DE Series Generator Set with Cat C1.1, C1.5, and C2.2 Engines Generator Lead Connections Caterpillar


Generator Lead Connections
`
1.1. Grounding the Frame
2.1. Neutral Connections
3.1. Single Units
4.1. Connection Diagrams
5.2. Wiring Code A for Three-Phase Configuration
6.2. Wiring Code B for Single-Phase Configuration or Three-Phase Configuration
7.2. Wiring Code D for Three-Phase Configuration
8.2. Wiring Code F for Single-Phase Configuration or Three-Phase Configuration
9.2. Wiring Code FF for Single-Phase Configuration
10.2. Single Phase with 4 Leads, Winding Dedicated Type M or Type M1
11.2. R 791 T Interference Suppression

------ DANGER! ------

DANGER: Shock/Electrocution Hazard-Do not operate this equipment or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings will result in serious injury or death.


------ WARNING! ------

Personal injury or death can result from high voltage.

When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.

Improper test equipment can fail and present a high voltage shock hazard to its user.

Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.

When servicing or repairing electric power generation equipment:

  • Make sure the unit is off-line (disconnected from utility and/or other generators power service) , and either locked out or tagged DO NOT OPERATE.

  • Remove all fuses.

  • Make sure the generator engine is stopped.

  • Make sure all batteries are disconnected.

  • Make sure all capacitors are discharged.

Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.


------ WARNING! ------

Accidental engine starting can cause injury or death to personnel working on the equipment.

To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.

Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.


Grounding the Frame

In any generator set installation, the frame of the generator must be positively connected to an earth ground. This connection is the first connection that is made at the installation. This connection is the last connection that should be removed. If the generator set is on flexible mounting pads, the ground connection must be flexible in order to avoid possible breakage in later operation.

Ground connection cable or straps should have at least the current carrying capacity of the largest line lead to the connected load. Joints in cables or straps must be clean, free of electrical resistance, and protected from possible oxidation. Bolted ground connection joints eventually oxidize. The joints are frequent sources of radio frequency interference (RFI). Joints that are silver soldered and bolted are preferred.

Neutral Connections

The generators with a Wye Configuration usually have the neutral ground when the generator is installed. Grounding the neutral is for preventing damage to equipment.

If the neutral wire is grounded and one of the phase leads becomes grounded, the excessive current will open a load circuit breaker. Also, the excessive current will cause the generator voltage to collapse. The result depends on the following items: electrical characteristics of the generator , type of fault and trip rating of the circuit breaker. An undervoltage device may be required in order to provide an adequate short circuit protection.

There are some cases when the neutral wire is not grounded. An ungrounded generator neutral lead is acceptable when the possibility of grounds to the phase leads has been eliminated. An example of such measures are ground fault protective circuits. Ground fault protection requires the entire group of distribution circuits to be treated as a system. The owner should contact a certified consultant if a new distribution system is being developed. The owner should also contact a certified consultant if an existing system should be modified for the ground fault protection.

Single Units

Each unit should be connected to a common ground.

In a three-phase, four-wire system, the neutral wire should be grounded according to local wiring codes.

Be sure to check your local wiring codes.

Connection Diagrams

The connections are located in the enclosure for the control panel.

Change the position of the wire terminals in order to modify the connection. The code for the winding is specified on the nameplate.

Wiring Code A for Three-Phase Configuration



Illustration 1g00952030


Illustration 2g00952058
Factory connection for "A" wiring code

Table 1
L-L Voltage for Wiring Code A 
Winding  50 Hz  60 Hz 
190-208  190-240 
220-230 
190-208 

R 230 voltage sensing - 0 => (T8) / 110 V => (T11)

R 438 LS voltage sensing - 0 => (T3) / 220 V => (T2)

Wiring Code B for Single-Phase Configuration or Three-Phase Configuration



Illustration 3g00952097


Illustration 4g00952196
Factory connection for "B" wiring code

Table 2
L-L Voltage for Wiring Code B 
Winding  50 Hz  60 Hz 
110-120  120 
120-130 
110-120 

R 230 voltage sensing - 0 => (T8) / 110 V => (T11)

R 438 LS voltage sensing - 0 => (T3) / 110 V => (T2)

Wiring Code D for Three-Phase Configuration



Illustration 5g00952201


Illustration 6g00952365
Factory connection for "D" wiring code

Table 3
L-L Voltage for Wiring Code D 
Winding  50 Hz  60 Hz 
380-415  380-480 
440-460 
380-416 

R 230 voltage sensing - 0 => (T8) / 110 V => (T11)

R 438 LS voltage sensing - 0 => (T3) / 380 V => (T2)

Wiring Code F for Single-Phase Configuration or Three-Phase Configuration



Illustration 7g00952381
Voltage LM equals one half of voltage LL.


Illustration 8g00952390
Factory connection for "F" wiring code

Table 4
L-L Voltage for Wiring Code F 
Winding  50 Hz  60 Hz 
220-240  220-240 
250-260 
200  220-240 

R 230 voltage sensing - 0 => (T8) / 110 V => (T11)

R 438 LS voltage sensing - 0 => (T3) / 220 V => (T2)

Wiring Code FF for Single-Phase Configuration



Illustration 9g00952416
Voltage LM equals one half of voltage LL.


Illustration 10g00952430
Factory connection for "FF" wiring code

Table 5
L-L Voltage for Wiring Code FF 
Winding  50 Hz  60 Hz 
220-240  220-240 
250-260 
200  220-240 

R 230 voltage sensing - 0 => (T1) / 110 V => (T4)

R 438 LS voltage sensing - 0 => (T10) / 220 V => (T1)

Single Phase with 4 Leads, Winding Dedicated Type M or Type M1



Illustration 11g00952989
Wiring diagram for a connection in series

Table 6
Voltage at 50/60 Hz  Connect.  Output 
L-L  L-M  T2 - T3 
220  110  T1 T4  T2 - T3 
230  115 
240  120 

R 230 voltage sensing - 0 => (T1) / 110 V => (T2)



Illustration 12g00953002
Wiring diagram for a parallel connection

Table 7
Voltage at 50/60 Hz  Connect.  Output 
L-L  L-M  T1 - T3
T2 - T4 
110  T1 - T3 T2 - T4 
115 
120 

R 230 voltage sensing - 0 => (T1) / 110 V => (T2)

R 791 T Interference Suppression



Illustration 13g00953025
Connect the interference suppression, as shown. The letters in the circles represent the wiring codes for the generators.
(BLK) Black
(BLU) Blue
(WHT) White
(A) Wiring code "A"
(B) Wiring code "B"
(D) Wiring code "D"
(F) Wiring code "F"
(FF) Wiring code "FF"

Information System:

2005/04/25 Cover Plate, Flange are Available for Use During Flow Tests on the Main Hydraulic Pumps {0738, 5070, 5084}
C1.5 GEN SET Electric Power Generation Refill Capacities and Recommendations
120M, 12M, 140M, 160M, 140, 150 and 160 Motor Graders Governor (Air Compressor) - Test and Adjust
Electronic Installation Guide{1000}
Reuse and Salvage for Cast Iron Cylinder Blocks {0679, 1201, 1201}
2005/02/21 Information Release Memo, PELJ0481 , "Product Line Expansion for Caterpillar Low and Medium Pressure Hose and Coupling Products" {5057}
120M, 12M, 140M, 160M, 140, 150 and 160 Motor Graders Drawbar
C9 Urban Transit Bus Engine Air Compressor - Remove and Install
3500 Petroleum Engines and Petroleum Generator Sets Control Panel
2005/01/31 Improved Lifters are Now Used {1102, 1121, 1123}
C9 Urban Transit Bus Engine Idler Pulley - Remove and Install
3516C HD Petroleum Well Service Engine Reference Material
3508C, 3512C and 3516C Marine Engines Auxiliary Water Pump - Remove
Reuse Guideline for Hydraulic Cylinder Position Sensor {5574, 5736}
3500 Engines Auxiliary Water Pump - Disassemble
3500 Engines Auxiliary Water Pump - Assemble
3508B, 3512B and 3516B Generator Set Engines Exhaust Elbow - Remove and Install
3126B Engines Cooling System - Check - Overheating
374F Excavator Bucket Linkage - Inspect/Adjust
C15 and C18 Engines for Caterpillar Built Machines Diagnostic Codes
C27 and C32 Generator Set Engines E194 High Exhaust Temperature
C27 and C32 Generator Set Engines E361 High Engine Coolant Temperature
C27 and C32 Generator Set Engines E360 Low Engine Oil Pressure
3508C, 3512C and 3516C Marine Engines Engine Oil Pump - Remove