DIESEL GENERATOR SET
STANDBY
750 ekW 938 kVA
60 Hz 1800 rpm 480 Volts
Caterpillar is leading the power generation
marketplace with Power Solutions engineered
to deliver unmatched flexibility, expandability,
reliability, and cost-effectiveness.
Image shown may not
reflect actual package.
FEATURES
FUEL/EMISSIONS STRATEGY
• EPA Certified for Stationary
Emergency Application
(EPA Tier 2 emissions levels)
DESIGN CRITERIA
• The generator set accepts 100% rated load in one
step per NFPA 110 and meets ISO 8528-5 transient
response.
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 expansion
attachments, factory designed and tested
• Flexible packaging options for easy and cost
effective installation
SINGLE-SOURCE SUPPLIER
• Fully prototype tested with certified torsional
vibration analysis available
WORLDWIDE PRODUCT SUPPORT
• Cat dealers provide extensive post sale support
including maintenance and repair agreements
• Cat dealers have over 1,800 dealer branch stores
operating in 200 countries
• The Cat® S•O•SSM program cost effectively detects
internal engine component condition, even the
presence of unwanted fluids and combustion
by-products
CAT® C27 ATAAC DIESEL ENGINE
• Utilizes ACERT™ Technology
• Reliable, rugged, durable design
• Four-cycle diesel engine combines consistent
performance and excellent fuel economy with
minimum weight
• Electronic engine control
CAT GENERATOR
• Designed to match the performance and output
characteristics 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 set
size, weight, and concrete strength.
IBC Certification requires that the anchoring
system used is reviewed and approved by a
Professional Engineer
• Seismic Certification per Applicable Building
Codes: IBC 2000, IBC 2003, IBC 2006, IBC 2009,
CBC 2007
• Pre-approved by OSHPD and carries an
OSP-0084-10 for use in healthcare projects in
California
STANDBY 750 ekW 938 kVA
60 Hz 1800 rpm 480 Volts
FACTORY INSTALLED STANDARD & OPTIONAL EQUIPMENT
System
Air Inlet
• Air cleaner
Cooling
• Package mounted radiator
Exhaust
• Exhaust flange outlet
[ ] Exhaust mufflers (except Tier 4)
Fuel
[ ] Oversize and premium generators
[ ] Permanent magnet excitation (PMG)
[ ] Internal excited (IE)
[ ] Anti-condensation space heaters
Power Termination
• Primary fuel filter with integral water separator
• Secondary fuel filters
• Fuel priming pump
• Matched to the performance and output
characteristics of Cat engines
• Load adjustment module provides engine relief upon
load impact and improves laod acceptance and
recovery time
• IP23 protection
• Bus bar
Control Panel
• EMCP 4 Genset Controller
Generator
Standard
Optional
[ ] EMCP 4.2
[ ] EMCP 4.3
[ ] EMCP 4.4
[ ] Generator temperature monitoring and protection
[ ] Load share module
[ ] Digital I/O module
[ ] Remote monitoring software
[ ] Rubber vibration isolators
Mounting
Starting/Charging
General
[ ] Circuit breakers, UL listed
[ ] Circuit breakers, IEC compliant
• Paint - Caterpillar Yellow except rails and radiators
gloss black
2
[ ] Battery chargers
[ ] Oversize batteries
[ ] Jacket water heater
[ ] Heavy duty starting system
[ ] Charging alternator
[ ] Air starting motor with control and silencer (3500 &
C175 models only)
The 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 PM
STANDBY 750 ekW 938 kVA
60 Hz 1800 rpm 480 Volts
SPECIFICATIONS
CAT GENERATOR
CAT EMCP 4 SERIES CONTROLS
Frame size.........................................................................598
596
Excitation................................................ Permanent Magnet
SE
Pitch.............................................................................. 0.8667
Number of poles...................................................................4
Number of bearings...................................... Single bearing
Number of Leads.............................................................. 012
Insulation....................... UL 1446 Recognized Class H with
tropicalization and antiabrasion
- Consult your Caterpillar dealer for available voltages
IP Rating.........................................................Drip Proof IP22
Alignment.............................................................. Pilot Shaft
Overspeed capability........................................................150
Wave form Deviation (Line to Line)............... Less than 5%
deviation
Voltage regulator.............. 3 Phase sensing with selectible
volts/Hz
Voltage regulation............Less than +/- 1/2% (steady state)
Less than +/- 1% (no load to full load)
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
CAT DIESEL ENGINE
C27 TA, V-12, 4-Stroke Water-cooled Diesel
Bore.......................................................... 137.20 mm (5.4 in)
Stroke....................................................... 152.40 mm (6.0 in)
Displacement.........................................27.03 L (1649.47 in3)
Compression Ratio....................................................... 16.5:1
Aspiration........................................................................... TA
Fuel System................................................................... MEUI
Governor Type....................................................ADEM™ A4
3
February 26 2013 12:08 PM
STANDBY 750 ekW 938 kVA
60 Hz 1800 rpm 480 Volts
TECHNICAL DATA
Open Generator Set - - 1800 rpm/60 Hz/480 Volts
EPA Certified for Stationary Emergency Application
(EPA Tier 2 emissions levels)
DM9071
Generator Set Package Performance
Genset Power rating @ 0.8 pf
Genset Power rating with fan
Fuel Consumption
100% load with fan
75% load with fan
50% load with fan
Cooling System1
Air flow restriction (system)
Engine coolant capacity
Inlet Air
Combustion air inlet flow rate
937.5 kVA
750 ekW
Exhaust System
Exhaust stack gas temperature
Exhaust gas flow rate
Exhaust flange size (internal diameter)
Exhaust system backpressure (maximum allowable)
Heat Rejection
Heat rejection to coolant (total)
Heat rejection to exhaust (total)
Heat rejection to aftercooler
Heat rejection to atmosphere from engine
Heat rejection to atmosphere from generator
Alternator2
Motor starting capability @ 30% voltage dip
Frame
Temperature Rise
Lube System
Sump refill with filter
Emissions (Nominal)3
NOx g/hp-hr
CO g/hp-hr
HC g/hp-hr
PM g/hp-hr
202.9 L/hr
162.4 L/hr
116.2 L/hr
53.6 Gal/hr
42.9 Gal/hr
30.7 Gal/hr
0.12 kPa
55.0 L
0.48 in. water
14.5 gal
58.7 m³/min
2073.0 cfm
509.3 º C
158.9 m³/min
203 mm
10.0 kPa
948.7 º F
5611.5 cfm
8 in
40.2 in. water
324 kW
742 kW
138 kW
100 kW
46.2 kW
18426 Btu/min
42197 Btu/min
7848 Btu/min
5687 Btu/min
2627.4 Btu/min
2035 skVA
596
130 º C
234 º F
68.0 L
18.0 gal
5.25 g/hp-hr
.25 g/hp-hr
.03 g/hp-hr
.021 g/hp-hr
For ambient and altitude capabilities consult your Cat dealer. Air flow restriction (system) is added to existing restriction from factory.
Generator temperature rise is based on a 40ºC ambient per NEMA MG1-32. UL 2200 Listed packages may have oversized generators
with 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 for
measuring HC, CO, PM, NOx. Data shown is based on steady state operating conditions of 77ºF, 28.42 in HG and number 2 diesel fuel
with 35º API and LHV of 18,390 btu/lb. The nominal emissions data shown is subject to instrumentation, measurement, facility and engine
to engine variations. Emissions data is based on 100% load and thus cannot be used to compare to EPA regulations which use values
based on a weighted cycle.
1
2
4
February 26 2013 12:08 PM
STANDBY 750 ekW 938 kVA
60 Hz 1800 rpm 480 Volts
RATING DEFINITIONS AND CONDITIONS
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 specific
customer requirements. Consult your Cat representative
for details.
Applicable Codes and Standards: AS1359, CSA C22.2 No
100-04, 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/EC
Standby - Output available with varying load for the
duration of the interruption of the normal source power.
Average power output is 70% of the standby power
rating. Typical operation is 200 hours per year, with
maximum expected usage of 500 hours per year.
5
February 26 2013 12:08 PM
STANDBY 750 ekW 938 kVA
60 Hz 1800 rpm 480 Volts
DIMENSIONS
Package Dimensions
Length
Width
Height
NOTE: For reference only - do not use for
installation design. Please contact
your local dealer for exact weight
and dimensions. (General
Dimension Drawing #4316806).
4141.6 mm 163.05 in
1823.3 mm 71.78 in
2210.5 mm 87.03 in
Reference PPPI
Section 2 for final
weights and
dimensions
www.Cat-ElectricPower.com
Performance No.: DM9071
2013 Caterpillar
All rights reserved.
Feature Code: C27DR55
Materials and specifications are subject to change without notice.
The International System of Units (SI) is used in this publication.
Gen. Arr. Number: 3678056
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.
Source: U.S. Sourced
February 26 2013
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*8, 8*C6*;-8 :--<65+ .*5?
EBC8*><6: 7>97?
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!$ !
<;6;>C, :*7*@6<6;B 6? ;E, 9*469>9 *<;6;>C, *@-=, ?,* <,=,< *;
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-5 ;E, ,5+65, 7,8.-89*5:, ?E,,; ,, B->8 *;,876<<*8 ;,:E56:*<
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$! $ "!
" 96??6-5? 65.-89*;6-5 6? 78,?,5;,C *; K5-965*<K *5C K-;,5;6*<
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5,,C ;- @, =,86.6,C @B B->8 *;,876<<*8 ;,:E56:*< 8,78,?,5;*;6=,
!-+ -5 ;- ;E, L* E8,.MNE;;7?3''7C+;:*;:-9':C*'<*B->;N ;*8+,;MN@<*5FN
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.,C,8*< 8,+><*;6-5 *77<6:*@6<6;B *5C ;69, <65,? .-8 697<,9,5;*;6-5
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,+><*;6-5 A*;:E :-=,8? 8,+><*;6-5? 65 ,..,:; *5C .>;>8, 8,+><*;6-5
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96+E; @, 7,5C65+ *5C 9*B 5,,C *;;,5;6-5 -. ;E, ,5+65, 78-C>:;
+8->7 (-8 *CC6;6-5*< ,96??6-5? 65.-89*;6-5 <-+ -5 ;- ;E, " A,@
7*+,
CC6;6-5*< 78-C>:; 65.-89*;6-5 .-8 ?7,:6.6: 9*8F,; *77<6:*;6-5 6?
*=*6<*@<,
>?;-9,8K? 9*B E*=, ?7,:6*< ,96??6-5 ?6;, 8,D>68,9,5;? ;E*; 5,,C ;- @,
=,86.6,C @B ;E, *;,876<<*8 8-C>:; 8->7 ,5+65,,8
& ( 3
6,?,< 68:>6; B7, *5C &&2 *<*5:, 3 ")
" ( 3
96??6-5? 3 "
*+, ) -. (,!( $:;
2< = 7
$ ( 3
->5C -A,8 3 "
->5C 8,??>8, 3 "
( 3
+86:><;>8, 3 "
(68, >97 3 ")
,5,8*;-8 ,; 3 "
,5,8*;-8 0*?1 3 "
5C>?;86*< 6,?,< 3 "
5C>?;86*< 0*?1 3 "
886+*;6-5 3 ")
!-:-9-;6=, 3 "
"*865, >46<6*8B 3 "
"*865, 8-7 04:,7; 1 3 "
"*865, 8-7 0 -5<B1 3 "
"& 3 "
6< (6,<C 0,;8-<,>91 3 "
..#&6+EA*B 8>:F 3 ")
5#&6+EA*B 8>:F 3 "
*;, ,<,*?,C 3 ''
*+, -. Systems Data
Page 1 of 3
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
Air Intake System
Answer
Unit
14.9
24.9
129
248
4.4
122
252
153.2
85.0
343
IN WTR
IN WTR
DEG F
DEG F
IN HG
DEG F
DEG F
LB/MIN
IN HG
DEG F
14.5
29.0
230
178
198
OUTLET
109
5
12
15
30,617.8
GAL
GAL
DEG F
DEG F
DEG F
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
MAX ALLOW INTAKE RESTR W/DIRTY ELEMENT
MAX ALLOW INTAKE MANIFOLD TEMP
MAX ALLOW INTAKE MAN TEMP (30C/86F DAY)
ALLOW PRESS DROP-COMPR OUT TO MANF IN
MAX TURBO INLET AIR TEMPERATURE
MAX AIR FILTER INLET AIR TEMPERATURE
CHARGE AIR FLOW AT RATED SPEED
TURBO COMPR OUT PRESS AT RATED SPD (ABS)
TURBO COMPR OUT TEMP AT RATED SPEED
Cooling System
ENGINE ONLY COOLANT CAPACITY
TOTAL SYS COOLANT CAP (PKG GENSETS ONLY)
MAX ALLOW ENGINE COOLANT OUTLET TEMP
REGULATOR START-TO-OPEN TEMP
REGULATOR FULL OPENING TEMPERATURE
REGULATOR LOCATION
AMBIENT COOLING CAPABILITY AT RATED SPD
MAX UNINTERRUPTED FILL RATE
MIN ALLOW COOLANT LOSS-PERCT OF TOTAL
COOL LOSS-MAX % OF PUMP PRESS RISE LOSS
RADIATOR AIR FLOW (PKG GENSETS ONLY)
Engine Spec System
CYLINDER ARRANGEMENT
NUMBER OF CYLINDERS
CYLINDER BORE DIAMETER
PISTON STROKE
TOTAL CYLINDER DISPLACEMENT
COMPRESSION RATIO (TO ONE)
CRANKSHAFT ROTATION (FROM FLYWHEEL END)
CYLINDER FIRING ORDER
CYLINDER FIRING ORDER - CONTINUED
CYLINDER FIRING ORDER - CONTINUED
CYLINDER FIRING ORDER - CONTINUED
NUMBER 1 CYLINDER LOCATION
STROKES/COMBUSTION CYCLE
APPLICATION CLASS
VEE
12
5.4016
6.0000
1,649
16.5
CCW
1-10-9
6-5-12
11-4-3
8-7-2
FRONT-LF
4
GEN
DEG F
GPM
PERCENT
PERCENT
CU FT/MIN
CYL
IN
IN
CU IN
STROKES
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Systems Data
ENGINE DUTY CYCLE
EMISSION CERTIFICATION AGENCIES
EMISSION CERTIFICATION YEAR
STD - AFTERCOOLER DESIGN TEMP
GENSET LINE FREQUENCY
GENSET VOLTAGE RANGE
GENERATOR FRAME SIZE
Exhaust System
Page 2 of 3
STDB
EPA TIER 2
2006
120
60
480
596
DEG F
HZ
The installed system must comply with the system limits below for all
emissions certified engines to assure regulatory compliance.
MAX ALLOW SYS BACK PRESS
MANIFOLD TYPE
MAX ALLOW STATIC WT ON EXHAUST CONN
MAX ALLOW STATIC BEND MOMENT ON EXH CONN
EXHAUST ELBOW DIAMETER
Fuel System
MAX FUEL FLOW TO TRANSFER PUMP (TO ENG)
MAX ALLOW FUEL SUPPLY LINE RESTRICTION
MAX ALLOW FUEL TMP FROM TRANSFER PUMP IN
MAX FUEL FLOW TO RETURN LINE (FROM ENG)
MAX ALLOW FUEL RETURN LINE RESTR
NORMAL FUEL PRESSURE-CLEAN SYSTEM
FUEL SYSTEM TYPE
MAX TFR PUMP PRMG LIFT W/O PRMG PUMP
Lube System
RECOMMENDED OIL TYPE (API OR CAT SPEC)
OIL FILTER TYPE
LUBE SYSTEM OIL COOLER TYPE
MAXIMUM ALLOWABLE OIL TEMP
NOM OIL PRESS W/SAE 10W30 OIL @ 99 DEG C
MIN LI OP W/SAE 10W30 OIL @ 99 DEG C
CRANKCASE VENTILATION TYPE
REAR SUMP STD/OPT/NAP
REAR SUMP REFILL VOLUME W/FILTER CHANGE
REAR SUMP CAPACITY @ ADD MARK
REAR SUMP CAPACITY @ FULL MARK
Mounting System
C/G LOC - X DIMENSION - FRM REAR FACE OF BLK - (REF TM7077)
C/G LOC - Y DIMENSION - FRM CL OF CRANKSHAFT - (REF TM7077)
C/G LOC - Z DIMENSION - FRM CL OF CRANKSHAFT - (REF TM7077)
STD - FLYWHEEL HOUSING SIZE-SAE NUMBER
DRY WT ENG ONLY (DRAINED OF FLUIDS)
ENGINE LENGTH
ENGINE WIDTH
Starting System
MIN CRANKING SPD REQUIRED FOR START-RPM
LOWEST AMBIENT START TEMP W/O AIDS
40.2
DRY
110
0
7.9921
129.0
8.9
149
58.6
10.2
90.9
DI
12.1
CJ-4
FUL-FL,S-O
SHL & TUBE
230
68.0
64.0
TO ATM
STD
72
49
62
IN WTR
LB
FT LB
IN
GPH
IN HG
DEG F
GPH
IN HG
PSI
FT FUEL
DEG F
PSI
PSI
QT
QT
QT
22.9527
11.4960
0.2756
#0
6,420
76.7715
59.1337
IN
IN
IN
100
32
RPM
DEG F
LB
IN
IN
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Systems Data
Page 3 of 3
Caterpillar Confidential: Green
Content Owner: Commercial Processes Division
Web Master(s): PSG Web Based Systems Support
Current Date: Friday, July 19, 2013 10:33:38 AM
© Caterpillar Inc. 2013 All Rights Reserved.
Data Privacy Statement.
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Caterpillar Generator Data
Page 1 of 8
GENERATOR DATA
JULY 22, 2013
For Help Desk Phone Numbers Click here
Selected Model
Engine: C27
Fuel: Diesel
Frequency: 60
Duty: STANDBY
Generator Frame: 598
Generator Arrangement: 3870794
Excitation Type: Self Excited
Connection: SERIES STAR
Genset Rating (kW): 750.0
Genset Rating (kVA): 937.0
Pwr. Factor: 0.8
Application: EPG
Line Voltage: 480
Phase Voltage: 277
Rated Current: 1127.0
Status: Current
Version: 40953 /40864 /41474 /11205
Spec Information
Generator Specification
Frame: 598 Type: SR4B
Winding Type: RANDOM WOUND
Connection: SERIES STAR
Phases: 3
Poles: 4
Sync Speed: 1800
No. of Bearings: 1
Flywheel: 18.0
Housing: 0
No. of Leads: 12
Wires per Lead: 4
Generator Pitch: 0.8667
Generator Efficiency
Per Unit Load
0.25
0.5
0.75
1.0
kW
187.5
375.0
562.5
750.0
Efficiency %
92.2
94.6
94.9
94.7
Reactances
Per Unit
Ohms
SUBTRANSIENT - DIRECT AXIS X''d
0.1453
0.0357
SUBTRANSIENT - QUADRATURE AXIS X''q
0.1489
0.0366
TRANSIENT - SATURATED X'd
0.2128
0.0523
SYNCHRONOUS - DIRECT AXIS Xd
2.9289
0.7198
SYNCHRONOUS - QUADRATURE AXIS Xq
1.4893
0.3660
NEGATIVE SEQUENCE X2
0.1469
0.0361
ZERO SEQUENCE X0
0.0968
0.0238
Time Constants
OPEN CIRCUIT TRANSIENT - DIRECT AXIS T'd0
3.0770
SHORT CIRCUIT TRANSIENT - DIRECT AXIS T'd
0.2235
OPEN CIRCUIT SUBSTRANSIENT - DIRECT AXIS T''d0
0.0097
SHORT CIRCUIT SUBSTRANSIENT - DIRECT AXIS T''d
0.0078
OPEN CIRCUIT SUBSTRANSIENT - QUADRATURE AXIS T''q0
0.0090
SHORT CIRCUIT SUBSTRANSIENT - QUADRATURE AXIS T''q
0.0074
EXCITER TIME CONSTANT Te
0.1443
ARMATURE SHORT CIRCUIT Ta
0.0406
Short Circuit Ratio: 0.44
Seconds
Stator Resistance = 0.0047 Ohms
Voltage Regulation
Voltage level adustment: +/Voltage regulation, steady state: +/Voltage regulation with 3% speed change: +/Waveform deviation line - line, no load: less than
Telephone influence factor: less than
Field Resistance = 1.875 Ohms
Generator Excitation
5.0%
0.5%
0.5% Excitation voltage:
5.0% Excitation current
50
No Load
8.27 Volts
1.77 Amps
Full Load, (rated) pf
Series
Parallel
40.46 Volts
Volts
7.11 Amps
Amps
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Caterpillar Generator Data
Page 2 of 8
Selected Model
Engine: C27
Fuel: Diesel
Frequency: 60
Duty: STANDBY
Generator Frame: 598
Generator Arrangement: 3870794
Excitation Type: Self Excited
Connection: SERIES STAR
Genset Rating (kW): 750.0
Genset Rating (kVA): 937.0
Pwr. Factor: 0.8
Application: EPG
Line Voltage: 480
Phase Voltage: 277
Rated Current: 1127.0
Status: Current
Version: 40953 /40864 /41474 /11205
Generator Mechanical Information
Center of Gravity
Dimension X -788.4 mm -31.0 IN.
z
z
z
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 PTP
Overspeed Capacity = 150% of synchronous speed
Generator Torsional Data
J1 = Coupling
J2 = Rotor
J3 = Exciter
and Fan
TOTAL J = J1 + J2 + J3
End
K1 = Shaft Stiffness between
K2 = Shaft Stiffness between
J1 + J2 (Diameter 1)
J2 + J3 (Diameter 2)
J1
11.8 LB IN.
K1
s2
1.336 N m s2
Min Shaft Dia 1
116.8 MLB IN./rad
5.0 IN.
13.2 MN m/rad
127.0 mm
J2
103.3 LB IN.
s2
11.673 N m s2
Total J
K2
Min Shaft Dia 2
J3
20.4 MLB IN./rad
3.3 IN.
1.5 LB IN. s2
2.3 MN m/rad
83.8 mm
0.171 N m s2
116.7 LB IN. s2
13.18 N m s2
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Caterpillar Generator Data
Page 3 of 8
Selected Model
Engine: C27
Fuel: Diesel
Frequency: 60
Duty: STANDBY
Generator Frame: 598
Generator Arrangement: 3870794
Excitation Type: Self Excited
Connection: SERIES STAR
Genset Rating (kW): 750.0
Genset Rating (kVA): 937.0
Pwr. Factor: 0.8
Application: EPG
Line Voltage: 480
Phase Voltage: 277
Rated Current: 1127.0
Status: Current
Version: 40953 /40864 /41474 /11205
Generator Cooling Requirements Temperature - Insulation Data
Cooling Requirements:
Heat Dissipated: 42.0 kW
Air Flow:
Temperature Data: (Ambient 40 0C)
Stator Rise:
105.0 0C
Rotor Rise:
112.2 m3/min
Insulation Class: H
105.0 0C
Insulation Reg. as shipped: 100.0 Mȍ minimum at 40 0C
Thermal Limits of Generator
Frequency:
60 Hz
Line to Line Voltage: 480 Volts
B BR 80/40
851.0 kVA
F BR -105/40
1025.0 kVA
H BR - 125/40
1125.0 kVA
F PR - 130/40
1125.0 kVA
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Caterpillar Generator Data
Page 4 of 8
Selected Model
Engine: C27
Fuel: Diesel
Frequency: 60
Duty: STANDBY
Generator Frame: 598
Generator Arrangement: 3870794
Excitation Type: Self Excited
Connection: SERIES STAR
Genset Rating (kW): 750.0
Genset Rating (kVA): 937.0
Pwr. Factor: 0.8
Application: EPG
Line Voltage: 480
Phase Voltage: 277
Rated Current: 1127.0
Status: Current
Version: 40953 /40864 /41474 /11205
Starting Capability & Current Decrement
Motor 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 Amps
Instantaneous Line - Neutral Fault Current: 8636 Amps
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Caterpillar Generator Data
Page 5 of 8
Selected Model
Engine: C27
Fuel: Diesel
Frequency: 60
Duty: STANDBY
Generator Frame: 598
Generator Arrangement: 3870794
Excitation Type: Self Excited
Connection: SERIES STAR
Genset Rating (kW): 750.0
Genset Rating (kVA): 937.0
Pwr. Factor: 0.8
Application: EPG
Line Voltage: 480
Phase Voltage: 277
Rated Current: 1127.0
Status: Current
Version: 40953 /40864 /41474 /11205
Generator Output Characteristic Curves
Open 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
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Caterpillar Generator Data
Page 6 of 8
Selected Model
Engine: C27
Fuel: Diesel
Frequency: 60
Duty: STANDBY
Generator Frame: 598
Generator Arrangement: 3870794
Excitation Type: Self Excited
Connection: SERIES STAR
Genset Rating (kW): 750.0
Genset Rating (kVA): 937.0
Pwr. Factor: 0.8
Application: EPG
Line Voltage: 480
Phase Voltage: 277
Rated Current: 1127.0
Status: Current
Version: 40953 /40864 /41474 /11205
Generator Output Characteristic Curves
Zero 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
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Caterpillar Generator Data
Page 7 of 8
Selected Model
Engine: C27
Fuel: Diesel
Frequency: 60
Duty: STANDBY
Generator Frame: 598
Generator Arrangement: 3870794
Excitation Type: Self Excited
Connection: SERIES STAR
Genset Rating (kW): 750.0
Genset Rating (kVA): 937.0
Pwr. Factor: 0.8
Application: EPG
Line Voltage: 480
Phase Voltage: 277
Rated Current: 1127.0
Status: Current
Version: 40953 /40864 /41474 /11205
Reactive Capability Curve
Click to view Chart
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Page 1 of 1
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Caterpillar Generator Data
Page 8 of 8
Selected Model
Engine: C27
Fuel: Diesel
Frequency: 60
Duty: STANDBY
Generator Frame: 598
Generator Arrangement: 3870794
Excitation Type: Self Excited
Connection: SERIES STAR
Genset Rating (kW): 750.0
Genset Rating (kVA): 937.0
Pwr. Factor: 0.8
Application: EPG
Line Voltage: 480
Phase Voltage: 277
Rated Current: 1127.0
Status: Current
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: Green
Content Owner: Commercial Processes Division
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D I G I T A L
V O L T A G E
R E G U L A T O R
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.
Caterpillar is leading the power generation
marketplace with Power Solutions engineered
to deliver unmatched flexibility, expandability,
reliability, and cost-effectiveness.
FEATURES
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Microprocessor based control featuring choice
of 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 Shutdown
fault conditions
Generator paralleling with reactive droop
compensation and reactive differential
compensation
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 the
Caterpillar dealer network
● Over 1,800 dealer branch stores operating
in 166 countries.
● 99.7% of parts orders filled within 24 hours.
The best product support record in the industry.
● Caterpillar dealer service technicians are
trained to service every aspect of your electric
power generation system.
COMPLETE SYSTEM INTEGRATION
Fully designed and factory tested to work
seamlessly with Cat Generator using Shunt,
PMG, or AREP excitation systems and
EMCP controls.
LEHE3225
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
D I G I T A L
V O L T A G E
R E G U L A T O R
SPECIFICATIONS
General Specifications
Voltage Regulation
Temperature Drift
Response Time
±0.25% no load to full load
±1.0% for a 40° C change
Maximum of 10 milliseconds
Variable Sensing Range
Control Power
Regulator Filtering
90 to 600 Volts
24 Vdc Supply (18 to 30 Vdc, 5VA)
THF 3% per IEC34-1
TIF of 50 NEMA MG1-22.43
0.5% Voltage regulation with 40% THD
1.47 kg (3.25 lb)
Harmonic Tolerance
Weight
Environmental
Operating Temperature
Storage Temperature
Relative Humidity
Salt Spray
Vibration
–40° C to 70° C (–40° F to 158° F)
–40° C to 85° C (–40° F to 185° F)
95% non-condensing 30° C to 60° C
5% for 48 hrs at 38° C at 115% nominal operating voltage
4.5G (peak) 18-2000 Hz in 3 perpendicular planes
Shock
Certifications
CE Approved
UL Recognized
CSA Listed
20G
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
LEHE3225
2
D I G I T A L
V O L T A G E
R E G U L A T O R
Programmable Variables
Voltage vs Frequency Characteristic
Fine Voltage Level
Droop Adjustment
Overvoltage Setpoint
Overvoltage Time Delay
Undervoltage Setpoint
Undervoltage Time Delay
Gain
Single Phase or Three Phase Sensing
Under Frequency Point
Knee Frequency
Minimum Voltage Setpoint
Range of Adjustment
Two slope ranges adjustable from 1 to 10 PU in 0.1 increments
–10% to +10% in 0.1% increment
0 to 10% in 0.1% increment
105 to 135% of rated voltage in 1.0% increment
2 to 30 seconds in 1 second increments
60 to 95% of rated voltage in 1.0% increment
10 to 120 seconds in 1 second increments
1 to 20% in 0.1% increments
20 to 40 Hz
45 to 65 Hz in 0.1 Hz increments
50 to 100% of rated voltage
Var Operating Mode
PF Operating Mode
Line Drop (IR) Compensation
Loss of Excitation
Loss of Excitation Time Delay
Over Excitation
Time Delay — Fixed Time Option
Loss of Sensing Time Delay
Diode Fault Monitor
Soft Start Function
100% to –100% in 0.001 increments
0.6 lead to 0.6 lag in 0.01 increments
0 to 10% in 0.1% increment
0.1 to 1.0 PU leading vars
0.1 to 9.9 seconds in 0.1 second increments
0 to 12 Adc in 0.1 Adc increments
0 to 10 sec in 0.1 sec increments
0 to 25 sec in 1 sec increments
1 to 10A rms field ripple current
1 to 120 sec
LEHE3225
3
D I G I T A L
V O L T A G E
R E G U L A T O R
REGULATION CHARACTERISTIC — FIGURE 1
Underfrequency Point (20-40 Hz)
100
Generator Output Voltage
Decreasing Slope 1 (1 – 10 V/HZ)
75
Decreasing Slope 2 (1 –10 V/HZ)
50
5 Hz (Fixed)
25
Minimum Voltage Setpoint (50-100%)
Knee Frequency
20
40
60
80
100
% of Nominal Frequency
LEHE3225
4
D I G I T A L
V O L T A G E
R E G U L A T O R
OUTLINE DRAWING — FIGURE 2
10.88 (276.4)
P6
7.50 typ.
(190.5)
P12
P9
J4
0
6.38 (162.1)
0
5.50 typ.
(139.7)
2.87 (72.9)
2.81 (71.4)
0.59 (15.0)
0
0.16 (4.06)
LEHE3225
5
D I G I T A L
V O L T A G E
R E G U L A T O R
EXAMPLE CONNECTION DIAGRAM — FIGURE 3
A
11
GEN
B
CTB
10
C
+
52
PMG
7
10
8
9
10
+
10
P6-4 (F2,-)
P6-5 (F1,+)
P6-1
FIELD OUTPUT
P6-2
P6-3
POWER INPUT
VAR/PF
CONTROL
EXCITATION
DISABLE
FAULT
RESET
P9-9
P9-7
P9-8
P12-1
P12-2
P12-10
CURRENT
SENSING
RAISE/LOWER
INPUTS
P9-6
P12-11
P12-12
VOLTAGE
SENSING
P9-4
P9-5
4
P12-8 (+)
P12-7 (-)
24 Vdc CONTROL
POWER
ALARM
DRIVER
P12-4 (-)
24 Vdc _
SHUTDOWN
FAULT DRIVER
P12-9 (+)
5
P12-5 (-)
52a
P12-6 (+)
5
S1
2
3
1
Required only for Var/PF control. Var/PF is active with 52a closed, inactive with 52a open.
2
Excitation is disabled when closed, enabled when open.
3
Momentary closure resets any shutdown fault.
4
S1 (SPDT, spring -return to center-off position) adjusts regulator setpoint.
5
Normally-off, turns on for user alarm or trip.
6
Analog input voltage between -10 and +10 Vdc provides adjustment of operating setpoint.
7
External fuses should be sized to match the PMG and protect the field. Maximum fuse size
should be limited to Bussmann type KTK-12 or equivalent.
8
Three-phase PMG is shown. For single-phase PMG, omit P6-3 connection.
9
Sensing potential transformer is required if line voltage exceeds 660 Vac.
10
Item not supplied by Caterpillar.
11
When generator rotation is ACB, the connections shown for CTB should be reversed.
LEHE3225
6
GROUND
+/-10 VDC
CONTROL INPUT
10
1
P6-6
P12-3 (-)
6
ATTACHMENTS
C32 JACKET WATER
HEATER
With Circulating Pump
This is a factory-installed jacket water heater for
increased cold-starting capability. The system
includes heater, isolation valves, circulation
pump, hoses and generator space heater relay.
FEATURES
FACTORY INSTALLED
● Completed with hoses, circulating pump,
and isolation valves
● Base frame mounting minimizes engine
induced vibration
● Automatically disconnected when engine is
running 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
LEHE6018-01
SPECIFICATIONS
Unit Specifications
220
Design Voltage
240
Rating
Frequency
Phase
9 kW
50/60
1
9 kW
50/60
1
Amps
Flow Rate
41
32 L/min
(10 gpm)
95W
24 VDC
21.1°-98.8° C
37
32 L/min
(10 gpm)
95W
24 VDC
21.1°-98.8° C
(70°-210° F)
16.3 kg
(36 lb)
(70°-210° F)
16.3 kg
(36 lb)
Circulation Pump Rating
Control Voltage
Adjustable Thermostat
Shipping Weight
ATTACHMENTS
C32 JACKET WATER HEATER
WITH CIRCULATING PUMP
DESCRIPTION
HEATER OPERATION/WIRING
A 10-gallon per minute pump is located at the
heater outlet to pull the coolant through the
heater. An adjustable thermostat probe is located
inside the heater tank near the inlet of the heater
and responds to the temperature of the coolant
entering the tank. The figure below shows the
general heater design.
HEATER DESIGN DESCRIPTION
The jacket water heater package is designed to
efficiently pre-heat the C32 engine by heating
and circulating the engine’s coolant. The forced
coolant circulation allows the design to operate
at a higher wattage and efficiency than standard
thermal 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.
11.48
7.87
OUTLET, 1NPT
(FEMALE)
PRESSURE DIE CAST ALUMINUM
TANK W/ RUBBER INSULATING SLEEVE
CONTROL BOX W/ TERMINAL
STRIP & CONTACTOR
INLET, 1NPT
(FEMALE)
19.48
FLOW DIRECTION
13.88
5.98
3
11.43
2
PUMP, 1/25HP 240V
1PH 10GPM
1
1.26
13.78
2X KNOCKOUTS,
Ø.50
1 4.86
NONMETALLIC ENCLOSURE
& COVER
FLOW
DIRECTION
2X KNOCKOUTS,
Ø.75
PLUG, DRAIN
1/4NPT
LEHE6018-01
ADJ. T-STAT
(THIS END)
2
ATTACHMENTS
C32 JACKET WATER HEATER
WITH CIRCULATING PUMP
DESCRIPTION (continued)
ADJUSTABLE THERMOSTAT SETPOINT
Due to the high amperage associated with the
9 kW heater, the thermostat is wired such that it
opens and closes a contactor that controls the
heating elements. To maintain uniform engine
temperature while the engine is not operating,
the system pump requires either a 220 or a
240 VAC supply and must run continuously
independent of heater thermostat. The pump
and heating elements are de-energized whenever
the engine starts.
The figures below show the wiring diagram for
the engine jacket water heater systems.
WIRING DIAGRAM
AC-CB2
AC/DC BOX
(CONTROL PANEL)
JACKET WATER TERMINAL BOX
(MOUNTED ON RAIL)
CR1
L1
L1
JACKET WATER HEATER
9KW
T1
1L1
1
CUSTOMER
SUPPLY
240 VAC
L2
CR1
L2
T2
2
50
AMP
4
1L2
AC-CB1
CR2
JWH+
31
A2
A1
CR1
32
JWH–
T
21
10
AMP
CR2
11
21
CR2
H1
H1
P
12
H4
H4
22
SPACE HEATER
H1
H2
H2
H3
H3
H4
OPTIONAL
BATTERY
CHARGER
A
B
LEHE6018-01
3
3
ATTACHMENTS
C32 JACKET WATER HEATER
WITH CIRCULATING PUMP
JACKET WATER HEATER GROUP GENERAL DIMENSION
Conduit Opening
on Pump
2 ⳯ 3⁄8-16 Mounting Clamps
118.3
(4.6")
117.5
(4.6")
1 - 11 - 1⁄2 NPT
Outlet
352.6
(13.8")
205.1
(8.0")
81.3
(3.2")
288.6
(11.4")
293.2
(11.5")
2 ⳯ 3⁄4 Conduit
Opening
350.5
(13.8")
Ø 103.1 (Ø 4.0")
2 ⳯ 1⁄2 Conduit
Opening
494.7
(19.4")
Aluminum Body
with Rubber
Insulation Sleeve
Two Styles of Mounting
Brackets Available
1.3
(33.0")
17.7
(0.696")
70.9
(2.79")
1 - 11 - 1⁄2 NPT
Intlet
Package Dimensions
Length
Width
Height
Shipping Weight
U.S. sourced
LEHE6018-01 (06-06)
494.7 mm
195 mm
350.5 mm
16.3 kg
19.4 in
7.68 in
13.8 in
36.0 lb
Note: Unless otherwise specified;
all dimensions are for reference.
(Drawing # 273-3766, 274-4541).
Information contained in this publication may be considered confidential.
www.cat-electricpower.com
Discretion is recommended when distributing.
Materials and specifications are subject to change without notice.
© 2006 Caterpillar
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.
Cat Batteries
®
Cat Batteries – Greater Starting Power –
Lower Maintenance – Longer Life
Caterpillar. The difference counts.™
Cat Premium High Output (PHO) batteries are used in all Caterpillar
support. We offer you the right parts
Machines and Engine Gen-Sets. They are designed to meet stringent
and service solutions, when and where
Caterpillar design specifications, which provide industry leading cold
you need them.
cranking amp (CCA) capability and maximum vibration resistance.
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The Cat Dealer network of highly
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Specifications for Cat Premium High Output Batteries – Available Worldwide
Nominal Weight
BCI
Group
Size
8D
Cold
Cranking
Amps”
1500
Reserve
Capacity
Minutes’
465
Part No.
153-5720
8D
101-4000
1400
400
12
4D
153-5710
1400
425
12
4D
153-5700
1125
305
12
4D
9X-9730
1300
400
12
Volts
12
Amp Hr.
Capacity
@ 20 Hrs.
210
BCI Overall Dimensions
Construction
C
Add Water
Maintenance
Check Hours
MF
190
LAC+
1000
20.7 (526.5)
10.96 (278)
9.76 (248)
132 (60)
86 (39)
18.0 (17.0)
200
C
MF
20.47 (520)
8.58 (218)
9.76 (248)
119 (54)
–
–
145
C
MF
20.47 (520)
8.58 (218)
9.76 (248)
101 (46)
–
–
190
LAC+
1000
20.75 (527)
8.58 (218)
9.76 (248)
119 (54)
81 (37)
14.8 (14.0)
15.9 (15.0)
Length
In (mm)
20.47 (520)
Width
In (mm)
10.8 (275)
Height
In (mm)
9.76 (248)
Wet
Lb (kg)
132 (60)
Dry
Lb (kg)
–
Nominal
Acid to Fill
Qt (liter)
–
4D
9X-9720
1000
275
12
140
LAC+
1000
20.75 (527)
8.58 (218)
9.76 (248)
101 (46)
59 (27)
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 Construction
C = Calcium Lead Alloy Grid Design
MF = Maintenance Free
MFA = Maintenance Free with Accessible Vent Caps
S = 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 Posts
SDT = Dual, Top mounted Terminals, Stud and SAE Post,
Marine Deep Cycle/Starting Battery
SC = Silver (Ag) Calcium Alloy Grids for resistance to high
underhood temperatures
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
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• 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
BCI
Group
Size
Part No.
Nominal Weight
BCI Overall Dimensions
Cold
Cranking
Amps”
Reserve
Capacity
Minutes’
Volts
Amp Hr.
Capacity
@ 20 Hrs.
Construction
Length
In (mm)
Width
In (mm)
Height
In (mm)
Wet
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)
450
12
190
C/MFA/TB
20.7 (526)
11.0 (279)
10.0 (254)
134 (61)
Bus-Special Terminal
8D
250-0473
1450
Automotive/Light Truck & SUV
22F
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)
31 (14)
Automotive/Light Truck & SUV, Severe Service/High Temperature, Silver Lead Alloy Technology
25
250-0488
600
90
12
45
ST/MF
9.1 (230)
6.8 (175)
8.8 (225)
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)
Construction Notes:
LA = Low Maintenance, Low Antimony Grids
LAC = Low Maintenance, Hybrid Construction
C = Calcium Lead Alloy Grid Design
MF = Maintenance Free
* = Side Terminals
S = Stud Terminals
DT = Dual Terminal
TB = Transit Bus one piece end Terminal.
Right end of Battery.
1/2"-13 Steel positive stud
3/8"-16 Steel negative stud
SC = Silver (Ag) Calcium Alloy Grids – for
resistance to high underhood temperatures
MFA = Maintenance Free, Calcium Grids,
Accessible Vent Caps
ST = Silver (Ag) Calcium Alloy Heavy
Duty Grids
3
" = 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)
Cat General Service Batteries – Available Worldwide
Wet Batteries
Continued
BCI
Group
Size
Cold
Cranking
Amps”
Part No.
Reserve
Capacity
Minutes’
Volts
Amp Hr.
Capacity
@ 20 Hrs.
Construction
Length
In (mm)
BCI Overall Dimensions
Width
In (mm)
Height
In (mm)
Nominal Weight
Wet
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)
275
32
12
25
C/MF
7.8 (198)
5.1 (130)
7.3 (185)
16.5 (7)
–
6
215
@ OP
10.3 (262)
7.1 (180)
10.9 (277)
63 (29)
Lawn & Garden
U1
8C-3636
Golf Cart/Scissor & High Lifts
GC-2
75 amps
@ 80° F
115 mins.
8C-3641
Dual Terminal Batteries
24/24F/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 Batteries
BCI
Group
Size
Part No.
Cold
Cranking
Amps”
BCI Overall Dimensions
Reserve
Capacity
Minutes’
Volts
Amp Hr.
Capacity
@ 20 Hrs.
Length
Construction In (mm)
Width
In (mm)
Height
In (mm)
Nominal Weight
Wet
Lb (kg)
Dry
Lb (kg)
Nominal
Acid to Fill
Qt (liter)
4.5 (4.3)
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)
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 Truck
22F
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)
350
8
175
LA +
20.8 (528)
7.3 (185)
10.6 (269)
90 (41)
60 (27)
11.5 (10.9)
Marine/Recreational
8V
8C-3640
980
Construction Notes:
LA = Low Maintenance, Low Antimony Grids
LAC = Low Maintenance, Hybrid Construction
C = Calcium Lead Alloy Grid Design
MF = Maintenance Free
MFA = Maintenance Free, Calcium Grids, Accessible Vent Caps
ST = Silver (Ag) Calcium Alloy Heavy Duty Grids
SC = Silver (Ag) Calcium Alloy Grids – for resistance to high
underhood temperatures
* = Side Terminals
S = Stud Terminals
DT = Dual Terminal
OP = 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
Valve Regulated Lead Acid (VRLA) Batteries
Gelled (GEL) Electrolyte, Marine/Recreational, Deep Cycle Capability
Nominal Weight
BCI Overall Dimensions
BCI
Group
Size
4D
8D
Part No.
Cold
Cranking
Amps”
Reserve
Capacity
Minutes’
152-8006
152-7242
1050
1265
375
475
Volts
Amp Hr.
Capacity
@ 20 Hrs.
12
12
183
225
Construction
Length
In (mm)
Width
In (mm)
Height
In (mm)
Wet
Lb (kg)
MF-G/VRLA
MF-G/VRLA
20.8 (528)
20.8 (528)
8.5 (216)
11.1 (282)
10 (254)
10 (254)
129.8 (59)
160.8 (73)
Marine Cranking Amps (MCA) = Cold cranking Amps divided by 0.8
MF-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.
Important: Alternator and charger instructions:
" = For 30 seconds at 0° F (-18° C)
For 12-volt Gel Batteries charge to 13.8 volts but no more than
' = Minimum of 25 amp output at 80° F (27° C)
14.1 volts at 68° F (20° C)
Absorbed Glass Mat (AGM) Batteries, Designed for High-rate Uninterruptible Power Supplies (UPS) or Standby Applications
Discharge Ratings
Power
Watts
per Cell
Discharge
Rating in
Amperes
BCI
Group
Size
Part No.
For 15 mins.
to 1.67 V.P.C.
@ 77° F
(25° C)
For 15 mins.
to end voltage
of 1.75 V.P.C.
@ 77° F
(25° C)
U1
250-0474
119
60
45
250-0475
168
85.4
24
250-0476
253
127
27
250-0477
314
31
250-0478
31(A)
4D(H)
Amp Hour @
20 hour rate
to 1.75 volts
per cell @
77° F (25° C)
BCI Overall Dimensions
Nominal Weight
Length
In (mm)
Width
In (mm)
Terminal
Height
In (mm)
1
7.71 (196)
5.18 (132)
7.18 (182)
6.18 (157)
24 (11)
2
8.84 (225)
5.31 (135)
8.7 (221)
8.14 (207)
38.5 (18)
MF-AGM/VRLA
2
10.2 (259)
6.8 (173)
9.14 (232)
8.12 (206)
53 (24)
12
MF-AGM/VRLA
2
12.72 (323) 6.8 (173)
8.68 (220)
8.12 (206)
63 (29)
4.68
12
MF-AGM/VRLA
3
12.93 (329) 6.75 (171)
8.75 (222)
8.58 (218)
69 (31)
238
6.66
12
MF-AGM/VRLA
3
13.5 (342)
11.25 (286) 11.08 (281)
98 (45)
318
9.91
12
MF-AGM/VRLA
4
21.73 (552) 8.82 (210)
9.34 (237)
129 (59)
Normal
Voltage
Construction
1.46
12
MF-AGM/VRLA
2.42
12
MF-AGM/VRLA
3.65
12
156
4.41
377
192
250-0479
475
250-0483
624
Terminal
6.77 (172)
Container
Height
In (mm)
Wet
Lb (kg)
8.74 (222)
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 handles
Sealed 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 Cell
WPC = Watts per Cell. Ratings conform to IEEE-485 Standards
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.
UL Recognized Component
AGM batteries have a longer production lead time than regular lead-acid type batteries
Important: 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)
Valve Regulated AGM Batteries – Terminal Locations
4-BCI Group 4D
1-BCI Group U1
2-BCI Groups 45, 24, 27
3-BCI Group 31
VRLA batteries are a UL Recognized Component and
are I.C.C.A., I.C.A.O., I.M.D.G., I.A.T.A. and D.O.T.
Air Transport Approval pending.
Terminals
1 = 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
Battery Information
Cat Premium High Output Batteries – Built Tough to Exceed
Demanding Performance Test Requirements:
BCI Terminal Locations
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 without
developing internal/external leaks
GP 2E
3 EH
4EH
• Battery must pass a high rate discharge test after the vibration testing
Five 72-hour Deep Discharge/Recharge Test Cycles
GP 3EE & 3ET
• Battery must recover to 25 charging amps within 20 minutes and meet
Industry Electrical Performance Standards
30 Day Complete Discharge Test
GP 4DLT
• Battery must recover to 25 charging amps within 60 minutes and meet
Industry Electrical Performance Standards after recharging
GP 4D
6D
8D
4B
SAE J2185 Life Cycle Test
• Battery subject to deeper discharge and charge cycles at extreme
temperatures not normally encountered in starting a machine or vehicle
Cold Soak Test
GP 31
28
• Battery cold soaked at sub-freezing temperatures and then tested by
starting an equally cold engine
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-Volt
GP 1,2,3,4
5D, 7D, GC2,
GC2H, 3D,
17 HF, 19L
GP 40R, 41, 42, 43
96R, 97R, 98R
Side Terminal
GP70, 71, 72, 73, 74
75, 76, 77, 78, 101
Battery Accessories
Group 31 – Charging Posts for Stud Terminals – Part # 4C-5637
Screw-in Charging Posts for Side Terminals – Part # 4C-5638
Wing 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 # 177-2330
Battery Voltmeter – Part # 4C-6600
Battery Load Tester – Part # 4C-4911
Booster Cable 12' (3.66 m) – Part # 4C-4933
Booster Cable 20' (6.00 m) – Part # 4C-4937
Heavy Duty Commercial Fast Charger (110V) – Part # 4C-4921
Heavy Duty Commercial Fast Charger (220V) – Part # 4C-4910
Extra Vent Caps (6) for Dry Batteries – Part # 7N-0060
GP21, 24, 24H, 25, 26, 27, 27H,
29H, 30H,34,50, 51, 52, 57, 58,
59, 65, 86, U1, 12T, 24T
U2(L TERMINAL)
Transit Bus Terminal for 8D Part # 250-0473
One piece end terminal.
Right end of Battery.
1/2" - 13 Steel Positive Stud
3/8" - 16 Steel Negative Stud
Type B
Note: Ratings and Part Numbers are subject to change without notice.
Recycle all scrap batteries.
We accept lead-acid batteries
for recycling.
6
Cat Batteries
World Wide Application Flexibility
Marine Commercial Vessels
Maintenance Free 4D, 8D and Group
31 Batteries. General Service Line
Line valve regulated (VRLA) Gel
batteries. High Marine Cranking
Amps (MCA) and Deep Cycling
capabilities.
Automotive-Truck-Bus & RV
A wide selection of popular BCI group
sizes. Maintenance Free, Severe Service
and Deep Cycle models. Application
Specific Group 31 Truck Batteries.
Commercial & Recreational
A wide selection of premium batteries
in most BCI group sizes for light
commercial, recreational, agricultural
and industrial applications.
Marine Pleasure Craft
Premium High Output BCI Group 31,
Dual Terminal Deep Cycle Batteries.
General Service Line BCI group
24M, 27M and 8V sizes.
Electric Power Generation
Premium High Output Maintenance Free
and Accessible batteries in BCI group
4D, 8D, & 31 sizes. High Cold Cranking
Amp (CCA) Capability. General Service
Line valve regulated (VRLA)
AGM batteries for UPS or stationary
power applications.
Construction & Mining
Premium High Output Maintenance Free
batteries. BCI group 4D, 8D and 31
Sizes. Industry leading cold cranking
amps (CCA) and maximum vibration
resistance.
7
Cat Batteries
Heavy-duty Forged Terminal Post Bushings
Built-in Flame
Arrestor
Robust
Reinforced
Case
Vibration
Resistant
Plates &
Elements
Rugged
Separators
Heavy-duty Grids
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.
CAT, CATERPILLAR, their respective logos and “Caterpillar Yellow,” as well as corporate and product identity
used herein, are trademarks of Caterpillar and may not be used without permission.
Caterpillar. The difference counts.
™
PEHJ0073-01
Printed in the U.S.A.
© 2005 Caterpillar
All Rights Reserved
For more information, see us today or visit
our web site at www.cat.com
BATTERY CHARGER
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
208-240 V
AC and DC Fuses
2 input and 2 output)
Output voltage
24V
Frequency
Operating temperature
50/60 Hz
-20°C ( -4°F)
to +60°C (140°F)
Housing constructed of rustproof anodized
aluminum.
STANDARDS
· C-UL listed to UL 1236
· NFPA 70, NFPA 110
· CSA 22.2 No 107 certified
· UL 1564
· CE DOC to EN 60335
· IBC Seismic Certification
LEHE0141-02
· Electronically current limited at 105% of rated output
· Alarm system
· Digital Display
· Lightning and voltage transient protection
· Protection of connected equipment against load
dump protection
· Constant voltage, current limited, 4-rate automatic
equalization
· IP 20 housing
· AC isolated from DC
· Temperature Compensation
- On board temperature sensor with remote port
· Auto AC line compensation
· Output regulated by sensed battery voltage
BATTERY CHARGER
Output
Amps
Volts
Input
Hz
Volts
110-120
208-240
10
24
50/60
Width
195 mm
(7.66")
Depth
165 mm
(6.50")
Height
318 mm
(12.50")
Weight
10.4 kg
(23 lb)
Feature codes
BTC1024
BTC1025
BTC1028
BTC1032
BTC1035
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.
www.Cat-ElectricPower.com
LEHE0141-02 (03-12)
2
©2012 Caterpillar
All Rights Reserved.
Printed in U.S.A.
ENGINE CONTROLLER
ADEM™ A4 Engine
Controller
The ADEM™ A4 is the main Electronic Control
Module (ECM) used on select diesel engines.
The ADEM A4 is an integral part of the innovative
ACERT® Technology that provides higher degree
of control over a large number of combustion
variables than ever before. The ADEM A4 is
designed to control/interface Electronic Unit
Injector (EUI) equipped engines. The ADEM A4
engine system is composed of the ADEM A4 ECM,
control software, sensors, actuators, fuel injectors,
and interface to the generator system. The prime
benefit of an ADEM A4 engine system is to better
control and maintain the particulate emissions,
both steady state and transient, while improving
engine performance.
FEATURES
RELIABLE, DURABLE
All ADEM A4 controllers are designed to survive
the harshest environments.
● Environmentally sealed, die-cast aluminum
housing isolates and protects electronic
components from moisture and dirt
contamination.
● Rigorous vibration testing ensures product
reliability and durability.
● Accuracy maintained from –40° C to 85° C
● Electrical noise immunity to 100 volts/meter
● Internal circuits are designed to withstand
shorts to +battery and –battery.
● Atmosphere cooled
SIMPLE SERVICING
Each ADEM A4 system works in combination
with the Caterpillar® ET service tool software to
keep the engine operating at peak performance.
● Displays measured parameters
● Retrieves active and logged event code
documenting abnormal system operation
● Performs calibrations and diagnostic tests
● Supports flash programming of new software
into the ADEM A4 ECM
LEHE5347-00
SELF DIAGNOSTICS
Each ADEM A4 ECM has a full compliment of
diagnostics. The ECM can detect faults in the
electrical system and report those faults to
the service technician for quick repair.
● Self-diagnostic capability pinpoints operational
problems in need of attention.
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
ENGINE CONTROLLER
DESCRIPTION
The ECM is housed in an environmentally sealed
casting. All wiring connections to the ECM are
made using two sealed connectors: a single
seventy-pin connector and a single one hundred
twenty-pin connector.
INFORMATION MANAGEMENT
The ECM stores information to assist with
electronic troubleshooting. Active and logged
diagnostic codes, active events, logged events, fuel
consumption, engine hours, and instantaneous
totals aid service technicians when diagnosing
electronic faults and scheduling preventive
maintenance.
ENGINE SPEED GOVERNING
Desired engine speed is calculated by the ECM and
held within ±0.2 Hz for isochronous and droop
mode. The ECM accounts for droop that is
requested. The proper amount of fuel is sent to
the injectors due to these calculations. The ECM
also employs cooldown/shutdown strategies,
acceleration delays on startup, acceleration ramp
times, speed reference and a low/high idle switch
is also available via communications to the EMCP 3.
CALIBRATIONS
Engine performance is optimized through injection
timing. Auto/manual sensor calibrations are
standard features.
ON-BOARD SYSTEM TESTS
System tests are available to assist in electronic
troubleshooting. These tests include: injector
activation, injector cutout, and override of
control outputs.
FUEL LIMITING
Warm and cold fuel-air ratio control limits are
controlled by the ECM. Electronic monitoring
system derates, torque limit, and cranking limit,
programmable torque scaling, and cold cylinder
cutout mode are standard features.
DATA LINK INTERFACES
The ADEM A4 communicates with the EMCP 3 via
the J1939 Communication network. Additionally,
the ADEM A4 can communicate with the Cat ET
electronic service tool and the PL1000E, PL1000T.
FUEL INJECTION TIMING
Master timing for injection is controlled by the
ECM control. Temperature dependencies are
accounted for in the fuel injection calculations.
ELECTRONIC SENSING
The following sensing is available on the
ADEM A4: oil pressure, fuel pressure, fuel
temperature, atmospheric pressure, air inlet
temperature, turbo outlet pressure, engine
coolant temperature, engine speed, throttle,
position, exhaust temperature, engine control
switch position, oil filter pressure differential,
fuel filter pressure differential, air filter pressure
differential, crankcase pressure, and remote
e-stop switch position.
ELECTRONIC MONITORING
Electronic monitoring of vital engine parameters
can be programmed. Warning, derate, and
shutdown event conditions may be customized
by the user.
LEHE5347-00
2
ENGINE CONTROLLER
SPECIFICATIONS
Humidity tolerance
0 to 90% relative humidity over operating
temperature range
Impervious to:
salt spray, fuel, oil and oil additives, coolant,
spray cleaners, chlorinated solvents, hydrogen
sulfide and methane gas, and dust
Input and output protection
all inputs and outputs are protected against
short circuits to +battery and –battery
Input voltage range (24 VDC nominal)
18 to 32 VDC
Mounting
engine mounted
Reverse polarity protected
Shock, withstands 20 g
Temperature range
Operating: –40° C to 85° C (–40° F to 185° F)
Storage: –50° C to 120° C (–58° F to 248° F)
Vibration
withstands 8.0 g @ 24 to 2 kHz
LEHE5347-00
3
EMCP 4
EMCP 4.2
GENERATOR SET
CONTROLLER
Caterpillar is leading the power generation market
place with power solutions engineered to deliver
unmatched performance, reliability, durability and
cost-effectiveness.
Image shown may not reflect actual package
FEATURES
GENERAL 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.
• 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 nonvolatile memory.
• 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
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.
LEHE0138-00
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
STANDARD FEATURES
Generator Monitoring
Generator Protection
Engine Monitoring
Engine Protection
• 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 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)
• Coolant temperature
• Oil pressure
• Engine speed (RPM)
• Battery voltage
• Run hours
• Crank attempt and successful start counter
• Enhanced engine monitoring (with electronic engines)
• 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
2
EMCP 4.2 GENERATOR SET CONTROLLER
OPTIONAL MODULES
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.
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.
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.
LEHE0138-00
3
EMCP 4.2 GENERATOR SET CONTROLLER
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
monitoring capability of the EMCP 4 and is
capable of reading up to twenty Type J or K
thermocouple inputs. The thermocouple
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.
DIGITAL INPUT/OUTPUT MODULE
The Digital Input/Output (DI/O) module serves to
provide expandable Input and Output capability
of the EMCP 4 and is capable of reading 12 digital
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.
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.
www.Cat-ElectricPower.com
LEHE0138-00
LEHE0138-00 (03-10)
4
©2010 Caterpillar
All Rights Reserved.
Printed in U.S.A
EMCP 4
EMCP 4 CAN
ANNUNCIATOR
The EMCP 4 CAN annunciator serves to display
generator set system alarm conditions and status
indications. The annunciator has been designed
for use on the EMCP 4 accessory communication
network for local applications, but may be used
for either local or remote applications, providing
customers with enhanced site flexibility.
In local applications, the annunciator may be
mounted on the package generator set with the
EMCP 4 Controller to provide a complete
package-mounted monitoring solution.
The annunciator may also be mounted separate
from the generator set to provide remote indication
of system operating and alarm conditions.
The EMCP 4 annunciator is configurable to the
standards of NFPA 99/110 for emergency standby
generator systems.
FEATURES
SPECIFICATIONS
●
Technical Data
Electrical
Battery Voltage Functional Range: 9 to 32 VDC
Power Consumption
Maximum: ⬇ 12 watt at 24 VDC
Standby: ⬇ 5 watt at 24 VDC
Control Power: 12-24 VDC
Communication: Accessory Data Link
Single, 6-pin Connector
Alarm
Sound Level 80 db
●
●
●
●
●
●
●
●
●
●
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 status
indication of the accessory communication
network.
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 emergency
standby generator systems.
Provides custom label kit including software for
customer’s specific alarms and arrangement
Designed and tested to meet stringent impulse
shock and operating vibration requirements
Uses high quality shielded twisted-pair cable
for robust remote communications
Graphic symbols are provided next to each pair
to 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
LEHE0139-01
PHYSICAL
Weight
ENVIRONMENTAL
Operating Temperature
Storage Temperature
Relative Humidity
CERTIFICATIONS
UL Recognized
2.5 lb or ⬇ 1.13 kg
–40° C to 70° C
–40° F to 158° F
–50° C to 70° C
–58° F to 158° F
90%
EMCP 4
LED COLOR SCHEME
STANDARD LED CONFIGURATION
Each pair of LED’s on the annunciator consists of
two of three colors: green, yellow and red, which
allows for custom configuration of status, warning
and shutdown conditions.
The available colors and combinations are:
●
●
●
●
●
●
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
●
●
●
●
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
Annunciator Dimensions
LEHE0139-01 (04-10)
A
158 mm
6.22 in
B
C
60 mm
288 mm
2.37 in
11.34 in
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.
www.Cat-ElectricPower.com
© 2010 Caterpillar
All rights reserved.
Printed in U.S.A.
EMCP 4
EMCP 4 RS-485
ANNUNCIATOR
The EMCP 4 RS-485 annunciator serves to display
generator set system alarm conditions and status
indications. The annunciator has been designed
for use on the EMCP 4 RS-485 annunciator data
link for remote applications, providing customers
with enhanced site flexibility.
The EMCP 4 annunciator is configurable to the
standards of NFPA 99/110 for emergency standby
generator systems.
FEATURES
SPECIFICATIONS
●
Technical Data
Electrical
Battery Voltage Functional Range: 9 to 32 VDC
Power Consumption
Maximum: ⬇ 12 watt at 24 VDC
Standby: ⬇ 5 watt at 24 VDC
Control Power: 12-24 VDC
Communication: RS-485
Single, 8-pin Connector
Alarm
Sound Level 80 db
●
●
●
●
●
●
●
●
●
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 status
indication of the RS-485 communication network.
Includes alarm horn with lamp test and
alarm acknowledge pushbuttons.
Configurable to NFPA 99/110 requirements for
local and remote annunciation on emergency
standby generator systems.
Provides custom label kit including software for
customer’s specific alarms and arrangement
Designed and tested to meet stringent impulse
shock and operating vibration requirements
Uses high quality shielded twisted-triad cable
for robust remote communications
Graphic symbols are provided next to each pair
to indicate various alarms and events
The annunciator can be mounted remotely
up to 1200 m (4,000 ft).
Provides superior visibility of the LED’s in
direct sunlight
PHYSICAL
Weight
ENVIRONMENTAL
Operating Temperature
Storage Temperature
Relative Humidity
CERTIFICATIONS
UL Recognized
LEHE0142-01
2.5 lb or ⬇ 1.13 kg
–40° C to 70° C
–40° F to 158° F
–50° C to 70° C
–58° F to 158° F
90%
EMCP 4
LED COLOR SCHEME
STANDARD LED CONFIGURATION
Each pair of LED’s on the annunciator consists of
two of three colors: green, yellow and red, which
allows for custom configuration of status, warning
and shutdown conditions.
The available colors and combinations are:
●
●
●
●
●
●
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
●
●
●
●
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
Annunciator Dimensions
LEHE0142-01 (05-10)
A
158 mm
6.22 in
B
C
60 mm
288 mm
2.37 in
11.34 in
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.
www.Cat-ElectricPower.com
© 2010 Caterpillar
All rights reserved.
Printed in U.S.A.
MODULES
DISCRETE INPUT/
OUTPUT (I/O) MODULE
GENERAL DESCRIPTION
FEATURES/BENEFITS
The Cat® Discrete Input/Output (I/O) module
serves to provide expandable Input and Output
capability for your package generator set.
The Discrete I/O Module is capable of reading
12 discrete inputs and setting eight (8) relay outputs.
●
The Cat® Service Tool ET is used to configure the
Discrete I/O module, while all monitored Input
and Output status conditions are viewable on
the EMCP 3 control panel.
The Discrete I/O Module can be Package or Remote
mounted (up to 800 feet) and features rugged
packaging and watertight Deutsch IPD connectors.
These features all add to the sense of value and
dependability that comes with your purchase
of Cat products.
OPERATOR INTERFACE
●
All Discrete I/O status conditions are available
for viewing with the EMCP 3.2 & 3.3 Controllers.
●
●
●
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
●
LEHE4754-02
Capable of reading twelve (12) discrete inputs
and setting eight (8) relay outputs
CAN communication network eliminates
the need for multiple relays, which translates
to less wiring and fewer opportunities for
mechanical failures.
Remote customer communications are
supported by MODBUS protocol using RS-485
(via EMCP 3.2 & 3.3), which easily interfaces
with existing plant systems and equipment.
Set points are stored in nonvolatile memory,
preventing loss during a power outage.
Reads twelve (12) discrete inputs and sets
eight (8) Form C relay outputs rated for rated
resistive loads of:
2A @ 30 VDC for Normally Closed (NC) relays
2A @ 125 VAC for Normally Closed (NC) relays
2A @ 30 VDC for Normally Open (NO) relays
2A @ 125 VAC for Normally Open (NO) relays
DISCRETE INPUT/
OUTPUT (I/O) MODULE
GENERAL SPECIFICATIONS (CONT’D)
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Encapsulated in a rugged aluminum housing
with watertight connectors (IP67 rating)
Suitable for moist, high shock and vibration
environments
Modules are designed for package mounting on
power generator sets or remotely, up to 800 ft.
Configuration is accomplished with Cat ET
Service Tool.
Multiple Discrete I/O modules can be used on
the 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 temperatures
exceeding 85° C, the temperature scanner may
deviate 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 of
external filtering.
Maximum level of current draw of 400 mA
+ 50 mA per energized relay @ 12 VDC
Isolation voltage: 4000 VAC (RMS), 50/60 Hz for
1 min. between coil and contacts, 750 VAC,
50/60 Hz for 1 min. between contacts of the
same polarity
System throughput: All channels are scanned
in 100 mSec.
Input level characteristics:
Low-Level input voltage: 0 to 0.8V
High-Level input voltage: 3.75 to 24V
Inputs have internal pull-up resistors.
Inputs that generate a warning message
auto-reset whenever the input returns to
non-active state.
LEHE4754-02
●
●
●
●
●
●
●
Inputs that generate a shutdown message
continue to broadcast that message until the
input returns to non-active state and a reset
message is received from the EMCP 3.2 or 3.3.
Each output is configured to activate based
upon the message that is received on the
CAN 2 Data Link and can be configured to
activate on Alarm, Shutdown or Diagnostic
condition – 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 boot
up) with equipment system time via an explicit
command from the EMCP 3.2 & 3.3 –
synchronization time is accurate to within 1 sec.
Converts between physical I/O and CAN 2
data link commands.
Monitored parameters and diagnostics as well
as setpoints are customizable to customer
specification
Module operates normally with loss of
communication link, retaining configured
values in non-volatile memory.
Remains energized during engine cranking.
Discrete I/O Module Configuration Parameters:
The Discrete I/O Module is configurable to
display the following parameters for each
of the available Inputs:
Active State (Active High or Active Low)
Input Time Delay (0-120 seconds).
2
DISCRETE INPUT/
OUTPUT (I/O) MODULE
TYPICAL CONNECTIONS – POWER AND CAN BUS:
Available Inputs/Outputs:
The Discrete I/O Module is configured to accept
inputs for the following conditions, with the listed
condition displayed at the EMCP 3 controller:
Description
Input Output
Fuel Level Secondary Tank
X
X
Starting Air Pressure
X
Fuel Pressure
X
Fuel Filter Differential Pressure
X
Fuel Level (Primary Tank)
X
X
Engine Oil Level
X
Oil Filter Differential Pressure
X
Engine Oil Pressure
X
Crankcase Pressure
X
Air Filter Differential Pressure
X
Engine Coolant Temperature
X
Engine Coolant Level
X
X
Extinguisher System Pressure
X
X
Battery Voltage
X
Ambient Air Temperature
X
Inlet Air Temperature
X
Exhaust Temperature
X
Fuel Temperature
X
Engine Oil Temperature
X
Engine Overspeed
X
Emergency Stop Shutdown
X
Gen. Bearing Temperature #1
X
Gen. Winding Temperature (1-3)
X
Ruptured Fuel Basin-Primary Tank
X
X
Engine Failure to Start Shutdown
X
Generator Frequency
X
Generator Voltage
X
Generator Reactive Power (VAR)
X
Generator AC Current
X
Generator Reverse Power (kW)
X
Voltage Regulator Failure
X
Service Interval Warning
X
Air Shutoff Damper Close
X
X
Gen. Supplying Load
X
X
Battery Charger Failure
X
X
Gen. Breaker Closed
X
X
Utility Breaker Closed
X
X
Engine in Cooldown
X
Generator Control Not in Auto
X
Unexpected Engine Shutdown
X
User Defined Input (1-12)
X
LEHE4754-02
5
6
7
8
4
3
2
1
FRONT VIEW
MODULE MOUNTED CONNECTOR
DEUTSCH P/N: DT13-08PA
1 = PWR+
2 = CAN-H
3 = CAN-L
4 = PWR-
5 = SHIELD
6,7,8 = NOT USED
TYPICAL CONNECTIONS – DISCRETE I/O MODULE:
INPUT
DIN
GND
LOAD
LOAD
NO
NC
OUTPUT
3
C
DISCRETE INPUT/
OUTPUT (I/O) MODULE
DIMENSIONS
FRONT VIEW
(8-Pin Connector)
BACK VIEW
(40-Pin Connector)
SIDE VIEW
Grounding
Lug
BOTTOM VIEW
Connectors excluded from overall dimensions.
FRONT VIEW OF
MODULE MOUNTED CONNECTOR
DEUTSCH P/N: DRC13-40PB
POLARIZING
KEY
INPUTS
1
GND
OUTPUTS
OUTPUTS
55
6
10
10
11
15
16
20
21
25
26
30
31
35 35
36
36
40
40
Dimensions: inches [mm]
INPUTS
DIN1
DIN2
DIN3
DIN4
DIN5
DIN6
DIN7
DIN8
DIN9
DIN10
DIN11
DIN12
GND
GND
GND
GND
Pin
1
11
21
31
2
12
22
32
3
13
23
33
4
14
24
34
NO - Normally Open
NC - Normally Closed
C - Common
LEHE4754-02 (09-10)
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.
OUTPUTS
NC_1
C_1
NO_1
NC_2
C_2
NO_2
NC_3
C_3
NO_3
NC_4
C_4
NO_4
NC_5
C_5
NO_5
NC_6
C_6
NO_6
NC_7
C_7
NO_7
NC_8
C_8
NO_8
Pin
5
6
7
15
16
17
25
26
27
35
36
37
8
9
10
18
19
20
28
29
30
38
39
40
www.Cat-ElectricPower.com
© 2010 Caterpillar
All Rights Reserved.
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.