VR6B Voltage Regulator Installation For 480V Sensing VR3 Regulators On 3500 Generator Sets {4467} Caterpillar


`
VR6B Voltage Regulator Installation For 480V Sensing VR3 Regulators On 3500 Generator Sets {4467} [REHS2505]
ELECTRICAL AND STARTING SYSTEM
REGULATOR GP-VOLTAGE
VR6B Voltage Regulator Installation For 480V Sensing VR3 Regulators On 3500 Generator Sets {4467}
1.1. Introduction
2.1. Safety Precautions
3.1. Parts List
4.1. Service Tools
5.1. System Schematics
6.2. Self-Excited Generators
7.2. Permanent Magnet Generators
8.1. Installation of 242-9702 Voltage Regulator Gp
9.1. Installation of 242-9703 Voltage Regulator Gp
Electric Power Generation:
SR4 (S/N: 5TA1-UP; 5UA1-UP; 5VA1-UP; 5YA1-UP; 5ZA1-UP; 6AA1-UP; 6LA1-UP; 6NA1-UP; 6PA1-UP; 6SA1-UP; 2ED1-UP; 5TD1-UP; 8FD1-UP; 3EF1-UP; 8ZL1-UP; 2SM1-UP)
Engine:
3512 (S/N: 24Z1-UP)
3516 (S/N: 25Z1-UP)
G3516 (S/N: 4EK1-UP)

Introduction

This Special Instruction provides installation instructions for converting a 3500 generator set from a 480V sensing VR3 regulator to a 240V sensing VR6B regulator. This Special Instruction also provides information concerning the installation instructions for the related components that are required for proper operation of the VR6B regulator. The VR6B system is designed for used on the 3500 generator set. A VR6B regulator is included in the 242-9702 Voltage Regulator Gp group and is also included in the 242-9703 Voltage Regulator Gp group.

Note: The VR6B regulator is designed for only 240V sensing.

The 242-9702 Voltage Regulator Gp is the replacement for the 149-6131 Regulator that is use for self-excited generators. The 242-9703 Voltage Regulator Gp is the replacement for the 155-3819 Voltage Regulator As that is use for permanent magnet generators.

For correct operation and maintenance information of a particular product, the service technician should have the appropriate Operation and Maintenance Manual (OMM) for the equipment that is to be serviced.

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

Personal injury or death can result from improper troubleshooting and repair procedures.

The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.

----------------------

Safety Precautions

When servicing or repairing electric power generation equipment, do the following:

  • Make sure that the unit is "off-line", that is, disconnected from the utility and/or other generators that could provide power service. The unit should be locked out if possible or tagged "DO NOT OPERATE".

  • Make sure that the generator engine is stopped.

  • Verify that the Generator set Start Key is in the OFF position. Temporarily remove the key to prevent inadvertent start of the machine.

  • Make sure that all batteries are disconnected.

  • Verify the generator main circuit breaker is in the OPEN position. Verify the generator main circuit breaker is locked out.

  • Make sure that all capacitors are discharged.

  • Lock out all switchgear and automatic transfer switches that are associated with the generator.

  • Make sure residual voltage in the rotor, stator, and the generator is discharged.

Parts List

Table 1
242-9702 Voltage Regulator Gp    
Part Number     Description    
202-8634     Voltage Regulator As    
243-3204     Potential Transformer Gp    
216-8748     Film    

Table 2
243-3204 Potential Transformer Gp    
Part Number     Description     Quantity    
243-3128     Transformer     1    
6V-8189     Nut     4    
7C-0100     Flexible Mount     4    
8C-0572     Washer     4    

Table 3
242-9703 Voltage Regulator Gp    
Part Number     Description    
202-8634     Voltage Regulator As    
243-3205     Potential Transformer Gp    
216-8748     Film    

Table 4
243-3205 Potential Transformer Gp    
Part Number     Description     Quantity    
243-3129     Transformer     1    
6V-8189     Nut     4    
7C-0100     Flexible Mount     4    
8C-0572     Washer     4    

Service Tools

Table 5 lists some tools that may be helpful for installation of the VR6B system.

Table 5
Service Tools    
Part Number     Description    
9U-7330     Digital Multimeter
(Option) for frequency and duty cycle measurements    
146-4080     Digital Multimeter Gp    
225-8266     Ammeter Tool Gp    
6V-7070     Digital Multimeter    
    Set of Wrenches    
    Ratchet    
    Set of Sockets    

System Schematics

Self-Excited Generators




Illustration 1g01130752

Wiring Illustration for Self-Excited Generators in the 242-9702 Voltage Regulator Gp

Permanent Magnet Generators




Illustration 2g01131186

Wiring Illustration for Permanent Magnet Generators for the 242-9703 Voltage Regulator Gp

Installation of 242-9702 Voltage Regulator Gp

  1. Remove the generator left side access panel cover.

  1. Install the 243-3204 Potential Transformer Gp in the lower generator tray which is located below the voltage regulator. Use materials supplied with the 243-3204 Potential Transformer Gp to secure the 243-3128 Transformer to lower generator tray.

    Note: Drilled and tapped holes are provided for the shock mounts.

  1. Disconnect the wiring to the VR3 voltage regulator at the regulator and at the generator.

  1. Disconnect the VR3 voltage regulator from the mounting bracket.

  1. Install the VR6B voltage regulator, supplied with 242-9702 Voltage Regulator Gp , in place of the VR3. Use existing mounting hardware.

    Note: Refer to Specifications System Operation Troubleshooting, Testing and Adjusting, RENR2480 to verify all VR6B jumper connections that are needed to meet customer requirements.

  1. For wiring the VR6B system for self-excited generators, refer to Illustration 1. As Illustration 1 shows, connect the voltage regulator sensing leads from terminals 20, 22, and 24 of the transformer assembly to either the optional Radio Frequency Interference (RFI) filter or to terminals 20, 22, and 24 of the VR6B regulator. Make all other wiring connections as shown in Illustration 1.

  1. Verify all terminal point connections on both the transformer assembly and the VR6B voltage regulator are secured.

  1. Verify that finished wiring is not placed over sharp corners and is not stretched tightly.

  1. Secure wiring to established wiring bundles with wire ties.

  1. Install generator left side access panel cover.

  1. Energize the system and perform normal starting sequence.

  1. Verify generator voltage and operation. If necessary, refer to the Specifications Systems Operation Troubleshooting Testing and Adjusting, RENR2480 manual for troubleshooting and/or additional information.

Installation of 242-9703 Voltage Regulator Gp

  1. Remove the generator left side access panel cover.

  1. Install the 243-3205 Potential Transformer Gp in the lower generator tray which is located below the voltage regulator. Use materials supplied with the 243-3205 Potential Transformer Gp to secure the 243-3129 Transformer to lower generator tray.

    Note: Drilled and tapped holes are provided for the shock mounts.

  1. Disconnect the wiring to the VR3 voltage regulator at the regulator and at the generator.

  1. Disconnect the VR3 voltage regulator from the mounting bracket.

  1. Install the VR6B voltage regulator, supplied with 242-9703 Voltage Regulator Gp , in place of the VR3. Use existing mounting hardware.

    Note: Refer to Specifications System Operation Troubleshooting, Testing and Adjusting, RENR2480 to verify all VR6B jumper connections that are needed to meet customer requirements.

  1. For wiring the VR6B system for permanent magnet generators, refer to Illustration 2. As Illustration 2 shows, connect the voltage regulator sensing leads from terminals 20, 22, and 24 of the transformer assembly, to either the optional Radio Frequency Interference (RFI) filter or to terminals 20, 22, and 24 of the VR6B regulator. Make all other wiring connections as shown in Illustration 2.

  1. Verify all terminal point connections on both the transformer assembly and the VR6B voltage regulator are secured.

  1. Verify that finished wiring is not placed over sharp corners and is not stretched tightly.

  1. Secure wiring to established wiring bundles with wire ties.

  1. Install generator left side access panel cover.

  1. Energize the system and perform normal starting sequence.

  1. Verify generator voltage and operation. If necessary, refer to the Specifications Systems Operation Troubleshooting Testing and Adjusting, RENR2480 manual for troubleshooting and/or additional information.

Information System:

C9 Engines for Caterpillar Built Machines Aftercooler - Test
C7 Engines for Caterpillar Built Machines Lubrication System
C7 Engines for Caterpillar Built Machines Cooling System
C7 Engines for Caterpillar Built Machines Air Inlet and Exhaust System
C7 Engines for Caterpillar Built Machines Fuel System
C7 Engines for Caterpillar Built Machines Basic Engine
3508C, 3512C and 3516C Marine Engines Electronic Unit Injector - Install
3508C, 3512C and 3516C Marine Engines Electronic Unit Injector - Remove
C0.5, C0.7, C1.1/3011C, C1.5/3013C, C1.6 and C2.2/3024C/3024CT Industrial Engines and Engines for Caterpillar Built Machines Crankshaft Rear Seal - Install
C0.5, C0.7, C1.1/3011C, C1.5/3013C, C1.6 and C2.2/3024C/3024CT Industrial Engines and Engines for Caterpillar Built Machines Water Temperature Regulator - Remove and Install
C0.5, C0.7, C1.1/3011C, C1.5/3013C, C1.6 and C2.2/3024C/3024CT Industrial Engines and Engines for Caterpillar Built Machines Coolant Temperature Switch - Remove and Install
3508C, 3512C and 3516C Marine Engines Fuel Priming Pump - Remove and Install
3508B, 3512B and 3516B Generator Set Engines Electric Starting Motor - Remove and Install
3500 Engines Prelubrication Oil Pump - Remove and Install
G3612 and G3616 Engines Specifications
307D, 311D, 312D, 313D, 315D, 318D, 319D, 320D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 340D, 345D, 349D, 374D, 390D and M325D Excavators Air Conditioning and Heating Air Conditioning and Heating System Sensor Operation
C32 Marine Engines CAN Data Link Circuit - Test
G3606 and G3608 Engines Specifications
C32 Marine Engines Cat Data Link Circuit - Test
C0.5, C0.7, C0.7, C1.1/3011C, C1.5/3013C, C1.6 and C2.2/3024C/3024CT Industrial Engines and Engines for Caterpillar Built Machines Electrical System
C-10, C-12, C-15 and C-16 Industrial Engines Engine Speed/Timing Sensor - Calibrate
C0.5, C0.7, C1.1/3011C, C1.5/3013C, C1.6 and C2.2/3024C/3024CT Industrial Engines and Engines for Caterpillar Built Machines Troubleshooting
Replacing the MIDS Display with an Advisor M2 Display{7490}
345C Excavator Leaving the Machine