RENR7941

CÑERPItlAR' December2003

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Gaterpillar Digital Voltage Regulator

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 ¡01658146

lmportantSafetyInformation
Most accidentsthat involveproductoperation,maintenanceand repairare caused by failureto
observebasic safetyrulesor precautions.
An accidentcan oftenbe avoidedby recognizingpotentially
hazardoussituationsbeforean accidentoccurs.A personmust be alertto potentialhazards.This
personshouldalso havethe necessarytraining,skillsand toolsto performthesefunctionsproperly.
lmproper operation, lubrication, maintenance or repair of this product can be dangerous and
could result In injury or death.
Do not operate or perform any lubrlcatlon, malntenanceor repalr on thls product, untll you have
read and understood the operatlon, lubrlcatlon, malntenanceand repalr informatlon.
Safetyprecautionsand warningsare providedin this manualand on the product.lf these hazard
warningsare not heeded,bodilyinjuryor deathcould occur to you or to other persons.
The hazardsare identifiedby the "SafetyAlert Symbol"and followedby a "SignalWord" such as
'DANGER",'WARNING"or "CAUTION".The SafetyAlert "WARNING" label is shownbelow.

The meaningof this safetyalert symbolis as follows:

Attentlon! Become Alert! Your Safety Is Involved.
The messagethat appearsunder the warningexplainsthe hazardand can be eitherwrittenor
pictoriallypresented.
Operationsthat may cause productdamageare identifiedby "NOTICE"labelson the productand in
this publication.
Caterpillar cannot ant¡cipateevery posslble circumstance that might involve a potential hazard.The
warnings In thls publlcation and on the product are, therefore, not all Inclusive. lf a tool, procedure,
work method or,operating technique that ls not speclfically recommended by Caterpillar ls used,
you must satisff yourself that it is safe for you and for others. You should also ensure that the
product wlll not be damaged or be made unsafe by the operation, lubrication, malntenance or
repalr procedures that you choose. ')
The information,specifications, in this publicationare on the basis of informationthat
and illustrations
was availableat the time that the publicationwas written.The specifications, torques,pressures,
measurements, adjustments,illustrations,and otheritemscan changeat any time.Thesechangescan
affectthe servicethat is given to the product.Obtainthe completeand mostcurrentinformationbefore
you start any job. Caterpillardealershavethe most currentinformationavailable.

When replacementparts are required for this

productCaterpillarrecommendsusing Caterpil-
lar replacementparts or pans wfth equlvalent
specificationsincluding,but not limitedto, phys-
lcal dimenslons,type,strengthand materlal.
Faitureto heedthis warningcan leadto prema-
ture failures,productdamage,personalinjury or
death.

¡t ,
¡

- )
 3
Tableof Contents

Tableof Contents
SpecificationsSection
Electrical 4
.........................
Dimensions Z
.....................

SystemsOperation$ct¡on
Generallnformation ........I
StartupProfileFunction 10
....................
Loadingand StoppingProfite
VoltageRegulation ........12
LineLossCompensation ......................................
12
Fleactive
VoltageDroop......... ...........13
CrossCurrentCompensation 13
...............................
KVARRegulation ........... 14
...................
PowerFactorRegulation 15
...................
Parameters 16
...................
RemoteCommunication .............. ..... 16

Testingand AdjustingSection
Testing and Adjusting
Generallnformation ......19
SeMceTools.......... ......19
StartupProcedure ........19
ParameterViewingdrd ConfiguringProcedure.... 20
Tioubleshooting.............. ..................
lg
No Voltage- Troubleshoot .....................................'{g
LowVoltage- Troubleshoot ...................................
45
HighVoltage- Troub|eshoot ..........,,....
..................
46
UnstableVoltage- Troubleshoot ................
...........4T
PoorVoltageRegulation- Troubleshoot ................
48
No LíneLossCompensation - Tioubleshoot .........49
No VoltageDroop- Troubleshoot
WiringDiagrams ...........51

IndexSection
Index.......... ....;............................
57

I
^
SpecificationsSection

SpecificationsSection
i 01915719

Electrical
SMCS Code:4467
Table 1

Regulatortemperaturedrift Lessthan x|lIo Íor any 40 "C (72 "F) changeoverthe ambientoperating
lemperaturerange.
ConfigurableVoltVHzcharacteristic Twosfope.rang..es adjustablefrom 1 to ,tOyft1'z.See the Regulation
Characteristiclllustration.
Regulatorresponset¡me Maximumof 10 milliseconds.
Begulatorsensing
lrug ltvts 3-phasesensingis standard.
singrephasesensingis available.
Variable senserange:90 to 600volts.
Regulatorstability Th.eregulatorrespondsto the fundamentalcomponentof the sensed
voltageand remainsstablefor total harmonicdistortionof the generator
outputvoltagewaveform,up to 20/".
Telephoneinfluencefac-tor(TlF) Lessthan 50. complieswith MIL sTD 461c part 9 and vDE 0875 reverN.
Fine voltageadjustrange t 10%of regulatorsensingvoltage.
Regulatorvoltagegaid ltine loss compensat¡on) Adjustablefrom 0 to 10olo.
Faultdetectionand identification Diagho-sticsidentifyoperationoutsideof programmedlimits.Specific
fault informationis availableevenatterttré uñ¡thas been poweieooown.
CANBUSonly
Harmonictolerance The dlgitalvoltage-regulator maintainsprecisecontrolof the generator
outputwith up lo 20% harmonicdistortionin the generatoroulputvoltage.
Reactivedroopadjustment Adjustablefrom 0 to 10%.
Overexcitationprotection Shutsoff generatoroutputwhen excitationcurrentexceedsnormal
operatingcurrentsfor 10 secondsor instantaneous
shutoffif outputcurrent
exceedsapproximatly28 Amperes.
Ambientoperatingtemperature -40 "C (-40 "F) to +70'C (+ 1SS"F).
Storagetemperaturerange \ -40'C (-40'F) to +85 "C (+ 1BS.F).
Powerdissipat¡on 5 watts at ¡dle,55 watts at rated output.
Shock Withstandsup to 20 g's in three mutuallyperpend¡cularplanes.
Vibration Withstands4.5 g's at frequenciesbeiween1g and 2000 Hz in three
mutuallyperpendicularplanes. ,
Salt fog 5% saltsprayfor 48 hoursat 39'C (100.4"F) at11}o/oof the nominal
operatingvoltage
Weight 1.47kg (3.24tbl.
Electromagnetic
compatibility Meets89/336/EECElectromagnetic Compat¡bility
Directive.
Powersupply 24 r 6 volt DC powersupplyrequired(0.5 amp),
(continued)
 5
Specifications
Section
:

per Standard508, UL FileNo. E97035

UL Recognized
CertifiedperStandardCANICSA-C22.2
No.14-95,CSADileNo.LR 23131
Conformsto the followingstandards:RadiatedEmissionsEN50081-2,
Radiatedlmmunity(electricfield)EN61000-4-3 (10 v/m), Radiated
lmmunity(conducted) EN61000-4-0 (10 VRMS),ConductedEmissions
EN50081-2(EN55011, ClassA), ESDlmmunityEN50082-2(4 KV contact,
8 KV air),EFT lmmunityEN50082-2(2 KV couplingclamp),Magnetic
lmmunityEN50082-2(30ARMS,50 Hz),SafetyEN61010-1

PoINT(20To 40 Hz)
UNDERFREOUENCY
GENERATOR OUTPUTVOLTAGE

U
ú7s
F
J
DECREASINGSLOPE 2
(0 To 10 V/Hz)
J

z .-------!r---l-------- MtNtMUMVOLTAGESETPO|NT(50 - 100 %)

=50
z
L

be 5 HZ {FTXED)

KNEEFREOUENCY
I

% OF NOM INAL FREQUENC Y

901040043
 Summaryof OperatingParameters
Parameter Specifications
120 to 15000Volts
VoltageRegulation
Rating
GeneratorTYPe PM
SE
AREP

Powerlnput Voltage Frequency Burden(Gontinuous)

80 to 264 Volts(36) 50 to 400 Hz 1150VA or 1900VA
100to 280 Volts(1@)
OumutRating MaximumContinuous Marimumn Forcing (10 Seconds)
Voltage Gurrent Voltage Current
63 0r 125 Volts 12or 10Amperes 125or 250Volts | 25 or 20 Amperes
Sensing Voltage Maximum VA Burden per g
90 to 600 Volts 1V A

Reative DrooP Maximum Current Maximum VA Burden

5 Amperes 1V A
Exciter Field Minimum Resistance MaximumResistance
Resi€tance
3 Ohms 39 Ohms
 7
SpecificationsSection

i01915854

Dimensions
SMCS Code:4467

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lllustrat¡on2 901040044
Dimensionsof the DigitalVohageRegulator
(A) 276.4mm (10.88¡nch) (D) 162.1mm (6.38¡nch) (G)15.0mm(0.59inch)
4{B) 190.5mm (7.50 inch) {El72.9 mm (2.87ínch) (H)4.06mm(0.16inch)
(C) 139.7mm (5.50inch) (n71,4 mm (2.81inch)
SystemsOPerationSection
i01917398

lnformation
General
SilCS Code: 4402

s010408
(3) 'Pl 2' Connector (5) 14" Connector
(4) "P9'Connector

r DigitalVoltageRegulatoris a Connector"P6"is a six-pinheaderthat mateswith

based voltageregulator.The main a six-pinconnector.Connector"P9"is a nine-pin
of a digitalvoltageregulatoris to regulate headerthat mateswith a nine-pinconnector.
voltageof a genEator that is used Connector"P12"is a Wvelve-pinheaderthat mates
¡tnegeneratorset. Controlpowerfor with a twelve-oinconnector.
VoltageRegulatoris suppliedfrom an
DCVsource.The power stageof the The regulatorhas a nine-pinD-subconnectorthat
Regulatorcan be suppliedfrom is labeled"J4".This connectoris used for interface
e. highfrequency, permanentmagnet with IBM-compatible personalcomputers.
(PMG), fromthe generatoroutput(shunt
ü,or from auxiliarywindingsthat are Note:The CaterpillarDigitalVoltageRegulator
Qnsomegenerators,Connectionsto the shouldbe hard-wiredto earthgroundwith at leasta
Regulator are madethroughthree 16 AWGcopperwire that is attachedto the ground
type connectors.The communication terminal"P6-6".
talVoltageRegulator and a service
usinga CANBUSprotocol. Note:Whenthe unitis configuredin a systemwith
otherdevices,a separatelead shouldbe used to
Voltage
Regulator_ hasthreemultiple-pin, groundthe bus fromeach device.
onnectors.
Thesebonnectors arelabeled
.and"P12",See illustration
3.
1
:l
 9
SystemsOperationSection

the digital voltage regulatoris Connector'P9"

remotelyfrom the generator,special
be given during installation
to ensure
proceduresare followedto
electromagnetic noisefrom reducingthe
of the regulatoror other system

mountingthe regulatorremotely,the
wires,PMGwires,and exciterfield wires
r be routedin theirownseparatetray
Theoptionalcustomer wiríngshould
from all othersignalsin a control
luit. The voltagesensingwiresshould
together.Exciterfield wiresshouldalso
together.
lllustration5 901013761
Pinoutfor the "pg'Connector

Table4
P9 Terminal Functions
Terminal Funct¡on
P9-1 GANbus- High
P9-2 CANbus- Low
P9-3 CANbus- Drain(Shietd)
P9-4 ContactSense - Lower
P9-5 ContactSense- Ra¡se
P9-6 ContactSense- Common
P9-7 ContractSense- ExcitationDisable
P9-8 ContactSense - FaultResel
lllustraüon
4 9 0 1013614 P9-9 ContactSense- Var/pF Enablé
,Pinoutbr the "p6' Connector

Table3 Connector"P12',
P6 Terminal Funct¡ons
Termlnal Function
P6-1 PowerInput
< I
P6.2 PowerInput
P6-3 PowerInput
PS4. F-
P&5 F+
P6-6 ChassisGround

lllustration6 901013628
Pinoutfor the'Pl2o Connector
 o Knee Frequency
Pl2 Terminal Funct¡ons
o Underfrequency
Point
fem¡nal Funct¡on
B-phasegenefatorcurrentsensing(CT1)
The digitalvoltageregutatorwiil begin to buíld
P12-1 voltagefollowing a volts per hertz profile after
P12-2 generator
B-phase (CT2)
currentsens¡ng the configurableunderfrequency point has been
*10 DCV Input(B),-
reached.When the speed reachesthe knee
P12-3 frequencypoint,the loading/stopping-profile takes
P124 AlarmOutputDriver effect.The startupprofilefunctibirwill'not be
FaultShutdownDriver
in¡tiatedagainunlessthe frequencydrops belowthe
P12-5 underfrequency point.The underfrequency point is
P12-6 t10 DCV lnput(A),+ defaultedto 25 Hz, with a rangeof 2ó to 4ó Hz. This
18to 30 V ControlPowerInput(B-) ís the same underfrequency setpointused by the
P12-7 loading/stopping setpoint.The kneefrequeniy point
P12-8 18to 30 V GontrolPowerInput(B+) is the pointat whichthe digitalvottageégutatorwitl
DriverSupply(50)
regulateto the voltagespecifiedby the generator
?12-9 output voltage parameter.
P12-14 GeneratorVoltageSensing- C
P12-11 GeneratorVoltageSensing- B
P12-12 GeneratorVoltageSensing- A

TheCaterpillarDigitalVoltageRegulatorhas the
followingfeatures:
¡ Threecontrolmodes.

1. Automatic
voltage,aregulation
(AVR)
2. Powerfactor(PF)regulation

3, Reactivepower(VAR)regulation
r Programmable
stabilitysettings
. Softstartcontrolwith an adjustabletime setting
in AVRmode
¡ Dualslopevoltageversusfrequency(VlHz)
cnaracteristic
o Three-phase
or single-phaspvoltagesensing
o Single-phase
currentsensing
o Fieldcurrentand field
voltagesensing
. Tenprotectionfunctions

¡01932679
StartupprofileFunction
,SltCS Code: 4467
. prorire
tothestarrup
H".i,3,lT!ti,:i"tjtá:"_:erateü
r:Generator
RatedVoltage
 11
Section

i01933190

g and StoppingProfile
Code= 4467

POINT(2OTO40Hz)
UNDERFREQUENCY_
GENERATOROUTPUTVOLTAGE

DECREASING SLOPE1
r¡J (0 To 10 V/Hz)
H7s
e
J DECREASING SLOPE2
o (0 To 10 V/Hz)
a
z
=s0
2

s *1
ii 5 HZ(F|XED)

K N E EFR E OU E N C Y

40 s0 80 100

% OF NOM INALF REQUE N C Y

. S01012488
lllustration7

The parametersthat are relatedto the loadingand
stoppingprofileare listedbelow.
¡ GeneratorOutputVoltage
o Knee Frequency
o DecreasingV/Hz Slooe 1,
¡ DecreasingV/HzSlope 2
o MinimumVoltage
o Underfrequency
Point
Voltageregulatorsare generallyof the volts
per hertz type or the constant voltage type.
The digitalvoltageregulatorcan performas a
constantvoltage regulatoror a volts per hertz type
regulatordependingon user configuration. Volts
"a,per hertztype regulatorsare commonlyused with
reciprocatinginternalcombustionenginedriven
generatorsets because they provide an automatic
meansfor the engineto recoverfrom a largeblock
toad.In the digitalvoltageregulator,the block load
recoveryperformanceis configuraQle so that it may
be field optimizedfor each specifii application.
Whenthe generatoris runningand if a largeload is
applied,the frequencyand voltagewill drop. The
loading/stopping functionminimizesthe amount
of time that it takesthe engineand generatorto
recoverand increasesthe abilityto pick up large
loads.
As a large load is applied,the engine speed
will begin to drop (frequencydecreases).As the
frequencydecreasesbelowthe kneefrequency,the
voltagereferencewill decreaseon a Volts/Hzslope
accordingto the decreasingslope 1 value.lf the
frequencydecreasecontinuesbeyondthe knee
frequencymiqus5 Hz, then the voltagereference
will decreasebn a Volts/Hzslope accordingto the
decreasingslope2 value untilthe minimumvoltage
levelis reached.The digitalvoltageregulatorwill
try to regulatethe generatoroutput voltage at the
minimumvoltage,unlessthe underfrequency point
is reachedwherethe generatoroutputvoltagewill
decreaseto a minimumvalue.
As the engine recoversfrom the load increase,
the voltage will increasein the reverseorder as it
decreased,unlessthe frequencydropped below
the underfrequency point.lf the frequencydropped
belowthe underfrequency point,the startupprofile
will be used for the recoverv.
 1D
dvdemsOPerationSection
tnsomeapplicationsit is desirableto maintain
a constantvoltageat the possiblesacrificeof a
ároerfrequencydip during load transients.The
.lioltatvottageregulatorcan accommodatethese
ó"pt¡cations if the knee frequencyis configuredfor
o'lbwervaluethan normal.The actualvaluewill
áependon the specificapplication.Whenused in
thióapplication, the load transientsmust be kept
smallin orderto allowthe engineto recoverwithout
droppingbelowthe kneefrequency.
Whena largeblock load is switchedon to the
svstem, the enginespeed temporarilydecreases
ai the engineproducesthe additionalpower
requirement by burningmorefuel. lf the regulatoris
setto act as a volts per hertz type, it will reduce the
outputvoltageaccording to the slope of the V/Hz
curve.Thereductionin voltagereducesthe power
requirement of the load, thus allowingthe engineto
recover fasterfor a given block load. lf the regulator
issetto act as a constantvoltagetype,the regulator
willnotreducethe outputvoltagefor a change in
speed(additionof block load).Therefore,it will
takethe enginea longertime to regainspeed and
supplythe totalpowerrequirement of the load. lf the
regulatoris set to act as a constantvoltage type,
caremustbe takento keep block load applications
smallenoughso that the enginecan recoverin
acceptable time.
{
iorgs32¿o
VoltageRegulation
SMCSCode: 4467
Theparameters that are relatedto voltageregulation
arelistedbelow.
r RatedGeneratorVoltage
¡ Generator
PT PrimaryVoltageRating
r Generator
PT SecondaryVbttageRating
¡ VoltageSetpoint
r Generator
Frequency
¡ KneeFrequency
o IntegralGain
r DerivativeGain
,ne Proportional
Gain
r LoopGain
Once startup has been achievedand the generator
output frequencyis above the corner frequency,
the regulatorwill normallyact to keep the generator
output voltage constant.As changes in generator
loadingcausethe voltageto sag or rise, the
regulatorwill automaticallyadjust generator
excitationto maintainthe outputvoltage.lf loading
causesthe generatorfrequencyto drop below the
kneefrequency,the loadingand stoppingprofileas
previouslydescribedwill be followed.See System
Operation,'LoadingAnd StoppingProfile".
A remotevoltage adjust toggle switch may be used
to fine tune the generatoroutputvoltage.When
used, the active value of voltage referencemay be
adjustedr10%.
The PC softwarecan be used in order to adjust the
voltagealso.Clickingon the "Raise"and "Lower"
buttonson the "Metering"screenwill raiseor lower
the referencevoltage.Each click of the "Raise'
buttonwill incrementthe voltageby 0.1 V. Each
click of the "Lower"buttonwill decrementthe
voltageby 0.1 V.
io't933223
Line Loss Compensation
SMGSCode:4467
ln some installations
wherea singlegeneratorís
used with fong feederlinesto the load, it may be
advantageousto provideline loss compensation.
'Lineloss compensationis commonlyreferredto
as lR compensation.In this mode,a CT must be
providedin orderto measurethe generatorcurrent.
The parametersthat are relatedto line loss
compensationare listedbelow.
¡ Rated GeneratorVoltage
r GeneratorPT PrimaryVoltageRating
¡ GeneratorPT SecondaryVoltageRating
r VoltageSetpoint
,
¡ GeneratorFrequency
o Knee Frequency
o lntegralGain
o DerivativeGain
o ProportionalGain
¡ Loop Gain
i
é
4
I
I

GeneratorCT CurrentPrimaryRating
GeneratorCT CurrentSecondaryRating
Load Comp Mode
lR Compensation
RatedGeneratorCurrent
flowingthrougha long conductorcauses
voltagedrop due to the resistanceof the wire.
, the voltageat the load end of the
will be lowerthan the voltageat the
end due to the voltagedrop alongthe
ductor. This conditionis commonlyreferredto
linelosses.In orderto improvethe powerquality,
¡:. tne digitatvoltageregulatorcan compensatefor
thisphenomenon.As generatorload increases,the
;$egulatorwill causethe outputvoltageto riseslightly
:.'.at the generatorterminalsin order to compensate
t,:'forline losses.Voltagegain controlsthe amount
-l of compensation.lt shouldbe adjustedto yield a
.r,Constant voltageat the locationof the load.
Lineloss compensationis mutuallyexclusiveto
, reactivevoltage droop. These two functionswork
oppositeof one anotherand can not be used at
the sametime. lf a Cl is providedbut line loss
compensation is not 6esired,the setpointpercent
mustbe set to zero.
i01933441
ReactiveVoltageDroop
SMCSCod¡e:.4467
Parametersthat are related to voltage regulation
with reactivedroop are listed below.
. RatedGeneratorVoltage
¡ GeneratorPT PrimaryVoltfoe Rating
r GeneratorPT SecondaryVoltageRating
r VoltageSetpoint
o GeneratorFrequency
¡ Knee Frequency
o IntegralGain
ol DerivativeGain
o Proportional
Gain
. Loop Gain
r GeneratorCT CurrentPrimaryRari1ng
13
Section
o GeneratorCT CurrentSecondaryRating
o Load Comp Mode
o Droop Percentage
o RatedGeneratorCurrent
Whengeneratorsoperatein parallel,two primary
objectivesare for the generatorsto share both
the real power requirementsand the reactive
power requirements of the systemelectricalload.
The enginegovernorswill controlsharingof the
real power requirements(kW) and the voltage
regulatorwill controlsharing of the reactivepower
requirements(KVAR)of the total system load. lf the
outputvoltageof one generatoris slightlyhigher
than the other generators,it will supply lagging
reactivecurrentto the other generatorsconnected
in the group.This currentwill circulatebetween
generators,possiblycausingampereoverloading.
One methodof minimizingthis effectis to cause
an individualgenerator'soutputvoltageto sag, or
'droop",in proportionto the laggingreactivecurrent
flow from it as measuredwith a currenttransformer
(CT).For properreactiveload sharing,the regulator
must know the rated generatoroutputcurrent,
the CT current at rated generatorcurrent and the
desiredpercentageof outputvoltagedroop when
the generatoris at rated reactiveoutputcurrent.
As reactivelagginggeneratoroutput current
increases,the regulatorwill cause the output
voltageto droop (lowerthe voltage)proportionally.lf
the measuredreactiveoutputcurrentis leading,the
outputvoltagewill rise.In eithercase,this actionwill
tend to reduce the reactivecurrentfor better KVAR
sharingwith otherunits.The droop percentage
controlshow muchthe generatoroutputvoltagewill
vary for a given amountof reactivecurrent.ll is
importantthat the connectedCT polarity is correct
for the voltageto droop with laggingcurrentflow.
Reactivedroop compensationis mutuallyexclusive
to line droop compensation. Thesetwo functions
work oppositeof one anotherand can not be used
at the sametime.
i0'1933453
GrossCúrrentCompensat¡on
SMCSCode:4467
Parametersrelatedto voltage regulationwith cross
currentcompensation (CCC)are listedbelow
o Rated GeneratorVoltage
o GeneratorPT PrimaryVoltageRating
o GeneratorPT SecondaryVoltageRating
o VoltageSetpoint
 14
Systems OperationSection

o GeneratorFrequency However,becausethe CT secondarycircuits are all

interconnected, the CT signalseenby any individual
o Knee Frequency regulatoris not representativeof the actual current
flowingin that particulargenerator.Any displayor
o IntegralGain calculationsthat might use that signalas if it were
the actualgeneratorcurrentwill provideerroneous
r DerivativeGain results.
o FroportionalGain Reactivevoltage droop needs to be selected and
an enablecontactneedsto be closed in orderto
o Loop Gain enablecross currentcompensation. See Testing
and Adjusting,"WiringDiagrams"for a wiring
o GeneratorCT CurrentPrimaryRating diagramof the crosscurrentcompensationcircuit.
o GeneratorCT CurrentSecondaryRating
¡01933462
r Load Comp Mode
KVARRegulation
. Droop Percentage
SMCS Cod,ez4467
o RatedGeneratorCurrent
Parametersthat are relatedto KVARregulationare
listed below.
Crosscurrentcompensationis often used to
minimizecirculatingcurrentflow betweentne o Rated GeneratorVoltage
generatorswhich are connectedin parallel.The
advantageof this operatingmode is that all o GeneratorPT PrimaryVoltageRating
generatorscontributein order to establishthe
same outputvoltageto the load. Crosscurrent o GeneratorPT SecondaryVoltageRating
compensationis onlyrusedfor parallelingmultiple
gensets.Crosscurrdntcompensationis not used ¡ VoltageSetpoint
when parallelingwith a utility.Operationis similarr
to the reactivevoltage droop mode except that ' o GeneratorFrequency
the secondarycircuitsof the currenttransformers
of all generatorsare interconnected in a series o Knee Frequency
string.Eachgeneratoris initiallyadjustedin order
to providethe same outputvoltage.Whenall o IntegralGain
generatorssharethe samecurrent,in magnitude
and phase(accordingto the CT ratio),therewill be o DerivativeGain
no significantcurrentoutputon the secondaryof
any generatorCT. lf one of the generatorscarries o Proportional
more currentor the currentthat the generator Gain
carriesis laggingor leadingrelativeto the others, o Loop Gain
a net differencecurrentsignalwill be createdin
that CT.lf that generatoris srrpplyingmorereactive o RatedGeneratorCurrent
(lagging)currentthan othergenerators,the phase
polarityand the magnitudeof the signalreturnedto
o GeneratorCT CurrentPrimaryRating
the digitalvoltageregulatorwill be such to cause a
slightdecreasein the generatedvoltage,reducing o GeneratorCT CurrentSecondaryRating
the amountof reactivecurrent.Less reactive(or
more leading)currentwill causethe generator a
o OperatingMode
voltageto rise.The net resultis that the generated
voltageand the outputcurrentof each generator o VARSetpoint
is trimmedtowardan operatingpointwhereall
generatorswill sharethe same load currentin
proportionto the CT ratio,with the littleor no o VAR IntegralGain
pirculatingcurrentbetweenthem.Drooppercentage
'controlsthe amountof individualgeneratorvoltage o VARLoop Gain
droop (or rise)for a givenarnountof CT signal.
 Whenthe generatoris connectedín parallelwith
an infinitebus (utility),the voltageof ihe oenerator
is controlledby the infinitebus.lhe vottale of the
. generator.wíll change as the infinitebus voltage
changes.lt is not possibleto controlthe svstem
voltagewhen the generatoris connectedtb an
infinitebus. ln this instance,it is necessaryfor the
digital voltage regulatorto regulatethe reáctive
pgwer outputwhich is suppliedby the generator.
There are two methodsfor regulaúngthé reactive
powef output.
e KVARRegulation
o PowerFactor(pF) Regulation
Note: KVARstands for Kilo-Volt-Ampere-Reactíve,
whichis the unit of measurementfor reactivepower.
by the digitatvottageregutator
!olfaOg-.i9.legulated
in the KVARoperatingmode so that the generator
proouces a constant value of reactive power
(KVARs)regardlessof the real poweroútputof the
generator.ln this case, the powerfactor(generator)
will change when the real power outputdf the
generatorchanges.A currenttransformer(CT)
is necessaryfor this mode to work. KVARmode
must be selectedín the "Metering',screen,and the
contactfor the KVARIPF enable must be closed.
Referto the followingcontacts;"pg-6"and ,,pg-g',.,
In KVARmode,the generatorwill supplya constant
amountof reactivepower to the systemas set by
the refe.ren^ce(KVAR)regardlessof the real power
output(kW)of the generatorset. The geneátor
will.supplyreal power (kW) to the system.This
is determinedby the enginegovernbrand/orthe
devicethat is used for sharingthe load. Typically
utilityloads are too reactive.This can cauéécurént
overloadingof the systemdue to large reactive
currentrequirements.In the KVARmbde.the
generatorcan supply a fixed amountof reactive
power to the system.
\
For stableoperationof the generatorin the KVAR
regulatingmode,the generátormust be connected
to a utilityor.a systemthat is much largerthan the
generator.When the breaker (tie) is closed to the
utility,connectterminalpg-9 and terminalp9,6 in
orderto enablethe KVARmode.Whenthe terminal
P9-9and terminatp9-6 are disconnectedfióm
each other,the regulatorwill be in a voltagecontrol
operatingmode with the followingor withóutthe
Iollowing:droop and line loss compensation.
'¡!
i01933601
PowerFactorRegülation
SltfCS Code:4467
\ to work.PF operatingmode must be selected.
P,arametersthat are related to pF regulationare
¡rstedbelow.
o Rated GeneratorVoltage
r GeneratorPT PrimaryVoltageRating
o GeneratorPT SecondaryVoltageRating
r VoltageSetpoint
r GeneratorFrequency
¡ Knee Frequency
o lntegralGain
o DerivativeGain
o Proportional
Gain
o Loop Gain
e RatedGeneratorCurrent
o GeneratorCT CurrentprimaryRating
¡ GeneratorCT CurrentSecondaryRating
o OperatingMode
o PF Setpoint
o PF IntegralGain
o PF Loop Gain
Whenthe generatoris connectedin parallelwith
an infinitebus (utility),the voltageof ihe generator
rs controiledby the infinitebus. The voltageof the
g,enerator.willchangeas the infinitebus üoltage
changes..ltis not possibleto controlthe system
voltagewhen the generatoris connectedtb an
infinitebus. In this instance,ít is necessaryfor the
digitalvoltageregulatorto regulatethe reáctive
power outputwhich is suppliedby the generator.
Thereare two methodsfor'regulaúngthé reactive
poweroutput.
o KVARRegulation
¡ PowerFactoy'Regulation
Note: KVARstandsfor kilo-Volt-Ampere-Reactive,
which is the unitof measurement
for reactivepower.
Whenthe digitalvoltageregulatoris in the power
Iactor operatingmode, it regulatesso that the
generatorproduces a constant power factor,
regardlessof the real poweroutputof the generator.
rn rnrscase,the reactivecurrentwill chanOewhen
the real poweroutputof the generatorchainqes.A
cunenttransformer(CT) is necessaryfor thii mode
 OperationSection

stableoperationof the generatorin the pF

¡ulatingmode,the generatormust be connected
a utilityor systemthat is much largerthan the
liienerator.When the tie breaker is clósed to the
iutility,connect terminalsP9-9 and p9-6 in order
$ito enabtethe PF mode. When the terminatsp9-9
#anO P9-6 are disconnectedfrom each other,the
;y,egulator.willbe in a voltagecontroloperatíngmode
iwithor withoutdroop or line losscompensation
,'prevíously described."pF" mode musi be selected
as 0rg^go-o
in meteringscreenand the "KVAR/PF'
:-L ^
^t ^^^J
n^¡ ^- r-
contactmust
1i;:begl|seq, Referto the followingcontacts:"p9-6"
0@ o@
fand "P9-9".Whenthe contactié not closedthe
regulatoroperatesin AVR mode.

llfustrationI 901008946
ir i01935584

,Parameters
SMCSCode:4467

GeneralInformation
Parametersare pieces of informationwhich are
usedwithinthe memoryof the dígitalvoltage
regulato! Each parameterhas a Jpecific rañge of
values.Parameterstell the digital úoftageregúlator
how !o operate.Servl6epersónnelcariconfígure
c_ertatlparametersto the requirementsof a d ecific
síte.Configurationchangesthe valueof a paiticutdi
parameter. Thereis an upper and lowerlimitfor
the value of each paramet'er.The limitscan not be
exceeded.

In order to view or configurethe valuesof the

parameterssee TestingAnd Adjusting,,,parameter
ViewíngAnd ConfiguriñgeroceáLit;:' - *

i01938981

RemoteCommunication
\
SMCS Code:4467

Thedigitalvoltageregutatorhas the capabilityto

communicatewith a remote personalcómputeror
programmable logic controller.The J4 connecror
ot the digitalvoltageregulatorprovidesan RS_232
port¡ecessary for The RS-232port
.communication.
S^1!-p'n communication media inctudinga wiré for
X:^"91u9,9 wire for Transmit,and a comrñonSignal
¡irou¡d. The commonsignal ground is NOT a
oondtnggroundand shouldnot be groundedto
the
oc,9seorframe. lt is to be connected-tothe RS_232
qeviceSignalGround
conneotionpoint.Cable
fngjn s_|r^ould
be timitedto 15'm (50 ft) maximum
Ior the RS-232signalwiring
 Pin Function Name Direction
1 t{/A
2 TransmitData TXD FromRegulator
3 Receive Data RXD To Regulator
4 N/A
5 Signal Ground GND t¡iA
6 1'l/A
7 NiA

I N/A
9 N/A

DCD 1 I 1
2 2 TXD RX 3 2 TXD
? 3 RXD TX T 3 RXD
DTR 4 4 4
5 5 GN D GND 7 5 GND

DSR 6 6 6
7 7 7
I 8 6
N.C. N.C.
RI I o I

901008993
lllustration9

Note:Batterypower(24Ydc) must be availableat Establishing

Gommun¡cation
P12-8(B+) and P12-7(B-) in orderfor the remote
communicationsport to operate. Communication betweenthe voltageregulator
and the PC softwaremust be establishedbefore
A windowsprogramis availableto communicate viewingthe meteringvalues,readingsettings,or
with the digitalvoltageregulator.The program changingsettings.PC softwarescreensettingsare
is called CaterpillarPC Software.For proper updatedonly aftercommunication is openedor
connectionof the digital voltage regulatorto the the communication settingshave been changed.
personalcomputer,see Testingand Adjusting, Open the voltage regulatorcommunicationport
'Wiring Diagrams",the illustrationRemote by clicking"Communications" on the menu bar,
Communications. hoveringthe mousepointerover "OpenCommPort"
and clicking"RS-232Port".
CaterpillarPC Softwareallowsthe user to perform
the followingoperations.
o Viewingand modifyingthe parametersin a
windowedPC environment
r Sendingthe parametersto the digitalvoltage
regulator
r Savingthe existingdigital voltageregulator
settingsto a file
r Viewingthe meteringand iault information

For informationon changingand viewingthe

901016734
metersof the voltage regulator,see Testing lllustrationl0
Adjusting,"ParameterViewingánd Configuring
When "RS-232Port" is selected,the "Password"
dialog box appearsand promptsyou to entera
password.See illustration10.Eachvoltrageregulator
is deliveredw¡th "cat" as the password.
Terminating
Commun¡cation
Voltageregulatorcommunicationis terminated
by clicking "Communications" on the menu bar
and clicking"CloseComm Port".The userwill be
prompedto savethe settingsto the EEPROM. This
questionis asked even if no changeswere made
to the voltageregulatorsettings.Whenthe close
command is execute (with a Yes or No to save
settíngsto the EEPROM), communication with the
voltage regulatoris terminated.lf the PC software
is exitedthe (by clicking Fileon the Menu bar and
then Exit)withoutfirst closingcommunication, the
optionwill still be given to savethe settingsto the
EEPROM.

lllustraüon11 901016736

After the correct passwordis entered,the "Comm

Port"screenis displayed.See illustration11.Select
"Comm1", "Comm2", "Comm3", orlComm 4" as
the activecommunication port on your PC and click
the "lnitialize"button.The PC softwareinitializes
communicationby obtainingthe configuration
settingsfrom the voltige regulator.
f

t
lllustraüon12 901016737

Note:The CaterpillarPC softwaremay display

the "Pleasewait..."dialog box that is shownin
illustration12 when initializingcommunication,
obtainingconfigurationsettings,or performingother
tasks.lt is importantto wait untilthe box disappears
beforetryingto executecommunication commands.
lssuingcommandswhilethe "Pleasewait..."dialog
box is presentmay disruptcommunication between
the PC softwareand the voltageregulator.
 Testingand Adjusting
Section

Testingand Adjusting
i01942916

GeneralInformation
SMCS Code=4467

PREVENTATIVE
MAINTENANCE
Theonly preventivemaintenancethat is requiredon
the voltageregulatoris to periodicallycheck that
the connectionsbetweenthe voltageregulatorand
the systemare clean and tight. Voltageregulator
units are manufacturedusing state-of-the-art,
surface-mounttechnology.As such, Caterpillar
recommendsthat no repair proceduresbe
attemptedby anyoneotherthan Caterpillardealer
technicians.
lllustration14 groobsgrt4
8T-0900 AC/DCClampOn Amm€ter
The 8T-0900 Ammetermay be used to measure
currentup to 1200 amperes.When you are
measuringline currenton multiplelead units,
measurethe currentin each conductorper phase
and add the currentstogether.See Special
lnstruction,SEHS8420,"Usingthe 8T900AC/DC
Clamp-OnAmmeter0651"foithe correctoperation
of the 8T-0900 Ammeter.

i01041654 i01991688

ServiceTooÉ StartupProcedure
¡:)
SMCSCode: 0785 SMCS Code:4467

lllustration.lg
lS goo2412o3
lllustration'15 901021519
6V-7070 CaterpitlarD¡gitalMultimetor

CaterpillarDigitalMultimeterscan be used to
rneasurevoltage,resistanceor currentup to 10
amperes.Rectifierscan also be checked bv
usingthe diode function.See SpecialInstruótion,
SEHS7734, "Use Of The 6V-7020And 6V-7800
nMultimeter"for the correctoperationof the 6V-7070
ulgitalMultimeter.
The Cat Digltal Voltage Regutator presents an
electrical shocldelectrocution hazard.This hazard
wlll cause serious injury or death.
Service by trained personnel only.
The termlnals and heat sinks are llve at hazaldous
voltages when power is applled and for up to 8
minutes after power is removed.

¡
I

rq
i
g
g
!
5
1. Connectthe digitalvoltageregulator.Referto Installingthe CaterpillarPC
TestingAnd Adjusting,"WiringDiagrams"for a
properillustration.
Takecare to follownotesand
Software
observepolarities.
CaterpillarPC Softwarecontainsa setup utility
that installsthe programon the PC. An uninstall
2. Apply batterypoweronly to the digitalvoltage
regulator.Verifythat all of the parametersare utilityis loadedwith the programthat can be used
properlyadjustedfor the application. to removethe applicationfrom the PC. Use the
followingprocedureto instaflthe PC software.
3. Startthe engine.Makethe final adjustments,as
required. 1. Insertthe CD-ROMinto the PC'sCD-ROMdrive

4. Recordall settings. 2. Click the WindowsStartbuttonand then select

"Run".In the "Open:"field,enter"D:/Setup,exe",
where D is the designatorletterfor your PC
i01956126 CD-ROMdrive.Thenclick "OK".
ParameterViewingand WhenCaterpillarPC Softwareis installed,a folder
ConfiguringProcedure with the nameCaterpillaris added to the Windows
programmenu.This folder ís accessedby clicking
SMCSCode:4467-NQ the "Start"buttonand pointingto "Programs".

In orderto viewand configurethe parametersof the

digitalvoltageregulator,a PC with the Caterpillar
PC softwareis required.

Note:Beforeperformingthis procedure,studythe
list of parametersin orderto determinethe desired
parameterand the cgrrespondingrangeof values.
The valueof some farametersare only for viewing
by the user and may not be configurable. ..)
Note:lt will be convenientto have the entirelist
of parametersavailablewhile performingthis
procedure.See SystemOperation,"Parameters"

The CaterpillarPC Softwareprovides the

communication link betweenthe voltageregulator
and the user.All voltageregulatorsettingsare
enteredand read throughthis software.Withinthis
software,voltage regulatorsettingscan be saved
in a computerfile and used laterto configureother
unitswith the same settings.
\
CaterpillarPC Softwareoperates with an
lBlr/-compatiblepersonnelcomputers(PCs)using
MicrosoftWindows95 or lateroperatingsystems.
Theminimumrecommendedoperatingrequirements
are listedbelow:
o lBM-compatiblePC, 486DX2or faster(100 MHz
or highermicroprocessor
is recommended)
o CD-ROMdrive

o One availableserialport
 StartingCaterpillarPCSoftware

lllustration16 901033156

The PC softwareis started by clickingthe r ControlGain Settings

Windows"Start"button,pointingto "Programs",the
"Caterpillar"foldet and then ctñking the voltage ¡ ProtectionsSettings
regulatoricon.At startup,a dialog box with the
Prggramtitle and versionnumberis displayed ¡ Metering/Operation
and Alarms
briefly.After this diatog box iq disptaved,the
"SystemConfigurationn screeil is disjlayeA.See
lllustration
16.

EstablishingCommunieation
Communicatíon betweenthe voltageregulatorand
the PC must be establishedbeforéany settings
can be viewedor changed.For more information
on establishingcommunications,see Systems
Uperation,"RemoteCommunication"

QhangingSettings
fhe settingsare arrangedinto.thefollowingfive
groups:

¡ Systemconfiguration
\
o SettingAdjustments
22
Testingand AdjustingSection

lllustration17 901033158

SystemsConfigurationscreen
(1) SystemConfigurationbuüon (4) ProtectionSetting buüon (7) EEPROMbutton
(2) SettingAdjustmentbutton (5) Metering/Operation button
(3) ControlGain Button (6) Get FromUnit button

Eaih settinggroup has a correspondingbuttonthat Sendingand ReceivingSettings

can be selectedto accesst[¡at group of settings.
See lllustration17.The five sbttinggroupscan also
be accessedby clicking "Screens"on the menu
bar and then selectingthe desiredsettinggroup
from the list.Once a settinggroup is accessed,the
individualssettingsof the group can be viewed
and changed.
A settingis changedby clickingwithinthe setting
field and typingthe setting.The minimum,maximum
and increments(steps)for a settingare displayed
on the statusbar when the cursoris placedwithin
that settingfield.A changedsettingis sent to the
¡voltageregulatorwhen the Enterkey on the PC is
pressed.A settingin a field withthe pull-downmenu
is sent to the voltageregulaücrwhen the settingis
selectedfrom the pull-downmenu.
Whencommunication is enabled,voltageregulator
settingscan be sent or receivedthroughthe PC
software.
SendingSettings
Settingschangesare sent to the voltageregulator
by pressingthe Enterkey on the PC or by selecting
a settingfrom a pull-downmenu.This causesthe
selectedsettingdisplayedon the settingscreento
becomethe voltage regulatorsetting.
ReceivingSettings
Voltageregulatorsettingsare retrievedby clicking
the "Get FromUnit" button(6). This causesthe
currentsettingsof the voltageregulatorto be
displayedon the "settings"screen.
 SavingSettingsto the Memoryof the
VoltageRegulator
Settingsare saved in nonvolatilemerrory(EEPROM).
In the.eventof a power loss, these are the settings
that will be active at start-up. lf the settingsare
changed and sent to the voltage regulatoi but the
settingsare not sent to the EEPROM,the changed
settingswill be lost if the operating power to thé
voltageregulatoris lost, Whenexitingan application
or closingcommunication, the softwárewiil prompt
the userto save the settingsto the EEpROM.Thi's
questionis asked even if no changeswere made
to the sett¡ngs.Whencommunication is enabled,
s9ttj19 changl¡jrare saved to the EEpROMby
clickingthe "EEPROM"button(Z).The opportLnity
t9 save the settingsto the EEpROMis aiso given-
througha dialogbox when the applicationis exited
or communication is closed.

SettingDefinitions
Eachof,thefivesettinggroupshavea corresponding
screen in the PC software.The settingof each
screen are categorizedby one or more tabs. ln
the-.following
paragraphs,settingare arrangedand
oetrnedaccordingto the organizationof the pC
applicationscreensand tabs.
t

SystemConfiguration .\
The "SystemConfiguration" screenconsists
of one tab labeled "Configuration".Ctick the
"Configure"button('l) in order to accessthe
"SystemConfiguration" screenor click ,'Screens"
on
the menubar and click "SystemConfiguration',.
 i" I

24
Testingand AdjustinqSection

Conflguration liab

lllustration18
901033156

la]g9_Y"|qgg (!).. .r¡g raredACsenerator

votrase
rs enreredin this field.
Voltageswíthinthe range lJ_S^"ggT9"yJp - Thesecondary
ACvottase
ratng of the PT is entered in this field. Voltages
of 90 ro 15000ACV may be"enteráO¡n i nCV
increments. yitlit J!:grange of g0 and 600 ACV máy be entereo
in 1 ACV increments.
Rated Current(A) - The maxjmumrated AC
generatorcurrentis enteredih this settinofield. CT Primary - The AC current ratíng of the primary
windingof the CT is entered¡n tfi¡jfeú. -Clrr"nt"
Currentswithin the range of zs ió-gééij nln'peres
within the range of 75 to 9999 nmpereé miy Ue
may be enteredin 1 Amperesincrements.
enteredin 1 Amperesincrements.
RatedkVAR - This field is a read_ontyfield that
CT Secondary Thisfield is a read-onlyfield that
displaysthe rated,calculatedreactive'pówér, baseO .-
orspraysthe ratbdvalueof the currentthát is present
on the valt¡esthat are enteredin the Rátedúoltage
and Ratedcurrentfields. 1t^t:_..:g"dary windingof the CT.This regufatoris
oesrgned for a 5 Amperesecondarywindifu only.
Frequency- This settingis used to selecta nominal
Pgyer InputFrequency (Hz) - The frequencvvatue
systemoperatingfrequencyof 50 Hz or 60H2.
power apptiedto the'vottage
9]_t.T-:pgrating
reguratoris enteredin this field. This would*be
flI !ll"y ff) - Thepri1q.yACvottase
ratinsof thefrequencyof th_e
tne potentiattransformer(pT) enteredin thisield.
¡s .permanentmagnetgenerator
or.me lrequencyof the
the^rangebf generatorin the óase of
!9tt3-o3s-v,iit¡in óriandrsooóÁóv may serr-^excited
generator.Frequencies
oe enteredin 1 ACV increments. withinthe range
of 50 to 400 Hz may be enferedin 1 Hz incráments.
 25
. Testingand AdiustingSection

SensingMode - This settingis used to configure

the voltageregulatorfor the single-phaseor
three-phasevoltagesensing.

PC SoftwarePart Number - This is a read-onlyfield

that displays the version of the PC softwarepart
number.

EmbeddedSottwarePart Number - This is a

read-onlyfield that displaysthe versionof tl;re
embedded softwarepart number.

HardwarePartNumber- This is a read-onlyfield

that displays the version of the Hardwarepart
number.

SerialNumber- This is a read-onlyfield that

displaysthe serialnumberof the voltageregulator
connectedto the PC. Communication betweenthe
voltageregulatorand the PC must be enabledin
orderto read the firmwareversion.

SettingAdjustments
The "SettingAdjustments"screen consistsof two
tabs labeled"Setpoint"and "Startup".Click the
"Settings"button(2) in orderto accessthe "setting
Adjustments"screenor click "screens"on the menu
bar and click "SettingrAdjustments".
26
Testingand AdjustingSection
Setpoint Tab
l,li: .,
-:,,r
Meterim
lllustration
19
AVRVoltage(V) - This settingfield is used to enter
the desiredgeneratoroutputterminalvoltage.The
rangeof voltagesis dependenton the value in the
"VoltageAdjustmentBand(% of rated)"field.Values
may be enteredin incrementsof 0.1 ACV.
VAR (% of rated)- The VARsetpointdetermines
the level of generatorVARsthat are maintained
by the voltageregulatorwhen the digitalvoltage
regulatoris in the VARmode.Percentagevalues
withinthe range of -100 to 100 percentmay be
enteredin incrementsof 0.1 percent.A settingin
the overexciteddirectionwill have a positivevalue
and a settingin the underexciteddirectionwill have
a negativevalue.
901009341
PowerFactor - The Power Factor setpoint
determinesthe levelof generatorpower factor
that is maintainedby the voltageregulatorwhen
the voltageregulatoris in the powerfactor mode.
Settingswithinthe range of -1.000to 1.000may
be enteredin incrementsof 0.001.A settingin the
laggingdirectionwill have a positivevalueand a
settingin the leadingdirectionwill have a negative
value.
LoadCompensation Mode:Mode - Threesettings
mav be selectedfrom the drop-downmenufor this
opératingmode:Off, Droop,or Line Drop.Selecting
SelectingDroop
Off disablesall load compensation.
enablesthe reactivedroop compensationfeatureof
the voltageregulator.SelectingLine Drop enables
the voltageregulatorto compensatefor a line drop
by increasingthe generatoroutputvoltageas the
generatorload increases.
 27
Section

Mode:SetPoint(%) - This
-ánabled
onlYwhen DrooPor Line
aAás tne Load ComPensationmode.
,of zeroto 10.00 PercentmaY be
of 0.01.

Band(/" of rated) - This setting

a oercentageof the rated generator
; dsedto limitthe rangeof the AVR
valueof zero to 15.00
of 0'01.
in increments
be entered

901039638

Pll. e¿l - TheSoftStartBiassetting KneeFrequenJy(Hz) -The KneeFrequencysetting

s thegeneratorvoltageoffsetduringi
aLrercentag" uárreóió.00to 90.00ñay
redin incrementsof 0.01percent
Time(sec) - The Soft Start Time
sJhe lengthof time for the generator
:ri1g^e.torncreaseto the prescribedlevel.
:::ry.q seconds'may
1?0.00 beentered
of 0.01seconds.
definesthe value of frequencythat causesthe
voltage regulatorto adjust the voltage setpoint
so that the generatorterminalvoltagefollowsthe
selectedvolts per hertzslope.A valueof 45.00to
65.00hertzmay be enteredin incrementsof 0.01
hertz.Knee Frequencyshouldtypicallybe set from
0.2 to 2 Hz less than than the Gensetoperating
frequency.The kneefrequencyshouldb'eadjusted
closerto the nominalfrequencyin applications
wherethe Gensetengineand governoris slow in
recoveringfrequencyduring a transientload event.
 fromCornerFreq.(Hz) - This field is a
field.The fixed value is subtractedfrom
Frequencyvaluein order to determine
) generator underfrequency operation
,fromslope 1 to sloPe2.

(YlHz)- Whenthe generatorfrequency

rnthe cornerfrequencyand the corner
minus5 hertz,the voltagesetpointis
adjustedso that the generatorvoltage
per hertzslope 1. Slope#1 is adjusted
ng field.A settingof zeroto 10.00may
in increments of 0.01.

2 (VlHz)- Whenthe generatorfrequencyis

thecornerfrequencyminus5 hertzand the
Frequency"setting,the voltagesetpoint
adjustedso that the generator
volts per hertz slope #2. Slope#2
by this settingfield.A settingof zero to
be enteredin incrementsof 0.01.
per Hz slope value can be used to
trans¡entresponsetime.

Voltage(% of rated)- The Minimum

settingdefinesthe voltagelevelwhere
regulatortransitionsfrom the
ncy characteristic to a constantvoltage
c. The MinimumVoltagesettingis
)d as a percentageof nominalgenerator
A valueof 50.00to 100.00percentmay bS
in increments of 0.0i.
Frequency (Hz) - The MinimumFrequency
-ft41,nirrT
Setting
definesthe valueof the generatorfrequency
whérethe-excitation is removed.A frequency
yaluéof 20.00to 40.00 hertzmay be entereóin
Incrementsof 0.01 hertz.

Cg rol Gain
_ ':.i

llle pqrypl Gain screenconsists of a singtetao

.Gain"
'ControtGain".Ctick bütton(3)
Fbelgd
In {he
orcfer
to accessthe ',ControlGain"screenor click
"ücreens"
on the menubar and click .ConkolGain',.

ContrclGainTab
ScreencUooradedelp
ProportionalGain Kp - fnl settingselectsthe
proportionalconstantstabilityparameter.The
voltageregulatorsuppliesa valuethat is equivalent
to Kp multipliedby the errorbeWveenthe voltage
setpointand the actualgeneratoroutputvoltage.Kp
valuesof 0 to 1,000may be enteredin increments
of 0.01.
lf the transientresponsehas too much overshoot,
thenKp may be decreased.lf the transientresponse
is too slow,then Kp may be increased.
lnlegralGain Ki - This settingselectsthe integral
constantstabilityparameter.The voltageregulator
suppliesa valuethat is equivalentto Ki multipliedby
the integralof the errorbetweenthe voltagesetpoint
and the actualgeneratoroutputvpltage.Ki values
of 0 to 1,000may be enteredin irlcrements of 0.01.
29
Testingand AdjustingSection
fE/1rlrüos
-
g01009252
Increasingthe value of Ki decreasesthe time t
requiredto reachsteady staIe. /¡'¿mfa AUu¿,t"i& _/'e*-
a-{Uni W V Ar4r{*,e "
DerivativeGain Kd - This settingsele6tsthe /
derivativeconstantstabilityparameter.The voltage
regulatorprdvidesan outputvaluethat is equivalent
to Kd multipliedby the derivativeof the error
betWeenthe voltagesetpointand the actual
generatoroutputvoltage.Kd valuesof 0 to 1,000
may be enteredin incrementsof 0.01.
lncreasingthe value of Kd reducestransient
responseringing.
NoiseFifterTimeConstantTd - This settingselects
the noisefiltertime constantand is used in order to
reducehigh-frequency noise.Valuesof 0.00 to 1.00
may be enteredin increments of 0.01.
30
Testingand AdjustingSection

LoopGain Kg - This setting adjusts the loop-gain

levelof the PID algorithm.Loop Gainvaluesof 0 to
1,000may be enteredin incrementsof 0.0'1.Loop
gain Kg is an overallgain multiplieraffectingall
gain parameters,and shouldbe used as a firstgain
adjustment.IncreasingLoop Gain may be used
to increasetransientresponseand reducetime
to steadystate.Decreasingloop gain will reduce
overshoot-but will lengthentime to steadystate.

VAR IntegralGain Ki - This setting adjuststhe

integralgain and determinesthe characteristic
of the voltageregulatordynamicresponseto a
changedVARsetting.Ki valuesof 0 to 1,000may
be enteredin increments of 0.01.

VAR Loop Gain Kg * This setting adjusts the

loop-gainlevelof the Pl algorithmfor VARcontrol.
Valuesof 0 to 1,000may be enteredin increments
of 0.01.

PF lntegralGain Ki * This settingadjuststhe

integralgain and determinesthe characteristic
of the voltageregulatordynamicresponseto a
changedpowerfactorsefting.Valuesof 0 to 1,000
may be enteredin incrementsof 0.01.

PF Loop Gain Kg - This settingadjuststhe

loop-gainlevelof the f;l algorithmfor powerfactor
control.Valuesof 0 tó 1,000may be enteredin
increments of 0.01

PID Pre-Settings- One of 20 presetstabilityranges

withinthe voltageregulatorcan be selectedfrom
this pull-downmenu.Selectionof one of the 20
presetstabilityrangesdisablesthe Proportional
Gain (Kp), IntegralGain (Ki),and DerivativeGain
(Kd) settingsof the ControlGain tab. Selecting
"(CustomPID Settings)"from the PID Pre-Settings
menu enablesthe Kp, Ki, and Kd settings.
Caterpillardoes not recommendusingthe current
"PlD Pre-Settings"in the list except the "Custom
PIDSettings".The defaultsettingsfromthe "Custom
PIDSettings"will work well fqr mostSR4and SR4B
generatorapplications.lf an adjustmentis to be
made,the "Loop Gain Kg" shouldbe used as a
first adjustmentapproach.

"PlD" Button- Pressthe PID buttonin order to

open the PID Calculatorscreen.See illustration 22.
The PID Calculatoris used in order to calculate
proportionalgain (Kp), integralgain (Ki), and
derivativegain (Kd) for a PlDtype controller.The
generatorand the excitertime constantvaluesare
enteredintothe PID Calculatorin orderto calculate
thesevalues.AVRoverallgain (Kg) and derivative
tilter time constantTd can be entéredand saved
in a file. Referto the "PlD Cqfculator"sectionfor
additionalinformation.
 31
and AdjustíngSection

PIDCalculator

Excitation Contol Data

........ lFenÉratorl*lame
Gen.Infom¡tion.
lffegfillLldlntr\l.l E
['do] - [5econdr]
Gen.Timef,snstanl ......,.F[ñ--
uervd*e uarnlho¡ H
F Delault
Exciter
Timef,onstant
TimeCnnstent
tTdl.. . ..
Timefanst¡nt[Te]-[Secondsf F]3
Exciter :

PID Record L¡fi

Information
Generatsr

i* llll:rylI lJ¡*r!"*t*
féT PCSoftwane
i
--g:*J
lllustration22 901009819

ThePID parameters are calculatedfor the desired
systemresponsewith a settlingtime of about
one{hirdof the generatortimeconstantand about
10 percentovershoot.
ExcitationControl Data
\ The maximumpossibleexcitertime constantis 3
Gen. Information- Uo to 20 charactersof
descriptivetext for the generatorcan be enteredin
thisfield.Whena PID recordis created,this text
identifiesthe record.
Gen Time Conslant[-'do]-[Seconds]- The
open-circuitgeneratortime constant(T'do)can be
selectedfromthis pull-downmenu,Timeconstant
valuesof 1 to.15secondscan be enteredin 0.05
secondincrements.
Note: Valuesfor specificgeneratorscan be obtained
from the TechnicalMarketingInformation System.
ExcilerTime Constant['e]-[Seconds]- The exciter
time constant(Te)can be selectedfrom this
pull-downmenu.The valuedisplayedin this menu
dependon the generatortime constant(T'do)that
is selected.Availablevaluesrangefromone{iftieth
to one-halfof T'do in 0.01 secondincrements.
seconos.
DefaultExciterTime Constant- When this box
is checked,manualselectionof the excitertime
constantis disgbledand Te is set at one-sixththe
valueof the generatortime constant(T'do).This is
not recommended for SR4and SR4Bgenerators.
AVR Control Parameters
ProportionalGain(Kp) - Thisis a read-onlyvalue.
The value is calculatedfrom the valuesthat are
selectedfrom the generatortime constant(T'do)
and excitertimeconstant(Te)pull-downmenus.

Gain(Ki) - Thisis a read-onlyvalue.The

Integral
valueis calculatedfrom the valuesthat are selected
fromthe generator time constant(T'do)and exciter
timeconstant(Te)pull-downmenus.
 DerivativeGain (Kd) - This is a read-onlyvalue.The
valueis calculatedfrom the valuesselectedfrom
i6s generatortimeconstant(T'do)and excitertime
:@nstant(Te)pull-downmenus.
value
-frequenc
ded to
n zero to
Enteringi

gain is
¡ 1000.00

td'
'll. Thisarea of the PID Calculatorscreen lists all of the
,ri.,savedPID recordsthat are available.
'ai RemoveRecordButton- Recordsin the PIDRecord
,:: Listcan be selectedand deletedby clickingthis
.i button.
:.¡t

:,.'AddFtecordButton- A recordcontainingthe
.-r'exc¡tationcontrol data and AVRcontrol párameters
-:: can be added to the PID RecordList by clicking
thisbutton.The "Spve"buttonmust be pressedin
' orderto save the/recordin the list.
,;: .
:'i UpdateCAif PC SoftwareButton -Transfers thdAVR
:r..controlparameterscalculatedin the PID calculator
'. and recordedto the ControlGain Screen.
:' CloseButton- Clickingthis buttonclosesthe PID
Calculatorand returnsto the ControlGain screen.
 -

TabbT
Power Inpgt to Voltage Regutato(pM /
SE / AREP Systems) Power Input lo Exciter

Nominal lequirements Full Forcing

/'¡ Requlrements
;#"
Volpge Regulator Range of
Exc¡ter
Inputto Freguency Number Not¡inal
Exciter
Nominal Exciter
Exciter
T¡me Full
Forcing
Fult
Forcing
Phases Voltage Current Constant
Voltage
Input Input Te Current
Kato 70
2600 PM to 24OHz 3 35V 104 3.7 ohms 0.22sec 65V 154
Frame 105V
Kato
2800 PM 120V 90 Hz 1 50v
Frame 5A 10 ohms 0.18sec 90v 104
5100 PM 140V 120 Hz 3 40v 4A 10 ohms o.22 ANV
r00 SE 140V 60 Hz I 40v 4A 10 ohms 0.22sec 60v 104
't00 ABEP 140V 50/180Hz 2x1 40v 4A 10 ohms 0.22 sec 60v 104
1400
,4P PM 180V 2OOl240Hz 3 45V 4.54 10 ohms 0.056sec 80v 104
t400
4P SE 50/60 Hz 45V 4.54 10ohms 0.056sec
1400
t4P AREP 140V 50/180Hz 2x1 45V 4.5A 10 ohms 0.056sec 80v 104
1600
t4P PM 180V 2OOl240Hz 3 60v 6A 10 ohms 0.059 sec 150V 15A
1600
t4P SE 50/60 Hz 60v 6A 10 Ohms 0.059 sec
1600
t4P AREP 240 V 50/'180Hz u1 60v. 6A 10 ohms 0.059 sec 150V 'l5A
1800
t4P PM 180V 240 Hz 3 84V 4A 21 ohms 0.22 sec 190V 8.5A
1800
l4P SE 240V 60 Hz 1 84V
1800
AREP 240V {
I 21 ohms 0.22sec 190V 8.54

l4P 60 Hz 84V 4A 2'l ohms 0.22 sec 190V 8.54

70
sR4 PM to 240 Hz 3 35V 104 3.7 ohms O.22sec 65V 154
105V
SR4 SE 240V 60 Hz 1 35V 104 3.7 ohms 0.22 sec 65V 15A
ProtectionSettings
The"Protection Settings"screenconsistsof a single
tab labeted"protectio-n".
Ct¡ckthó-;,Fróiá"tion,,
buttonto accessthe "proteclioñéettingJ;
screen
or click "Screens"on the menu bar ari'd
click
n, rrotectionSettings".
Protection Tab
Gan '--- -t
----[
lllustration23
'SHUTDOWNOVERRIDE"Buüon - This button
is used to preventexcitationshutdownfor any
protectedfunction.The buttondisplays' ENABLED"
whenselectedand the buttondisptays'DISABLED'
whenthe buttonis deselected.
GeneratorOvervoltage: gnáOleO- Selectingthe
"Enabled"checkbofenablesgeneratorovirvoltage
protection.Deselectingthe Enabledcheckbox
disablesgeneratorovervoltageprotectionand the
associatedsettinos.
I tl;];:,
lzzrzoffi iT1E2At.r
901009884
GeneratorOvervoltage: FaultType * Two options
can be selectedfrom this pull-downmenu,"Alarm"
or "Shutdown".When "Alarm"is selectedand a
generatorovervoltageconditionis detected,the
Alarmoutput driver energizes,a J'|939 alarm
messageis sent via the CAN communication
port, and the FaultLED will be lit constanily.For
units equippedwith an RS-232communicátion
port, an Alarmfault will be annunciatedvia the
PC software.When "shutdown"is selectedand
a generatorovervoltageconditionis detected,
the FaultShutdownoutput driverenergizes,a
J1939shutdownmessageis sent, and the Fault
LEDu¡illflash.For unitsequippedwith an RS-232
communication port, a Shutdownfault will be
annunciatedvia the PC software.The voltage
regulator does NOT disable excltation when a
Generator Overvoltage fault ¡s detected.
 GeneratorOvervoltage:Trip Value (%) - Th¡s
settingdeterminesthe voltagethresholdwherean
overvoltagetrip will occur.Voltagevaluesof 105 to
135 percentof the rated voltagemay be enteredin
incrementsof 1 percent.
GeneratorOvervoltage:Time Delay(Secs) - This
seftingassignsthe lengthof time from when an
overvoltagecondition is detected until the voltage
regulatorissuesan alarmor shutsdown excitation,
A time valueof 2.0 to 30 secondsmay be entered
in 0.1 secondincrements.
ReverseVAR:Enabled- Selectingthe "Enabled"
checkboxenablesreverseVAR protection.
Deselectingthe Enabledcheckboxdisablesreverse
VARprotectionand the associatedsettings.
Note:lf ReverseVARprotectionis enabledand the
CT connectionsare reversed,a reverseVARalarm
or shutdownwill occur.
ReverseVAR: FaultType - Two options can be
selectedfrom this pull-downmenu,"Alarm"or
"Shutdown".When "Alarin"is selectedand loss
of excitationis detected,the Alarmoutputdriver
energizes, a J1939alarmmessageis sentvia
the CAN communicationport, and the Fault
LED is lit constantly.f,or unitsequippedwith an
RS-232communicatiónport, an Alarmfaultwíll be
annunciatedvia the PC boftware.When"Shutdow¡"
is selectedand loss of bxcitationis detected, ¡J
the FaultShutdownoutput driverenergizes,a
. J1939shutdownmessageis sent via the CAN
communication port, and the FaultLEDflashes.For
unitsequippedwith an RS-232communication port,
a Shutdownfault will bé annunciatedvia the PC
software.The voltageregulatordoes NOTdisable
excitationwhen a Lo6sof Excitation(Reversevar)
fault is detected.
ReverseVAR:Trip Value(%) - This setting
determinesthe levelof reverseVARflow,expressed
as a percentageof nominal,lpositive VARflow,
wherea loss of excitationtrip occurs.A valueof
10 to 100 percentmay be enteredin incrementsof
1 percent.
ReverseVAR:Time Detay(Secs) - This setting
assignsthe lengthof time from when the reverse
VARtrip value is exceededuntil the voltage
regulatorissuesan alarmor shutsdown.A time
valueof 0.1 to 9.9 secondsmay be enteredin 0.1
secondincrements.
Undervoltage:
."Generator Enabled- Selecting
¡lhe."Enabled"
checkdoxenablesgenerator
undervoltage
protection.Desglectiñgthe "Enabled"
..
cneckboxdisablesgeneratorundervoltage
. protectionand the associatedsettings.
GeneratorUndervoltage:FaultType - Two options
can be selectedfrom this pull-downmenu,"Alarm"
or "Shutdown".When "Alarm"is selectedand
generatorundervoltageis detected,the Alarm
outputdriverenergizes,a J1939 alarmmessage
is sent via the CAN communicationport, and the
FaultLED is on constantly.For unitsequippedwith
an RS-232communicationport, an Alarm fault
will be annunciatedvia the PC software.When
"Shutdown"is selectedand generatorundervoltage
is detected,the Shutdownoutputdriverenergizes,
a J1939shutdownmessageis sent via the CAN
communication port, and the FaultLEDflashes.For
unitsequippedwith an RS-232communication port,
a Shutdownfault will be annunoiatedvia the PC
software.The voltage regulatordoes NOT disable
excitationwhen a GeneratorUndervoltagefault is
detected.
GeneratorUndervoltage:Trip Value (%) - This
settingdeterminesthe levelof voltage,expressed
as a percentageof nominalgeneratorvoltage,
wherea generatorundervoltage trip occurs.A value
of 60 to 95 percentmay be enteredin 1 percent
increments.
GeneratorUndervoltage:Time Delay(Secs) - This
settingassignsthe lengthof time from when a
generatorundervoltageconditionis detecteduntil
the voltageregulatorissuesan alarmor shutsdown
excitation.A time valueof 10.0to 120.0seconds
may be enteredin 0.1 second increments.
OverExcitation:Type - Twooptionscan be selected
.fromthis pull-downmenu,"lnv Time"(for inverse
'curves) or "Threshold"(for a fixed time delay).
The voltageregulatordisablesexcitationwhen an
overexcitationfault is detectedunlessa global
ShutdownOverridecommandis in effect.
OverExcitation:TtipValue(Amps)- This setting
determinesthe levelof field currentthat will cause
an overexcitationtrip. Valuesof 0 to 12.0amperes
may be enteredin 0.1 amperesincrements.The
requiredvalue for the SR4and SR4Bgenerators
is 12 amperes.
Over Excitation:Time pelay (Secs) - This
settingassignsthe lengthof time from when an
overexcitation
bonditionis detectedand when the
voltageregulatorissuesan alarmor shuts down
the exóitation.A time valueof 1.0 to 10.0seconds
may be enteredin 0.1 second increments.The
requiredvalue for the SR4 and SR4Bgenerators
is 10 seconds.
 ExciterDiodeMonitor(EDM):Trip Vatue(Amps) -
This settingdeterminesthe levelof currentthat is
indicativeof a failedexciterdiode. lf the current
levelexceedsthe diode fault thresholdsetpointfor
five seconds,a diode fault is detected.The voltage
regulatordisablesexcitationwhen a diode fault
is detected unless a global ShutdownOverride
commandis in effect.A value of 1.0 to 10.0
amperesmay be enteredin 0.1 ampereincrements.

Loss of Sensing(LOS):Time Delay(Secs) -

The value of this seüingdeterminesthe time
delay betweenwhen a loss of sensingvoltageis
recognizedand the voltageregulatorresponds
by removingthe field excitation.A time value
of zero to 25.0 seconds may be enteredin 0.1
secondincrements.. The voltageregulatordisables
excitationwhen a Lossof GeneratorSensingfault
is detectedunlessa global ShutdownOverride
commandis in effect.

FaultResetToo Long: Enabled- Selectingthe

"Enabled"checkboxenablesthe voltageregulator
to issuean alarmor a shut down fault if the fault
resetinputis closedlongerthan 10 seconds.

FaultResetTooLong:FaultType - . Twooptionscan
be selectedfrom this pull-downmenu,"Alarm"or
"Shutdown". When"Alarm"is selectedand the Fault
ResetcontactinputrBmainsclosedfor morethan 10
seconds,the Alarmóutputdríverenergizes,a J1g39
alarmmessageis sent via the CAN communicat¡on
port, and the Fault LED lights constantly.For
unitsequippedwith an RS-2S2communication
port, an Alarmfault will be annunciatedvia the
PC software.When "shutdown"is selectedand
the FaultResetcontactinput remainsclosedfor
morethan 10 seconds,the FaultShutdownoutout
driverenergizes,a J1g3galarmmessageis sent
via the CAN communication port, and the Fault
LEDlightsconstantly.For unitsequippedwith an
RS-232communication port, the voliageregulator
will attemptto annunciatethe Shutdownfault v¡a
the PC software.The voltage regulatordoes NOT
disableexcitationwhen a fá.¡lt neset ClosedToo
Longconditionis detected.

Metering,Operation,and Alarms
The "Metering,Operation,and Alarms,'screen
consistsof a singletab labeled,,Metering".
Click
the "Metering"buttonto access the ,,Metering,
uperation,and Alarms"screenor click ,,Screens"
the menubar and click ,,Metering/Operation,,.
.',::l.on
 ileterlng Tab

lllustration24
901010266

F,IJQLTAGE (V):Vab - Thisfietd is a read_onty (Hz):Freq - This fietd is a read-onty

ileld that displaysthe phase{o_phase ' .SLflEg
voltageof freldthat displaysthe valueof the frequencyof ine
pnaseA and phase B.
generatorvoltage.

flSIyqLT,lcE(V):Vbc- Thisfietdis a read-onty gFry POWEnltWatts - This fietd is a read-onty

disptays
the,phase-to_phase
vottageof '
5'9,thlt
pnaseB andphaseC. fieh thpt disptaysthe vatueof reatpo*éi in"t ts
oerngoutputfrom the generator.

,|TlJgtr¡eE ff): Vca - Thisfietdis a read-onty GEN POWER:kVA - Thisfietd is a read_onty

ileldthatdisplaysthe phase_to_phase voltageof fietd
that displaysthe value of apparentpowerthat is
.*Pnase C and phaseA. being output by the generator.

R5)JqLTc! (v), Vavs- rhis fietdis a read-onty GEN POWER:kVAR - Thisfíeld is a read-ontyfield
rtelothatdisplaystheaverage valueof the three that displaysthe vatueof reactivepowei tñát ¡s
Phase+o-pháse voltages. being outputby the generator.

9uRRENT(A):lb - ThisfietdL a read-onty

.fl.E|ll
tleldthat GEN POWER:PF - This fietd is a read-ontvfietd
displaysthevalueof thecurrenion tn" that displaysthe valueof the powerfactoríhat the
tt-phase of the generator.
generatoris operatingat.
AUXDC INPUT(V):Vaux - Thisfield is a read-only
field that displaysthe levelof dc controlvoltage
that is applied from a remotedevice to the voltage
regulatorterminalsP12-3(B) and P12-6(A).
EXCITERFIELD:Vfd (V) - This field is a read-onty
field that displaysthe value of the exciterfield
voltage.
EXCITEHFIELD:lfd (A) - This field is a read-onty
field that displaysthe value of the exciterfietd
current.
OPERATING MODE - One of three operating
modesmay be selectedas active:'AVR","VAR',
or "PF".Whenan operatingmode is active,the
correspondingindicatorcolor changesfrom black
to red for "AVR"mode.Whenan operatingmode is
active;the correspondingindicatorcolor changes
from black to greenfor the "VAR"mode and the
"PF"mode.
Note:WheneitherKVARor PF mode are selected,
the appropriatebuttonmust be selectedand the
Auxiliarybreakercontactthat is connectedto Pg-6
(KVAR/PF enablecontact)and P9-g(contactsense
common)must be closed.
FINEADJUSTMENT.*The "Raise"and "Lower"
buttonscontrolthe flne adjustmentof the operating
setpoint.Thesebuttonsperformthe samefunction
as closingthe appropriateset of contactsconnectéd
to the ContactSense- Raiseínput(terminalpg-5)
and ContactSense- Lowerinput (terminalPg-4)of
the voltageregulator.Eachclick of the Raisebutton
increasesthe voltagesetpointby 0.1 V each click
of the Lowerbuttondecreasesthe voltagesetpoint
by 0.1 V.
Note:The PT ratiowill affectthis settino.
SETPOINT: AVR (V) - This seningt¡efl is used ro
enterthe desiredgeneratorterminalvoltage.The
bacf(groundcolor of this fieH is greenwhen the
voltageregulatoris in AVRmode.
Note:The PT ratio will affect this setting.
SETPOINT:VAR (o/.of nom.) - This setting
oeterminesthe levelof generatorVARsmaintained
by the voltage regulatoiwhenoperatingin VAR
mode.The backgroundcolor of this field is green
whenthe voltageregulatoris regulatingtne VRR
setpoint.A percentagevalueol zeroto t0O.Omay
0e enteredin 0.1 percentincrements.
SETPOINT:PowerFactor- This seüing determines
the level of power factor regulationmalntainedby
the voltageregulator.The backgroundcolor of
this field is greenwhen the voltageregulatoris
regulatingthe power factor setpoint.A power factor
valueof -0.600 to 0.600may be enteredin 0.001
increments.
STAIUS- Fourindicatorsindicatethe operating
s,tgtusof the voltageregulator;"Droop","LineDróp",
"UnderFrequency",and "SoftStart".
The Droopind¡catorturns red when the Reactive
Droop Compensation featureis selected.The
ReactiveDroop Compensationfeature is used
during parallelgeneratoroperatíonto assistin the
sharing of reactiveload.
The Line Drop indicatorturns red when the Line
Drop Compensation featureis selectedThe Line
Drop Compensation featureis used to compensate
for voltagedrops in the linesbetweenthe generator
and the load.
The UnderFrequencyindicatorturns red whenthe
generatorfrequencydecreasesbelowthe Knee
Frequencysettingand excitationis terminated.
The Soft Start indicatorturns red when the Soft Start
feature is active to controlthe time for generator
voltageto ramp up duringstartup.
CONTACTINPUTS- Five indicatorsprovidethe
statusof the voltageregulatorswitch inputs:
"Lower",.VAR/ PF","ExcÍtationDisable",
.,,"Raise",
and "FaultReset".
The Raiseindicatorturns red when contactclosure
al terminalsP9-5(ContactSense- Raise)and p9-6
(ContactSense- Common)is detected.
The Lowerindicatorturnsred when contactclosure
at terminalsP9-4(ContactSense- Lower)and pg-6
(ContactSense- Common)is detected.
The Var/PFindicatorturns red when contactclosure
at terminalsPg-9(ContactSense- yarlpFEnable)
and P9-6(ContactSense- Common)is detected.
The Excitationt
Disableindicatorturns red when
contactclosureat terminalsPg-7(ContactSense
- ExciiationDisabte)and P9-6(CdntacfSenr" -
Common)is detected.
The FaultResetindicatorturns red when contact
closureat terminalsP9-8(ContactSense- Fault
Reset)and Pg-6(ContactSense- Common)is
detected.
 ALABMS- Ten indicatorsannunciatealarm
conditions.Alarm indicatorsíncludethe following
alarms:"lnternalMemoryFailure","lnternal
WatchdogFailure","ExciterDiode Monitor,'.
"ExcitationLoss", "GeneratorOvervoltage',,
"GeneratorUndervoltage","Overexcitation',, "Loss
of Sensing","FieldOvercurrent", and
r. , qt tu '.Fault
I qult Reset
nEDEI
TooLong". When the voltage regulator
r9 r r r r lv ¡ reoulatordetects an
rvvqrswr ugtgvto qt I

alarm.condition,the appropriateindicatorchanges
from black to red.

ALARMS:ShutdownOverrideStatus - This
indicationprovidesthe status(position)of the
'ShutdownOverrideButton".The buttondisplays
'ENABLED"when setectedand ',DISABLED;,when
deselected.

SettingsFiles
CaterpillarPC softwareenablesyou to print a list of
voltageregulatorsettings,save voltageregulator
seüingsin a file, and open a settingsfile iñ order
to u.pload.those settingsto a voltageregulator.A
settingsfife may also be openedanOeó¡teOw¡tn
any text editing software.

Í
 Test¡ngand AdjustingSection

Printingthe Settings Files

lllustration25 901040303
Print lcon

901016740
 1/2 :J¡J e l- I

tAT PCSnftwam
Settings
Tille

:i1..,,r PCVesion {.ü0.01

.i,, D¡te EcTime Mandry,
May13,?Bffi,3?€:13
PM
Commentr ;¡¡i CüMMEHTS ¡'Í'

t
R ¿ ütd IIJ IR {Q 0- $ Pow r fr c r or J : ?5
Scn= ing lfoilc ; I l 0-3i ¡r gl c -
R¿tcil ÉcnÉ¡¿tor Fr:qrxnry: 0 f0=60 l l s .
R¡tt4 Éene¡:tor llol;rgc : J.?0 {üolt= }
, Gcncr:tor FT Frinrry Voltrgc F.:ting: 1e0 f U ol tr )
É*n+¡¡t+r PT 3+corid.:ry V+lü¡g€ R¡ting: ¡¿0 (U +l t?J
Érnr¡¡to- CT Prir:'ry Clrrtcnt Reting: 60ü { tunp=}
Gcne-¡tor *! Ecc+ndrry lur¡crÉ Rtting: 5 {erp=}
R¡ted Gcne¡¿to¡ tu¡nü: 60q [ &¡F= ]
Fourr Input ltcqucncy: ó0 [i t¡]

lllustratíon27 90 1016741

A printoutof voltageregulatorsett¡ngscan be useful

for recordkeepingor comparisonpurposes.The
voltageregulatorsettingscan be printedby clicking
the printicon (1) or clicking"File"on the menubai
and thenclicking"Print".Whenthe pr¡ntcommand
is given,a dialog box providesthe opportunityto
add a title and commentsto the settinoslist. See
illustration
26. Eachentrv is l¡m¡tedto á maximum
of 54 characters.Aftertñis informationis entered,
clickon "OK".The "PrintSeüings"box will appear.
Seeillustration27. This dialog6ox is used in order
to selectthe desiredprinter,changeand verifythe
printersettings,and previewthe printedsettings
list.Clickon the "Print"buttonin orderto pr¡ntthe
settingslist.
 Section

Savingthe Settings Files

lllustration
2g
90104O30S
Savelcon

Saving.the voltageregulatorsettingsin a file for

uploadingto othervoltageregulatorunitssaves
time when configuiingmuttipteunitswith the
:etup
samesettings.A settingsfile can also be created
In the PC softwarewithoutbeing connected
to
a voltageregulator.The settiñgJof the desired
screenscan be changedand-thesesettinoscan
tnenbe saved to a file. Once a settingsfile is
crg|ted,the file can be edited usinq ánv texr
edifingsoftware,and the tfe cán ine-nOJ saveO
tor
uploading.
Asettingsfile is createdby clicking
the save icon
.ll1 9l by clicking"Fite"on the menu bar and then
"Save".-When the commandis given,
l',".Ilg
:^*.Yu As" diatogbox is disptayedwhérethe
.l?Iing. areassigñeáa fitenameandthensaved.
regutator settings fitesareautomaticaily
'*il,l:'lugu,
tvena ".dv2" extension.
Uploadingthe Settings Files to the
Voltage Regulator
A voltageregulatorsettingsfile downloadedfrom a
voltage regulatoror creatédwithin the pC software
ga1 be uploadedto multiplevoltageregulatorunits.
Only a.vottageregutatoróettingstile wiífrá; .¿uZ',
extensioncan be uploadedtoá voltaqereoulator
unit. Beforeuploadinga file, communicatioñ must
be initiatedwitf the voltageregulatorthat is to
receivethe seftings.see"syste"ms ópéiái¡on,
"HemoteCommunication".
The upload processis startedby clickinothe
open icon or clicking"File"on the menu-barand
thenclicking"Open".An ,,Open"dialoobox is
then displayedwherethe desiredsettiñqsfile is
navigatedto and selected.Clicking,'Opén"uploads
the settingsfile.
 i0195e57 Resetingthe voltageregulatormay be achíeved
eitherby momentarilyclosingthe Fault Reset
Troubleshooting contactinputor by cycling24Ydccontrolpower.

SMCSCode:4467
i01954619
lf the voltageregulatordoes not operateas No Voltage- Troubleshoot
expected,first check the programmablesettings
toi tne appropriatefunction.Use the following SMCSGode: 4467-035
troubleshooting procedureswhen difficultiesare
encounteredin the operationof the excitation
system.

AIarmor ShutdownFaults
Faultsthat are discussedin this sect¡onwill not
causeexcitationto be turned off unlesssome
externalmeansof removingexcitationis wired into
the Alarmor the ShutdownFaultoutputdriver.
Shutdownfaults that always cause excitationto be
turnedoff are discussedin Testingand Adjusting,
"No Voltage- Troubleshoot".Open communication
withthe voltageregulatorin order to determine
whichfault conditionhas occurred.
lllustration29 90 1021519
lf an ExcitationLoss (reverseVAR) fault has
occurred,a reverseVARconditionhas been
detectedin excessof the programmedthreshold
for longerthan the ppogrammed time delay.lf an The Cat Digital Voltage Regulator presents an
incorrectfault detectionis suspected,verifythat electrlcal shocldelectrocutlon haza¡d.Thls hazad
the programmedsettingsare compatiblew¡ththej wlll cause serious Injury or death.
application.lf settingsare correct,it is possible
to get an incorrectfault detectionif the generator Service by trained personnel only.
voltageand the generatorcurrentsensinginputs
to the voltageregulatorare not properlywired for oThetermlnals and heat sinks are llve at hazardous
ABC rotation.Verifycorrectwiringof the generator voltages when power ls applled and for up to I
voltageand generatorcurrentsensinginputsto minutes after power is removed.
the voltageregulator.See Testingand Adjusting,
"WiringDiagrams".
1. Verifythat all of the wiring is properlyconnected.
lf a GeneratorOvervoltagefault has occurred,a Referto Testingand Adjusting,"Wiring
generatorovervoltageconditionhas been detected Diagrams".
at the generatorvoltageser¡singinput(s)of the
voltageregulatorin excessóf the programmed OK - lf the wiringconnectionsare correct,go
mresholdfor longerthan the programmedtime to step 2.
clelay.SeeTestingand Adjusting,"High Voltage-
¡roubleshoot". NOTOK - lf the wiringis improperlyconnected
or the wiring is loose,reconnectthe wiring
Í a GeneratorUndervoltagefault has occurred, properly.
.
álgeneratoruná"róriágelondition has been
delectedat the generator
oeneratórvoltage
voltaoesensing
sensinoinput(s)
inou of srgP.
voltageregulatorin excessof the programmed
sholdfor longer
lonoerthan the progr
oroorammedtime 2. Veritythat the generatoris running at rated
.See_Testin-Oand Adjustlng,"Low Voltage- speed.

OK - lf the generatoris spinningat ratedspeed,

FaultResetcontactinout is closedfor more go to step 3.
10 seconds,a FaultRésetTooLong fault has
. Removethe short acrossthe FaultReset NOTOK - lf the generatoris not at ratedspeed,
input. increasegeneratorspeed to the ratedvalue.

STOP.
3. The digital voltage regulatoris PMG power or
ShuntPowered.
PMGpower - Proceedto step f,
ShuntPowered- Proceedto step 5.
4. Check for correct input power to the voltage
regulator.Referto Specification,"Electrical",for
inputpower requirements.
OK - lf voltageis present,go to step 5.
NOTOK - lf PMGvoltageis not present,referto
the generatormanualfor the repairprocedures
and check for an open circuit.
STOP.
5. Verifythat the residualvoltageappliedto the
powerinput is at least6 ACV.
OK - lf the appliedvoltageis 6 ACV or greater,
go to step 6.
NOTOK - lf the appliedvoltageis less than 6
ACV referto the generatormanualand flashthe
generatorfield. l¡stall blockingdiodesin series
withthe batterfin orderto preventdamageto
the voltageregulatorandlorthe battery. :\
STOP.
6. Verifythat the fuse is not open.
OK - lf no fusesare open, go to step 6.
NOTOK - Replaceany fusesthat are open.
STOP.
7. Verifythat the commonalarm/Shutdown LED
indicatoron the voltagqregulatoris not flashing.
OK - lf no protectivefault has causedthe
excitationto be turnedoff, go to step 14.
NOTOK - lf the LED indicatoris flashing,open
communications with the voltageregulatorto
determineif a protectiveshutdownlault has
occurredthat would cause excitationto be
turnedoff. lf protectiveshutdownfault has
sccurredthat would cause excitationto be
, turnedoff, go to step g.
8. lf an ExciterDiode Monitor(EDM)fault has
occurred,stop the machine,insurethat the
powerinput to the voltage regulatoris removed,
and unplug"P6" on the voltageregulator.Refer
to the generatormanualfor instructionson
checkingthe rotatingexciter diodes. Have the
rotatingexciter diode assemblychecked for
open or shorted diodes. lf an open or shorted
diode is present in the rotatingexciter diode
assembly,refer to the generatormanualfor
instructionson how to replacethe rotatingrecifier
assembly.After repairsare complete,resetthe
voltageregulatorby momentarilyclosingthe
Fault Resetcontact or by cycling 24V control
power.The generatormay be restarted.lf there
is no problemwith the rotatingexciter diode
assembly,the EDM trip va¡uemay be set too
low An EDM fault may occur with good rotating
exciterdiodesundervaryingloadsif the trip level
is set too low. Set the EDM trip level to a value
greaterthanthe RMSripplecurrentpresentin the
exciterfield under normaloperatingconditions
in orderto preventa falseirip. Beconnect"P6".
Resetthe voltageregulatorby momentarily
closingthe FaultResetcontactor by cycling24V
controlpower.The generatormay be restarted.
lf an ExciterDiode Monitor(EDM)fault has not
occurred,go to step 9.
9. lf an Over Excitationfault has occurred,stop the
machineand have the generatorand/ or load
conditionscheckedfor a generatoror load fault
that could cause excessiveexciterfield current
to flow.Also have the systemchecked for loose
or open connectionsto the voltageregulator
sensinginputs.Any faultsmust be repaired.After
repairsare complete,resetthe voltageregulator
by momentarily closingthe FaultResetcontact
or by cycling24V controlpower.The generator
may be restarted.lf no generatoror load fault
has occurredand thereare no looseor open
connectionsto the sensinginputsof the voltage
regulator,verifythat the Over Excitationtrip level
and the delay settingsare properlyadjustedfor
the generator.Set the Over Excitationtrip level
slightlyabovethe requirementof the application
but not so high as to renderthe protection
ineffectiveor damage the system. Resetthe
voltagerégulatorby momentarilyclosingthe
FaultResetcontactor by cycling 24V control
pbwer.The generatormay be restarted.lf an
Over Excitationfault has not occurred,go to
step 10.
Note:SR4and SR4Bgeneratorsmay requireup to
12 Amperesfor full load excitation.A 10 second
delay is neededin orderto insure300 percentshort
circuitcurrentrequirements.
 $.lf a Loss of Sensingfault has occurred,stop NOT OK - lf after resettingthe voltage regulator
the machineand havethe systemcheckedfor anotherInternalWatchdogFailurefaultoccurs,
bose or open connectionsto the voltagesensing replacethe voltageregulator.
inputsof the voltageregulator.Also, have the
oeneratorandl or load conditionscheckedfor STOP.
á generatoror load faultthat could causethe
sensedvoltageto be low lf the generatoris 14.Replacethe voltageregulatorunit. lf replacing
equippedwith voltagetransformers for stepping the voltageregulatorunit does not correctthe
the generatorvoltage down to levels usable by problem,go to step 15.
the voltage regulator,verifythat the transformers
are functionaland that any transformerfuses l5.There is a problemwith the generator.Refer
are not open. lf transformerfusesare found to to the generatormanualto troubleshootthe
be open,replacethe fuses.Any faultsmust be problem.
repaired.After repairsare complete,resetthe
voltageregulatorby momentarily closingthe
FaultResetcontactor by cycling24V control i01s54791
power.The generatormay be restarted.lf a Loss Low Voltage- Troubleshoot
of Sensingfault has not occurred,go to step 11.
SMCS Code: 4467-035
11.|f a FieldOvercurrent
fault has occurred,stop
the machineand havethe generatorandl or load
conditionscheckedfor a generatoror load fault
that could causeexcessiveexciterfield current
to flow.Also havethe systemcheckedfor loose
or open connectionsto the voltageregulator
sensinginputs.A FieldOvercurrentfault is
detectedwhen outputcurrentfrom the voltage
regulatorexceedsapproximately 28 A.
OK - lf a Field dvercurrentfault has not
occurred,go to step 12.

NOTOK - Any fault must be repaired.After

repairsare complete,resetthe voltageregulator
by momentarily closingthe FaultResetcontact lllustration30 90 1021519
or by cycling 24V controlpower.The generator
may be restarted.

STOP.
12.lf an InternalMemorvFailurefaulthas occurred.
try resettingthe voltageregulatorby momentarily
closingthe FaultResetcontactor by cycling24V
controlpower.
\
STOP.- lf an InternalMemorvfault has not
occurred,go to step 13.
., :.,.,NOTOK - lf afterresettingthe voltageregulator
anotherInternalMemoryFáitureoccürs,réptace
the voltageregulator.
The Cat Digital Voltage Regulator presents an
electr¡cal shock/electrocution hazard.This hazard
wlll cause serious Injury or death.
Service by trained personnel only.
The termlnals and heat sinks are live at hazardous
voltages when power is applied and for up to I
minutes after power is removed.
1. Verifythat the voltageadjustmentis not set too
low,

OK - lf the voltageadjustmentis correct,go to

step 2.
an lnternalWatchdogFailurefault has
reset the voltage regulatorby NOTOK - lf the voltage adjustmentis too loq
)mentarily
closingthe FaultResetcontactor adjustthe voltageto the correctsetpoint.
cycling24 volt control.power.
STOP,
i lf an lnternalWatchdogFailurefault has
_-
t occurred,go to step 14. 2. Verifythat the underfrequencysetpoint(knee
1 frequency)is not greaterthan the generator
rrequency.
 46
Testingand AdjustingSection

OK - lf the underfrequency
setpointis correct, NOT OK - lf the turns ratio of the sensing
go to steP3. potentialtransformeris incorrect,replaceihe
sensingpotentialtransformer.
NOTOK - lf the underfrequency setpointis
too high, adjustthe setpointbelowthe rated STOP.
generatorfrequency.
8. Low generatoroutput voltage may occur when
STOP. operatingin droop mode with an inductiveload.
lf the low voltageconditionis not causedbv the
3. Verifythat the generatoris runningat rated droop function,go to step 9.
speed.
9. Replacethe voltage regulator.
OK - lf the generatoris runningat ratedspeed,
go to step 5.
i01954865
NOTOK - lf the generatoris not at rated speed,
increasethe generatorspeed to the rated level. HighVoltage- Troubleshoot
STOP. SMCS Gode: 4467-Ogs

4. PMGpoweror Shuntpoweredregulator

PMGpower - Proceedto step5.

Shuntpowered- Proceedto step6.

5. Checkfor the correctinput powerto the voltage

regulator.Referto"Specification,,,Electrical,'
for
inputpower requifements.

OK - lf the voltageis at the requiredlevel,go'

to step 7.

NOTOK - lf the voftageregulatorinputvoltageis lllustration3l 901021519

low,referto the generatormanualforpMG re-oair.

STOP.

5. Verifythat the potentialtransformer(if used) Tfe Qat Digital VoltageRegutatorpresentsan

nas rne correctturns ratioand is supplyingthe electricalshocUelectrocution
hazarU.frus hazard
correctvoltageto the powerinput. will cause eerious Inlury or death.

OK - lf the turns ratioof {he power potent¡al Service by tralned personnel only.
transformeris correct, go to step 7. '
The terminals and heat sinks are ilve at hazardous
NOTOK - lf the turns ratio of the potent¡al voltages when power ls applied and for up to g
transformeris incorrect,is sizedtoo small,or the m¡nutes after power ls removed.
transformeris not supplyingthe correctpower,
replacethe potentialtiansfórmer. 1. Verifythat tñe volüageadjustmentis not set too
his!.
STOP.
OK -^lf the voltageadjustmentis correct,go to
that the sensingpotentialtransformer{if step 2.
. =Zt t_e1it¡i
used)has the correctturns ratioand is operating
fii:t'i*!., 6¡
correctly.
r.^r.,' r,
NOTOK - lf the voltageadjustmentis too high,
adjust the voltage to the coirect setpoint.
; i 9K - lf the sensingpoterüiattransformeris
operatingconecily, gjo to step g.
STOP.

2. Verifythat the sensingpotentialtransformer(if

used) has the correctturns ratio.
 OK - lf the sensingpotentialtransformeris o1955489
correct,go to step 3.
UnstableVoltage-
NOTOK - lf the turns ratio of the sensing
potentialtransformeris incorrect,replace the
Troubleshoot
sensingpotentialtransformerwith the correct SMCS Gode: 4467-035
one.

STOP.

3. High generatoroutputvoltagemay occur when

operatingin droop mode with a capacitiveload.
lf the highvoltageconditionis not causedby the
droopfunction,go to step 4.

4. High generatoroutput voltage may occur when

operatingin line drop compensationmode with a
largegeneratorload. lf the high voltagecondition
is not caused by the line drop compensation
function,go to step 5.

5. Verifythat the fuses for the sensingpotential lllustration32 90102.l519

transformer(if used) are not open.

OK - lf the fuses for the sensingpotential

transformerare correct, go to step 6.
NOTOK - lf the fusesfor the sensingpotential
transformerare gpen, replacethe fuses.
STOP.
6. Verifythat the auxiliaryinput voltagegoing to
the voltageregulatoris presentor abnormally
high.Higherthan normalvoltageat this inputwill
causea higherthan normalgeneratorvoltage.lf
voltageis presenton the auxiliaryinput,remove
the input by removingthe wiringgoing to the
voltageregulator.lf the wire is removedand the
generatorvoltagereturnsto the desiredlevel,
¡nvestigate wherethe voltageís comíngfrom,
possiblea VAR/PFcontrolleror anothersource
of control.lf the auxiliaryinput voltageis not
presentor abnormally hi$h,go to step 7.
7. Replacethe voltage regulator.
The Cat Digital Voltage Regulator presents an
efectrfcal shock/electrocutlon haza¡d.Thls hazard
wlll cause serlous Injury or death.
Servlce by trained personnel only.
The terminals and heat sinks are live at hazardous
voltages when power ls applied and for up to g
minutes after power is remored.
1. Verifythat the governorfor the engine is
operatingproperly.
OK - lf the governoris operatingproperly,go
to step 2.
NOTOK - lf the governoris not operating
properly,referto the enginemanualin orderto
troubleshootthe problem.
STOP.

2. Yerifythatrthesensingand input power leads

are connectedsecurely.

Oú - lt the sensingor input power lead

connectionsare secure,go to step 3.

NOTOK - lf the sensingor inputpowerleadsare

not connectedsecurely,tightenthe connections.

STOP.

3. Verifythat the voltageregulatorstabilityrange is

set to the properrange.
 I
Testíngand AdjustingSection

OK - lf the stabilityrange settingis correct,go 2. Checkfor groundedfield leads.

to step 4.
NOTOK - lf the stabilityrange settingis
incorrect,resetthe stabilityrange.
STOP.
4. Veri'Íythat the stability level is properly set. !f
the stabilitylevel is not properlyset, resetthe
stabilitylevel.
OK - lf the field leads are not grounded,go to
step 3.
NOTOK - lf the field leadsare grounded,isolate
the field leadsfrom ground.
STOP.
3. Checkfor groundedpMG leads.

OK - lf the PMG leads are not grounded,go to

step 4.
PoorVoltageRegulation-
NOTOK - lf the pMG leads are grounded,
Troubleshoot isolatethe PMGleadsfrom grounó.
SMCSCode: 4467-035 STOP.

4. Verifythat the generatorfrequencyis

not.droppingbelow the voltageregulator
underfrequency setpointwhen load is applied
to the generator.

OK - lf poor regulationis not relatedto voltage

regulatorunderfrequency operation,go to ste[ S.

l,lOJO.T- lf the.generatorfrequencyis dropping

belowthe underfrequency setpoint,reduce'the'
setpointif possible.Also check the engineand
generatorfor proper sizing in relation[o tne
appliedload.
lllustration33 g0'1021519
STOP.

Note:Measurethe PMGvoltagefrom line to line.

The Cat Digltal Voltage Regulator prcsents an
e|ectr¡calshock/electrocution hazad- This hazard
wlll cause serious Inlury or death.
Serviceby tralned personnel only.
Theterminals and heat sinkl are flve at hazatdous
lqltages when power is apptied and for up ro 8
m¡nutesafter power is removed.
rs properlygrounded.
9I - [ the vottageregutatoris property
grounded,go to step 2.
, IOJ O.K- lf the vottageregulatoris not property
*: connecta áeOicáteO
.g_r,ou$9q, groundwiré to'
terminalP6-6on the voltageregúator.
'::l:1.'
!1,.srop.
5. Verifythat regulationis not being affected by
normaldroop operation.lf droop operationis not
affectingregulation,go to step 6. '
6. Verifythat regulationis not being affectedby
normalline loss compensation. lf line loss
compensation is not affectingregulation,replace
the voltage regulator.
On new applicationsand when commissionino.
check the PIQvalue. lf voltagefluctuatesat
steady-stateN.L. or F.L.,reduce Kg or if at 1.0
reducqKp. RecalculateplD in calculator.
Note:Self Excited(shuntpowered)generatorswill
have a greaterinput power voltagelhan pMG
generators.Thiswill requirea lowergain settings
(Kg firstthen Kp if necessary)on coriparablysized
machine.AdjustKg valuesfirst,then Kp valúes
to reach acceptablesteady-stateand tiansient
responses.
 i01955501
No Line Loss Compensation
- resistiveload. lf only a resistiveload is being
Troubleshoot
SMCSGode: 4467-035
*r$*tr* *.
lllustrat¡on34 901021519
The Gat Digital Voltage Regulator presents an
efectrical shock/electrocut¡onhaza¡d.This hazard
will causeseriouslnjury or death.
f
Service by trained personnelonly.
Theterminalsand heat sinks are live at hazardous
voltages when power ls applied and for up to 8
m¡nutes after power ls removed.
1. Verifythat the voltageregulatoris programmed
for linelosscompensation.lf the voltageregulator
is programmedfor line loss compensation, go
to step 2.
2. Verifythat the voltageregulatorline drop setting
is not adjustedto 0%. lf the line drop settingis
adjustedto 0%, increase\hesetpointabove07o.
lf the line drop settingis adjustedto above0%,
go to step 3.
3. Checkfor an open in the circuitconnectedto
voltageregufatorterminalsP12-1 and P12-2
and CT2. lf there is an open circuit,repairas
necessary.lf thereis not an open circuit,go to
step 4.
4. Ve{y that all connectionsare correctaccording
to Testingand Adjusting,"WiringDiagrams".lf
connectionsare incorrect,correctthe problem.lf
connectionsare correct,go to step 5.
5. Verifythat the load that is being applied to
the generatorfor droop testingis not a purely
appliedto the generator,apply an inductive
load and retest.lf the load being appliedto the
generatoris inductive,go to step 6.
6. Verifythat the currentsensingtransformerthat
is being úsed is compatiblewith the voltage
regulator.For example,a currentsensing
transformerwith a 'l-ampereoutputratingwould
producevery little droop since the voltage
regulatorhas a S-amperecurrenttransformer
input.lf the currenttransformerinput is incorrect,
replacethe currentsensingtransformerfor
compatibility.lf the currenttransformerinput is
correct,go to step 7.
7. ll all of the previoussteps fail to correct the
malfunction,replacethe voltageregulator.
i01955495
No VoltageDroop -
Troubleshoot
SMCSCode: 4467-035
lllustral¡on35 90 1021519
The Cat Dlgital Voltage Regulatorpresents an
electr¡calshqpk/electrocution
hazard.This hazard
willcauseseriousinjuryor death.
Serviceby trainedpersonnelonly,
Thetermlnalsandheats¡nksarelive at hazardous
voltageswhen powerls apptiedand for up to I
mlnutesafterpoweris removed.
1. Verifythat the voltageregulatoris programmed
for droop mode. If the voltageregulatoris
programmedfor droop mode,go to step 2.
 Verifythat the voltage regulatordroop setting is
not ádjustedto 0% droop. lf the droop setting
is adjustedto 0% droop, increasethe setpoínt
aboveO"/".lfthe droop settingis adjustedto
aboveOo/",go to steP 3.

3. Checkfor an open in the circuitconnectedto

voltageregulatorterminalsP12-1 and P12-2
and CT2. lf there is an open circuit, repair as
necessary.lf there is not an open circuit, go to
steP 4.
Verifythat all connectionsare correct according
to Testingand Adjusting,"WiringDiagrams".lf
connectionsare incorrect,correctthe problem.lf
connectionsare correct,go to step 5.

Verífythat the load that is being applied to

the generatorfor droop testing is not a purely
resistiveload. lf only a resistiveload is being
appliedto the generator,apply an inductive
loadand retest.lf the load being appliedto the
generatoris inductíve,go to step 6.

Verifythat the current sensingtransformerthat

is being used is compatiblewith the voltage
regulator.For example,a currentsensing
transformerwith a 1-ampereoutput rating would
produce very lit$e droop since the voltage
regulatorhas a S-amperecurrenttransformer
input.lf the currenttransformerinputis incorrpct,
replace the current sensing transformerfor
compatibility.lf the currenttransformerinput is
correct,go to step 7.

lf all of the previoussteps fail to correct the

malfunction,replacethe voltageregulator.
 51

i01951525

WiringDiagrams

rñ-l
I
) ](
o'* B Iiir i

r
I GTB
lr
rl l l
PMG l:'-:
L-
\-,\-z\-A-/

r+l
24Vdc
-\ Z^v-iz^v1 +

P e ' , r ( F 2 , -l )Pe s( F 1 ,+ )lPÉ1 lPs2 P&3 Pl2n P12.2 l P12- 10 l Pl 2- 11 l P12- 12 P12-8(+) P12-7 l-',) P6-6

CURRENT VOLTAGE 24 Vdc CONTROL

FIELDOUTPUT POWERINPUT GROUND
SENSING SENSING POWER

CAT DigitalVoltageRegulator
VAR/PF EXCTTATTONI FAULT RAISE/LOWER I ALARM SHUTDOWN +/-10VDG
CONTROL yDISABLE I RESET INPUTS I DRIVER FAI.JLTDRIVEF CONTROLINPUT
P9-9 P9-7 P+8 m.6 | Pe-{ | m-5 I P124(-) | P12{(+) P12-5(-) P12-6(+l I P12.s(-)
:i

52a q q I sr o.

901015474
lllustraüon36
Typicalconnectionsfor PMG power,ABC roiation,and lhree-phasesensing
E,
iásting and AdiustingSection

l-i'-
A

r;
I
I
I
:
fl G EN
I CTB
FI

tl
lll¡
- l.sz t
Li--
ii

L- f r----.,
\_-,v\--^J 24Ydc
a\aY-\a\ ffi +
t--7--T
) ) )
P&2 Pe3 fP12-10lP12-t1lPlz-rz Pl2-1 | P12-2 P r 2 - s ( +)l e t z - z ¡ ¡ I P&6
Pa4(F2,-) lFGs(F1,+) | Pel
CURRENT 24VdcCONTROLI cnOU¡,¡o
áo orrru, | ,o*=r,*ru,| :?h$tr SENSING POWER I ""-

CAT DigitalVoltageRegulator
rlulr ALARM +/-10VDC
VAR/PF EXCTTATIONI lRAlsE/LowER SHUTDOWN
DRIVER FAULTDRIVEF CONTROLINP|'JT
CONTROL DIsABLElnEserllNPUTs
F€.9 Ps-7 | Ps-g I Ps-6 | Ps4 | Pe-s P124 (-) Pr2-s(+) | Pl2-s(-) P12- 6( +) | P123( - )

52a I { { ls'' ó..

\\{',

i 901015488
fllustrat¡on
37
Typicalconnectionsfor Shunt power,ABC rotation,and single'phasesensing
 F i , -t l
rr-
)
GEN
CTB
tJ rr-
rl

I l- r_,
\/\_^.'v \_,\._^,^_/
I
v-1 I ri-
I 52 1
I

24Vc€,
r-Y^v Y1 /-Y^Y1"1 +
I

Ps4(Fz,-)lr,ss(Fr,+)
(t
P&l
;$
PG2 P63 Pr2-10 P|z-lr P72-12 Pt2-t P1?-2 Pr2-8{+} I Pl2-7 (-) PA6
VOLTAGE CURRENT 24 Vdc CONTROL
FIELDOUTPUT POWERINPUT GROUND
SENSING SENSING POWER

CATDigitalVoltageRegutator
VAR/PF EXCITATION FAULT RAISE/LOWER ALARM SHUTDOWN +/-10VDC
CONTROL DISABLE RESET INPUTS DRIVER FAULTDRIVER CONTROL INPUT
m-s w-7 P+S P9+ P9.4 P9-5 P12*1(-) Pt2-e(+) | P12-sC) P12.6(+) I Pr2.3(-)

52a
s1 e' .

Illustration38 .a 901015546
Typicalconnectionsfor Shunt power,ABC otation, and three-phasesensing
 T;-
A

) l( u'* CTB
g iili
l -. e rlli
irr I

L
fi
l:r J
I

\J\,^.-'\J
24Vdr.
a'\-\t^\-\ +

Pe4{F2,1 lF5.s(Fr,+) P&1 w2 PS3 Pr2-1 | P12-2 )12-14 Pl2-11 P12-12 Pt2-8 (+) P12-7l-l Pe6
CURRENT VOLTAGE 24 Vdc CONTROL
FIELDOUTPUT FOWERINPUT GROUND
SENSING SENSING POWER

CAT DigitalVoltageRegulator
VAR/PF EXCITATION FAULT RAISE/LOWER ALARM SHUTDOWT.¡ +/-10VDC
CONTROL DISABLE RESET INPUTS DRIVER FAI,JLTDRIVER CONTROLINPUT
P9-9 m-7 P$.A PgSl P9{l P9- 5 P12-1(-) | Pr2-s(+) P12-5(-) P12-6(r) I P12-3(-)

s2ar { { l*,1

lllustraüon39 901015576
Typicalconnoctionsfor PMG power,ABC rotation,and single.phasesensing

i
É
a
a
ñ
 b
) ]( oer,rI :
N

t PMG

I
\-r.\'A.,\J
L,

ii
24Vdc
/^Y^/^Y1 +
iI
PÉ4(F2.-) lPesFl.+) PFr I Psz P&3 P12-1 P12-2 Pl 2- 10 l PI2- 11 l P12- f2 P12-8(+) | P12-7(-) P&6
CURRENT VOLTAGE 24 Vdc CONTROL
FIELDOUTPUT POWERINPUT POWER GROUND
EENSING SENSING
CAT DigitalVoltageRegulator
VAFI/PF EXCITATION FAULT RAISE/LOWER ALARM SHUTDOWI\I +/-10VDC
CONTROL DISABLE RESET INPUTS DBIVER FATJLTDRIVER CONTROLINPUT
F€.9 P9-7 P}B P s€l P e'{l P s.s Pr2.4(-) | Pf2-ei+) P12-s(-) Pr2-6{+) | Pr2-3(-)

s1 0-.
:
¡

lllustration40 901015427
Typicalconnect¡onsfor a PMG PowerInputand a single-phasegenerator
 25WATT

CCCENABLE
CONTACT

25WATT

lllushation4l 9010110047
Crosscunent compensat¡on

.l
¡
I
I
r-- L
I
 57
Index Section

Parameters ....................
16
Generallnformation .......................
16
- Troubleshoot
PoorVoltageRegulation ................
48
PowerFactorRegulation ..........-........
15

ReaciiveVoltageDroop.......... ...........13
RemoteCommunication............... ..... 16
Establishing 17
Communication..............................
TerminatingCommunication 1I
..............................

ServiceToo1s........... ......19
Specifícatíons
Section
StartupProcedure .........19
StartupProfileFunction...... 10
...............
SyslemsOperation Section........ .........I

Tableof Contents...... .......3

TestingandAdjusting ................. .......19
Testingand AdiustingSection ...........19
Troubleshooting
............... 43
..................
Afarmor ShutdownFau|ts.......... 43
........................

.U
K
14
r....................,...
KVARRegu|ation.......................... Unstabf 47
...........
e Voltage- Troubleshoot.................

L v
LineLossCompensation 12
....................................... VoltageRegulation
11
LoadingandStoppingProfile\................................
LowVoftage- Troubleshoot 45
...................
................
w
N WiringDiagrams..... .......51
a
No Une LossCompensation - Troubleshoot.......... 49
NoVoltage- Troubleshoot 43
.....................................
NoVoltageDroop- Troub|eshoot...........................
49

P
Jq
ParameterViewingand ConfiguringProcedure.... 20
Changing 21
...................
Seüings.............,.............
lnstaffing
the Caterpillar
PC Sottware 20
................
Sending-and ReceivingSettings....... 22
.................
settinqDefinitions. ....,..23
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Starting
Caterpillar 21
PC Software........................

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