- Power Module:
- PM3516 (S/N: BPD1132-1156)
- PM3516 (S/N: BPD1160-1177,1179-1197,1200-1202)
Introduction
This Special Instruction provides the information in order to adjust the 3516C Power Module for either 50 Hz operation or 60 Hz operation.
Important Safety Information
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.
You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.
Reference Information
The following publications can be used for reference.
ReferenceSee Systems Operation, Troubleshooting, Testing and Adjusting, RENR7902, "EMCP3" for more information.
ReferenceSee Specifications, Systems Operation, Testing and Adjusting, RENR7941, "Caterpillar Digital Voltage Regulator (CDVR) " for more information.
ReferenceSee Systems Operation, Testing and Adjusting, RENR4928, "3500 Engines for Caterpillar Built Power Modules" for more information.
ReferenceSee Troubleshooting, RENR4929, "3500B Engines for Caterpillar Built Power Modules with the ADEM 2 Electronic Control Module" for more information.
Glossary
Cat Datalink (CDL) - The Cat Datalink (CDL) is a serial communications system that is used for communication with other microprocessor based devices. The CDL is a proprietary data link that is used for Caterpillar equipment. The panel for the electronic monitoring system utilizes the CDL for communication. The CDL is also used for communication with ET.
Caterpillar Electronic Technician (ET) - Cat ET is a service tool that uses a software program in order to run on a personal computer (PC).
Electronic Control Module (ECM) - The ECM is the engine's control computer. The ECM provides power to the electronics. The ECM monitors data that is input from the engine's sensors. The ECM acts as a governor in order to control engine speed.
J1939 CAN Data Link - This data link is an SAE diagnostic communications data link that is used to communicate between the electronic engine and the instrument clusters.
Procedure
- Turn the keyswitch (24 VDC) to the OFF position. Disconnect all shore power that is supplied to the Power Module.
- Open the rear doors of the trailer. The appropriate fan drive pulley must be installed for the desired operation. Refer to the steps that follow.
- Open the left hand radiator door. Remove the radiator door from the radiator support frame. Remove the bolts from the right hand radiator motor access panel. Remove the access panel from the radiator support frame. This will allow access to the motor for the radiator fan and to the pulley shaft.
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| Illustration 1 | g02069797 |
(A) Reserve Radiator Pulley Mounting Location (B) Radiator Fan Drive Pulley and Pulley Shaft | |
- Loosen the two nuts for the belt tension in order to loosen the belts for removal from the currently installed pulley. Refer to the steps below.
Note: The 229-8528 Pulley (50 Hz) will be the larger in diameter pulley. The 293-4391 Pulley (60 Hz) will be the smaller diameter pulley.
- Remove the belts from the pulley on the motor.
- Remove the three bolts from the pulley on the motor.
- Use the three bolts to remove the pulley.
- To remove the pulley for pulleys with standard mounting, thread the bolts that were removed in Step 7 into the tapped holes in sheave hub. Tighten progressively until the bushing is free from sheave taper. Proceed to Step 7.c.
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Illustration 2 g02073773
Standard Mounting
- To remove the pulley for pulleys with reverse mounting, thread the bolts that were removed in Step 7 into the tapped holes in bushing flange. Tighten progressively until the bushing is free from sheave taper.
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Illustration 3 g02073774
Reverse Mounting
- Remove the assembly from the shaft.
- Install the removed pulley at the reserve radiator pulley mounting location that is shown in Illustration 1.
- Loosen the set screw for the shaft key.
- Remove the existing hub. Remove the paint from the contact surfaces on the stub shaft. Degrease the surfaces.
- Temporarily position the replacement pulley onto the stub shaft.
- Install the existing hub so that there will be a 3 mm (0.19 inch) protrusion of the stub shaft end beyond the surface of the hub.
- Tighten the set screw for the shaft key to 19 N·m (14 lb ft) in order to hold the hub position.
- Slide the hub onto the pulley. Install the capscrews. Progressively tighten the capscrews to 40 N·m (29.5 lb ft).
- Check alignment of drive pulley to driven pulley with a level. If the alignment is off ±1.5875 mm (0.0625 inch), then follow Step 7 through Step 14 in order to loosen and reinstall the drive pulleys.
- Install the belts.
- Adjust the belt tension using the tensioning rods.
- Install the left hand radiator swing door and the right hand radiator motor access panel. Check the radiator door "Open" warning switch for proper engagement.
- Close the rear doors.
- Turn the keyswitch (24 VDC) to the ON position. Connect all shore power that is supplied to the Power Module.
- Caterpillar Electronic Technician (Cat ET) must be used in order to communicate with the EMCP3. Connect the Cat ET communication cable to the EMCP3.3 communication port.
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Table 1 Flash Files Part Number Description 277-0457 Engine Ratings Electronic Software Gp (50 Hz) 277-0456 Engine Ratings Electronic Software Gp (60 HZ)
- Flash the ADEM with the desired flash file using the Cat Data Link and Cat ET. After the ADEM has been flashed, you must double check the Engine Overspeed Setting. Go to the "Service" tab and select "Monitoring System".
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| Illustration 4 | g02071316 |
ECM Monitoring System | |
- Search for the description "Engine Overspeed" and change the setting if it is not correct.
"Engine Overspeed"
- 50 Hz ... 18% over rated speed (1770 rpm)
- 60 Hz ... 18% over rated speed (2124 rpm)
- 50 Hz ... 18% over rated speed (1770 rpm)
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| Illustration 5 | g02071335 |
Check Engine Overspeed Setting | |
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| Illustration 6 | g02071337 |
Change the Trip Points for the Engine Overspeed. | |
- Query for the ECMs on the J1939 network.
Note: Occasionally, one of the ECMs may not show up the first time you connect. Continue to disconnect and reconnect to the J1939 until both the EMCP3.3 and the CDVR appear as available.
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| Illustration 7 | g02071433 |
Query for J1939 network. (C) Press this key in order to connect. (D) Press this key in order to disconnect. | |
- Click the plus sign next to "Digital Voltage Regulator" in order to see the "CDVR" submenus. Click on "Monitor". Change the setting "Voltage Regulator Power Input Frequency Configuration". This value should be equal to four times the generator frequency for PMG Generators. It should be equal to one times the generator frequency for Self-Excited Generator or AREP Generators.
Note: Unless the potential transformers and current transformers in the generator are changed, do not change the values.
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| Illustration 8 | g02071974 |
Voltage Regulator Power Input Frequency Configuration | |
- Click on the "Protection" submenu. Change the following list of parameters.
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Table 2 "Generator Rated Frequency" 50 Hz 60 Hz Show/hide tableTable 3 "Generator Rated Voltage" 50 Hz 400 V 60 Hz 480 V Show/hide tableTable 4 "Generator Rated Current" 50 Hz 400 V 1600 kW 2890 amp (0.8 PF) 60 Hz 480 V 1825 kW 2747 amp (0.8 PF)
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| Illustration 9 | g02071996 |
Protection Submenu | |
- Use Illustration 10 for the calculation of the generator rated current.
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| Illustration 10 | g02072034 |
- Click on the "Voltage Regulator Control Parameters" submenu of the CDVR and change the following parameters.
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Table 5 "Generator Nominal Output Voltage" 50 Hz 400 V 60 Hz 480 V Show/hide tableTable 6 "Voltage Regulator Corner Knee Frequency" 50 Hz 49.8 Hz 60 Hz 59.8 Hz Note: The voltage regulator corner knee frequency is equal to the desired frequency minus 0.2 Hz.
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| Illustration 11 | g02072114 |
Digital Voltage Regulator Control Parameters Submenu | |
- Click the plus sign next to "EMCP3.3" in order to see the "EMCP" submenu. Find the submenu for "Engine Speed Monitor". Change the following parameters.
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Table 7 "Engine Overspeed Setpoint" 50 Hz 1770 rpm 60 Hz 2124 rpm Show/hide tableTable 8 "Engine Underspeed Warning Event Threshold" 50 Hz 1290 rpm 60 Hz 1548 rpm Note: The speed for the Underspeed Warning is the speed below the rated speed that the "EMCP" will issue a warning to the operator. The setting for the Underspeed Warning should be 86% of the rated speed.
Show/hide tableTable 9 "Engine Underspeed Shutdown Event Threshold" 50 Hz 1230 rpm 60 Hz 1476 rpm Note: This is the speed that is below the rated speed that the "EMCP" will initiate a shutdown of the genset. The Engine Underspeed Shutdown should be 82% of the rated speed.
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| Illustration 12 | g02072137 |
EMCP3.3 Submenu | |
- Click on the "Generator AC Monitor" submenu. Change the following parameters.
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Table 10 "Generator Rated Frequency" 50 Hz 60 Hz Show/hide tableTable 11 "Generator Rated Voltage" 50 Hz 400 V 60 Hz 480 V Show/hide tableTable 12 "Generator Rated Power" 50 Hz 1600 kW 60 Hz 1825 kW Show/hide tableTable 13 "Generator Rated Apparent Power" 50 Hz 400 V 1600 kW 2000 kVA (0.8 PF) 60 Hz 480 V 1825 kW 2281 kVA (0.8 PF)
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| Illustration 13 | g02072153 |
Generator AC Monitor Submenu | |
- Refer to the formula in Illustration 14 in order to calculate the generator rated apparent power.
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| Illustration 14 | g01950118 |
- Click on the "AVR Desired Voltage Request" submenu.
Note: This menu is currently not available for "EMCP3.2" and "EMCP3.1".
Show/hide tableTable 14 "Generator Nominal Output Voltage" 50 Hz 400 V 60 Hz 480 V Show/hide tableTable 15 Parameter Changes Summary 50 Hz 60 Hz ADEM 3 Flash File Part Number 277-0457 277-0456 Engine Overspeed 1770 rpm 2124 rpm CDVR Monitor Voltage Regulator Power Input Frequency Configuration 200 Hz 240 Hz Protection Generator Rated Frequency 50 Hz 60 Hz Generator Rated Voltage 400 V 480 V Generator Rated Current 2890 amp 2747 amp Voltage Regulator Control Parameters Generator Nominal Output Voltage 400 V 480 V Voltage Regulator Corner Knee Frequency 49.8 Hz 59.8 Hz EMCP 3.3 Engine Speed Monitor Engine Overspeed Setpoint 1770 rpm 2124 rpm Underspeed Warning Event Threshold 1290 rpm 1548 rpm Underspeed Shutdown Event Threshold 1230 rpm 1476 rpm Generator AC Monitor Generator Rated Frequency 50 Hz 60 Hz Generator Rated Voltage 400 V 480 V Generator Rated Power 1600 kW 1825 kW Generator Rated Apparent Power 2000 kVA 2281 kVA AVR Desired Voltage Request Generator Nominal Output Voltage 400 V 480 V
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| Illustration 15 | g02072157 |
"EMCP3.3 AVR Desired Voltage Request" | |
- Reset any faults that are displayed on the EMCP3, ECM, or CDVR.
- Go to the switchgear. Go to the "System Setup" screen on "HM1". Select 400 V / 50 Hz for 50 Hz operation and 480 V / 60 Hz for 60 Hz operation. A light background and dark letters indicates that the feature is selected.
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| Illustration 16 | g02072233 |
(E) Shows 50 Hz Operation is not selected (F) Shows that 60 Hz Operation is selected | |
- Move the "Engine Control Switch" to the OFF position. Reset any faults.
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| Illustration 17 | g02072236 |
(G) ECS Switch in the OFF position (H) SYNC Switch in the OFF position | |
- Place the "Sync Switch" in the OFF position.
- Go to the EMCP3 panel on the genset. Place the EMCP control panel to "AUTO" operation mode. Go to the switchgear and Use the "ECS Switch" in order to start the unit in "MANUAL" mode. Check for desired voltage and frequency.
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| Illustration 18 | g02072353 |
(J) MANUAL Position "ECS Switch" | |
- If there are no faults or errors shown, the conversion procedure is complete. Otherwise refer to the steps in the conversion procedure in order to troubleshoot.