CAT + Caterpillar G399 Gas Engine Operation & Maintenance Manual by Heavy Equipment Manual

Product:GASENGINE

Model:G399GASENGINE49C

Configuration:G399ENGINE49C00261-UP

OperationandMaintenanceManual

MediaNumber-SEBU6150-02PublicationDate-21/06/1994DateUpdated-14/05/2012

Foreword

Thismanualcontainsoperationinstructionsandmaintenanceinformation.

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedone. Read-study-andkeepithandy.

Illustrationsguidetheoperatorthroughthecorrectproceduresofchecking,starting,operatingand stoppingtheenginedrivengenerator.

Themaintenancesectionisaguidetoequipmentcareandhasillustratedstep-by-stepinstructions.

Somephotographsinthispublicationmayshowdetailsorattachmentsthatmaybedifferentfrom yourequipment.Also,guardsandcoversmayhavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmayhavecausedchangestoyour enginedrivengeneratorwhichmaynotbecoveredinthispublication.

Wheneveraquestionarisesregardingyourenginedrivengeneratororthispublication,pleaseconsult yourCaterpillardealerforthelatestavailableinformation.

GeneratorIdentification

EveryCaterpillarGeneratorhasaserialnumberstampedonthenameplateandontheframe.The plateislocatedontheleftsideofthegenerator.Thenumberidentifiesthegeneratortype,capacity, andnominalvoltageofthegenerator.

OrderingParts

QualityCaterpillarreplacementpartsareavailablefromCaterpillardealersthroughouttheworld. Theirpartsstocksareuptodateandincludeallpartsnormallyrequiredtoprotectyourinvestmentin Caterpillarequipment.

Whenorderingparts,yourordershouldspecifythequantity,partnumber,partnameandserial number,arrangementnumberandmodificationnumberoftheequipmentforwhichthepartsare

needed.Ifindoubtaboutthepartnumber,pleaseprovideyourdealerwithacompletedescriptionof theneededitem.

WedJun1202:51:49UTC+05302024

Product:GASENGINE

Model:G399GASENGINE49C

Configuration:G399ENGINE49C00261-UP

OperationandMaintenanceManual

SR4GENERATORSANDCONTROLPANELS

MediaNumber-SEBU6150-02PublicationDate-21/06/1994DateUpdated-14/05/2012

Safety

WarningSignsandLabels

Thereareseveralspecificsafetysignsonyourgenerator.Theirexactlocationanddescriptionofthe hazardarereviewedinthissection.Pleasetakethetimetofamiliarizeyourselfwiththesesafetysigns.

Makesurethatyoucanreadallsafetysigns.Cleanandreplacetheseifyoucannotreadthewordsor seethepictures.Whencleaningthelabelsuseacloth,waterandsoap.Donotusesolvent,gasoline, etc.

Youmustreplacealabelifitisdamaged,missingorcannotberead.Ifalabelisonapartthatis replaced,makesureanewlabelisinstalledonthereplacedpart.SeeyourCaterpillardealerfornew labels.

Donotoperatethisequipmentunlessyouhavereadandunderstandthe instructionsintheOperationGuide.Improperoperationisdangerous andcouldresultininjuryordeath.ContactanyCaterpillardealerfora replacementguide.Properoperationisyourresponsibility.

Ifthisgeneratoristobeconnectedtoautilityelectricaldistribution system,itmustbeisolatedfromthedistributionsystembymeansof;

A.Openingthemainswitchinthecaseofaportablegenerator temporarilyconnectedtothesystemor,

This is the sample of the manual if you need complete manual Click Here to download

B.Adoublethrow(transfer)switchinthecaseofapermanent connectiontothesystem.

Failuretodosocouldresultinpersonalinjuryordeathduetoelectrical shock.

Theabovewarningdoesnotapplywhenageneratorandutility distributionsystemaredesignedandapprovedbytheutilitytorunin parallel.

Installation

AllelectricalequipmentsuppliedbyCaterpillarshouldbeinstalledinaccordancewiththe ApplicationandInstallationManual,formLEBX6213andconformtonationalandlocalelectrical codesoftheareaandcountywheretheequipmentisoperating.

General

Donotallowunauthorizedoruntrainedpersonnelonornearequipment.

Donotwearlooseclothingorjewelrywhileworkingaroundequipment.

Stoptheenginebeforemakingadjustmentsorrepairstotheengineorgeneratorunlessotherwise specified.

Attacha"DONOTOPERATE"tagonthestartswitch,startbutton,airstartknoband/orremote startingsystem,beforeservicingtheengineorgenerator.Thesetags,FormSEHS7332,areavailable fromyourCaterpillardealer.

Besuretheremotestartingsystemisinoperativeontheequipmentbeingserviced.

Disconnectandtapethebatterygroundleadorputtheautomaticstart-stopswitchtotheSTOP positionbeforeworkingontheequipmenttopreventaccidentalstarting.

Topreventinjury,installguardsoverallexposeddriveshafts,pulleysandanyapplicationwith exposedrotatingparts.

Alwaysusetoolsthatareingoodconditionandbesureyouunderstandhowtousethembefore performinganyservicework.Removealltools,electricalcordsandanyotherlooseitemsfromthe enginebeforestarting.

Enginespeeds,temperaturesandloadarethebestindicationsofperformance.Relyonyour instruments,recordandcomparereadingstodetectdevelopingabnormalities.

Wearahardhat,faceshield,clothing,shoes,respiratororotherprotectiveitemswhennecessary.

Whenusingpressureair,alwaysuseapprovedsafetyequipment.

Wearearprotectivedevicestopreventhearingdamage,ifworkinginsideanenclosedengineroom withenginerunning.

Climbing

Someenginesinpermanentinstallationsmayrequiretheuseofclimbingequipmenttoprovideaccess fornormalroutinemaintenance.Itistheresponsibilityoftheownerand/orusertoprovidesafeaccess whichconformstoSAEJ185and/orlocalbuildingcodes.

Keepallclimbingequipment,ladders,stairs,platformscleanandfreeofslipperysurfacesand trippinghazards.

Securetheclimbingequipmentsoitwillnotmoveorfallwhileinuse.

Neverjumpfromanelevatedplatform,ladder,orstairs.

Maintainallclimbingequipmentsoitisinsafeoperatingcondition.

FireorExplosionPrevention

Besuretheengineroomisproperlyventilated.

Keeptheengineroomandfloorareaclean.

ObserveNOSMOKINGsigns.Donotsmokearoundbatteries.Hydrogengasgeneratedbycharging batteriesisexplosive.Keepbatteriesinawellventilatedarea.

Neverstoreflammableliquidsneartheengine.

Storeoilyragsinmetalcoveredcontainers.

Alwayshaveafireextinguisheronhandandknowhowtouseit.Inspectandhaveitservicedas recommendedonitsinstructionplateorlabel.

Donotusecarbontetrachloridefireextinguishers.Fumesaretoxicandtheliquidhasadeteriorating effectoninsulation.

ElectricalShockPrevention

Allelectricalequipmentmustbegroundedaccordingtolocalbuildingcodes.

Alwaysdisconnecttheenginestartercircuitwhenworkingonthegenerator.

Besureallelectricalpowerisdisconnectedfromelectricalequipmentbeingserviced.

Donotworkonelectrically"hot"equipment.

Donottouchtheheatsinkonthegeneratorregulatorwhenthegeneratorisrunning.Itiselectrically "hot."

Checkallconnectionsperiodicallyfortightnessandinsulation.

Insulateallconnectionsanddisconnectedwires.

Keepallelectricalequipmentcleananddry.

BurnPrevention

Donottouchanypartofanoperatinggenerator.Allowthegeneratortocoolbeforeanyrepairsare performed.

PreparingtoStart

Besureallprotectiveguardsandcoversareinstalledifanenginemustbestartedtomakeadjustments orchecks.Tohelppreventanaccidentcausedbypartsinrotation,workcarefullyaroundthem.

Starting

Donotstarttheengineormoveanyofthecontrolsifthereisawarningtagattachedtothecontrols.

Makesurenooneisworkingon,orclosetotheengineorenginedrivencomponents,beforestarting it.

Startandoperatetheengineinawellventilatedarea.Ifitisnecessarytooperateinaclosedarea,vent theexhausttotheoutside.

Stopping

Stoptheengineaccordingtothe"StoppingTheEngine"instructionstoavoidoverheatingand acceleratedwearoftheenginecomponents.

OnlyusetheEmergencyStopbuttoninanemergencysituation.DoNotstarttheengineuntilthe problemnecessitatingtheemergencystophasbeenlocatedandcorrected.

Oninitialstartupandoverhaul,bepreparedtoSTOPtheengineshouldanoverspeedoccur.Thismay beaccomplishedbycuttingthefuelandairsupplytotheengine.

WedJun1202:52:19UTC+05302024

Product:GASENGINE

Model:G399GASENGINE49C

Configuration:G399ENGINE49C00261-UP

OperationandMaintenanceManual

SR4GENERATORSANDCONTROLPANELS

MediaNumber-SEBU6150-02PublicationDate-21/06/1994DateUpdated-14/05/2012

ReferenceLiterature

ThefollowingliteraturecanbeobtainedthroughanyCaterpillardealer.

OperationandMaintenanceManuals

SEBU6123,3114&3116Industrial,PrimePowerandStandbyGeneratorSetEngines

SEBU5851,3204IndustrialEngine

SEBU6367,3208Industrial&GeneratorSetEngines

SEBU6160,3208StandbyGeneratorSetEngine

SEBU5559,3304&3306MarineEngines

SEBU5779,3304,3306,3304B&3306BIndustrialEngines

SEBU6328,3304B&3306BIndustrialandGeneratorEngines

SEBU5791,3406&3406BIndustrialEngines

SEBU5415,3408&3412IndustrialEngines

SEBU6336,3406BStandbyGeneratorSetEngine

SEBU6767,3412EPGGenerator

SEBU5853,3508,3512&3516IndustrialEngines

SEBU6156,3508StandbyGeneratorSetEngine

SEBU5405,D346,D348&D349IndustrialEngines

SEBU5364,D353IndustrialEngine

SEBU5347,D353MarineEngine

SEBU5698,D379,D398&D399Industrial&GeneratorSetEngines

SEBU5561,D379B,D398B&D399BMarineEngines

SEBU6148,3406NaturalGasEngine

SEBU5560,G342CNaturalGasEngine

SEBU5678,G379,G398&G399NaturalGasEngines

SEBU6618,XQ125RentalGeneratorSet

SEBU6499,XQ225RentalGeneratorSet

SEBU6455,XQ350RentalGeneratorSet

Owner'sManuals

SEBU6369,3304B&3306BMarineEngines

SEBU5881,3406BMarineEngine

SEBU5454,3408MarineEngine

SEBU5547,3412MarineEngine

SEBU6100,3508,3512&3516MarineEngines

ServiceManualModules

TheModulesthatfollowareincludedintheServiceManualSENR7958.

SENR5809,ElectronicModularControlPanelII

SENR4027,SR4ControlPanel(4W-8000)

SENR3906,VR4VoltageRegulator

SENR3903,SR4controlPanel(9Y-1400)

SENR3535,SR4ElectronicModularControlPanel

ServiceManuals

SENR7958,SR4ElectricSetGenerator

SENR6480,3412GeneratorSetEngine

SENR6430,524/1724,8290GovernorSystem

SENR4676,2301ASpeedGovernor

SENR3880,3508,3512,&3516GeneratorSetEngines

SENR3585,2301ALoadSharingGovernor

NOTE:SpecificGeneratorSetServiceManuals(except3300SeriesEngines)willincludethe necessaryserviceinformationforthegeneratorandcontrolpanel.For3300SeriesEngines,order ServiceManualSENR7968.

SpecialInstructions

SEHS9124,CleaningandDryingofElectricSetGenerators,includedintheServiceManual SENR7958

Additionalliteraturemaybecomeavailableandmaynotbeincludedabove.ContactyourCaterpillar dealertochecktheavailability,formnumber,andpriceofallliteraturebeforeplacingorders.

WedJun1202:58:02UTC+05302024

Product:GASENGINE

Model:G399GASENGINE49C

Configuration:G399ENGINE49C00261-UP

OperationandMaintenanceManual SR4GENERATORSANDCONTROLPANELS

MediaNumber-SEBU6150-02PublicationDate-21/06/1994DateUpdated-14/05/2012

GeneralInformation

TheSR4BrushlessGeneratorissuitableforapplicationtoallkindsofloads,including,butnot limitedto:mixedloadsofmotorsandlights,SCR-controlledequipment,computercenters, communicationinstallations,andpetroleumdrillingapplications.Theeliminationofbrushesinthe fieldcircuitreducesmaintenance,improvesreliabilityandprovidesahigherdegreeofprotectionin potentiallyhazardousatmospheres.

Thegeneratorsetpackagescanbeutilizedforprimeorstand-bypowergeneration,inlandbasedor marineapplications.

SR4generatorsareutilizedinsinglephase,halfwaveexcitationandregulation,andthreephase,full waveexcitationandregulation.Thegeneratorsareeitherfourpoleorsixpoledesignwithfour,six, tenortwelveleadconfigurationdependingonframesize.Theyarecapableofproducingelectrical powerineither50Hzor60Hzapplications.

GeneratorIdentification

Thegeneratoridentificationandinformationplateislocatedontheleftsideofthegenerator.

Whenserviceisrequired,usetheinformationgivenontheseplates.Theinformationcontainsthe serialnumber,modelnumberandthegeneratorset(engineandgenerator)rating.Allpertinent generatordataisalsoincludedontheplatetoprovidethenecessaryinformationtoorderparts.

and

OutputLeadWiring

Allgeneratorleadwiringinformationcanbefoundontheinformationplate,oronadecalonthe powerleadsideofthegeneratorfortwelveleadgeneratorsets.Ifthegeneratorisequippedwitha circuitbreaker,thedecalwillbemountedonthesheetmetalofthecircuitbreakerpanel.

WedJun1202:53:01UTC+05302024

Product:GASENGINE

Model:G399GASENGINE49C

Configuration:G399ENGINE49C00261-UP

OperationandMaintenanceManual

MediaNumber-SEBU6150-02PublicationDate-21/06/1994DateUpdated-14/05/2012

GeneratorExcitationSystems

PermanentMagnetExcitedGenerators

Permanentmagnetpilotexcited(PMPE)generatorsreceivepowerforthevoltageregulatorfroma pilotexciter,ratherthanthemainarmatureasinself-excitedgenerators.Thepilotexciterconsistsof permanentmagnet(PM)andPMarmature.Thepilotexciteroperatesindependentlyfromthe generatoroutputvoltage.Constantexcitationduringlargeloadapplicationispossible,becausethe irregularitiesthatoccuringeneratoroutputvoltage(causedbyloadconditions)arenotfedbackinto theexciter.Theindependentoperationalsoallowsthegeneratortobettersustainanoverloadfora shortduration.

Self-ExcitedGenerators

Self-Excitedgeneratorsreceivepowerforexcitationandvoltagesensingfortheregulatorfromthe mainarmature(stator)outputofthegenerator.Thevoltageregulatorsensesthegeneratoroutput voltageandprovidesregulatedoutputtothegeneratorexciter.Theexciterthenprovidespowertothe mainrotatingfield(rotor).Asthemainfieldrotates,avoltageisinducedintothemainarmature (stator)tocausesageneratoroutput.

WedJun1202:54:04UTC+05302024

Product:GASENGINE

Model:G399GASENGINE49C

Configuration:G399ENGINE49C00261-UP

OperationandMaintenanceManual SR4GENERATORSANDCONTROLPANELS

MediaNumber-SEBU6150-02PublicationDate-21/06/1994DateUpdated-14/05/2012

GeneratorLeadConnections

LeadNumbering

Eachcoilleadismarkedaccordingtothefollowingdiagrams.Thediagramscontainedshowthefour, six,ten,andtwelveleadconfigurationsavailableinpresentdaySR4generators.

Thestandardgeneratordiagramandtheterminalconnectionsareonthenameplateofeachgenerator. Numberingisclockwisefromthetopandfromtheoutsideinward.

6LeadWyeConfiguration

TerminalT4,T5andT6becometheneutralconnectionwhentiedtogetherinthe6LeadWye Configuration.

10LeadWyeConfiguration

TerminalT0istheneutralleadforthe4leadand10leadgenerators.

12LeadWyeConfiguration

TerminalsT10,T11,andT12becometheneutralconnectionwhentiedtogetherinthe12LeadWye Configuration.

12LeadDeltaConfiguration

Inthe12LeadDeltaConfigurationTerminalsT6andT9becometheneutralconnectionwhentied togetherandgrounded,reflectingtheTerminalT2,T10connectionasthehighphase.

GroundingtheFrame

Inanygeneratorsetinstallation,theframeofthegeneratormustbepositivelyconnectedtoanearth groundortothehullofavessel.Thisconnectionisthefirstonemadeatinstallation,andthelastone toberemoved.Ifthegeneratorsetisonflexibleorresilientpads,thegroundconnectionmustbe flexibletoavoidpossiblebreakageinlateroperation.

Groundconnectioncableorstrapsshouldhaveatleastthecurrentcarryingcapacityofthelargestline leadtotheconnectedload.Jointsincablesorstrapsmustbeclean,freeofelectricalresistance,and

protectedfrompossibleoxidation.Boltedgroundconnectionjointseventuallyoxidize,andare frequentsourcesofradiofrequencyinterference.Silversoldered,boltedjointsareelectricallyand mechanicallysound.

NeutralConnections

"Y"-connectedgeneratorsusuallyhavetheneutralgroundedwhenthegeneratorisinstalledunless definitemeasuresaretakentopreventgroundsontheloadside.Thegroundingoftheneutralisto preventloadsideequipmentdamage.

Iftheneutralwireisgroundedandoneofthephaseleadsbecomesgrounded,theexcessivecurrent willopenaloadcircuitbreakerorcollapsethegeneratorvoltage.Theresultdependsontheparticular generatorelectricalcharacteristics,typeoffault,andcircuitbreakertriprating.Anundervoltage devicemayberequiredtoprovideadequateshortcircuitprotection.

Therearesomeinstancesinwhichitisundesirabletogroundtheneutralwire.Intheseapplications wheredefinitemeasures(groundfaultprotectivecircuits)havebeentakentopreventgroundstothe phaseleads,anungroundedgeneratorneutralleadisacceptable.

Groundfaultprotectionrequiresthattheentiregroupofdistributioncircuitsbestudiedandtreatedas asystem.Theownershouldengageacertifiedandregisteredconsultantifanewdistributionsystem isbeingdeveloped,orifanexistingsystemistobemodifiedforgroundfaultprotection.

SingleUnits

FourWire:Inathreephase,fourwiresystem,theneutralwireshouldbegroundedaccordingtolocal wiringcodes.

Inapplicationswheredefinitemeasuresaretakentopreventgroundstotheloadleads,anungrounded neutralcanbeused.Besuretocheckyourlocalwiringcodes.

MultipleUnits

Operationofmultiplegeneratorsinparallel,havingallneutralsgrounded,mayresultincurrent circulatingthroughtheneutralconnections.Toeliminatethepossibilityofcirculatingcurrents, groundtheneutralofonlyonegenerator.Ifmultiplegeneratorsarealternatedonline,aswitchshould beinstalledintheneutralgroundcircuitofeachgenerator,soallbutoneneutralgroundcircuitcanbe opened.Besureoneneutralgroundcircuitisclosed.

ParalleltoUtility

WhenaWyeconnectedgeneratoristooperateinparallelwithautilitysystem(infinitebus),andthe secondaryoftheutilitysystemstep-downtransformerisalsoaWyeconnection,groundingofboth Wyeneutralsmayresultincirculatingcurrentsthroughtheneutrals.Plus,thecoordinationofa groundfaultprotectionrequiresanentiresystemstudy.Thisstudyshouldbedonebyacertifiedand registeredconsultantfamiliarwithgeneratorsystemstodeterminethegroundingmethodtobeused.

WedJun1202:53:12UTC+05302024

Product:GASENGINE

Model:G399GASENGINE49C

Configuration:G399ENGINE49C00261-UP

OperationandMaintenanceManual

MediaNumber-SEBU6150-02PublicationDate-21/06/1994DateUpdated-14/05/2012

GeneratorPerformance&Options

GeneratorLoading

Whenageneratorisinstalledorreconnected,besurethetotalcurrentinonephasedoesnotexceed thenameplaterating.Eachphaseshouldcarrythesameload,allowingtheenginetoworkatitsrated capacity.Anelectricalunbalancecanresultinanelectricaloverloadandoverheatingifonephase exceedsthenameplateamperage.

Whenoperatingwithsignificantsinglephaseloads,thethreephase/singlephaseloadcombinations mustliebelowthelineonthegraph.

BlockLoading

Blockloadingistheinstantaneousapplicationofanelectricalloadtoageneratorset.Thisloadmay beanywherefromamoderatepercentageoftheratedloaduptotheratedload.

Theblockloadingcapabilityofageneratorsetdependsuponenginetransientresponse,voltage regulatorresponseandtype,altitudeofoperation,typeofload,andtheamountofloadatthetimethe blockloadisapplied.

Ifblockloadderatingisrequired,referto(InternationalStandardsOrganization)ISO3046orSAE J1349Standards.AlsoreferenceEngineDataSheets,BlockLoadingTransientResponseLEKX4066 andTransientResponseLEKX4067.

PowerFactor

Powerfactormaybethoughtofastheefficiencyoftheload-theratioofapparentpowertototal power.Powerfactorisexpressedasadecimalanddenotesthatportionofcurrentsuppliedtoasystem doingusefulwork.Theportionofcurrentnotdoingusefulworkisabsorbedinmaintainingthe magneticfieldinmotors.Thiscurrent,althoughitiscalledthereactiveload,doesnotrequireengine powertomaintainit.

Inmostapplicationselectricmotorsandtransformersdeterminethepowerfactorofthesystem. Inductionmotorsusuallyhavea0.8orsmallerpowerfactor.Incandescentlightingisaresistiveload ofabout1.0powerfactor,orunity.

Thepowerfactorofasystemmaybedeterminedbyapowerfactormeterorbycalculations. DeterminethepowerrequirementinkWbymultiplyingthepowerfactorbytheKVAsuppliedtothe system.Asthepowerfactorgoesup,thetotalcurrentsuppliedtoaconstantpowerdemandwillgo down.A100kWloadata0.8powerfactorwilldrawmorecurrentthana100kWloadat0.9power factor.Highpowerfactorwillresultinfullengineloadatlessthangeneratorratedamperage.Alower powerfactorincreasesthepossibilityofoverloadingthegenerator.

NOTE:CaterpillarGeneratorsaredesignedfora0.8powerfactorunlessotherwisespecified.

LowIdleAdjustment

Electricsetsnormallyhaveahigherlowidlesettingthandoindustrialengines.Lowidlewillbe approximately2/3thefullloadspeedof60Hzunits(4/5fullloadspeedof50Hzunits).

OnelectricsetswithsomeWoodwardgovernors,thereisnolowidlestop.Onelectricsetswith mechanicalgovernorsandnaturalgaselectricsets,thelowidleissetatthefactory,andshouldonly beadjustedbyyourCaterpillardealerifadjustmentisrequired.

NOTE:Operatingtheelectricsetatlowidlespeedforanextendedtimewillcausesomevoltage regulatorstoshutoff.Theelectricsetmustbecompletelyshutdown,andrestartedtoallowthe voltageregulatortoagainproduceanoutput.

OilfieldGenerator

ForSCRControlledElectricRigs

OilfieldgeneratorsarenowavailableforusewithSCRcontrolledelectricoilrigs,thatdonotusea voltageregulator.Thefunctionofthegeneratorcontrolisperformedbythedrillingelectricalcontrol system.

Consultthedrillrigbuilderonquestionspertainingtogeneratorcontrol(voltageregulation, paralleling,loadsharing,etc.).

GeneratorOptions

SpaceHeaters

SR4generatorsareavailablewithspaceheatersinstalledforoperationinhighhumidityconditions. Formoreinformationonspaceheaters,refertothetopic"GeneratorMaintenance"inthismanual.

EmbeddedTemperatureDetectors

SR4generatorsareavailablewithembeddedtemperaturedetectors.Thedetectorsareinstalledinthe slotsofthemainarmature(stator).Thedetectorsareused,withcustomerprovidedequipment,to measureand/ormonitorthemainarmaturewindingtemperature.Threetypesoftemperaturedetectors areavailable.ContactyourCaterpillardealerformoreinformation.

BearingTemperatureDetectors

BearingtemperaturedetectorsareavailableforlargeframeSR4generators.Bearingtemperature detectorsmeasureand/ormonitormainbearingtemperature.Bearingtemperaturemeasurementsmay helptopreventprematurebearingfailure.Twotypesoftemperaturedetectorsareavailable.Contact yourCaterpillardealerformoreinformation.

WedJun1202:53:36UTC+05302024

Product:GASENGINE

Model:G399GASENGINE49C

Configuration:G399ENGINE49C00261-UP

OperationandMaintenanceManual SR4GENERATORSANDCONTROLPANELS

MediaNumber-SEBU6150-02PublicationDate-21/06/1994DateUpdated-14/05/2012

GeneratorSetControlPanel(103-1582&107-6307If Equipped)

ControlPanel,EMCPII

ThegeneratorsetElectronicModularControlPanelII(EMCPII)islocatedontopofthegenerator regulatorhousing.Thecontrolpanelconsistsofamainpanelwithindicators,metersandcontrol switches.Thiscontrolpanelmaybeequippedwithoptionalmodulestomatchthecustomersneeds andrequirements.Therightsidemaybeblank,orcontainoneofthealarmmodules,ora synchronizinglightsmodule.

TheleftsideofthecontrolpanelcontainstheGeneratorSetControl(GSC).Thisisthe"main" componentofthesystemandalsodisplaysgeneratoroutput,faultconditionsandkeyengine parameters.

MainControlPanel

Themaincontrolpanelmayormaynotcontainallofthecomponentsshownbelow.Some componentsareoptional,andmaynotberequiredforyourparticularapplication.

(1)PL;panellights(optional).

(2)GS;governorswitchorSP;speedpotentiometer(optional)(GSshown).

(3)SAS;startingaidswitch(optional).

(4)ECS;enginecontrolswitch.

(5)ALM;alarmmoduleorSLM;synchronizinglightsmodule(optional)(ALMshown).

(6)VAR;voltageadjustrheostat.

(7)ESPB;emergencystoppushbutton.

(8)GSC;generatorsetcontrol.

(9)PLS;panellightswitch(optional).

*Panellights(PL)(1)arecontrolledbypanellightsswitch(PLS)(9).

*Voltageadjustrheostat(VAR)(6),isusedtoadjustthegeneratoroutputvoltagetothedesired level.

*Optionalgovernorswitch(GS)orspeedpotentiometer(SP)(2)isusedtoraiseorlowerthe enginespeedwhenthegovernorisequippedwithaspeedadjustmotor.Iftheengineis equippedwithanelectricgovernor,aspeedpotentiometerismountedinthislocation.

*Startingaidswitch(SAS)(3)isusedtoinjectetherintotheengineforstartingincoldweather conditions.Thisswitch(whenmovedtotheONposition)energizesandmetersaspecific amountofetherinaholdingchamber.Whentheswitchisreleased,thesolenoidreleasesthe ethertotheengine.

*Emergencystoppushbutton(ESPB)(7)isusedtoshutdowntheengineduringanemergency situationbyshuttingoffthefuelandactivatingtheoptionalairshutoff(ifequipped).

*Enginecontrolswitch(ECS)(4),determinesthestatusofthecontrolpanel.IntheAutomatic position(3o'clock),theenginewillstartautomaticallywhenevertheremoteinitiatingcontactis closed.Theenginewillshutdownaftertheinitiatingcontactopensandadjustablecooldown timeelapsed.Thecooldowntimecanbeprogrammedtogivea0to30minutecooldownperiod beforetheengineshutsdown.

IntheManualRunposition(6o'clock),theenginewillstartandrunaslongastheECSswitch remainsinthisposition.

IntheStopposition(9o'clock),thefuelsolenoidshutstheenginedown,afteraprogrammablecool downtimeperiod.

IntheOff/Resetposition(12o'clock),thefaultlightsareresetandtheengineshutsdown immediately.

GeneratorSetControl(GSC)

TheleftsideofthecontrolpanelcontainstheGeneratorSetControl(GSC).Thisisthe"main" componentofthesystem,andalsodisplaysgeneratoroutput,generatorsetfunctions,faultconditions andkeyengineparameters.

TheGSCacceptsinformationfromtheoperator,magneticpickup,oilpressureandwatertemperature sensors,andoptionalremotesources.Thisinformationisusedtodeterminethe"on/off"stateofthe engine'sair,fuel,andstarter.

Intheverybasicoperatingconditions,theGSCreceivesasignaltorunthegeneratorset.TheGSC turnsontheengine'sfuelandstarter.Whentheenginespeedreachesthecrankterminationspeed,the starterisdisengaged.WhentheGSCreceivesasignaltostoptheengine,itshutsthefueloff.

*Controlsnormalstartingandstoppingoftheengine.

*Showsengineconditionsandgeneratoroutputinformationontwodisplays.Thedisplaysalso showfaultcodesandGSCprogramminginformation.

*Monitorsthesystemforfaults.Ifafaultoccurs,theGSCperformsacontrolledfault shutdownorprovidesafaultalarmannunciation.TheGSCusesindicatorsanddisplaysto describethefault.

*Containsprogrammablefeaturesforcertainapplicationsorcustomerrequirements.

*CycleCrank-TheGSCcanbeprogrammedtocrank-restcranketc.foradjustabletime periods.RefertotheServiceManualModuleSENR5809forprogramminginstructions.

*2301or2301AControl-Whentheengineoilpressureincreasespastthelowoilpressureset point,theGSCwillindicatetothegovernorthatitshouldincreaseenginespeedfromIDLEto RATEDrpm.

*CoolDown-Uponreceivingasignaltoperformanormalshutdown,theGSCwillwaita preprogrammedamountoftimebeforeshuttingtheenginedownbymeansofthefuelcontrol.

*AutomaticOperation-Whileintheautomaticmode,theGSCcanbestartedbyaremote initiatesignal(contactclosure).Uponlossofthesignal(contactopening),theGSCwill performanormalshutdown.

*AlarmModuleCommunication-TheGSCcantransmitfaultandalarmconditionstoan alarmmodule.

*PowerDown-TheElectronicModularControlPanelII(EMCPII)systemisdesignedto removepowerfromtheGSCwhenintheoff/resetmodeandtheproperjumperwireis removed.TheGSCwillnotallowthepowerdownuntilthecrankterminationrelayandthefuel controlrelayareboth"off"forabout70seconds.Ifthewireisnotremoved,theGSCwill remainpoweredup.

RefertotheServiceManualModuleSENR5809forthewiringdiagramandjumperwirelocation.

*FuelSolenoidType-TheGSCcanbeprogrammedtoworkwitheitheranenergizedtorun(ETR) fuelsystemoranenergizedtoshutdown(ETS)fuelsystem.

FaultIndicators

Theeightfaultindicators,locatedonthefrontoftheGSC,areusedtoshowanddescribeafaultthat ispresent.

*TheyellowfaultalarmindicatorFLASHESwhentheGSCdetectsafaultthatisanalarm condition.Theenginecontinuestorunandstart.Thefaultalarmindicatorisaccompaniedbyan alarmfaultcodethatisshownonupperdisplaywhenalarmcodeskeyispressed.Referto SENR5809forfaultcodedescriptions.

*TheredfaultshutdownindicatorFLASHESwhentheGSCdetectsafaultthatisashutdown condition.Theengineisshutdownifitisrunningandisnotallowedtostart.Thefault

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