assistance, the troubleshooting and solution may require more time, and may not be reimbursed. “Self” means that the technician can perform the troubleshooting and repair independently and will be reimbursed for the specified time. If the troubleshooting and repair is expected to take more time than noted, please contact the Product Support Center for guidance and authorization. To qualify for allowable hours, the technician must also have the required PLC download (Level 1) or access to (Level 2) tools and associated hardware. The Cat® switchgear Product Support Center can be reached at: U.S. Toll Free: 866-883-3879 U.S. Direct: 678-746-5000 EMAIL: [email protected] If the Cat switchgear has a Caterpillar serial number beginning with the prefix SWG, the Dealer Solution Network (DSN) can also be contacted for assistance with product issues. Please refer to most current Warranty Bulletin (Cat Switchgear) for additional information.
Table of Contents
Component Codes...................................................................... 3
Segmented Repair Times............................................................ 4
Generator Breaker Fails to Close ................................................ 5
Generator Breaker Fails to Open................................................ 6
Utility Breaker Fails to Close ...................................................... 7
Utility Breaker Fails to Open ...................................................... 9
Tie Breaker Fails to Open ......................................................... 10
Distribution Breaker Fails to Close ........................................... 11
Distribution Breaker Fails to Open ........................................... 12
NOTE: For touchscreen and communication issues in the U.S.
call (866) 883-3879 or for Int’l (678) 746-5000 or by email to [email protected]
COMPONENT CODE COMPONENT DESCRIPTION CODE MEANING
4491 Switchgear High level general troubleshooting switchgear code. Use when a more appropriate code does not exist.
Software449S Processor Concept programming software449L PL 1000 & PL 2000 HMI Proface programming software449H PL 3000 HMI RSView programming software449R Remote RSView remote software449B MB+ Communications Modbus+ intra-switchgear communications449G Generator Communications Communications between switchgear and generator
Hardware449T Touchscreen Display for user control, interface and monitoring
449C Programmable Logic Controller1420 Circuit Breaker4494 Protective Relay1417 Fuse4493 Control Relay4495 25 Relay Sync. check relay4459 Wiring4475 Control Power Transformer (CPT)449M Metering Monitors switchgear and generator1904 Transducer4476 Current Transformer (CT)4475 Potential Transformer / Voltage Transformer
SWITCHGEAR COMPONENT CODE INFORMATION
Contains user project and graphics for user control, interface and monitoringTouchscreen Processor449P
Page 3 of 12
COMPONENT JOB L1* L1 L2* L2CODE CODE TRAINED QUALIFIED TRAINED QUALIFIED
TROUBLESHOOTING
Software 4491 035 X X X 1.0 4.0MB+ Communications 449B 035 X X X 1.0 1.0Generator Communications 449G 035 X X 0.3 0.3 1.0Hardware 4491 035 X 1.0 2.0 1.0 4.0Circuit Breaker 1420 035 X X 0.5 0.5 1.0Metering 449M 035 X X X X 1.5
Job Set Up 4491 587 0.3 0.3 0.3 0.3 0.3Download Processor 449S 591 X X X 1.0 1.0Download PL 1000 & PL 2000 HMI 449L 591 X X X 0.5 0.5Download PL 3000 HMI 449H 591 X X X 1.0 1.0Download Remote 449R 591 X X X 1.0 1.0Replace Touchscreen 449T 010 X 0.5 0.5 0.5 0.5Replace Touchscreen Processor 449P 010 X X 2.0 2.0 2.0Replace PLC** 449C 010 X X 1.0 1.0 1.0Replace Transducer 1904 010 X X X X 0.5Replace 25 Relay 4495 010 X X 0.6 0.6 0.6Reports 4491 030 0.5 0.5 0.5 0.5 0.5Site Clean Up 4491 071 0.3 0.3 0.3 0.3 0.3
* To qualify for allowable hours, technician must also have the required PLC download (Level 1) or access (Level 2) tools and associated hardware.** If there are multiple PLC's, Multiply "Hours Allowed" times the number of PLC's
CAT SWITCHGEAR SEGMENTED REPAIR TIMES
HOURS ALLOWED PER EXPERTISE LEVEL
REPAIRS
NONE
Page 4 of 12
None Level 1 Trained
Level 1 Qualified
Level 2 Trained
Level 2 Qualified
A. Generator not running w/ assist self self self self
w/ assist self self self self Shut CB 4491
a. Sensing fuses blown (primary) x x w/ assist x self Investigate reason for blowing fuses, repair and replace fuses 449Mb. Sensing fuses blown (secondary) x x w/ assist x self Investigate reason for blowing fuses, repair and replace fuses 449Mc. Faulty PLC block x x self self self Troubleshoot PLC block and replace if necessary 1904
w/ assist self self self self Place sync. switch in auto 4491w/ assist self self self self Place system switch in auto 4491
No problem xx x w/ assist w/ assist w/ assist
a. Check bias to speed / voltage regulator x x w/ assist w/ assist self Follow 5.a. 449Gb. Gen in sync window? (+/-6 degrees) YES Proceed to next step x
NO x x w/ assist w/ assist w/ assist
a. Check wiring on terminals 1&2, 3&4 1) Wiring OK? YES x x w/ assist x self Proceed to 6.b. 449MNO x x w/ assist x self Correct wiring 449M
b. Check relay portion of device YES x x w/ assist x self
NO x x w/ assist x self Replace 25 device. 4495
a. Output row plugged in? YES x x x x x Proceed to 7.b. xNO x x w/ assist x self
b. CBCL (circuit breaker close) relay pickup? YES x x w/ assist w/ assist self
x x w/ assist w/ assist w/ assist
NO x x w/ assist w/ assist self
a. PLC run light lit? YES x x x x x Proceed to 9.b. xNO x x self self self
b. MB+ light flashing fast and steady? YES x x x x x No problem with PLC. Troubleshoot other causes. xNO x x x self self
9. Gen PLC problem8. Metering problem (see B.2. above)
Note: for LV systems, control power comes from a control power transformer which requires the bus to be energized. Voltage on the primary and secondary should be checked. Be sure to check PT ratios if you are unsure of your readings.
Verify 24VDC at terminal 13. If 24VDC is present here, replace closing coil. (NOTE: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately)
SYMPTOM - Generator Breaker Will Not Close Automatically
PLC has a communication problem. Verify address of PLC and network integrity. 449B
PLC has lost its program. Re-download program, or replace with a pre-programmed PLC from Product Support Center. 449S / 449B
7. PLC sending close signal, but breaker is not closing (indicated by LED's on PLC base)
Plug in output row. (Note: equipment may operate when this step is performed)
Check control power (120VAC, 48VDC, or 125VDC) available.
x
1. Generator mounted CB is open
C. Generator running and producing voltage, but breaker will not close
1. Synchronizing selector switch on touchscreen not in auto2. System not in auto3. Generator removed by gen demand
2. Metering problem
3. Generator problem
4. Gen breaker tripped / locked out by 86
CAPABILITY FOR EXPERTISE LEVEL
B. Generator running but not producing voltage as indicated on touchscreen
Troubleshoot voltage regulator and speed regulator. Verify wiring to generator
File on Genset Claim
Tune gen to get it near 12 O'clock. If breaker still won't close, proceed to next step. 449G
Investigate reason for breaker trip and repair. Reset breaker, reset 86. 1420
1420
Check relay with meter. When off, should have 24 VDC on terminal 5, 0 VDC on terminal 6. When on, should have 24 VDC on both terminals 5 & 6. If you don't get these readings replace the 25 device.
4495
Check fuses and wiring up to closing coil on breaker. If control power is reaching coil, but breaker will still not close, breaker problem. Call Product Support Center for guidance and to report the issue.
1420
1420
SOLUTION COMPONENT CODE
Start gen, at touchscreen to verify PLC output. Be certain it's not being held out on a previous shutdown that has not been cleared. 4491
5. Gen not syncing to bus
6. Bad sync check relay
1) Relay on red light is illuminated when synchroscope is near 12 O'clock? (IF lighting someplace else, then phasing is probably incorrect) Verify Phasing
Page 5 of 12
None Level 1 Trained
Level 1 Qualified
Level 2 Trained
Level 2 Qualified
A. Breaker already open x x x x x No problem. xx x x x x No problem. x
C. Sync control switch not in auto x x x x x Place switch in auto 4491x x x x x No problem. x
1. PLC run light illuminated? YES x x x x x Proceed to E.2. xNO x x self self self
2. MB+ light flashing fast & steady? YES x x x x x
NO x x self self self
1. Output row plugged in? YES x x x x x Proceed to F.2. xNO x x w/ assist x self
2. CBOP (circuit breaker open) relay pickup? YES x x w/ assist w/ assist self
x x w/ assist w/ assist w/ assist
NO x x w/ assist w/ assist self
COMPONENT CODE
449S / 449B
SOLUTION
Check fuses and wiring up to closing coil on breaker. If control power is reaching coil, but breaker will still not close, breaker problem. Call Product Support Center for guidance and to report the issue.
1420
SYMPTOM - Generator Breaker Will Not OpenCAPABILITY FOR EXPERTISE LEVEL
B. System mode will not allow opening
D. Disconnect KW not reached
E. PLC problem
PLC has lost its programming. Re-download program, or replace with a pre-programmed PLC from Product Support
Note: For low voltage systems, control power comes from a control power transformer which requires the bus to be energized. Voltage on the primary and secondary should be checked. Be sure to check PT ratios if you are not sure of your readings.
No problem with PLC. Troubleshoot other causes x
F. PLC sending open signal, but breaker is not opening (indicated by LEDs on PLC base)
PLC has a communication problem. Verify address of PLC and network integrity 449B
Plug in output row. (Note: equipment may operate when this step is performing) 4491
Check control power (120VAC, 48VDC or 125VDC) available 1420
Verify 24VDC at terminal 13. If VDC is present here, replace closing coil. (Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately)
1420
Page 6 of 12
None Level 1 Trained
Level 1 Qualified
Level 2 Trained
Level 2 Qualified
w/ assist self self self self Energize utility 4491
1. Mode exit timer timing out? YES w/ assist self self self self Press "Immediate Transfer" to bypass timer. 4491NO x x x x x Proceed to next step x
2. System in E-Mode? (as indicated on YES w/ assist self self self self
NO x x x x x Proceed to next step x
YES w/ assist self self self self
NO x x x x x Proceed to next step x
x x w/ assist x x Clear fault on utility, reset 86 and close breaker. 4494x x w/ assist w/ assist self
w/ assist self self self self
1. Sensing fuses blown (primary) x x w/ assist x self
2. Sensing fuses blown (secondary) x x w/ assist x self
3. Faulty PL block x x self self self Troubleshoot block and replace if necessary 1904
1. Check wiring on terminals 1 & 2, 3 & 4 a. Wiring OK? YES x x w/ assist x x Proceed to G.1. 449MNO x x w/ assist x x Correct wiring 449M
2. Check relay portion of device
YES x x w/ assist x self
NO x x w/ assist x self Replace 25 device 4495
No problem. System will restore from E-Mode automatically. 4491
SYMPTOM - Utility Breaker Will Not Close Automatically SOLUTION COMPONENT CODE
A. Utility not energized
CAPABILITY FOR EXPERTISE LEVEL
C. Multifunction relay see fault on utility, resulting in a breaker tripD. Breaker function interlocked with another breaker
B. Mode will not allow breaker closure
3. Utility Re-close Switch in LOCKOUT?
Investigate reason for blowing fuses, repair and replace fuses. 449M
E. Utility synchronizer selector switch not in auto
Ensure all breakers in lineup are installed and the correct position to meet any interlocks. 1420
At Utility control screen, place SYNC SEL SWITCH in AUTO, or use INSTANT AUTO. 4490
Investigate reason for blowing fuses, repair and replace fuses. 449M
Check relay with meter. When off, should have 24VDC on terminal 5, 0VDC on terminal 6. When on, should have 24VDC on both terminals 5 & 6. If you don't have this, replace 25 device.
4495
Coordinate with end user, determine why switch was placed in LOCKOUT, then, if safe, place switch in the AUTO position.
4491
G. Bad sync check relay
F. Metering problem
a. Relay on red light illuminates when Synchroscope near 12 O'clock (if illuminated someplace else, then phasing is probable incorrect) Verify phasing
Page 7 of 12
1. PLC run light illuminated? YES x x x x x Proceed to H.2. xNO x x x self self
2. MB+ light flashing fast and steady? YES x x x x x No problem with PLC, troubleshoot other causes xNO x x self self self
1. Output row plugged in? YES x x x x x Proceed to I.2. xNO x x w/ assist x self
YES x x w/ assist w/ assist self
x x w/ assist w/ assist w/ assist
NO x x w/ assist w/ assist self Verify 24VDC at terminal 13. If VDC is present here, replace closing coil. (Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately)
1420
Plug in output row. (Note: equipment may operate when this step is performed) 4491
Check control power (120VAC, 48VDC, 125VDC) available 1420
Check fuses and wiring up to closing coil on breaker. If control power is reaching coil, but breaker will still not close, there is a problem with the breaker. Call the Product Support Center for guidance and to report the issue. 1420
PLC has a communication problem. Verify address of PLC and network integrity. 449B
H. PLC problem
PLC has lost its program. Re-download program or replace with a pre-programmed PLC from the Product Support Center.
449S / 449B
I. PLC sending close signal, but breaker is not closing (indicated by LEDs on PLC base)
2. CBCL (circuit breaker close) relay pickup?
Note: For low voltage systems, control power comes from a control power transformer which requires the bus to be energized. Voltage on the primary and secondary should be checked. Be sure to check PT ratios if you are unsure of your readings.
Page 8 of 12
None Level 1 Trained
Level 1 Qualified
Level 2 Trained
Level 2 Qualified
x x x x x No Problem xx x x x x No Problem x
C. Sync control switch not in auto w/ assist w/ assist w/ assist w/ assist w/ assist Place switch in auto 4491x x x x x No Problem x
1. PLC run light illuminated? YES x x x x x Proceed to E.2. xNO x x x x self
2. MB+ light is flashing fast and steady YES x x x x x
1. Output row plugged in? YES x x x x x Proceed to F.2. xNO x x w/ assist x self
2. CBOP (circuit breaker open) relay YES x x w/ assist w/ assist self
x x w/ assist w/ assist w/ assist
NO x x w/ assist w/ assist self
x x w/ assist w/ assist self
SOLUTION COMPONENT CODE
E. PLC problem
A. Breaker already open
CAPABILITY FOR EXPERTISE LEVEL
B. System mode will not allow opening
D. Disconnect KW not reached
SYMPTOM - Utility Breaker Will Not Open
F. PLC is sending open signal, but breaker not opening (indicated by LEDs on PLC base)
Plug in output row. (Note: equipment may operate when this step is performed) 4491
Check control power (120VAC, 48VDC or 125VDC) available 1420
449S / 449B
PLC has lost its program. Re-download program or replace it with a pre-programmed PLC front the Product Support Center
No problem with PLC. Troubleshoot other causes. x
G. Utility breaker electrically interlocked with another breaker Meet interlock conditions according to drawings and sequence of operation. If interlock conditions are met, verify wiring between the breakers for interlock circuit.
1420
Check fuses and wiring up to closing coil on breaker. If control power is reaching coil, but breaker will still not close, breaker has a problem. Call the Product Support Center for guidance and to report the issue.
Verify 24VDC at terminal 13. If 24VDC is present here, replace closing coil. (Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately.)
1420
1420
Note: For low voltage systems, control power comes from a control power transformer which requires the bus to be energized. Voltage on the primary and secondary should be checked. Be sure to check PT ratios if you are unsure of your readings.
Page 9 of 12
None Level 1 Trained
Level 1 Qualified
Level 2 Trained
Level 2 Qualified
A. Breaker already open x x x x x No Problem xx x x x x No Problem x
w/ assist self self self self Place switch in auto 4491x x x x x No Problem x
1. PLC run light illuminated? YES x x x x x Proceed to E.2. xNO x x self self self
YES x x x x x
NO x x self self self
1. Output row plugged in? Yes x x x x x Proceed to F.2. xNO x x w/ assist x self
YES x x w/ assist w/ assist self
x x w/ assist w/ assist w/ assist
NO x x w/ assist w/ assist self
Check fuses and wiring up to closing coil on the breaker. If the control power is reaching the coil, but the breaker still will not close, there is a breaker problem. Contact the Product Support Center for guidance and to report the issue.
No problem with PLC. Troubleshoot other causes. x2. MB+ light is flashing fast and steady?
Verify 24VDC at terminal 13. If 24VDC is present here, replace the closing coil. )Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately.)
1420
Note: For low voltage systems, control power comes from a control power transformer which requires the bus to be energized. Voltage on the primary and secondary should be checked. Be sure to check PT ratios if you are unsure of your readings.
Check control power (120VAC, 48VDC or 125VDC) available. 14202. CBOP (circuit breaker open) relay pickup?
F. PLC is sending open signal, but breaker is not opening (indicated by LEDs on PLC base)
SOLUTION COMPONENT CODE
1420
Plug in output row. (Note: equipment may operate when this step is performed.)
4491
PLC has a communication problem. Verify address of PLC and network integrity.
449B
PLC has lost its program. Re-download program, or replace it with a pre-programmed PLC from the Product Support Center.
449S / 449B
E. PLC problem
CAPABILITY FOR EXPERTISE LEVEL
B. System mode will not allow openingC. Sync control switch not in autoD. Disconnect KW not reached
SYMPTOM - Tie Breaker Will Not Open
Page 10 of 12
None Level 1 Trained
Level 1 Qualified
Level 2 Trained
Level 2 Qualified
x x x x x No Problem xw/ assist self self self self
x x w/ assist w/ assist self
1. PLC run light illuminated? YES x x x x x Proceed to D.2. xNO x x self self self
YES x x x x x
NO x x self self self
1. Output row plugged in? YES x x x x x Proceed to E.2. xNO x x w/ assist x self
YES x x w/ assist w/ assist self
x x w/ assist w/ assist w/ assist
NO x x w/ assist w/ assist self
SOLUTION COMPONENT CODE
2. MB+ light is flashing fast and steady?
Note: For low voltage systems, control power comes from a control power transformer which requires the bus to be energized. Voltage on the primary and secondary should be checked. Be sure to check PT ratios if you are unsure of your readings.
2. CBCL (circuit breaker close) relay pickup?
Verify 24VDC at terminal 13. If 24VDC is present here, replace the closing coil. (Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately.)
1420
Plug in output row. (Note: equipment may operate when this step is performed.)
4491
Check control power (120VAC, 48VDC or 125VDC) available. 1420
Check fuses and the wiring up to closing coil on the breaker. If control power is reaching the coil, but the breaker will still not close, there is a breaker problem. Call the Product Support Center for guidance and to report the issue.
1420
Place breaker in AUTO on Load Shed Control Screen. 1420
Correct the reason for breaker tripping, reset the breaker and reclose.
PLC has a communication problem. Verify address of PLC and network integrity.
449B
1420
PLC has lost its program. Re-download program, or replace with a pre-programmed PLC from the Product Support Center.
449S / 449B
No problem with PLC. Troubleshoot other causes. x
E. PLC is sending close signal, but breaker is not closing (indicated by LEDs on PLC base)
D. PLC problem
B. Breaker has been manually overridden to OPEN
SYMPTOM - Distribution Breaker Won't Close AutomaticallyCAPABILITY FOR EXPERTISE LEVEL
C. Breaker is tripped
A. Breaker has been shed by the system
Page 11 of 12
None Level 1 Trained
Level 1 Qualified
Level 2 Trained
Level 2 Qualified
x x x x x No Problem xw/ assist self self self self
x x x x x
1. PLC run light illuminated? YES x x x x x Proceed to D.2. xNO x x self self self
YES x x x x x
NO x x self self self
1. Output row plugged in? YES x x x x x Proceed to E.2. xNO x x w/ assist x self
YES x x w/ assist w/ assist self
x x w/ assist w/ assist w/ assist
NO x x w/ assist w/ assist self
Note: For low voltage systems, controlpower comes from a control power transformer which requires the bus to be energized. Voltage on the primary and secondary should be checked. Be sure to check PT ratios if you are unsure of your readings.
Verify 24VDC at terminal 13. If 24VDC is present here, replace the closing coil. (Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately.)
1420
Check fuses and the wiring up to closing coil on the breaker. If control power is reaching the coil, but the breaker will still not close, there is a breaker problem. Call the Product Support Center for guidance and to report the issue.
1420
4491
Check control power (120VAC, 48VDC or 125VDC) available. 14202. CBOP (circuit breaker open) relay pickup?
C. Breaker is tripped
D. PLC problem
E. PLC sending open signal, but breaker not opening (indicated by LEDs on PLC base)
Plug in output row. (Note: equipment my operate when this step is performed.)
No automation problem. Cause of breaker trip should be corrected.
2. MB+ light flashing fast and steady?
x
PLC has lost its program. Re-download program, or replace with a pre-programmed PLC from the Product Support Center. 449S / 449B
PLC has a communication problem. Verify address of PLC and network integrity.
No problem with PLC. Troubleshoot other causes. x
449B
CAPABILITY FOR EXPERTISE LEVEL
A. Breaker has been added to the systemPlace breaker in AUTO on Load Shed Control Screen. 1420B. Breaker has been manually overridden to CLOSE
SYMPTOM - Distribution Breaker Will Not Open SOLUTION COMPONENT CODE
Page 12 of 12
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