STANDBY 750 ekW 938 kVA 60 Hz 1800 rpm 480 Volts 750 KW … · Control Panel • EMCP 4 Genset Controller [ ] EMCP 4.2 [ ] EMCP 4.3 [ ] EMCP 4.4 [ ] Generator temperature monitoring

DIESEL GENERATOR SET

STANDBY

750 ekW 938 kVA60 Hz 1800 rpm 480 VoltsCaterpillar is leading the power generation

marketplace with Power Solutions engineered

to deliver unmatched flexibility, expandability,

reliability, and cost-effectiveness.

Image shown may notreflect actual package.

FEATURES

FUEL/EMISSIONS STRATEGY

• EPA Certified for StationaryEmergency Application(EPA Tier 2 emissions levels)

DESIGN CRITERIA

• The generator set accepts 100% rated load in onestep per NFPA 110 and meets ISO 8528-5 transientresponse.

UL 2200 / CSA - Optional

• UL 2200 listed packages• CSA Certified

Certain restrictions may apply.Consult with your Cat® Dealer.

FULL RANGE OF ATTACHMENTS

• Wide range of bolt-on system expansionattachments, factory designed and tested

• Flexible packaging options for easy and costeffective installation

SINGLE-SOURCE SUPPLIER

• Fully prototype tested with certified torsionalvibration analysis available

WORLDWIDE PRODUCT SUPPORT

• Cat dealers provide extensive post sale supportincluding maintenance and repair agreements

• Cat dealers have over 1,800 dealer branch storesoperating in 200 countries

• The Cat® S•O•SSM program cost effectively detectsinternal engine component condition, even thepresence of unwanted fluids and combustionby-products

CAT® C27 ATAAC DIESEL ENGINE

• Utilizes ACERT™ Technology• Reliable, rugged, durable design• Four-cycle diesel engine combines consistent

performance and excellent fuel economy withminimum weight

• Electronic engine control

CAT GENERATOR

• Designed to match the performance and outputcharacteristics of Cat diesel engines

• Single point access to accessory connections• UL 1446 recognized Class H insulation

CAT EMCP 4 CONTROL PANELS

• Simple user friendly interface and navigation• Scalable system to meet a wide range of

customer needs• Integrated Control System and Communications

Gateway

SEISMIC CERTIFICATION

• Seismic Certification available• Anchoring details are site specific, and are

dependent on many factors such as generator setsize, weight, and concrete strength.IBC Certification requires that the anchoringsystem used is reviewed and approved by aProfessional Engineer

• Seismic Certification per Applicable BuildingCodes: IBC 2000, IBC 2003, IBC 2006, IBC 2009,CBC 2007

• Pre-approved by OSHPD and carries anOSP-0084-10 for use in healthcare projects inCalifornia

STANDBY 750 ekW 938 kVA60 Hz 1800 rpm 480 Volts

FACTORY INSTALLED STANDARD & OPTIONAL EQUIPMENT

System Standard OptionalAir Inlet • Air cleaner

Cooling • Package mounted radiator

Exhaust • Exhaust flange outlet [ ] Exhaust mufflers (except Tier 4)

Fuel • Primary fuel filter with integral water separator• Secondary fuel filters• Fuel priming pump

Generator • Matched to the performance and outputcharacteristics of Cat engines

• Load adjustment module provides engine relief uponload impact and improves laod acceptance andrecovery time

• IP23 protection

[ ] Oversize and premium generators[ ] Permanent magnet excitation (PMG)[ ] Internal excited (IE)[ ] Anti-condensation space heaters

Power Termination • Bus bar [ ] Circuit breakers, UL listed[ ] Circuit breakers, IEC compliant

Control Panel • EMCP 4 Genset Controller [ ] EMCP 4.2[ ] EMCP 4.3[ ] EMCP 4.4[ ] Generator temperature monitoring and protection[ ] Load share module[ ] Digital I/O module[ ] Remote monitoring software

Mounting [ ] Rubber vibration isolators

Starting/Charging [ ] Battery chargers[ ] Oversize batteries[ ] Jacket water heater[ ] Heavy duty starting system[ ] Charging alternator[ ] Air starting motor with control and silencer (3500 &

C175 models only)General • Paint - Caterpillar Yellow except rails and radiators

gloss blackThe following options are based on regional and

product configuration:[ ] Seismic Certification per Applicable Building Codes:IBC 2000, IBC 2003, IBC 2006, IBC 2009, CBC 2007[ ] EU Certificate of Conformance (CE)[ ] UL 2200 package[ ] CSA Certification[ ] EEC Declaration of Conformity[ ] Enclosures- sound attenuated, weather protective[ ] Automatic transfer switches (ATS)[ ] Integral & sub-base fuel tanks[ ] Integral & sub-base UL listed dual wall fuel tanks

February 26 2013 12:08 PM2


SPECIFICATIONS

CAT GENERATOR

Frame size......................................................................... 596Excitation................................................ Permanent MagnetPitch.............................................................................. 0.8667Number of poles...................................................................4Number of bearings...................................... Single bearingNumber of Leads.............................................................. 012Insulation....................... UL 1446 Recognized Class H withtropicalization and antiabrasion- Consult your Caterpillar dealer for available voltagesIP Rating.........................................................Drip Proof IP22Alignment.............................................................. Pilot ShaftOverspeed capability........................................................150Wave form Deviation (Line to Line)...............Less than 5%deviationVoltage regulator.............. 3 Phase sensing with selectiblevolts/HzVoltage regulation............Less than +/- 1/2% (steady state)Less than +/- 1% (no load to full load)

CAT DIESEL ENGINE

C27 TA, V-12, 4-Stroke Water-cooled DieselBore.......................................................... 137.20 mm (5.4 in)Stroke....................................................... 152.40 mm (6.0 in)Displacement.........................................27.03 L (1649.47 in3)Compression Ratio....................................................... 16.5:1Aspiration........................................................................... TAFuel System................................................................... MEUIGovernor Type....................................................ADEM™ A4

CAT EMCP 4 SERIES CONTROLS

EMCP 4 controls including:- Run / Auto / Stop Control- Speed and Voltage Adjust- Engine Cycle Crank- 24-volt DC operation- Environmental sealed front face- Text alarm/event descriptions

Digital indication for:- RPM- DC volts- Operating hours- Oil pressure (psi, kPa or bar)- Coolant temperature- Volts (L-L & L-N), frequency (Hz)- Amps (per phase & average)- ekW, kVA, kVAR, kW-hr, %kW, PF

Warning/shutdown with common LED indication of:- Low oil pressure- High coolant temperature- Overspeed- Emergency stop- Failure to start (overcrank)- Low coolant temperature- Low coolant level

Programmable protective relaying functions:- Generator phase sequence- Over/Under voltage (27/59)- Over/Under Frequency (81 o/u)- Reverse Power (kW) (32)- Reverse reactive power (kVAr) (32RV)- Overcurrent (50/51)

Communications:- Six digital inputs (4.2 only)- Four relay outputs (Form A)- Two relay outputs (Form C)- Two digital outputs- Customer data link (Modbus RTU)- Accessory module data link- Serial annunciator module data link- Emergency stop pushbutton

Compatible with the following:- Digital I/O module- Local Annunciator- Remote CAN annunciator- Remote serial annunciator

February 26 2013 12:08 PM3

598SE


TECHNICAL DATA

Open Generator Set - - 1800 rpm/60 Hz/480 Volts DM9071

EPA Certified for Stationary Emergency Application

(EPA Tier 2 emissions levels)

Generator Set Package Performance

Genset Power rating @ 0.8 pfGenset Power rating with fan

937.5 kVA750 ekW

Fuel Consumption

100% load with fan75% load with fan50% load with fan

202.9 L/hr 53.6 Gal/hr162.4 L/hr 42.9 Gal/hr116.2 L/hr 30.7 Gal/hr

Cooling System1

Air flow restriction (system)Engine coolant capacity

0.12 kPa 0.48 in. water55.0 L 14.5 gal

Inlet Air

Combustion air inlet flow rate 58.7 m³/min 2073.0 cfm

Exhaust System

Exhaust stack gas temperatureExhaust gas flow rateExhaust flange size (internal diameter)Exhaust system backpressure (maximum allowable)

509.3 º C 948.7 º F158.9 m³/min 5611.5 cfm203 mm 8 in10.0 kPa 40.2 in. water

Heat Rejection

Heat rejection to coolant (total)Heat rejection to exhaust (total)Heat rejection to aftercoolerHeat rejection to atmosphere from engineHeat rejection to atmosphere from generator

324 kW 18426 Btu/min742 kW 42197 Btu/min138 kW 7848 Btu/min100 kW 5687 Btu/min46.2 kW 2627.4 Btu/min

Alternator2

Motor starting capability @ 30% voltage dipFrameTemperature Rise

2035 skVA596130 º C 234 º F

Lube System

Sump refill with filter 68.0 L 18.0 gal

Emissions (Nominal)3

NOx g/hp-hrCO g/hp-hrHC g/hp-hrPM g/hp-hr

5.25 g/hp-hr.25 g/hp-hr.03 g/hp-hr.021 g/hp-hr

1 For ambient and altitude capabilities consult your Cat dealer. Air flow restriction (system) is added to existing restriction from factory.2 Generator temperature rise is based on a 40ºC ambient per NEMA MG1-32. UL 2200 Listed packages may have oversized generatorswith a different temperature rise and motor starting characteristics.3 Emissions data measurement procedures are consistent with those described in EPA CFR 40 Part 89, Subpart D & E and ISO8178-1 formeasuring HC, CO, PM, NOx. Data shown is based on steady state operating conditions of 77ºF, 28.42 in HG and number 2 diesel fuelwith 35º API and LHV of 18,390 btu/lb. The nominal emissions data shown is subject to instrumentation, measurement, facility and engineto engine variations. Emissions data is based on 100% load and thus cannot be used to compare to EPA regulations which use valuesbased on a weighted cycle.

February 26 2013 12:08 PM4


RATING DEFINITIONS AND CONDITIONS

Applicable Codes and Standards: AS1359, CSA C22.2 No100-04, UL142, UL489, UL601, UL869, UL2200, NFPA 37,NFPA 70, NFPA 99, NFPA 110, IBC, IEC60034-1, ISO3046,ISO8528, NEMA MG 1-22, NEMA MG 1-33, 72/23/EEC,98/37/EC, 2004/108/ECStandby - Output available with varying load for theduration of the interruption of the normal source power.Average power output is 70% of the standby powerrating. Typical operation is 200 hours per year, withmaximum expected usage of 500 hours per year.

Ratings are based on SAE J1349 standard conditions.These ratings also apply at ISO3046 standard conditions.Fuel Rates are based on fuel oil of 35º API (16º C or 60º F)gravity having an LHV of 42 780 kJ/kg (18,390 Btu/lb)when used at 29º C (85º F) and weighing 838.9 g/liter(7.001 lbs/U.S. gal.).Additional Ratings may be available for specificcustomer requirements. Consult your Cat representativefor details.

February 26 2013 12:08 PM5


DIMENSIONS

Package Dimensions

Length 4141.6 mm 163.05 in

Width 1823.3 mm 71.78 in

Height 2210.5 mm 87.03 in

NOTE: For reference only - do not use forinstallation design. Please contactyour local dealer for exact weightand dimensions. (GeneralDimension Drawing #4316806).

www.Cat-ElectricPower.com

2013 CaterpillarAll rights reserved.

Materials and specifications are subject to change without notice.The International System of Units (SI) is used in this publication.

CAT, CATERPILLAR, their respective logos, "Caterpillar Yellow," the"Power Edge" trade dress, as well as corporate and product identity used

herein, are trademarks of Caterpillar and may not be used withoutpermission.

21374523

Performance No.: DM9071

Feature Code: C27DR55

Gen. Arr. Number: 3678056

Source: U.S. Sourced

February 26 2013

6

Reference PPPISection 2 for finalweights anddimensions

Juliab

Text Box

SYSTEMS DATA [C27DR55] JULY 19, 2013 For Help Desk Phone Numbers Click here

Reference Number: DM9071 Version Symbol: Change Level:

Sales Model: C27 DI TA AA Eff. Serial Number Prefix: MJE Engr. Model:

Description Answer UnitAir Intake System The installed system must comply with the system limits below for all emissions certified engines to assure regulatory compliance.MAX ALLOW INTAKE RESTR W/CLEAN ELEMENT 14.9 IN WTR MAX ALLOW INTAKE RESTR W/DIRTY ELEMENT 24.9 IN WTR MAX ALLOW INTAKE MANIFOLD TEMP 129 DEG F MAX ALLOW INTAKE MAN TEMP (30C/86F DAY) 248 DEG F ALLOW PRESS DROP-COMPR OUT TO MANF IN 4.4 IN HG MAX TURBO INLET AIR TEMPERATURE 122 DEG F MAX AIR FILTER INLET AIR TEMPERATURE 252 DEG F CHARGE AIR FLOW AT RATED SPEED 153.2 LB/MIN TURBO COMPR OUT PRESS AT RATED SPD (ABS) 85.0 IN HG TURBO COMPR OUT TEMP AT RATED SPEED 343 DEG F Cooling SystemENGINE ONLY COOLANT CAPACITY 14.5 GAL TOTAL SYS COOLANT CAP (PKG GENSETS ONLY) 29.0 GAL MAX ALLOW ENGINE COOLANT OUTLET TEMP 230 DEG F REGULATOR START-TO-OPEN TEMP 178 DEG F REGULATOR FULL OPENING TEMPERATURE 198 DEG F REGULATOR LOCATION OUTLETAMBIENT COOLING CAPABILITY AT RATED SPD 109 DEG F MAX UNINTERRUPTED FILL RATE 5 GPM MIN ALLOW COOLANT LOSS-PERCT OF TOTAL 12 PERCENT COOL LOSS-MAX % OF PUMP PRESS RISE LOSS 15 PERCENT RADIATOR AIR FLOW (PKG GENSETS ONLY) 30,617.8 CU FT/MIN Engine Spec SystemCYLINDER ARRANGEMENT VEENUMBER OF CYLINDERS 12 CYL CYLINDER BORE DIAMETER 5.4016 IN PISTON STROKE 6.0000 IN TOTAL CYLINDER DISPLACEMENT 1,649 CU IN COMPRESSION RATIO (TO ONE) 16.5CRANKSHAFT ROTATION (FROM FLYWHEEL END) CCWCYLINDER FIRING ORDER 1-10-9CYLINDER FIRING ORDER - CONTINUED 6-5-12CYLINDER FIRING ORDER - CONTINUED 11-4-3CYLINDER FIRING ORDER - CONTINUED 8-7-2NUMBER 1 CYLINDER LOCATION FRONT-LFSTROKES/COMBUSTION CYCLE 4 STROKES APPLICATION CLASS GEN

Page 1 of 3Systems Data

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ENGINE DUTY CYCLE STDBEMISSION CERTIFICATION AGENCIES EPA TIER 2EMISSION CERTIFICATION YEAR 2006STD - AFTERCOOLER DESIGN TEMP 120 DEG F GENSET LINE FREQUENCY 60 HZ GENSET VOLTAGE RANGE 480GENERATOR FRAME SIZE 596Exhaust System The installed system must comply with the system limits below for all emissions certified engines to assure regulatory compliance.MAX ALLOW SYS BACK PRESS 40.2 IN WTR MANIFOLD TYPE DRYMAX ALLOW STATIC WT ON EXHAUST CONN 110 LB MAX ALLOW STATIC BEND MOMENT ON EXH CONN 0 FT LB EXHAUST ELBOW DIAMETER 7.9921 IN Fuel SystemMAX FUEL FLOW TO TRANSFER PUMP (TO ENG) 129.0 GPH MAX ALLOW FUEL SUPPLY LINE RESTRICTION 8.9 IN HG MAX ALLOW FUEL TMP FROM TRANSFER PUMP IN 149 DEG F MAX FUEL FLOW TO RETURN LINE (FROM ENG) 58.6 GPH MAX ALLOW FUEL RETURN LINE RESTR 10.2 IN HG NORMAL FUEL PRESSURE-CLEAN SYSTEM 90.9 PSI FUEL SYSTEM TYPE DIMAX TFR PUMP PRMG LIFT W/O PRMG PUMP 12.1 FT FUEL Lube SystemRECOMMENDED OIL TYPE (API OR CAT SPEC) CJ-4OIL FILTER TYPE FUL-FL,S-OLUBE SYSTEM OIL COOLER TYPE SHL & TUBEMAXIMUM ALLOWABLE OIL TEMP 230 DEG F NOM OIL PRESS W/SAE 10W30 OIL @ 99 DEG C 68.0 PSI MIN LI OP W/SAE 10W30 OIL @ 99 DEG C 64.0 PSI CRANKCASE VENTILATION TYPE TO ATMREAR SUMP STD/OPT/NAP STDREAR SUMP REFILL VOLUME W/FILTER CHANGE 72 QT REAR SUMP CAPACITY @ ADD MARK 49 QT REAR SUMP CAPACITY @ FULL MARK 62 QT Mounting SystemC/G LOC - X DIMENSION - FRM REAR FACE OF BLK - (REF TM7077) 22.9527 IN C/G LOC - Y DIMENSION - FRM CL OF CRANKSHAFT - (REF TM7077) 11.4960 IN C/G LOC - Z DIMENSION - FRM CL OF CRANKSHAFT - (REF TM7077) 0.2756 IN STD - FLYWHEEL HOUSING SIZE-SAE NUMBER #0DRY WT ENG ONLY (DRAINED OF FLUIDS) 6,420 LB ENGINE LENGTH 76.7715 IN ENGINE WIDTH 59.1337 IN Starting SystemMIN CRANKING SPD REQUIRED FOR START-RPM 100 RPM LOWEST AMBIENT START TEMP W/O AIDS 32 DEG F



Caterpillar Confidential: GreenContent Owner: Commercial Processes DivisionWeb Master(s): PSG Web Based Systems SupportCurrent Date: Friday, July 19, 2013 10:33:38 AM© Caterpillar Inc. 2013 All Rights Reserved.Data Privacy Statement.



GENERATOR DATA JULY 22, 2013 For Help Desk Phone Numbers Click here

Selected ModelEngine: C27 Generator Frame: 598 Genset Rating (kW): 750.0 Line Voltage: 480Fuel: Diesel Generator Arrangement: 3870794 Genset Rating (kVA): 937.0 Phase Voltage: 277Frequency: 60 Excitation Type: Self Excited Pwr. Factor: 0.8 Rated Current: 1127.0Duty: STANDBY Connection: SERIES STAR Application: EPG Status: Current

Version: 40953 /40864 /41474 /11205

Spec Information

Generator SpecificationFrame: 598 Type: SR4B No. of Bearings: 1Winding Type: RANDOM WOUND Flywheel: 18.0Connection: SERIES STAR Housing: 0 Phases: 3 No. of Leads: 12Poles: 4 Wires per Lead: 4Sync Speed: 1800 Generator Pitch: 0.8667

Generator EfficiencyPer Unit Load kW Efficiency %

0.25 187.5 92.20.5 375.0 94.6

0.75 562.5 94.91.0 750.0 94.7

Reactances Per Unit OhmsSUBTRANSIENT - DIRECT AXIS X''d 0.1453 0.0357SUBTRANSIENT - QUADRATURE AXIS X''q 0.1489 0.0366TRANSIENT - SATURATED X'd 0.2128 0.0523SYNCHRONOUS - DIRECT AXIS Xd 2.9289 0.7198SYNCHRONOUS - QUADRATURE AXIS Xq 1.4893 0.3660NEGATIVE SEQUENCE X2 0.1469 0.0361ZERO SEQUENCE X0 0.0968 0.0238

Time Constants SecondsOPEN CIRCUIT TRANSIENT - DIRECT AXIS T'd0 3.0770SHORT CIRCUIT TRANSIENT - DIRECT AXIS T'd 0.2235OPEN CIRCUIT SUBSTRANSIENT - DIRECT AXIS T''d0 0.0097SHORT CIRCUIT SUBSTRANSIENT - DIRECT AXIS T''d 0.0078OPEN CIRCUIT SUBSTRANSIENT - QUADRATURE AXIS T''q0 0.0090SHORT CIRCUIT SUBSTRANSIENT - QUADRATURE AXIS T''q 0.0074EXCITER TIME CONSTANT Te 0.1443ARMATURE SHORT CIRCUIT Ta 0.0406

Short Circuit Ratio: 0.44 Stator Resistance = 0.0047 Ohms Field Resistance = 1.875 Ohms

Voltage RegulationVoltage level adustment: +/- 5.0%Voltage regulation, steady state: +/- 0.5%Voltage regulation with 3% speed change: +/- 0.5%Waveform deviation line - line, no load: less than 5.0%Telephone influence factor: less than 50

Generator Excitation No Load Full Load, (rated) pf

Series ParallelExcitation voltage: 8.27 Volts 40.46 Volts VoltsExcitation current 1.77 Amps 7.11 Amps Amps

Page 1 of 8Caterpillar Generator Data

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Version: 40953 /40864 /41474 /11205

Generator Mechanical Information

Center of Gravity

Dimension X -788.4 mm -31.0 IN.Dimension Y 0.0 mm 0.0 IN.Dimension Z 0.0 mm 0.0 IN.

"X" is measured from driven end of generator and parallel to rotor. Towards engine fan is positive. See General Information for details "Y" is measured vertically from rotor center line. Up is positive. "Z" is measured to left and right of rotor center line. To the right is positive.

Generator WT = 2321 kg * Rotor WT = 791 kg * Stator WT = 1530 kg 5,117 LB 1,744 LB 3,373 LB

Rotor Balance = 0.0508 mm deflection PTPOverspeed Capacity = 150% of synchronous speed

Generator Torsional Data

J1 = Coupling and Fan

J2 = Rotor TOTAL J = J1 + J2 + J3

J3 = Exciter End

K1 = Shaft Stiffness between J1 + J2 (Diameter 1)

K2 = Shaft Stiffness between J2 + J3 (Diameter 2)

J1 K1 Min Shaft Dia 1 J2 K2 Min Shaft Dia 2 J3

11.8 LB IN. s2 116.8 MLB IN./rad 5.0 IN. 103.3 LB IN. s2 20.4 MLB IN./rad 3.3 IN. 1.5 LB IN. s2

1.336 N m s2 13.2 MN m/rad 127.0 mm 11.673 N m s2 2.3 MN m/rad 83.8 mm 0.171 N m s2

Total J

116.7 LB IN. s2

13.18 N m s2




Version: 40953 /40864 /41474 /11205

Generator Cooling Requirements - Temperature - Insulation Data

Cooling Requirements: Temperature Data: (Ambient 40 0C)Heat Dissipated: 42.0 kW Stator Rise: 105.0 0CAir Flow: 112.2 m3/min Rotor Rise: 105.0 0C

Insulation Class: H Insulation Reg. as shipped: 100.0 M minimum at 40 0C

Thermal Limits of Generator

Frequency: 60 HzLine to Line Voltage: 480 VoltsB BR 80/40 851.0 kVAF BR -105/40 1025.0 kVAH BR - 125/40 1125.0 kVAF PR - 130/40 1125.0 kVA




Version: 40953 /40864 /41474 /11205

Starting Capability & Current DecrementMotor Starting Capability (0.4 pf)

SKVA Percent Volt Dip

114 2.5

235 5.0

362 7.5

496 10.0

638 12.5

788 15.0

947 17.5

1,116 20.0

1,296 22.5

1,488 25.0

1,694 27.5

1,914 30.0

2,150 32.5

2,404 35.0

2,679 37.5

2,977 40.0

Current Decrement Data

E Time Cycle AMP

0.0 7,710

1.0 5,240

2.0 4,654

3.0 4,314

4.0 4,019

5.0 3,746

7.5 3,138

10.0 2,623

12.5 2,188

15.0 1,822

20.0 1,255

25.0 853

30.0 576

35.0 414

40.0 318

45.0 259

Instantaneous 3 Phase Fault Current: 7710 Amps Instantaneous Line - Line Fault Current: 6636 AmpsInstantaneous Line - Neutral Fault Current: 8636 Amps




Version: 40953 /40864 /41474 /11205

Generator Output Characteristic CurvesOpen Circuit Curve

Field Current

Line - Line Volt

0.0 0

6.9 288

8.2 336

9.6 384

11.4 432

14.2 480

19.0 528

28.8 576

50.1 624

98.5 672

Short Circuit Curve

Field Current

Armature Current

0.0 0

19.2 677

22.4 789

25.6 902

28.8 1,015

32.0 1,128

35.2 1,240

38.4 1,353

41.6 1,466

44.8 1,579




Version: 40953 /40864 /41474 /11205

Generator Output Characteristic CurvesZero Power Factor Curve

Field Current

Line - Line Volt

32.0 0

40.4 240

42.0 288

44.1 336

47.5 384

53.9 432

67.4 480

97.3 528

165.7 576

324.1 624

Air Gap Curve

Field Current

Line - Line Volt

0.0 0

6.8 288

8.0 336

9.1 384

10.3 432

11.4 480

12.5 528

13.7 576

14.8 624

16.0 672




Version: 40953 /40864 /41474 /11205

Reactive Capability Curve

Click to view Chart



Page 1 of 1

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Version: 40953 /40864 /41474 /11205

General Information

DM7828 Caterpillar Custom Generators (50 Hz, 60 Hz) Data for Custom SR4, SR4B, SR4B-HV, SR5 and SR5-HV Caterpillar generators built by Leroy Somer – USA and Leroy Somer – France. Refer to DM7821 for explanation of all generator data in Technical Marketing Information (TMI) except generator efficiency for which the explanation is given below. GENERATOR EFFICIENCY Generator efficiency is the percentage of engine flywheel (or other prime mover) power that is converted into electrical output. The generator efficiency shown is calculated by the summation of all losses method, and is determined in accordance with the IEC Standard 60034. The efficiency considers only the generator. There is no consideration of engine or parasitic losses here.

Caterpillar Confidential: GreenContent Owner: Commercial Processes DivisionWeb Master(s): PSG Web Based Systems SupportCurrent Date: Monday, July 22, 2013 11:36:40 AM© Caterpillar Inc. 2013 All Rights Reserved.Data Privacy Statement.



D I G I T A LV O L T A G E R E G U L A T O R

W H E R E T H E W O R L D T U R N S F O R P O W E R

FEATURES

● Microprocessor based control featuring choiceof three control modes standard:

Automatic Voltage Regulation (AVR)Power Factor Regulation (PF)Reactive Power Regulation (Var)

● Programmable stability settings● Soft start control with an adjustable time

setting in AVR control mode● Dual Slope Underfrequency (volts/hertz)

regulation● Three-phase or single-phase generator voltage

(RMS) sensing/regulation in AVR mode● Single-phase generator current sensing for

regulation purposes● Field current and field voltage sensing● Five contact sensing inputs for system interface● One common LED for visual indication of

Alarm and Shutdown fault conditions● Fault Shutdown Driver and Alarm Output

Driver for indication of Alarm and Shutdownfault conditions

● Generator paralleling with reactive droopcompensation and reactive differentialcompensation

● Line drop compensation ● Remote communication interface via CAN 2.0B● Ten generator protective functions ● UL 508A Recognized and CE certified

WORLDWIDE PRODUCT SUPPORT

● Worldwide parts availability through theCaterpillar dealer network

● Over 1,800 dealer branch stores operatingin 166 countries.

● 99.7% of parts orders filled within 24 hours.The best product support record in the industry.

● Caterpillar dealer service technicians aretrained to service every aspect of your electricpower generation system.

COMPLETE SYSTEM INTEGRATION

Fully designed and factory tested to workseamlessly with Cat Generator using Shunt,PMG, or AREP excitation systems andEMCP controls.

Caterpillar is leading the power generationmarketplace with Power Solutions engineeredto deliver unmatched flexibility, expandability,reliability, and cost-effectiveness.

LEHE3225

The Cat Digital Voltage Regulator is a

microprocessor based control designed

to provide precise voltage control, robust

transient response, and generator protection

with industry leading features and versatility.


2

LEHE3225

SPECIFICATIONS

General Specifications

Voltage Regulation ±0.25% no load to full load

Temperature Drift ±1.0% for a 40° C change

Response Time Maximum of 10 milliseconds

Variable Sensing Range 90 to 600 Volts

Control Power 24 Vdc Supply (18 to 30 Vdc, 5VA)

Regulator Filtering THF 3% per IEC34-1TIF of 50 NEMA MG1-22.43

Harmonic Tolerance 0.5% Voltage regulation with 40% THD

Weight 1.47 kg (3.25 lb)

Environmental

Operating Temperature –40° C to 70° C (–40° F to 158° F)

Storage Temperature –40° C to 85° C (–40° F to 185° F)

Relative Humidity 95% non-condensing 30° C to 60° C

Salt Spray 5% for 48 hrs at 38° C at 115% nominal operating voltage

Vibration 4.5G (peak) 18-2000 Hz in 3 perpendicular planes

Shock 20G

Certifications

CE Approved

UL Recognized

CSA Listed

PROTECTIVE FUNCTIONS ● Generator Overvoltage● Generator Undervoltage● Loss of Excitation● Instantaneous Field Overcurrent● Over Excitation● Loss of Sensing● Diode Fault Monitor● Internal Watchdog Failure● Internal Memory Failure● Fault Reset Closed Too Long


3

LEHE3225

Programmable Variables Range of Adjustment

Voltage vs Frequency Characteristic Two slope ranges adjustable from 1 to 10 PU in 0.1 increments

Fine Voltage Level –10% to +10% in 0.1% increment

Droop Adjustment 0 to 10% in 0.1% increment

Overvoltage Setpoint 105 to 135% of rated voltage in 1.0% incrementOvervoltage Time Delay 2 to 30 seconds in 1 second increments

Undervoltage Setpoint 60 to 95% of rated voltage in 1.0% incrementUndervoltage Time Delay 10 to 120 seconds in 1 second increments

Gain 1 to 20% in 0.1% increments

Single Phase or Three Phase Sensing

Under Frequency Point 20 to 40 Hz

Knee Frequency 45 to 65 Hz in 0.1 Hz increments

Minimum Voltage Setpoint 50 to 100% of rated voltage

Var Operating Mode 100% to –100% in 0.001 increments

PF Operating Mode 0.6 lead to 0.6 lag in 0.01 increments

Line Drop (IR) Compensation 0 to 10% in 0.1% increment

Loss of Excitation 0.1 to 1.0 PU leading varsLoss of Excitation Time Delay 0.1 to 9.9 seconds in 0.1 second increments

Over Excitation 0 to 12 Adc in 0.1 Adc incrementsTime Delay — Fixed Time Option 0 to 10 sec in 0.1 sec increments

Loss of Sensing Time Delay 0 to 25 sec in 1 sec increments

Diode Fault Monitor 1 to 10A rms field ripple current

Soft Start Function 1 to 120 sec


4

LEHE3225

REGULATION CHARACTERISTIC — FIGURE 1

Underfrequency Point (20-40 Hz) 100

75

50

25

20 40 60 80 100

% of Nominal Frequency

Generator Output Voltage

Decreasing Slope 1 (1 – 10 V/HZ)

Decreasing Slope 2 (1 –10 V/HZ)

5 Hz (Fixed)

Minimum Voltage Setpoint (50-100%)

Knee Frequency


5

LEHE3225

OUTLINE DRAWING — FIGURE 2

0.16 (4.06)0

0.59 (15.0)

2.81 (71.4)2.87 (72.9)

5.50 typ.(139.7)

0

0

6.38

(162

.1)

10.88 (276.4)

7.50 typ.(190.5)

P6

P12

P9J4


6

LEHE3225

EXAMPLE CONNECTION DIAGRAM — FIGURE 3

10 9 10

8 7 PMG

CTB

+ GEN

10 11

52 10

FIELD OUTPUT

P6-4 (F2,-) P6-5 (F1,+) P6-1 POWER INPUT

P6-2 P6-3 CURRENT SENSING

P12-1 P12-2 P12-10 VOLTAGE SENSING

P12-11 P12-12

P9-6 RAISE/LOWER

INPUTSP9-4 P9-5

+/-10 VDC CONTROL INPUT P12-6 (+) P12-3 (-)

VAR/PF CONTROL

P9-9 EXCITATION

DISABLE P9-7

FAULT RESET

P9-8 P12-4 (-) ALARMDRIVER

SHUTDOWN FAULT DRIVER

P12-9 (+) P12-5 (-)

GROUND P6-6

24 Vdc + _

24 Vdc CONTROLPOWER

P12-8 (+) P12-7 (-)

1 52a 2 3 S1

4 10

5 5 6

A B C

Required only for Var/PF control. Var/PF is active with 52a closed, inactive with 52a open.

Excitation is disabled when closed, enabled when open.

Momentary closure resets any shutdown fault.

S1 (SPDT, spring -return to center-off position) adjusts regulator setpoint.

Normally-off, turns on for user alarm or trip.

Analog input voltage between -10 and +10 Vdc provides adjustment of operating setpoint.

External fuses should be sized to match the PMG and protect the field. Maximum fuse sizeshould be limited to Bussmann type KTK-12 or equivalent.

Three-phase PMG is shown. For single-phase PMG, omit P6-3 connection.

Sensing potential transformer is required if line voltage exceeds 660 Vac.

Item not supplied by Caterpillar.

When generator rotation is ACB, the connections shown for CTB should be reversed.

1 2 3 4 5 6 7

8 9 10 11

FEATURES SPECIFICATIONS

A T T A C H M E N T S

C32 JACKET WATERHEATERWith Circulating Pump

FACTORY INSTALLED

● Completed with hoses, circulating pump,and isolation valves

● Base frame mounting minimizes engineinduced vibration

● Automatically disconnected when engine isrunning via the generator space heater relay

● Thermostat is factory pre-set to 49° C (120° F)● A control box with the element, pump, and

thermostat pre-wired for ease of installation● Heavy-duty (0.25" steel) mounting brackets● Control box has a contactor to cycle the heater

elements on and off per the heater thermostat● Uniform heating over entire cooling system● Reduced temperature at outlet extends hose

and coolant life● Longer heating element life● Available with CE or UL/CSA compliant

packages

This is a factory-installed jacket water heater forincreased cold-starting capability. The systemincludes heater, isolation valves, circulationpump, hoses and generator space heater relay.

LEHE6018-01

Unit Specifications

Design Voltage

220 240

Rating 9 kW 9 kW

Frequency 50/60 50/60

Phase 1 1

Amps 41 37

Flow Rate 32 L/min 32 L/min(10 gpm) (10 gpm)

Circulation Pump Rating 95W 95W

Control Voltage 24 VDC 24 VDC

Adjustable Thermostat 21.1°-98.8° C 21.1°-98.8° C

(70°-210° F) (70°-210° F)

Shipping Weight 16.3 kg 16.3 kg(36 lb) (36 lb)

DESCRIPTION

A T T A C H M E N T SC 3 2 J A C K E T W A T E R H E A T E RW I T H C I R C U L A T I N G P U M P

LEHE6018-01 2

HEATER DESIGN DESCRIPTION

The jacket water heater package is designed toefficiently pre-heat the C32 engine by heatingand circulating the engine’s coolant. The forcedcoolant circulation allows the design to operateat a higher wattage and efficiency than standardthermal siphon tank heaters (tank heaters).This design results in the following benefits:● Reduction of the maximum coolant temperatures

associated with tank heater design.● Increase life of heater hoses, engine seals,

and heating elements.● Improve heat transfer efficiency from elements

to engine coolant.● More uniform engine temperature distribution.● Application of a thermostat with a reduced

thermal differential.● Lower customer utility costs and increased

heater reliability.● Heater thermostat’s setpoint is preset from

the factory.

HEATER OPERATION/WIRING

A 10-gallon per minute pump is located at theheater outlet to pull the coolant through theheater. An adjustable thermostat probe is locatedinside the heater tank near the inlet of the heaterand responds to the temperature of the coolantentering the tank. The figure below shows thegeneral heater design.

5.98

1.26

13.78

13.88

4.86

11.43

3

PLUG, DRAIN1/4NPT ADJ. T-STAT

(THIS END)

2X KNOCKOUTS, Ø.75

NONMETALLIC ENCLOSURE & COVER

2X KNOCKOUTS,Ø.50

PUMP, 1/25HP 240V1PH 10GPM

FLOW DIRECTION

FLOW

DIRECTION

1

1

2

19.48

7.87

11.48

OUTLET, 1NPT(FEMALE)

CONTROL BOX W/ TERMINALSTRIP & CONTACTOR

PRESSURE DIE CAST ALUMINUMTANK W/ RUBBER INSULATING SLEEVE

INLET, 1NPT(FEMALE)


LEHE6018-01 3

WIRING DIAGRAM

CUSTOMERSUPPLY240 VAC

L1

L2

AC-CB2

50AMP

AC-CB1

AC/DC BOX(CONTROL PANEL)

JWH+ CR2

31 32

JWH–

10AMP

CR2

CR211 12

21 22

H1

H4

OPTIONALBATTERYCHARGER

AB

SPACE HEATER

H1

H2

H3

H4

H4

H1

21

A1

L1

L2

A2

T1

T2

CR1

CR1

CR1

JACKET WATER TERMINAL BOX(MOUNTED ON RAIL)

JACKET WATER HEATER9KW

1L1

1L2

1

2

3

4

T

P

H2

H3

DESCRIPTION (continued)

ADJUSTABLE THERMOSTAT SETPOINT

Due to the high amperage associated with the9 kW heater, the thermostat is wired such that itopens and closes a contactor that controls theheating elements. To maintain uniform enginetemperature while the engine is not operating,the system pump requires either a 220 or a240 VAC supply and must run continuouslyindependent of heater thermostat. The pumpand heating elements are de-energized wheneverthe engine starts.The figures below show the wiring diagram forthe engine jacket water heater systems.


JACKET WATER HEATER GROUP GENERAL DIMENSION

Information contained in this publication may be considered confidential. www.cat-electricpower.comU.S. sourced Discretion is recommended when distributing.

Materials and specifications are subject to change without notice. © 2006 Caterpillar LEHE6018-01 (06-06) CAT, CATERPILLAR, their respective logos and “Caterpillar Yellow,” as well as corporate and product All Rights Reserved.

identity used herein, are trademarks of Caterpillar and may not be used without permission. Printed in U.S.A.

Note: Unless otherwise specified;all dimensions are for reference.(Drawing # 273-3766, 274-4541).

Package Dimensions

Length 494.7 mm 19.4 in

Width 195 mm 7.68 in

Height 350.5 mm 13.8 in

Shipping Weight 16.3 kg 36.0 lb

117.5(4.6")

118.3(4.6")

Conduit Openingon Pump

1 - 11 - 1⁄2 NPTOutlet

352.6(13.8")

2 � 3⁄8-16 Mounting Clamps

2 � 3⁄4 ConduitOpening

2 � 1⁄2 ConduitOpening Aluminum Body

with RubberInsulation Sleeve

Ø 103.1 (Ø 4.0")

494.7(19.4")

70.9(2.79")

17.7(0.696")

1.3(33.0")

Two Styles of MountingBrackets Available

288.6(11.4")

293.2(11.5")

350.5(13.8")

81.3(3.2")

205.1(8.0")

1 - 11 - 1⁄2 NPTIntlet

Cat® Batteries

Caterpillar. The difference counts.™

Cat Dealers define world – class product

support. We offer you the right parts

and service solutions, when and where

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Cat Batteries – Greater Starting Power –Lower Maintenance – Longer LifeCat Premium High Output (PHO) batteries are used in all CaterpillarMachines and Engine Gen-Sets. They are designed to meet stringentCaterpillar design specifications, which provide industry leading coldcranking amp (CCA) capability and maximum vibration resistance.

Maintenance Free or low maintenance designs are available in wet and dryconfigurations.

General Service Line batteries are available in Maintenance Free or lowmaintenance designs and in wet or dry configurations. Wide selections ofBCI group sizes are available for automotive, light truck, bus, industrial,agricultural, marine, recreational and valve regulated (VRLA-AGM & Gel)applications.

Premium High Output – Maximum Vibration Resistance• Vibration Resistance...five times the Industry Standard

• Exclusive “flat top” BCI group 4D & 8D batteries are Maintenance Freeand have the industries highest cold cranking amps (CCA)

• Popular BCI group 31 Maintenance Free batteries with industry leadingcold cranking amps...up to 1000 (CCA), for electric power, machine oron-highway truck and bus applications. Deep cycle models available fortruck, marine or recreational usage

BCI Cold Reserve Amp Hr. Add Water NominalGroup Cranking Capacity Capacity Maintenance Length Width Height Wet Dry Acid to FillSize Part No. Amps” Minutes’ Volts @ 20 Hrs. Construction Check Hours In (mm) In (mm) In (mm) Lb (kg) Lb (kg) Qt (liter)8D 153-5720 1500 465 12 210 C MF 20.47 (520) 10.8 (275) 9.76 (248) 132 (60) – –

8D 101-4000 1400 400 12 190 LAC+ 1000 20.7 (526.5) 10.96 (278) 9.76 (248) 132 (60) 86 (39) 18.0 (17.0)

4D 153-5710 1400 425 12 200 C MF 20.47 (520) 8.58 (218) 9.76 (248) 119 (54) – –

4D 153-5700 1125 305 12 145 C MF 20.47 (520) 8.58 (218) 9.76 (248) 101 (46) – –

4D 9X-9730 1300 400 12 190 LAC+ 1000 20.75 (527) 8.58 (218) 9.76 (248) 119 (54) 81 (37) 14.8 (14.0)

4D 9X-9720 1000 275 12 140 LAC+ 1000 20.75 (527) 8.58 (218) 9.76 (248) 101 (46) 59 (27) 15.9 (15.0)

31 175-4390 1000 180 12 90 C/S MFA 12.9 (328.4) 6.74 (171.2) 9.29 (236) 60 (27) – –

31 175-4370 825 190 12 100 C/S** MFA 12.9 (328.4) 6.74 (171.2) 9.29 (236) 60 (27) – –

31 175-4360 710 185 12 100 C/S*** MFA 12.9 (328.4) 6.74 (171.2) 9.29 (236) 60 (27) – –

31 250-0480 710 185 12 100 C/SDT*** MF 12.9 (328.4) 6.74 (171.2) 9.29 (236) 60 (27) – –

31 115-2422 1000 170 12 90 C SAE MFA 12.9 (328.4) 6.74 (171.2) 9.46 (240.3) 60 (27) – –

31 115-2421 950 170 12 90 C SAE + MFA 12.9 (328.4) 6.74 (171.2) 9.46 (240.3) 60 (27) 44 (20) 6.6 (6.2)

31 9X-3404 950 165 12 100 C SAE MF 13 (330.2) 6.77 (172) 9.46 (240.3) 58 (26) – –

31 3T-5760 750 165 12 100 C SAE MF 13 (330.2) 6.77 (172) 9.46 (240.3) 55 (25) – –

24 153-5656 650 110 12 52 SC MF 10.98 (278.9) 6.85 (174) 9.0 (229.1) 39 (18) – –

65 230-6368 880 140 12 80 SC MF 11.9 (303.4) 7.5 (190.8) 7.5 (191.4) 45.5 (21) – –

74 153-5660 650 110 12 52 SC* MF 10.98 (278.9) 7.0 (178.2) 8.15 (206.9) 39 (18) – –

58 175-4280 500 70 12 35 SC MF 9.96 (253.1) 7.2 (182.5) 6.9 (176) 31 (14) – –

2 153-5690 765 210 6 90 LAC+ 1000 10.24 (260) 6.8 (173) 8.72 (221.6) 37 (17) 22 (10) 4.8 (4.5)

Construction Notes:LAC = Low Maintenance, Hybrid ConstructionC = Calcium Lead Alloy Grid DesignMF = Maintenance FreeMFA = Maintenance Free with Accessible Vent CapsS = Stud Terminals+ = Shipped Dry Only* = Side Terminals** = Starting and Deep Cycle Battery*** = Deep Cycle and Starting Battery" = For 30 seconds at 0° F (-18° C)' = Minimum of 25 amp output at 80° F (27° C)SAE = Uses SAE PostsSDT = Dual, Top mounted Terminals, Stud and SAE Post,Marine Deep Cycle/Starting BatterySC = Silver (Ag) Calcium Alloy Grids for resistance to highunderhood temperatures

BCI Overall DimensionsNominal Weight

Specifications for Cat Premium High Output Batteries – Available Worldwide

Rugged Design – Built Tough – Reliable Starting

• Positive and Negative plates are anchored to container bottom and locked at the top of cell element for maximum vibration resistance.

• Heavy-duty forged terminal post bushings provide maximum strength and resistance to acid seepage.

• Hefty full-frame grids, no sharp edges, optimum acid/paste combination provides better charge acceptance after deep discharge.

• Manifold vented cover with built-in Flame Arrestor…a safety feature that directs corrosive gases away from the battery and hold-downs.

• Thick, robust container resists rugged treatment typical of heavy-duty commercial use. Embossed part number & descriptors for easy serviceability.

2

World’s Toughest Batteries

Cat General Service Batteries – Available Worldwide

Wet BatteriesBCI Cold Reserve Amp Hr.Group Cranking Capacity Capacity Length Width Height Wet Size Part No. Amps” Minutes’ Volts @ 20 Hrs. Construction In (mm) In (mm) In (mm) Lb (kg)

Truck/Agricultural/Industrial 1 8C-3617 650 180 6 100 C/MF 9.0 (229) 6.9 (175) 8.8 (224) 33.5 (15)

2 8C-3629 780 215 6 90 LA 10.4 (264) 6.9 (175) 8.8 (224) 36.5 (17)

3EE 8C-3620 400 95 12 54 LA 19.3 (490) 4.3 (109) 9.0 (229) 43 (20)

3EH 8C-3632 925 250 6 115 LA 19.3 (490) 4.3 (109) 10.0 (254) 47.5 (22)

4 8C-3633 1010 270 6 125 C/MF 12.5 (318) 6.9 (175) 9.5 (241) 47 (21)

4D 8C-3623 900 260 12 115 LA 20.8 (508) 8.5 (216) 10.1 (257) 97 (44)

4DLT 8C-3622 900 240 12 100 LA 20.0 (508) 8.2 (208) 8.2 (208) 79 (36)

7D 8C-3635 950 350 6 156 LA 15.8 (401) 7.0 (178) 9.2 (234) 59.5 (27)

8D 8C-3624 1375 430 12 190 LA 20.7 (526) 11.0 (279) 10.0 (254) 130 (59)

24F 3T-5858 650 120 12 55 SC/MF 10.6 (269) 6.8 (173) 9.0 (229) 40 (18)

27 8C-3601 675 120 12 65 SC/MF 12.0 (305) 6.7 (170) 9.0 (229) 45.5 (21)

27F 8C-3602 675 120 12 65 SC/MF 12.4 (315) 6.7 (170) 9.0 (229) 45.5 (21)

30H 8C-3627 850 180 12 100 C/MF 13.0 (330) 6.8 (173) 9.5 (241) 57.5 (26)

31 8C-3628 760 170 12 80 C/MF/S 13.0 (330) 6.8 (173) 9.5 (241) 54.5 (25)

Bus-Special Terminal8D 250-0473 1450 450 12 190 C/MFA/TB 20.7 (526) 11.0 (279) 10.0 (254) 134 (61)

Automotive/Light Truck & SUV22F 3T-5859 425 65 12 35 SC/MF 9.4 (239) 6.8 (173) 8.3 (211) 29.5 (13)

24 3T-5857 650 120 12 55 SC/MF 10.2 (259) 6.8 (173) 9.0 (229) 38.5 (17)

26 8C-3600 540 80 12 45 SC/MF 8.8 (224) 6.8 (173) 8.0 (203) 24.5 (11)

41 8C-3605 660 110 12 64 SC/MF 11.5 (292) 6.9 (175) 6.9 (175) 37 (17)

42 250-0490 475 70 12 40 SC/MF 9.5 (241) 6.9 (175) 6.9 (175) 29 (13)

55/56/62 8C-3611 585 95 12 52 SC/MF/DT 8.8 (224) 6.0 (152) 8.5 (216) 33 (15)

58 8C-3612 580 85 12 53 SC/MF 10.0 (254) 7.2 (183) 6.9 (175) 31.5 (14)

75 7X-6100 720 100 12 60 SC/MF * 9.0 (229) 7.0 (178) 7.3 (185) 34.5 (16)

75/86 250-0489 540 85 12 47 SC/MF/DT 9.7 (248) 7 (178) 8.1 (206) ! 32 (15)

Automotive/Light Truck & SUV, Severe Service/High Temperature, Silver Lead Alloy Technology25 250-0488 600 90 12 45 ST/MF 9.1 (230) 6.8 (175) 8.8 (225) 31 (14)

35 250-0487 600 90 12 45 ST/MF 9.1 (230) 6.8 (175) 8.8 (225) 31 (14)

34/78 250-0486 690 100 12 60 ST/MF/DT 10.7 (273) 6.8 (175) 8 (203) ! 39 (18)

65 250-0484 650 105 12 55 ST/MF 12 (304) 7.3 (187) 7.6 (194) 39 (18)

BCI Overall Dimensions Nominal Weight

Construction Notes:LA = Low Maintenance, Low Antimony GridsLAC = Low Maintenance, Hybrid ConstructionC = Calcium Lead Alloy Grid DesignMF = Maintenance Free

SC = Silver (Ag) Calcium Alloy Grids – forresistance to high underhood temperaturesMFA = Maintenance Free, Calcium Grids,Accessible Vent Caps ST = Silver (Ag) Calcium Alloy Heavy Duty Grids

* = Side TerminalsS = Stud TerminalsDT = Dual TerminalTB = Transit Bus one piece end Terminal. Right end of Battery. 1/2"-13 Steel positive stud 3/8"-16 Steel negative stud

" = For 30 seconds at 0° F (-18° C)' = Minimum of 25 amp output at 80° F (27° C)! For height with removable adapter,add 7/8" (22 mm)

3

Premium Batteries for a Wide Range of ApplicationsIdeal for Automotive, Light Truck, Bus, Marine, Industrial, Agricultural, Stationary Power and RecreationalUsage.• Maintenance Free and low maintenance… Accessible or Sealed• Deep Cycle and Valve Regulated (VRLA) Gelled or Absorbed Glass Mat (AGM) batteries• Hefty full frame grids, no sharp edges. Optimum acid/paste combination provides better charge acceptance

after deep discharge• Silver (Ag) Calcium Grids for high temperature automotive usage• Commercial batteries have Anchor Lock elements for vibration resistance• Flame Arrestor Safety Vents to direct corrosive gases away from the battery and hold-downs

Wet Batteries Continued

BCI Cold Reserve Amp Hr.Group Cranking Capacity Capacity Length Width Height Wet Size Part No. Amps” Minutes’ Volts @ 20 Hrs. Construction In (mm) In (mm) In (mm) Lb (kg)

Marine-Deep Cycle Capability 24M 8C-3638 650 120 12 55 SC/MF/DT/~ 10.8 (274) 6.8 (173) 9.4 (239) 40 (18)

27M 8C-3639 625 150 12 80 @ /S/DT 12.5 (318) 6.8 (173) 9.4 (239) 49 (22)

Lawn & GardenU1 8C-3636 275 32 12 25 C/MF 7.8 (198) 5.1 (130) 7.3 (185) 16.5 (7)

Golf Cart/Scissor & High Lifts75 amps@ 80° F

GC-2 8C-3641 115 mins. – 6 215 @ OP 10.3 (262) 7.1 (180) 10.9 (277) 63 (29)

Dual Terminal Batteries24/24F/74 127-0824 930 130 12 63 SC/MF/DT 10.9 (277) 7.0 (178) 9.0 (229) 45 (20)

34/78 127-0826 875 120 12 66 SC/MF/DT 10.8 (274) 6.9 (175) 8.0 (203) ! 41 (19)

75/86 250-0489 540 85 12 47 SC/MF/DT 9.7 (248) 7 (178) 8.1 (206) ! 32 (15)

34/78 250-0486 690 110 12 60 ST/MF/DT 10.7 (273) 6.8 (175) 8 (203) ! 39 (18)

Dry BatteriesBCI Cold Reserve Amp Hr. NominalGroup Cranking Capacity Capacity Length Width Height Wet Dry Acid to FillSize Part No. Amps” Minutes’ Volts @ 20 Hrs. Construction In (mm) In (mm) In (mm) Lb (kg) Lb (kg) Qt (liter)

Truck/Agricultural/Industrial 1 8T-9734 650 180 6 100 C/MF + 9.0 (229) 6.9 (175) 8.8 (224) 33.5 (15) 17.5 (8) 4.5 (4.3)

3D 8T-9730 1400 675 6 320 LA + 20.4 (518) 8.7 (221) 10.0 (254) 120 (54) 84 (38) 11.0 (10.4)

7D 8T-9731 950 350 6 156 LA + 15.7 (399) 7.0 (178) 9.1 (231) 59.5 (27) 34 (15) 7.5 (7.1)

24F 9X-1382 650 120 12 50 SC/MF + 10.6 (269) 6.8 (173) 9.0 (229) 40 (18) 26 (12) 6.0 (5.7

26 145-4517 540 80 12 48 SC/MF + 8.8 (224) 6.8 (173) 8.0 (203) 29.5 (13) 23 (10) 3.5 (3.3)

26R 145-4518 540 80 12 48 SC/MF + 8.8 (224) 6.8 (173) 8.0 (203) 29.5 (13) 23 (10) 3.5 (3.3)

27 3E-8925 675 120 12 55 SC/MF + 12.0 (305) 6.7 (170) 9.0 (229) 45.5 (21) 29.5 (13) 6.5 (6.2)

Automotive/Light Truck22F 9X-1384 425 65 12 32 SC/MF + 9.4 (239) 6.8 (173) 8.3 (211) 29.5 (13) 18 (8) 4.5 (4.3)

24 9X-1383 650 120 12 50 SC/MF + 10.2 (259) 6.8 (173) 9.0 (229) 40 (18) 26 (12) 6.0 (5.7)

Marine/Recreational8V 8C-3640 980 350 8 175 LA + 20.8 (528) 7.3 (185) 10.6 (269) 90 (41) 60 (27) 11.5 (10.9)

Cat General Service Batteries – Available Worldwide



Construction Notes:LA = Low Maintenance, Low Antimony GridsLAC = Low Maintenance, Hybrid ConstructionC = Calcium Lead Alloy Grid DesignMF = Maintenance FreeMFA = Maintenance Free, Calcium Grids, Accessible Vent Caps ST = Silver (Ag) Calcium Alloy Heavy Duty GridsSC = Silver (Ag) Calcium Alloy Grids – for resistance to highunderhood temperatures* = Side TerminalsS = Stud Terminals

DT = Dual TerminalOP = Offset Post with Horizontal Hole Stainless Steel 5/16" Bolt & Hex Nut" = For 30 seconds at 0° F (-18° C)' = Minimum of 25 amp output at 80° F (27° C)! For height with removable adapter, add 7/8" (22 mm)@ = Deep Cycle – Antimony Grids~ = Marine Starting+ = Shipped Dry Only# = Wing Nut for 8C-3638 & 8C-3639 is Part # 3B-0723

4

Absorbed Glass Mat (AGM) Batteries, Designed for High-rate Uninterruptible Power Supplies (UPS) or Standby Applications

Power DischargeWatts Rating inper Cell Amperes

For 15 mins. Amp Hour @For 15 mins. to end voltage 20 hour rate

BCI to 1.67 V.P.C. of 1.75 V.P.C. to 1.75 volts Terminal ContainerGroup @ 77° F @ 77° F per cell @ Normal Length Width Height Height Wet Size Part No. (25° C) (25° C) 77° F (25° C) Voltage Construction Terminal In (mm) In (mm) In (mm) In (mm) Lb (kg)

U1 250-0474 119 60 1.46 12 MF-AGM/VRLA 1 7.71 (196) 5.18 (132) 7.18 (182) 6.18 (157) 24 (11)

45 250-0475 168 85.4 2.42 12 MF-AGM/VRLA 2 8.84 (225) 5.31 (135) 8.7 (221) 8.14 (207) 38.5 (18)

24 250-0476 253 127 3.65 12 MF-AGM/VRLA 2 10.2 (259) 6.8 (173) 9.14 (232) 8.12 (206) 53 (24)

27 250-0477 314 156 4.41 12 MF-AGM/VRLA 2 12.72 (323) 6.8 (173) 8.68 (220) 8.12 (206) 63 (29)

31 250-0478 377 192 4.68 12 MF-AGM/VRLA 3 12.93 (329) 6.75 (171) 8.75 (222) 8.58 (218) 69 (31)

31(A) 250-0479 475 238 6.66 12 MF-AGM/VRLA 3 13.5 (342) 6.77 (172) 11.25 (286) 11.08 (281) 98 (45)

4D(H) 250-0483 624 318 9.91 12 MF-AGM/VRLA 4 21.73 (552) 8.82 (210) 9.34 (237) 8.74 (222) 129 (59)

MF-AGM/VRLA = Maintenance Free-Absorbed Glass Mat (AGM) Battery. Battery has Flame Arrestor and is low-pressure self sealing.Housed in flame-retardant polypropylene (rated 28 LOI) 12-Volt Monoblocks(A) = Battery is 2.5 in (63.5 mm) taller and 0.57 in (13 mm) longer than standard Group 31(H) = Battery has handlesSealed Valve-Regulated Lead Acid (VRLA) with electrolyte absorbed in separators consisting of a sponge-like mass of matted glass fibers.Preferred for high-rate performance in uninterruptible power supply (UPS) or standby applications.VPC = Volts per CellWPC = Watts per Cell. Ratings conform to IEEE-485 StandardsVRLA batteries use recombination reaction to prevent the escape of hydrogen and oxygen gases normally lost in a flooded lead acid battery. They are non-spillable, never need watering and should never be opened.

AGM batteries have a longer production lead time than regular lead-acid type batteriesImportant: Alternator and charger instructions: for 12-volt AGM Batteries charge to 14.4 volts but no more than 14.6 volts at 68° F (20° C)

Gelled (GEL) Electrolyte, Marine/Recreational, Deep Cycle CapabilityBCI Cold Reserve Amp Hr.Group Cranking Capacity Capacity Length Width Height WetSize Part No. Amps” Minutes’ Volts @ 20 Hrs. Construction In (mm) In (mm) In (mm) Lb (kg)

4D 152-8006 1050 375 12 183 MF-G/VRLA 20.8 (528) 8.5 (216) 10 (254) 129.8 (59)8D 152-7242 1265 475 12 225 MF-G/VRLA 20.8 (528) 11.1 (282) 10 (254) 160.8 (73)

Marine Cranking Amps (MCA) = Cold cranking Amps divided by 0.8MF-G/VRLA = Maintenance Free Gel Battery. Sealed, Valve-Regulated Lead Acid (VRLA) battery with gelled electrolyte.Starting/Deep Cycle Marine or Recreational Use Battery. Could be used for Gen-Sets or UPS type applications requiring a sealed battery.VRLA batteries use recombination reaction to prevent the escape of hydrogen and oxygen gases normally lost in a flooded lead acid battery. They are non-spillable, never need watering and should never be opened." = For 30 seconds at 0° F (-18° C) ' = Minimum of 25 amp output at 80° F (27° C)



1-BCI Group U1 2-BCI Groups 45, 24, 27 3-BCI Group 314-BCI Group 4D

Valve Regulated Lead Acid (VRLA) Batteries

UL Recognized Component

Terminals1 = Lead terminal. L shaped. Terminals have square holes.2 = Lead terminal with brass inserts. 1/4-20 x 0.25 Deep Female Thread.3 = Lead terminal with brass inserts. Centerline terminals. 1/4-20 x 0.25 Deep Female Thread. 4 = End terminals with brass inserts. 1/4-20 (UNC) Female Thread. Ratings conform to IEEE-485 Standards.

5

Valve Regulated AGM Batteries – Terminal Locations

Important: Alternator and charger instructions:For 12-volt Gel Batteries charge to 13.8 volts but no more than14.1 volts at 68° F (20° C)

Discharge Ratings

VRLA batteries are a UL Recognized Component andare I.C.C.A., I.C.A.O., I.M.D.G., I.A.T.A. and D.O.T.Air Transport Approval pending.

Battery Information

Battery AccessoriesGroup 31 – Charging Posts for Stud Terminals – Part # 4C-5637Screw-in Charging Posts for Side Terminals – Part # 4C-5638Wing Nut – Part # 2B-9498 for Part #’s 175-4390/175-4370/175-4360/8C-3628 Wing Nut – Part # 3B-0723 for Part #’s 8C-3638 and 8C-3639 Digital Battery Analyzer – Part # 177-2330Battery Voltmeter – Part # 4C-6600Battery Load Tester – Part # 4C-4911Booster Cable 12' (3.66 m) – Part # 4C-4933Booster Cable 20' (6.00 m) – Part # 4C-4937Heavy Duty Commercial Fast Charger (110V) – Part # 4C-4921Heavy Duty Commercial Fast Charger (220V) – Part # 4C-4910Extra Vent Caps (6) for Dry Batteries – Part # 7N-0060

Note: Ratings and Part Numbers are subject to change without notice.

Transit Bus Terminal for 8D Part # 250-0473One piece end terminal.Right end of Battery.1/2" - 13 Steel Positive Stud3/8" - 16 Steel Negative Stud

BCI Terminal LocationsCat Premium High Output Batteries – Built Tough to ExceedDemanding Performance Test Requirements:100 hour Vibration Testing – Five Times the Industry Standard• Battery must be able to withstand vibration forces without suffering

mechanical damage, loss of capacity, loss of electrolyte or withoutdeveloping internal/external leaks

• Battery must pass a high rate discharge test after the vibration testingFive 72-hour Deep Discharge/Recharge Test Cycles• Battery must recover to 25 charging amps within 20 minutes and meet

Industry Electrical Performance Standards30 Day Complete Discharge Test• Battery must recover to 25 charging amps within 60 minutes and meet Industry Electrical Performance Standards after recharging

SAE J2185 Life Cycle Test• Battery subject to deeper discharge and charge cycles at extreme

temperatures not normally encountered in starting a machine or vehicleCold Soak Test• Battery cold soaked at sub-freezing temperatures and then tested by

starting an equally cold engine

Recycle all scrap batteries.We accept lead-acid batteriesfor recycling.

GP 2E3 EH4EH

GP 3EE & 3ET

GP 4D6D8D4B

GP 4DLT

GP 3128

GP21R, 22R, 22F, 22HF, 22NF, 24F,24R, 26R, 27F, 27R, 33, 34R, 35, 36R,47, 48,49, 51R, 54, 55, 56, 58R, 85,U1R(L), 22NL, 29 HR, 30HR, 27 HF,29NF

6-VoltGP 1,2,3,45D, 7D, GC2,GC2H, 3D,17 HF, 19L

GP 40R, 41, 42, 4396R, 97R, 98R

Side TerminalGP70, 71, 72, 73, 7475, 76, 77, 78, 101

GP21, 24, 24H, 25, 26, 27, 27H,29H, 30H,34,50, 51, 52, 57, 58,59, 65, 86, U1, 12T, 24T

U2(L TERMINAL)

Type B

6

Cat Batteries

World Wide Application Flexibility

Marine Commercial VesselsMaintenance Free 4D, 8D and Group31 Batteries. General Service LineLine valve regulated (VRLA) Gelbatteries. High Marine CrankingAmps (MCA) and Deep Cyclingcapabilities.

7

Automotive-Truck-Bus & RVA wide selection of popular BCI groupsizes. Maintenance Free, Severe Serviceand Deep Cycle models. ApplicationSpecific Group 31 Truck Batteries.

Commercial & RecreationalA wide selection of premium batteries in most BCI group sizes for lightcommercial, recreational, agricultural and industrial applications.

Marine Pleasure CraftPremium High Output BCI Group 31,Dual Terminal Deep Cycle Batteries.General Service Line BCI group24M, 27M and 8V sizes.

Electric Power GenerationPremium High Output Maintenance Freeand Accessible batteries in BCI group4D, 8D, & 31 sizes. High Cold CrankingAmp (CCA) Capability. General ServiceLine valve regulated (VRLA)AGM batteries for UPS or stationarypower applications.

Construction & MiningPremium High Output Maintenance Freebatteries. BCI group 4D, 8D and 31Sizes. Industry leading cold crankingamps (CCA) and maximum vibrationresistance.

Cat BatteriesHeavy-duty Forged Terminal Post Bushings

Built-in FlameArrestor

Robust Reinforced Case

VibrationResistantPlates & Elements

Heavy-duty Grids RuggedSeparators

For more information, see us today or visitour web site at www.cat.com

Robust Components = Long Life + Reliable Starts• Heavy-duty forged terminal post bushings provide maximum strength and resistance to acid seepage that causes corrosion

and black posts. Thicker internal terminal posts provide lower electrical resistance and higher cold cranking amp output.• Rugged microporous polyethylene envelope separators protect against “shorts” and vibration damage. Deep Cycle

batteries utilize double insulated Glass mat separators for longer cycling life.• Maintenance Free batteries utilize calcium lead alloy on both positive and negative plates that reduces gassing and water

consumption. Automotive batteries have Silver (Ag) Calcium Alloy Grids for resistance to high underhood temperatures.• Heavy-duty, full frame battery grids with no sharp edges. An optimum acid/paste combination provides better charge

acceptance after a deep discharge.• Positive and Negative plates are anchored to the container bottom and the cell element is locked at the top for maximum

vibration resistance. Straps are thicker, heavier and cast (not welded) into the plates.• Manifold vented cover with built-in Flame Arrestor…a safety feature that directs corrosive gases away from the battery

and hold-downs.• Robust reinforced case provides extra strength in all temperature extremes. Brickwork design on sides reduces chance of

punctures and case flexing. Embossed part number and descriptors for easy serviceability.

Caterpillar. The difference counts.™PEHJ0073-01 Printed in the U.S.A. © 2005 Caterpillar All Rights Reserved

CAT, CATERPILLAR, their respective logos and “Caterpillar Yellow,” as well as corporate and product identityused herein, are trademarks of Caterpillar and may not be used without permission.

BATTERY CHARGER

LEHE0141-02

UL 10 AMP BATTERY CHARGER

This battery charger offers accurate, automatic charging of lead-acid and nickel cadmium batteries. The output voltage automatically adjusts to changing input, load, battery and ambient conditions. This prevents battery over-charging and consequent loss of battery electrolyte.

Standard features include AC line compensation, precision voltage regulation, current limiting, automatic 2-rate charging, voltmeter and ammeter, temperature compensation and UL Listing.

The user interface is easy to understand with digital metering, NFPA 110 alarms and a battery fault alarm.

Image Shown may not Reflect Actual Package

SPECIFICATION FEATURES

Input Supply 110-120 V · Electronically current limited at 105% of rated output

208-240 V · Alarm system

AC and DC Fuses 2 input and 2 output) · Digital Display

Output voltage 24V · Lightning and voltage transient protection

Frequency 50/60 Hz · Protection of connected equipment against load

Operating temperature -20°C ( -4°F) dump protectionto +60°C (140°F) · Constant voltage, current limited, 4-rate automatic

Housing constructed of rustproof anodized equalizationaluminum. · IP 20 housing

· AC isolated from DC STANDARDS · Temperature Compensation · C-UL listed to UL 1236 - On board temperature sensor with remote port· NFPA 70, NFPA 110 · Auto AC line compensation · CSA 22.2 No 107 certified · Output regulated by sensed battery voltage· UL 1564· CE DOC to EN 60335· IBC Seismic Certification

BATTERY CHARGER

2

OPTIONS

NFPA 110 alarm package as follows:· AC on Green led (indication)

· AC fail Red led and form C contact (2A)

· Float mode LED

· Fast charge LED

· Temp comp active LED

· Low battery volts Red led and Form C contact

· High Battery Volts Red led and Form C contact

· Charger fail Red led and Form C contact

· Battery fault Red led and Form C contact - Battery disconnected- Battery polarity reversed- Mismatched charger battery voltage- Open or high resistance charger to battery connection- Open battery cell or excessive internal resistance

Information contained in this publication may be considered confidential. Discretion is recommended when distributing. Materials and specifications are subject to change without notice.

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.


LEHE0141-02 (03-12) ©2012 Caterpillar All Rights Reserved.

Printed in U.S.A.

Amps Volts Hz Volts110-120208-240

Width Depth Height Weight195 mm 165 mm 318 mm 10.4 kg(7.66") (6.50") (12.50") (23 lb)

BTC1024 BTC1028 BTC1035BTC1025 BTC1032

Output Input

10 24 50/60

Feature codes

FEATURES

E N G I N E C O N T R O L L E R

ADEM™ A4 EngineController

RELIABLE, DURABLE

All ADEM A4 controllers are designed to survivethe harshest environments.● Environmentally sealed, die-cast aluminum

housing isolates and protects electroniccomponents from moisture and dirtcontamination.

● Rigorous vibration testing ensures productreliability 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.● Atmosphere cooled

SIMPLE SERVICING

Each ADEM A4 system works in combinationwith the Caterpillar® ET service tool software tokeep the engine operating at peak performance.● Displays measured parameters● Retrieves active and logged event code

documenting abnormal system operation● Performs calibrations and diagnostic tests● Supports flash programming of new software

into the ADEM A4 ECM

SELF DIAGNOSTICS

Each ADEM A4 ECM has a full compliment ofdiagnostics. The ECM can detect faults in theelectrical system and report those faults to the service technician for quick repair.● Self-diagnostic capability pinpoints operational

problems in need of attention.

ADVANCED FEATURES

● Isochronous or droop speed control● Enhanced performance from fuel injection

timing and limiting● Adjustable monitoring of vital engine

parameters● Idle/rated speed setting● Programmable speed acceleration ramp rate● Adjustable cooldown duration● Data link interfaces● Cat Data link● CAN J1939

OPTIONAL FEATURES

● Ether control system support● Remote monitoring and control support

LEHE5347-00

The ADEM™ A4 is the main Electronic ControlModule (ECM) used on select diesel engines.The ADEM A4 is an integral part of the innovativeACERT® Technology that provides higher degreeof control over a large number of combustionvariables than ever before. The ADEM A4 isdesigned to control/interface Electronic UnitInjector (EUI) equipped engines. The ADEM A4engine system is composed of the ADEM A4 ECM,control software, sensors, actuators, fuel injectors,and interface to the generator system. The primebenefit of an ADEM A4 engine system is to bettercontrol and maintain the particulate emissions,both steady state and transient, while improvingengine performance.


LEHE5347-00 2

DESCRIPTION

The ECM is housed in an environmentally sealedcasting. All wiring connections to the ECM aremade using two sealed connectors: a singleseventy-pin connector and a single one hundredtwenty-pin connector.

ENGINE SPEED GOVERNING

Desired engine speed is calculated by the ECM andheld within ±0.2 Hz for isochronous and droopmode. The ECM accounts for droop that isrequested. The proper amount of fuel is sent tothe injectors due to these calculations. The ECMalso employs cooldown/shutdown strategies,acceleration delays on startup, acceleration ramptimes, speed reference and a low/high idle switchis also available via communications to the EMCP 3.

FUEL LIMITING

Warm and cold fuel-air ratio control limits arecontrolled by the ECM. Electronic monitoringsystem derates, torque limit, and cranking limit,programmable torque scaling, and cold cylindercutout mode are standard features.

FUEL INJECTION TIMING

Master timing for injection is controlled by theECM control. Temperature dependencies areaccounted for in the fuel injection calculations.

ELECTRONIC MONITORING

Electronic monitoring of vital engine parameterscan be programmed. Warning, derate, andshutdown event conditions may be customizedby the user.

INFORMATION MANAGEMENT

The ECM stores information to assist withelectronic troubleshooting. Active and loggeddiagnostic codes, active events, logged events, fuelconsumption, engine hours, and instantaneoustotals aid service technicians when diagnosingelectronic faults and scheduling preventivemaintenance.

CALIBRATIONS

Engine performance is optimized through injectiontiming. Auto/manual sensor calibrations arestandard features.

ON-BOARD SYSTEM TESTS

System tests are available to assist in electronictroubleshooting. These tests include: injectoractivation, injector cutout, and override ofcontrol outputs.

DATA LINK INTERFACES

The ADEM A4 communicates with the EMCP 3 viathe J1939 Communication network. Additionally,the ADEM A4 can communicate with the Cat ETelectronic service tool and the PL1000E, PL1000T.

ELECTRONIC SENSING

The following sensing is available on the ADEM A4: oil pressure, fuel pressure, fueltemperature, atmospheric pressure, air inlettemperature, turbo outlet pressure, enginecoolant temperature, engine speed, throttle,position, exhaust temperature, engine controlswitch position, oil filter pressure differential,fuel filter pressure differential, air filter pressuredifferential, crankcase pressure, and remote e-stop switch position.


LEHE5347-00 3

Humidity tolerance0 to 90% relative humidity over operatingtemperature range

Impervious to:salt spray, fuel, oil and oil additives, coolant,spray cleaners, chlorinated solvents, hydrogensulfide and methane gas, and dust

Input and output protectionall inputs and outputs are protected againstshort circuits to +battery and –battery

Input voltage range (24 VDC nominal)18 to 32 VDC

Mountingengine mounted

Reverse polarity protected

Shock, withstands 20 g

Temperature rangeOperating: –40° C to 85° C (–40° F to 185° F)Storage: –50° C to 120° C (–58° F to 248° F)

Vibrationwithstands 8.0 g @ 24 to 2 kHz

SPECIFICATIONS

EMCP 4

LEHE0138-00

EMCP 4.2GENERATOR SET CONTROLLERCaterpillar is leading the power generation market place with power solutions engineered to deliver unmatched performance, reliability, durability and cost-effectiveness.

FEATURESGENERAL DESCRIPTION The Cat® EMCP 4.2 offers fully featured power metering, protective relaying and engine and generator control and monitoring. Engine and generator controls, diagnostics, and operating information are accessible via the control panel keypads; diagnostics from the EMCP 4 optional modules can be viewed and reset through the EMCP 4.2.

FULL RANGE OF ATTACHMENTS • Wide range of system expansion attachments, designed specifically to work with the EMCP 4. • Flexible packaging options for easy and cost effective installation.

WORLD WIDE PRODUCT SUPPORT • Cat dealers provide extensive pre and post sale support. • Cat dealers have over 1,600 dealer branch stores operating in 200 countries.

FEATURES • A 33 x 132 pixel, 3.8 inch, graphical display denotes text alarm/event descriptions, set points, engine and generator monitoring, and is visible in all lighting conditions. • Textual display with support for 28 languages, including character languages such as Arabic, Chinese, and Japanese. • Advanced engine monitoring is available on systems with an electronic engine control module. • Integration with the Cat Digital Voltage Regulator (CDVR) provides enhanced system performance. • Fully featured power metering, protective relaying, engine and generator parameter viewing, and expanded AC metering are all integrated into this controller.

• Real-time clock allows for date and time stamping of diagnostics and events in the control’s logs as well as service maintenance reminders based on engine operating hours or calendar days. • Up to 40 diagnostic events are stored in the non- volatile memory.

Image shown may not reflect actual package

• Ability to view and reset diagnostics on EMCP 4 optional modules via the control panel removes the need for a separate service tool for troubleshooting. • Set points and software stored in non-volatile memory, preventing loss during a power outage. • Reduced power mode offers a low power state to minimize battery power requirements. • Three levels of security allow for configurable operator privileges. • Selectable units

Temperature: °C or °F Pressure: psi, kPa, bar Fuel Consumption: Gal/hr or Liter/hr

STANDARDS • UL Recognized • CSA C22.2 No.100,14, 94 • Complies with all necessary standards for CE Certification 98/37/EC Machinery Directive – BS EN 60204-1 Safety of Machinery 89/336/EEC EMC Directive – BS EN 50081-1 Emissions Standard – BS EN 50082-2 Immunity Standard 73/23/EEC Low Voltage Directive – EN 50178 LVD Standard • IEC529, IEC60034-5, IEC61131-3 • MIL STND 461

EMCP 4.2 GENERATOR SET CONTROLLER

LEHE0138-00 2

STANDARD FEATURES

Generator Monitoring

• Voltage (L-L, L-N) • Current (Phase) • Average Volt, Amp, Frequency • kW, kVAr, kVA (Average, Phase, %) • Power Factor (Average, Phase) • kW-hr, kVAr-hr (total) • Excitation voltage and current (with CDVR) • Generator stator and bearing temp (with optional module)

Generator Protection

• Generator phase sequence • Over/Under voltage (27/59) • Over/Under frequency (81 O/U) • Reverse Power (kW) (32) • Reverse Reactive Power (kVAr) (32RV) • Overcurrent (50/51)

Engine Monitoring

• Coolant temperature • Oil pressure • Engine speed (RPM) • Battery voltage • Run hours • Crank attempt and successful start counter • Enhanced engine monitoring (with electronic engines)

Engine Protection

• Control switch not in auto (alarm) • High coolant temp (alarm and shutdown) • Low coolant temp (alarm) • Low coolant level (alarm) • High engine oil temp (alarm and shutdown) • Low, high, and weak battery voltage • Overspeed • Overcrank

Control

• Run / Auto / Stop control • Speed and voltage adjust • Local and remote emergency stop • Remote start/stop • Cycle crank

Inputs & Outputs

• Two dedicated digital inputs • Six programmable digital inputs • Six programmable form A dry contacts • Two programmable form C dry contacts • Two digital outputs

Communications • Primary and accessory CAN data links • RS-485 annunciator data link • Modbus RTU (RS-485 Half duplex)

Language Support

Arabic, Bulgarian, Chinese, Czech, Danish, Dutch, English, Estonian, Finnish, French, German, Greek, Hungarian, Icelandic, Italian, Latvian, Lithuanian, Japanese, Norwegian, Polish, Portuguese, Romanian, Russian, Slovak, Slovene, Spanish, Swedish, Turkish

Environmental

• Control module operating temperature: -40°C to 70°C • Display operating temperature: -20°C to 70°C • Humidity: 100% condensing 30°C to 60°C • Storage temperature: -40°C to 85°C • Vibration: Random profile, 24-1000 Hz, 4.3G rms


LEHE0138-00 3

OPTIONAL MODULES

CAN ANNUNCIATOR The EMCP 4 CAN Annunciator serves to display genset system alarm conditions and status indications. The annunciator has been designed for use on the accessory communication network and may be used in either local (package mounted) or remote (up to 800 feet) application. A maximum of three annunciators may be used with a single EMCP 4.2.

REMOTE MONITORING SOFTWARE The EMCP 4 remote monitoring software package is a PC based program which allows the user to monitor and control a generator set, and is capable of running on a Windows based operating system. The remote monitoring software allows the user to configure data monitoring and data acquisition processes for monitoring, graphing, and logging of genset data.

RS-485 ANNUNCIATOR The EMCP 4 RS-485 Annunciator serves to display genset system alarm conditions and status indications. The annunciator has been designed for use on the long distance annunciator datalink and is used for remote (up to 4000 feet) application.


0

OPTIONAL MODULES RTD MODULE The RTD module serves to provide expandable generator temperature monitoring capability of the EMCP 4 and is capable of reading up to eight type 2-wire, 3-wire and 4-wire RTD inputs. The RTD Module has been designed for use on the Accessory Communication Network and may be used in either local (package mounted) or remote (up to 800 feet) application. A maximum of one RTD Module may be used with a single EMCP 4.2.

THERMOCOUPLE MODULE The thermocouple module serves to provide expandable engine and generator temperature

DIGITAL INPUT/OUTPUT MODULE monitoring capability of the EMCP 4 and is The Digital Input/Output (DI/O) module serves to capable of reading up to twenty Type J or K

thermocouple inputs. The thermocouple provide expandable Input and Output capability of the EMCP 4 and is capable of reading 12 digital module has been designed for use on the

accessory communication Network and may be used in either local (package mounted) or remote (up to 800 feet) application. A maximum of one thermocouple modules may be used with a single EMCP 4.2 on each datalink.

inputs and setting 8 relay outputs. The DI/O module has been designed for use on the accessory Communication Network and may be used in either local (package mounted) or remote (up to 800 feet) application. A maximum of four DI/O modules may be used with a single EMCP 4.2.

LEHE0138-0 4

Information contained in this publication may be considered confidential. Discretion is recommended when distributing. Materials and specifications are subject to change without notice.

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.


©2010 CaterpillarAll Rights Reserved.

LEHE0138-00 (03-10) Printed in U.S.A

E M C P 4

LEHE0139-01

EMCP 4 CANANNUNCIATOR

The EMCP 4 CAN annunciator serves to displaygenerator set system alarm conditions and statusindications. The annunciator has been designedfor use on the EMCP 4 accessory communicationnetwork for local applications, but may be usedfor either local or remote applications, providingcustomers with enhanced site flexibility.

In local applications, the annunciator may bemounted on the package generator set with theEMCP 4 Controller to provide a completepackage-mounted monitoring solution.

The annunciator may also be mounted separatefrom the generator set to provide remote indicationof system operating and alarm conditions.

The EMCP 4 annunciator is configurable to thestandards of NFPA 99/110 for emergency standbygenerator systems.


● The EMCP 4 annunciator provides sixteen (16)individual points of annunciation, with two (2)LED’s included for each point.

● An additional pair of LED’s provides statusindication of the accessory communicationnetwork.

● Includes alarm horn with lamp test and alarm acknowledge pushbuttons.

● Configurable using standard Cat® Service Tool● Configurable to NFPA 99/110 requirements for

local and remote annunciation on emergencystandby generator systems.

● Provides custom label kit including software forcustomer’s specific alarms and arrangement

● Designed and tested to meet stringent impulseshock and operating vibration requirements

● Uses high quality shielded twisted-pair cablefor robust remote communications

● Graphic symbols are provided next to each pairto indicate various alarms and events

● The annunciator can be mounted either locally,on the package generator set, or remotely(up to 240 m (800 ft).

● Provides superior visibility of the LED’s in direct sunlight

Technical Data

ElectricalBattery Voltage Functional Range: 9 to 32 VDC

Power ConsumptionMaximum: � 12 watt at 24 VDCStandby: � 5 watt at 24 VDCControl Power: 12-24 VDC

Communication: Accessory Data LinkSingle, 6-pin ConnectorAlarm

Sound Level 80 db

PHYSICAL

Weight 2.5 lb or � 1.13 kg

ENVIRONMENTAL

Operating Temperature –40° C to 70° C–40° F to 158° F

Storage Temperature –50° C to 70° C–58° F to 158° F

Relative Humidity 90%

CERTIFICATIONS

UL Recognized

E M C P 4

LED COLOR SCHEME

Each pair of LED’s on the annunciator consists oftwo of three colors: green, yellow and red, whichallows for custom configuration of status, warningand shutdown conditions. The available colors and combinations are:

STANDARD LED CONFIGURATION

● Emergency stop shutdown● Overcrank shutdown● Low coolant temperature warning● High coolant temperature warning/shutdown● Low oil pressure warning/shutdown● Overspeed warning/shutdown● Low coolant level warning/shutdown● Low fuel level warning/shutdown● EPS supplying load status● Control switch not in auto warning● High battery voltage warning/shutdown● Low battery voltage warning/shutdown● BATT charger AC failure warning/shutdown● Low cranking voltage● Engine running● Tier 4 SCR

Row LED 1 LED 2

1 Red Yellow

2 Red Yellow

3 Red Yellow

4 Red Yellow

5 Red Yellow

6 Red Green

7 Red Yellow

8 Red Yellow

9 Red Yellow

10 Red Yellow

11 Red Yellow

12 Red Yellow

13 Green Yellow

14 Green Yellow

15 Red Green

16 Red Yellow

Annunciator Dimensions

A 158 mm 6.22 in

B 60 mm 2.37 in

C 288 mm 11.34 in

Information contained in this publication may be considered confidential. Discretion is recommended when distributing. www.Cat-ElectricPower.com

Materials and specifications are subject to change without notice.CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” © 2010 Caterpillar

LEHE0139-01 (04-10) trade dress as well as corporate and product identity used herein, are trademarks All rights reserved.of Caterpillar and may not be used without permission. Printed in U.S.A.

E M C P 4

LEHE0142-01

EMCP 4 RS-485ANNUNCIATOR

The EMCP 4 RS-485 annunciator serves to displaygenerator set system alarm conditions and statusindications. The annunciator has been designedfor use on the EMCP 4 RS-485 annunciator datalink for remote applications, providing customerswith enhanced site flexibility.

The EMCP 4 annunciator is configurable to thestandards of NFPA 99/110 for emergency standbygenerator systems.


● The EMCP 4 annunciator provides sixteen (16)individual points of annunciation, with two (2)LED’s included for each point.

● An additional pair of LED’s provides statusindication of the RS-485 communication network.

● Includes alarm horn with lamp test and alarm acknowledge pushbuttons.

● Configurable to NFPA 99/110 requirements forlocal and remote annunciation on emergencystandby generator systems.

● Provides custom label kit including software forcustomer’s specific alarms and arrangement

● Designed and tested to meet stringent impulseshock and operating vibration requirements

● Uses high quality shielded twisted-triad cablefor robust remote communications

● Graphic symbols are provided next to each pairto indicate various alarms and events

● The annunciator can be mounted remotelyup to 1200 m (4,000 ft).

● Provides superior visibility of the LED’s in direct sunlight

Technical Data

ElectricalBattery Voltage Functional Range: 9 to 32 VDC

Power ConsumptionMaximum: � 12 watt at 24 VDCStandby: � 5 watt at 24 VDCControl Power: 12-24 VDC

Communication: RS-485Single, 8-pin ConnectorAlarm

Sound Level 80 db

PHYSICAL

Weight 2.5 lb or � 1.13 kg

ENVIRONMENTAL

Operating Temperature –40° C to 70° C–40° F to 158° F

Storage Temperature –50° C to 70° C–58° F to 158° F

Relative Humidity 90%

CERTIFICATIONS

UL Recognized

E M C P 4

LED COLOR SCHEME

Each pair of LED’s on the annunciator consists oftwo of three colors: green, yellow and red, whichallows for custom configuration of status, warningand shutdown conditions. The available colors and combinations are:

STANDARD LED CONFIGURATION

● Emergency stop shutdown● Overcrank shutdown● Low coolant temperature warning● High coolant temperature warning/shutdown● Low oil pressure warning/shutdown● Overspeed warning/shutdown● Low coolant level warning/shutdown● Low fuel level warning/shutdown● EPS supplying load status● Control switch not in auto warning● High battery voltage warning/shutdown● Low battery voltage warning/shutdown● BATT charger AC failure warning/shutdown● Low cranking voltage● Engine running● Tier 4 SCR

Row LED 1 LED 2

1 Red Yellow

2 Red Yellow

3 Red Yellow

4 Red Yellow

5 Red Yellow

6 Red Green

7 Red Yellow

8 Red Yellow

9 Red Yellow

10 Red Yellow

11 Red Yellow

12 Red Yellow

13 Green Yellow

14 Green Yellow

15 Red Green

16 Red Yellow

Annunciator Dimensions

A 158 mm 6.22 in

B 60 mm 2.37 in

C 288 mm 11.34 in

Information contained in this publication may be considered confidential. Discretion is recommended when distributing. www.Cat-ElectricPower.com

Materials and specifications are subject to change without notice.CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” © 2010 Caterpillar

LEHE0142-01 (05-10) trade dress as well as corporate and product identity used herein, are trademarks All rights reserved.of Caterpillar and may not be used without permission. Printed in U.S.A.

DISCRETE INPUT/OUTPUT (I/O) MODULE

GENERAL DESCRIPTION FEATURES/BENEFITS

The Cat® Discrete Input/Output (I/O) moduleserves to provide expandable Input and Outputcapability for your package generator set.The Discrete I/O Module is capable of reading12 discrete inputs and setting eight (8) relay outputs.

The Cat® Service Tool ET is used to configure theDiscrete I/O module, while all monitored Inputand Output status conditions are viewable onthe EMCP 3 control panel.

The Discrete I/O Module can be Package or Remotemounted (up to 800 feet) and features ruggedpackaging and watertight Deutsch IPD connectors.

These features all add to the sense of value anddependability that comes with your purchaseof Cat products.

OPERATOR INTERFACE

● All Discrete I/O status conditions are availablefor viewing with the EMCP 3.2 & 3.3 Controllers.

● Capable of reading twelve (12) discrete inputsand setting eight (8) relay outputs

● CAN communication network eliminatesthe need for multiple relays, which translatesto less wiring and fewer opportunities formechanical failures.

● Remote customer communications aresupported by MODBUS protocol using RS-485(via EMCP 3.2 & 3.3), which easily interfaceswith existing plant systems and equipment.

● Set points are stored in nonvolatile memory,preventing loss during a power outage.

COMMUNICATION

● Single, standard 40-pin connector● CAN 2 (Accessory Data Link)● MODBUS RS-485 (Customer Communication)

via the EMCP 3.2 & 3.3 controllers

GENERAL SPECIFICATIONS

● Reads twelve (12) discrete inputs and setseight (8) Form C relay outputs rated for ratedresistive loads of:

2A @ 30 VDC for Normally Closed (NC) relays2A @ 125 VAC for Normally Closed (NC) relays2A @ 30 VDC for Normally Open (NO) relays2A @ 125 VAC for Normally Open (NO) relays

M O D U L E S

LEHE4754-02

LEHE4754-02 2

D I S C R E T E I N P U T / O U T P U T ( I / O ) M O D U L E

● Encapsulated in a rugged aluminum housingwith watertight connectors (IP67 rating)

● Suitable for moist, high shock and vibrationenvironments

● Modules are designed for package mounting onpower generator sets or remotely, up to 800 ft.

● Configuration is accomplished with Cat ETService Tool.

● Multiple Discrete I/O modules can be used onthe CAN 2 communications network.

● Protected against 95% humidity non-condensing,30° C to 60° C.

● Operating temperature range of –40° C to 85° C(–40° F to 185° F) – for ambient temperaturesexceeding 85° C, the temperature scanner maydeviate in accuracy an additional ±1° C.

● Storable temperature range is –50° C to +120° C.● Designed to meet relevant European standards

for EMI/RFI/Immunity without the use ofexternal filtering.

● Maximum level of current draw of 400 mA+ 50 mA per energized relay @ 12 VDC

● Isolation voltage: 4000 VAC (RMS), 50/60 Hz for1 min. between coil and contacts, 750 VAC,50/60 Hz for 1 min. between contacts of thesame polarity

● System throughput: All channels are scannedin 100 mSec.

● Input level characteristics:Low-Level input voltage: 0 to 0.8VHigh-Level input voltage: 3.75 to 24VInputs have internal pull-up resistors.

● Inputs that generate a warning messageauto-reset whenever the input returns tonon-active state.

● Inputs that generate a shutdown messagecontinue to broadcast that message until theinput returns to non-active state and a resetmessage is received from the EMCP 3.2 or 3.3.

● Each output is configured to activate basedupon the message that is received on theCAN 2 Data Link and can be configured toactivate on Alarm, Shutdown or Diagnosticcondition – or a combination of all three.

● Optical isolation is provided for the CAN line● Retains current date and time relative to

synchronization every 24 hours (or upon bootup) with equipment system time via an explicitcommand from the EMCP 3.2 & 3.3 –synchronization time is accurate to within 1 sec.

● Converts between physical I/O and CAN 2data link commands.

● Monitored parameters and diagnostics as wellas setpoints are customizable to customerspecification

● Module operates normally with loss ofcommunication link, retaining configuredvalues in non-volatile memory.

● Remains energized during engine cranking.

Discrete I/O Module Configuration Parameters:

The Discrete I/O Module is configurable todisplay the following parameters for eachof the available Inputs:

Active State (Active High or Active Low)Input Time Delay (0-120 seconds).

GENERAL SPECIFICATIONS (CONT’D)

LEHE4754-02 3


Available Inputs/Outputs:

The Discrete I/O Module is configured to acceptinputs for the following conditions, with the listedcondition displayed at the EMCP 3 controller:

Description Input OutputFuel Level Secondary Tank X XStarting Air Pressure XFuel Pressure XFuel Filter Differential Pressure XFuel Level (Primary Tank) X XEngine Oil Level XOil Filter Differential Pressure XEngine Oil Pressure XCrankcase Pressure XAir Filter Differential Pressure XEngine Coolant Temperature XEngine Coolant Level X XExtinguisher System Pressure X XBattery Voltage XAmbient Air Temperature XInlet Air Temperature XExhaust Temperature XFuel Temperature XEngine Oil Temperature XEngine Overspeed XEmergency Stop Shutdown XGen. Bearing Temperature #1 XGen. Winding Temperature (1-3) XRuptured Fuel Basin-Primary Tank X XEngine Failure to Start Shutdown XGenerator Frequency XGenerator Voltage XGenerator Reactive Power (VAR) XGenerator AC Current XGenerator Reverse Power (kW) XVoltage Regulator Failure XService Interval Warning XAir Shutoff Damper Close X XGen. Supplying Load X XBattery Charger Failure X XGen. Breaker Closed X XUtility Breaker Closed X XEngine in Cooldown XGenerator Control Not in Auto XUnexpected Engine Shutdown XUser Defined Input (1-12) X

TYPICAL CONNECTIONS – POWER AND CAN BUS:

TYPICAL CONNECTIONS – DISCRETE I/O MODULE:

NO NC C

LOADLOAD

OUTPUT

INPUTGNDDIN

5

4

FRONT VIEWMODULE MOUNTED CONNECTOR

DEUTSCH P/N: DT13-08PA

1 = PWR+2 = CAN-H3 = CAN-L4 = PWR-

5 = SHIELD6,7,8 = NOT USED

6 7 8

3 2 1

FRONT VIEW OF

MODULE MOUNTED CONNECTOR

DEUTSCH P/N: DRC13-40PB

5 6 10

4035 3631

1 10

40

5

15

25

35

6

16

26

36

30

2011

21

POLARIZING

KEY

NO - Normally OpenNC - Normally ClosedC - Common

INPUTS Pin OUTPUTS Pin

DIN1 1 NC_1 5DIN2 11 C_1 6DIN3 21 NO_1 7DIN4 31 NC_2 15DIN5 2 C_2 16DIN6 12 NO_2 17DIN7 22 NC_3 25DIN8 32 C_3 26DIN9 3 NO_3 27DIN10 13 NC_4 35DIN11 23 C_4 36DIN12 33 NO_4 37GND 4 NC_5 8GND 14 C_5 9GND 24 NO_5 10GND 34 NC_6 18

C_6 19NO_6 20NC_7 28C_7 29

NO_7 30NC_8 38C_8 39

NO_8 40

INPUTS GND OUTPUTSOUTPUTS

Dimensions: inches [mm]

BOTTOM VIEW

SIDE VIEW

FRONT VIEW(8-Pin Connector)

GroundingLug

BACK VIEW(40-Pin Connector)

Connectors excluded from overall dimensions.

DIMENSIONS


Information contained in this publication may be considered confidential.Discretion is recommended when distributing. www.Cat-ElectricPower.com

Materials and specifications are subject to change without notice.CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” © 2010 Caterpillartrade dress as well as corporate and product identity used herein, are trademarks All Rights Reserved.

LEHE4754-02 (09-10) of Caterpillar and may not be used without permission. Printed in U.S.A.

Power Systems________________________________________

15 Middle Avenue • Holtsville, NY 11742 • (631) 654-4464 • FAX (631) 654-4480

Caterpillar Factory Testing GEN SET Test Report at 0.8 PF – Factory test of engine generator set only at Caterpillar facility. Test duration is appx. 2 hours. Results reported at full load are: engine RPM, frequency, average voltage, line to line voltages for all three phases, average current, line currents for all three phases, and observed power -- all at 0.8 Power factor. Engine RPM, average voltage and line to line voltages for all three phases are reported at no load.

Documents

STANDBY 750 ekW 938 kVA 60 Hz 1800 rpm 480 Volts 750 KW … · Control Panel • EMCP 4 Genset Controller [ ] EMCP 4.2 [ ] EMCP 4.3 [ ] EMCP 4.4 [ ] Generator temperature monitoring