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Contents
Cat Generator Paralleling Switchgear
Sheet 40
001
CatGenerator
Paralleling
Swit
chgear
Cat
Generator Paralleling Switchgear
Introduction
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.0-2
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.0-4
Cat Switchgear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.1-1
Standard and Custom Configurable Products . . . . . . . . . . . . . . . . . . .
40.1-2
Cat Switchgear Control Technology Features. . . . . . . . . . . . . . . . . . . .
40.1-3
XLM Switchgear
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.2-1
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.2-2
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.2-3
Technical DataXLM One-Line Diagrams . . . . . . . . . . . . . . . . . . . . . .
40.2-4
Functional Sequences of Operations. . . . . . . . . . . . . . . . . . . . . . . . . . .
40.2-1
EGP Switchgear
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.3-1
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.3-2
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.3-3
Technical DataEGP One-Line Diagrams . . . . . . . . . . . . . . . . . . . . . . .
40.3-4
Functional Sequences of Operations. . . . . . . . . . . . . . . . . . . . . . . . . . .
40.3-1
Medium Voltage Systems
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.4-1
XLM Medium Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.4-4
EGP Medium Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.4-8
Custom Systems
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.5-1
Technical DataOne-Line Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . .
40.5-2
Specifications
See Eatons Product Specification Guide
, available on CD or on the Web.
CSI Format: . . . . . . . . . . . . . . . . . . . . . . . . . 1995 2010Low Voltage XLM
UL 1558 Switchgear . . . . . . . . . . . . . . . . Section 16426E Section 26 23 13.1
Low Voltage XLMUL 891 Switchboard . . . . . . . . . . . . . . . . Section 16429E Section 26 24 13.3
Medium Voltage XLMMetal-Clad Switchgear. . . . . . . . . . . . . . Section 16346E Section 26 13 26.1
Low Voltage EGPUL 1558 Switchgear . . . . . . . . . . . . . . . . Section 16426G Section 26 23 13.1
Low Voltage EGPUL 891 Switchboard . . . . . . . . . . . . . . . . Section 16429G Section 26 24 13.3
Medium Voltage EGPMetal-Clad Switchgear. . . . . . . . . . . . . . Section 16346G Section 26 13 26.1
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Introduction
General Description
002
Introduction
General Description
Cat
Generator Paralleling Switchgearis a product developed through a jointventure between Caterpillar and EatonCorporation. Caterpillar, an industryleader in electric generator sets, andEaton, an industry leader in Low andMedium Voltage Switchgear havecombined forces to create CatGenerator Paralleling Switchgear...the most reliable and feature richproduct available in the market today!
Cat Switchgear has been designedto integrate hand-in-glove withCaterpillars on-package, microproces-sor-based engine control. Exclusivelyfrom your Caterpillar dealer, you cannow get the markets best efficiency,reliability and dependability all in
one package.
Cat Switchgear combines the provenlow voltage Magnum DS power circuitbreaker and Magnum Switchgear withCat Switchgear control technology.Cat controls technology is for optimalpower generation and electrical
distribution system performance.It provides advanced, industry-leading, microprocessor-basedengine generator set controlprovided exclusively in Cat Switch-gear. Medium voltage systemscombine VCP-W breakers and VacCladMetal-Clad switchgear with the sameproven generator control technology.
Applications
Emergency/legally requiredstandby systems
Optional standby backup systems
Distributed generation
Peak shaving
Prime power
Reliable, flexible and powerful.Cat Switchgear is designed with themost critical power needs in mind:
Data center/data processing
Healthcare
Critical industrial/chemicalprocesses
Distributed generation/cogeneration
Water/wastewater treatment
Government/military
Banking/credit card processing
Landfill gas power
Cat Switchgear Features
Built-in redundancy
Reliability
Touchscreen interface
Simple, intuitive operation
Advanced communications
capabilities
Integrated digital technology
Advanced generator control andprotection
Detailed engine and electrical reports
Best-in-class footprint
XLM Medium Voltage
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Cat Generator Paralleling Switchgear
Sheet 40
Introduction
General Description
003
Standards
Low Voltage Cat Switchgear conformsto the following applicable standards:
NEMA
Standard SG-5
CSA
ANSI C37.20.1
ANSI C37.51
UL
Standard 1558
NFPA 110, NFPA 99 and NFPA 70
The switchgear uses Magnum DSBreakers that are designed to NEMAStandard SG-3; ANSI StandardsC37.13, C37.16, C37.17 and UL 1066.Optional switchboard constructionis available that is built to UL Standard891. These switchboards use MagnumSB Breakers for generator mains,utility mains and electrically operatedfeeders, and molded-case breakers fornon-switched feeders.
Medium Voltage Cat Switchgearconforms to the following applicablestandards:
NEMA SG-5
ANSI/IEEE C37.20.2
CSA-C22.2 No. 31-M89
EEMAC G8-3.2.
NFPA 70, 99, 110
The switchgear uses VCP-W vacuumcircuit breakers that are designedto meet or exceed all applicableIEEE/ANSI standards including C37.06.
Common ComponentsThroughout the Entire Facility
Cat Generator Paralleling Switchgearis built with Eatons industry-leadingMagnum DS low voltage drawoutswitchgear with Magnum DSbreakers and VacClad mediumvoltage switchgear with VCPWvacuum breakers. This allows theuse of common components on boththe normal power systems and thegenerator power systems. Commonand interchangeable breakers, relays,switchgear assembly parts, breakermaintenance procedures, and so on
can be used to help reduce the overalloperating cost and increase themaintainability of the entire facility.
Overview
Detailed Engine Data
Generator Set Control Screen
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Introduction
Definitions
004
Definitions
The terms and acronyms below arereferenced throughout this sectionon Generator Paralleling Switchgear.These definitions can help the readerfully understand the topics discussed.
Alternator
: A device for convertingmechanical energy into alternatingcurrent electrical energy. It mayalso be called an AC or synchronousgenerator.
ATS
: Automatic Transfer Switch.
Automatic Transfer Switch
: A switchdesigned to sense the loss of onepower source and automaticallytransfer the load to another sourceof power.
Closed-Transition Transfer
: A transferbetween sources that provides amomentary paralleling of both power
sources during a transfer in eitherdirection. This results in no interrup-tion of power to the loads during thetransfer. The closed transition transferis only possible when the sources areproperly synchronized and interfaced.
DGPS Distributed Generation PowerSystem
: Typically a local enginegenset and automation connectedto the utility system to peak shaveor export power.
EGP Switchgear (Engine GeneratorParalleling Switchgear)
: Parallelsmultiple engine/gensets to serve loadstransferred via downstream ATS units.
EGPT Switchgear
: Same as EGPexcept with a controlled emergencygenerator bus tie breaker betweensets of generators to segregate loadsor areas of the bus.
EMCP 3.S
: A Caterpillar microproces-sor module for switchgear control,rugged, industrially hardened,microprocessor-based synchronizerand load controller designed towork exclusively with Cat engine-generator sets.
EMCP Electronic Modular ControlPanel
: A Caterpillar microprocessormodule for engine/genset control.
Emergency Generator Bus Tie
: A bustie breaker used in EGP type systemsto segregate groups of generators and/
or loads. Emergency Generator BusTie breakers are used where criticalloads, required to be powered in10 seconds, exceed the capacity ofa single genset.
EPS Emergency Power System
:The emergency power sources andemergency distribution to down-stream loads.
EPSS Emergency Power System Sup-plier
: Supplier of all the components ofthe EPS, such as the Caterpillar dealer.
Emergency Standby PowerApplication
: Typical usage of 50 hoursper year with a maximum of 200 hours
per year. Generators can be appliedat their Standby rating with a typicalvariable load factor of 70%.
Emergency Tie Breaker
: A feederbreaker that is used to connect anEGP type system to a separate pieceof Normal (utility) switchgear.
Feeder Breaker Controls
: Automationcontrols to allow control of thedistribution feeder devices for loadshed/load add control and monitoring.
Generator
: A machine for convertingmechanical energy into electricalenergy. The electrical energy maybe direct current (DC) or alternating
current (AC).
Generator Bus Tie
: A bus tie used inXLM type systems for separating thegenerator bus and/or loads from thenormal utility fed bus and/or loads.
Generator Demand Priority
: Controlsthat automatically match the onlineengine generator capacity to theload to avoid unnecessary enginegenset operation when loads arelow. (Alternatively called Load SenseLoad Demand.)
Generator Tie Breaker
: A feederbreaker that is used to connect anXLM type system to a separate pieceof Normal (utility) switchgear.
Governor
: A device that regulatesprime mover speed by adjusting the
fuel input to maintain constant speed.
HMI Human Machine Interface
:Typically a touchscreen used bythe operator for interfacing with theparalleling generator system.
LM Switchgear (Load ManagementSwitchgear)
: A single generatorused in distributed generationpower systems. Includes automationcontrols that allow for the load tobe served simultaneously by bothutility and generator power sourceswhile managing how much eachsource contributes.
Load Shed/Load Add
: Automation
controls to control distribution devices(turn OFF and restore ON) when onlypartial emergency engine gensets areavailable for duty. Typically accom-plished by assigning Priority levels toeach controlled distribution device.
Master Controls: All processors,HMI and programming to implementthe desired modes of operationof engine gensets in a parallelingswitchgear system.
NFPA 110Standard for Emergencyand Standby Power Systems:Standard for the assembly, installationand performance of electrical power
systems to supply critical and essentialneeds during outages of the primarypower source.
NPS Normal Power System: Theutility service entrance equipmentand distribution circuits to down-stream loads.
NPSS Normal Power System Supplier:Supplier of all the components of theNPS, such as the distribution equip-ment vendors authorized distributor.
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Cat Generator Paralleling Switchgear
Sheet 40
Introduction
Definitions005
Paralleling: The procedure of connect-ing two or more generators, or otherpower sources, of the same phase,voltage and frequency characteristicssupplying the same load.
Peak Shaving: Process by which
utility customers minimize peakdemand utility charges or exportspower to the utility grid.
Prime Power Application: PrimePower is when the genset is the onlypower source.
Processor: A specially configuredlogic controller with appropriate input-output capability and programming.
SAW (Surface Acoustic Wave):A premium touchscreen sensingtechnology that offers maximumprotection from wear or contaminants.
Station Battery: A power supplyused for control of switchgear.
Synchronizer: A device that willsynchronize an on-coming electricgenerator set with the bus or anotherelectric generator set, and allows
multiple power sources to beconnected in parallel.
Synchroscope: An instrument thatprovides a visual indication of propertime for closing of the breaker whensynchronizing generators to connectthem in parallel with another source.
TFT (Thin Film Transistor): A typeof touchscreen display technologyused in HMI devices that offers highlevels of brightness and clarity.
Utility Protection: A collection ofprotective relays or a multifunctionrelay required by the utility to detectabnormal conditions and open theutility breaker.
XLM Switchgear (Emergency
Transfer [Xfer] and Load ManagemenSwitchgear): Parallels multipleengine/gensets and the utility to servdownstream loads. Typically doesnot include downstream ATS units.
XLMT Switchgear: Same as XLMexcept with a controlled generatorbus tie breaker between the utilitybus and the engine genset bus.
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Cat Generator Paralleling Switchgear
Sheet 40
Introduction
Switchgear Selection007
Cat Switchgear Selector
Table 40.1-1. Cat Switchgear Selector
TabSection
VoltageRange
AvailableSwitchgearListings
ParallelMultiple
Gensets
ParallelWith
Utility
Standby
Application
Transfer
Switches
Modes of Operation ApplicationConsiderations
Emergency
(Standby)
SoftLoad
(ClosedTrans
ition)
PeakShaving
LoadShed/
LoadAdd
Export
Transfer and Load Management Paralleling Switchgear (XLM)
40.2 208600V UL 1558UL 891
XLM product is used when genera-tors will be paralleled with a utility(even if utility breaker is not locatedin the same line-up as generatorbreakers). Allows closed transitiontransfer to/from utility, continuousparalleling with utility for peakshaving or exporting.
Emergency Generator Paralleling Switchgear (EGP)
40.3 208600V UL 1558UL 891
EGP product is used to parallelmultiple gensets to a common buswhere interconnect with the utilityis not necessary. EGP systems aretypically used where there aredownstream Transfer Switches.
Medium Voltage Paralleling Switchgear
40.4 2.427 kV ANSI C37.20.2ANSI C37.20.3
Medium Voltage product is forapplications in excess of 600 Vac.Systems are available in any ofthe configurations above (XLM orEGP). Medium Voltage systems usevacuum circuit breakers for generator and distribution switching.
Custom Paralleling Switchgear Products
40.5 20827 kV UL 1558UL 891ANSI C37.20.2ANSI C37.20.3
Custom Products are available tomeet the most demanding or uniqusystem requirements. (Ex., multipleutilities, multiple ties, special loadcontrol, custom sequence ofoperations, and so on)
G
XLM
GG
EGP
52
MV
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Introduction
Standard and Custom Configurable Products008
Standard ConfigurableProducts
Cat Switchgear is available in twostandard product configurations:
XLM(Emergency Transfer (Xfer)and Load Management)
EGP (Emergency GeneratorParalleling)
These configurations are availablefor both low voltage and mediumvoltage applications and representthe most typical paralleling switchgearconfigurations seen in the industry.Additionally, custom configurationsare available to meet the demandsof even the most unique andcomplicated systems.
XLM
XLM(Emergency Transfer (Xfer)and Load Management) switchgearis used when the Generators areparalleled with a normal utility(or multiple utility) power source(s).XLM switchgear allows closed transi-tion, soft-loading and unloading fromutility, and peak shaving capabilitywhere generators operate continu-ously in parallel with the utility.Typically, XLM switchgear eliminatesthe need for automatic transferswitches. Data centers, industrialprocess, and other critical processloads are prime candidates for XLMswitchgear. For detailed XLM product
description, specifications, layouts,and so on, refer to Section 40.2.
EGPEGP(Emergency Generator Parallel-ing) switchgear is used for parallelingmultiple generators that are notdirectly connected to a utility source.EGP switchgear is primarily used
in applications where downstreamautomatic transfer switches providethe switching between normal andemergency sources. This is what istypically required in medical facilities,hospitals, and water/wastewatertreatment facilities when multiplegenerator sets are paralleled.For detailed EGP product description,specifications, layouts, and so on, referto Section 40.3.
Medium Voltage Switchgear
Medium voltage switchgear isavailable in custom configurations,as well as standard configurationslisted in this section. Medium voltageCat Switchgear uses the same controltechnology and operator interface,and has all of the same features andfunctions as the low voltage systems.At the heart of all medium voltageCat Switchgear systems is EatonsVac-Clad metal-clad switchgear withtype VCP-W vacuum circuit breakers.For detailed medium voltage (5 and15 kV class) product descriptions,specifications, layouts, and so on, referto Section 40.4.
Custom Products
Custom switchgear is available tomeet the needs of the most demand-ing, unique or complicated systemconfigurations. Custom engineered
systems are available for specialsystem requirements such as: customsequences of operation, special loadcontrol requirements, multiple utilityand tie combinations, unique switch-gear locations or layouts, and so on.No matter how complicated or uniquethe system, Cat Switchgear has thepower and flexibility to handle it. Fordetailed custom product description,specifications, layouts, and so on, referto Section 40.5.
Cat C175 Genset
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Cat Generator Paralleling Switchgear
Sheet 40
Introduction
Cat Switchgear009
Cat Switchgear Control Technology Features
Figure 40.1-1. Cat Switchgear Automation ArchitectureHigh Redundancy Package
Features are common to all Low andMedium Voltage configurations.
Cat Switchgear uses the EMCP 3.S,an advanced, industry-leading,multifaceted, microprocessor-basedgenerator set control designed towork exclusively with Cat engine-generator sets.
Redundancy and Fault ToleranceCat Switchgear Control Technologyprovides maximum efficiency andreliability. With Cat Switchgear, singlepoints of failure are eliminated
because of the multiple levels ofredundancy and fault tolerance thatare built into the system:
1. True Distributed Processing.A separate automation controllerfor each power source ensuresthe system continues to operateeven if a single controller fails.This architecture allows the useof redundant Moving MasterTechnology.
2. Moving Master Technology.Master control functions, such asmodes of operation, load shedcontrols, generator demand prioritycontrols, and dead bus logic, andso on, reside in the Generator #1EMCP 3.S. If Generator #1 control-ler fails for any reason, the nextgenerator controller will assumemaster control functions withoutinterruption. Each generator con-troller is redundant to the first andcontains all the settings necessaryto assume master control func-tions. This technology ensures that
if a generator set is available, CatSwitchgear will automatically bringit to the bus.
3. Seamless and Bumpless Transfer.With Moving Master Technology,each EMCP 3.S controller monitorssystem status and data for eachgenerator. Should the EMCP 3.Sfunctioning as the Master controllerfail, the new Master already has allthe pertinent status and data toseamlessly assume the mastercontroller functions.
4. Distributed Manual Control. In thhighly unlikely case of a completloss of system automation, distriuted manual control is available.
5. Redundant CommunicationProcessing.Two independentcommunication processors arebuilt into the EMCP 3.S to controthe Ethernet Channels A and B.
6. Redundant Ethernet SupervisoryNetworks. Each EMCP 3.Scontroller contains dual Ethernetports and is connected to dual,independent Ethernet networks.
7. Instant Auto Switch. If the touchscreen fails, an Instant Autoswitch is provided to place alldigital controls in the Autoposition, protecting your facilityfrom power outages. A functionatouchscreen is not required forcomplete automatic operation ofCat Switchgear.
Remote Operator Station
Ethernet
ATS
ATS
ATS
Modbus
CatATS
to SCADA or BMS
Cat SwitchgearFor systems with utility
interconnect (XLM Type)
Redundant 100 MHz Ethernet
EMCP 3.S(Master)
EMCP 3.S(Redundant
Master)
EMCP 3.S(Redundant
Master)
EMCP 3.S EMCP 3.S
Generator 1 Generator 2 Generator X Redundant Utility/ Tie Controllers
Utility ProtectiveRelay
RedundantEthernet I/O
Touchscreen
TouchscreenProcessor
EthernetSwitch A
EthernetSwitch B
Data Table Interface
Redundant Hardwired SignalsEmergency Start- ATS Run Request- Utility Fail"First Up Dead Bus" Logic
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Cat Switchgear010
8. Remote Operator Stations.Theremote operator station functionscompletely independent of thelocal operator interface touch-screen. If the local operator inter-face touchscreen fails, it will not
affect the operation of the remotestation connected to the system.
9. Hardwired Emergency StartBackup.Each system is designedwith a hardwired emergency startbackup system installed in theevent of a catastrophic networkcommunications failure, utilityEMPC 3.S controller failure, ormaster I/O failures. The hard-wired emergency start backupsystem will initiate a generatorstart signal to ALL of the generatorEMCP 3.S controllers based onany ATS start signal or a UtilityFailure signal. This ensures that
the system is always alerted of autility outage or ATS Run Requestso generators can be started andpower can be restored.
10. Hardwired First Up Dead BusBackup. Each system is designedwith a hardwired hot bus backupsystem installed in the event of acatastrophic network communica-tions failure. This feature preventsmultiple units from closing to aDead Bus at the same time.Once the first generator breakercloses to the bus, a hardwired HotBus signal is passed to all EMCP
3.S controllers and Ethernet I/O.11. Best Source DC System. Control
power is protected against singlepoint of failure by the use of a24 Vdc Best Source DC system.Each engine battery and a stationbattery are connected to acommon DC bus. Each enginebattery and the station battery arefurnished with their own batterycharger. The entire system isprotected so that no individualbattery/charger fault will affectthe rest of the system.
12. Redundant Utility Fail Indication.
For systems with utility intercon-nections (XLM type systems), twoindependent utility failure signalsare present in each processor. Thisensures that the system is alwaysalerted of a utility outage sogenerators can be started andpower can be restored.
Touchscreen InterfaceCat Switchgear technology uses atouchscreen for operator interface,monitoring and control of the parallel-ing switchgear. The screens give theoperator an instantaneous, easily
understandable view of the entiresystem status. This feature is standardin all Cat Switchgear.
To access system controls, all youhave to do is touch the correspondingportion of the screen. The entireengine generator set can be controlledfrom one touchscreen. The easy-to-use touchscreen interface makesit possible to view, monitor andperform multiple functions including:
Metering
Engine data
Protective relay settings
Annunciators Adjust load shed controls and
generator demand priority
Synchronize and parallel
Set modes of operation
Voltage and frequency adjustments
With Cat Switchgear, its simple. Allthe critical information you need isdisplayed in a manner that is easy tounderstand. Graphics look exactly likethe meters and gauges on conventionalswitchgear. At a glance, users can easilysee how the system is performing and,based on real-time information canquickly do whats necessary to corrector optimize system performance.
Generator Metering
Engine Data
Generator Control
Generator Annunciator
Automated Joint Commission Report
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Introduction
Cat Switchgear011
Table 40.1-2. PowerLynx Control Configuration Comparison
Cat SwitchgearControl TechnologyCat Switchgear offers two differentlevels of touchscreen operatorinterface. Each level gives differentoptions for trending, reporting, andlogging capabilities.
High Redundancy Package
19-inch color LCD TFT touchscreen
SAW (surface acoustic wave)LCD touchscreen technology forunsurpassed reliability
Historical trending of enginegenerator and electrical parameters
Unlimited alarm and event logging
Ability to save and archive trend andlogging data
Automated reporting capability
Alarm reports
Log reports Generator system reports
Joint commissioncompliant reports
Optional automatic transferswitch control
Moving master
Redundant control network
Features High Redundancy Standard
Redundancy and Fault Tolerance Features
True distributed processing Standard Standard
Best source 24 Vdc system Standard Standard
Moving master redundancy Standard Optional
Redundant control network Standard Optional
Redundant utility/tie automation processors Standard Optional
Redundant Ethernet I/O Standard Optional
Display Features and Options
Local touchscreen display 19-inch color 15-inch color
3-D generator view for engine data Standard Standard
Dynamic system overview one-line Standard Standard
Full redundant touchscreen Optional Optional
System tuning capabilities via touchscreen Standard Standard
Balance of plant monitoring or control Optional Optional
Individual genset unit display Optional Optional
Logging and Reporting Features
Historic trending Standard Not available
Real-time trend Standard Not availableAlarm and event logging Unlimited 100 events
Save/export alarm logs Standard Not available
Full feature remote monitoring/control Optional Optional
Automated reporting Standard Standard
Custom automated reporting(ex., Joint Commission Test Report, etc.)
Optional Not available
Connectivity to BMS or SCADA systems Optional Optional
ATS Monitoring and Control
Cat ATS monitoring and control Optional Optional
Cat ATS remote settingscapability via touchscreen
Optional Not available
Cat UPS monitoring only Optional Optional
Non-Cat ATS monitoring only Optional Optional
Non-Cat ATS monitoring and control Optional Not available
Non-Cat UPS monitoring only Optional Not available
Standard Package
15-inch color TFT touchscreen
High reliability resistive LCDtouchscreen technology
Limited alarm and event logging
Available moving master
Available redundant network
High-Speed Integrated Control SysteCat Switchgear uses a high-speedindustrially hardened network forsystem control. The high redundancypackage includes a redundant supervsory communication network. Thisensures that the loss of one or moreprocessors or a supervisory communcation network will not affect theintegrity of the switchgear automationThis feature ensures proper systemperformance under any condition.
Best-in-Class FootprintCat Switchgear technology usesless than one-third of the componentof conventional generator parallelingswitchgear. This translates into lesswiring, a smaller footprint, highermean time between failures, andlower mean time to repair.
Integrated Digital TechnologyIntegrated with Cat on-package gensecontrols, Cat controls have built-insynchronizer, power factor controllerand load sharing functions. CatSwitchgear products do not require
additional discrete components,such as synchronizers, cross-currentcompensation devices, speed/voltagedrop controllers, load sharingmodules, and so on.
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Introduction
Cat Switchgear012
Cat Switchgear SystemAdvantagesCat Switchgear performs generatorprotective functions internal to theEMCP 3.S controller. With Cat
technology, you can monitor, process,compare, display and transmit datawith a high degree of precision andcontroland that control translatesinto high reliability and functionality.
EMCP 3.S technology provides CatSwitchgear with enhanced featuresthat set the standards for the industry.
Unequaled fault tolerance
World-leading operator interface
Sophisticated communications abilities
Superior connectivity
Additional Cat Switchgearadvantages include:
Less installation wiring
Smaller footprint provides betterutilization of available space
Detailed engine and electrical reports
Low cost redundancy
Enhanced performance
UL, NFPA, CSA and IEEE compliant
Higher mean time between failure
Lower mean time to repair
Advanced CommunicationsCapabilitiesCat Switchgear technology isequipped with exceptional remotecommunications technologies,enabling you to control and monitoryour engine generator sets fromanywhere at anytime. Whetherat home, in the office, or on theroad, you can access controls andinformation on a real-time basis andrespond immediately...even controlmultiple facilities from a singlecentralized site.
Whether on-site or off-site, the available remote communicationspackage gives you the identicalinterface and same capabilities asstanding in front of the generator orCat Switchgear. Although identical,
the remote communications runcompletely independent of theparalleling switchgear automation.This ensures remote communicationdevices or systems will not affectthe reliability of your Cat Switchgear.
Figures 40.1-2and 40.1-3showexamples of remote communicationconnections to the Cat Switchgear.
Communications with BuildingManagement or SCADA Systems
Cat Switchgear can also easilycommunicate data to third partyBuilding Management, SCADA orother monitoring systems. For theseapplications, a Data Table Interfaceacts as a firewall between your CatSwitchgear system and the BuildingManagement or SCADA System. TheData Table Interface serves up therequested data to the third-partymonitoring system, but stays
completely independent of all criticalgenerator control automation. Thisensures remote communicationdevices or systems will not affectthe reliability of your Cat Switchgear.
Figure 40.1-2. On-Site RemoteEthernet Network with Multiple Users
Cat Switchgear
Ethernet Port
Switchgear PC- Dedicated Static
I.P. Address- Ethernet Port
Key Points:
1. Dedicated Ethernet LAN
or
2. Utilize customers' LANCoordinationwith network administrators may benecessary for connection and security issues.
3. Supports multiple clients.
End User PC- Full Control or View Only (depending on password)- Dedicated Static
I.P. Address
HUB or Switch
End User PC- Full Control or View Only
(depending on password)- Dedicated Static
I.P. Address
End User PC- Full Control or View Only (depending on password)- Dedicated Static
I.P. Address
Cat. 5 cable (up to approx. 300)
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Cat Generator Paralleling Switchgear
Sheet 40
Introduction
Cat Switchgear013
Figure 40.1-3. Off-Site Remote(TCP-IP) Web-Based Connection with Multiple Users (View Only)
On-Site
Your Company
Network
Off-Site
Cat Switchgear
Ethernet Port
Cat. 5 cable(up to approx. 300')
Switchgear PC
Remote Client- Web Browser
Remote Client- Web Browser
Remote Client- Web Browser
Remote Client
- Web Browser
VPN
TUNNEL
VPN TUNNEL
View Only
View Only
VPN Device
Firewall Device- VPN Access
Firewall Device- VPN Access
- 1 Web Server
- Ethernet Port
Provided withCat Switchgear
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September 2011
Cat Generator Paralleling Switchgear
Sheet 40
XLM Switchgear
General Description015
XLM
XLM2 Switchgear
General DescriptionCat XLM SwitchgearGeneratorParalleling Switchgear for EmergencyTransfer (Xfer) and Load Managementcontrol of multiple engine generatorsets with one utility source. For
systems with multiple utility and/ortie breakers, please refer to theCustom Configurable SwitchgearSection 40.5. For medium voltageapplication, refer to Section 40.4.
Automatic transfer to emergencyupon utility failure
Automatic start, synchronize,parallel, and load share on a com-mon bus for emergency operation
Closed transition transfer back toutility upon stable return of power,with soft generator unloading
Closed transition Load ManagementMode with soft loading and unload-ing of generator system
Closed transition transfer toEmergency Mode to facilitatemaintenance, or for storm threatavoidance with soft loading andunloading of generator system
Load shed/load add
Generator demand priority Cost-effective, technically superior
alternative to conventional ATSarrangement
Cat Switchgear brings the power andreliability of microprocessor technol-ogy to your generator switchgearapplication. Through the use of theoperator interface touchscreen displaywith easy-to-follow graphical representations, the Cat Switchgear merges thfeatures of:
Power monitoring
Switchgear automation
Generator set control Optional remote communications
Figure 40.2-1. XLM2 Low Voltage Switchgear PR = Protective Relay.
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September 2011
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XLM Switchgear
Standard and Optional Equipment016
Equipment
Standard EquipmentXLM
Low voltage XLM systems useMagnum DS power circuit breakerswitchgear and Magnum power
circuit breakers. For completetechnical details on Magnum DSswitchgear, see Tab 20
Operator Interface Touchscreen(Choose one of the following):
19.00-inch surface acoustic waveLCD TFT color touchscreen withkey switch
15.00-inch resistive LCD TFT colortouchscreen
Direct data communication toCat microprocessor-based enginegenerator set control network
Full function 0.5% accuracy analogand digital AC metering for utility:
voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR
Full function 0.5% accuracy analogand digital AC metering for genera-tors: voltage 1-2, 2-3, 3-1; current 1, 2,3; frequency; power factor; kW; kVAR
Full function engine gauges; RPM,DC battery voltage, oil pressure,engine coolant temperature, enginehours, number of starts
Full function synchronizing and par-alleling controls with selection forautomatic or manual synchronizing
NFPA 110 engine/generator status,pre-alarm, lamp test button, shut-
down fault annunciation and 85 dBAalarm horn with silence button
Full function 0.5% accuracy analogand digital AC metering for system:voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR
System control functions for auto(standby for emergency), closedtransition to emergency and loadmanagement
Automatic load shed control withon-screen operator adjustments foressential, critical, and non-essentialloads. Manual load shed/load addcontrol
Automatic generator demand prior-ity with on-screen operator adjust-ments for automatic addition andremoval of generator to the load bus
System status and alarm annucia-tion with color display and 85 dbAalarm horn with silence button
Password secured settings andadjustments for generator and sys-tem setups and protective relaying
Alarm summary reports
Settings reports
Engine and generator load charts
3-D engine data (available withADEM 3 or ADEM 4 Governor)
UL 891, UL 1558 or CSA listedand labeled
NEMA 1 or NEMA 3R, deadfrontfreestanding construction
Copper bus, braced for 100 kA
Three-phase, four-wire, 100%neutral,1/4-inch x 2.00-inch copperground bus
Available in 600V, 480/277V or208/120V, 60 Hz
UL 1066 listed power circuitbreakers, 42200 kAIC, two-step
stored energy drawout mountedelectrically operated with long timeand instantaneous trip, and circuitbreaker control switch with lights
Continuous cross bus ratings upto 10,000A at 600 Vac
Mechanical lugs for incoming andoutgoing conductors
Top or bottom conduit entry
Plug together control connectionsacross shipping split
Optional EquipmentXLM
Distribution sections withelectrically operated drawoutUL 1066 circuit breakers
Circuit breaker trip functionsshorttime and/or ground fault (in additionto long time and instantaneous)
Steel barriers between switchboardor switchgear sections for compart-mentalization
Bus/cable barriers
Distribution sections with groupmounted UL 489 molded case circuitbreakers. (UL 891 construction only)
Also available in 150 kA (UL 891)or 200 kA (UL 1558) bus bracingconfigurations
Also available in 8000 and
10,000A continuous cross busratings at 600 Vac
Also available with 4000, 5000 and6000A UL1066 breakers
Trip unit metering and communica-tions (Digitrip 520M, 520MC and 1150)
Also available in 5 kV, 15 kV and27 kV class configurations (seeSection 40.4)
Remote monitoring and control
Building Automation Systemor SCADA communicationsModbus or Ethernet
Remote notification
Historical data trending
Tie Breaker ApplicationMany systems require the use of tiebreakers to meet Code or system per-formance requirements. Tie breakerscan be used anywhere throughout theline-up to segment or isolate desiredsources, loads or sections of bus.
Generator Bus Tie
Generator Bus Ties can be used toseparate the normal electric servicesources from the generator sources.This can also allow separation of loadbreakers to either side of the generatorbus tie breaker in order to allowisolation of load banks, or dedicatedemergency loads. This separationalso may be required by NFPA orlocal codes.
Generator bus tie breakers can beapplied to serve several purposes.
1. Starting of large loadsthegenerator bus tie can be opened toallow multiple generators to beparalleled before being connectedto large load(s). Once multiplegenerators are paralleled, thegenerator bus tie can be closedto power the large loads.
2. Load banksthe generator bustie can allow the generators to beisolated from the normal utility fedbus. Having a distribution breakeror set of load take-off lugs on thegenerator side of the bus allowsthe generators to be load banktested without affecting anynormal utility fed loads.
3. Emergency standby systemswith automatic transfer switchesthe generator bus tie providesisolation between the normal andemergency buses. During a lossof utility power, the generator
bus tie can be opened to isolateall normal loads and allowrestoration of power to emergencyloads. Once emergency loads arerestored, the emergency bus tiecan be reclosed to restore powerto normal loads.
Note: See Page 40.2-8for an exampleof an XLM system with generator bustie breaker.
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September 2011
Cat Generator Paralleling Switchgear
Sheet 40
XLM Switchgear
Features017
Cat XLM Switchgear
Utility Metering
0.5% accuracy
Voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR;
synchroscope
Utility Protective Relaying
15automatic synchronizer
27/59under/overvoltage relay
81 O/Uunder/overfrequency relay
Multi-function utility grade,drawout with:
47phase sequence/phasefailure relay
32reverse direction relay,utility grade, drawout
32/51reverse directionovercurrent relay, utility grade,drawout
32/62reverse direction timingrelay, utility grade, drawout
86reverse power lockout relay,manual reset
25sync check relay
Generator Metering
0.5% accuracy
Voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR;synchroscope
Generator Protective Relaying
27/59under/overvoltage relay
81 O/Uunder/overfrequency relay
32reverse power relay
40loss of excitation(reverse VAR) relay
25sync check relay
Engine Gauges
RPM meter
Engine battery volt meter
Oil pressure gauge
Engine coolant temperature gauge
Engine Monitoring and Alarms
Low coolant temperature pre-alarm
High coolant temperature pre-alarm
and shutdown Low oil pressure pre-alarm and
shutdown
Low fuel alarm (diesel only)
Low engine battery alarm
Overcrank shutdown
Overspeed shutdown
Engine/Generator Control
Automatic engine start
Adjustable engine cool-down timer
15automatic synchronizer
65microprocessor engine gover-nor load sharing and soft loadingcontrol
90VAR/PF and cross currentcompensation controller
System Metering
0.5% accuracy
Voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR
System Protective Relaying
27/59bus under/overvoltage relay
81 O/Ubus under/overfrequencyrelay
System Control
Automatic standby mode Emergency mode with closed
transition to normal
Closed transition to emergency mode
Load management mode
Automatic load shed control withbus underfrequency protection andone four-pole,10A,120 Vac, Form C,dry contact output for each loadshed level (1 level for eachgenerator in the system)
Automatic generator demandpriority control
Master shutdown button
Power Supply Automatic best DC source selector
24 Vdc station battery, sealed jar,4-hour, external 120 Vac emergencypower required for charger
Power from 24 Vdc engine crankingbatteries
Processor power supplies24 Vdc
Technology Communications
Automation networkhigh speed,high reliability, industrially hardened
Optional remote communicationsnetworkEthernet, modem
Optional communication to
building automation or SCADAsystems for general monitoringModbusRTU or Ethernet
Circuit Breakers
100% rated UL 1066 power circuitbreakers available 8006000A withtwo-step stored energy mechanism
42 kAIC standard (50200 kAoptional)
Some ratings are only availableunder certain UL ratings(UL 1558200 kA)
Drawout mounted (fixed optional)some ratings are only availableunder certain UL ratings.(UL 1558200 kA)
5 cycle closing
Electrically operated
Auxiliary and bell alarm contacts
Electronic trip unit with long time aninstantaneous trip functions (shorttime and ground fault optional)
Enclosure and Bussing
Available as UL 1558, UL 891 or CSAlisted and labeled
Optionally service entrance rated
NEMA 1 or NEMA 3R, deadfrontfreestanding construction
Copper bus
100 kA bus bracing (150200 kAoptional)
Three-phase, four-wire, 100%neutral bus, 1/4-inch x 2.00-inchground bus
Also available in UL listed andlabeled medium voltage
Environment
0C to 50C
0 to 95% humidity, noncondensing
Seismic Qualification
Refer to Tab 1for information onseismic qualification for this andother Eaton products.
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September 2011
Cat Generator Paralleling Switchgear
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XLM Switchgear
Technical Data018
XLM SwitchgearOne-Line Diagrams
Figure 40.2-2. Typical Electrical System with XLM1 Switchgear (One Generator Source, One Utility Source)(For Multiple Utility Sources, see Custom Configurable Switchgear Section 40.5) PR = Protective Relay.
Figure 40.2-3. XLM1 Low Voltage Switchgear Layout
4000A, 5000A and 6000A breakers available in 44.00-inch wide struc-ture. Contact your local Caterpillar Electric Power dealer for more details.
Low voltage switchgear for up to 3500 kW generator set ratingsat 480V is also available. Contact local Caterpillar Electric Power dealerfor more details.
66.00 (1676.4) with D1 (optional as shown).
Max.Utility
Bkr.Siz
e
GeneratorkW (480V)
Generator
BreakerSize
Main
BusRating
Max.Fe
eder
BreakerSize Dimensions
Weight
Lbs(kg)
Min. Max.
Height Width Depth
800 0 532 800 1600 1600 99.00(2514.6)
44.00(1117.6)
72.00(1828.8)
3300(1498)
1600 533 1064 1600 1600 1600 3400(1544)
2000 1065 1330 2000 2000 2000 3600(1634)
3000 1331 2000 3000 3200 3200 78.00(1981.2)
3700(1680)
Conduit Space for 22.00-Inch (558.8 mm) Wide StructuresTop or Bottom Entry
StructureDepth
Rear Conduit Opening RecommendedNumber of 3.50 or4.00-Inch Conduits
Width Depth
66.00 (1676.4)72.00 (1828.8)78.00 (1981.2)84.00 (2133.6)
16.00 (406.4)16.00 (406.4)16.00 (406.4)16.00 (406.4)
19.30 (490.2)25.30 (642.6)31.30 (795.0)37.30 (947.4)
9121518
FRONT ELEVATION
SECT 1
CELL A
CELL B
CELL C
CELL D
R
MDS-CXX
52N1
52N1
CONTROLS
SECT 2
MDS-CXX
52G1
52G1
CONTROLS
O P E N C L O S E D
G R
SECT 3
MDS-CXX
52D1
DIST
CONTROLS
HORN
HORN
SI LENC E
TOU C HSC REEN
DISA B LE ENA B LE
86UCLOS
SR750
SYSTEM
CONTROLS
96.06(2440.0)
22.00(558.8)
22.00(558.8)
22.00(558.8)
66.00(1676.4)
HMI19
TOUCHSCREEN
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September 2011
Cat Generator Paralleling Switchgear
Sheet 40
XLM Switchgear
Technical Data019
Figure 40.2-4. Typical Electrical System with XLM2 Switchgear (Two Generator Sources, One Utility Source)(For Multiple Utility Sources, see Custom Configurable Switchgear Section 40.5) PR = Protective Relay.
Figure 40.2-5. XLM2 Low Voltage Switchgear Layout
FRONT ELEVATION
R
MDS-CXX
52N1
MDS-CXX
52G1
O P EN C L O SE D
G R
MDS-CXX
52D1HORNHORNSILENCETOUCHSCREENDISABLEENABLE
MDS-CXX
52D2
O P EN C L O SE D
G R
MDS-CXX
52G2
SECT 1
CELL A
CELL B
CELL C
CELL D
52N1
CONTROLS
SECT 2
52G2
CONTROLS
52G1
CONTROLS
SECT 3
DIST
CONTROLS
86UCLOS
SR750
SYSTEM
CONTROLS
96.06(2440.0)
22.00(558.8)
22.00(558.8)
22.00(558.8)
66.00(1676.4)
HMI19
TOUCHSCREEN
4000A, 5000A and 6000A breakers available in 44.00-inch wide structure.Contact your local Caterpillar Electric Power dealer for more details.
Low voltage switchgear for up to 3500 kW generator set ratingsat 480V is also available. Contact local Caterpillar Electric Power dealerfor more details.
Max.
Utility
Bkr.S
ize
GeneratorkW (480V)
Gene
rator
BreakerSize
MainBusR
ating
Max.
Feeder
BreakerSize Dimensions
Weight
Lbs(kg)
Min. Max.
Height Width Depth
800 0 532 800 1600 1600 99.00(2514.6)
66.00(1676.4)
72.00(1828.8)
5000(2270)
1600 533 1064 1600 1600 1600 5200(2361)
2000 1065 1330 2000 2000 2000 5600(2542)
3000 1331 2000 3000 3200 3200 84.00(2133.6)
5800(2633)
Conduit Space for 22.00-Inch (558.8 mm) Wide StructuresTop or Bottom Entry
StructureDepth
Rear Conduit Opening RecommendedNumber of 3.50 or4.00-Inch Conduits
Width Depth
66.00 (1676.4)72.00 (1828.8)78.00 (1981.2)84.00 (2133.6)
16.00 (406.4)16.00 (406.4)16.00 (406.4)16.00 (406.4)
19.30 (490.2)25.30 (642.6)31.30 (795.0)37.30 (947.4)
9121518
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September 2011
Cat Generator Paralleling Switchgear
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XLM Switchgear
Technical Data020
Figure 40.2-6. Typical Electrical System with XLM3 Switchgear (Three Generator Sources,One Utility Source)(For Multiple Utility Sources, see Custom Configurable Switchgear Section 40.5) PR = Protective Relay.
Figure 40.2-7. XLM3 Low Voltage Switchgear Layout
FRONT ELEVATION
SECT 1
CELL A
CELL B
CELL C
CELL D
R
MDS-CXX
52N1
CONTROLS52N1
SECT 2
MDS-CXX
52G1
CONTROLS52G2
O P E N C L O SE D
G R
SECT 4
MDS-CXX
52D1
CONTROLSDIST
HORNHORN
SILENCETOUCHSCREEN
DISABLEENABLE
MDS-CXX
52D2
CONTROLS52G1
O P E N C L O SE D
G R
MDS-CXX
52G2
SECT 3
MDS-CXX
52G3
O P E N C L O SE D
G R
MDS-CXX
52D3
CONTROLS52G3
96.06(2440.0)
22.00(558.8)
22.00(558.8)
22.00(558.8)
22.00(558.8)
88.00(2235.2)
86UCLOS
SR750SYSTEM
CONTROLS
HMI
19
TOUCHSCREEN
4000A, 5000A and 6000A breakers available in 44.00-inch wide struc-ture. Contact your local Caterpillar Electric Power dealer for more details.
Low voltage switchgear for up to 3500 kW generator set ratingsat 480V is also available. Contact local Caterpillar Electric Power dealerfor more details.
Max.Utility
Bkr.Size
GeneratorkW (480V)
Generator
Brea
kerSize
MainBusRating
Max.Feeder
Brea
kerSize Dimensions
Weig
ht
Lbs(kg)
Min. Max.
Height Width Depth
800 0 532 800 1600 1600 99.00(2514.6)
88.00(2235.2)
72.00(1828.8)
7100(3223)
1600 533 1064 1600 1600 1600 7300(3314)
2000 1065 1330 2000 2000 2000 7700(3496)
3000 1331 2000 3000 3200 3200 84.00(2133.6)
7800(3541)
Conduit Space for 22.00-Inch (558.8 mm) Wide StructuresTop or Bottom Entry
StructureDepth
Rear Conduit Opening RecommendedNumber of 3.50 or4.00-Inch Conduits
Width Depth
66.00 (1676.4)72.00 (1828.8)78.00 (1981.2)84.00 (2133.6)
16.00 (406.4)16.00 (406.4)16.00 (406.4)16.00 (406.4)
19.30 (490.2)25.30 (642.6)31.30 (795.0)37.30 (947.4)
9121518
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September 2011
Cat Generator Paralleling Switchgear
Sheet 40
XLM Switchgear
Technical Data021
Figure 40.2-8. Typical Electrical System with XLM4 Switchgear (Four Generator Sources, One Utility Source)(For Multiple Utility Sources, see Custom Configurable Switchgear Section 40.5) PR = Protective Relay.
Figure 40.2-9. XLM4 Low Voltage Switchgear Layout
FRONT ELEVATION
SECT 1
CELL A
CELL B
CELL C
CELL D
R
MD S -C X X
52N1
CONTROLS52N1
SECT 2
MD S -C X X
52G1
CONTROLS52G2
O P E N C L O S E D
G R
SECT 4
MD S -C X X
52D1
CONTROLSDIST
CONTROLSSYSTEM
HORNHORN
S I LENC ETOUC H S C R EEN
DISABL EENA B LE
MD S -C X X
52D2
CONTROLS52G1
O P E N C L O S E D
G R
MD S -C X X
52G2
SECT 3
MD S -C X X
52G3
O P E N C L O S E D
G R
CONTROLS52G3
CONTROLS52G4
O P E N C L O S E D
G R
MD S -C X X
52G4
SECT 5
MD S -C X X
52D3
MD S -C X X
52D4
96.06(2440.0)
22.00(558.8)
22.00(558.8)
22.00(558.8)
22.00(558.8)
22.00(558.8)
88.00(2235.2)
86UCLOS
SR750
HMI
19
TOUCHSCREEN
4000A, 5000A and 6000A breakers available in 44.00-inch wide struc-ture. Contact your local Caterpillar Electric Power dealer for more details.
Low voltage switchgear for up to 3500 kW generator set ratingsat 480V is also available. Contact local Caterpillar Electric Power dealerfor more details.
Max.Utility
Bkr.Size
GeneratorkW (480V)
Gener
ator
BreakerSize
Main
BusRating
Max.Feeder
BreakerSize Dimensions
Weigh
t
Lbs(kg)
Min. Max. Height Width Depth
800 0 532 800 1600 1600 99.00(2514.6)
110.00(2794.0)
72.00(1828.8)
9100(4131)
1600 533 1064 1600 1600 1600 9300(4222)
2000 1065 1330 2000 2000 2000 9500(4313)
3000 1331 2000 3000 3200 3200 84.00(2133.6)
9800(4449)
Conduit Space for 22.00-Inch (558.8 mm) Wide StructuresTop or Bottom Entry
StructureDepth
Rear Conduit Opening RecommendedNumber of 3.50 or4.00-Inch Conduits
Width Depth
66.00 (1676.4)72.00 (1828.8)78.00 (1981.2)84.00 (2133.6)
16.00 (406.4)16.00 (406.4)16.00 (406.4)16.00 (406.4)
19.30 (490.2)25.30 (642.6)31.30 (795.0)37.30 (947.4)
9121518
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September 2011
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XLM Switchgear
Technical Data022
Figure 40.2-10. Typical Electrical System with XLMT4 Switchgear (Four Generator Sources, One Utility Source, One Generator Bus Tie Breaker)(For Multiple Utility Sources, see Custom Configurable Switchgear Section 40.5) PR = Protective Relay.
Figure 40.2-11. XLMT4 Low Voltage Switchgear Layout
FRONT ELEVATION
SECT 1
CELL A
CELL B
CELL C
CELL D
R
MD S -C X X
52N1
CONTROLS52N1
SECT 4
MD S -C X X
52G1
CONTROLS52G2
O P E N C L O S E D
G R
SECT 2
MDS-CXX
52D1
CONTROLSDIST
CONTROLSSYSTEM
HORNHORN
S ILENC ETOUCHSCREEN
D IS A B LEENA B LE
MD S -C X X
52D2
CONTROLS52G1
O P E N C L O S E D
G R
MD S -C X X
52G2
SECT 6
MD S -C X X
52G3
O P E N C L O S E D
G R
CONTROLS52G3
CONTROLS52G4
O P E N C L O S E D
G R
MD S -C X X
52G4
MD S -C X X
52D3
SECT 3
MD S -C X X
52D4
CONTROLS52T1
O P E N C L O S E D
G R
MD S -C X X
52T1
SECT 5
MDS-CXX
52D5
CONTROLSDIST
MDS-CXX
52D6
MDS-CXX
52D7
96.06(2440.0)
22.00(558.8)
22.00(558.8)
22.00(558.8)
22.00(558.8)
22.00(558.8)
22.00(558.8)
110.00(2794.0)
86UCLOS
SR750
HMI
19
TOUCHSCREEN
4000A, 5000A, and 6000A breakers available in 44.00-inch wide struc-ture. Contact your local Caterpillar Electric Power dealer for more details.
Low voltage switchgear for up to 3500 kW generator set ratingsat 480V is also available. Contact local Caterpillar Electric Power dea ler
for more details.
Max.
Utility
Bkr.Size
Generator
kW (480V)
Generato
r
BreakerS
ize
Main
BusRatin
g
Max.
Feeder
BreakerS
ize Dimensions
Weight
Lbs(kg)Min. Max.
Height Width Depth
800 532 800 1600 800 99.00(2514.6)
132.00(3352.8)
72.00(1828.8)
9100(4131)
1600 1064 1600 1600 1600 78.00(1981.2)
9300(4222)
2000 1330 2000 2000 2000 84.00(2133.6)
9500(4313)
3000 2000 3000 3200 3200 9800(4449)
Conduit Space for 22.00-Inch (558.8 mm) Wide StructuresTop or Bottom Entry
StructureDepth
Rear Conduit Opening RecommendedNumber of 3.50 or4.00-Inch Conduits
Width Depth
66.00 (1676.4)72.00 (1828.8)78.00 (1981.2)84.00 (2133.6)
16.00 (406.4)16.00 (406.4)16.00 (406.4)16.00 (406.4)
19.30 (490.2)25.30 (642.6)31.30 (795.0)37.30 (947.4)
9121518
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September 2011
Cat Generator Paralleling Switchgear
Sheet 40
XLM Switchgear
Technical Data023
Table 40.2-1. Typical Control Circuit WiringLow Voltage Systems
All control wiring to be stranded copper unless specified otherwise. Conductor size may have to be increased for voltage drop over long distances. Recommend 20% spares of each size single conductor and one of each multi-conductor cable. Separate metallic conduits should be used for each Signal Type. Signal Level and DC Control Signal 30 Vdc wires may be combined in the
same conduit.
Note: Specific project and equipment requirements will determine exact number and type of control wiring required.
Function (Quantity)/Size/Type of Cable
SignalType
Description
Generator Control
Cat engine generator setcommunications
Diesel(1) x #16 AWG shieldedtwisted pair (Belden 8719)
Signal level Network communications for monitoringand display of engine data to switchgear
Gas(1) x #16 AWG shieldedtwisted quad
Signal level
Control panel discrete control interface (16) x 1/c #14 AWG (includes spares) DC control 30 Vdc Discrete control (start/stop, emergency stopand crank terminate, includes spares, etc.)
Best source 24 Vdc (4) x 1/c #10 AWG(2 x + 24 Vdc and 2 x24 Vdc)
DC control 30 Vdc 24 Vdc from generator battery system tosupplement switchgear 24 Vdc control voltage
Voltage regulation (VR) control (1) x #16 AWG twisted pair(Belden 8719)
Signal level Bipolar DC bias signal for voltage control
(3) x 1/c #14 AWG (additional forCDVR only)
DC control 0 Vdc
Speed control (governor) Type 2301A speed controller(2) x #16 AWG shieldedtwisted pair (2301A)
DC control 30 Vdc Bipolar DC bias signal for speed control
ADEMIII speed controller(1) x #16 AWG shielded twistedtriplet (Belden 8618)
Signal level
(Additional for pro act gov. only)
(3) x #14 AWG XHHW Cu
DC control 30 Vdc
Air fuel ratio (AFR) controller Gas only(1) x #16 AWG shieldedtwisted pair
Signal level For gas engines equipped with AFRcontroller only
Battery Systems
Power for 24 Vdc station battery charger (3) x 1/c #12 AWG(in master section)
AC control 120 Vac/20A emergency circuit for 24 Vdcbattery charger power
24 Vdc station batteries (4) x 1/c #10 AWG (2 x + 24 Vdc and2 x24 Vdc) (next to switchgear)
DC control 30 Vdc 24 Vdc supply to switchgear controls from24 Vdc battery system
24 Vdc station battery charger malfunction (2) x 1/c #14 AWG DC control 30 Vdc Alarms
Generator battery charger malfunction (2) x 1/c #14 AWG DC control 30 Vdc Alarms
Fuel Systems
Low fuel tank level (master fuel tank)Fuel tank rupture basin (master fuel tank)High fuel tank level (master fuel tank)Other fuel tank alarms (master fuel tank)
(2) x 1/c #14 AWG(2) x 1/c #14 AWG(2) x 1/c #14 AWG(2) x 1/c #14 AWG (each)
DC control 30 VdcDC control 30 VdcDC control 30 VdcDC control 30 Vdc
AlarmsAlarmsAlarmsAlarms
Low fuel tank level (day tank)
Fuel tank rupture basin (day tank)High fuel tank level (day tank)Other fuel tank alarms (day tank)
(2) x 1/c #14 AWG
(2) x 1/c #14 AWG(2) x 1/c #14 AWG(2) x 1/c #14 AWG (each)
DC control 30 Vdc
DC control 30 VdcDC control 30 VdcDC control 30 Vdc
Alarms
AlarmsAlarmsAlarms
Generator Protection Systems
Genset mounted CB statusGenerator differential CTs
(2) x 1/c #14 AWG(6) x 1/c #10 AWG (at gen.)
DC control 30 VdcAC control
Alarms87G relay alarm/shutdown
Generator RTD leads (1) x #14 AWG shielded twisted quadper reading (at generator)
DC control 30 Vdc Indication/alarms/shutdown
Engine thermo-couples (2) x 1/c #14 AWG thermo-couple wireper reading (at generator)
DC control 30 Vdc Indication/alarms/shutdown
Automatic Transfer Switch Interface (Per ATS)
Cat ATS monitoring and control (1) x #16 AWG shielded twisted pair(Belden 8471)
Signal Level Monitoring and control of ATS functions
Engine startDiscrete ATS positionATS load shed
(2) x 1/c #14 AWG(4) x 1/c #14 AWG(2) x 1/c #14 AWG
DC control 30 VdcDC control 30 VdcDC control 30 Vdc
Engine start requestNormal and emergency ATS statusload shed / load add
Miscellaneous (Optional)Miscellaneous enclosure alarmsMiscellaneous aux. equipment alarmsSwitchgear 120 Vac space heaters
(2) x 1/c #14 AWG per required alarm(2) x 1/c #14 AWG per required alarm(3) x 1/c #10 AWG per 10 structures
DC control 30 VdcDC control 30 VdcAC control
Alarms/shutdownAlarms/shutdowns120 Vac for space heaters (single-phase/30A)
Remote monitoring/control PC (1) x 4 Pair #24 AWG UTP Cat. 5(Ethernet) or(1) 4 conductor fiberoptic cable (Belden I100466variesbased on Installation requirements)
Signal level Communication signal to remotemonitoring/control PC workstation or LAN
Building management/SCADA interface (1) x #18 AWG shielded twisted pair(Belden 3073)
Signal level Communication signal to buildingmanagement or SCADA system
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Cat Generator Paralleling Switchgear
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XLM Switchgear
Functional Sequence of Operations024
XLM Functional Sequence of Operations
A. The EPS Automation shall be provided with thefollowing Modes of Operation:
1. Automatic/Standby Mode
a. The utility main breaker is closed serving utilitypower to the generator/load bus.
b. The generator main breakers are open.
c. The automation is standing by to act in response to autility failure.
2. Emergency Mode (Standby)
a. Utility Failure
1. Utility protective relaying senses utility voltageor frequency out of tolerance.
2. The utility main breaker is opened.
3. A run request is sent to the generator plant.
4. The first generator up to voltage and frequencyis closed to the bus.
5. [With Generator Bus Tie Breaker]
The generator bus tie breaker is closed.
6. The remaining generators are synchronized andparalleled to the bus as they come up to voltageand frequency.
7. The system is now in Emergency Mode.
b. Utility Restoration and Exit from Emergency Mode
1. Utility protective relaying senses utility voltageand frequency within tolerance.
2. Following an adjustable time delay (which can beabbreviated by the operator) to ensure that theutility power source is stable, the generator plantis passively synchronized and paralleled to theutility source by closing the utility main breaker.
3. The generator plant is soft ramp unloaded until
the utility source is nominally serving the entiresystem load.
4. The generator breakers are opened.
5. The generators are allowed to run for theirprogrammed cool-down period.
6. The system is now back in Automatic/Standby Mode.
3. Transfer to Emergency Mode
a. Entry
1. The operator places the System Mode Selector Switchinto the Closed Transfer to Emergency position.
2. A run request is sent to the generator plant.
3. The first generator up to voltage and frequencyis closed to the bus at no load.
4. The remaining generators are synchronized andparalleled to the bus at no load as they come upto voltage and frequency.
5. When all generators are on the bus they are softramp loaded until the generator plant is nominallyserving the entire load on the bus and theutility main breaker is opened.
OR
5. [With Generator Bus Tie Breaker] When all generatorsare on the bus, they are paralleled across the genera-tor bus tie breaker. They are then soft ramp loadeduntil the generator plant is nominally serving all ofthe load on the bus and the utility main is opened.
6. The system is now running in Emergency Mode.
b. Exit from Emergency Mode
1. The operator removes the System Mode SelectorSwitch from Transfer to Emergency position andreturns it to the Auto position.
2. Following an adjustable time delay (which can beabbreviated by the operator), the generator plantis passively synchronized and paralleled to theutility source by closing the utility main breaker.
3. The generator plant is soft ramp unloaded untilthe utility source is nominally serving the entiresystem load.
4. The generator breakers are opened
OR
4. [With Generator Bus Tie Breaker] The generatorbus tie breaker is opened and then all of generatorbreakers are opened.
5. The generators are allowed to run for theirprogrammed cool-down period.
6. The system is now back in Automatic/Standby Mode.4. Load Management Mode
a. Entry
1. Select one of the modes of operation:
i. Import LimitThe user places the Import/Export toggle switch in the Import positionand places the Base Load/Utility Trackingtoggle switch in the Utility Tracking position.The user sets the Utility Import set point tothe desired amount of kW that they wantto import through the Utility Circuit Breakerduring Load Management Mode.
ii. Export LimitThe user places the Import/Exporttoggle switch in the Export position and placesthe Base Load/Utility Tracking toggle switch in the
Utility Tracking position. The user sets the UtilityExport Set point to the desired amount of kWthat they want to export through the UtilityCircuit Breaker during Load Management Mode.
iii. Base Load ImportThe user places theImport/Export toggle switch in the Importposition and places the Base Load/UtilityTracking toggle switch in the Base Load posi-tion. The user sets the Base Load set point tothe desired amount of kW that they want thegenerator plant to assume during Load Man-agement Mode. The controls shall not allowthe generator plant to export kW throughthe Utility Circuit Breaker and shall alwaysmaintain a nominal amount of Utility kWimported through the Utility Circuit Breaker.
iv. Base Load ExportThe user places theImport/Export toggle switch in the Exportposition and places the Base Load/UtilityTracking toggle switch in the Base Loadposition. The user sets the Base Load set pointto the desired amount of kW that they wantthe generator plant to assume during LoadManagement Mode. The controls shall allowthe generator plant to export kW through theUtility Circuit Breaker.
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Cat Generator Paralleling Switchgear
Sheet 40
XLM Switchgear
Functional Sequence of Operations025
2. The user places the System Mode SelectorSwitch in the Load Management position.
3. A run request is sent to the generator plant.
4. The generators are allowed to run for a five-minute warm-up time (which can be abbreviated
by the operator).
5. The generators are synchronized and paralleledto the bus at no load after completion of thewarm-up time.
6. When all generators are on the bus they are softramp loaded until the generator plant is nominallyserving the required amount of the load on thebus to meet the mode of operation selected.
7. The generator output is dynamically adjusted tomaintain the set point to meet the mode of opera-tion selected. If at any time the system is unableto maintain the set point then a Set pointExceeded alarm shall be sounded.
8. Should the utility fail at any time during LoadManagement operation, the utility protectiverelays shall cause the utility main to open and belocked out, thus placing the system in EmergencyMode until the Utility is restored (as described inEmergency Mode exit).
b. Exit
1. The operator removes the System Mode SelectorSwitch from Load Management position andreturns it to the Auto position.
2. The generator plant is soft ramp unloaded untilthe utility source is nominally serving the entiresystem load and the generator main breakersare opened.
3. The generators are allowed to run for theirprogrammed cool-down period.
4. The system is now back in Automatic/Standby Mode.
5. No Load Test Mode
a. Entrance into No Load Test Mode
1. The No Load Test Switch is placed in theON position.
2. All available generators are started.
3. All generators come up to voltage and frequencyand remain running disconnected from the bus.
4. The system is now in No Load Test Mode.
b. Exit from No Load Test Mode
1. The No Load Test Switch is placed in theOFF position.
2. The generators are allowed to run for theirprogrammed cool-down period.
3. The system is now back in Automatic/Standby Mode.
6. Utility Fail Test Mode
a. Entrance into Utility Fail Test Mode
1. The Utility Fail Test Switch is placed in theON position.
2. Voltage sensing at the utility protective relay is
opened, which simulates a loss of utility.
3. The system enters into Emergency Modeas described in the Emergency Modesequence above.
b. Exit from Utility Fail Test Mode
1. The Utility Fail Test Switch is placed in theOFF position.
2. Voltage sensing at the utility protective relayis restored, which simulates the return ofutility power.
3. The system exits from Emergency Modeas described in the Emergency Modesequence above.
B. When the Generator Sets are carrying the facility loadthe EPS Automation shall support two (2) sub-modes:Load Shed/Load Add, and Generator Demand Priority.
1. Load Shed Control
a. The System Controls shall include a Load ShedControl function to control the loads served by thegenerator plant.
b. The Load Shed Control shall have one Essential LoaShed Priority Level for each generator in the systemplus one Non-Essential Load Shed Priority Level(which is always shed in the Emergency Modeof operation).
c. The Load Shed Control shall control each of thedistribution circuit breakers that are shown onthe drawings. Distribution circuit breakers to becontrolled shall be electrically operated. Eachelectrically operated distribution circuit breakershall be field selectable to be assigned to any ofthe available Load Shed Priority Levels.
1. Provide the following controls for eachEssential Load Shed Priority Level
i. Shed Delay Timer, adjustable from0 to 1024 seconds
ii. Add Delay Timer, adjustable from0 to 1024 seconds
iii. Load Shed Override Selector (shed/auto/add
iv. Status indicators to show whether the
Priority Level is Added or Shed
2. Provide the following controls for eachNon-Essential Load Shed Priority
i. Load Shed Override Selector (shed/auto/add
ii. Status indicators to show whether thePriority Level is Added or Shed
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September 2011
Cat Generator Paralleling Switchgear
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XLM Switchgear
Functional Sequence of Operations026
3. Additionally, the Load Shed Controls shall have:
i. Load Shed Control Switch (On/Off)
ii. User-settable Load Shed % (as a function ofon-line generator capacity)
iii. User-settable Load Shed Time Delay
iv. User-settable Load Add % (as a function ofon-line generator capacity)
v. User-settable Load Add Time Delay
vi. User-settable Bus Underfrequency set point
vii. User-settable Bus Underfrequency time delay
viii. Bus Underfrequency Reset Pushbutton
ix. Bus Underfrequency indicator
4. Conditional Load ShedUpon entrance intoEmergency Mode of operation, the Load ShedControl shall shed all Essential and Non-Essentialloads. As generators come to the bus, Essential
Priority Level loads shall be added conditionallybased on the number of generators on line.When the first generator comes to the bus,Priority Level 1 loads shall be added; Secondgenerator, priority 2, and so forth. After a timedelay that allows all operational generators tocome to the bus, Load Shed Mode shall shift toLoad Sensitive Mode.
5. Load Sensitive Load ShedAfter all generatorshave been given sufficient time to come to thebus, load shed shall shift to Load Sensitivemode. The system shall compare currentgenerator online capacity (in kW) to currentload requirements. If surplus capacity is greaterthan the calculated Load Add set point, after theLoad Add Time Delay the next Load Shed Priorityshall be added. This calculation shall continueuntil all Sheddable Loads are added, or untilsurplus capacity is less than the calculated LoadAdd set point. If surplus capacity is less than thecalculated Load Shed set point, after the LoadShed Time Delay the next Load Shed Priorityshall be shed. This calculation shall continue untilall Sheddable Loads are shed, or until surpluscapacity is greater than the calculated Load Shedset point. The Load Shed Control, in its automaticshedding and adding of loads, shall not overrideany manual load shed/add operation.
6. Should the load bus frequency fall below the userselected bus underfrequency set point for aperiod longer than the bus underfrequency time
delay, then all Priority Level loads shall be shedand load addition shall not resume until the oper-ator has depressed the Bus Underfrequency Resetbutton. The bus underfrequency protection shalloverride any manual load add operation.
NOTE: The following applies to systems with two ormore generators.
2. Generator Demand Priority Control
a. The System Controls shall include a GeneratorDemand Priority Control function to automatically
match the on-line generator capacity to the loads toavoid unnecessary operation of all the generatorswhen the loads are low.
b. The following controls shall be provided for eachgenerator:
1. User-settable Generator Priority Selector
2. Status indicator for the Generator Priority Selected
3. Status indicator for generator On-line or Off-line
c. The Generator Demand Priority Control shall havethe following controls:
1. Generator Demand Priority Control Switch (On/Off)
2. User-settable Generator Remove % (as a functionof a single generator capacity)
3. User-settable Generator Remove Delay
4. User-settable Generator Add % (as a function of asingle generator capacity)
5. User-settable Generator Add Delay
d. Upon entrance into Emergency or Load Managementmodes, all generators shall be started and paralleledto the bus. After the Remove Time Delay, generatorsshall be removed from the bus as a function of thegenerator percentage loading by the user selectedGenerator Remove time delay. Generators shallbe removed from the bus in descending priority.Should the generator percentage loading increaseto the user selected Generator Add limits for theuser selected Add Delay, the next generator shallbe started, synchronized and paralleled to the bus.Generators shall be added to the bus in ascendingpriority order. Should the generator plant ever reach95% loading, the next priority generator shall bestarted and added to the bus with no time delay.
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CA08104001E For more information, visit: www.eaton.com/consultants
September 2011
Cat Generator Paralleling Switchgear
Sheet 40
EGP Switchgear
General Description027
EGP
EGP Switchgear
General DescriptionCat Emergency GeneratorParalleling (EGP) Switchgear formultiple engine generator sets.
Automatic start, synchronize,
parallel and load/VAR share ona common bus
Main lugs output to feed down-stream emergency distribution
Optional emergency distributioncircuit breakers
Load shed/load add
Generator demand priority
For use with multiple downstreamAutomatic Transfer Switches
Cat Switchgear is designed tointegrate hand-in-glove withCat Automatic Transfer Switches.EGP Switchgear is optionallyavailable with direct communication
to Cat ATSs to provide fingertipcontrol and monitoring of all yourfacility ATSs from one convenientcentral location
Cat Switchgear brings the power andreliability of microprocessor technol-ogy to your generator switchgearapplication. Through the use of theoperator interface touchscreendisplay with easy-to-follow graphical
representation, Cat Switchgearmerges the features of:
Power monitoring
Switchgear automation
Generator set control
Optional remote communications
Figure 40.3-1. EGP3 Low Voltage Switchgear (Three Generator Sources)
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Cat Generator Paralleling Switchgear
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EGP Switchgear
Standard and Optional Equipment028
Equipment
Standard EquipmentEGP
Low voltage EGP systems useMagnum DS power circuit breakerswitchgear and Magnum power
circuit breakers. For completetechnical details on Magnum DSswitchgear, see Tab 20
Operator interface touchscreen(Choose one of the following):
High Redundancy Product,19.00-inch surface acoustic waveLCD TFT color touchscreen withkey switch
Standard product, 15-inchresistive LCD TFT colortouchscreen
Direct data communication to Catmicroprocessor-based engine gen-erator set control network (EMCP)
System overview screen withone line mimic diagram thatdepicts real-time metering, statusand control
Full function 0.5% accuracy analogand digital AC metering for genera-tors: voltage 1-2, 2-3, 3-1; current1, 2, 3; frequency; power factor;kW; kVAR
Full function engine gauges: RPM,DC battery voltage, oil pressure,engine coolant temperature,engine hours, number of starts
3-D engine data
Full function synchronizing and par-
alleling controls with selection forautomatic or manual synchronizing
NFPA 110 engine/generatorstatus, pre-alarm, lamp test button,shutdown fault annunciation and 85dBA alarm horn with silence button
Full function 0.5% accuracy analogand digital AC metering for system:voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR
System control functions forauto (standby for emergency), testwithout load and test with load
Automatic load shed control withon-screen operator adjustmentsfor essential (Life/Safety), criticaland non-essential loads. Manualload shed/load add control
Automatic generator demand
priority with on-screen operatoradjustments for automatic additionand removal of generator to theload bus
System status and alarm annuncia-tion with color display and 85 dbAalarm horn with silence button
Password secured settings andadjustments for generator andsystem setups and protectiverelaying
Alarm summary reports
Settings reports
Engine and generator load charts
Engine trend data
UL 891, UL 1558 or CSA listedand labeled
NEMA 1 or NEMA 3R, deadfrontfreestanding construction
Copper bus, braced for 100 kA
Three-phase, four-wire, 100%neutral, 0.25-inch x 2.00-inch copperground bus
Available in 600V, 480/277V or208/120V, 60 Hz
UL 1066 listed power circuit breakers,42200 kAIC, two-step stored energydrawout mounted electricallyoperated with long time andinstantaneous trip, and circuit
breaker control switch with lights
Continuous cross bus ratings up to10,000A at 600 Vac
Mechanical lugs for incoming andoutgoing conductors
Top or bottom conduit entry
Plug together control connectionsacross shipping splits
Optional EquipmentEGP
Distribution sections withelectrically operated drawoutUL 1066 circuit breakers
Circuit breaker trip functionsshorttime and/or ground fault
(in addition to long time andinstantaneous)
Steel barriers between switchboardor switchgear sections for compart-mentalization
Bus/cable barriers
Distribution sections with groupmounted UL 489 molded case circuitbreakers (UL 891 construction only.)
Also available in 150 kA or 200 kAbus bracing configurations
Also available in 8000 and 10,000A
continuous cross bus ratings at600 Vac
Also available with 4000, 5000 and6000A UL 1066 breakers
Trip unit metering and communica-tions (Digitrip 520M, 520MCand 1150)
Also available in 5 kV, 15 kV and27 kV class configurations(See Section 40.4)
Remote monitoring and control
Building Automation Systemor SCADA communicationsModbus or Ethernet
Remote notification
Historical data trending
Communication to Cat ATS units
Automated Joint Commissionreport
Tie Breaker ApplicationMany systems require the use of tiebreakers to meet Code or system per-formance requirements. Tie breakerscan be used anywhere throughout theline-up to segment or i
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