LEKX5320

3500 EPG
Technical Information Kit

rd
3 Edition
1 Generator Chart
2 Operating Characteristics
3 Application Notes
4 Generator Protection
5 Generator Maintenance
6 Special Quotations
7 Voltage Regulators
8 Transient Response
9 Wiring Diagrams
10 Miscellaneous
3500 EPG Technical Information Kit 3rd Edition Ð January 1999 Table of Contents Ð Page 1
Table of Contents
Page Number
Section 1 Ð Generator Chart
Generator Characteristics Ð Terminology 2
Generator Chart Ð Definitions 16
Generator Chart 19
Voltage Part Numbers 29
General Dimensions 30
Generator / Rotor Weights 35
Section 2 Ð Operating Characteristics

Dealer Generator Chart 2
Generator Chart for Compatibility 14
Efficiency Generator Chart at 0.8 pf 26
Rotor and Stator Test Data 36
Motor Starting Capability 49
Thermal Limits at Design Voltage 57
Thermal Limits at Off Design Voltage 68
2/3 Pitch Estimated Thermal Limits 78
Altitude / Ambient Temperature Derate Factors 79
Generator Withstand Curve 81
Insulation Systems 82
Torsional Data Reports 83
Bearings Used on Generators 88
Section 3 Ð Application Notes

Cross Current Paralleling with SR4B Generators 2
Currents Ð Circulating in Paralleled Generators 6
Generator Sets Ð Parallel Operation 11
Caterpillar Zero Droop Voltage for Parallel Operation 19
Harmonic Wave Distortion Ð Cause and Effects 28
Two Thirds or Not Two Thirds 34
Non-Linear Loads on Standby Generator Sets 47
Section 4 Ð Generator Protection

Type J Thermocouple Chart 2
Copper RTD Chart 3
Platinum (392) RTD Chart 4
RTD Kits 8
Current Transformers 9
Droop Transformer Chart 11
Section 5 Ð Generator Maintenance
Alignment of Single Bearing Generators 2
Alignment of Two Bearing Generators 6
Recommended Storage Procedures 10
Megger Test Procedure 12
Megger Insulation Example Test Results 14
Insulation Resistance Variation with Temp. Graph 16
Installation Procedure for Type ÒJÓ Thermocouples 17
Section 6 Ð Special Quotations

Quotation Worksheet Explanation 2
Quotation Worksheets 3
Caterpillar Generator Set Testing 6
Custom Quote Tests 12
Example Test Report 20
Section 7 Ð Voltage Regulators

VR3F Voltage Regulator 2
DVR Voltage Regulator 5
Voltage Regulator Selection Chart 8
Regulator Part Numbers 10
Regulator Protection 11
CAT Control Panels 12
Section 8 Ð Transient Response

Generator Set Transient Response 2
Inrush Current Data for Various Loads 7
Transient Response and Motor Starting Analysis 9
Example Report
Test Report Terminology 11
Section 9 Ð Wiring Diagrams

3500 Shutoffs, Junction boxes & Diagrams 3
Lead Connection Diagrams
A. 10/12 Lead, Wye and Delta Connection 5
B. 6 Lead Wye / 6 Lead Delta Connection 6
C. 4 Lead Wye Connection 7
Connection Diagrams for Generators, VR3 & VR4
Voltage Regulators
A. Self Excited with Direct Connection to Generator 8
Table of Contents – Generator Chart
Page Number
Generator Characteristics Ð Terminology 2
Generator Chart Ð Definitions 16
Generator Chart 19
Voltage Part Numbers 29
General Dimensions 30
Generator / Rotor Weights 35
The information contained in this publication is the property of Caterpillar Inc.

and/or its subsidiaries. Without written permission, any copying, transmittal to
others, and any use except that for which it is provided is prohibited. There
are no warranties, express, or implied, including but not limited to, any
implied warranties of merchantability or fitness for a particular purpose.
Caterpillar Inc.
3500 EPG Technical Information Kit 3rd Edition Ð March 1999 Section 1 Ð Page 1
Generator Characteristics—Terminology
The Technical Marketing Information (TMI) contains a great amount of data relating to
Caterpillar Generators. Information is arranged by sales model of engine using the specific
generator rating and arrangement number. This data sheet explains the data in the
Technical Marketing Information and, where possible, its use by professional engineers or
others who calculate performance or predict reactions to various loads.
Generator information includes:

Efficiency
Excitation
Ratings
Resistance
Reactance
Time Constants
Regulation
Short Circuit Ratio
Winding Pitch
Motor Starting Capability
Temperature Rise Decrement Curves
Heat Dissipation
Component Weights
Center of Gravity
Temperature Rise
Air Flow
Insulation Class
All Caterpillar Generators are identified by an arrangement number within the Caterpillar
parts system. The part number identifies the machine by type and primary design voltage at
a specified frequency (50 Hz or 60 Hz). Generators with 12 leads can be connected in delta
configuration. Parts service items can be found in the appropriate engine parts book. Every
generator has the original part number and the serial number stamped into the generator
frame. The data plate also lists the generator part number and serial number. The serial
number must be used when locating specific service parts in a parts book.
Hz (Frequency)
Data listed relates directly to the generator operating frequency. Parts books also list the
generator frequency.
Frame number
This information is primarily a factory design control number. It has no relation to the frame
numbering system of NEMA design electric motors. Larger frame numbers indicate a larger
generator. The first two digits relate to the diameter of the generator stator. The last digit
relates to the length of the stator iron core.
kW
The electrical rating of the generator. All data in the electrical and mechanical listing is
identified as P (prime power) and S (standby power) and follow the various NEMA
requirements.
At prime power, the generator itself is rated on a continuous (24 hours per day) duty basis.
The rating is expressed in kilowatts at 0.8 power factor. The figures appearing in the data
sheet are kW. A common ratio, kW divided by 0.8 permits calculation of kV•A on all
Caterpillar Generators.
Rated Volts, Line Leads, Wires Per Lead

All SR4 Generators have 4, 6, 10, or 12 line leads. These can be connected in delta
configuration. Larger generators use more than one wire per line lead. This feature eases
the problem of forming very heavy conductors inside a limited space for terminal
connections.
All leads are identified. If more than one wire is used per line lead, each of these wires is
identified by a line lead number. Thus, on smaller generators, there would be only one wire
marked ÒT1Ó. However, on larger generators, there will be two or more wires marked ÒT1Ó.
These are to be connected together to form one lead. The first voltage listed is the line-to-
line voltage at the specified frequency when the generator leads are connected for the low
voltage. The second voltage listed is the line-to-line voltage at the specified frequency
when the reconnectable line leads are series connected for high voltage.
Line-to-neutral voltages for wye-connected generators can be calculated by dividing the

listed voltage by √3 (square root of 3 is equal to 1.732). Example: Line-to-line voltages (listed
voltages) are 240 or 480. Line-to-neutral voltages become 138.5 or 277. Generators have a
voltage level adjustment at least equal to the listed percentage (+) of the listed voltages.
Voltage Regulation
Two figures are listed. One concerns the maximum steady-state voltage change that will
occur if the engine speed change under load moves 3% from nominal speed. Assume the
generator is correctly adjusted at 1854 rpm (61.8 Hz) and 1800 rpm (60 Hz). The generator
voltage will not change more than 2% if the load changes move the speed between 1800
rpm and 1854 rpm.
The other figure concerns an engine with an isochronous (speed recovery) governor. In this
instance, load changes do not result in permanent speed changes. The regulator will hold
the generator voltage to +1% of nominal voltage.
Rated Amperes
Two values are listed for all SR4 Generators. The larger number describes the line ampere
(current) rating when the generator is connected for the listed low voltage (coils are parallel
connected). The smaller ampere figure describes the line ampere rating when the
generator is connected for the listed high voltage. Line ampere ratings generally limit the
kV•A rating of a generator. The product of the listed line amperes, the related line-to-line
voltage, and 1.732 equals the kV•A. Exceeding the line ampere rating can reduce
generator life because of excessive winding temperature. Heat output of the generator
armature increases approximately with the square of the current. Doubling the current will
result in about four times the heat output.
As a general rule, the listed line ampere rating should not be exceeded to gain the listed
kV•A rating when the voltage level is reduced to its minimum adjustment. It is not necessary
to reduce the line ampere load to keep within the kV•A limit when the voltage level is at
maximum adjustment.
Generator set kilowatt rating will be exceeded before the line ampere rating is reached
when supplying a resistive load (power factor approximately equal to 1.0). Line ammeters
are the most important monitoring devices on the generator set.
Number of Poles / Synchronous Speed

All SR 4 Generators are four- or six-pole machines. Pole relates to the number of magnetic
poles developed in the rotating field. Magnetic poles in a four-pole generator are arranged
north-south-north-south. The number of poles (north-south-north-south) and the desired
frequency (cycles per second or hertz) determine the synchronous speed in revolutions per
minute (rpm):
S S
120 x f
rpm =
number of poles
If 50 Hz is desired from a four-pole generator, the generator must be driven at 1500 rpm. If a
six-pole generator must be driven at 1000 rpm:
120 x f
1000 rpm = f = 50
6
The generated frequency of a specific machine is entirely a function of the driven speed.
Overspeed Capability Ñ Percent

All Caterpillar Generators have a 150% overspeed capability above 60 Hz synchronous
speeds and a 180% overspeed capability above 50 Hz synchronous speeds. Overspeed
protection controls on the engine are generally adjusted to function at a speed 18% to 20%
above the generator synchronous speed; the engine overspeed safety shutdown device on
a four-pole, 50 Hz generator set should be adjusted to function at 1770 rpm + 20 rpm.
Electronic overspeed controls have a built-in test feature that permits complete check of the
system without over speeding the engine and generator. Mechanical overspeed controls
should be removed from the engine for testing. On-engine full-speed testing of mechanical
overspeed units should be kept to a minimum. Mechanical contactors can be driven
through the 1:2 speed increasing tachometer drive directly from the engine.
Stator Resistance
Figure quotes are coil resistance in Ohms with the stator temperature at 25°C. The following
diagrams show the points at which the listed resistance value or a multiple of it applies:
3 2
If the generator coils are connected in parallel for low voltage:
• For resistance of 1-2, 2-3, or 3-1 (line to line), listed value applies.
• For resistance of 1-0, 2-0, or 3-0 (line to neutral), divide the listed value by 2.
9 8
6 5
3 2
If the generator coils are connected in series for high voltage:
• For resistance of 1-2, 2-3, 3-1 (line-to-line), multiply the listed value by 4.
• For resistance of 1-4, 2-5, 3-6, 7-0, 8-0, 9-0 (individual coil resistance), use the listed
value.
• For resistance of 1-0, 2-0, and 3-0, multiply the listed value by 2.
Resistance measurements will be valid only if made with instruments capable of measuring
very low resistance. Do not attempt to use an Ohmmeter. The inaccuracy is too great to
have any value.
The resistance values apply only at 25°C (77°F). Correction must be applied at other
temperatures. For temperatures other than 25°C, multiply the listed value by 0.00393 and by
the total temperature difference between 25°C and the existing temperature. Add the
result to the listed value if the temperature is higher. Subtract the result if the temperature is
lower.
Example: Stator resistance at 25°C is 0.0077 Ohms. At 75°C the resistance will increase by
(75 Ð 25) × 0.00393 × 0.0077 = 0.0015. This value must be added to the listed value:
0.0077 + 0.0015 = 0.0082 Ohms at 75°C.
At 4°C the resistance will decrease by (25 Ð 4) × 0.00393 × 0.0077 = 0.0006. This value
must be subtracted from the listed value: 0.0077 - 0.0006 = 0.0071 Ohms.
Internal temperature of generator coils can be found by a reverse process. The generator
stator resistance must be accurately measured.
By comparison with the established 25°C resistance, the average winding temperature can
be found: resistance was measured as 0.0108 Ohms. At 25°C this generator has a stator
resistance of 0.0077 Ohms. The increase due to temperature is 0.0108 Ð 0.0077 = 0.0031
Ohms. Then 0.0031 = (25 + T) × 0.0077 × 0.00393.
0.0031 = 0.00075653 + 0.00003026 × T
0.00325 = 0.00003126T
T = 77.6°C
Insulation Resistance
This value is the minimum insulation resistance of the generator stator. It is measured
according to NEMA procedure using two times the rated voltage plus 1000 volts. Insulation
of the rotor is also within this minimum. The rotor resistance is measured at 1500 volts.
Caution must be exercised in these measurements. All test circuits must be clear of any
connections, including terminal boards or leads to control panels. High voltage testing is not
recommended for periodic inspection as each application severely stresses insulation. Low
voltage testing is permissible.
Transient Reactance
Note: This expression will be used to explain reactance values in general and to show some
of the related arithmetic and uses of the five listed reactance values.
The term Òtransient reactanceÓ is usually expressed by the symbol XÕd. It is one of the five
reactance figures frequently used by engineers when comparing generator capability with
load requirement, or when comparing one generator capability with load requirement, or
when comparing one generator with another. R e a c t a n c e f i g u r e s a r e a l w a y s u s e d
w i t h t h e r e l a t e d k V •A
A r a t i n g ( c a l l e d B a s e K V •AA), the related ampere rating
( c a l l e d B a s e A m p e r e s ) , a n d t h e r e l a t e d v o l t a g e ( c a l l e d B a s e V o l t a g e ) . The
listed figures are per unit values (abbreviated, P.U. or p.u.). ÒPer unitÓ is a decimal fraction of
some whole value. ÒTwenty percentÓ (20%) indicates part of some whole value but could
also be written as 0.20. ÒPer unitÓ is a pure number. It has no label such as volts, amperes, or
Ohms. Reactances are also expressed in percent (100% x per unit).
The five listed reactance per unit values describe the line-to-neutral value at the kV•A and
ampere conditions (or volt condition) listen in the same price list reference number and
rating. These line-to-neutral reactance per unit values can be directly converted to a line-to-
neutral ohmic value by use OhmÕs law and the per unit value: divide the line-to-neutral rated
voltage by the rated line amperes. The result will be Ohms. Multiply the result by the per unit
value. The result is Ohms reactance.
Example: Transient reactance = 0.2490 per unit. The base voltage is 480, base ampere is 263.
Generator voltage listed is line-to-line. This must be converted to line-to-neutral voltage: 480
divided by the √3 equals 277 volts, which is the Òbase voltageÓ.
277
Transient Reactance, ohms = x 0.2490
263
= 0.262 Ohms
Most engineers prefer a presentation in the following order: line-to-line voltage, prime power
kV•A, line amperes (at the listed line-to-line voltage), and the line-to-neutral reactances in
the per unit value.
Various ratings on a specific generator do not change the reactance. However, the per unit
value reactances do change directly with the rating.
Example: Determine the per unit value of transient reactance of a generator at a 180 base
kV•A at 480 volts. At 219 kV•A, 480 volts, the reactance is 0.2490 P.U. Per unit values change
directly with the base kV•A.
180
x 0.2490 = 0.2046 per unit
219
The reactance in ohms has not changed because at 180 kV•A, the line ampere rating would
be 216 amperes. The calculation shows:
277 volts
x 0.2046 = 0.262 Ohms
216 amperes
Per unit reactance changes inversely (volts down, reactance up) with the square of the
voltage ratio if the kV•A rating remains the same. Example: At 480 volts the listed transient
reactance is 0.2490. The base voltage is to be decreased from 480 volts to 416 volts. The
kV•A is to remain the same. The per unit transient reactance at the lower voltage is:
(480/416)2 x 0.2490 =0.3310 per unit
The ohmic line-to-neutral transient reactance has not changed. Line-to-neutral voltage is
now:
416 volts
= 240 volts
1.732
Since the kV•A rating is to remain at 219 kV•A, the line ampere rating is:
219 kVA x 1000
= 303 amperes
1.732 x 416
Transient reactance in ohms is:

240 volts x 0.3310
= 0.262 Ohms
303 amperes
Other terms relating to reactances:
Direct Ñ All of the figures quoted in the TMI are Òdirect axisÓ reactance per unit values.
Occasionally, engineers will ask for quad axis figures. Quadrature axis figures are supplied
when appropriate.
Saturated Ñ Where applicable, figures are calculated at magnetic saturation.

Occasionally, engineers will ask for the unsaturated value of a reactance. Where
applicable, this can be supplied upon specific request.
Transient reactance (per unit) figures are used to approximate the current at the time a
circuit breaker opens under three-phase, short-circuit conditions. A circuit breaker will
probably open at 7 cycles (0.13 seconds at 60Hz), which is within the time transient
reactance values apply (about 6 cycles to 5 seconds). The calculation requires two
valuesÑbase amperes and the transient reactance. For a generator at 60 Hz, 480 volts,
divide the base amperes by the transient reactance per unit value:
Example: Generator base amps = 263 A

Transient reactance = 0.2490
263 amperes
= 1056 amperes
0.249
Transient reactance is also used by some engineers to determine the approximate voltage
dip on a generator when starting large motors.
SR4 Generators have transient reactance per unit values ranging from 0.16 to 0.45.
Subtransient Reactance
This term is usually expressed as XÓd with a per unit (P.U.) value of 0.1 to 0.3 for SR4s and 0.1 to
0.2 for SR4Bs. Engineers frequently request the percent subtransient reactance. Per unit
values are directly convertible to percent: 0.1 becomes 10%, 0.3 becomes 30%. Engineers
also request the subtransient impedance. This implies the Ohmic line-to-neutral reactance
since the stator resistance is less than 2% of the line-to-neutral impedance. Calculate the
subtransient line-to-neutral reactance as:
volts, line-to-neutral
x X"d
base amperes
For a generator at 60 Hz, 219 kV•A, with XÓd = 0.120 and base amperes of 263:
480 volts
= 277 volts, line-to-neutral
1.732
277
x 0.1201 = 0.1265 Ohm
263 Amperes
The subtransient reactance applies to a time period ranging from zero to five cycles. The per
unit value is often used to determine the maximum current in event of a short circuit. The
RMS* symmetrical current will be the rated amperes divided by the subtransient reactance
per unit value. Under three-phase short circuit, this generator can produce:
263
=2190 amperes RMS
0.1201
SYMMETRICAL
Asymmetrical refers to a current, which is not centered, or symmetrical, to a fixed reference

axis.
ASYMMETRICAL
DC
Component
The point in time at which the short circuit occurs determines if the resultant current is initially
symmetrical or asymmetrical or a combination of each. If the fault occurred the instant the
voltage is crossing the zero line, the current will be asymmetrical. The resulting value is known
as maximum asymmetrical current. If the fault occurred when the voltage is at a positive or
negative peak, the resultant current will be symmetrical. A fault occurring at any point in
time between zero crossing, and the positive or negative peak will produce a lesser value of
asymmetrical current.
In time Ñ within one to five cycles Ñ the asymmetrical current declines to a very low value.
From that time forward, the symmetrical current is the only significant current.
* RMS means root mean square and is the value indicated by the more common electric
measuring equipmentÑammeters, voltmeters. Symmetrical refers to a current that remains
centered about a fixed reference axis.
The asymmetrical current is also known as the ÒDC (direct current) componentÓ.
The maximum asymmetrical short circuit RMS current can be found by multiplying the RMS
symmetrical value by 1.732 (square root of 3). In the above example, the generator will
produce 2190 × √3 = 3793 RMS amperes, asymmetrical.
Calculations involving circuit breakers normally require peak currents. Symmetrical and
asymmetrical currents from an SR 4 Generator can be converted to peak values by
multiplying either value by the square root of 2 (1.414). In the above example, the generator
will produce:
2190 × √2 = 3096 peak symmetrical amperes
or
3793 × √2 = 5363 peak asymmetrical amperes
Note that a smaller subtransient reactance per unit value results in higher available short-
circuit current. Available short-circuit current is sometimes expressed as a multiplier (called
available current ratio), which is the reciprocal of the per unit subtransient reactance. For
this generator,
1 ÷ 0.1201 = 8.3096.
Rated current times that multiplier equals RMS symmetrical current:

263 amperes × 8.326 = 2190
Per unit subtransient reactance values of SR4 Generators are about one-half the transient
reactance per unit value.
Synchronous Reactance
This term is identified by the symbol Xd and has a per unit value of 2.0 and 3.9 in SR 4
Generators. This factor is used to determine the steady-state fault current capability of a
separately excited generator. (The short-circuit current which would be produced after five
seconds.) Self-excited generators, such as the SR 4, lose excitation before five seconds.
Hence, the synchronous reactance factor cannot be used to determine the actual steady-
state fault current. The factor does, however, give a comparison with other generators by
considering the probable performance if excited from a separate source.
Negative Sequence Reactance

This factor has a symbol X2 and a per unit value that approximates the value of the
subtransient per unit reactance value. Engineers use this figure when calculating probable
fault currents in event of a line-to-line short circuit from a particular generator. Calculation is
very similar to that used for subtransient short circuits. For a generator at 60 Hz, 219 kV•A, 263
amperes, and X2 of 0.1543:
rated amperes x 1.732
amperes, RMSSC = X"d + X2
236 x 1.732 236 x 1.732

= = 1660 amperes
0.1201 + 0.1543 0.2744
1660 amperes is the RMS effective symmetrical current. The peak symmetrical value is found
by multiplying the above result by √2.
1660 × 1.414 = 2347 amperes
RMS asymmetrical value is determined from:

RMS × √3 = 1660 × 1.732 = 2875
The peak asymmetrical value is the RMS asymmetrical value multiplied by 1.414, which
equals 4065 amperes.
Zero Sequence Reactance

This reactance factor has the symbol Xo and a per unit value of 0.03 to 0.13 or approximately
one-third the value of the subtransient per unit reactance figure. The factor is used to
determine probable value of line-to-neutral, short-circuit currents and possible line-to-ground
currents in the event the neutral is grounded and a line-to-ground fault occurs. Fault current
calculation is similar to those of line-to-line calculation:
rated amperes x 3
amperes, RMS =
X"d + X2 + X0
For a generator at 60 Hz, 219 kV•A, 263 amperes and X0 of 0.0450:

263 x 3 263 x 3
= = 2470 amperes, RMS, symmetrical
0.1201 + 0.1543 + 0.0450 0.3194
The peak value can be found by multiplying the RMS value by √2:
2470 × √2 = 3493 amperes, peak, symmetrical
RMS asymmetrical value can be found by multiplying the RMS symmetrical value by √3.
Note: Available currents resulting from different types of faults are different. The line-to-
neutral short circuit is often the highest value and the most likely to occur.
Open Circuit Time Constant

Figures listed are in seconds. These are determined from a test performed as follows. The
generator is operating at normal rated voltage with no load. The main rotating field is
supplied from a separate source, usually a battery. The rotating field input is short circuited
and the voltage across the generator output terminals will reduce. Time, in seconds, for the
generator terminal voltage to reach 36.8% of its original value is recorded as the open circuit
time constant. The figure is primarily used in the design of voltage regulators. Some
engineers use the open circuit time constant along with another factor called generator
time constant, which can be supplied upon request. Individually and together, these two
time constants provide switchgear and distribution designers with information needed to
study the possible voltage changes resulting from sever load changes.
Generator Time Constant is a measure of the magnetic inertia in a generator and gives an
indication of machine performance under short circuit conditions. The factor is determined
by actual running tests where the generator output is short circuited and the reaction is
recorded. The time elapsed between short circuit application and voltage decline to 36.8%
of normal is the generator time constant. The symbol is TD-SC and it has a value in seconds
approximately equal to 10% of the open circuit time constant.
Exciter Field ResistanceÑOhms, Exciter Voltage No Load, Rated Load and

Exciter Amperes No Load, Rated Load
The preceding three factors are closely related and are very helpful when troubleshooting a
difficulty involving the field circuit breaker of an SR4 Generator.
1. Exciter field resistance is given in Ohms as measured at the lead terminals of the
exciter field. The actual resistance is more easily determined by measuring any
applied voltage and the resulting current. OhmÕs lay applies: R = E/I. If E = 6.0
volts, I = 2,5 amperes, the exciter field has a resistance of 2.4 Ohms.
2. Exciter voltage is also measured at the input leads to the exciter field. Input
voltage is lowest when there is no load on the generator and rises by a factor of
about there under load. Exciter field current is also low at no load and will rise by
a factor of three under full load.
Generator main field voltage and current are not listed because they cannot be
measured on an SR4 Generator. There is no way of opening the circuit to insert
instruments while the generator is operating. However, a static test can be
performed with a variable source of DC voltage.
Derate Altitude (m)

D e r a t e T e m p e r a t u r e ( °C
C)
These two factors relate directly to the density of the cooling air forced through the
generator. Derating is not required below 1000 m (3280 ft). NEMA design considerations
require generator derating of 1% per 100 m (330 ft) above 1000 m. A 100 kV•A generator
operating at 2000 m (6,560 ft) altitude would be derated to 90 kV•A. NEMA design
machinery derating is very similar to that of European design machinery as shown by this
comparison:
Typical European Altitude NEMA Design

Design Derated to Meters Derated to
96% 1500 95%
91% 2000 90%
87% 2500 85%
83% 3000 80%
Air density decreases as cooling air temperature increases. At higher cooling air
temperatures, derating of the generator may be required. NEMA recommendations suggest
that the permissible temperature rise of the machine be reduced 10°C (i.e., from 105°C to
95°C) when cooling air temperature is 40°C up to and including 50°C. NEMA also suggests
permissible temperature rise of the machine be reduced 20°C (i.e. from 105°C to 85°C) when
cooling air temperature is 50°C up to and including 60°C (140°F). These recommendations
may affect the generator rating. Some Caterpillar Generators do not require a temperature
rise decrease until the ambient cooling air temperature is 50°C. The generator may not
require derating as its actual operating temperature rise could be considerably below the
105°C limit for prime power or 130°C at the standby rating. The following compares
European practice of rating decrease with NEMA permissible temperature rise decrease
using a typical SR 4 Generator.
Typical SR 4
Typical European Generator at
Design Generator Cooling Prime Power
Percent of 40°C Air Percent of 40°C
Ambient Rating Temperature Ambient Rating
107% 25°C 100%
96% 45°C 100%
93% 50°C 100%
91% 55°C 95%
88% 60°C 92%
In most instances, altitude and temperature will cause derating of the engine and, therefore,
limit the available power from the generator. Actual derating of the generator itself is
normally not necessary.
See information on temperature rise.
Efficiency at 0.8 Power Factor

Efficiency data accounts for all losses in the generator. Losses include:
Approximate
Percent of
Loss Input Power
Stator Resistance 1.3%
Cooling Air Power 1.3%
Mechanical Friction 1.3%
Excitation System Power 2.3%
The percentage figures are typical of a 400 kW, 60 Hz machine supplying 400 kW at 0.8
power factor. Excitation system power and stator resistance power loss would be less if the
load was 1.0 power factor. Caterpillar Generators have the greatest efficiency near _ full
load.
T e m p e r a t u r e R i s e °C
C Stator/Rotor Insulation Temperature Class
Figures quoted are Òwill not exceedÓ temperatures. The actual temperature under the load
conditions will probably be less than the listed figure. Figures have been determined by heat
run tests.
Temperatures quoted for the insulation class (Class F is standard) are normally accepted
operating temperatures for the materials involved.
Heat Dissipated - Btu/min, kW

Air Flow Required - cfm/m3/ m i n
These two factors are directly related. All losses in the generator convert to heat, which must
be dissipated by radiation and by cooling air flow. To convert Btu to kcal/min, multiply by
0.0252 kcal/Btu. Total heat loss can also be calculated in either kW or Btu/min. For heat loss
in kW, multiply the kW rating by (100 Ð efficiency).
For total loss in Btu/min, multiply the kW loss by 56.8 Btu/kW x minute.
To convert required air flow in m3 to air flow in cu ft, multiply the listed figure by 35.31 cu
ft/m3.
Air flow is calculated on an average air temperature rise of 11°C (20°F) as it passes through
and around the generator. This volume of air must always be included in engine room
ventilation requirements.
Rotor Weight
This figure indicates the total weight of the generator rotor. When used with the formula for
inertia, the flywheel effect of the generator can be found. Engineers may use these figures
when generator loads are sudden or cyclic.
Inertia Data
When the information is given to an engineer, it must be correctly identified.
These figures list the mass moment of inertia in System International units and English units.
Other symbols used to designate inertia of rotating machinery are WK2, WR2, and GD2. The
Caterpillar inertia presentation of:
Force x Distance x Time2
2
N•m sec = Newton x meter x Second2
2
lb/in sec = lb x in. x Second2
is recognized anywhere in the world and can be readily converted to other inertia
designations.
To convert to moment of inertia (WK2) in SI units, multiply N•m sec2 by 9.803 m/sec2. Multiply
lb/in sec2 by 2.683 to get inertia (WK2) in lb/sq ft, the common English unit designation.
Inertia data is essential to studies of transient response, such as the effect of a larger
generator with more rotor weight and greater mass moment of inertia.
Stator Weight
Figures in kilograms and pounds give an indication of the capacity of a generator.
Engineers generally assume that a heavier stator contains more working copper and iron.
Total Weight
These figures are the sum of rotor weight and stator weight.
Center of Gravity
Listed information gives the location of the generator center of gravity in three planes. With
the total generator weight, the information can be used to determine the center of gravity
of an assembly consisting of engine, generator, radiator, and base. Combined calculations
require reducing all values to moments (lb.in or kg/mm). These are summed algebraically in
each plane of reference.
Mounting Flange Number

This relates to the engine flywheel housing the generator is mounted on.
Waveform Deviation Factor

This figure is an indication of the degree that a generated voltage differs from a perfect sine
wave. Present standards require that the factor not exceed 10% of the line-to-line
generated voltage at no load. SR 4 Generators do no exceed 5%. This characteristic is also
known as Wave-Shape Deviation Factor. Deviation from a perfect sine wave is primarily the
result of harmonics, generated as a field pole passes a conductor. There are many design
techniques available to make the deviation factor very low. These may or may not have
importance when the generator is under normal load.
Telephone Influence Factor

This factor is usually identified as TIF. European standards refer to it as Telephone Harmonic
Factor or THF. The factor is an indication of the possible effect of generated harmonics on
adjacent telephone circuits.
The factor related to interference by magnetic induction. This is rarely a problem today as
telephone lines are in conduit, shielded cable or buried. However, some engineers use this
factor to predict the amount of electrical noise induced or conducted into control circuits
that may trigger SCR devices.
Acceptable limits set by various standards groups relate to generator kV•A capacity. Up to
300 kV•A, the factor is 350; 300 to 600 kV•A, the factor is 250; and 700 to 5000 kV•A, the
factor is 150. The actual values are always determined at rated frequency, rated voltage,
but on open circuit. SR4 Generators are well below the listed limits. These generators are
limited in harmonics that might trigger an SCR system or device. This feature accounts for
the very low wave form deviation factor.
Generator Chart
Generator chart was created to be a quick reference look up guide. It represents all current
Caterpillar generators intended for use on 3500 size engines. This includes all 680, 690, 800,
and 820 frame generators as well as the few 580 frame generators made for the 3508
engines. The date at the top of each page is the date of printing and, therefor, the date
considered ÒcurrentÓ. Updates will be made with each new price book. These updates will
occur in EDS as 1W-9515 Chart Generator. This chart is maintained by the Power Systems
EPG group in Lafayette, Indiana.
Generator Chart Terminology

Exc. Type (Exciter Type)
OF - Oil Field Ð Self excited with dual windings
SE - Self excited
PM - Permanent Magnet
APPL (Application)
IND - Industrial
GD - Grid Ð 4160 volt stator
MAR - Marine Society approved
HE - Coastal insulation protection
PMOD - Power module
SB - Standby use only
OF - Oil field
50 Hz Operating Voltage
Represents the normal stator voltage connections at 50 Hz. See the ratings chart in
the Price List for the potential derating at other voltages.
50 Hz SB kVA
Target standby kVA rating of the generator at 0.8 power factor, 50 Hz. (Unless
otherwise noted.)
60 Hz Operating Voltage
Represents the normal stator voltage connections at 60 Hz. See the ratings chart in
the Price List for the potential derating at other voltages.
60 Hz SB kVA
Target standby kVA rating of the generator at 0.8 power factor, 60 Hz. (Unless
otherwise noted.)
Connections Ð Leads, Wires, and Size

Leads - Number of leads
Wire - Total number of leads used to make all the leads
Size - Size of wires used, in SAE units
Bearing # and LOC
# - The number of bearings
LOC - Bearing location
I/B - In board Ð Exciter is between the engine coupling and the
generator bearing
O/B - Out board Ð Generator bearing is between the exciter and
the engine coupling
CC - Close coupled Ð The two bearing generator is close
coupled
Blank - The two bearing generator is NOT close coupled
Space Heater
Y - Yes, space heater is standard
N - No, space heater is not standard. Kits can be ordered.
Stator Temp. Det. (Stator Temperature Detectors)

RTD - Resistance Thermal Detector - Copper
RTD-PT - Resistance Thermal Detector - Platinum
T/C - Type ÒJÓ Iron Constantan Thermocouple
--- - None installed
Winding Type
FW - Form wound
RW - Random wound
Winding Insulation
COASTAL - Coastal insulation protection
1VI&1DE - Vacuum Impregnation treatment with 1 Dip and bake with Epoxy
overcoat
1VPI&1DE - Vacuum Pressure Impregnation treatment with 1 Dip and bake
with Epoxy overcoat
2DE&BE - 2 Dips and Bakes with Epoxy overcoat
4DE&BE - 4 Dips and Bakes with Epoxy overcoat
Pitch
Stator winding pitch. See EDS 70.4 for further explanation.
Inertia NMS^2
Measured in metric units of (Newton)(Meters)(Seconds)2
Package Restrict Codes

A - Vibration isolators are needed in some cases
B - No over sizing on smaller engines is allowed
C - Can only be used at 50Hz in most cases
D - Can only be used at 60Hz in most cases
E - Mounts to narrow base only
F - Soft mounts to base
G - Not for use with Phase 2 Diesel 3516 engines
H - Not for use with Diesel 3508 engines
Sales Model
Frame sizes available
Sales Model 4 Pole 6 Pole
3516 696 Ð 828 804 Ð 809
3516B 825 Ð 828 --
3516G 822 Ð 824 --
3512 691 Ð 824 683 Ð 804
3512B 692 Ð 825 --
3512G 693 Ð 695 --
3508 690 Ð 697 587 Ð 686
3508B 692 Ð 695 --
3508G 691 Ð 692 --
Note: Some frame sizes are applicable to more than one sales model. See package
restrict codes and price book for further restrictions. Oversized generators are not
considered in this chart.
Voltage Part Numbers
Part number Voltage Frequency Connection
EPG / Gas
5N - 9589 200 50 Hz WYE
5N - 9590 400 50 Hz WYE
5N - 9603 415 50 Hz WYE
5N - 9621 500 50 Hz WYE
5N - 9591 3,300 50 Hz WYE
5N - 9584 4,160 50 Hz WYE
5N - 9620 6,000 50 Hz WYE
5N - 9619 6,300 50 Hz WYE
5N - 9618 6,600 50 Hz WYE
5N - 9617 6,900 50 Hz WYE
5N - 9616 10,000 50 Hz WYE
5N - 9615 11,000 50 Hz WYE
5N - 9614 15,000 50 Hz WYE
5N - 9593 208 60 Hz WYE
5N - 9594 240 60 Hz WYE
5N - 9595 300 60 Hz WYE
5N - 9592 380 60 Hz WYE
5N - 9596 416 60 Hz WYE
5N - 9597 480 60 Hz WYE
5N - 9598 600 60 Hz WYE
5N - 9624 2,400 60 Hz WYE
5N - 9613 3,300 60 Hz WYE
5N - 9599 4,160 60 Hz WYE
5N - 9612 6,000 60 Hz WYE
5N - 9611 6,300 60 Hz WYE
5N - 9610 6,600 60 Hz WYE
5N - 9609 6,900 60 Hz WYE
5N - 9608 7,200 60 Hz WYE
5N - 9607 12,470 60 Hz WYE
5N - 9606 13,200 60 Hz WYE
5N - 9605 13,800 60 Hz WYE
5N - 9601 120 60 Hz DELTA
5N - 9602 240 60 Hz DELTA
5N - 9600 2,400 60 Hz DELTA
Marine
5N - 9585 190 50 Hz WYE
5N - 9586 380 50 Hz WYE
5N - 9587 220 60 Hz WYE
5N - 9588 440 60 Hz WYE
Petroleum
5N - 9598 600 60 Hz WYE
General Dimensions
General dimension drawings for the SR4B 4 pole and 6 pole generators are now available on
standardized sheets for your convenience. These drawings also detail the dimensions for
many of the common attachments currently available for the SR4B generators. They can be
viewed through the Rastar system.
132-3667 690 Frame sizes Ð 2 Bearing

Sheet # 1- Generator general dimensions (Printed on the following pages)

2- Shown with optional EMCP II B-series box
3- Shown with optional EMCP II standard box
4- Shown with optional Low Voltage extension box
5- Shown with cable access box
6- Shown with optional circuit breaker
7- Shown with optional air cleaner group
8- FG Wilson shown with marshalling box and control panel
9- FG Wilson terminal box with optional circuit breaker box
Generator and Rotor Weights
These weights are as provided by the supplier
* - Weight unavailable at time of printing
Type A Model Frame Arrang. # Group # EMI # Rotor Wt.(kg) Total Wt.(kg)
SR4 A643 447 1212720 1212719 45034700 810 2340

SR4 A643 447 1213193 1213192 45056700 850 850
SR4 A646 450 1155120 1155119 45034800 1080 3900
SR4 A547 587 7C3078 7W8703 40056800 620 1600
SR4 A547 587 7C3079 7W8704 40056900 620 1600
SR4 A513 589 1155122 1155121 45034900 590 1640
SR4 A533 589 7C1617 7C1603 40057600 640 1740
SR4 A533 589 7C1618 7C1604 40057700 640 1740
SR4 A501 681 1151569 1151568 45030400 770 2060
SR4 A501 681 4P2239 4P2238 40097200 770 2060
SR4 A501 681 7C1619 7C1605 40057800 770 2060
SR4 A501 681 7C1620 7C1606 40057900 770 2060
SR4 A498 683 1287422 1287421 45068700 * *
SR4 A498 683 7C3064 7W8673 40054000 770 1890
SR4 A498 683 7C3065 7W8674 40054100 770 1890
SR4 A499 684 7C3066 7W8675 40054200 780 2010
SR4 A499 684 7C3067 7W8676 40054300 780 2010
SR4 A524 684 7C3228 7W8692 40059500 660 2020
SR4 A534 685 1151441 1151440 45030300 940 2490
SR4 A534 685 1155124 1155123 45035000 940 2490
SR4 A534 685 4P2241 4P2240 40093200 940 2490
SR4 A534 685 6I3095 6I3094 45004800 1020 2610
SR4 A534 685 6I4860 6I4859 45033900 940 2490
SR4 A534 685 7C1621 7C1607 40058000 940 2490
SR4 A534 685 7C1622 7C1608 40058100 940 2490
SR4 A534 685 7C2624 7C2617 40059100 990 2620
SR4 A534 685 9Y9429 9Y9421 40074600 940 2490
SR4 A500 686 6I4854 6I4853 45008000 980 2460
SR4 A500 686 7C3068 7W8677 40054400 980 2420
SR4 A500 686 7C3069 7W8678 40054500 980 2460
SR4 A601 687 1151438 1151437 45030200 990 2550
SR4 A601 687 1155126 1155125 45035100 990 2550
SR4 A502 687 1287420 1287419 45063300 * *
SR4 A601 687 4P2243 4P2242 40097300 960 2510
SR4 A502 687 6I4852 6I4851 45007900 1050 2590
SR4 A601 687 7C2626 7C2619 40059400 1800 4480
SR4 A502 687 7C3070 7W8681 40054600 1040 2480
SR4 A502 687 7C3071 7W8682 40054700 1050 2570
3500 EPG Technical Information Kit 3rd Edition - March 1999 Section 1 - Page 35
SR4 A601 687 7C3543 7C3537 40060700 960 2510
SR4 A601 687 7C3544 7C3538 40060800 990 2550
SR4 A535 689 1213195 1213194 45044900 3160 3160
SR4 A535 689 4P4566 4P4565 40095200 1220 3160
SR4 A535 689 6I2677 6I2676 45009400 1320 3220
SR4 A535 689 6I4840 6I4839 45012100 1330 3340
SR4 A535 689 6I4842 6I4841 45013500 1220 3160
SR4 A535 689 7C1623 7C1609 40058200 1220 3160
SR4 A535 689 7C1624 7C1610 40058300 1220 3160
SR4 A605 804 1268026 1268025 45068600 1810 4710
SR4 A605 804 1287418 1287417 45063400 1810 4710
SR4 A605 804 4P7273 4P7272 40097400 3080 1250
SR4 A605 804 7C4914 7C4913 40061900 1240 2940
SR4 A604 805 6I4834 6I4833 45013400 1220 3000
SR4 A604 805 7C3547 7C3541 40060900 1220 3000
SR4 A604 805 7C3548 7C3542 40061000 1220 3000
SR4 A507 806 1210375 1210374 45056600 1320 3430
SR4 A505 806 1213199 1213198 45045200 620 3110
SR4 A507 806 6I3093 6I3092 45004700 1320 3430
SR4 A505 806 6I4848 6I4847 45007700 1260 3180
SR4 A505 806 6I4850 6I4849 45007800 1260 3110
SR4 A507 806 7C1625 7C1611 40058400 1330 3330
SR4 A507 806 7C1626 7C1612 40058500 1330 3330
SR4 A505 806 7C3072 7W8685 40055100 1340 3170
SR4 A505 806 7C3073 7W8686 40055200 1340 3170
SR4 A507 806 7C3266 7W7963 40059000 1330 3530
SR4 A507 806 7C5095 7C5094 40062500 1330 3530
SR4 A507 806 9Y9430 9Y9422 40074700 1330 3330
SR4 A537 807 1151526 1151525 45030100 1450 3610
SR4 A537 807 1213197 1213196 45045100 1440 3750
SR4 A506 807 1213201 1213200 45045300 1500 3550
SR4 A506 807 1268024 1268023 45068500 1810 4710
SR4 A506 807 1287416 1287415 45063500 1810 4710
SR4 A537 807 4P2247 4P2246 40085400 1450 3610
SR4 A537 807 4P3016 4P3015 40090400 1440 3690
SR4 A506 807 4P7271 4P7270 40097500 1510 3640
SR4 A537 807 6I3089 6I3088 45004500 1440 3750
SR4 A537 807 6I4830 6I4829 45013300 1450 3610
SR4 A537 807 7C1627 7C1613 40058600 1450 3610
SR4 A537 807 7C1628 7C1614 40058700 1450 3610
SR4 A506 807 7C3074 7W8687 40055300 1510 3480
SR4 A537 807 7C4122 7C4121 40061700 1450 3610
SR4 A610 807 7C9127 7C9126 40080700 1450 3960
SR4 A506 807 9Y7181 9Y7180 40066500 1500 3550
SR4 A597 808 1083050 1063652 45019200 1610 4260
SR4 A597 808 1083051 1083052 45019300 1790 4340
SR4 A728 808 1097874 1097873 45022800 1640 4340
SR4 A597 808 4P4572 4P4571 40095500 1600 4110
SR4 A597 808 6I3091 6I3090 45004600 1600 4120
SR4 A597 808 7C2625 7C2618 40059200 1600 4110
SR4 A597 808 9Y3874 9Y3872 40069600 1600 4110
SR4 A597 808 9Y3875 9Y3873 40798600 * *
SR4 A525 809 1268022 1268021 45068400 1810 4710
SR4 A525 809 1287414 1287413 45063200 1810 4710
SR4 A602 809 6I4828 6I4827 45008200 1810 4710
SR4 A602 809 6I4836 6I4835 45014000 1810 4710
SR4 A525 809 6I4844 6I4843 45007500 1820 4250
SR4 A525 809 6I4846 6I4845 45007600 1820 4130
SR4 A602 809 7C2627 7C2620 40059400 1800 4480
SR4 A525 809 7C3076 7W8693 40055800 1830 *
SR4 A600 809 9Y1411 9Y1408 40080500 1800 4360
SR4 A602 809 9Y2936 9Y2934 40073700 1800 4480
SR4 A769 812 1287412 1287411 45063600 1170 4750
SR4 A866 812 1479516 1479517 45100100 2060 4385
SR4 A867 812 1479518 1479519 45100200 2060 4385
SR4 A741 815 1287424 1287423 45068300 1810 4710
SR4 A599 815 1429900 1429899 45091900 2120 5110
SR4 A741 815 6I4856 6I4855 45034400 2150 5060
SR4 A599 815 7C2630 7C2623 40059600 2120 5110
SR4B A910 663 1586410 1586409 46036000 * *
SR4B A911 667 1586412 1586411 46036100 * *
SR4B A760 690 1441686 1441685 46010100 790 2420
SR4B A697 690 1441744 1441743 46028000 800 2420
SR4B A742 690 1441832 1441831 46010300 800 2460
SR4B A742 690 4P4534 4P4533 46000300 800 2460
SR4B A697 690 9Y0158 9Y0157 46000200 800 2430
SR4B A760 690 9Y0515 9Y0513 46000100 790 2420
SR4B A743 691 1155102 1155101 46000500 840 2570
SR4B A696 691 1216849 1216848 46001300 880 2750
SR4B A698 691 1216851 1216850 46001400 900 2770
SR4B A743 691 1216853 1216852 46001500 900 2790
SR4B A698 691 1216855 1216854 46001700 900 2770
SR4B A698 691 1216857 1216856 46001100 900 2760
SR4B A743 691 1216859 1216858 46001200 900 2770
SR4B A698 691 1216861 1216860 46001600 900 2770
SR4B A696 691 1441688 1441687 46010400 830 2550
SR4B A696 691 1441690 1441689 46011200 880 2750
SR4B A698 691 1441746 1441745 46028100 850 2570
SR4B A698 691 1441748 1441747 46028500 900 2770
SR4B A743 691 1441834 1441833 46010600 850 2590
SR4B A743 691 1441836 1441835 46011400 900 2800
SR4B A698 691 1441972 1441971 46010900 850 2570
SR4B A698 691 1441974 1441973 46011700 900 2770
SR4B A698 691 1442024 1442023 46028400 850 2570
SR4B A698 691 1442026 1442025 46028800 900 2770
SR4B A698 691 1479438 1479437 46028300 850 2550
SR4B A698 691 1479440 1479439 46028700 900 2760
SR4B A743 691 4P4542 4P4541 46000800 850 2590
SR4B A698 691 4P4582 4P4581 46000900 850 2570
SR4B A698 691 9Y0160 9Y0159 46000700 850 2570
SR4B A698 691 9Y0395 9Y0394 46000400 850 2550
SR4B A696 691 9Y0517 9Y0516 46000600 830 2550
SR4B A698 691 9Y1424 9Y1423 46001000 850 2570
SR4B A744 692 1155104 1155103 46001900 950 2800
SR4B A678 692 1214612 1214611 46002700 930 2890
SR4B A688 692 1214614 1214613 46002800 950 2900
SR4B A744 692 1214616 1214615 46002900 950 2920
SR4B A688 692 1214618 1214617 46003100 1000 3000
SR4B A688 692 1214620 1214619 46002500 1000 3000
SR4B A744 692 1214622 1214621 46002600 1000 3010
SR4B A688 692 1214624 1214623 46003000 940 2890
SR4B A678 692 1441692 1441691 46012000 880 2680
SR4B A678 692 1441694 1441693 46012800 930 2890
SR4B A688 692 1441750 1441749 46028900 900 2700
SR4B A688 692 1441752 1441751 46029300 950 2900
SR4B A688 692 1441768 1441767 46012100 900 2700
SR4B A744 692 1441838 1441837 46012200 890 2720
SR4B A744 692 1441840 1441839 46013000 950 2920
SR4B A688 692 1441976 1441975 46012500 950 2800
SR4B A688 692 1441978 1441977 46013300 1000 3000
SR4B A688 692 1442028 1442027 46029200 890 2690
SR4B A688 692 1442030 1442029 46029600 940 2890
SR4B A688 692 1479442 1479441 46029100 950 2800
SR4B A688 692 1479444 1479443 46029500 1000 3000
SR4B A744 692 4P4544 4P4543 46002200 890 2720
SR4B A688 692 4P4584 4P4583 46002300 890 2690
SR4B A688 692 9Y0162 9Y0161 46002100 900 2700
SR4B A688 692 9Y0397 9Y0396 46001800 950 2800
SR4B A688 692 9Y0453 9Y0452 46002400 500 2800
SR4B A678 692 9Y0520 9Y0519 46002000 880 2680
SR4B A679 693 1214626 1214625 46003500 1000 3090
SR4B A689 693 1214628 1214627 46003600 1020 3110
SR4B A745 693 1214630 1214629 46003700 1020 3100
SR4B A679 693 1441696 1441695 46013600 950 2900
SR4B A679 693 1441698 1441697 46014400 1000 3100
SR4B A689 693 1441754 1441753 46029700 970 2920
SR4B A689 693 1441756 1441755 46030100 1020 3110
SR4B A689 693 1441772 1441771 46013700 970 2920
SR4B A745 693 1441842 1441841 46013800 970 2900
SR4B A745 693 1441844 1441843 46014600 1020 3100
SR4B A745 693 1441964 1441963 46014000 970 2920
SR4B A745 693 4P4546 4P4545 46003400 970 2900
SR4B A689 693 9Y0164 9Y0163 46003300 970 2920
SR4B A679 693 9Y0522 9Y0521 46003200 950 2900
SR4B A746 695 1155106 1155105 46003900 1080 3180
SR4B A680 695 1221179 1221178 46004700 1110 3280
SR4B A690 695 1221181 1221180 46004800 1130 3290
SR4B A746 695 1221183 1221182 46004900 1130 3330
SR4B A690 695 1221185 1221184 46005100 1130 3320
SR4B A690 695 1221187 1221186 46004500 1130 3340
SR4B A746 695 1221189 1221188 46004600 1130 3360
SR4B A690 695 1221191 1221190 46005000 11120 3300
SR4B A680 695 1441700 1441699 46015200 1060 3130
SR4B A680 695 1441702 1441701 46016000 1120 3280
SR4B A690 695 1441758 1441757 46030500 1090 3180
SR4B A690 695 1441760 1441759 46030900 1130 3290
SR4B A690 695 1441776 1441775 46015300 1080 3180
SR4B A746 695 1441846 1441845 46015400 1080 3140
SR4B A746 695 1441848 1441847 46016200 1130 3330
SR4B A746 695 1441968 1441967 46015600 1080 3180
SR4B A690 695 1441984 1441983 46015700 1080 3140
SR4B A690 695 1441986 1441985 46016500 1130 3320
SR4B A690 695 1442036 1442035 46030800 1080 3150
SR4B A690 695 1442038 1442037 46031200 1130 3300
SR4B A690 695 1479450 1479449 46030700 1080 3150
SR4B A690 695 1479452 1479451 46031100 1130 3340
SR4B A746 695 4P4568 4P4567 46004200 1080 3140
SR4B A690 695 4P4586 4P4585 46004300 1080 3150
SR4B A690 695 9Y0166 9Y0165 46004100 1080 3180
SR4B A690 695 9Y0399 9Y0398 46003800 1080 3150
SR4B A690 695 9Y0455 9Y0454 46004400 1080 3140
SR4B A680 695 9Y0524 9Y0523 46004000 1060 3130
SR4B A681 696 1441666 1441665 46016800 1140 3290
SR4B A691 696 1441704 1441703 46031300 1150 3310
SR4B A691 696 1441724 1441723 46016900 1150 3310
SR4B A747 696 1441812 1441811 46017000 1150 3310
SR4B A691 696 1479454 1479453 46031700 1150 3310
SR4B A747 696 4P4570 4P4569 46005400 1150 3350
SR4B A691 696 9Y0170 9Y0169 46005300 1150 3310
SR4B A681 696 9Y0526 9Y0525 46005200 1140 3290
SR4B A860 697 1441668 1441667 46017600 * *
SR4B A861 697 1441706 1441705 46031900 * *
SR4B A862 697 1441814 1441813 46017800 * *
SR4B A861 697 1441990 1441989 46018100 * *
SR4B A861 697 1442042 1442041 46032400 * *
SR4B A861 697 1479456 1479455 46032300 * *
SR4B A748 822 1155108 1155107 46006200 1300 3870
SR4B A748 822 1412016 1412015 46009700 * *
SR4B A682 822 1441670 1441669 46018400 1250 3630
SR4B A682 822 1441708 1441707 46032500 1250 3630
SR4B A748 822 1441816 1441815 46018700 1260 3670
SR4B A692 822 1441992 1441991 46019100 1260 3670
SR4B A692 822 1442080 1442079 46019600 1260 3820
SR4B A748 822 1479490 1479489 46019400 1300 3870
SR4B A748 822 4P4574 4P4573 46006400 1260 3670
SR4B A692 822 4P4588 4P4587 46006500 1260 3810
SR4B A692 822 9Y0457 9Y0456 46006600 1260 3660
SR4B A682 822 9Y0528 9Y0527 46006300 1250 3630
SR4B A749 824 1155110 1155109 46006700 1440 4200
SR4B A749 824 1412020 1412019 46009900 * *
SR4B A683 824 1441674 1441673 46021000 * *
SR4B A693 824 1441712 1441711 46033500 1430 4100
SR4B A693 824 1441732 1441731 46021100 1430 4100
SR4B A749 824 1441820 1441819 46021300 1410 4080
SR4B A693 824 1441996 1441995 46021700 1430 4100
SR4B A693 824 1442068 1442067 46022100 * *
SR4B A693 824 1442084 1442083 46022200 1410 4090
SR4B A749 824 1479494 1479493 46022000 1440 4200
SR4B A749 824 4P4576 4P4575 46006900 1410 4080
SR4B A693 824 4P4590 4P4589 46007000 1410 4080
SR4B A693 824 9Y0460 9Y0459 46007100 1440 4140
SR4B A683 824 9Y0530 9Y0529 46006800 1430 4100
SR4B A750 825 1155112 1155111 46007200 1550 4480
SR4B A684 825 1441678 1441677 46023600 1540 4330
SR4B A694 825 1441716 1441715 46034500 1540 4330
SR4B A694 825 1441736 1441735 46023700 1540 4330
SR4B A750 825 1441824 1441823 46023900 1510 4370
SR4B A750 825 1441952 1441951 46034900 1540 4330
SR4B A694 825 1442000 1441999 46024300 1510 4270
SR4B A694 825 1442072 1442071 46024700 * *
SR4B A694 825 1442088 1442087 46024800 1540 4330
SR4B A750 825 1479498 1479497 46024600 1550 4480
SR4B A684 825 1604022 1604021 46034700 1540 4330
SR4B A750 825 4P4578 4P4577 46007400 1510 4370
SR4B A694 825 4P4597 4P4596 46007500 1550 4420
SR4B A694 825 9Y0462 9Y0461 46007600 1510 4270
SR4B A684 825 9Y0532 9Y0531 46007300 1540 4330
SR4B A751 826 1155114 1155113 46007700 * *
SR4B A685 826 1441680 1441679 46024900 1710 4910
SR4B A695 826 1441718 1441717 46035000 1680 4920
SR4B A751 826 1441826 1441825 46025200 1680 4920
SR4B A695 826 1442002 1442001 46025600 1670 4850
SR4B A751 826 4P4580 4P4579 46007900 1680 4920
SR4B A695 826 4P4599 4P4598 46008000 1670 4870
SR4B A695 826 9Y0464 9Y0463 46008100 1670 4850
SR4B A685 826 9Y0534 9Y0533 46007800 1710 4910
SR4B A752 827 1155116 1155115 46008200 * *
SR4B A752 827 1441828 1441827 46026500 1890 5290
SR4B A756 827 1442004 1442003 46026700 1890 5290
SR4B A756 827 4P4601 4P4600 46008400 1890 5290
SR4B A752 827 7E9696 7E9695 46008300 1850 5370
SR4B A756 827 9Y0276 9Y0167 46008500 1850 5140
SR4B A771 828 1412012 1412011 46009500 * *
SR4B A865 828 1441830 1441829 46027400 1890 5290
SR4B A771 828 1442006 1442005 46027600 1890 5290
SR4B A912 862 1586414 1586413 46036300 * *
SR4B A912 862 1586424 1586423 46036200 * *
SR4B A905 862 1586434 1586433 46037200 * *
SR4B A913 864 1586416 1586415 46036500 * *
SR4B A913 864 1586426 1586425 46036400 * *
SR4B A906 864 1586436 1586435 46037300 * *
SR4B A914 866 1586418 1586417 46036700 * *
SR4B A914 866 1586428 1586427 46036600 * *
SR4B A907 866 1586438 1586437 46037400 * *
SR4B A915 867 1586420 1586419 46036900 * *
SR4B A915 867 1586430 1586429 46036800 * *
SR4B A908 867 1586442 1586441 46037501 * *
SR4B A916 868 1586422 1586421 46037100 * *
SR4B A916 868 1586432 1586431 46037000 * *
SR4B A909 868 1586444 1586443 46037600 * *
SR4B A909 868 1586446 1586445 46037701 * *
Weights of Gen components.xls
Table of Contents – Operating Characteristics
Page Number
Dealer Generator Chart 2
Generator Chart for Compatibility 14
Efficiency Generator Chart at 0.8 pf 26
Rotor and Stator Test Data 36
Motor Starting Capability 49
Thermal Limits at Design Voltage 57
Thermal Limits at Off Design Voltage 68
2/3 Pitch Estimated Thermal Limits 78
Altitude / Ambient Temperature Derate Factors 79
Generator Withstand Curve 81
Insulation Systems 82
Torsional Data Reports 83
Bearings Used on Generators 88
These charts are for INTERNAL USE ONLY!!

The following information was created to a quick reference look up guide. It
represents all the current Caterpillar generators intended for use on 3500 size
engines. The date on the top of each page is the date of printing and,
therefor, the date considered ÒcurrentÓ. Updates will be made with each
new price book. These updates will occur in EDS as Ò1W-9515 Chart
GeneratorÓ. This chart is maintained by the Power Systems EPG group in
Lafayette, Indiana.

Caterpillar Inc.
3500 EPG Technical Information Kit 3rd Edition - March 1999 Section 2 Ð Page 1
2/3 Pitch Estimated Thermal Limits
Frame Volts at 50 Hz thermal Ratings (EkW) 60 Hz thermal Ratings (EkW)

Size Poles 60 Hz 80¡C 90¡C 105¡C 130¡C 80¡C 90¡C 105¡C 130¡C
589 4 480 640 370 405 475 450 480 520 610
681 4 480 550 575 620 675 700 735 780 845
685 4 480 662 700 745 815 815 960 920 1000
685 4 4160 695 740 800 900 800 870 950 1070
687 4 480 795 870 955 1055
687 4 4160 705 750 820 910 880 930 1000 1100
689 4 480 885 900 930 1015 1075 1105 1150 1252
689 4 4160 900 950 1050 1170 1090 1150 1300 1450
690 4 480 520 555 595 655 650 690 730 810
691 4 380 705 750 815 905 870 930 1005 1120
691 4 4160 705 750 815 905 870 930 1005 1120
692 4 600 720 760 825 910 910 970 1030 1120
692 4 4160 720 760 825 910 910 970 1030 1120
695 4 380 900 950 1020 1120 1095 1155 1190 1350
695 4 600 900 950 1020 1120 1095 1155 1190 1350
695 4 4160 900 950 1020 1120 1095 1155 1190 1350
696 4 480/MAR 940 1000 1045 1190 1190 1250 1300 1450
696 4 480/HE 900 960 1040 1160 1175 1240 1340 1500
697 4 4160 1110 1130 1180 1300 1310 1340 1400 1540
805 4 480 1040 1060 1100 1225 1280 1300 1360 1500
806 4 480 1040 1080 1125 1255 1300 1350 1410 1570
806 4 4160 990 1025 1065 1190 1235 1280 1360 1500
807 4 480 1105 1170 1240 1370 1390 1465 1550 1710
807 4 4160 1100 1200 1320 1500 1350 1470 1630 1870
808 4 480 1185 1280 1460 1600 1500 1650 1825 2000
808 4 4160 1460 1600 1825 2000
809 4 480 1555 1800 1870 2160
809 4 4160 1555 1800 1870 2160
822 4 600 1110 1130 1180 1300 1310 1340 1400 1540
822 4 4160 1110 1130 1180 1300 1310 1340 1400 1540
824 4 380 1225 1300 1420 1570 1500 1600 1725 1920
824 4 480 1225 1300 1420 1570 1500 1600 1725 1920
825 4 480 1360 1425 1500 1640 1690 1770 1840 2025
825 4 4160 1360 1425 1500 1640 1690 1770 1840 2025
826 4 380 1630 1675 1760 1920 1975 2125 2110 2320
826 4 600 1630 1675 1760 1920 1975 2125 2110 2320
826 4 4160 1630 1675 1760 1920 1975 2125 2110 2320
827 4 480 1685 1790 1930 2140 2025 2150 2300 2525
827 4 4160 1685 1790 1930 2140 2025 2150 2300 2525
828 4 4160
686 6 480 465 500 570 615
687 6 480 570 625 725 775
804 6 4160 620 640 675 750 780 800 845 930
806 6 480 710 760 825 915 885 935 1005 1087
809 6 480 945 1040 1180 1300
809 6 4160 835 880 930 975 1030 1030 1150 1190
Altitude and Temperature Derate Factors
Altitude Ambient Temperature
Meters Feet 20¡C 30¡C 40¡C 50¡C 60¡C 70¡C
0 0 1.000 1.000 1.000 1.000 0.953 0.903
100 328 1.000 1.000 1.000 0.997 0.947 0.897
200 656 1.000 1.000 1.000 0.992 0.942 0.892
300 984 1.000 1.000 1.000 0.987 0.937 0.887
400 1,312 1.000 1.000 1.000 0.982 0.932 0.882
500 1,640 1.000 1.000 1.000 0.976 0.926 0.876
600 1,969 1.000 1.000 1.000 0.971 0.921 0.871
700 2,297 1.000 1.000 1.000 0.966 0.916 0.866
800 2,625 1.000 1.000 1.000 0.961 0.911 0.861
900 2,953 1.000 1.000 1.000 0.955 0.905 0.855
1,000 3,281 1.000 1.000 1.000 0.950 0.900 0.850
1,100 3,609 1.000 1.000 0.995 0.945 0.895 0.845
1,200 3,937 1.000 1.000 0.989 0.939 0.889 0.839
1,300 4,265 1.000 1.000 0.984 0.934 0.884 0.834
1,400 4,593 1.000 1.000 0.979 0.929 0.879 0.829
1,500 4,921 1.000 1.000 0.974 0.924 0.874 0.824
1,600 5,249 1.000 1.000 0.968 0.918 0.868 0.818
1,700 5,577 1.000 1.000 0.963 0.913 0.863 0.813
1,800 5,906 1.000 1.000 0.958 0.908 0.858 0.808
1,900 6,234 1.000 1.000 0.953 0.903 0.853 0.803
2,000 6,562 1.000 0.997 0.947 0.897 0.847 0.797
2,100 6,890 1.000 0.992 0.942 0.892 0.842 0.792
2,200 7,218 1.000 0.987 0.937 0.887 0.837 0.787
2,300 7,546 1.000 0.982 0.932 0.882 0.832 0.782
2,400 7,874 1.000 0.976 0.926 0.876 0.826 0.776
2,500 8,202 1.000 0.971 0.921 0.871 0.821 0.771
2,600 8,530 1.000 0.966 0.916 0.866 0.816 0.766
2,700 8,858 1.000 0.961 0.911 0.861 0.811 0.761
2,800 9,186 1.000 0.955 0.905 0.855 0.805 0.755
2,900 9,514 1.000 0.950 0.900 0.850 0.800 0.750
3,000 9,843 0.995 0.945 0.895 0.845 0.795 0.745
3,100 10,171 0.989 0.939 0.889 0.839 0.789 0.739
3,200 10,499 0.984 0.934 0.884 0.834 0.784 0.734
3,300 10,827 0.979 0.929 0.879 0.829 0.779 0.729
3,400 11,155 0.974 0.924 0.874 0.824 0.774 0.724
3,500 11,483 0.968 0.918 0.868 0.818 0.768 0.718
3,600 11,811 0.963 0.913 0.863 0.813 0.763 0.713
3,700 12,139 0.958 0.908 0.858 0.808 0.758 0.708
3,800 12,467 0.953 0.903 0.853 0.803 0.753 0.703
3,900 12,795 0.947 0.897 0.847 0.797 0.747 0.697
4,000 13,123 0.942 0.892 0.842 0.792 0.742 0.692
4,100 13,451 0.937 0.887 0.837 0.787 0.737 0.687
4,200 13,780 0.932 0.882 0.832 0.782 0.732 0.682
4,300 14,108 0.926 0.876 0.826 0.776 0.726 0.676
4,400 14,436 0.921 0.871 0.821 0.771 0.721 0.671
4,500 14,764 0.916 0.866 0.816 0.766 0.716 0.666
4,600 15,092 0.911 0.861 0.811 0.761 0.711 0.661
4,700 15,420 0.905 0.855 0.805 0.755 0.705 0.655
4,800 15,748 0.900 0.850 0.800 0.750 0.700 0.650
4,900 16,076 0.895 0.845 0.795 0.745 0.695 0.645
5,000 16,404 0.889 0.839 0.789 0.739 0.689 0.639
Multiply Derate factor times generator's maximum kW rating
Example:
Altitude = 4500 Meters Generator maximum rating = 1000EkW
Ambient Temperature = 50 C Derate factor = 0.766 (from chart)
Generator's rating at 4500 M and 50 C = (1000 x 0.766) = 766EkW
Torsional Data Reports
The following table lists what arrangements have had Torsional Reports done. This list does not represent all
arrangements that are currently available. To get a report that is not on the list, call the Lafayette Engine Center.
* Denotes that reports are available upon request
Frame Generator Engine Freq. Speed kW Torsional Notes

Size Arrangement Group Model (HZ) (RPM) Report
582 5N-8664 5N-7064 G3408 50 1500 234 97-1134-00
589 7C-1617 7C-1603 3508 50/60 1500/1800 N/A 7173
7C-1618 7C-1604 3508 50/60 1500/1800 N/A 7173
7C-1619 7C-1605 3508 50/60 1500/1800 N/A 7174
681 7C-1620 7C-1606 3508 50/60 1500/1800 N/A 7174
4P-2239 4P-2238 3508 50/60 1500/1800 N/A 7174
7C-3545 7C-3539 3512/3508 *
683 7C-3546 7C-3540 3512/3508 *
7C-3064 7W-8673 3516/3512/3508 * / * /7814 7814 1200 RPM
7C-3065 7W-8674 3516/3512/3508 50/60 1000/1200 N/A * / * /7169 7169 1000 RPM
684 7C-3067 7W-8676 3508 50/60 1000/1200 N/A 8354

7C-1621 7C-1607 3512/3508 50/60 1500/1800 N/A 7069/6919
7C-1622 7C-1608 3512/3508 50/60 1500/1800 N/A 7069/6919
7C-2624 7C-2617 3512/3508 50/60 1500/1800 N/A 7069/6919
685 9Y-9429 9Y-9421 3512/3508 50/60 1500/1800 N/A 7069/6919
4P-2241 4P-2240 3512/3508 50/60 1500/1800 N/A 7069/6919
6I-3095 6I-3094 3512/3508 50/60 1500/1800 N/A 7069/6919
7C-3068 7W-8677 3516/3512/3508 50/60 1000/1200 N/A * /7249/8346
686 6I-4854 6I-4853 3508 50/60 1000/1200 N/A 8346
7C-3069 7W-8678 3516/3512/3508 50/60 1000/1200 N/A * /7249/8346
7C-3543 7C-3537 3512 50/60 1500/1800 N/A 8466
7C-2626 7C-2619 3512 50/60 1500/1800 N/A 8466
7C-3544 7C-3538 3512 50/60 1500/1800 N/A 8466
4P-2243 4P-2242 3512 50/60 1500/1800 N/A 8466
687 7C-3070 7W-8681 3512 50/60 1000/1200 N/A 6235
6I-4852 6I-4851 3512 50/60 1000/1200 N/A 6235
7C-3071 7W-8682 3512 50/60 1000/1200 N/A 6235
7C-3549 7W-8822 3508 50/60 1000/1200 N/A 6235
6I-4842 6I-4841 3516/3512 50/60 1500/1800 N/A * / 6249
7C-1623 7C-1609 3512 50/60 1500/1800 N/A 6249
7C-1624 7C-1610 3512 50/60 1500/1800 N/A 6249
689 6I-2677 6I-2676 3512 50/60 1500/1800 N/A 6249
6I-4840 6I-4839 3512 50/60 1500/1800 N/A 6249
4P-4566 4P-4565 3512 50/60 1500/1800 N/A 6249
690 1-B 9Y-0515 9Y-0513 3508 50/60 1500/1800 640/800 8801 50 & 60 Hz
9Y-0517 9Y-0516 3508 60 1800 997 10238
144-1668 144-1667 3508 60 1800 997 10238
690 1-B 144-1744 144-1744 3508 60 1800 812 10238
9Y-0158 9Y-0157 3508 50 1500 570 95-1003-00 50 Hz
9Y-0158 9Y-0157 3508 60 1800 760 95-1004-00 60 Hz
4P-4534 4P-4533 3508 50/60 1500/1800 640/800 8801 50 & 60 Hz
9Y-0517 9Y-0516 3508 50/60 1500/1800 720/900 8822/8823 50/60 Hz
4P-4542 4P-4541 3508 50/60 1500/1800 720/900 8822/8823 50/60 Hz
4P4582 4P4581 3508 60 1800 997 10218
9Y-1424 9Y-1423 3508 50/60 1500/1800 720/900 8822/8823 50/60 Hz
9Y-0395 9Y-0394 3508 50/60 1500/1800 720/900 8822/8823 50/60 Hz
691 1-B 115-5102 115-5101 3508 50/60 1500/1800 720/900 8822/8823 50/60 Hz
9Y-0160 9Y-0159 3508 50 1500 548 96-1039-00 50 HZ
9Y-0160 9Y-0159 3508 60 1800 715 95-1012-00 60 HZ
9Y-0160 9Y-0159 3508 60 1800 715 95-1012-00 60 HZ
9Y-0160 9Y-0159 3508 60 1800 715 95-1012-00 60 HZ
121-6851 121-6850 3508 60 1800 910 10210
121-6861 121-6860 3508 60 1800 900 9459
144-1746 144-1745 3508 50 1500 673 10220
691 2-B 121-6853 121-6852 3508 60 1800 840 96-1042-00 60 Hz
9Y-0520 9Y-0519 3508 50/60 1500/1800 728/910 8659/8660 50/60 Hz
4P-4544 4P-4543 3508 50/60 1500/1800 728/910 8659/8660 50/60 Hz
9Y-0453 9Y-0452 3508 50/60 1500/1800 728/910 8659/8660 50/60 Hz
9Y-0397 9Y-0396 3508 50/60 1500/1800 728/910 8659/8660 50/60 Hz
115-5104 115-5103 3508 50/60 1500/1800 728/910 8659/8660 50/60 Hz
4P-4584 4P-4583 3508 50/60 1500/1800 728/910 8659/8660 50/60 Hz
692 1-B 9Y-0162 9Y-0161 3508 60 1800 900 96-1038-00 60 Hz
9Y-0520 9Y-0519 3508B 60 1800 1000 97-1112-00 60
9Y-0520 9Y-0519 3512 60 1800 1240 10237
144-1692 144-1691 3512 60 1800 1240 10237
9Y-0520 9Y-0519 3512 60 1800 910 8658 60 Hz
4P-4544 4P-4543 3512 60 1800 910 8658 60 Hz
9Y-0453 9Y-0452 3512 60 1800 910 8658 60 Hz
9Y-0397 9Y-0396 3512 60 1800 910 8658 60 Hz
115-5104 115-5103 3512 60 1800 910 8658 60 Hz
4P-4584 4P-4583 3512 60 1800 910 8658 60 Hz
4P-4584 4P-4583 3512 60 1800 1000 96-1051-00
9Y-0520 9Y-0519 3512 60 1800 1105 10207
121-4612 121-4611 3508 50/60 1500/1800 800/1000 9144 50 & 60 Hz
121-4614 121-4613 3508 50/60 1500/1800 800/1000 9144 50 & 60 Hz
121-4616 121-4615 3508 50/60 1500/1800 800/1000 9144 50 & 60 Hz
692 2-B 121-4618 121-4617 3508 50/60 1500/1800 800/1000 9144 50 & 60 Hz
121-4620 121-4619 3508 50/60 1500/1800 800/1000 9144 50 & 60 Hz
121-4622 121-4621 3508 50/60 1500/1800 800/1000 9144 50 & 60 Hz
121-4624 121-4623 3508 50/60 1500/1800 800/1000 9144 50 & 60 Hz
9Y-0522 9Y-0521 3512 50/60 1500/1800 880/1100 8777/8776 50/60 Hz
693 1-B 9Y-0522 9Y-0521 3512 60 1800 1183 10217
4P-4546 4P-4545 3512 50/60 1500/1800 880/1100 8777/8776 50/60 Hz
9Y-0522 9Y-0521 3508 50 1500 880 8775 50 Hz
121-4628 121-4627 3508B 60 1800 968 10209
144-1844 144-1843 3508B 60 1800 968 10209
138-7740 138-7739 3512 50 1500 967 8776 50
693 1-B 4P-4546 4P-4545 3508 50 1500 880 8775 50 Hz
9Y-0164 9Y-0163 3512 60 1800 1100 9505 60 HZ
144-1842 144-1841 3512 60 1800 1100 9505
9Y-0164 9Y-0163 G3516 60 1800 N/A 96-1044-00 60 Hz
9Y-0164 9Y-0163 3512 60 1800 1100 9505
9Y-0164 9Y-0163 3516 60 1800 1000 96-1044-00
121-4626 121-4625 3508 9143 50 & 60 Hz
121-4628 121-4627 3508 50 1500 880 9463 50 Hz
693 2-B 121-6851 121-6850 3508 95-1022-00 60 Hz
121-4630 121-4629 3508 9143 50 & 60 Hz
121-4628 121-4627 3508 60 1800 840 96-1022-00
144-1756 144-1755 3508B 60 1800 968 10301
9Y-0524 9Y-0523 3512 50/60 1500/1800 1000/1250 8837/8838 50/60 Hz
9Y-0166 9Y0165 3512 95-1005-00 60 HZ
4P-4568 4P-4567 3512 50/60 1500/1800 1000/1250 8837/8838 50/60 Hz
9Y-0455 9Y-0454 3512 50/60 1500/1800 1000/1250 8837/8838 50/60 Hz
695 1-B 122-1181 122-1180 3508 50 1500 800 96-1016-00 50 Hz
9Y-0399 9Y-0398 3512 50/60 1500/1800 1000/1250 8837/8838 50/60 Hz
9Y-0524 9Y-0523 3512 60 1800 1356 10294
115-5106 115-5105 3512 50/60 1500/1800 1000/1250 8837/8838 50/60 Hz
4P-4586 4P-4585 3512 50/60 1500/1800 1000/1250 8837/8838 50/60 Hz
9Y-0166 9Y-0165 3512 60 1800 1250 95-1005-00
9Y-0526 9Y-0525 3516 60 1800 1275 8630 60 Hz
9Y-0526 9Y-0525 3512 50/60 1500/1800 1020/1275 8631/8632 50/60 Hz
4P-4570 4P-4569 3516 60 1800 1275 8630 60 Hz
696 1-B 4P-4570 4P-4569 3512 50/60 1500/1800 1020/1275 8631/8632 50/60 Hz
9Y-0170 9Y-0169 3512 60 1800 1250 96-1021-00 60 Hz
9Y-0170 9Y-0169 3516 60 1800 1275 9509 60 Hz
9Y-0170 9Y-0169 3512 60 1500 1030 97-1136-00
144-1666 144-1665 3512B 60 1800 1515 10206
697 144-1814 144-1813 3512B 60 1800 1335 10272
7C-4914 7C-4913 3512/3516
804 4P-7273 4P-7272 3508
128-7418 128-7417 3512 60 1200 900 96-1036-00 60 Hz
7C-3547 7C-3541 3516/3512 50/60 1500/1800 N/A 8389/7793A
805 6I-4834 6I-4833 3516/3512 50/60 1500/1800 N/A 8389/7793A
7C-3548 7C-3542 3516/3512 50/60 1500/1800 N/A 8389/7793A
7C-1625 7C-1611 3516/3512 50/60 1500/1800 N/A 8388/8531
6I-3093 6I-3092 3516/3512 50/60 1500/1800 N/A 8388/8531
806 6I-4838 6I-4837 3516/3512 50/60 1500/1800 N/A 8388/8531
7C-1626 7C-1612 3516/3512 50/60 1500/1800 N/A 8388/8531
7C-3266 7W-7963 3516/3512 50/60 1500/1800 N/A 8388/8531
9Y-9430 9Y-9422 3516/3512 50/60 1500/1800 N/A 8388/8531
7C-3072 7W-8685 3516/3512 50/60 1000/1200 N/A/1175 7273/8341
6I-4848 6I-4847 3516/3512 50/60 1000/1200 N/A/1175 7273/8341
806 7C-3073 7W-8686 3516/3512 50/60 1000/1200 N/A/1175 7273/8341
6I-4850 6I-4849 3516/3512 50/60 1000/1200 N/A/1175 7273/8341
7C-3073 3516 50 1000 1080 96-1049-00
7C-3073 3516 60 1200 1175 96-1050-00
4P-2247 4P-2246 3516 50/60 1500/1800 N/A 7260
7C-1627 7C-1613 3516/3512 50/60 1500/1800 N/A 7260/7232
7C-4122 7C-4121 3516/3512 50/60 1500/1800 N/A 7260/7232
7C-2628 7C2621 3516/3512 50/60 1500/1800 N/A 7260/7232
6I-4830 6I-4829 3516/3512 50/60 1500/1800 N/A 7260/7232
807 6I-4832 6I-4831 3516/3512 50/60 1500/1800 N/A 7260/7232
6I-3089 6I-3088 3516/3512 50/60 1500/1800 N/A 7260/7232
7C-1628 7C-1614 3516/3512 50/60 1500/1800 N/A 7260/7232
4P-3016 4P-3015 3516/3512 50/60 1500/1800 N/A 7260/7232
4P-7271 4P-7270 3512
9Y-7181 9Y-7180 3516
9Q-6569 9Q-6568 3512 60 1800 1150 97-1135-00
807 2-B 7C-9127 7C-9126 3512 50/60 1500/1800 N/A 7232
9Y-3874 9Y-3872 3516 50/60 1500/1800 N/A 8006
9Y-3875 9Y-3873 3516 50/60 1500/1800 N/A 8006
808 7C-2625 7C-2618 3516 50/60 1500/1800 N/A 8006
7C-2625 7C-2618 3512 50 1500 1020 97-1095-00
6I-3091 6I-3090 3516 50/60 1500/1800 N/A 8006
4P-4572 4P-4571 3516 50/60 1500/1800 N/A 8006
808 2-B 108-3050 106-3652 3516 50/60 1500/1800 N/A 8721
108-3051 108-3052 3516 50/60 1500/1800 N/A 8721
9Y-2936 9Y-2934 3516 50/60 1500/1800 N/A 7320
9Y-2937 9Y-2935 3516 50/60 1500/1800 N/A 7320
7C-2627 7C-2620 3516 50/60 1500/1800 N/A 7320
9Y-1411 9Y-1408 3516/3512 50/60 1000/1200 N/A 7268/ *
7C-2629 7C-2623 3516/3512 50/60 1000/1200 N/A 7268/ *
809 6I-4844 6I-4843 3516/3512 50/60 1000/1200 N/A 7268/ *
7C-3076 7W-8693 3516/3512 50/60 1000/1200 N/A 7268/ *
7C-3077 7W-8694 3516/3512 50/60 1000/1200 N/A 7268/ *
6I-4846 6I-4845 3516/3512 50/60 1000/1200 N/A 7268/ *
128-7414 128-7413 3512B 50 1200 1015 10280
6I-4828 6I-4827 3516 50/60 1500/1800 N/A 8689
809 2-B 136-2354 136-2353 3512 60 1200 660 96-1024-00 60Hz
6I-4836 6I-4835 3516 50/60 1500/1800 N/A 8689
815 7C-2630 7C-2623 3516 50/60 1000/1200 N/A 8578
9Y-0528 9Y-0527 3516 50 1500 1280 9521 50 Hz
9Y-0528 9Y-0527 3516 50/60 1500/1800 N/A 9304 60/50 Hz
822 4P-4574 4P-4573 3516 60 1800 1500 96-1041-00 60 Hz
4P-4574 4P-4573 3516 60 1800 1617 10219
4P-4588 4P-4587 3516 PENDING
9Y-0457 9Y-0456 3516 60 1800 1500 9520 60 Hz
156-7130 156-7129 3516 60 1800 1500 9520
4P-4574 4P4573 3512 60 1800 1150 97-1061-00
149-9188 149-9187 3512 60 1800 1150 97-1061-00
822 160-0088 160-0087 3512 60 1800 1150 97-1061-00
4P4574 4P-4573 3512 60 1800 1150 97-1061-00
9Y-0457 9Y-0456 3512B 60 1800 1500 97-1082-00 1 bearing
9Y-0528 9Y-0527 3516 50 1800 1500 97-1141-00
4P-4576 4P-4575 3516 60 1800 1600 95-1006-00 60 Hz
4P-4576 4P-4575 3516 60 1800 1500 9522 60 Hz
129-7686 129-7685 3512 60 1800 1250 96-1013-00* 60 Hz
824 9Y-0460 9Y-0459 3516B 60 1800 1640 9523 60 HZ
144-1674 144-1673 3516 60 1800 1879 10205
141-2022 141-2021 3516 60 1800 1750 8704
4P-4578 4P4577 3516 9858
825 9Y-0462 9Y-0461 3516 60 1800 1825 96-1037-00 60 HZ
9Y-0462 9Y-0461 3516 60 1800 2000 97-1108-00 60
4P-4580 4P-4579 3516 60 1800 1600 96-1031-00 60 HZ
826 4P-4580 4P-4579 3516 60 1800 1800 97-1105-00 60
4P-4580 4P-4579 3516 50 1500 1655 10208
144-1926 144-1525 3516 60 1800 1800 97-1137-00
9Y-0276 9Y-0167 3516 60 1800 1825 95-1001-00 60 Hz
9Y-0276 9Y-0167 3516 60 1800 1937 10216
827 128-7842 128-7841 3516 60 1800 1825 95-1001-00 60 Hz
7E-9696 7E-9695 3516B 60 1800 2000 97-1116-00 60
144-1828 144-1827 3516B 60 1800 1960 10260 2 bearing
144-1828 144-1827 3516B 60 1800 1960 10307
Table of Contents – Application Notes
Page Number
Cross Current Paralleling with SR4B Generators 2
Currents Ð Circulating in Paralleled Generators 6
Generator Sets Ð Parallel Operation 11
Caterpillar Zero Droop Voltage for Parallel Operation 19
Harmonic Wave Distortion Ð Cause and Effects 28
Two Thirds or Not Two Thirds 34
Non-Linear Loads on Standby Generator Sets 47
The information contained in this publication is the property of Caterpillar

Inc. and/or its subsidiaries. Without written permission, any copying,
transmittal to others, and any use except that for which it is provided is
prohibited. There are no warranties, express, or implied, including but not
limited to, any implied warranties of merchantability or fitness for a
particular purpose.
Caterpillar Inc.
3500 EPG Technical Information Kit 3rd Edition – January 1999 Section 3 – Page 1
Cross Current Paralleling with SR4B Generators
Refer to the following for more information about paralleling with Cross Current
Compensation:
LEHX1423 (EDS 75.1) Ð Currents Ð Circulating in Parallel Generators

LEKX1349 (EDS 75.3) Ð Generator Sets Ð Parallel Operation
LEKX8142 (EDS 75.5) Ð Caterpillar Zero Droop Voltage for Parallel Operation
SEBD0515 Ð Principles of Electric Set Governors, Parallel Operation, Alternators,
and Regulators
Compatibility
1. Ensure that each generator has droop CTs with the same secondary current.
a. SR4B generators use 5 Amp secondary droop CTs. These CTs are located on the
back side of the T2 power bus bar. All sensing is done through the Droop CT on
the B phase.
b. The large SR4 generators have traditionally used a 1 Amp secondary droop CT.
If the CT is a 1 Amp secondary type, then it must be replaced with a 5 Amp
secondary type to ensure equal load sharing. Actually, the CTs Caterpillar uses
are marked as 5 Amp secondary, but the CTs are sized to deliver no more than 1
Amp based on the expected primary current. We recommend using a 5 Amp CT
mounted directly to the T2 power buss bar to allow all current in the B phase to be
sensed as it is done on the large SR4B.
2. It is not necessary for all generators to have the same droop CT part number.
Different transformer ratios are necessary depending on the level of current (and
power) supplied by each generator. Droop CTs are sized for 110% of the full current
rating for the generator.
3. VR3 and VR3F regulators are not internally isolated between the droop connections
and the sensing terminals. Therefore, when two or more of the connected
generators include VR3 or VR3F regulators, isolation transformers must be used. These
isolation transformers may be one of two forms:
i. Sensing isolation transformers (TX1 and TX2 in the diagram)
ii. Droop isolation transformer (TX3 in the diagram)
4. The Digital Voltage Regulator (DVR) has internal isolation, which precludes the need
for additional isolation transformers. However, transformers may be used if desired.
Technical Issues
1. For generators with Sensing Isolation Transformers (TX1, TX2) and / or DVRs:
Shorting contacts must be provided across each Droop CT in the circuit to

prevent the regulator from using droop when the generator is not in parallel with
the main buss. The contact should be closed (shorted) when the generator is off-
line.
2. For generators which utilize a Droop Isolation Transformer (TX3):
The Droop Isolation Transformer must be a 1:1 transformer. Voltage levels are only
a few volts and less than 1 VA requirement. Shorting contacts must be provided
across each Droop Isolation Transformer on the side opposite the regulator. These
contacts prevent the regulator from using droop when the generator is not in
parallel with the main buss. The contact should be closed (shorted) when the
generator is off-line.
3. The control of the shorting contacts for each generator must be tied to the Circuit
Breaker auxiliary contact. When the CB is open, the shorting contact must be closed.
When the CB is closed, the shorting contacts must be open.
4. For low voltage SR4 generators, the factory supplied 1 Amp CT is bolted directly to
the inside of the terminal box back panel and has only one of the many wires of the
T2 phase wrapped through the CT window. If the CT is a 1 Amp secondary type, then
it must be replaced with a 5 Amp secondary type in order to have equal load
sharing. We recommend using a 5 Amp CT mounted directly to the T2 power bus bar
in order to allow all current in the B phase to be sensed just as is done on the large
SR4B. This configuration will require a bit of math to determine the correct ratio to use
since more current than before will be sensed through the CT window when using all
wires rather than only one wire. See Example 1 for a detailed explanation.
5. For medium voltage, the transformer is shipped loose and there is only one wire for
each phase since the level of current is so low. In this case, the 1 Amp CT is simply
replaced by its direct equivalent 5 Amp CT. See the Droop Transformer list to
determine the old ratio then divide by 5 for the replacement transformer. See
Example 2 for a detailed explanation.
6. For retrofit of SR4 generators with 5 Amp secondary CTs, it is also necessary to change
the droop potentiometer. By changing to a droop transformer which supplies 5 times
more current than the factory shipped design, we have created an incompatibility
with the VR3 and VF3F voltage regulators. To solve this, a 1Ω power resistor must be
place across the Droop CT (between the 5 and 6 leads of the transformer). A new
droop potentiometer is then used between the 1Ω power resistor and the VR3 or
VR3F droop terminals (5 & 6). The new droop potentiometer is, in effect, a variable
voltage divider network. The maximum voltage across VR3 or VR3F pins 5 & 6 is 2
volts. A part number is given in the parts list. Values of the resistors within this module
are shown on the geometry drawing for the module. The DVR does not require a
droop Potentiometer with any generator, but does require a 1Ω power resistor.
7. Each connected generator must have the Droop CT in the same phase, usually T2.
Also, all CTs must be correctly polarized such that all the secondary connections are
series additive (see EDS 75.5).
Example 1
806 frame SR4 arrangement number 7C-1626. From the Droop Transformer Chart, we
determine that the droop CT is part number 4P-4477 which has a ratio of 7500:5 (or
1500:1). We know this is sized as a 1 Amp secondary CT because it is an SR4 generator
with the CT mounted on the terminal box frame rather than on the bus bar.
Begin by determining how many wires per phase exist for his generator either by looking
at it or by using the Generator Chart. The Generator Chart lists 7C-1626 as 6 leads with 48
wires. 48 is the total number of wires. Therefore, divide 48 by 6 to the number of wires per
phase ⇒ 8.
Next, take the original ratio of 7500:5 and divide by 5 to get the equivalent of a 5 Amp
secondary. Then multiply the result by the number of wires per phase (8 in this example)
to get the new transformer turns ratio.
# of Wires per Phase 7500 8

Original Turns Ratio x = x = 2400 => 2400:5
5 5 5
If the resulting turns ratio matches one in the list of available transformers, use the
indicated CT. If not, pick the next larger CT. In this example, the ratio does not match
one in the list. The next larger transformer is 2500:5 with part numbers 122-6589 or 7E-1117
depending on the type you prefer.
As a double check for the result, take the nameplate current rating and divide by the
new CT ratio. The result should be between 1 and 4.5 Amps (Caterpillar sizes CTs at 110%
of rated).
Nameplate Amps 5
= 2255 x = 4.5
CT Ratio 2500
Example 2
806 frame SR4 arrangement number 7C-3266. From the Droop Transformer chart, we
determine that the transformer ratio is part number 7W-6589 which has a ratio of 3000:5
(or 600:1). We know this is shipped as a 1 Amp secondary CT because it is an SR4
generator with the CT originally shipped loose and there are no buss bars to use as an
installing platform.
All medium voltage generators have only one wire per phase. Therefore, no
compensation due to multiple wires will need to be performed for the new installation.
Take the original ratio of 3000:5 and divide by 5 to get the equivalent 5 Amp secondary.
The result is the new transformer turns ratio. If the resulting turns ratio matches the one in
the list of available transformers, use the indicated CT. If not, pick the next larger CT. In
the example, the ratio matches one in the list. The ratio is 600:5 and transformer number
is 119-0977.
A double check of the CT output gives a value of 2.21, which fits between 1 and 4.5.
Parts
• 115-5142 (Wago), 170-5400 (Allen Bradley) Ð Main terminal strip for regulator
connections supplied with large SR4B generators, but convenient for use on large SR4
generators.
• 122-9204 (Wago), 177-7793 (Allen Bradley) Ð Variable voltage divider droop plug in
module for use with terminal strip 115-5142, 170-5400 and a VR3.
• 122-9205 (Wago), 177-6312 (Allen Bradley) Ð Jumper droop module for use with
terminal strip 115-5142, 170-5400 when used with a DVR (in place of 122-9204, 177-
7793 module).
• 154-3488 Ð Low voltage sensing isolation transformers (240, 380, 480, 600 : 240).
• 149-0590 Ð Medium voltage sensing isolation transformers (2400, 3300, 4160 : 120, 240).
• 130-8239 Ð Low voltage sensing isolation transformers (240, 480 : 240, 480).
• 130-8240 Ð Low voltage sensing isolation transformer (480:120) for SE to PM conversion.

Used to power the PM.
• 123-6046 - 1Ω Power resistor
Currents – Circulating in Paralleled Generators
Reprint of EDS 75.1 (LEHX1423)
When two or more generator sets are operated in parallel, a current may circulate
between the generators. This current will exist when the internal voltage generated by
each generator is slightly different, but the terminal or bus voltages the same. In the most
elementary form, current will flow out the line leads of one generator, through the
paralleling bus, and into the second generator. It does not flow into the load. This
current, called Òcirculating current,Ó is in addition to the normal line current supplied to
the connected load. When more than two generators are in parallel, current could flow
out of any generator and into one or more of the other generators. Circulating currents
can take many paths into and out of the several generators.
We are concerned with theses Òwattless amperesÓ only when they interfere with normal
generator set operation or when the normal on-line kVA capacity of the generators must
be reduced because of excessive line currents. With no-load (zero kilowatts) on a
generator in a parallel system, Caterpillar generators can readily tolerate a circulating
current equal to 20% - 25% of the line ampere rating shown on the generator mane
plate. At load conditions (100% kW load), Caterpillar generators will tolerate a circulating
current of up to 10% of the rated line amperes.
Since circulating currents pass through the generator coils, these currents heat the coils
the same as does the load current. Further, since circulating currents are superimposed
on the load current passing through the circuit breaker, circulating currents can cause a
breaker to trip as the breaker could ÒseeÓ an actual ampere overload. More complex
control systems include Òreverse currentÓ relays which sense counter flow currents.
Currents in excess of the relay setting will actuate the circuit breaker mechanism.
Observed line current (as indicted by panel ammeters) in a parallel generator set system
is a summation of two or three currents:
1. Load Current Ð That current which is supplied to the load. It may be in phase with the
voltage (unity power factor) or somewhat out of phase with the voltage (power
factor less than unity).
2. Harmonic Current Ð Usually third harmonic current which flows through the entire
system when ÒYÓ connected paralleled generators have their neutral leads
connected, either directly or through an earth or ground connection.
3. Circulating Current Ð That current which flows between generators for reasons
explained below.
Each of the above currents contribute heat to the generator coils, the amount being
equal to the square of the sum total current times the resistance of the coils. Thus if the
current doubles, the heat loss increases by a factor of four. Coil heating reflects in
possible overheating and lowered efficiency. In very large generators, this is an
important consideration. Significance of efficiency decreases with smaller generators.
However, coil heat is always a factor, as it must be removed by ventilation or radiation to
keep coil temperatures to an acceptable maximum.
The load alone determines the load current. Reactors or switches can be placed in
neutral leads to reduce or eliminate third harmonic currents. Proper generator
adjustment can bring operating circulating currents to a minimum.
Circulating currents perform an important function. They account for misadjustment of

the generator voltage control system as well as slight variations in the control systems.
The kilowatt (or horsepower) load on parallel alternators is entirely a function of the
driving source. Thus, to increase the load demand on one generator set in a parallel
system, the governor speed setting of that generator set must be increased.
Changing the voltage setting on one generator does not change the kilowatt load
division between generators. This fact is often confusing, as observation of line ammeters
after a voltage level adjustment will indicate a current increase, leading to the belief
that one generator has picked up Òload.Ó It has not. Instead, currents circulating
between generator have changed. The panel ammeters indicate this change.
Paralleled alternators must operate at the same terminal voltage since they are
physically connected through the paralleling bus. If internally generated voltages are
not exactly equal, one alternator will automatically supply an exciting or magnetizing
current to the other alternator to raise its internally generated voltage. At the same time,
the second alternator will supply a current to the first, which will lower the generated
voltage of this unit. The net result of circulating or ÒcrossÓ current is equal generated
voltages.
This action is inherent and automatic. The amount of circulating current flow is entirely a
function of the internal voltage generated by each of the several alternators in the
parallel system.
The amount and type of connected load also affect internally generated voltage.
Induction motors, for example, will tend to lower the generated voltage because the
motors require magnetizing current in addition to power producing current. The
generator which is trying to produce the higher generated voltage will supply a
proportionately greater share of the magnetizing current not only to the motors, but to
other generators on the bus.
When generators are run in parallel, a current sensing system must be added to each
voltage regulator. The current sensing system samples the generator line current not only
in quantity, but also in its phase (angular) relation to the voltage. The current sensing or
droop system produces a voltage that adds to, or subtracts from, the voltage sensed by
the voltage regulating system. (This accounts for the mane often used: Voltage Droop
System.) The resultant regulating voltage level (plus or minus the droop voltage) causes
the regulator to adjust the alternator exciting current downward for lowered generated
voltage, or upward for increased generated voltage. Within limits, the complete
regulator keeps individual generated voltages nearly equal and amperes balanced.
In any alternator power system Ð single or multiple Ñthe system voltage level is
established by the level of generator excitation. When the system is supplying a purely
resistive load (unity power factor), generator excitation is normally expected to come
from the individual generator exciters (static or rotary). If one generator exciter in a
parallel system is somewhat deficient, the additional excitation level will be supplied by
circulating currents from other generators on the bus.
When a system is supplying induction motors, a higher exciting or magnetizing current is
needed to provide the magnetic forces in the motors. This motor excitation subtracts
from the total generator excitation, driving the generated voltage downward. All of the
voltage regulators in the system sense this decrease and individually raise the excitation
level and the generated voltage of their respective generators.
If the voltage regulator action and resultant generator performance are precisely
uniform, each generator would supply its exact proportion of additional magnetizing
current. In practice, this does not occur. Very small differences result in relatively large
differences of current supplied. The voltage droop system senses these currents (in
amount and in phase or power factor) and causes the voltage regulator to react in the
correct direction, raising or lowering the individual excitation level. The result is controlled
division of total line current.
Droop systems will function correctly only of the current sensing transformers of the
several generators are all in the same phase or line lead. (T-2 in Caterpillar SRCR
Generators, T-8 on SR4 Generators.)
Droop systems are proportionate. This means that droop system reaction is proportionate
to the ampere load on an individual generator set. Example: The total kW load on the
system is 150 kW at 0.8 p.f. One generator is supplying 50 kW and the other 100kW. The
total kVA (187.5) should be proportioned with 62.5 kVA oh the 50 kW unit and 125 kVA on
the 100kW unit. Indicated individual line amperes would also be proportionate, with one
third of the total current coming from the 50kW unit and two thirds of the load current
coming from the 100kW unit.
Operating conditions as just described are not always possible over the entire load range
of the generators. Electrical and mechanical variations generators cause a small
difference in ampere or kVA division. Neither is exactly proportionate to kW load division.
The difference shows up in the panel ammeter indications: the sum of individual
generator line currents exceeds the load current.
Acceptable levels of circulating current result of the published procedures are followed
for voltage level, regulator gain, and voltage droop on SRCR and SR4 generators. These
adjustments are always made with the generator at or near operating temperature.
When a ÒcoldÒ unit is paralleled to the bus, circulating currents may be noted. However,
these will decrease as the incoming generator reaches its operating temperature. These
currents are seldom cause for concern. Where excessive circulating currents do exist,
the cause is generally found to be error in the adjustment procedure or in operating
procedure.
When different sizes of generators are used, or where different types of voltage regulators
are used, the best adjustment results from using the actual plant load. Voltage droop
levels should be established from a reference voltage level, and a reference frequency.
It is generally desirable to have the same voltage droop on all generators. This means
that each generator should reduce its voltage an equal amount (3% to 5%) between no-
load and expected full load. Where different size generators are involved, it may be
impractical to make the full load droop adjustment on the larger generators. A close
approximation can be made by considering the droop system as a linear device. Select
a plant load equal to at least three-fourths of the smaller generator capacity. Set the
required droop on this smaller unit (example 5%). Transfer-parallel this same load to the
larger generator and establish the reference frequency. Set the droop proportionate to
the capacity.
Example 5% was set on the smaller unit with full load. That load is one-half the
larger generator capacity. Set the droop on the larger generator at 2.5%. The
resulting adjustment will be quite adequate.
Operating error can cause very high circulating currents. These generally occur where
indicating instruments are limited to voltmeters and ammeters. It is entirely possible to
have one generator set absorbing power from the system, and the ammeters showing
ÒcorrectÓ currents. To avoid this, the operator should always have the incoming
generator set running slightly fast, as shown by synchronizing light brilliance at 6 to 10
times per minute prior to closing the circuit breaker. This will assure that the incoming
generator supplies power (kW) to the load at the time of breaker closure. Load is then
added to the incoming generator set by increasing the setting of its governor control, or
decreasing the setting of the on-line generator set governor controls.
Operating refinements to regulator adjustment are easily made on installations equipped

with VAR meters, power factor meters, or wattmeters and line ammeters. (If the system
includes only ammeter, regulator adjustment must be made with a single unit on the
line.) Where power factor of VAR meters show equal indications, each generator is
supplying its share of the load current reactive amperes, and circulating current
between generators is at a minimum.
Example: Load power factor is 0.8. Generator No. 1 indicates 0.7 p.f. Generator
No. 2 indicates 0.85 p.f. These meter readings tell the operator that Generator
No. 1 is supplying too much magnetizing current to the load, and possibly to
Generator No. 2. The magnetizing current of Generator No. 1 can be reduced
simply by lowering its voltage level. Or, if desired, by raising the voltage level of
Generator No. 2, the operating power factors can be equalized. Circulating
current is then at a minimum.
Wattmeters and ammeters can provide the information necessary to accomplish

operating or on-line voltage level adjustments.
Example:
Load = 500 kW, Load Line = 750 Amperes, Voltage = 480 V
Generator No. 1, Load = 250 kW, Line = 350 Amperes
These meter readings indicate that Generator No. 2 is supplying more than its
share of magnetizing current. This is true because Generator No. 1 is operating at
a power factor of 0.86 which is higher than the load power factor of 0.80, and
Generator No. 2 is operating at a power factor of 0.67 which is lower than the
load power factor. Decreasing the voltage level setting of Generator No. 2 will
reduce its magnetizing current and increase the power factor. At the same time,
the magnetizing current from Generator No. 1 will increase, and its power factor
will decrease.
When loads are not equal, the calculated power factor of each generator can be used
to correctly distribute magnetizing current and keep the circulating currents to a
minimum.
Example:
Load = 700kW, Load Line = 1,100 Amperes, Voltage = 460 V
It should be obvious that the voltage level setting on Generator No. 2 is too low.
Adjustments could be made to one or both until No. 1 shows a line ampere
reading of about 390, and the line ampere reading of No. 2 shows about 700
amperes. At these conditions, both generators will be operating at h the same
load power factor of 0.8. Circulating current is at a minimum. Refinements as
described above will assure highly satisfactory operation of paralleled generator
sets.
Summary
Circulating currents exist in paralleled generators when the several generators are
attempting to operate at different voltages although they are connected together
through the common bus. These circulating currents reduce the effective excitation of
one or more generators, and increase the effective excitation of others. Generator
voltage is directly related to exciter output. Hence an attempted generator voltage
difference is the result of different exciter output. Exciter output is controlled by the
voltage regulator, and ultimate control of circulating current is a function of the
regulator.
Effect of Circulating Currents on Load Sensing Electronic Governors
The Woodward 2301 load sensing governor can react to excessively large circulating
currents. With correct adjustment of voltage regulators, the load sensing governor
responds to true power or kW load on the generator set. However, when the value of
circulating current between generators approaches the value of the actual load
current, the governors may react to these excessive circulating currents and change the
kW load division between generator sets. Load transfer may be slow, or it may be rapid.
There is no predictable pattern since the observed action depends on the condition of
the generator voltage regulators controlling the several generators.
Incorrectly adjusted voltage regulators are the most common cause of the Òload shiftÓ
problem. It is generally found that initial generator adjustments fail to include adequate
voltage droop or cross-current compensation. This difficulty can also cause operating
errors.
Some commercially available generator control panels for use with commercially
available generators include a switch that bypasses the voltage droop circuit in the
voltage regulator. These switches have various names such as ÒSingle-ParallelÓ or ÒDroop
In Ð Droop Out.Ó Operators incorrectly position these switches during parallel operation,
causing one or more generators to operate without voltage droop or cross-current
compensation. Circulating currents can greatly increase under these conditions.
Governors will generally react.
Switchboard wiring errors, such as reverse-connected current transformers (used as part

of the droop or cross-current system), can also cause load shift problems. In these
instances, the voltage droop system causes a rise in generated voltage as the line
current increases. Circulating currents can increase rapidly, and possibly cause circuit
breakers to open. Governor reaction may be noted just prior to circuit breaker opening.
Generator Sets — Parallel Operation
Reprint of EDS 75.3 (LEKX1349)
This technical data sheet is divided into two parts:
Preparing Generator Sets for Parallel Operation

This section describes those tests and adjustments required when two or more
generator sets are prepared initially to operate in parallel as one system.
Procedure for Paralleling Generator Sets

This section describes the actual paralleling operation required each time a set is
paralleled with another.
I. Preparing Generator Sets for Parallel Operation
Two or more AC generators will operate satisfactorily in parallel provided these

fundamental conditions are satisfied.
A. Phase sequence must be the same.
B. Frequencies must be the same.
C. Voltages must be the same.
D. Engine governors must have speed droop (one can be isochronous).

Exception: Electronic load sharing governors.
E. Generators must have voltage droop (or cross-current compensation).
Phase sequence must be the same.
The condition of the units being correctly phased or operating with voltages in phase,
means that the individual sine waves appear in sequence. Voltages must be capable of
being superimposed, so instantaneous voltage differences do not exist in the same
phase of units being paralleled.
Figure 1
A three-phase generator must be phased to a system at initial installation. Three
synchronizing lamps connected as shown in Figure 1 is the suggested method. If a two-
lamp synchronizing system is installed on the control panel, a three-light system should be
temporarily installed. With a three-lamp system, phase sequence relative to the on-line
machine can be positively observed, as shown in Figure 2. If phase sequence is correct
on the incoming generator, the lamps will become light and dark together. If the phase
sequence is not correct, the lamps will never be all light or be all dark at the same time.
To change phase sequence or rotation in a three-phase system (to correct phase
rotation), interchange any two line leads from the incoming machine. Once correct
phase sequence or rotation is established, it is permanent unless leads to the bus bar are
disconnected.
Note: At initial installation, the droop transformers (part of the exciter control
system) must be in the same line leads to the bus bars. SR4 Generators have the
droop transformer in the T2 line lead. Hence, all T2 leads should be connected to
the same bus bar (through the circuit breakers).
Figure 2A Figure 2B
Correct and Incorrect Phase Sequence Using Three Lamps for Comparison With
On-Line Power System
Frequencies must be the same.
To meet the second and fourth conditions, the engine governors must be adjusted to
give similar frequency under conditions of proportionate load sharing. If one set is trying
to operate at a lower frequency than the others, the active or kW load will not be
proportionately shared and motoring current will flow to the lower frequency machine to
make it run at synchronous speed. It is impossible to have stable parallel operation if two
or more units are set for isochronous (zero speed droop) operation, except with an
electric load proportioning governor such as the Woodward 2301A system. For best
results in almost all other cases, all units should have 3% speed droop from no load to full
load. (1.8 cycles at 60 Hz, 1.5 cycles at 50 Hz.) Active load (kW) sharing is regulated by
the engine governors, not the generators. If all units to be paralleled are built by
Caterpillar and the engines are equipped with 3% speed regulation governors, set no
load speeds at 1236 rpm (61.8 Hz) for 6-pole generators or 1854 rpm (61.8 Hz) for 4-pole
machines on 60 Hz systems. On 50 Hz systems, set no load speeds at 1030 rpm (51.5 Hz)
for 6-pole generators or 1545 rpm (51.5 Hz) for 4-pole generators.
62.0
Frequency (Hz)
61.0
60.0
Engine 1
Engine 2
59.0
0 10 20 30 40 50 60 70 80 90 100
Percent Load
Figure 3
For parallel operations where some of the machines are non-Caterpillar and/or some of
the machines are equipped with hydraulic governors, the speed droop characteristics of
each machine should be checked. See Figure 3 for speed droop characteristics. The
procedure for checking can best be illustrated by the following example:
Conditions: 60 Hz System
Set No. 1 Competitive engine, generator Ñ 1800 rpm, governor characteristics unknown
Operate both machines for approximately one hour to obtain stable heat
conditions. Note: A convenient method of bringing generators up to normal
operating temperatures is to parallel them and purposely allow circulating
currents to flow between generators, making sure not to exceed about one-half
of the generatorsÕ full load current ratings.) Set no load speed on engine No. 1 at
1854 rpm, using its speed adjustment or synchronizing control. If possible, add
loads of approximately 25%, 50%, and 80 - 100%. Check and record frequency or
speed at each load. Plot these points on Figure 3. Do not be too concerned with
differences in plotted points or variations from these points at light loads. If it is
possible to get only one load point, attempt to obtain it as near full load as
possible. Most engine-governor characteristics are not entirely linear. Many
governors achieve most of their speed droop at nearly full load.
Set No. 2 Cat Generator Set Ñ 1200 rpm, Woodward UG8 Governor
Turn the speed droop on engine No. 2 to zero and set the no-load speed to
1200 rpm, using the speed adjustment or synchronizing control. Then turn the
droop control until the no-load speed rises to 1236 rpm. Load the set and plot the
points as in Step One. If the points taken are below the points from Step No. 1,
the speed droop is too large and possibly can be readjusted until the points
match Set No. 1. The closeness of the plots indicates the closeness of the load
sharing. Governor instability may occur as the droop is reduced. If this happens,
operate the machine at a droop setting that keeps the governors stable.
Note: When taking frequency or speed points, use an accurate frequency meter
or tachometer and take several readings on each point.
Voltages must be the same.
If the voltage load characteristics (voltage droop) of the units are not the same,
proportionate reactive load sharing will not result. Circulating current will flow between
the units. Caterpillar Generators use a voltage droop transformer to maintain
proportionate reactive load sharing. Similar voltage droop is achieved by adjusting the
voltage droop control on the generator, see EDS 70.0.1 and 71.0. A circulating current of
20-25% of nameplate line ampere rating is not harmful at no load in parallel operation.
The circulating current should decrease as load is increased and should be no more than
10% of rated line amperes at full load. When checking for circulating current, be sure
that both generator ammeters and the load ammeter are connected in the same
phase. Voltage droop should be set in individual generators, depending on the load
power factor involved. If the load is pure resistance or incandescent lighting load (1.0
pf), a 2% voltage droop from no load to full load should be satisfactory. If the load is
reactive (primarily motors of 0.8 pf), a 5% voltage droop should be used, see Figure 4.
Figure 4
The selected system voltage should be compatible with each generator set to be used.
Assume the competitive generator (above) has a nameplate voltage of 480 volts and
the Caterpillar SR4 Generator 460 volts. A system voltage will have to be selected within
the voltage adjustment range of each generator. In this example, 470 volts will be
selected as the system voltage. The sets to be paralleled should be operated for at least
one hour to ensure stable operating temperatures while adjustments are made. If the
generator sets to be paralleled are all Caterpillar units, proceed as follows:
Use the same voltmeter for all voltage measurements.
1. Turn generator voltage droop control to zero droop position.
2. Run the engine at full governed speed (approximately 3% above rated load speed).
3. Turn generator voltage level control until the no load voltage is equal to the selected
system voltage.
4. Apply nameplate rated load and adjust the engine governor to rated speed. Use an
accurate speed indicator or frequency meter.
5. Adjust generator regulator gain control until the full load voltage is equal to the
selected system voltage.
6. Leave the regulator gain control in this position.
7. Again operate the engine at full governed speed at no load. Repeat Steps 3, 4, 5,
and 6 until the loaded voltage equals the no load voltage.
8. Readjust voltage level control until the line voltage is approximately 2%-5% above the
selected voltage.
9. Adjust voltage droop control clockwise, approximately one fourth of full range.
10. Apply nameplate rated load and adjust the governor to rated speed. (Same
conditions as Step 3.)
11. Turn voltage droop control until voltage is equal to selected system voltage at rated
load.
12. Repeat the last three steps until the generator voltage is equal to system voltage at
rated load and rated speed is approximately 2%-5% above system voltage at no
load and no load speed.
Follow the above procedure for each SR 4 Generator to be paralleled. The units will then
be properly adjusted for parallel operation. This procedure is also outlined inside the
right-hand corner of the regulator housing on Caterpillar Generators.
For generators other than SR4 and for paralleling SR4 Generators with other types and
makes of generators, it is advisable to first determine the voltage speed characteristics
voltage droop) of each unit in the system. After the machines are thoroughly warmed,
the voltage level adjustment of each should be set so the no load voltage is 2%-5%
above system voltage.
Apply and remove individual machine load, recording load (current or kilowatts) and
voltage. Make voltage droop adjustments to approximately duplicate one of the curves
in Figure 4. Without further adjustment, parallel the machines at high idle (no load) using
the procedure outlined in the section of this data sheet.
Record the value of any no load circulating current.
Apply available load, observe, and record the line current for each machine.
If operation is satisfactory, leave voltage controls locked in position determined. If

operation is unsatisfactory, adjust voltage level and voltage droop. At the same time,
make sure frequency limits and operating temperatures are uniform and constant. The
procedures described for determining phase sequence, setting engine speed droop,
and generator voltage droop must be repeated when a new or different unit is added to
the system. Once these initial adjustments are made and the controls are locked in
position, it should not be necessary to go through this procedure again.
II. Procedure for Manually Paralleling Generator Sets
To parallel a generator set with one or more generator sets already on the line, the first
three conditions outlined in Section I (see Page 1) must first be met. If there is a
difference between the frequencies or voltages of the generators being paralleled,
there will be an undesirable line voltage disturbance when the incoming generator
circuit breaker is closed. Extensive damage may result if generators are paralleled while
the voltages are out of phase. Always use synchronizing lamps or a synchroscope and
exercise care in the paralleling operation.
By use of synchronizing lamps, as shown in Figure 5, an idle unit can be put in service with
no disturbance. The dark lamp method is most commonly used as the indicator of when
to close the incoming circuit breaker. This method lights the synchronizing lamps when
there is a potential between the phases of the incoming and the on-line generators. This
means that when all the lamps are dark, the generators are synchronized. To
synchronize an idle unit with an on-line generator, proceed as follows:
Figure 5
The on-line circuit breaker should be closed and the incoming circuit breaker
should be open.
With the incoming unit governor control lever in the full governed speed position,
turn on the synchronizing lamps switch and observe the lamps for the frequency
at which they flash. By means of the governor control, vary the incoming engine
speed until the synchronizing lamps come on and fade out about six to ten times
a minute. Always have the incoming generator initially slightly higher in
frequency. Doing this will assure that the incoming engine will absorb a small
amount of load instead of consuming power when initially connected to the bus.
To put the generator set on the line in sync (at the proper time) wait until the
lamps are dark, then very quickly, while the lamps are still dark, close the circuit
breaker. The incoming generator is now in parallel with the bus and on-line
generator.
After the circuit breaker is closed, one of the following two conditions will exist:
1. First condition Ñ the unit on the bus was at no load. In this condition both units in the
parallel system are at idle and ready to receive the load.
2. Second condition Ñ the unit on the bus was carrying load. The engine governor of
this unit was operating some place below high idle. The generator voltage regulator
was operating some place below open circuit voltage. Load division between
generator sets will remain as described until:
a. The governor control of the incoming generator set is advanced. Part of the total
load will then be transferred from the set which was on the line to the oncoming
set. Frequency will rise.
b. The governor control of the on-line generator set is reduced. Load will be
transferred to the oncoming generator set. Operating frequency will go down.
After paralleling, the governor control on the incoming unit should be advanced
to the full governed speed position. This causes the incoming unit to pick up its
proportional share of the kilowatt loading. If kilowatt meters are installed, the
readings should be approximately proportional to the ratings of the units
paralleled. If desired, various loads can be placed on either generator set by
adjustment of the governor control. At the same time, also with govenor control
speed setting, operating frequency can be set as desired.
Another panel instrument is the synchroscope, as shown in Figure 6. It is used instead of

the synchronizing lights for synchronizing two or more generator sets. The direction the
pointer rotates indicates whether the frequency of the incoming generator is slower or
faster than the frequency of the on-line generator. Similarly, the frequency at which the
pointer rotates indicates the magnitude of difference in speed between the generator
sets. For paralleling, engine speed is changed until the synchroscope pointer rotates very
slowly (less than 10 rpm), again keeping the incoming generator set faster than the on-
line generator set. When the pointer is at 0 position, the circuit breaker can be closed
(the units are synchronized).
Figure 6
To remove a generator set from the line, follow these steps:
Before removing a generator from the line, be sure that the on-line is equal to or
less than the rated capacity of the units remaining on the line.
Slowly reduce the speed setting of the outgoing generator to remove load from
the generator.
Open circuit breaker.
A short cooldown period of running at idle, with no load, is suggested before engine
shutdown.
Also refer to related articles:
• Engine Data Sheet 75.2, Transfer Paralleling
• Engine Data Sheet 75.1, Circulating Currents
• Form FE36060-1: Principles of Electric Set Governors, Parallel Operation, Alternators

and Regulators
Caterpillar Zero Droop Voltage
For Parallel Operation
Reprint of EDS 75.5 (LEKX8142)
Scope
This Engine data sheet provides detailed technical guidance for installing and adjusting
the Caterpillar automatic voltage regulators (ARVs) to operate various Cat Generators
with zero droop voltage in parallel operation.
General Introduction
For parallel operation, there are two fundamentally different reactive power equalization
methods Ð individual open-loop compensation (which is the standard method on
Caterpillar Generators) and a feedback method called differential compensation.
The individual compensation method, also known as reactive droop correction, is

described in the Operation and Maintenance Manual, SEBU5717-02, so it will now be
considered further here.
In the Differential compensation method, also known as crosscurrent compensation, the

regulator is biased by the difference in reactive current outputs of the paralleled
generators. When reactive current is shared equally, there is no biasing effect and a flat
voltage characteristic is obtained. The biasing exists only during transient periods when
unequal or unproportional reactive load sharing exists.
The Caterpillar Automatic Voltage Regulator can be wired for zero droop voltage, no
load to full load, and maintain volts-per-hertz regulation to prevent engine stall due to
heavy block loads. To make this feature more attractive, zero droop voltage control is
possible with Cat Generators paralleled with Cat Generators of same or different sizes
and competitive generators of same and different sizes. Crosscurrent compensation
makes this possible. Any type of droop or isochronous governor can be used.
The combination of zero droop voltage control and volts-per-hertz regulation make Cat
Generator Sets extremely versatile when selecting parallel power for any installation.
Output voltage is unchanged after loads have been applied or rejected and generators
have again reached steady-state operation. This is the advantage to zero droop.
Voltage at any point in time during steady load operation of units in parallel is
unchanged Ð regardless of the load. Regulators operating with voltage droop, on the
other hand, allow system voltage to change with addition or subtraction of load after
steady-state conditions are reached.
Standard Cat SR4s, SRCRs and VR3s use 5% adjustable droop. Zero droop voltage
control with volts-per-hertz regulation is illustrated below.
LOAD REJECTION
No Load SINGLE UNIT

STEADY STATE WITH GAIN
Voltage
1/2 Load
STEADY STATE PERSENT CHANGE IN VOLTAGE
Full Load LIMITED BY VOLTAGE DROOP CONTROL
TIME
LOAD ACCEPTANCE
Figure 1
LOAD REJECTION
STEADY STATE
VOLTAGE
1/2 Load Full Load No Load
TIME
LOAD ACCEPTANCE
Figure 2
IMPORTANT: Treat VR3 self-excited or permanent magnet similar to the single-phase,

half-wave excitation (A1-/A2-type ARV). See Figure 3.
Crosscurrent Compensation
Basic Principles:
Each generatorÕs current is measured with a current transformer (CT) in one line, usually
T2. When paralleling, all CTs must be correctly polarized such that all the secondary
connections are series additive. See Figure 3.
If the generators are of different sizes, the CT ratios should be proportional to their ratings
such that for rated output, the secondary currents are equal. For example, see Table 1.
Rated kW Rated pf Volts Rated CT Ratio Secondary Current

Amps at Rated Load
100 0.8 480 150 150:5 5.0 Amps
200 0.8 480 300 300:5 5.0 Amps
50 0.8 480 75 75:5 5.0 Amps
Table 1
Note: CTs supplied with Caterpillar Generators have 5.0 Amp secondary and are
already matched to the generator ratings.
Each CT has a droop variable resistor (droop rheostat) across its output. The voltage
developed across this resistor is sensed by the regulator to provide a signal to reduce or
increase the field excitation. All rheostats (potentiometers) must have the same ohmic
value. When one generator is run individually, the voltage developed across the
potentiometer will cause the generator output voltage to ÒdroopÓ as the lagging
reactive current is increased.
When the reactive compensation circuits of two or more generators are connected
together is a series mode, if the currents in the two generators are equal (or
proportionally equal) and in phase, the CT secondary currents will be equal and in phase
and there will be no differential current flow in the potentiometer. Thus there will be no
voltage drop across those resistors and no droop in generator output voltage will result.
If the generator currents become unbalanced, the CT secondary currents will no longer
be the same. In the generator with the higher current, this will result in a forward voltage
across its droop potentiometer, which will reduce its excitation. The other generator will
see a reverse voltage, which will increase its excitation. This action will cause the currents
to return to a balanced state.
Important Notes and Procedures on Adjustments for Crosscurrent Compensation

1) kW load sharing is a function of the engine governor only. Adjust governor setting for
proper kW balance before attempting to adjust reactive kVAR unbalance.
2) For parallel operation, the following adjustments must be made following crosscurrent
compensation wiring between the voltage regulators and crosscurrent transformers.
A) Turn the gain potentiometer to the full CCW position.
B) Turn the droop potentiometer to the full CCW position.
C) On each generator, adjust the voltage level potentiometer to the rated no load
voltage.
D) Apply full rated load with 0.8 pf to the individual generator.
E) Adjust the gain potentiometer to compensate for voltage drop due to governor
speed droop at rated load, if the governor is not an isochronous governor.
F) Adjust the droop potentiometer to obtain 5% droop when operating as a single

unit at full load 0.8 pf.
G) Remove the load.
H) Parallel the generators at no load and adjust for minimum circulating current, if
any, using the voltage level potentiometer.
I) Apply full rated resistive and reactive loads.
J) Adjust to minimum circulating current using the droop potentiometer.
Figure 3
Paralleling two or more Cat Generators with a minimum of one CRCR generator
or a generator equipped with single-phase, half-wave regulators (A1-/A2-type or
VR3). Isolation transformers required for each generator. (See Table 2 for
potential transformer selection.)
Note A: The shorting contact for the current transformers (CTs) is to be open only when
corresponding main line circuit breaker is closed. A slave relay may be used for
shorting contact, piloted by a main line circuit breaker auxiliary contact. The
Shorting contacts for the potential transformers are a Ònice to haveÓ rather
than a Òmust haveÓ.
Note B: On single-phase, half-wave regulators (tan A1-/A2-type ARVs) built before May
1984, the ÒdroopÓ resistor is connected as a rheostat (see Figure 6). On May
1984 and later regulators (black A1-/A2-type ARVs), this resistor is connected as
a potentiometer. (See Figure 7)
Note C: If only two generators are in the system, two transformers as described in Table
1 are needed or only one 1:1 ratio / 10 VA transformer is sufficient. The winding
resistance must not exceed 0.25 ohm at both primary and secondary.
When using similar regulators, the proceeding instructions will provide correct operation.
With a combination of pre- and post-May 1984 regulators (tan and black A1s) or a
combination of new Cat and competitive regulators, the newer models (black A1/A2)
should be modified to make them electrically similar to the earlier models by adding a
link from the center to the clockwise end of the droop potentiometer. (See Figure 8)
Figure 4
Two or more generators with 3-phase full wave regulators (multi-card only, not
VR3) have no isolation transformer requirement. Only one regulator is grounded
to minimize circulating currents.
Figure 5
Note A: When using the APM 300, the Cat CT must be replace by a 5 Amps secondary
CT. The resistor R (25 ohms, 10 watts) will be set to approximately 16 ohms.
CT
R1
PRE – MAY 1984

Rheostat Connection
Figure 6
CT
Reg.
R1
POST – MAY 1984

Potentiometer Connection
Figure 7
Add
CT
Reg.
R1
Figure 8
Paralleling Multiple Generators (Under the Standard Method [Open Loop] on Caterpillar
Generators) With Automatic Shofting Contacts
When paralleling several generators with the Caterpillar standard reactive droop control,
the voltage of the first generator on the line will drop due to the reactive load. The
second unit on the line will now be at a much higher voltage and may not parallel,
depending on how the switchgear is set up.
Shown in Figure 9 is a scheme that provides zero droop when multiple units are paralleled
in an automatic droop control. When generator No.1 is in single unit operation, its droop
CT is shorted by the other generators (Nos. 2 and 3) off the line, the same time its own
droop shorting contact is open. Contacts 1 in parallel with Series 2 and 3 across CT No. 1
are not needed. They only add to safety.
Figure 9
*Normally closed contacts open when corresponding generator circuit breaker is
closed.
Transformers must be polarized, i.e., both primary and secondary must be connected for
the same polarity, If the transformer has polarity markings, use these markings. If not
polarity marked, determine polarity by attached procedure.
Transformer Polarity Verification
1. Select a transformer and call it Trans #1.
2. Identify the primary winding (115V).
3. Arbitrarily select one of the primary winding leads and mark it H1.
4. Arbitrarily select one of the secondary winding leads and mark it X1. Mark the other
secondary winding lead X2. If the secondary winding has a center tap, do not use;
but tape end of wire for insulation.
5. Connections for polarity test (Figure 10).
Figure 10
6. Preliminary test of transformers:
a. Apply 115 V ac across H1 and H2 (see Figure 10). Measure this applied voltage.
b. Measure voltage of Trans #1 form X1 to X2. This will be approximately 12 V ac.
c. Measure voltage from H2 to X1. If the polarity is marked correctly, the measure
voltage is equal to the sum of the H1 to H2 voltage (step 6.a.) and the X1 to X2
voltage (step 6.b.). If the measured voltage is equal to the difference of the two
voltages, the polarity marking is incorrect. To correct the marking, reverse X1 and
X2 marking and reconnect the wire from H1 to X2 and retest to verify that the
voltage adds.
d. Trans #1 now has correct polarity markings.
7. Select a second transformer and call it Trans #2. Be sure Trans #1 and Trans #2 have
the same stock number.
8. For Trans #2, repeat steps 2, 3, and 4.
9. Connections for polarity test of Trans #1 and #2:
a. Connect the H1 leads together and then connect the H2 leads together (see
Figure 11).
b. Connect the X2 lead of Trans#1 to the X1 lead of Trans #2 (see Figure 11).
Figure 11
10. Preliminary Test of Transformers:
a. Apply 115 V ac across H1 and H2 (see Figure 11).
b. Measure voltage of Trans #2 from X1 to X2. This will be approximately 12 V ac.
c. If both transformers have the same secondary voltage, 12 V ac, proceed to step
11. If transformers are different, need to obtain the same type of transformer.
11. Polarity test of transformers:
a. Repeat step 10.a.
b. Measure voltage from Trans #1, X1 to Trans #2, X2. If the measured voltage is 0 V
ac, then the transformers have incorrect polarity markings. If it measures 24 V ac,
the polarity is correct.
c. If the polarity marking is correct, install the transformers. If the polarity marking is
incorrect, on Trans #2, reverse X1 and X2 lead markings. Reconnect Trans #2 to
agree with the connection diagram. Retest. If the voltage measures 24 V ac, the
polarity is correct and the transformers may be installed.
12. If another transformer is required, repeat steps 7 through 11.
Harmonic Wave Distortion – Cause and Effects
The case for oversize generators and 2/3 pitch
Reprint of LEXX4343
Harmonic distortion means that the sine wave of the fundamental 50 or 60 Hz frequency
is contaminated with other sine waves having the frequencies at multiples of the
fundamental. The largest harmonics tend to be of the lower orders, such as the third,
fifth, or seventh. Due to symmetry in sources and loads, the even orders usually cancel.
If severe, harmonics can cause overheating, malfunctions, false meter readings, or
failures.
Harmonic distortion has two sources Ð voltage distortion, which is influenced by generator
design, and current distortion, caused by non-linear loads. Voltage distortion from
generators varies with design, but in SR4 generators, no single harmonic exceeds three
percent of the fundamental. On the other hand, non-linear loads such as UPSÕs, switch
mode power supplied, gas discharge lighting, adjustable speed motor drives, etc. Often
cause current distortion in excess of 30 percent at discrete orders. (NOTE: A non-linear
load is any load where current doesnÕt vary linearly with voltage.)
Because of their sheer size, which gives very low system impedance, utility sources can
tolerate large harmonic currents without experiencing significant voltage distortion.
Since generator sets are so much smaller, with impedances dozens of times greater than
utilities, distorted current waveforms from a large non-linear load can cause distortion of
the generator voltage waveform many times greater than the generator causes itself. If
so, this can cause problems with other loads on the same system, or even with the load
causing the distortion.
Oversize Generators
Voltage waveform distortion from non-linear loads is proportional to voltage source
impedance. Since bigger generators have lower impedance, a common and effective
strategy to reduce distortion is to oversize the generator by using a kW multiplier (up to
2.0) that varies with the type of non-linear load. Since oversizing the generator doesnÕt
produce real load, the engine doesnÕt need to be oversized too.
2/3 Pitch
The case for or against 2/3 pitch is far less easily understood than for oversize generators.
As an example, 2/3 pitch generators develop less third harmonics which circulate in the
windings of delta connected generators, so some manufacturers of small delta
connected generators use 2/3 pitch to avoid derating. On the hand, longer pitch
generators produce less fifth harmonics, which circulate in line voltages and can
overheat motors. However, since load induced harmonics are generally so much
greater than those from the generator, Caterpillar uses an ÒoptimumÓ pitch around 4/5
to 5/6. This makes much better use of the active material than 2/3 pitch, minimizes fifth
and seventh order harmonics, and provides less than three percent third harmonics.
Caterpillar reference material available on this subject
• EDS 70.0.5 – Generator Technical Information Summary

Pages 3 and 4 contain a discussion of waveform harmonics.
• EDS 70.3 – Understanding Static UPS Systems and Generator Set Considerations
A 21- page document detailing the types and design of UPS systems, how to size gen
sets to power them, the harmonics they include, and the resulting problems for other
loads and the generator.
• EDS 70.4 – Generator Winding Pitch and Harmonics
A seven-page tutorial about winding pitch and harmonics, including the
disadvantages of 2/3 pitch.
• 3500 EPG Technical Information kit: “Non-Linear Loads on Standby Gen Sets.”
This is an excellent reference for any size hen set. It defines non-linear loads, shows
typical for different load types, discusses issues of generator and regulator design
and the various application problems to be expected, as well as how to minimize
them.
3500 EPG Technical Information Kit: ÒTwo Thirds or Not Two Thirds.Ó
Also a good reference for any size gen set. It lists factors that coil pitch influences,
identifies optimum pitch, the effect of pitch on harmonics, shows waveforms, and
discusses where 2/3 pitch should and should not be used.
2/3 Pitch
Misconception Facts
Generators are the In high quality generators such as the Cat SR4s, no single voltage
source of harmonics harmonic exceeds three percent of the fundamental. Careful
selection of pitch and skew and careful design of the rotor pole
head provides a near sinusoidal voltage waveform with minimum
third and other harmonics. Many loads, on the other hand, cause
current harmonics over 30 percent of the fundamental (see figure
1). If the system is not properly sized these load current harmonics
can distort the generator voltage waveform.
Caterpillar does not Most standard Cat generators are 4/5 to 5/6 pitch, but Cat also
offer 2/3 pitch offers 2/3 pitch by SER. About one percent of generators are
generators ordered 2/3 pitch, partly for spec compliance. Also, recent 4160
volt generators are connected in delta to provide 2400 volts.
These large generators are designed 2/3 pitch to avoid third
harmonics circulating in the delta stator winding. SR4 generators
250 kW and below have sufficient stator margin that 2/3 pitch is not
required for delta connections.
2/3 pitch is best for To minimize circulating neutral currents in paralleled generators, all
paralleling. generators should be the same pitch; 2/3 pitch has no advantage.
Paralleling a 2/3 pitch generator with generators having other
pitches will increase neutral current.
2/3 pitch minimizes 2/3 pitch does minimize generator induced third order harmonics,
harmonics. but nearly maximizes other harmonics such as the fifth and seventh
(fig.2). Fifth order is particularly bad for motors, because it causes
motor heating by reducing torque output, and by causing cyclic
torque reversals in the motor and in the load.
2/3 pitch avoids 2/3 pitch allows manufacturers of some small delta connected
generator derating. generators to avoid derating due to circulating third order currents
inside the delta stator winding. However, 2/3 pitch reduces the
fundamental design voltage a generator can develop by about 14
percent (see figure 2) meaning a bigger generator is required to
produce the desired rating. This is simply a different form of
derating. Optimum pitch (4/5 to 5/6 pitch) reduces the
fundamental voltage by only three to four percent.
2/3 pitch generators 2/3 pitch generators have one undisputed claim; they produce less
are good insurance third harmonic voltage distortion in their waveform than any other
against possible pitch. Third harmonic currents can flow only in (a) the neutral of
problems. grounded, wye connected generators or (b) the stator of delta
connected generators. This low third harmonic voltage is useful in a
narrow set of circumstances:
1. If many single phase non-linear loads are directly
connected to a three-phase generator, the load
induced third harmonic currents can cause high
neutral currents. In this case, the low zero sequence
reactance of a 2/3 pitch generator will reduce the
voltage distortion. If the non-linear load is three phase,
or a transformer is used between the load and
generator, 2/3 pitch has no advantage.
1. Where it is necessary to parallel with other 2/3 pitch
generators.
1. When generators with little stator temperature margin
must be connected delta.
1. Where 2/3 pitch must be provided for a spec
requirement.
2/3 pitch allows using 2/3 pitch may actually contribute to instrument errors or relay
lower cost line-to- malfunctions because third order current harmonics caused by
neutral sensing meters non-linear loads are increased by the very low zero sequence
and protective relays
reactance of these generators.
in the switchgear.
Optimum Pitch
Advantages Disadvantages
Results in about 10 percent smaller generator The third order is the highest harmonic in the
than 2/3 pitch because of less reduction of waveform, although it is controlled to three
the foundational design voltage. percent distortion or less.
The fifth and seventh order harmonics are Applications requiring 2/3 pitch (such as to
minimized, which minimizes potential parallel with existing 2/3 pitch generators)
problems with driven equipment such as must be filled by SER.
electrical motors.
The zero sequence reactance is several Neutral currents during normal operation are
times greater than with 2/3 pitch (7.5 times in higher than with 2/3 pitch in the specific
one test machine). This substantially reduces case where a number of single phase non-
fault currents in the neutral when paralleled linear loads are directly connected (no
with a utility or other generators. transformer) from line-to-neutral to a
grounded three-phase wye connected
generator. In severe cases this could
overload the neutral.
Definition of Pitch
The pole pitch of a generator is the angle between adjacent rotor poles; 90 degrees for
a 4-pole generator. If each stator coil spans the same angle as the poles, it is called full
pitch. As an example of less than full pitch, a 2/3 pitch generator coil would span 60
degrees if the rotor angle is 90 degrees.
A full pitch generator maximizes every harmonic voltage and is rarely if ever used. A
generator with less than full pitch loses some of the fundamental voltage capability, but
can reduce harmonic voltage capability, but can reduce harmonic voltages much
more (see figure2).
Besides determining the fundamental voltage and the harmonic voltages, the coil pitch
also controls the zero sequence reactance of the generator. This reactance determines
how much current can flow in the generator neutral. A low impedance will allow higher
current to flow for a given voltage difference. Conversely, at a given current flow, a low
impedance would result in less voltage distortion.
Harmonic Distortion
Figure 1
Largest single order distortion is less than three percent of the fundamental.
Single order distortions often exceed 30 percent of the fundamental.
Note: Lowest Harmonic RMS
of 3rd, 5th and 7th orders
(Optimum Pitch) is
between 4/5ths & 6/7ths
pitch
Two Third’s or Not Two Third’s
Graham R. Phillips
Magnetek, Inc.
Summary
The best pitch for the coils in a generator stator winding has been the subject of
considerable debate in recent years. Most recently this debate has centered on the
performance of generators supplying non-linear loads.
This article details the effects of coil pitch on a generatorÕs characteristics and discusses
how changing the pitch affects the performance of the generator and the system,
which it supplies, with particular reference to non-linear loads.
Definition of Coil Pitch

The pole pitch of a generator is the angle between adjacent poles. For a 4-pole
machine this angle is 90°. If each stator coil spans the same 90°, then this is called a full
pitch winding. If the coil span is 60°, the winding pitch is 60/90, 2/3 or 66.6%. See Figure 1.
Factors Influenced by Coil Pitch

1. The Zero-Sequence Reactance
The Zero Sequence Reactance is the internal reactance of the generator for any
zero sequence currents. That is any currents that flow in the neutral of the machine.
Typical values for zero sequence reactance as coil pitch is changed are shown in
Figure 2. These values are Òper unitÓ, normalized for a constant synchronous
reactance.
2. The Voltage Generated in the Coil
The voltage generated in each coil is reduced as the coil pitch is shortened. Figure 3
shows the pitch factor for the fundamental component of voltage for variation of coil
pitch. The pitch factor is the factor by which the generated voltage is reduced
compared to a full pitch winding. Reduced voltage from the coils means in effect
that the output power of a specific size generator is reduced.
3. The Harmonic Content of the Voltage
The harmonic content of the generated voltage varies with the coil pitch of the
stator winding. Curves showing the pitch factor versus coil pitch are shown in Figure
3. These curves show that specific Harmonics are cancelled out in the winding for
specific pitches. The third and all triplen harmonics are cancelled by a 2/3 thirds pitch
winding. The fifth and all multiples of fifth harmonic are cancelled by a 4/5 pitch
winding. In a practical machine, the poles are shaped to make the flux pattern close
to sinusoidal so that the harmonics in the flux are low and therefore the generated
harmonic voltages are low. These voltages are further reduced by the pitch factor.
Determining the Optimum Pitch of a Generator Winding

There are five considerations in determining the pitch of a Generator winding.
1. Neutral Circulating Currents.
Neutral harmonic circulating currents are produced when two or more generators,
having different harmonic voltage content in their line to neutral voltages, are
paralleled with the neutrals tied together. The value of these currents depends on
the difference between the voltages of the machines at each harmonic and the
impedance of the complete circuit. Usually the resistive component of his
impedance is low enough to be neglected. The third harmonic current is the major
component and is normally the only component considered.
The general formula for this current is:
In = 3 * (V1 - V2) / (Xo1 + Xo2 + Xn)
Where V1 is the 3rd harmonic voltage of Gen. #1

V2 is the 3rd harmonic voltage of Gen. #2
Xo1 is the zero sequence reactance of Gen. #1
Xo2 is the zero sequence reactance of Gen. #2
Xn is the neutral connection reactance.
In is the neutral 3rd harmonic circulating current.
The factor of 3 arises because all three-phase currents add in the neutral.
Reactance values are 3 times the fundamental frequency values.
Because a 2/3 pitch generator has, theoretically, no generated 3rd harmonic

circulating current, it is often thought that the 2/3 pitch machine is ideal for this
application. Due to generator manufacturing tolerances, however, there is always
some 3rd harmonic voltage generated in a machine and because the 2/3 pitch
generator has a very low zero sequence reactance that small voltage can produce
a high 3rd harmonic circulating current, possibly higher than a non-2/3 pitch machine.
Small unbalanced fundamental frequency voltages can result in high neutral currents
at the fundamental frequency when the zero sequence reactance is low.
To ensure low third harmonic neutral circulating currents, the following precautions
should be observed.
a. Where possible paralleled generators should be identical design and

manufacture (not necessarily 2/3 pitch). This will ensure that the generated
harmonic voltages are equal and will therefore cancel.
b. If the generators are of different sizes, the coil pitches should be the same.
c. If the generators are different, the 3rd harmonic circulating current and itÕs
heating effect in each generator should be calculated. If the heating effect in
either generator is too great then a neutral reactor or resistor should be inserted in
each generator neutral to limit the current to an acceptable value.
The effects of any neutral circulating current on protective relays must be

considered. Preferably, these devices should be insensitive to harmonic currents.
The circulating current is calculated using the formula:
In = 3 * (V1 - V2) / (Xo1 + Xo2 + Xn)
The heating effect of this current in each generator is calculated using the formulae:
Current in generator windings.
Iw = sqrt [Ig2 + (In2 /9)]
Increased heating due to this increased current.
= (Iw / Ig)2 * 100%
Where Ig = Rated generator full load current.

In = Neutral 3rd harmonic circulating current.
Iw = RMS sum of fundamental plus harmonic currents.
Note: The 3rd harmonic neutral current can be quite high without causing much
additional winding heating.
E.g. Two paralleled generators with a 3rd harmonic neutral circulating current of 50%
of rated full load current will result in only 2.8% additional winding heating.
2. Short Circuit Current for a Line to Neutral Fault.
The line to neutral short circuit current for a generator is calculated using the formula:
Isc = (3 * Ig ) / (XÕÕd +X2 + X0)
E.g. For a typical 4/5 pitch generator:
Isc = (3 * 100) / (0.17 +0.2 + 0.07) * 100% = 682%
E.g. For a typical 2/3 pitch generator:
Isc = (3 * 100) / (0.17 +0.2 + 0.004) * 100% = 802%
The line to neutral short circuit current of a 2/3 pitch generator will always be higher
than longer pitch machine and thus more susceptible to damage from heating or
magnetic forces under these conditions.
3. Internal Impedance to Harmonic Currents.
Harmonic currents from the load produce voltage drops in the generator reactance,
which results in harmonic distortion of the voltage waveform.
a. Line to Line Loads
The internal reactance of a generator to harmonic currents from line to line
loading is the negative sequence reactance. This reactance, X2, is the average
value of the direct and quadrature sub-transient reactances, XÕÕd and XÕÕq. The
value of X2 for generators with the same synchronous reactance does not vary
with coil pitch.
Therefore the voltage wave-form distortion due to harmonic currents from a three
phase line to line connected load is not affected by coil pitch.
b. Line to Neutral Loads.
The zero sequence reactance, Xo, of a generator is the reactance presented to

any unbalance currents, that is to any currents flowing in the neutral of the
machine. A 2/3 pitch generator has a very low zero sequence reactance and
therefore any 3rd or other triplen harmonic currents produced in the load will result
in only a low harmonic voltage drop in the generator.
A longer pitch generator will have a higher zero sequence reactance which will
limit the triplen harmonic currents from the load. The effect on the voltage wave-
form will depend on the value of these harmonic currents and the zero sequence
reactance.
4. Line to Line and Line to Neutral Harmonic Voltages.
The coil pitch of a generator winding affects the generated harmonic voltages. As
shown on Figure 3, a 2/3 pitch coil will cancel any generated 3rd harmonic voltages.
A 4/5 pitch coil will cancel any 5th harmonic voltages and a 6/7 pitch coil will cancel
any 7th harmonic voltages.
For a three phase wye connection there is no 3rd (or multiples of the 3rd) harmonic
generated in the line to line voltages. Any triplen harmonics appear only in the line
to neutral voltages.
Where the load is connected line to line or supplied through a delta/wye transformer,
any triplen harmonics generated are not seen by the load. The 2/3 pitch winding
therefore has no advantage in these cases and a greater pitch will reduce 5th and 7th
harmonics that do appear on the load.
Where the loads are connected line to neutral, the 3rd harmonic content on the
generator voltage must be considered.
5. The Most Effective Use of Active Material.
The optimum generator design is one which produces the greatest output for a given
amount of material while meeting the limitations of maximum temperature rise and
any efficiency specifications.
The art of designing a generator is to build a machine that meets all performance
requirements at the lowest manufacturing cost.
One of the limitations is the voltage generated in the coils for the flux density in the air
gap.
The greatest voltage is obtained from a full pitch coil but this coil pitch produces too
high harmonic voltages and has long end turns.
The best compromise is a coil pitch, which minimizes harmonics while not having too
low a pitch factor to reduce the voltage output.
For a generator designed for a three phase load with no neutral loading, the 3rd
harmonics are not a consideration so the best pitch is one, which minimizes the 5th
and 7th harmonics. Figure 3 shows this pitch to be about 83%.
Other considerations, which influence the choice of coil pitch, are:

a. The coil end turn length. (Greater pitch result in longer coil end turns with higher
losses.)
b. The number of effective turns required to obtain the desired flux density.
c. Practical limitations resulting from having integral slot and turn numbers.
d. Production tooling costs which limit the number of core diameter and length
combinations.
The optimum coil pitch based on these considerations is usually between 70 and 80%.
Where the loads are connected line to neutral without transformers (typically on
machines less than 100 kW), 2/3 pitch coils may be required to ensure low 3rd
harmonic content in the line to neutral voltage wave-form. This requirement will result
in a higher generator active material content.
Test Program
Two generator stators were built to obtain test results on the effects of changing the coil
pitch of a generator. The two stators were the same core diameter and length and the
same rotating field and exciter were used with each stator during the tests.
One stator was wound with 2/3 pitch and the other with 5/6 pitch coils. The number of
turns in the 5/6 pitch coils was adjusted to make the synchronous reactance of the
machine using that stator similar to the one with 2/3 pitch coils.
Calculated reactances (Per Unit):
2/ 3Pitch 5/ 6Pitch
Xd = 3.13 2.86
Xq = 1.60 1.46
XÕd = 0.21 0.19
XÕÕd = 0.14 0.13
X2 = 0.23 0.21
X0 = 0.006 0.16
Note that while most reactances of the 5/6 pitch machine are slightly lower than the 2/3
pitch, the zero sequence reactance is 26 time higher.
Harmonic Voltages
The harmonic analyses of the line to line and line to neutral voltages both on no load
and on a linear load shown below.
Line to Line
2/ 3 Pitch 5/ 6 Pitch
Harmonic No Load Full Load No Load Full Load
3rd 0.10% 0.35% 0.10% 0.10%
5th 1.75% 2.31% 0.49% 0.31%
7th 0.76% 0.35% 0.15% 0.19%
9th 0.08% 0.05% 0.07% 0.03%
11th 0.12% 0.95% 0.22% 0.58%
13th 0.26% 0.39% 0.28% 0.47%
15th 0.02% 0.02% 0.09% 0.04%
Total 1.93% 2.57% 0.46% 0.84%
Line to Neutral
2/ 3 Pitch 5/ 6 Pitch
Harmonic No Load Full Load No Load Full Load
3rd 0.20% 0.09% 2.53% 7.66%
5th 1.54% 2.11% 0.55% 0.23%
7th 0.77% 0.35% 0.17% 0.18%
9th 0.01% 0.1% 0.75% 1.15%
11th 0.18% 0.94% 0.11% 0.63%
13th 0.24% 0.43% 0.35% 0.5%
15th 0.07% 0.05% 0.54% 0.9%
Total 1.76% 2.38% 2.78% 7.84%
These tests confirm the high triplen harmonics in the line to neutral voltages and the lower
5th and 7th harmonics in the line to line voltages on the 5/6 pitch generator.
The tests also show low values of triplen harmonics in the 2/3 pitch generator line to
neutral voltage. These low voltages combined with the very low zero sequence
reactance could produce neutral circulating currents in paralleled machines.
Non-Linear Load Tests

Tests were run on both machines using SCR controlled and straight rectifier loads with
both single phase and three phase loads.
Oscilloscope photographs, Figures 4 - 9 show the waveform distortion produced by these

loads and the difference between the 2/3 and 5/6 pitch generators.
These traces confirm that with three phase loading, there is no significant difference in
the distortion between the two machines. With the line to neutral loading, there is some
distortion when using the 2/3 pitch generator, but even in this case, the reduction is far
less than may be expected from the difference in zero sequence reactances. This is
because the higher zero sequence reactance of the 5/6 pitch machine reduces the
load harmonic currents and consequently reduces the harmonic voltage drop.
Conclusion
2/3 pitch is not a Òcure-allÓ solution.
The optimum coil pitch for a generator depends on the system configuration and the
type of load. For minimum material content the optimum generator design is about _ or
75% pitch.
In a parallel operation situation, all of the effects of circulating and short circuit currents
must be considered. 2/3 pitch does not solve all problems.
When supplying non-linear loads, which have no neutral connection, the coil pitch has
no effect on voltage wave-form distortion. When these loads are connected line to
neutral of the generator, a 2/3 pitch winding will not reduce the wave-form distortion
compared to a greater pitch, as much as may be expected from the difference in zero
sequence reactances. This is confirmed by the test results.
The optimum coil pitch for minimum generated voltage harmonics is 5/6 or 83% for cases
where loads are connected three phase line to line. When loads are connected line to
neutral, without transformers, a 2/3 or 66.7% pitch winding will give minimum harmonic
content in the line to neutral voltage at the expense of higher harmonic content in the
line to line voltage
G.R. Phillips
10/3/91
Full Pitch Coil
2/ Pitch Coil
3
Figure 1
Zero Sequence Reactance
0.3
0.25
0.2
Xo P.U.
0.15
0.1
0.05
0
60 70 80 90
Pitch Angle
Pitch Angle Zero Sequence

(Degrees) X0
60.0 0.005
67.5 0.083
75.0 0.15
82.5 0.21
90.0 0.26
Note: Values normalized for constant Xd.
Figure 2
Figure 3
Single Phase Rectifier
Capacitive Load
2/ 3 Pitch Generator
Harmonic Current Voltage
3 40.2% 23.4%
5 11.1% 7.2%
7 7.3% 4.0%
9 2.5% 3.7%
11 1.8% 3.3%
13 0.9% 2.8%
Total 42.4% 25.4%
3 33.6% 26.7%
5 9.3% 7.7%
7 5.6% 6.0%
9 4.7% 5.7%
11 4.9% 3.7%
13 4.5% 2.8%
Total 36.1% 29.4%
Figure 4
Single Phase SCR
Controlled Load
3 59.4% 8.21%
5 13.2% 6.5%
7 8.3% 5.0%
9 5.4% 4.5%
11 2.2% 2.2%
13 3.1% 4.3%
Total 61.7% 13.2%
3 59.5% 16.2%
5 14.0% 3.1%
7 7.0% 4.6%
9 4.6% 2.8%
11 2.4% 2.2%
13 3.2% 1.1%
Total 61.8% 17.5%
Figure 5
Three Phase Rectifier
Capacitive Load
5 19.9% 11.2%
7 11.7% 3.6%
11 2.9% 3.3%
13 2.6% 3.6%
Total 23.4% 12.7%
5 22.2% 10.0%
7 12.4% 3.0%
11 3.8% 3.4%
13 3.7% 3.2%
Total 25.9% 11.4%
Figure 6
Non-Linear Loads On Standby Generator Sets
Graham R. Phillips
MagneTek Inc.
Abstract
Many types of electrical load in todayÕs systems use electronic switching devices or other
non-linear components to control the power. The effect of these non-linear components is
to produce harmonic currents which in turn cause harmonic distortion of the voltage wave-
form. A standby generator normally has a much higher source impedance than the utility
supply which it replaces. Therefore, the voltage wave-form distortion when operating on the
generator is much higher than when operating on the utility. This paper discusses the causes
of this distortion, the effects, and some measures to ensure correct operation of a system
powered by a standby generator set.
General
A non-linear component is defined as a device in which the current flow does not follow the
applied voltage in a linear manner. These devices may be Thyristors (SCRÕs or Triacs),
Transistors, or similar components where the current is switched ON and OFF repetitively
during normal operation, or components with magnetic cores which saturate at some point
in the A.C. cycle thereby causing the current to change non-linearly.
The utility source voltage is normally a sine wave at the fundamental 60 Hz frequency with
negligible harmonic distortion. When a standby generator is used for the source, its voltage
will also be very close to a pure sine wave. That is, with very low harmonic distortion. A utility
supply normally has a very low source impedance. By comparison a generator has a
relatively high internal impedance.
When a linear load is connected to a generator, the voltage regulator will compensate for
the voltage drop in its internal impedance by adjusting the terminal voltage to the correct
value. The voltage wave-form will remain very close to a pure sine wave.
When a non-linear load is connected to a generator, the voltage regulator will compensate
for the voltage drop in its internal impedance by adjusting the terminal voltage to the
correct value. The voltage wave-form will remain very close to a pure sine wave.
When a non-linear load is connected to a generator the voltage regulator will adjust the
terminal voltage to the correct value but because of the long time constant of the
generator field. The regulator cannot change the generator field fast enough to
compensate for deviations from a sine wave. As a result the voltage wave-form will be
distorted to a much greater degree than when the same load is connected to the low
source impedance utility.
Wave-form distortion is usually called Harmonic Distortion and the lower frequency
components of this distortion are usually integral multiples of the fundamental frequency.
Switch-mode controls using Thyristors or Transistors, however, do produce components which
are not integer multiples of the fundamental and they also produce very high frequency
currents which may be beyond the range of normal harmonic analyzers. The two main
causes of these components are:
1. High frequency switching at rates which are not synchronous with or multiples of the
supply frequency.
2. ÒRingingÓ caused by sudden changes of current in the parasitic inductances and
capacitances of the circuit.
SCR motor drives cause a ÒnotchingÓ distortion of the supply voltage. This notching is a result
of a brief short circuit from line to line as the SCRÕs switch the D.C. from line to line, or when a
free-wheeling diode is used, during the clearing time of the diode. These notches can be
from 5 to 100 microseconds wide and if there is no inductance in the line leads, can pull the
voltage down readily measured with a harmonic analyzer as the frequencies they produce
are very high, often about the range of the analyzer. IN addition, the small number of pulses
per cycle reduce their average value. An oscilloscope with at least 50 MHz bandwidth
provides the best method of check line notching. IEEE Standard 519 has a specific limit for
line notching.
An evaluation of the harmonic content of the load current is very useful for determining
corrective measures to be take, but, because of the above effects, may be deceiving.
A knowledge of the characteristics of the various loads which may be encountered and
their effects is a substantial help in determining the best corrective measures.
Types of Non-Linear Loads

The most common types of non-linear load are listed below:
1. SCR Controlled D.C. Motor Drives

These drives may be single- or poly-phase and half- or full-wave controlled.
The Half-Wave Drives produce the most severe current harmonics and also introduce a
D.C. current component which can cause transformers to saturate and overheat.
The major current harmonics produced by these motor drives are as follows:
1-Phase 1/2 Wave 2nd, 3rd, 4th, 5th etc. plus D.C.
1-Phase Full Wave 3rd, 5th, 7th etc.
1
3-Phase /2 Wave 4th, 5th, 7th etc. plus D.C.
3-Phase Full Wave 5th and 7th
6-Phase Full Wave 11th and 13th
These Drives can draw high current pulses when an SCR switches ON while a free-
wheeling diode is conducting. The diode takes a finite time to clear and this causes
voltage wave-form notching. Poly-phase Drives produce notching during SCR
commutation.
See Illustrations 1,2, and 3.
2. Variable Voltage A.C. Controls

These controls may be used for resistance loads such as heating or lighting or for reactive
loads such as speed control of induction motors. They usually use SCRÕs for switching.
The resistive load controls have step current changes at the instant of SCR turn-on, which
results in a step change in level of the voltage wave-form due to the source impedance.
For the reactive loads, the current rises slowly so that the voltage wave-form levels are
not as sharp.
The harmonic currents drawn by these controls are similar to the D.C. Motor Drives but do
not have the line-notching effects.
3. Variable Frequency A.C. Motor Drives

Large A.C. drives (over 200 H.P.) and older models in smaller sizes normally use SCR
control of the input power. These drives draw current harmonics similar to the D.C. drives
but without the notching effect. Some types of these drives may see some of the output
frequencies reflected back onto the input current. This may cause beat frequencies
which can result in light flicker and other annoying phenomena.
Most of the smaller A.C. drives being built at present use a rectifier input to a D.C. but
with a large capacitor.
These drives draw high currents when the line voltage exceeds the D.C. but voltage. The
current is normally limited only by the source impedance. When the source impedance
is high, as with a generator, this effect results in flattening the top of the voltage wave-
form.
See Illustration 4.
The current harmonics drawn by these controls are:

1-Phase Input 3rd, 5th, 7th, 9th etc.
3-Phase Input 5th, 7th, 11th, 13th etc.
6-Phase Input 11th, 13th, 23rd, 25th etc.
4. Battery Supported U.P.S.

U.P.S. Systems usually use SCRÕs or transistors to control the input current to the battery
during charging or floating.
In the larger sizes, these systems usually have input transformers which have sufficient
reactance to reduce the peak currents drawn when the SCR switches the line to the
battery. Further, these transformers are frequently arranged to provide 6- or 12-phase
input to the rectifiers. These units therefore generally have relatively low input current
harmonics.
The smaller U.P.S. systems often provide only minimal input current limiting and they may
have high input current harmonics.
The current harmonics drawn by U.P.S. Systems are:

1-Phase FW Input 3rd, 5th, 7th, 9th, etc.
3-Phase FW Input 5th, 7th, 11th, 13th, etc.
6-Phase FW Input 11th, 13th, 23rd, 25th, etc.
12-Phase FW Input 23rd, 25th, 47th, 49th, etc.
5. Rectifier Loads.
The input current to a rectifier depends of the nature of the load connected to the D.C.
output:
a. Resistive Loads Ð Input current for 3-phse is a 120° square wave with 11% ripple.
b. Inductive Loads Ð Inductance on the D.C. output will tend to maintain the current at
a constant value. Thus the input current will be rectangular wave-form.
c. Capacitive Loads Ð In this case the input current will be zero until the voltage reaches
the charged capacitor value, at which point it will raise to a high peak limited mainly
by the source impedance.
Note: Some rectifier systems provide input reactors or transformers which reduce the
peak input currents and thus reduce input current harmonics.
The current harmonics drawn by rectifier systems are:

1-Phase 1/2 Wave 2nd, 3rd, 4th, 5th plus D.C.
1-Phase Full Wave 3rd, 5th, 7th, 9th, etc.
1
3-Phase /2 Wave 3rd, 4th, 5th, 7th, etc plus D.C.
3-Phase Full Wave 5th, 7th, 11th, 13th, etc.
6. Discharge Lighting
There are two basic types of ballasts used for discharge lighting:
a. Reactor with capacitors for power factor correction. These ballasts control the lamp
current with saturating reactors. They are normally single-phase and draw high 3rd
harmonic currents. These ballasts are designed for operation on a pure sine wave
supply and deliver too much or too little current to the lamp when supplied by a
source where the voltage has been distorted by the lampÕs own 3rd harmonic
current.
b. Electronic ballasts. The latest-design electronic ballasts operate at a high power

factor and with low input current harmonic distortion. These units should not produce
voltage wave-form distortion on a standby generator. Many older types of
electronic ballasts do draw high input current harmonics and can cause voltage
wave-form distortion with resulting incorrect operation.
7. Saturating Reactors
Saturating reactors are sometimes used for A.C. power control. These controls draw high
3rd harmonic currents on single phase and high 5th and 7th harmonics on 3-phase systems.
8. Saturated Transformers
If a transformer is operated above its rated voltage the core may saturate. This will result
in high 3rd harmonic currents for a single-phase unit or high 5th and 7th harmonics for a 3-
wire 3-phase unit.
9. Welders
Welders draw erratic fluctuating current which cannot normally be analyzed by
harmonic methods. These current fluctuations will produce corresponding voltage
wave-form fluctuations due to a source impedance.
10. Computer and Electronic Power Supplies

Most Electronic equipment operates on low-voltage D.C. power. This low-voltage D.C. is
produced by the power sully section of the device.
Older model D.C. power supplies used transformers supplying a rectifier with a capacitor
output filter. In these units, the transformer reactance limits the peak current to the
capacitor and therefore limits the harmonic distortion of the input current.
More recent models use a rectifier input with the storage capacitor tied directly the
rectifier output. With these units, the input current is limited only by the source
impedance when the line voltage is higher than the capacitor. Single-phase versions on
these models draw very high 3rd harmonic currents.
The latest technology has recognized the problems caused by these high currents and
most manufacturers now offer ÒHigh Power FactorÓ units in which the input current is
electronically controlled to closely approximate a sine wave. Economic considerations
are still limiting the use of these power supplies but regulatory agencies are expected to
force their adoption soon.
The harmonic currents drawn by electronic power supplies are:

1-Phase Input 3rd, 5th, 7th, 9th etc.
3-Phase Input 5th, 7th, 11th, 13th etc.
6-Phase Input 11th, 13th, 23rd, 25th etc.
11. Integral Cycle Controls

Some heating systems use a control method where power is connected to the load for
several full cycles, then disconnected for several full cycles. The average power supplied
is the ratio of the number of ON cycles to the number of On plus OFF cycles. This method
does not cause wave-form distortion, but can result in problems if the response time of
the generator voltage regulator, or the engine governor, is close to the cycle time of the
control. A resonant condition may develop, producing excessive voltage or frequency
pulsation.
Standby Power Systems

Most standby generators are 3-phase. Larger sizes (generally about 100 kW) will be
operating at 480 volts or higher and will be supplying the loads through distribution
transformers. These transformers are generally DELTA/WYE connected, and any third
harmonic current on the secondary will not be reflected onto the generator.
The exception to this is discharge lighting, which is frequently powered from line to neutral at
277 volts. Even though this lighting load may be balanced on the three phases, the 3rd
harmonic currents from these lamps will add in the neutral and can cause severe voltage
distortion of the line to neutral voltages, as well as heating on the neutral leads.
Smaller generators (typically below 100KW) often power the load directly at 208/120 volts
with a WYE connection. When single-phase, non-linear loads are connected in a balanced
manner to this neutral connection. This can result in neutral currents up to 1.73 times the line
current.
Standby Power Systems

Most standby generators are 3-phase. Larger sizes (generally above 100 kW) will be
operating at 480 volts or higher and will be supplying the loads through distribution
transformers. These harmonic currents on the secondary will not be reflected onto the
generator.
The exception to this is discharge lighting, which is frequently powered from line to neutral at
277 volts. Even though this lighting load may be balanced on the three phases, the 3rd
harmonic currents from these lamps will add in the neutral and can cause severe voltage
distortion of the line to neutral voltages, as well as heating of the neutral leads.
Smaller generators (typically below 100 kW) often power the load directly at 208/120 volts
with a WYE connection. When single-phase, non-linear loads are connected in a balanced
manner to this generator, the 3rd (and multiples of the 3rd) will add in the neutral connection.
This can result in neutral currents up to 1.73 times the line current.
Generator Characteristics
Reactances
The Generator Reactances which are significant when considering the effects of current
changes at frequencies higher than the fundamental are the Sub-Transient and Zero
Sequence Reactances. The average value of the direct axis and quadrature axis
subtransient reactances, XÕÕd and XÕÕq, is given as the Negative Sequence Reactance, X2,
and this is the value which should be used to calculate the internal voltage drop due to
rapidly changing line currents as encountered with non-linear loads.
The Zero Sequence Reactance, Xo, is the value which is effective to unbalanced currents Ñ
that is, to any currents which flow in the neutral of the generator.
A generator for use with 3-phase non-linear loads should have a low Negative Sequence
Reactance. For loads connected line to neutral the Zero Sequence Reactance should be
low.
Generator Design
Most generators are designed to produce the desired power output with the minimum
material content. The limitations are magnetic core saturation and heating due to copper
losses. The result is that most generators of a given K.W. rating at a specific speed will be
about the same size and have similar reactance values.
The optimum coil pitch for minimum material content and minimum total harmonic content
is about 75%, or 3/4 pitch. If a low Zero-Sequence Reactance, or if a low-generated third
harmonic is required, the generator may be wound with 2/3-pitch coils with some sacrifice in
additional material content and in total harmonic content. The Zero-Sequence Reactance
is the only value which is significantly affected by coil pitch.
The Sub-Transient Reactance is mainly determined by the Damper Cage dimensions, and
the Time Constant by the cage material.
To reduce the other reactances normally means that additional active material must be
used in the generator. In other words the generator is oversized for the rating.
Voltage Regulator
The Voltage Regulator for a generator which is to supply non-linear loads must be capable
of operating correctly with the voltage wave-form as distorted by the load.
1. Voltage Sensing
The sensing circuits of the Regulator should respond to the fundamental component of
the voltage wave-form. The sensing circuits must respond rapidly to ensure good control
but should not be so fast as to be affected by the distortion caused by the load. Three
phase sensing makes the circuit less sensitive to distortion on individual phases.
2. Regulator Power
Power for the exciter field may be obtained from the generator output or from a
separate source such as a P.M. Pilot Exciter. The P.M. Pilot Exciter has the advantage
that itÕs output is not affected by the generator load current. When the exciter field
power is obtained from a generator output, care must be taken to ensure that any
wave-form distortion due to load current does not produce changes in the Regulator
output.
Test Results
Tests were run with two 50 kW generators. One unit was wound with 2/3 pitch and the other
with 3/4 pitch coils.
The reactance values were as follows:

2/3 Pitch _ Pitch
Negative Sequence
X2 0.20 Ohms 0.18 Ohms
Zero Sequence
X0 0.015 Ohms 0.050 Ohms
Various types of non-linear loads were connected to these generators and wave-form traces
photographed and the harmonic content analyzed. A True RMS, an Average Sensing and a
Moving Iron Switchboard type voltmeter were used to compare the readings.
The voltages recorded with various loads are tabulated in Table I to show the variations in
controlled and measured voltage which can be expected.
Some of the wave-form traces and harmonic analyses do not indicate any substantial
difference in the degree of distortion between the 2/3-pitch and the 3/4-pitch generators.
Types of Problems
1. System Instability
This is usually caused by one of the control circuits on the load operating incorrectly due
to the distorted voltage wave-form. This incorrect operation causes rapid changes in
load which the Regulator cannot follow. These problems are usually due to the line
synchronizing circuits and can be corrected with additional filtering to the control
circuits. This filtering must be approved by the control manufacture as the filter may
produce a phase shift which would cause incorrect operation.
It is possible that the generator Regulator control circuit may respond incorrectly to the
distorted wave-form, but most manufacturers now recognize the requirement that the
regulators operate with non-linear loads on the generator and have taken measures to
ensure that they do, or offer models specifically for use with non-linear loads.
2. Erratic Voltage
Erratic voltage changes are usually caused by incorrect operation of line synchronizing
circuits in the non-linear loads or possibly in the voltage regulator.
3. Incorrect Voltage
Various sensing methods are used in Voltage Regulators. The Regulator may sense
single-or three-phase voltage. Its sensing circuit may respond to the average, the R.M.S.
or to the fundamental component of the voltage. With a distorted wave-form each of
these sensing methods will result in a different regulated voltage.
Fundamental component sensing or true RMS sensing of all three phases normally
provides the most accurate voltage regulation. It should be noted, however that a
wave-for having the correct RMS value may not have a high enough peak value to
ensure correct operation of some power supplies.
4. Voltmeter Readings
Different types of meter will give different readings. Normally a True RMS meter will give
the closest to correct voltage reading. Average responding meters or moving Iron
switchboard meters can be considerably in error. (See Table I).
5. Ammeter Readings
The same factors apply to ammeter readings. An additional consideration with ammeter
readings is that many non-linear load currents contain a D.C. component. Current
transformers will not couple this D.C. component to the meter with the result that the
actual R.M.S. current value may be considerable higher than indicated.
6. Incorrect operation of Loads

Most electrical equipment is designed to operate from a sine wave supply. When the
voltage wave-form is severely distorted some devices may not operate correctly.
Magnetic equipment such as motors and transformers my overheat due to harmonic
currents when supplied from a distorted voltage wave-form. Equipment containing
capacitors may draw excessive currents resulting in overheating or blowing fuses.
Devices which rely on detecting the zero-crossing of the voltage wave-form for timing
are particularly sensitive to notching of the voltage wave-form.
Minimizing Problems
1. Filters
If the affected load is low power, a line filter can be fitted to that load at a reasonable
low cost. For high power loads a line filter is expensive and the problem can often be
solved by filtering the low power control circuits only. Note that this filtering must be
approved by the manufacturer to ensure correct operation.
If the generator voltage regulator is being affected by the distorted wave0form,

additional filtering mat be necessary on the regulator input. Note that this filter must be
approved by the manufacturer to ensure correct operation.
If a line filter is necessary to handle a large part of the load, it should be designed to
supply the specific current harmonics requited by the load.
Power Factor correction capacitors should not be connected to a generator for filtering
purposes without a full system study as they may cause resonances or loss of control of
voltage.
2. Generator Oversizing
Generators supplying non-linear loads need to be oversized to prevent damage from
overheating due to the additional losses generated by the harmonic current.
This oversizing will reduce internal reactance which will reduce the voltage wave-form
distortion.
Oversizing will usually have little effect in reducing ÒNotchingÓ as the internal impedance
of D.C. drives is normally very low compared to the generator.
Table II gives some general guidelines for oversizing a generator for various types of Non-
Linear Load. These guidelines cannot guarantee correct operation of the system since
the problems are associated with the sensitivity of the loads to the voltage wave-form.
3. Inertial Loads (Electrical Inertia)
Motors connected to a generator will reduce the effective reactance of the system
thereby reducing the voltage wave-form distortion caused by harmonic currents. Note
that the harmonic currents flowing in the motors will cause additional losses and heating
in the motors.
4. Pulsating Loads
Avoid supplying loads which have pulsations of current with a frequency of 2 to 10 cycles
per second. These pulsations are of similar time constant to the generator and engine
control systems and can produce resonances which result in large voltage and
frequency swings.
5. Generator Coil Pitch

In cases where line to neutral loads are connected directly to the generator, use a
machine with 2/3 coil pitch.
Where the load is isolated from the generator through a DELTA/WYE transformer, a longer
pitch machine will have lower effective reactances.
Conclusion
This paper has described some of the problems associated with the operation of non-linear
loads on standby generator sets.
These problems can be considered as a warning of things to come on the utility bus.
As more and more non linear loads are applied, the utility will no longer be able to maintain
the clean sine wave we have come to depend on.
Electronic equipment manufacturers must begin to consider the effect that their equipment
is having on the power source and design that equipment to obviate any problems.
The technology is available. The power supply manufacturers are already being forced to
use it to beat IEC Specs.
Let us heed the warning which the problems on standby generators presents. Let us design
our power electronic devices to draw clean sine wave input currents and so maintain a high
quality source voltage wave-form.
Table 1
Voltmeter Readings:
Test Condition Av. Resp. Moving Iron True RMS

No Load. 460 460 460
P.W.M. Inverter 452 456 460
D.C. Motor Drive 454 445 460
Full Wave Rectifier:
Capacitive Load 441 452 460
Resistive Load 441 458 460
Table 2
Oversize Factors for Generators Supplying Non-Linear Loads

Type of Load Oversize Factor
1. SCR ControlsÑResistive or Motor Load:
1 Phase 1/2 Wave (1 pulse) 2.0
1 Phase Full Wave (2 pulse) 1.6
2. SCR ControlsÑCapacitive or Battery Load:

3. Rectifiers:
4. Inverter Drives, UPS Systems, Switching Power Supplies:

SCR InputÑUse values for SCR with Capacitive Load
Rectifier InputÑUse Rectifier Values.
Unity P.F. Type Power Supplies. 1.0
5. Discharge Lighting, Fluorescent Lighting:

Unity P.F. Types 1.0
Other Types:
1 phase. 1.2
3 phase. 1.15
(Note: check neutral current.)
Note: Use of these factors does not guarantee correct operation as correct operation
depends on the sensitivity of the loads being supplied to the distorted wave-form.
These factors apply only to the Non-Linear portion of the load.
6 Pulse D.C. Motor Drive
2/ Pitch Generator
3
Current Voltage
5th 31.0% 5th 9.3%
7th 17.0% 7th 6.0%
11th 10.5% 11th 1.3%
13th 7.0% 13th 3.1%
3/ Pitch Generator
4
Current Voltage
5th 32.5% 5th 6.1%
7th 5.2% 7th 2.4%
11th 10.9% 11th 3.1%
13th 7.0% 13th 1.9%
Illustration 1
Single Phase Full Wave SCR Control
2/ Pitch Generator
3
Current Voltage
5th 32.3% 5th 10.6%
7th 8.0% 7th 5.6%
11th 2.7% 11th 1.9%
13th 4.1% 13th 5.1%
3/ Pitch Generator
4
Current Voltage
5th 29.5% 5th 11.4%
7th 9.1% 7th 8.5%
11th 1.7% 11th 2.9%
13th 3.9% 13 th 5.7%
Illustration 2
Single Phase Full Wave Rectifier
2/ Pitch Generator
3
Current Voltage
5th 40.2% 5th 23.4%
7th 11.1% 7th 7.2%
11th 7.3% 11th 4.0%
13th 2.5% 13th 3.7%
3/ Pitch Generator
4
Current Voltage
5th 42.0% 5th 26.6%
7th 13.8% 7th 7.5%
11th 5.5% 11th 6.1%
13th 3.8% 13th 5.4%
Illustration 3
Variable Frequency A.C. Drive
2/ Pitch Generator
3
Current Voltage
5th 22.0% 5th 9.2%
7th 12.6% 7th 1.7%
11th 4.5% 11th 4.1%
13th 3.9% 13th 3.5%
3/ Pitch Generator
4
Current Voltage
5th 22.2% 5th 9.9%
7th 12.3% 7th 3.0%
11th 3.4% 11th 3.8%
13th 3.2% 13th 3.7%
Illustration 4
Table of Contents – Generator Protection
Page Number
Type J Thermocouple Chart 2
Copper RTD Chart 3
RTD Kits 8
Current Transformers 9
Droop Transformer Chart 11

particular purpose.
Caterpillar Inc.
Type J Thermocouple, Iron vs. Copper-Nickel
Temperature vs. Absolute Millivolts
0 1 2 3 4 5 6 7 8 9
-200¡C -7.890 -7.912 -7.934 -7.955 -7.976 -7.996 -8.017 -8.037 -8.057 -8.076
-190¡C -7.659 -7.683 -7.707 -7.731 -7.755 -7.778 -7.801 -7.824 -7.846 -7.868
-180¡C -7.402 -7.429 -7.455 -7.482 -7.508 -7.533 -7.559 -7.584 -7.609 -7.634
-170¡C -7.122 -7.151 -7.180 -7.209 -7.237 -7.265 -7.293 -7.321 -7.348 -7.375
-160¡C -6.821 -6.852 -6.883 -6.914 -6.944 -6.974 -7.004 -7.034 -7.064 -7.093
-150¡C -6.499 -6.532 -6.565 -6.598 -6.630 -6.663 -6.695 -6.727 -6.758 -6.790
-140¡C -6.159 -6.194 -6.228 -6.263 -6.297 -6.331 -6.365 -6.399 -6.433 -6.466
-130¡C -5.801 -5.837 -5.874 -5.910 -5.946 -5.982 -6.018 -6.053 -6.089 -6.124
-120¡C -5.426 -5.464 -5.502 -5.540 -5.578 -5.615 -5.653 -5.690 -5.727 -5.764
-110¡C -5.036 -5.076 -5.115 -5.155 -5.194 -5.233 -5.272 -5.311 -5.349 -5.388
-100¡C -4.632 -4.673 -4.714 -4.755 -4.795 -4.836 -4.876 -4.916 -4.956 -4.996
-90¡C -4.215 -4.257 -4.299 -4.341 -4.383 -4.425 -4.467 -4.508 -4.550 -4.591
-80¡C -3.785 -3.829 -3.872 -3.915 -3.958 -4.001 -4.044 -4.087 -4.130 -4.172
-70¡C -3.344 -3.389 -3.433 -3.478 -3.522 -3.556 -3.610 -3.654 -3.698 -3.742
-60¡C -2.892 -2.938 -2.984 -3.029 -3.074 -3.120 -3.165 -3.210 -3.255 -3.299
-50¡C -2.431 -2.478 -2.524 -2.570 -2.617 -2.663 -2.709 -2.755 -2.801 -2.847
-40¡C -1.960 -2.008 -2.055 -2.102 -2.150 -2.197 -2.244 -2.291 -2.338 -2.384
-30¡C -1.481 -1.530 -1.578 -1.626 -1.674 -1.722 -1.770 -1.818 -1.865 -1.913
-20¡C -0.995 -1.044 -1.093 -1.141 -1.190 -1.239 -1.288 -1.336 -1.385 -1.433
-10¡C -0.501 -0.550 -0.600 -0.650 -0.699 -0.748 -0.798 -0.847 -0.896 -0.945
0¡C 0.000 -0.050 -0.101 -0.151 -0.201 -0.251 -0.301 -0.351 -0.401 -0.451
0 1 2 3 4 5 6 7 8 9
0¡C 0.000 0.050 0.101 0.151 0.202 0.253 0.303 0.354 0.405 0.456
10¡C 0.507 0.558 0.609 0.660 0.711 0.762 0.813 0.865 0.916 0.967
20¡C 1.019 1.070 1.122 1.174 1.225 1.277 1.329 1.381 1.432 1.484
30¡C 1.536 1.588 1.640 1.693 1.745 1.797 1.849 1.901 1.954 2.006
40¡C 2.058 2.111 2.163 2.216 2.268 2.321 2.374 2.426 2.479 2.532
50¡C 2.585 2.638 2.691 2.743 2.796 2.849 2.902 2.956 3.009 3.062
60¡C 3.115 3.168 3.221 3.275 3.328 3.381 3.435 3.488 3.542 3.595
70¡C 3.649 3.702 3.756 3.809 3.863 3.917 3.971 4.024 4.078 4.132
80¡C 4.186 4.239 4.293 4.347 4.401 4.455 4.509 4.563 4.617 4.671
90¡C 4.725 4.780 4.834 4.888 4.942 4.996 5.050 5.105 5.159 5.213
100¡C 5.268 5.322 5.376 5.431 5.485 5.540 5.594 5.649 5.703 5.758
110¡C 5.812 5.867 5.921 5.976 6.031 6.085 6.140 6.195 6.249 6.304
120¡C 6.359 6.414 6.468 6.523 6.578 6.633 6.688 6.742 6.797 6.852
130¡C 6.907 6.962 7.017 7.072 7.127 7.182 7.237 7.292 7.347 7.402
140¡C 7.457 7.512 7.567 7.622 7.677 7.732 7.787 7.843 7.898 7.953
150¡C 8.008 8.063 8.118 8.174 8.229 8.284 8.339 8.394 8.450 8.505
160¡C 8.560 8.616 8.671 8.726 8.781 8.837 8.892 8.947 9.003 9.058
170¡C 9.113 9.169 9.224 9.279 9.335 9.390 9.446 9.501 9.556 9.612
180¡C 9.667 9.723 9.778 9.834 9.889 9.944 10.000 10.055 10.111 10.166
190¡C 10.222 10.277 10.333 10.388 10.444 10.499 10.555 10.610 10.666 10.721
200¡C 10.777 10.832 10.888 10.943 10.999 11.054 11.110 11.165 11.221 11.276
210¡C 11.332 11.387 11.443 11.498 11.554 11.609 11.665 11.720 1.776 11.831
220¡C 11.887 11.943 11.998 12.054 12.109 12.165 12.220 12.276 12.331 12.387
230¡C 12.442 12.498 12.553 12.609 12.664 12.720 12.776 12.831 12.887 12.942
240¡C 12.998 13.053 13.109 13.164 13.220 13.275 13.331 13.386 13.442 13.497
250¡C 13.553 13.608 13.664 13.719 13.775 13.830 13.886 13.941 13.997 14.052
Example Voltage for 106 degrees is 5.594 mV
:
100¡C 5.268 5.322 5.376 5.431 5.485 5.540 5.594 5.649 5.703 5.758
100¡C 101¡C 102¡C 103¡C 104¡C 105¡C 106¡C 107¡C 108¡C 109¡C
Resistance / Temperature Table in Ohms
Copper RTD, 10 ohms at 25°C
0 1 2 3 4 5 6 7 8 9
-190 ¡C 1.472 1.430 1.389 1.348 1.306 1.265 1.223 1.182 1.141 1.099
-180 ¡C 1.884 1.843 1.802 1.761 1.719 1.478 1.437 1.596 1.554 1.513
-170 ¡C 2.295 2.254 2.213 2.172 2.131 2.090 2.049 2.008 1.967 1.925
-160 ¡C 2.705 2.664 2.623 2.582 2.541 2.500 2.459 2.418 2.377 2.336
-150 ¡C 3.113 3.072 3.031 2.990 2.950 2.909 2.868 2.827 2.746 2.746
-140 ¡C 3.519 3.478 3.438 3.397 3.356 3.316 3.275 3.235 3.194 3.153
-130 ¡C 3.923 3.883 3.843 3.802 3.762 3.721 3.681 3.640 3.600 3.559
-120 ¡C 4.327 4.286 4.246 4.206 4.165 4.125 4.085 4.045 4.004 3.964
-110 ¡C 4.728 4.688 4.648 4.608 4.568 4.527 4.487 4.447 4.407 4.367
-100 ¡C 5.128 5.088 5.048 5.008 4.968 4.928 4.888 4.848 4.808 4.768
-90 ¡C 5.526 5.487 5.447 5.407 5.347 5.327 5.288 5.248 5.208 5.168
-80 ¡C 5.973 5.884 5.844 5.804 5.765 5.725 5.685 5.646 5.606 5.566
-70 ¡C 6.318 6.279 6.239 6.200 6.160 6.121 6.081 6.042 6.002 5.963
-60 ¡C 6.712 6.673 6.633 6.594 6.555 6.515 6.476 6.437 6.397 6.358
-50 ¡C 7.104 7.065 7.024 6.987 6.947 6.908 6.869 6.830 6.791 6.751
-40 ¡C 7.490 7.452 7.413 7.374 7.336 7.297 7.259 7.220 7.181 7.143
-30 ¡C 7.876 7.838 7.799 7.761 7.722 7.683 7.645 7.806 7.588 7.529
-20 ¡C 8.263 8.224 8.185 8.147 8.108 8.070 8.031 7.992 7.954 7.913
-10 ¡C 8.649 8.610 8.572 8.533 8.494 8.456 8.417 8.378 8.340 8.301
0 ¡C 9.035 8.996 8.958 8.919 8.881 8.842 8.803 8.765 8.726 8.687
0 1 2 3 4 5 6 7 8 9
0 ¡C 9.035 9.074 9.112 9.151 9.189 9.228 9.267 9.305 9.344 9.383
10 ¡C 9.421 9.460 9.498 9.537 9.576 9.614 9.693 9.692 9.730 9.769
20 ¡C 9.807 9.846 9.885 9.923 9.962 10.000 10.039 10.078 10.116 10.155
30 ¡C 10.194 10.232 10.271 10.309 10.348 10.387 10.425 10.464 10.502 10.541
40 ¡C 10.580 10.618 10.657 10.696 10.734 10.773 10.811 10.850 10.889 10.927
50 ¡C 10.966 11.005 11.043 11.082 11.120 11.159 11.198 11.236 11.275 11.313
60 ¡C 11.352 11.391 11.429 11.468 11.507 11.545 11.584 11.622 11.661 11.700
70 ¡C 11.738 11.777 11.816 11.854 11.893 11.931 11.970 12.009 12.047 12.086
80 ¡C 12.124 12.163 12.202 12.240 12.279 12.318 12.356 12.395 12.433 12.472
90 ¡C 12.511 12.549 12.588 12.627 12.665 12.704 12.742 12.781 12.820 12.858
100 ¡C 12.897 12.935 12.974 13.013 13.051 13.090 13.129 13.167 13.206 13.244
110 ¡C 13.283 13.322 13.360 13.399 13.370 13.476 13.515 13.553 13.592 13.431
120 ¡C 13.669 13.708 13.746 13.785 13.824 13.862 13.901 13.940 13.978 14.017
130 ¡C 14.055 14.094 14.133 14.171 14.210 14.248 14.287 14.326 14.364 14.403
140 ¡C 14.442 14.480 14.519 14.557 14.596 14.635 14.673 14.712 14.751 14.789
150 ¡C 14.828 14.867 14.906 14.965 14.984 15.022 15.061 15.100 15.139 15.178
160 ¡C 15.217 15.256 15.295 15.334 15.373 15.412 15.451 15.490 15.529 15.568
170 ¡C 15.607 15.646 15.685 15.724 15.763 15.802 15.840 15.879 15.918 15.957
180 ¡C 15.996 16.035 16.076 16.113 16.152 16.191 16.230 16.269 16.308 16.347
190 ¡C 16.386 16.425 16.464 16.503 16.542 16.581 16.620 16.659 16.698 16.737
200 ¡C 16.776 16.815 16.854 16.893 16.932 16.971 17.010 17.049 17.088 17.127
210 ¡C 17.166 17.205 17.244 17.283 17.321 17.360 17.399 17.430 17.477 17.516
220 ¡C 17.555 17.594 17.633 17.472 17.711 17.750 17.789 17.828 17.867 17.906
230 ¡C 17.945 17.984 18.023 18.062 18.101 18.140 18.179 18.218 18.257 18.296
240 ¡C 18.335 18.374 18.413 18.452 18.491 18.530 18.569 18.608 18.648 18.687
250 ¡C 18.726 18.765 18.804 18.843 18.882 18.921 18.960 18.999 19.038 19.077
Example: Resistance Value for 106 degrees is 13.129 ohms
100 ¡C 12.897 12.935 12.974 13.013 13.051 13.090 13.129 13.167 13.206 13.244
100 ¡C 101 ¡C 102 ¡C 103 ¡C 104 ¡C 105 ¡C 106 ¡C 107 ¡C 108 ¡C 109 ¡C
392 Platinum, 100 Ohms at 0°C
0 1 2 3 4 5 6 7 8 9
-190 ¡C 21.37 20.94 20.50 20.06 19.63 19.19 18.75 18.31 17.87 17.44
-180 ¡C 25.72 25.29 24.85 24.42 23.98 23.55 23.12 22.68 22.25 21.81
-170 ¡C 30.03 29.60 29.17 28.74 28.31 27.88 27.45 27.02 26.58 26.15
-160 ¡C 34.31 33.89 33.46 33.03 32.60 32.18 31.75 31.32 30.89 30.46
-150 ¡C 38.57 38.15 37.72 37.30 36.87 36.45 36.02 35.59 35.17 34.74
-140 ¡C 42.80 42.38 41.96 41.53 41.11 40.69 40.26 39.84 39.42 38.99
-130 ¡C 47.00 46.58 46.16 45.74 45.32 44.90 44.48 44.06 43.64 43.22
-120 ¡C 51.19 50.77 50.35 49.93 49.52 49.10 48.68 48.26 47.84 47.42
-110 ¡C 55.35 54.93 54.51 54.10 53.68 53.27 52.85 52.44 52.02 51.60
-100 ¡C 59.48 59.07 58.66 58.25 57.83 57.42 57.00 56.59 56.17 55.76
-90 ¡C 53.61 63.19 62.78 62.37 61.96 61.55 61.14 60.72 60.31 59.90
-80 ¡C 67.71 67.30 66.89 66.48 66.07 65.66 65.25 64.84 64.43 64.02
-70 ¡C 71.80 71.39 70.98 70.57 70.16 69.75 69.35 68.94 68.53 68.12
-60 ¡C 75.87 75.46 75.05 74.65 74.24 73.83 73.43 73.02 72.61 72.20
-50 ¡C 79.92 79.52 79.11 78.71 78.30 77.90 77.49 77.08 76.68 76.27
-40 ¡C 83.96 83.56 83.16 82.75 82.35 31.94 81.54 81.14 80.73 80.33
-30 ¡C 87.99 87.59 87.19 86.78 86.38 85.98 85.58 85.17 84.77 84.37
-20 ¡C 92.01 91.61 91.20 90.80 90.40 90.00 89.60 89.20 88.80 88.39
-10 ¡C 96.01 95.61 95.21 94.81 94.41 94.01 93.61 93.21 92.81 92.41
0 ¡C 100.00 99.60 99.20 98.80 98.41 98.01 97.61 97.21 96.81 96.41
0 1 2 3 4 5 6 7 8 9
0 ¡C 100.00 100.40 100.80 101.19 101.59 101.99 102.39 102.79 103.18 103.58
10 ¡C 103.98 104.38 104.77 105.17 105.57 105.96 106.36 106.76 107.15 107.55
20 ¡C 107.95 108.34 108.74 109.13 109.53 109.92 110.32 110.72 111.11 111.51
30 ¡C 111.90 112.30 112.69 113.09 113.48 113.87 114.27 114.66 115.06 115.45
40 ¡C 115.84 116.24 116.63 117.03 117.42 117.81 118.20 118.60 118.99 119.38
50 ¡C 119.78 120.17 120.56 120.95 121.35 121.74 122.13 122.52 122.91 123.30
60 ¡C 123.70 124.09 124.48 124.87 125.26 125.65 126.04 126.43 126.82 127.21
70 ¡C 127.60 128.00 128.39 128.78 129.16 129.55 129.94 130.33 130.72 131.11
80 ¡C 131.50 131.89 132.28 132.67 133.06 133.45 133.83 134.22 134.61 135.00
90 ¡C 135.39 135.77 136.16 136.55 136.94 137.32 137.71 138.10 138.49 138.87
100 ¡C 139.26 139.65 140.03 140.42 140.81 141.19 141.58 141.96 142.35 142.74
110 ¡C 143.12 143.51 143.89 144.28 144.66 145.05 145.43 145.82 146.20 146.59
120 ¡C 146.97 147.36 147.74 148.12 148.51 148.89 149.28 149.66 150.04 150.43
130 ¡C 150.81 151.19 151.58 151.96 152.34 152.72 153.11 153.49 153.87 154.25
140 ¡C 154.64 155.02 155.40 155.78 156.16 156.55 156.93 157.31 157.69 158.07
150 ¡C 158.45 158.83 159.21 159.59 159.97 160.35 160.73 161.11 161.49 161.87
160 ¡C 162.25 162.63 163.01 163.39 163.77 164.15 164.53 164.91 165.29 165.67
170 ¡C 166.05 166.42 166.80 167.18 167.56 167.94 168.32 168.69 169.07 169.45
180 ¡C 169.83 170.20 170.58 170.96 171.33 171.71 172.09 172.46 172.84 173.22
190 ¡C 173.59 173.97 174.35 174.72 175.10 175.47 175.85 176.22 176.60 176.97
200 ¡C 177.35 177.73 178.10 178.47 178.85 179.22 179.60 179.97 180.35 180.72
210 ¡C 181.09 181.47 181.84 182.22 182.59 182.96 183.34 183.71 184.08 184.45
220 ¡C 184.83 185.20 185.57 185.95 186.32 186.69 187.06 187.43 187.81 188.18
230 ¡C 188.55 188.92 189.29 189.66 190.03 190.41 190.78 191.15 191.52 191.89
240 ¡C 192.26 192.63 193.00 193.37 193.74 194.11 194.48 194.85 195.22 195.59
250 ¡C 195.96 196.33 196.69 197.06 197.43 197.80 198.17 198.54 198.91 199.27
260 ¡C 199.64 200.01 200.38 200.75 201.11 201.48 201.85 202.22 202.58 202.95
270 ¡C 203.32 203.68 204.05 204.42 204.78 205.15 205.52 205.88 206.25 206.61
280 ¡C 206.98 207.35 207.71 208.08 208.44 208.81 209.17 209.54 209.90 210.27
290 ¡C 210.63 211.00 211.36 211.72 212.09 212.45 212.82 213.18 213.54 213.91
300 ¡C 214.27 214.63 215.00 215.36 215.72 216.09 216.45 216.81 217.17 217.54
310 ¡C 217.90 218.26 218.62 218.98 219.35 219.71 220.07 220.43 220.79 221.15
320 ¡C 221.51 221.87 222.24 222.60 222.96 223.32 223.68 224.04 224.40 224.76
330 ¡C 225.12 225.48 225.84 226.20 226.56 226.92 227.27 227.63 227.99 228.35
340 ¡C 228.71 229.07 229.43 229.79 230.14 230.50 230.86 231.22 231.58 231.93
350 ¡C 232.29 232.65 233.01 233.36 233.72 234.08 234.43 234.79 235.15 235.50
360 ¡C 235.86 236.22 236.57 236.93 237.29 237.64 238.00 238.35 238.71 239.06
370 ¡C 239.42 239.77 240.13 240.48 240.84 241.19 241.55 241.90 242.26 242.61
380 ¡C 242.96 243.32 243.67 244.03 244.38 244.73 245.09 245.44 245.79 246.15
390 ¡C 246.50 246.85 247.20 247.56 247.91 248.26 248.61 248.96 249.32 249.67
400 ¡C 250.02 250.37 250.72 251.07 251.43 251.78 252.13 252.48 252.83 253.18
410 ¡C 253.53 253.88 254.23 254.58 254.93 255.28 255.63 255.98 256.33 256.68
420 ¡C 257.03 257.38 257.73 258.08 258.43 258.78 259.12 259.47 259.82 260.17
430 ¡C 260.52 260.87 261.21 261.56 261.91 262.26 262.60 262.95 263.30 263.65
440 ¡C 263.99 264.34 264.69 265.03 265.38 265.73 266.07 266.42 266.76 267.11
450 ¡C 267.46 267.80 268.15 268.49 268.84 269.18 269.53 269.87 270.22 270.56
460 ¡C 270.91 271.25 271.60 271.94 272.29 272.63 272.97 273.32 273.66 274.01
470 ¡C 274.35 274.69 275.04 275.38 275.72 276.07 276.41 276.75 277.09 277.44
480 ¡C 277.78 278.12 278.46 278.80 279.15 279.49 279.83 280.17 280.51 280.85
490 ¡C 281.20 281.54 281.88 282.22 282.56 282.90 283.24 283.58 283.92 284.26
500 ¡C 284.60 284.94 285.28 285.62 285.96 286.30 286.64 286.98 287.32 287.66
510 ¡C 287.99 288.33 288.67 289.01 289.35 289.69 290.02 290.36 290.70 291.04
520 ¡C 291.38 291.71 292.05 292.39 292.73 293.06 293.40 293.74 294.07 294.41
530 ¡C 294.75 295.08 295.42 295.76 296.09 296.43 296.76 297.10 297.43 297.77
540 ¡C 298.11 298.44 298.78 299.11 299.45 299.78 300.11 300.45 300.78 301.12
550 ¡C 301.45 301.79 302.12 302.45 302.79 303.12 303.45 303.79 304.12 304.45
560 ¡C 304.79 305.12 305.45 305.79 306.12 306.45 306.78 307.11 307.45 307.78
570 ¡C 308.11 308.44 308.77 309.11 309.44 309.77 310.10 310.43 310.76 311.09
580 ¡C 311.42 311.75 312.08 312.41 312.74 313.07 313.40 313.73 314.06 314.39
590 ¡C 314.72 315.05 315.38 315.71 316.04 316.37 316.70 317.03 317.35 317.68
600 ¡C 318.01 318.34 318.67 319.00 319.32 319.65 319.98 320.31 320.63 320.96
610 ¡C 321.29 321.61 321.94 322.27 322.59 322.92 323.25 323.57 323.90 324.23
620 ¡C 324.55 324.88 325.20 325.53 325.86 326.18 326.51 326.83 327.16 327.48
630 ¡C 327.81 328.13 328.45 328.78 329.10 329.43 329.75 330.08 330.40 330.72
640 ¡C 331.05 331.37 331.69 332.02 332.34 332.66 332.99 333.31 333.63 333.95
650 ¡C 334.28 334.60 334.92 335.24 335.57 335.89 336.21 336.53 336.85 337.17
660 ¡C 337.50 337.82 338.14 338.46 338.78 339.10 339.42 339.74 340.06 340.38
670 ¡C 340.70 341.02 341.34 341.66 341.98 342.30 342.62 342.94 343.26 343.58
680 ¡C 343.90 344.22 344.53 344.85 345.17 345.49 345.81 346.13 346.44 346.76
690 ¡C 347.08 347.40 347.71 348.03 348.35 348.67 348.98 349.30 349.62 349.93
700 ¡C 350.25 350.57 350.88 351.20 351.52 351.83 352.15 352.46 352.78 353.10
710 ¡C 353.41 353.73 354.04 354.36 354.67 354.99 355.30 355.62 355.93 356.24
720 ¡C 356.56 356.87 357.19 357.50 357.81 358.13 358.44 358.76 359.07 359.38
730 ¡C 359.70 360.01 360.32 360.63 360.95 361.26 361.57 361.88 362.20 362.51
740 ¡C 362.82 363.13 363.44 363.75 364.07 364.38 364.69 365.00 365.31 365.62
750 ¡C 365.93 366.24 366.55 366.86 367.17 367.48 367.79 368.10 368.41 368.72
760 ¡C 369.03 369.34 369.65 369.96 370.27 370.58 370.89 371.20 371.51 371.81
770 ¡C 372.12 372.43 372.74 373.05 373.36 373.66 373.97 374.28 374.59 374.89
780 ¡C 375.20 375.51 375.82 376.12 376.43 376.74 377.04 377.35 377.65 377.96
790 ¡C 378.27 378.57 378.88 379.18 379.49 379.80 380.10 380.41 380.71 381.02
800 ¡C 381.32 381.63 381.93 382.24 382.54 382.84 383.15 383.45 383.76 384.06
810 ¡C 384.36 384.67 384.97 385.27 385.58 385.88 386.18 386.49 386.79 387.09
820 ¡C 387.40 387.70 388.00 388.30 388.60 388.91 389.21 389.51 389.81 390.11
830 ¡C 390.41 390.72 391.02 391.32 391.62 391.92 392.22 392.52 392.82 393.12
840 ¡C 393.42 393.72 394.02 394.32 394.62 394.92 395.22 395.52 395.82 396.12
850 ¡C 396.42 396.72 397.02 397.31 397.61 397.91 398.21 398.51 398.81 399.10
860 ¡C 399.40 399.70 400.00 400.30 400.59 400.89 401.19 401.48 401.78 402.08
870 ¡C 402.37 402.67 402.97 403.26 403.56 403.86 404.15 404.45 404.74 405.04
385 Platinum, 100 Ohms at 0°C
0 1 2 3 4 5 6 7 8 9
-190 ¡C 22.90 22.37 21.94 21.51 21.08 20.65 20.22 19.79 19.36 18.93
-180 ¡C 27.08 26.65 26.23 25.80 25.37 24.94 24.52 24.09 23.66 23.23
-170 ¡C 31.32 30.90 30.47 30.05 29.63 29.20 28.78 28.35 27.93 27.50
-160 ¡C 35.53 35.11 34.69 34.27 33.85 33.43 33.01 32.59 32.16 31.74
-150 ¡C 39.71 39.30 38.88 38.46 38.04 37.63 37.21 36.79 36.37 35.95
-140 ¡C 43.87 43.45 43.04 42.63 42.21 41.79 41.38 40.96 40.55 40.13
-130 ¡C 48.00 47.59 47.18 46.76 46.35 45.94 45.52 45.11 44.70 44.28
-120 ¡C 52.11 51.70 51.29 50.88 50.47 50.06 49.64 49.23 48.82 48.41
-110 ¡C 56.19 55.78 55.38 54.97 54.56 54.15 53.74 53.33 52.92 52.52
-100 ¡C 60.25 59.85 59.44 59.04 58.63 58.22 57.82 57.41 57.00 56.50
-90 ¡C 64.30 63.90 63.49 63.09 62.68 62.28 61.87 61.47 61.06 60.66
-80 ¡C 68.33 67.92 67.52 67.12 66.72 66.31 65.91 65.51 65.11 64.70
-70 ¡C 72.33 71.93 71.53 71.13 70.73 70.33 69.93 69.53 69.13 68.73
-60 ¡C 76.33 75.93 75.53 75.13 74.73 74.33 73.93 73.53 73.13 72.73
-50 ¡C 80.31 79.91 79.51 79.11 78.72 78.32 77.92 77.52 77.13 76.73
-40 ¡C 84.27 83.88 83.48 83.08 82.69 82.29 81.89 81.50 81.10 80.70
-30 ¡C 88.22 87.83 87.43 87.04 86.64 86.25 85.85 85.46 85.06 84.67
-20 ¡C 92.16 91.77 91.37 90.98 90.59 90.19 89.80 89.40 89.01 88.62
-10 ¡C 96.09 95.69 95.30 94.91 94.52 94.12 93.73 93.34 92.95 92.55
0 ¡C 100.00 99.61 99.22 98.83 98.44 98.04 97.65 97.26 96.87 96.48
0 1 2 3 4 5 6 7 8 9
0 ¡C 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51
10 ¡C 103.90 104.29 104.68 105.07 105.46 105.85 106.24 106.63 107.01 107.40
20 ¡C 107.79 108.18 108.57 108.96 109.34 109.73 110.12 110.51 110.90 111.28
30 ¡C 111.67 112.06 112.44 112.83 113.22 113.61 113.99 114.38 114.77 115.15
40 ¡C 115.54 115.92 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01
50 ¡C 119.39 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.85
60 ¡C 123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.30 126.69
70 ¡C 127.07 127.45 127.84 128.22 128.60 128.98 129.36 129.75 130.13 130.51
80 ¡C 130.89 131.27 131.65 132.04 132.42 132.80 133.18 133.56 133.94 134.32
90 ¡C 134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12
100 ¡C 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91
110 ¡C 142.29 142.66 143.04 143.42 143.80 144.18 144.55 144.93 145.31 145.69
120 ¡C 146.06 146.44 146.82 147.19 147.57 147.95 148.32 148.70 149.07 149.45
130 ¡C 149.83 150.20 150.58 150.95 151.33 151.70 152.08 152.45 152.83 153.20
140 ¡C 153.58 153.95 154.33 154.70 155.08 155.45 155.82 156.20 156.57 156.95
150 ¡C 157.32 157.69 158.07 158.44 158.81 159.19 159.56 159.93 160.30 160.68
160 ¡C 161.05 161.42 161.79 162.17 162.54 162.91 163.28 163.65 164.02 164.40
170 ¡C 164.77 165.14 165.51 165.88 166.25 166.62 166.99 167.36 167.73 168.10
180 ¡C 168.47 168.84 169.21 169.58 169.95 170.32 170.69 171.06 171.43 171.80
190 ¡C 172.17 172.54 172.91 173.28 173.64 174.01 174.38 174.75 175.12 175.48
200 ¡C 175.85 176.22 176.59 176.96 177.32 177.69 178.06 178.42 178.79 179.16
210 ¡C 179.52 179.89 180.26 180.62 180.99 181.36 181.72 182.09 182.45 182.82
220 ¡C 183.19 183.55 183.92 184.28 184.65 185.01 185.38 185.74 186.11 186.47
230 ¡C 186.83 187.20 187.56 187.93 188.29 188.66 189.02 189.38 189.75 190.11
240 ¡C 190.47 190.84 191.20 191.56 191.92 192.29 192.65 193.01 193.37 193.74
250 ¡C 194.10 194.46 194.82 195.18 195.55 195.91 196.27 196.63 196.99 197.35
260 ¡C 197.71 198.07 198.44 198.80 199.16 199.52 199.88 200.24 200.60 200.96
270 ¡C 201.32 201.68 202.04 202.40 202.76 203.11 203.47 203.83 204.19 204.55
280 ¡C 204.91 205.27 205.63 205.98 206.34 206.70 207.06 207.42 207.77 208.13
290 ¡C 208.49 208.85 209.20 209.56 209.92 210.28 210.63 210.99 211.35 211.70
300 ¡C 212.06 212.41 212.77 213.13 213.48 213.84 214.19 214.55 214.90 215.26
310 ¡C 215.62 215.97 216.33 216.68 217.04 217.39 217.74 218.10 218.45 218.81
320 ¡C 219.16 219.52 219.87 220.22 220.58 220.93 221.28 221.64 221.99 222.34
330 ¡C 222.70 223.05 223.40 223.75 224.11 224.46 224.81 225.16 225.52 225.87
340 ¡C 226.22 226.57 226.92 227.27 227.63 227.98 228.33 228.68 229.03 229.38
350 ¡C 229.73 230.08 230.43 230.78 231.13 231.48 231.83 232.18 232.53 232.88
360 ¡C 233.23 233.58 233.93 234.28 234.63 234.98 235.33 235.67 236.02 236.37
370 ¡C 236.72 237.07 237.42 237.76 238.11 238.46 238.81 239.15 239.50 239.85
380 ¡C 240.20 240.54 240.89 241.24 241.58 241.93 242.28 242.62 242.97 243.32
390 ¡C 243.66 244.01 244.35 244.70 245.05 245.39 245.74 246.08 246.43 246.77
400 ¡C 247.12 247.46 247.81 248.15 248.49 248.84 249.18 249.53 249.87 250.22
410 ¡C 250.56 250.90 251.25 251.59 251.93 252.28 252.62 252.96 253.30 253.65
420 ¡C 253.99 254.33 254.68 255.02 255.36 255.70 256.04 256.39 256.73 257.07
430 ¡C 257.41 257.75 258.09 258.43 258.77 259.12 259.46 259.80 260.14 260.48
440 ¡C 260.82 261.16 261.50 261.84 262.18 262.52 262.86 263.20 263.54 263.88
450 ¡C 264.22 264.55 264.89 265.23 265.57 265.91 266.25 266.59 266.92 267.26
460 ¡C 267.60 267.94 268.28 268.61 268.95 269.29 269.63 269.96 270.30 270.64
470 ¡C 270.97 271.31 271.65 271.98 272.32 272.66 272.99 273.33 273.67 274.00
480 ¡C 274.34 274.67 275.01 275.34 275.68 276.01 276.35 276.68 277.02 277.35
490 ¡C 277.69 278.02 278.36 278.69 279.02 279.36 279.69 280.03 280.36 280.69
500 ¡C 281.03 281.36 281.69 282.03 282.36 282.69 283.03 283.36 283.69 284.02
510 ¡C 284.35 284.69 285.02 285.35 285.68 286.01 286.35 286.68 287.01 287.34
520 ¡C 287.67 288.00 288.33 288.66 288.99 289.33 289.66 289.99 290.32 290.65
530 ¡C 290.98 291.31 291.64 291.97 292.30 292.62 292.95 293.28 293.61 293.94
540 ¡C 294.27 294.60 294.93 295.26 295.58 295.91 296.24 296.57 296.90 297.22
550 ¡C 297.55 297.88 298.21 298.53 298.86 299.19 299.52 299.84 300.17 300.50
560 ¡C 300.82 301.15 301.48 301.80 302.13 302.45 302.78 303.11 303.43 303.76
570 ¡C 304.08 304.41 304.73 305.06 305.38 305.71 306.03 306.36 306.68 307.01
580 ¡C 307.33 307.65 307.98 308.30 308.63 308.95 309.27 309.60 309.92 310.24
590 ¡C 310.57 310.89 311.21 311.53 311.86 312.18 312.50 312.82 313.15 313.47
600 ¡C 313.79 314.11 314.43 314.76 315.08 315.40 315.72 316.04 316.36 316.68
610 ¡C 317.00 317.32 317.65 317.97 318.29 318.61 318.93 319.25 319.57 319.89
620 ¡C 320.21 320.53 320.84 321.16 321.48 321.80 322.12 322.44 322.76 323.08
630 ¡C 323.40 323.71 324.03 324.35 324.67 324.99 325.30 325.62 325.94 326.26
640 ¡C 326.57 326.89 327.21 327.53 327.84 328.16 328.48 328.79 329.11 329.43
650 ¡C 329.74 330.06 330.37 330.69 331.01 331.32 331.64 331.95 332.27 332.58
660 ¡C 332.90 333.21 333.53 333.84 334.16 334.47 334.79 335.10 335.41 335.73
670 ¡C 336.04 336.36 336.67 336.98 337.30 337.61 337.92 338.24 338.55 338.86
680 ¡C 339.18 339.49 339.80 340.11 340.43 340.74 341.05 341.36 341.67 341.99
690 ¡C 342.30 342.61 342.92 343.23 343.54 343.85 344.16 344.47 344.79 345.10
700 ¡C 345.41 345.72 346.03 346.34 346.65 346.96 347.27 347.58 347.89 348.20
710 ¡C 348.51 348.81 349.12 349.43 349.74 350.05 350.36 350.67 350.98 351.28
720 ¡C 351.59 351.90 352.21 352.52 352.82 353.13 353.44 353.75 354.05 354.36
730 ¡C 354.67 354.97 355.28 355.59 355.89 356.20 356.51 356.81 357.12 357.43
740 ¡C 357.73 358.04 358.34 358.65 358.95 359.26 359.56 359.87 360.17 360.48
750 ¡C 360.78 361.09 361.39 361.70 362.00 362.31 362.61 362.91 363.22 363.52
760 ¡C 363.83 364.13 364.43 364.74 365.04 365.34 365.64 365.95 366.25 366.55
770 ¡C 366.86 367.16 367.46 367.76 368.06 368.37 368.67 368.97 369.27 369.57
780 ¡C 369.87 370.17 370.48 370.78 371.08 371.38 371.68 371.98 372.28 372.58
790 ¡C 372.88 373.18 373.48 373.78 374.08 374.38 374.68 374.98 375.28 375.58
800 ¡C 375.88 376.17 376.47 376.77 377.07 377.37 377.67 377.97 378.26 378.56
810 ¡C 378.86 379.16 379.45 379.75 380.05 380.35 380.64 380.94 381.24 381.53
820 ¡C 381.83 382.13 382.42 382.72 383.02 383.31 383.61 383.91 384.20 384.50
830 ¡C 384.79 385.09 385.38 385.68 385.97 386.27 386.56 386.86 387.15 387.45
840 ¡C 387.74 388.04 388.33 388.62 388.92 389.21 389.51 389.80 390.09 390.39
850 ¡C 390.68 390.97 391.27 391.56 391.85 392.14 392.44 392.73 393.02 393.31
860 ¡C 393.61 393.90 394.19 394.48 394.77 395.07 395.36 395.65 395.94 396.23
870 ¡C 396.52 396.81 397.10 397.39 397.68 397.97 398.26 398.55 398.84 399.13
RTD Kits and Spare Parts
These kits are to be used to add Bearing RTDs to generators which were initially built without
Bearing RTDs. Parts included in the kit include:
Instruction Sheet Tie Cable

RTD Resistor Assembly Screws
Hardware Kit Nuts
RTD Fitting Washers
Lead Assembly
SR4B RTD Kits
Single Bearing Generator - Platinum RTD (392 - 100 Ohm) 141-4158

Single Bearing Generator - Copper RTD (10 Ohm) 141-4159
Two Bearing Generator - Platinum RTD (392 - 100 Ohm) 141-4160
Two Bearing Generator - Copper RTD (10 Ohm) 141-4161
SR4 RTD Kits
Single Bearing Generator - Platinum RTD (392 - 100 Ohm) 6I-4906

Single Bearing Generator - Copper RTD (10 Ohm) 6I-4907
Two Bearing Generator - Platinum RTD (392 - 100 Ohm) 6I-4908
Two Bearing Generator - Copper RTD (10 Ohm) 6I-4909
SR4B RTD only
Platinum (392 - 100 Ohm) 119-8772

Copper (10 Ohm) 119-8773
SR4 RTD only
Platinum (392 - 100 Ohm) 114-9522

Copper (10 Ohm) 115-1503
Square Current Transformers
With 50” Length Leads
CAT Part Insulation Outer Dim. Inner Diam. Thickness CT Ratio
Number Class (V) (mm) (mm) (mm) (A)
6I-1952 600 153.2 107.95 29.2 600 to 5
7E-1112 600 153.2 107.95 29.2 800 to 5
7E-1113 600 153.2 107.95 29.2 1000 to 5
7E-1114 600 153.2 107.95 29.2 1200 to 5
7E-1115 600 153.2 107.95 29.2 1500 to 5
7E-1116 600 153.2 107.95 29.2 2000 to 5
7E-1117 600 153.2 107.95 29.2 2500 to 5
7E-1118 600 153.2 107.95 29.2 3000 to 5
7E-1119 600 153.2 107.95 29.2 4000 to 5
Round Current Transformers

With 50” Length Leads
CAT Part Insulation Outer Dim. Inner Diam. Thickness CT Ratio
Number Class (V) (mm) (mm) (mm) (A)
5N-5429 600 142.9 88.9 28.6 100 to 5
4W-8102 600 142.9 88.9 28.6 150 to 5
5N-5430 600 142.9 88.9 28.6 200 to 5
5N-5431 600 142.9 88.9 28.6 300 to 5
5N-5432 600 142.9 88.9 28.6 400 to 5
5N-5433 600 142.9 88.9 28.6 600 to 5
5N-5434 600 142.9 88.9 28.6 800 to 5
7W-8839 600 142.9 88.9 28.6 1000 to 5
7W-8838 600 142.9 88.9 28.6 1200 to 5
7W-8837 600 142.9 88.9 28.6 1500 to 5
7W-8836 600 142.9 88.9 28.6 2000 to 5
7W-8835 600 142.9 88.9 28.6 2500 to 5
7W-6598 600 142.9 88.9 28.6 3000 to 5
7W-7805 600 142.9 88.9 28.6 4000 to 5
Square Current Transformers
With Top Mounted Threaded Posts
New CAT CAT Part Insulation Outer Dim. Inner Diam. Thickness CT Ratio Usage
Part No. Number Class (V) (mm) (mm) (mm) (A)
144-9063 117-9721 600 153.2 107.95 29.2 200 to 5
144-9064 117-9722 600 153.2 107.95 29.2 300 to 5
Used on SR4B MV
144-9065 117-9723 600 153.2 107.95 29.2 400 to 5
Generators
119-0976 600 153.2 107.95 29.2 500 to 5
144-9068 128-0795 600 153.2 107.95 29.2 500 to 5
144-9066 119-0977 600 153.2 107.95 29.2 600 to 5
144-9067 119-0978 600 153.2 107.95 29.2 800 to 5
144-9069 137-0259 600 153.2 107.95 29.2 900 to 5
122-6585 600 153.2 107.95 29.2 1000 to 5
122-6586 600 153.2 107.95 29.2 1200 to 5
144-9057 122-6587 600 153.2 107.95 29.2 1500 to 5
Used on SR4B LV
144-9058 122-6588 600 153.2 107.95 29.2 2000 to 5
Generators
144-9059 122-6589 600 153.2 107.95 29.2 2500 to 5
144-9060 122-6590 600 153.2 107.95 29.2 3000 to 5
144-9062 128-0115 600 153.2 107.95 29.2 3500 to 5
144-9061 122-6591 600 153.2 107.95 29.2 4000 to 5
128-0116 600 153.2 107.95 29.2 4500 to 5
144-9056 117-9724 600 153.2 107.95 29.2 5000 to 5
Table of Contents – Generator Maintenance
Page Number
Alignment of Single Bearing Generators 2
Alignment of Two Bearing Generators 6
Recommended Storage Procedures 10
Megger Test Procedure 12
Megger Insulation Example Test Results 14
Insulation Resistance Variation with Temp. Graph 16
Installation Procedure for Type ÒJÓ Thermocouples 17

Caterpillar Inc.
3500 EPG Technical Information Kit 3rd Edition Ð January 1999 Section 5 Ð Page 1
Alignment of 1 Bearing, Close Coupled Generator
Reprint of 3L Ð 0414 - 02
Introduction
The following procedure details the alignment process for generator sets with single
bearing generators with close coupled adapters. Angular, as well as axial alignment
between the driven and driving equipment are equally important. Proper alignment
between the generator and engine is necessary for maximum performance and life from
the generator set. Angular misalignment between the driving and the driven unit can be
detected by checking the parallelism between the close coupled adapter on the
generator and the flywheel housing as shown in figure 1. Axial alignment is
accomplished by shimming between the flexplates and generator hub to place both
engine thrust bearing and the generator bearing in their mid-travel position. When the
generators are installed, the bolts must be tightened in pairs 180° apart. The pairs may
be tightened in any order.
Flywheel Housing Close Couple Adapter
Engine
X Generator
Figure 1: Checking Parallelism
Axial Alignment
A. Find the adapter to hub dimension (abbreviated N.E.P.) from the generator history
sheet. Take this number and multiply by 25.4 mm per inch and record this on Line 1 of
the data sheet.
B. To determine the number of shims required to provide proper axial alignment,

perform the calculations on Lines 3, 4, 5, and 6 of the data sheet.
C. Measure and record the crank endplay after the assembly steps outlined in Section
III. Record this value on Line 7 of the data sheet.
D. With the engine package assembled as in Step III, and with the engine at its far rear
position, measure the deflection of the rotor by prying forward on the generator hub.
The deflection should be monitored as the generator is being pried forward as the
flexplates may deflect the rotor back after the crowbar is removed from the
generator hub. This value should be 0.20mm or above. Record this value on Line 8 of
the data sheet.
Generators Mounted to Engine Support Rails
A. Figure 2 shows the mounting configuration in which the generator is mounted directly
to the engine support rails. Before installing the generator, ensure that the feet and
all the mounting holes are free from all grease, paint, rust, and dirt.
B. Using the crane, bring the generator close enough to the engine to begin threading
the 16 bolts that hold the close coupled adapter to the engine flywheel housing.
Bring the generator tight against the engine and tighten the 16 bolts finger tight.
C. Insert the initial shim pack between the engine support rails and the generator
mounting feet. Free the generator from the crane.
D. Loosen the bolts in the flywheel housing and visually insure that all 16 bolts are
centered within the clearance holes in the close coupled adapter. To compensate
for bolts that are not centered in the hole, shims may be added to or removed from
the generator mounting feet. Once the bolts are centered, torque them to
specification.
E. Loosen the 16 bolts until the washers will move. Check the gap between the close
coupled adapter and the flywheel housing with a feeler gauge (dimension X form
Figure 1) at the 3, 6, 9, and 12 oÕclock positions. For factory installation, this dimension
should be a minimum of 0.001 inch and a maximum of 0.003 inch. Torque the 16 bolts
to specification.
F. Insert the mounting bolts through the generator mounting feet and the engine
support rails. Ensure that the mounting bolts fit easily and do not interfere with the
rails.
G. Torque the mounting bolts to specification.
Close Coupled Adapter

Engine Generator
Engine Support Rail
Figure 2 : Generator Mounted to Engine Support Rails
Alignment Inspection in the Field
A. Once the generator set is in place, loosen the 16 bolts that hold the close coupled
adapter to the flywheel housing. . Check the gap between the close coupled adapter
and the flywheel housing with a feeler gauge (dimension X form Figure 1) at the 3, 6, 9,
and 12 oÕclock positions. For factory installation, this dimension should be a minimum of
0.001 inch and a maximum of 0.005 inch.
B. If the gap meets this criteria on all sides, the bolts may be torqued to specification. No
other alignment checks are necessary.
C. If the gap is not correct, the generator must be repositioned until there is at least a 0.001
inch, but not more than 0.005 inch gap on all sides. This may be done by loosening the
mounting bolts and adding or removing shims from the generator mounting feet.
D. Ensure that all 16 bolts are visually centered within the clearance holes in the close
coupled adapter. Torque all bolts to specification.
For a more details on the alignment procedure, see also SEHS7259-05 (12/97) Ð Special Instructions,
Alignment of Single Bearing Generators
DATA SHEET
1. Adapter to hub face dimension (mm) ____________

(From generator history sheet)
(From step A, Axial alignment
2. Flexplate thickness (mm) 13.6 mm__
3. Shim Thickness needed (mm) ____________ Line 1 minus line 2
4. Correction for thermal growth ____________ Line 3 minus 0.4 mm
5. Number of shims needed ____________ Line 4 divided by 0.8
6. Number of shims used ____________ Line 5 rounded to the nearest

whole number
7. Crank end play (after assembly) ____________ Should be the same endplay
measured before assembly;
found in the engine history
8. Total assembled rotor deflection (mm) ____________
Alignment of Two Bearing Generators
3500 Series Engines
Reprint of 3L Ð 0415
I. Introduction
The following procedure details the alignment process for electric sets with two
bearing generators. Proper alignment between the generator and the engine is
necessary for maximum performance and life from generator sets. Misalignment
between the driving and the driven unit can be detected by measuring face and
bore misalignment as shown below in Figure 1.
FACE GAP
(Top)
FACE GAP DIAMETER GAP
(Top) (Top)
COMPANION FLANGE
DRIVEN FLANGE
DRIVING EQUIPMENT
OUTPUT FLANGE BORE or PARALLEL
FACE OR ANGULAR MISALIGNMENT
MISALIGNMENT
PILOT SURFACES
DIAMETER GAP FACE GAP
FACE GAP (Bottom) (Bottom)
(Bottom)
(a) (b)
Figure 1 : (a) Face misalignment (b) Bore misalignment
II. Initial Installation
A. Before making any measurements for face or bore alignment, make sure all surfaces
to be measured are free from grease, paint, rust, and dirt as these agents will affect
the alignment measurements. When checking alignment, it is best to measure face
and bore alignment simultaneously (see Figure 4).
B. The allowable engine endplay is 0.178 Ð 0.635 mm and the allowable generator
endplay is 3.30 Ð 5.10 mm.
1. To measure crankshaft endplay, use a 1.5m prybar between the crankshaft and
cylinder block (make sure not to pry on the damper). Move the crankshaft all the
way toward the engine front until a definite ÒklunkÓ sound is heard.
2. Install a dial indicator in the face of the engine flywheel and preload it a
minimum of one tun. Zero the gauge.
3. Move the crankshaft all the way toward the rear of the engine and record the
indicator reading. The reading is the crankshaft endplay.
4. Repeat this procedure three (3) times in order to insure consistent measurements.
5. The endplay of the generator rotor is measured in a similar fashion except the dial
indicator is positioned on the coupling flange. Be certain that all prying takes
place against the generator hub.
6. Repeat this procedure three (3) times in order to insure consistent measurements.
C. When initially coupling the generator to the engine, pull the generator rotor to its
maximum forward position and hold in place with a wooden block (see Figure 2).
Also, move the engine crankshaft toward the front of the engine in order to remove
all endplay.
BLOCK OF WOOD
COUPLING
ROTOR SHAFT
Figure 2: Removal of Rotor Shaft Endplay
D. Initially, add five (5) shims to the generator mount pads. More shims may be required
during the alignment procedure. Next, position the generator such that the rotor hub
can be bolted to the flex coupling hub.
E. The generator should be positioned such that dimension X is 8.6 ± 0.8 mm for front
driven generators or x is 10.4 ± 0.8 mm for rear driven generators (see figure 3).
Note: If plates 2 or 3 have no conuterbore, measure dimension X for face E. If plates

2 and 3 have a counterbore, measure dimension X from face F.
F. Preload the dial indicators a minimum of one turn in position A (see Figure 4) and zero
them. Rotate the crankshaft and record the dial readings at position B, C, D, and
then back to A. Before taking indicator readings at each position, make sure all
endplay is removed from the crankshaft and generator shaft.
A A B
STATIONARY
SHAFT
B
ROTATE 360° D
D C
C
(a) (b) (c)
Figure 4: (a) Dial Set-up, (b) Face Alignment, (c) Bore Alignment
III. Requirements for face and bore prealignment.
A. Repeat the measurement in step E of section II.
B. Face prealignment:
1. A TIR between A and C of approximately 0.25 mm is permitted.
2. A TIR between B and D of approximately 0.25 mm is permitted. The readings at B

plus D must equal the reading at C.
C. Bore prealignment:
1. For rear driven units, a TIR between A and C must be 0.48 ± 0.05 mm.
2. For front driven units, a TIR between A and C must be 0.48 ± 0.05 mm.
3. A TIR between B and D of up to 0.25 mm is permitted. Again, the readings at B

TIR = Total Indicator Reading
If the dial indicator readings do not conform to the specified limits, readjust the mount
pads either horizontally or vertically and repeat steps E and F in section II until the
readings are within the acceptable limits. Once the dial indicator readings conform the
values above, the mounting pads can be welded in place.
IV. Requirements for final face and bore alignment
After welding the mount pads to the rails, allow the blocks to cool down to 120° F.
The alignment procedure should be repeated to make any necessary corrections
before torquing down the anchor bolts.
A. Repeat the measurement step in E of section II.
B. Face alignment:
1. A TIR between A and C of up to 0.20 mm is permitted.
2. A TIR between B and D of up to 0.20 mm is permitted. The readings at B and D

must equal the reading at C.
C. Bore alignment:
3. A TIR between B and D of up to 0.20 mm is permitted. Again, the readings at B

TIR = Total Indicator Reading
For more details on the alignment procedure, see also REHS0177 Ð Special Instructions,
Alignment of Two bearing Generators.
Recommended Generator Storage Procedure
Problem:
There is a potential risk for stators to fail in dusty and / or humid environments. Problems can
develop in the generator windings when dust, water, salt, or grease is present, or anytime the
generator windings are below the dewpoint.
Results
Contaminants such as dirt, dust, grease, oil films, salt, and water should not be allowed to
accumulate on the stator windings. These conditions increase the risk of moisture collecting
in the windings. Moisture can provide a conductive pathway between bundles of wire.
When this occurs, current will leak from the higher voltage bundle to the lower voltage
bundle. The current leak produces heat and causes a breakdown and charring of the
winding insulation. If the problem goes undetected, the windings may be severely
damaged.
The following preventive maintenance activities will reduce the risk of stator failure for
generators stored or operated is dusty and / or humid environments.
Storage
After a new generator arrives on site, it should be protected against moisture and dust until it
is installed.
When a generator is in storage, moisture condenses in the windings. To help minimize

condensation, always put the generator in a dry storage area.
When a generator is placed in storage, it is necessary that a Megger Insulation Resistance

Check be performed and the results recorded. The temperature and level of humidity
should also be recorded. This check will provide a baseline for future reference.
Note: It is important that this baseline be established when the unit is dry.
To guard against collective contaminants, the generator should be covered with a plastic
cover or similar type of protective cloth. The protective cover should extend to the ground,
but remain loose around the generator in order to allow it to properly breathe.
Caterpillar recommends maintaining the insulated parts and the air surrounding them at a
temperature of at least 5° C (9° F) higher than the room temperature in which the
equipment is located. This will also help prevent condensation. Normal methods of
providing the heat required are:
1. Space heaters.
2. Warm air blower. Do NOT exceed 206.7 kPa (30 psi).
3. Light bulb (60 Watt minimum) installed inside the motor proximity to the stator
core at the lowest possible location.
It is important that the shaft be rotated 10 revolutions every 60 days throughout the storage
period. This process help to insure that grease continues to cover all the bearing surfaces.
Removal from Storage
Operate space heaters for at least 24 hours prior to removing covers.
Remove all protective covers.
Before startup, visually inspect the generator for any foreign material such as rodents, etc.,
that may have nested in the generator. Use a megohmeter to check insulation resistance
(see Megger Insulation Test Procedure, sect 5, page xx) for insulation breakdown due to
moisture and / or foreign material.
A resistance reading that is 50 % less than the reading recorded when the unit was placed in
storage, or 100 megaohms for a new unit, is an indication that the winding has absorbed too
much moisture. Clean as necessary according to the Special Instructions, SEHS9124,
ÒCleaning and Drying of Electric Set GeneratorsÓ.
Visual Equipment Checks
The Generator should be checked periodically for any accumulation of dust, water, salt,
grease, or oil films. Clean as necessary according to the Special Instructions, SEHS9124,
ÒCleaning and Drying of Electric Set GeneratorsÓ.
Note: windings must be kept clean and dry. Any accumulation of dirt will trap moisture. This
moisture will reduce the insulationÕs dielectric strength, which helps cause the insulation to
fail.
Recommended Megger Insulation Test Procedure
for Main Stator
Taken from SEHS9124-01 Ð ÒCleaning and Drying of Electrical Set Generators
Caterpillar recommends the 4C4213 (or an equivalent) Insulation Tester for checking
insulation resistance on Caterpillar Generator Sets. Refer to NEHS0528, ÒOperating Manual
for 4C4213 Insulation TesterÓ for operating instructions. Consult SEHS9124-01 Ð ÒCleaning and
Drying of Electrical Set GeneratorsÓ for further maintenance instructions.
This procedure is recommended to be done every year. Comparing the results will provide a
simple guideline on the general condition of the stator. To increase the sensitivity of this
method, megger each phase or winding separately.
The Megger readings will vary with temperature and time. The temperature correction
factor can be determined from the table included in this section. The time variation is part of
the testing procedure.
Before starting the Megger test, make a visual check of the general appearance:
• Check for debris, animal nests, etc.
• Common contaminants: Oil, grease, dirt, salt, sand, moisture.
• Charring of insulation (Black discoloration of the insulation surface). Not to be
confused with dirty windings.
• Material movement: tie-cords, rotor bracing, etc.
1. S A F E T Y ! Take the generator out of service. Make sure the unit is disconnected and de-
energized before starting the test.
2. Visually inspect for moisture. If moisture exists, do not perform the megger test. Dry the
unit first. Refer to Special Instruction, SEHS9124, "Cleaning and Drying of Electric Set
Generators" for drying procedure.
3. Inspect installation to determine what equipment will be tested by the 4C4213 Megger.
4. Discharge the capacitance of the windings.
5. Disconnect T0 from ground.
6. Disconnect regulator sensing lead wires 20, 22, and 24.
7. Disconnect EMCP (I or II) transformer leads T1, T2, and T3.
8. Disconnect any sensing leads from switchgear or other devices.
9. Connect Megger tester RED (+) lead to an unpainted area on the generator frame.
10. Connect Megger tester BLACK (-) lead to T0.
11. Set voltage to 500 Volts for generators that are 600 Volts or less. Set voltage to 1000 Volts
for generators that are more than 600 Volts.
12. Use the 30 Ð 60 time resistance method.
a. Apply voltage.
b. Observe the readings at 30 seconds and again at 60 seconds.
c. Record the 60 second. This reading must be corrected for temperature.
d. Record the temperature.
e. Record the humidity.
f. Remove the voltage.
13. Evaluate the readings. The actual value of the resistance may vary greatly form one
generator to another. For this reason, the insulation condition must be evaluated based
on how the 60 second resistance readings compare to the readings taken on previous
dates (under similar conditions). A 60 second resistance reading that is 50% less than the
previous reading indicated that the insulation may have absorbed too much moisture.
The resistance after 60 seconds will be greater than or equal to the resistance after 30
seconds. If the insulation resistance after 60 seconds is not higher than the resistance
after 30 seconds, the windings should be cleaned and thoroughly dried. Refer to the
drying procedure in Special Instruction, SEHS9124, "Cleaning and Drying of Electric Set
Generators".
14. Discharge leads and windings before disconnecting Megger leads by switching Megger
to ÒOFFÓ.
Note: results from the insulation resistance checks give a good indication of when cleaning
and / or repairing is becoming more critical.
Generally insulation resistance will vary greatly with temperature. Tests should be made at
the same temperature and humidity (as near as possible) each time.
For additional information on insulation testing, refer to LEBQ4823 Ð ÒThe Complete Guide to
Electrical Insulation TestingÓ.
Good Insulation Characteristics
Bad (Wet, Dirty) Insulation Characteristics
Suggested Installation Procedure
for
Coil-Embedded Type "J" Thermocouples
Type J thermocouples are typically installed in Caterpillar SR4 and SR4B

generators in the stator windings on the drive end of the generator. In
factory installation, the thermocouples are embedded among the strands
of copper magnet wire.
If it is desired to duplicate the factory-embedded feature of the

thermocouple installation by rewinding the stator assembly of the
generator, the thermocouples are to be embedded in the drive end coil
head.
1. Install six thermocouples per generator among the stator coils on

the flywheel (exhaust air) end of the generator. Install them in the 12
o'clock area, 2 per phase. To differentiate phases, install a pair of
thermocouples on two adjacent coils at 12 o'clock. Then, from this first
pair, count 6 coils toward the 11 o'clock position and count 6 coils
toward the 1 o'clock position and install a pair of thermocouples in
each location.
2. Run the thermocouple leads back through the stator slots to the
lead hole opening in the shell. Bring out the thermocouple wires
through this lead hole and fasten them to a terminal block mounted
near the lead hole.
Table of Contents – Special Quotations
Page Number
Quotation Worksheet Explanation 2
Quotation Worksheets 3
Caterpillar Generator Set Testing 6
Custom Quote Tests 12
Example Test Report 20

particular purpose.
Caterpillar Inc.
Generator Quotation Worksheet
Special generator configurations are available to meet your customerÕs requests. Quote
numbers and prices for frequently requested variations are published in the TIR section of
the Price List. For special requirements not covered in the Price List or TIR, please fill out
the following quotation worksheet and send it to the appropriate application group in
Lafayette or Mossville to obtain a quote.
The following three pages are Generator Data Sheets that should be used when
requesting a custom quote. Please fill out the forms as completely as possible. The more
information that can be provided will aid the people in A & I to meet your customers
needs as closely as possible. Your name and phone need to be at the top so that the
people in Lafayette or Mossville can contact you with any questions, if necessary.
More of these forms can be obtained by ordering the following Caterpillar Form
Numbers:
88-000272-00 3500 Generator Data Sheet
88-000273-00 3600 Generator Data Sheet
88-000274-00 Addendum to Generator Data Sheet for Marine Certification (to
be turned with one of the previous two forms.)
Caterpillar Genset Testing
All gensets produced at the LEC receive CaterpillarÕs standard genset test before leaving
the factory. This is a performance test conducted in accordance with CaterpillarÕs
specification 3L-0284. The test, performed at 1.0 power factor, includes a full load warm-
up, stability testing and recording of genset performance characteristics at no-load and
at full-load, and transient load testing, with transient voltage and frequency recorded on
a strip-chart recorder as the load is switched. The genset performance characteristics
which are recorded include the following: fuel, water, oil, and boost pressures; jacket
water, and ambient air temperatures; fuel consumption; and electrical current, voltage,
frequency, power, and power factor. The LEC can also perform testing to Caterpillar
specification 3L-0438, which is identical to 3L-0284 is performed at 1.0 power factor and
3L-0438 is performed at 0.8.
The standard testing which is applied to high-voltage sets, however, is more extensive
than that which is applied to low- and medium-voltage units. In addition to the standard
genset test at 0.8 power factor (Caterpillar specification 3L-0438), the genset is given a 1
hour full rated load test and a transient response test. This includes load changes from no
load to full load and back to no load in steps of 25%, 50%, 75%, and 100%, all of which
are performed at 0.8 power factor.
In addition to our standard production genset tests, the LEC also can provide custom
testing of gensets according to customer request. Using the same test cells and
measuring devices that are used for our standard tests, the LEC can perform extended
load tests, transient load tests, simulated emergency shutdowns, and a wide array of
other tests as specified by IEEE, NEMA, ISO, and other technical standard organizations.
Any desired testing which is outside the scope of our standard tests can be ordered from
Caterpillar by means of a special quote. A set of specifications for testing is forwarded to
CatÕs Test Engineer, and the engineer reviews the specifications to determine the
feasibility and practicality of the desired testing. Several issues are taken into account by
the engineer in determining what testing can be quoted:
a) The performance capability of the genset.

b) The load capacity, cooling requirements, voltage capacity, and control and
measuring instrumentation of the test cells.
c) Cost, time requirements, test cell availability, etc.
Based upon this determination the engineer prepares a quote that details the scope of
the testing which Caterpillar will perform. This quote is then forwarded to the dealer.
Witness tests require a special quote that must be ordered through the proper channels.
When a test is to be witnessed by the customer, the test must be scheduled in advance
to coordinate the customerÕs travel schedule and the facility production schedule.
CaterpillarÕs 3500 family of generator sets are thoroughly tested in the specialized
facilities at our Lafayette, Indiana USA plant. This comprehensive testing assures
compliance to the ISO 8528-5 specification, which is so crucial in industry today.
Background:
Caterpillar 3500 series generator sets are tested at the same facility where they are built.
This gives many benefits including the excellent quality of the Lafayette plant and
responsive feedback to the assembly line regarding test results.
The Production Genset Test Cell represents the latest in test cell technology and flexibility.
The system has been designed to test 50 and 60 hertz 3500 gensets at unity and 0.8
power factors, with voltages ranging from 200 to 14,400 Volts AC.
The electrical power, which is generated during the test, is dissipated through resistive
and reactive load banks that are located outside of the test cell. Load banks were
selected as opposed to returning the power back into the factory due to the need to
accurately measure transient response characteristics.
The packages, some approaching 20 tons, are loaded into the test cell with an over-
head crane or on a Òlow boyÓ cart. Air, fuel, water, and instrumentation are then
connected to the unit prior to starting it. An industrial computer monitors and controls
the test based on the operatorÕs instructions. The computer also monitors alarms, and
activates the necessary shutdowns to prevent injury to the operator or damage to the
genset or test cell.
Two modes of operation are provided within the computer. The first mode allows the
operator to control the test by requesting the appropriate load for the test point and
manually acquiring data reports. This mode is useful during start-up and initial
adjustments on the package. The second mode of operation allows the operator to
preprogram a series of load points, the amount of time for each point, and the time
period for data logging. In this mode the system is capable of running an automatic test
sequence.
Scope of Test Procedure:
This specification covers the test procedure for production generator sets powered with
reciprocating internal combustion engines, and is representative of the testing
performed on the stand alone 3500 family of generator set configurations. The transient
response loads defined in this specification for generator sets with turbo-charged engines
fulfill ISO 8528/5. The purpose of our standard production generator set testing is to:
1. Check the mechanical and electrical integrity of the assembled generator sets.
2. Check the steady state and transient response characteristics of generator sets
for conformance to specification, assuring the production of quality electricity.
Test Cell Instrumentation:
Instrumentation selection is very critical to give the best accuracy and dependability for
the specific application. Below is the listing of parameters that are monitored, but not
necessarily recorded in the Test Cell. These measurements are fed through an I/O system
into a microcomputer where the appropriate display, analysis, and data storage
functions are performed. The test operator using this computer can control most features
in the Test Cell. Examples of some parameters that can be controlled this way are
ventilation dampers, coolant supply, fuel supply, compressed air supply, load bank and
transformer tap switching.
Maximum Permitted Error of Instrumentation
PARAMETER MEASURED ACCURACY (+/-)
ENGINE SPEED 5 RPM

CURRENT (% OF READING) 1.0%
VOLTAGE (% OF READING) 1.0%
REAL POWER (% OF READING) 1.0%
IMAGINARY POWER (% OF READING) 1.0%
POWER FACTOR (% OF READING 1.0%
FREQUENCY (% OF READING) 1.0%
FUEL RATE - DIESEL (% OF READING)* 0.5%
FUEL RATE - NG (% OF READING)* 1.0%
LOW HEAT VALUE - NG (% OF READING) 1.0%
BOOST 1 kPa
RESPONSE CHECK TIME .25 s
WATER TEMPERATURES 1° C
COMPRESSOR OUT PRESS. (NG) 1 kPa
INLET MANIFOLD PRESS - ABS (NG) I kPa ABS
INLET FUEL TEMPERATURE (NG) 1° C
INLET FUEL PRESSURE - ABS (NG) 1%
OIL PRESSURE 10 kPa
OIL TEMP TO BEARINGS 1° C
SUPPLY FUEL PRESSURE 10 kPa
INLET FUEL PRESSURE 5 kPa
INLET FUEL TEMPERATURE 1° C
BAROMETRIC PRESSURE 0.1 kPa
JACKET WATER PRESSURE 1 kPa
FUEL DENSITY 0.2° API
* % OF ENGINE FULL LOAD READING
NG = NATURAL GAS
General Instructions:
Generator set engines shall be tested in accordance with standard Caterpillar testing
procedures at the required full load rating prior to being assembled into a generator set
package. All generators shall have received their final production tests at the supplierÕs
plant prior to their assembly into generator sets.
Definitions:
The following are definitions of generator set characteristics per ISO 8528, ISO 3046, IEC
34-1, SAE J1349 and NEMA MG-1.
A. Frequency Ð The observed alternating current frequency at any given operating
point.
B. Full Load Power Ð Calculated from FL current, FL Voltage, and power factor.
C. Generator Set High Idle Speed Ð The steady state speed with no load on the
generator set, and with the generator set speed control adjusted to operated at
full load power and speed.
D. Generator Set Maximum No Load Speed Ð The steady state speed with no load
on the generator set and with the generator set speed control at the maximum
speed position.
E. Overshoot Ð The maximum speed obtained when all load is instantaneously

removed from a generator set while running at full load power and speed,
expressed as a percent of High Idle or Full Load Speed as defined in Article V.
F. Rated Frequency Ð The nominal advertised frequency.
G. Rated Power Ð The nominal power without fan.
H. Rated Voltage Ð The nominal advertised voltage.
I. Recovery Time Ð The time required for frequency or voltage cycling to return to
specified limits after a load change.
J. Safety Check Ð The procedure where the overspeed safety is demonstrated by

lowering the engine speed to 75 % of the overspeed setpoint value and
activating the 75% verification function located on the engine speed switch.
K. Speed Ð The rotational speed of the generator set in RPM at any given operating
point.
L. Steady State Stability Ð The steady state frequency or voltage stability is the
variation in frequency (+/- Hz) or voltage (+/-% rated), from the average
frequency or voltage during 20 seconds following the steady state recovery time
after a load change. The steady state stability limit shown in ÒGenerator Set
Performance Specification Tolerances for TestÓ applies to any load, including Ôno
loadÕ.
M. Test Current Ð The average of the three observed line currents at any given
operating point.
N. Test Voltage Ð The average of the three observed line to line voltages at any
given operating point.
O. Voltage Droop Ð The change in voltage from generator set high idle to full load
power and speed, expressed as a percentage of rated voltage.
General Test Procedure:
The generator set speed control shall not be adjusted at any time except where
specified in the test procedure. Unity power factor shall be maintained for all loaded
phases of this procedure. The power specified for all test points in this procedure is
observed power.
A. Run at the specified generator set low idle speed and perform a visual inspection for
the following.
1. Check for leaks.
2. Check for loose fasteners
3. Exercise the Emergency Stop, fuel On/Off control, and Overspeed protective
device.
B. Run at the specified generator set high idle speed and make the first adjustments.
Increase the generator set speed with the generator set speed control until it is within
the specified generator set high idle speed tolerance.
Make the preliminary adjustments to the power generator voltage regulator until it is
within the specified generator set rated voltage.
C. Warm up the generator set at various partial loads, full load power, and rated speed.
The generator set is to be considered warmed up and stabilized after 10 minutes at

full load power and speed or after achieving the following maximum variation per 2
minute period while running at full load power and speed:
D. Make the final generator set high idle speed adjustment and the final voltage level
adjustment.
1. Maintain full load power and speed from the proceeding warm up Article. Any
required speed adjustments are to be made with the generator set speed control
lever, speed adjusting motor, or electrical control setting screw.
2. While at full load power and speed, adjust the test voltage to rated voltage with
the voltage adjust potentiometer.
3. Without adjusting any generator set speed controls, remove all electrical loads.
The generator set is now operating at the generator set high idle speed.
Record the generator set high idle speed. No further adjustment shall be made
to the generator set high idle speed.
4. While at high idle, adjust the test voltage to rated voltage with the voltage level
potentiometer.
5. Repeat steps 2 and 4 as necessary. No further voltage adjustments should be
made when load may be changed from no load to full load or from full load to
no load and the test voltage remains within specification.
E. Record the following data at full load:
Power
All 3 line-to-line voltages
Test voltage Ð the average of all 3 line-to-line voltages
All 3-line currents
Test current Ð the average of all 3-line currents
Power factor
Speed
Frequency
Record the following data at no load:
All 3 line-to-line voltages

Test voltage Ð the average of all 3 line-to-line voltages
Speed
F. Transient Response Test
Run the specified load change sequence and record generator set transient
response.
Do not change any generator set settings. The power at each load specified in
Article VI.E. is to be determined after the load has been applied for 30 seconds.
The transient frequency and voltage will be recorded on a strip chart at a chart
speed of approximately 30 centimeters per minute. All load changes will be
performed at 30 second intervals in the following load sequence:
1. ISO Test Loads to 100%

2. 100% - 0%
3. 0% - 50%
4. 50% - 100%
5. 100% - 50%
6. 50% - 0%
T e s t R e p o r t s:
Test data from the standard production test can be provided, but must be ordered when
the initial order is placed. (A sample report is included as the last page of this
document.)
The standard production test can be performed at 0.8 power factor, but must be
ordered when the initial order is placed. The test is identical to the standard production
test described in this document with the exception that all loads are set at 0.8 power
factor.
Consult the Special Additions section of the Price List to obtain the necessary order code.
Custom Quote Tests
The following is a list of general conditions and custom genset tests that are available
from the Caterpillar Large Engine Center.
General
All testing in this quote is to be performed on the engine-generator package or the
generator alone. The package will be tested with all installed items. Shipped loose items
will NOT be installed for the package testing without a separate quote to cover the cost
of such activities. CaterpillarÕs factory genset tests are not intended to be complete
system tests. This quote does NOT include switchgear testing.
Due to test cell air handling capabilities, it will be necessary to conduct package tests
without the package radiator installed. This is due to a test cell wall located a short
distance from the front of the generator. The wall could cause hot radiator air to be
recirculated as inlet air, causing overheating and shutdown.
Prior to the testing described herein, the engine and the generator and the genset
package shall be pretested per their respective manufacturerÕs normal production test
standards or Military Standard 705C where stated. NO OTHER TEST STANDARDS SHALL BE
APPLIED TO THE TESTING DESCRIED IN THIS QUOTE.
Individual component testing of radiator, radiator fan, pumps, air filters, or others will NOT
be performed.
Exception is taken to any tests which are to be performed using any fuel other than No. 2
Diesel fuel OR Natural Gas.
Exception is taken to any ÒFactory InspectionÓ performed at Caterpillar that is not in

CaterpillarÕs scope of supply.
During the tests, while the genset is running, Customers will NOT be allowed to enter the
test cell.
This test must be ordered at least twenty (20) days prior to engine start-on-line date.
Purchase of this quote implies acceptance of the test procedure described herein.
Requests to modify the procedure after purchase are strongly discouraged and may
require requoting.
Generator Test
To be performed by the generator manufacturer at the generator manufacturerÕs
facility.
THESE TESTS WILL NOT BE WITNESSED
Test De scription
MIL STD 705C.301.1 Insulation Resistance of Main Stator and Exciter Winding
MIL STD 705C.302.1 Dielectric (Hi-pot) Test on Main Stator and Exciter Winding
MIL STD 705C.401.1 Winding Resistance of Main Stator
MIL STD 705C.410.1 Open Circuit Saturation Curves
MIL STD 705C.411.1 Short Circuit Saturation Curves
MIL STD 705C.412.1 Zero Power Factor Saturation Curves (<900kW)
MIL STD 705C.413.1 Rated Load Current Saturation Curves
MIL STD 705C.414.1 Rotating Exciter Saturation Curves
MIL STD 705C.415.0 Summation of Losses
MIL STD 705C.420.1 Short Circuit Ratio
MIL STD 705C.421.1 Direct Axis Synchronous Reactance Calculation (Xd)
MIL STD 705C.422.1 Negative Sequence Reactance & Impedance (X2)
MIL STD 705C.423.1 Zero Sequence Reactance (X0)
MIL STD 705C.425.1 Direct Axis Transient Reactance (XÕd)
MIL STD 705C.426.1 Direct Axis Subtransient Reactance Calculation (XÕÕd)
MIL STD 705C.427.1 Direct Axis Transient Short-circuit Time Constant
MIL STD 705C.428.1 Direct Axis Subtransient Short-circuit Time Constant
MIL STD 705C.430.1 Direct Axis Transient Open-circuit Time Constant
MIL STD 705C.432.1 short-circuit Time Constant of Armature Winding
MIL STD 705C.505.3 Overspeed
MIL STD 705C.507.1 Phase Sequence Test
MIL STD 705C.508.1 Phase Voltage Balance (Line to Line & Line to Neutral)
MIL STD 705C.509.1 Circulating Currents
MIL STD 705C.510.0 Rheostat Range (Manual Voltage Adjust)
MIL STD 705C.511.1 Regulator Voltage Adjust
MIL STD 705C.601.1 Voltage Waveform Oscillographic
MIL STD 705C.601.4 Voltage Waveform Harmonic
MIL STD 705C.602.1 Voltage Modulation
MIL STD 705C.611.1 Inherent Voltage Droop
MIL STD 705C.615.1 Inherent Voltage Regulation
MIL STD 705C.620.1 Voltage Unbalance with an Unbalanced Load (Line to
Neutral)
MIL STD 705C.620.2 Voltage Unbalance with an Unbalanced Load (Line to
Line)
MIL STD 705C.620.4 Voltage Unbalance with an Unbalanced Load (3 wire
001AWG)
MIL STD 705C.621.1 Unbalance Load Heating (per load unit)
MIL STD 705C.625.1 Short Circuit Test (Mechanical Strength)
MIL STD 705C.652.1 Shaft Current
MIL STD 705C.680.1 Temperature Rise (per load point)
Torsional Vibration Test

Torsional Graphic Tests will NOT be performed. Instead, TVA reports and calculations can
be ordered from the Special Addition Section of the EPG Price List. (Check TVATRS1 or
TVATRS2)
Package Pre-Test
After assembly into a package genset, the genset will be tested for two (2) hours at 100%
load, 0.8 power factor prior to the witness test.
The following data will be recorded at 30-minute intervals:
Frequency and speed

Fuel rate and specific fuel consumption
Real and Reactive power
Power factor
Cell air temperature
Jacket water inlet and outlet
Oil pressure
Fuel pressure
Phase voltages and currents
This test will NOT be witnessed.
NOTE: This test will NOT be witnessed without a separate quote to cover the costs
associated with witnessing this test.
Pre/Post Test Inspection

A cursory visual inspection of the generator set will be allowed prior to and following the
witness test.
NOTE: A full visual and dimensional inspection to verify conformity of the package to
approved and certified drawings will NOT be covered by this quote. A separate
quote would be required.
Generator Temperature Rise by Resistance Test

The temperature ÒRise by ResistanceÓ test will be performed to verity the temperature rise
of the generator. Before the loadbank cables are connected to the genset, the
temperature of the windings will be measured and resistance readings will be recorded
once again. The resistance data will be used to calculate the ÒRise by ResistanceÓ for
the generator windings per IEEE-115 Standards.
3 L - 0 2 9 3 (The full description of this test can be viewed through RAYSTAR.)

Testing with Caterpillar generator-mounted switchgear or when no switchgear ordered.
This test will be performed in accordance with 3L-0293. EkW, current and voltage
reading, engine speed, fuel and specific fuel consumption are determined at 3 load
points at rated speed. (Full load, three quarters load and half load.)
Standard Production Test at 1.0 pf

The 3L-0284 (The full description of this test can be viewed through RASTAR.) genset
package test will report the following results at full load: engine RPM, frequency, average
voltage, line-to-line current for all three phases, and observed powerÑall at 1.0 power
factor. Engine RPM, average voltage and line-to-line voltages for all three phases are
reported and no-load. This will be followed by a transient response test where the
following load steps (at 1.0 pf) will be applied:
ISO load steps Ð 100% - 0% Ð 50% - 100% - 50% - 0% Ð 100% - 0%
NOTES: 1) Only the ISO load steps to 100% are analyzed for recovery time, all remaining
load steps are for reference only and transient conformance is not required for
gensets with turbocharged engines.
2) This quote does not guarantee nor imply the ability of the unit to perform the
test(s) contained within this quote. This quote does not include any performance
guarantees.
3) Due to test cell air handling capabilities it will be necessary to perform this test
without the package radiator. This is due to a test cell wall located a short
distance from the front of the package genset, which could cause air
recirculation and overheating. Instead, a test cell heat exchanger will be used.
Standard Production Test at 0.8 pf
The 3L-0438 (The full description of this test can be viewed through RAYSTAR.) genset
package test will report the following results at full load: engine RPM, frequency, average
voltage, line-to-line current for all three phases, and observed powerÑall at 0.8 power
factor. Engine RPM, average voltage and line-to-line voltages for all three phases are
reported and no-load. This will be followed by a transient response test where the
following load steps (at 0.8 pf) will be applied:
ISO load steps Ð 100% - 0% Ð 50% - 100% - 50% - 0% Ð 100% - 0%
NOTES: 1) Only the ISO load steps to 100% are analyzed for recovery time, all remaining
load steps are for reference only and transient conformance is not required for
gensets with turbocharged engines.
2) This quote does not guarantee nor imply the ability of the unit to perform the
test(s) contained within this quote. This quote does not include any performance
guarantees.
3) Due to test cell air handling capabilities it will be necessary to perform this test
Manual Voltage Control

Start the genset and allow unit to obtain rated speed. Manually adjust the voltage
regulator to the minimum voltage output and record this value. Adjust the voltage
regulator to the maximum voltage output and record this value. Adjust the voltage
regulator back to rated voltage and continue with the test.
NOTE: This test will NOT be performed if genset is equipped with Digital Voltage
Regulator.
Start/Stop Test
Performed at Caterpillar on the entire genset package. The genset will be started, and
the time from initiation of the start signal to attainment of rated frequency and voltage
at no lead for five (5) minutes. The genset will be stopped by means of the emergency
stop button, and time from initiation of the stop signal to genset stoppage will be
recorded.
Start and Load Test

Performed at Caterpillar on the entire genset package. On a warm engine, the genset
will be started, and the time from initiation of the start signal to when frequency and
voltage first reach nominal values (NOT steady state) will be recorded. At the instant
when frequency and voltage reach nominal values, Rated Load (0.8 pf) will be applied
to the genset and the time from application of the load to attainment of rated
frequency and voltage will be recorded. This test will be performed TWICE.
Load Test
Load test to be performed on the complete engine-generator package:
30 minutes at 25% rated load @ 0.8 pf

30 minutes at 50% rated load @ 0.8 pf
1 hour at 75% rated load @ 0.8 pf
2 hours at 100% rated load @ 0.8 pf
1 hour at 110% rated load @ 0.8 pf
The following data will be recorded at 15-minute intervals:
Fuel rate and specific fuel consumption

Frequency and speed
Real and reactive power
Power factor
Cell air temperature
Jacket water inlet and outlet temperatures
Jacket water pump pressure
Oil pressure and temperature
Fuel pressure
Phase voltages and currents
NOTES: 1) Our intent is to provide a continuous load test without stoppage or interruption.
However, if stoppage does occur for any reason other than engine or generator
failure (for example, test cell lead bank failure), then the test will be restarted from
the point of stoppage (after sufficient warm-up) and NOT from the beginning.
CaterpillarÕs Test Engineer will have sole responsibility for determining the cause of
any stoppage.
2) Due to test cell air handing capabilities it will be necessary to perform this test
Vibration Test
This test WILL be performed at Caterpillar on the entire genset package in accordance
with Caterpillar Specifications. While the genset runs under the following conditions:
Rated speed, no-load

Rated speed, full-load
110% of full rated speed, no-load
Vibration readings will be taken ONCE at each of the following locations:
Engine front horizontal

Engine front vertical
Engine rear horizontal
Engine rear vertical
Engine rear roll
Generator rear horizontal
Generator rear vertical
Generator rear axial
Generator front horizontal
Generator front vertical
Noise test
While the genset runs at full load, noise levels (in dBa) will be measured at a height of
one meter and distance of one meter from the front and rear of the package, and from
the left and right sides of the engine and the generator (6 points).
NOTES: 1) Noise level readings will NOT be taken above or below the unit.
2) CaterpillarÕs test cells are NOT echoic or anechoic chambers. Noise levels
measured in the test cells do not necessarily reflect noise levels which will be
encountered at final installation.
THD
Voltage waveform Harmonic Distortion measurements will be taken ONCE while the
genset runs at the following loads:
Full load 0.8 pf
NOTES: 1) A BMI355 meter will be used to take the readings.

2) The BMI355 is limited to the 31st harmonic.
Voltage and Frequency Droop Test

Performed at Caterpillar on the entire genset package.
After each load change, frequency and average line to line voltage (not line to neutral)
will be recorded. With the generator operating at no-load, voltage and frequency WILL
be adjusted to rated values and recorded. The following step loads (at 1.0 pf) will be
applied to the genset:
0% Ð 50% - 0% - 50% - 0% - 50% - 0% - 50% - 100%
With the generator operating at full-load, voltage and frequency will be adjusted to
rated values and recorded. The following step loads (at 1.0 pf) will be applied to the
genset:
100% - 0% - 50% Ð 100% Ð 90% Ð 80% Ð 70% Ð 60% Ð 50% Ð 40% Ð 30% Ð 20% Ð 10% Ð0%
Plots of voltage and frequency vs. % rated load will be made, and voltage and
frequency droops will be calculated.
NOTE: Voltage and frequency transient responses WILL be recorded on a digital strip
chart recorder for one phase only. This quote does NOT guarantee nor imply the
ability of the unit to perform the test(s) contained within this quote. This quote
does NOT include any performance guarantees.
Frequency & Voltage Regulation, Stability, Transient Response Test

Performed at Caterpillar on the entire genset package. The following load steps will be
applied to the genset at 0.8 power factor and maintained long enough to record
voltage, current, frequency, and load:
0% Ð 25% Ð 50% Ð 75% Ð 100% Ð 75% Ð 50% Ð 25% Ð 0%

0% Ð 50% Ð 100% Ð 50% Ð 0%
0% Ð 75% Ð 0%
0% Ð 100% Ð 0%
0% Ð 100% Ð 90% Ð 80% Ð 70% Ð 60% Ð 50% Ð 40% Ð 30% Ð 20% Ð 10% Ð 0%
ability on the unit to perform the test(s) contained within this quote. This quote
does NOT include and performance guarantees.
MIL705C.608.1
Performed at Caterpillar on the entire genset package. The following load steps will be
applied to the genset at 0.8 power factor and maintained long enough to record
average voltage, average current, power, power-factor, frequency, and speed):
0% Ð 100% Ð 0% Ð 100% Ð 0% Ð 100% Ð 0%

0% Ð 75% Ð 0% Ð 75% Ð 0% Ð 75% Ð 0%
0% Ð 50% Ð 0% Ð 50% Ð 0% Ð 50% Ð 0%
0% Ð 25% Ð 0% Ð 25% Ð 0% Ð 25% Ð 0%
0% Ð 100% Ð 0% Ð 100% Ð 0% Ð 100% Ð 0%
The results will be recorded as follows:
1. Voltage and frequency transient responses WILL be recorded on a digital strip

chart recorder.
2. Average voltage and current, load, power factor, frequency, and speed WILL be
recorded after each load change.
3. Measure the steady state voltage variation at each _ load step. (Express as +/-
value)
4. Determine maximum overshoot and undershoot at each load step. (Express as
Value & %)
5. Determine the time to restore steady state voltage at each load step.
6. Determine the voltage regulation relative to no-load voltage. (Express in %)
7. Repeat steps 2-6 for frequency.
ability on the unit to perform the test(s) contained within this quote. This quote
does NOT include any performance guarantees.
Safety Alarm and Shutdown Tests

Overspeed shutdown will be tested by means of the verify function of the start-stop
panel. That is, overspeed will occur at a percent of the actual overspeed setting of the
engine speed switch.
If the set is equipped with a manual reset provision for the overspeed protective device,
attempts will be made to start the set. It will be recorded if starting is achieved. If the set
did not start, reset the overspeed protective device.
High water temperature and low oil pressure shutdowns will be tested in a similar manner
with the verify function of the start-stop panel. The sensors will be tripped manually. No
attempt will be made to alter the actual engine operating condition for the purpose of
this test.
The engine will be started and allowed to obtain rated speed, no-load. The engine will
be stopped using the E-stop button and/or mechanical shut-off lever. The test will be
performed ONCE for each shut down device.
NOTE: 1) This test will NOT be performed if the genset has remote mounted switchgear
that is shipped loose.
2) This test requires an engine/generator mounted control panel and will
otherwise NOT be performed.
3) Sensors will NOT be removed from the engine to demonstrate functionality or
calibration.
4) NO other test will be performed to satisfy these specifications.
5) NO attempt will be made to alter the actual engine operating condition for
the purpose of this test.
Oil Sample Analysis

Two oil samples will be taken, one prior to the test, the other at the conclusion of the test.
Both samples will be submitted to CaterpillarÕs metallurgical analysis lab and analyzed for
signs of unusual wear.
Observation of Test
The dealer WILL be provided two (2) weeks notice prior to the test date.
The test WILL add approximately four (4) weeks to the ship date.
Caterpillar MUST be informed of the names of all who will witness the testing, arrival times,
accommodation needs, etc., at least seven (7) days before the test date.
Purchase of this quote implies acceptance of the test procedure described herein.
Requests to modify the procedure after purchase of the quote are strongly discouraged,
and WILL require requoting.
Cell Calibration Data

Copies of the most recent test cell calibration data WILL be provided in the test report.
NIST Tracable certificates for the equipment used to calibrate the test cells ARE available,
but will NOT be provided as part of this quote.
Certified Test Report

A certified test report will be prepared and five (5) copies will be mailed to the dealer.
Table of Contents – Voltage Regulators
Page Number
VR3F Voltage Regulator 2
DVR Voltage Regulator 5
Voltage Regulator Selection Chart 8
Regulator Part Numbers 10
Regulator Protection 11
CAT Control Panels 12

particular purpose.
Caterpillar Inc.
The purpose of the VR3F regulator is to keep generator voltage at a rated value. There is
one control on the VR3F that is standard.
• The voltage level rheostat provides a no load voltage adjustment of
approximately +10 to Ð25%.
Additional features built into the VR3F are:

• Jumpers provide a means of selecting a 1 V/Hz or a 2 V/Hz slope. The 2 V/Hz
slope will help the generator set pick up a full block load.
• Jumpers provide a means of selecting a 50 Hz or a 60 Hz operating frequency.
Specifications
Power Input Output Rating Sensing Reactive Exciter Field

Droop Input Resistance
Voltage Type Volts Freq. VA Max. Min. Forcing V Max Amps VA Min. Max.
Rating Hz Continuous VA Burden Ohms Ohms
V A V A Burden
per ∅
240 Volt SE 200/240 50/60 1500 50 10 90 15 200/ 1 0.5 3 3 10
1∅ 240
480 Volt SE 200/240 50/60 1500 50 10 90 15 400/ 1 0.5 3 3 10
1∅ 480
120 Volt PM 70-110 200/ 1500 50 10 90 15 100/ 1 0.5 3 3 10
3∅ 240 120
240 Volt PM 70-110 200/ 1500 50 10 90 15 200/ 1 0.5 3 3 10
3∅ 240 240
480 Volt PM 70-110 200/ 1500 50 10 90 15 400/ 1 0.5 3 3 10
3∅ 240 480
R e g u l a t i o n A c c u r a c y : Under steady state conditions of constant temperature and

frequency, output voltage will vary less than 1% of its rated value for any load variation
between no load and its standby rating.
R e g u l a t o r D r i f t : Under steady state conditions of constant load, temperature, and

frequency, output voltage will vary less than 1/2% of its rated value within two minutes.
T e m p e r a t u r e D r i f t : Under steady state conditions of constant load and frequency,

output voltage will vary less than 1% for any 40¡C change over the range of -40¡C to
+70¡C.
R e g u l a t o r R e s p o n s e : Less than 20 milliseconds.
R e g u l a t o r S e n s i n g : Three phase sensing is standard with the option of single phase

sensing available on SE regulators only.
R e g u l a t o r S t a b i l i t y : The regulator will respond to the fundamental component of the

sensed voltage. Instability will not result when the total harmonic distortion of the
generator output voltage is less than 20%.
R e g u l a t o r F i l t e r i n g : Meets a Telephone Influence Factor (TIF) of 50. Optional filtering
packages which allows compliance with MIL STD 461B and VDE85 level N requirements
are available.
Voltage Adjust Range: -25% to +10% of nominal.
R e g u l a t o r G a i n : Minimum of +5% of nominal at full load and 1.0 PF.
R e g u l a t o r B u i l d - U p V o l t a g e : The regulator will build up voltage with the generator

output voltage as low as 6 volts. There is no minimum requirement for PM regulators.
V o l t / H z C h a r a c t e r i s t i c : Linearly proportional to frequency (RPM) up to a specific

corner frequency and constant voltage above the corner frequency. The V/Hz slope
and corner frequency are set at the following values: the slope is jumper selectable for 8
V/Hz or 16 V/Hz; the corner frequency will be set at 49.5 Hz for 50 Hz applications and 59.5
Hz for 60 Hz applications. The corner frequency, like the slope, is jumper selectable.
D r o o p A d j u s t m e n t : Minimum of 8% droop at full load and 0.8 PF. While at 8% and 0.8
PF, the range of allowable droop at 1.0 PF is plus or minus 1% of nominal rated voltage.
D r o o p V o l t a g e : At 5% droop, normal voltage measured across the 8 Ohm droop pot

is 1V - 1.5V.
D r o o p C u r r e n t : At 5% droop, normal current through the droop pot is typically 250 mA.
O v e r c u r r e n t P r o t e c t i o n : Limits the field forcing condition up to a minimum of 10

seconds and maximum of 30 seconds. The function is automatically reset when the
regulator is de-energized.
O v e r c u r r e n t P r o t e c t i o n : Shuts off the generator output when the excitation exceeds

the nominal values shown below for approximately 10 Ð 16 Seconds
SE Excitation voltage > 63 Vdc

PM Excitation current > 14 amp
F a u l t P r o t e c t i o n : Two fast acting, high interrupting capacity fuses are provided to

protect the AVR and excitation system components against potentially damaging
electrical faults.
A m b i e n t O p e r a t i n g T e m p e r a t u r e : -40¡C to +70¡C.
S t o r a g e T e m p e r a t u r e R a n g e : -40¡c to +85¡C.
P o w e r D i s s i p a t i o n : 50W.
S h o c k : Withstands up to 20 G's.
V i b r a t i o n : Withstands 4.5 G's at frequencies between 18 Hz and 2000 Hz.
S a l t S p r a y : Meets MIL STD 810C, method 509.1.
S e a l i n g : Withstands up to 35 KPA (5.08 psi)
W e i g h t : 1.8 Kg
Standard Accessories Available
S e r i e s B o o s t : Able to sustain the generator output at 300% rated current for a

minimum of ten seconds and a maximum of sixteen seconds before automatically
removing power to the exciter field. T h i s o p t i o n i s n o t r e q u i r e d f o r P M m a c h i n e s .
K V A R / P F C o n t r o l l e r : Allows the generator to parallel with utility power.
R e m o t e V o l t a g e A d j u s t : Controls voltage level with a 10 kOhm, 1 Watt remotely

mounted rheostat.
M a n u a l V o l t a g e C o n t r o l : Permits manual regulation of the generator output voltage

by controlling the field excitation.
P a r a l l e l i n g : A reactive droop network consisting of a current transformer, rheostat,

and control circuit that allows paralleling with other generators in either reactive droop
or cross current compensation (zero droop) modes.
F i l t e r i n g : Complies with the requirements of MIL-STD 461B Part 9, VDE 875 Level N,
EN50081-2, and EN50082-2.
DVR Voltage Regulator
For a full functional and service description, see SENR5833-02 (May 1996)
The Digital Voltage Regulator is a microprocessor based voltage regulator. The main
purpose of the digital voltage regulator is to regulate output voltage of a generator used
with an engine generator set. Service personnel can modify (program) certain
regulation characteristics. This will allow the engine generator set to function in the most
efficient manner. The digital voltage regulator can also integrate into one package
many options that were previously panel mounted: such as KVAR/PF controller, over-
excitation protection, fault detection, over-voltage protection, under-voltage protection,
diode monitor, reverse power relay, and system parameter monitoring.
Programmable parameters of the digital voltage regulator are:

• Voltage verses frequency (V/Hz) characteristic, two slope ranges adjustable
from 1 to 10 V/Hz for optimum performance.
• Fine voltage level adjustment (±10%.).
• Droop adjustment (up to 10% at 0.8 pf).
• Over-voltage trip point (105% to 140% of nominal) with adjustable trip time.
• Under-voltage trip point (60% to 95% of nominal) with adjustable trip time.
• Gain (0 to 10% of nominal).
• Single-phase or three-phase true RMS sensing.
• Under frequency trip point (15 to 40 Hz).
• Knee frequency (45 to 64 Hz)
The protective functions that the digital voltage regulator provides are:
• Over-voltage protection.
• Under-voltage protection.
• Loss of sensing.
• Rotating diode monitor (monitors the status of the rotating diodes and
operates the alarm relay in the event of failure of one or more of the diodes).
• Over-excitation protection.
• Loss of excitation (monitors excitation and will initiate a shutdown of the unit if
excitation is lost).
• Under frequency protection to avoid overheating of the rotor.
• Instantaneous field over current trip to protect the digital voltage regulator in
the event of output short circuit or improper connections.
• Optional reverse power relay (monitors generator output power and initiates
a shutdown of the unit if a reverse power condition is detected.
The digital voltage regulator can be set up for a specific application by using the
programmable parameters. Parameters are preset at the factory but may have to be
adjusted to meet the specific requirements of a site. The digital voltage regulator also
detects faults and sets the appropriate alarm or caution. Certain system parameters can
also be monitored on the display of the digital voltage regulator.
Specifications
Power Input Output Rating Sensing Reactive Exciter Field

Droop Input Resistance
Voltage Type Volts Freq. VA Max. Min. Forcing V Max Amps VA Min. Max.
Rating Hz Continuous VA Burden Ohms Ohms
V A V A Burden
per ∅
120 Volt PM/SE 70-120 50- 240 1500 44 11 60 15 79/ 1 5 1 3 10
3∅ 124
240 Volt PM/SE 70-120 50- 240 1500 44 11 60 15 125/ 1 5 1 3 10
3∅ 249
480 Volt PM/SE 70-120 50- 240 1500 44 11 60 15 250/ 1 5 1 3 10
3∅ 600
R e g u l a t i o n A c c u r a c y : Under steady state conditions of constant temperature and

frequency, output voltage will vary less than 0.25% of its rated value for any load
variation between no load and its standby rating.
R e g u l a t o r D r i f t : Under steady state conditions of constant load, temperature, and

frequency, output voltage will vary less than 1/2% of its rated value within two minutes.
R e g u l a t o r T e m p e r a t u r e D r i f t : Under steady state conditions of constant load and

frequency, output voltage will vary less than 0.5% for any 40¡C change over the range of
-40¡C to +70¡C.
R e g u l a t o r R e s p o n s e : Less than 10 milliseconds.
R e g u l a t o r S e n s i n g : True RMS 3-phase sensing is standard. Single phase sensing is

available. Variable sense range: 90 to 600 volts.
H a r m o n i c T o l e r a n c e : The regulator will respond to the fundamental component of

the sensed voltage. Instability will not result when the total harmonic distortion of the
generator output voltage is less than 20%.
T e l e p h o n e I n f l u e n c e F a c t o r ( T I F ) : Less than 50. Complies with MIL STD 461C Part 9,

and VDE 0875 Level N.
F i n e V o l t a g e A d j u s t R a n g e : ±10% of regulator sensing voltage.
R e g u l a t o r V o l t a g e G a i n ( I R c o m p e n s a t i o n ) : Adjustable 0 to 10%.
P r o g r a m m a b l e V o l t / H z C h a r a c t e r i s t i c : There are two slope ranges that are

adjustable from 1 to 10V/Hz. See SENR5833-01 for the Regulation Characteristic
illustration.
F a u l t D e t e c t i o n a n d I d e n t i f i c a t i o n : The diagnostics identify any operation outside

of the programmed limits. Specific fault information is available even after the unit has
been powered down.
R e g u l a t o r S t a r t - u p V o l t a g e : It meets the ISO8325-3 Class G2 specification.
R e a c t i v e D r o o p A d j u s t m e n t : It is adjustable from 0 to 10%.
O v e r - E x c i t a t i o n P r o t e c t i o n : This will shut off the generator output when excitation
current exceeds normal operating currents for 15 seconds or it will instantaneously shutoff
if output is shorted.
A m b i e n t O p e r a t i n g T e m p e r a t u r e : -40¡C to +70¡C.
S t o r a g e T e m p e r a t u r e R a n g e : -40¡c to +85¡C.
P o w e r D i s s i p a t i o n : Quiescent Ð5 watts, 55 watts at 15 amps.
S h o c k : Withstands up to 20 g's.
V i b r a t i o n : Withstands 4.5 G's at frequencies between 18 Hz and 2000 Hz in three

mutually perpendicular planes..
S a l t S p r a y : Meets MIL STD 810C, method 509.1.
S e a l i n g : Withstands up to 35 KPA (5.08 psi)
W e i g h t : 5.0 Kg
** 24 ± 6 volt power supply required (0.5 amp)
Customer Options
F a u l t S h u t d o w n O u t p u t D r i v e r : The Fault Shutdown Driver is intended to provide an

external signal to operate a circuit breaker shut trip and other alarm lights and / or horns
in the event of a shutdown fault.
A l a r m O u t p u t D r i v e r : The Alarm Driver is intended to provide an external signal to

operate alarm lights and / or horns in the event of an alarm condition.
E x c i t a t i o n D i s a b l e : The Excitation Disable switch is intended to provide a method of

disabling the regulator field output in a manner which is safe for the regulator internal
components. The generator will always have residual voltage still remaining. Therefore, it
is important to stop the genset if downstream maintenance is to be performed.
F a u l t R e s e t : The Fault Reset contact is provided as a method to reset a resettable

shutdown fault through the use of an external contactor.
U t i l i t y 5 2 / a C o n t a c t s : The Generator 52/a auxiliary contact is closed only when the

generator breaker is closed. The Utility 52/a auxiliary contact is closed only when the
breaker which ties the generator to the utility is closed. When BOTH of these breakers are
closed, the generator is assumed to be operating in parallel to the utility grid. This will
activate the KVAR/PF mode and enable the Reverse Power Relay.
R e m o t e V o l t a g e A d j u s t R h e o s t a t : The Remote Voltage Adjust Rheostat inputs are

provided to allow the use of a 10kW potentiometer to remotely change the regulated
voltage level.
R e m o t e K V A R / P F A d j u s t R h e o s t a t : The Remote KVAR/PF Adjust Rheostat inputs are

provided to allow the use of a 10KW potentiometer to remotely change the regulated
KVAR or PF level.
SR4 Generators – Voltage Regulator Selection
Self Excited Type of Permanent Magnet

Excitation
No. of
6 Lead Leads 10 / 12
Lead
Direct
Connect
Generator
60 Hz
Output
Voltage 149-6130
Note 1
380 480 600
No. of
6 Lead Leads 10 / 12
Lead
Sensing
7C-7542 7C-7542 7C-7543
Isolation
Transformers
Direct
Connect
149-6131 149-6131 149-6130
155-3820
Generator
60 Hz
Note 1: VR4 Regulator can be used in Output
standby applications less than 400kW. Voltage
Note2: Sensing transformers to be
provided in customerÕs switchgear.
380 480 600 4160
Optional Voltage Regulators 117-8552 Direct 6I-0909 Shipped

Standard DVR w/ Connect Loose
VR3 VR3-F DVR kVAR/pf
149-6130 155-3822
149-6131 155-3823
155-3821 155-3826 155-3831 155-3834
155-3819 155-3820 155-3820 155-3820
155-3820 155-3825 155-3832 155-3835
155-3819 155-3824 155-3833 155-3836
Note 2
SR4B Generators – Voltage Regulator Selection
Self Excited Type of Permanent Magnet

Excitation
Direct
Standard
Connected
VR3
149-6130
Direct LA-0459
Connected Optional Generator
155-3822 VR3F 60 Hz
Output
380 Voltage 4160
480 600
Sensing
Isolation 154-3488 154-3488 154-3488 149-3403
Transformers
Standard
DVR
155-3832
Optional
155-3835 LA-2916
DVR with
KVAR/PF
Transformer Group - Potential
820 Med Voltage 154-3478 690 Med Voltage 154-3475
820 Low Voltage (PM) 154-3477 690 Low Voltage (PM) 154-3454
820 Low Voltage (SE) 152-6671 690 Low Voltage (SE) 152-6670
Regulator Part Numbers
Regulator Part Number Old Number Old Number Old Number
VR3 240V SE 149-6130 9Y-8400 7C-1600
VR3 480V SE 149-6131 7C-2663
VR3 480V PM 155-3819 114-5511 113-7687 7E-8262
VR3 240V PM 155-3820 114-5510 116-7685 7E-8261
VR3 120V PM 155-3821 114-5509 113-7686 7E-8263
VR3F 240V SE 155-3822 4P-6845 6I-2963

VR3F 480V SE 155-3823 4P-7108
VR3F 480V PM 155-3824 105-4400
VR3F 240V PM 155-3825 105-4401
VR3F 120V PM 155-3826 105-4398
DVR 120V 155-3831 130-3471 116-7480

DVR 240V 155-3832 130-3472 116-7481
DVR 480V 155-3833 130-3473 116-7482
DVR V/PF 120V 155-3834 130-3474 116-7483
DVR V/PF 240V 155-3835 130-3475 116-7484
DVR V/PF 480V 155-3836 130-3476 116-7485
VR4 240V SE 7C-7557
Accessories
SE Manual Voltage Cont. 7V-2700
PM Manual Voltage Cont. 5N-0591
Series Boost Module 7C-2701
RFI Filter 240V 9Y-0968
RFI Filter, with bracket 121-5421
PM Fuse (10A) 155-8755** 9Y-6027*
Fuse Holder 158-6178**
281-623 (Wago Part Number)
Volt Adj. Pot., 10kΩ 7C-4471
Droop Rheostat, 8Ω 7C-8760
Droop Resistor, 1Ω 128-6046
Droop Module, VR3 177-7793** 122-9204*
Droop Module, DVR 177-6312** 122-9205*
Droop Module, Socket 1492-R4P (Allen Bradley Part Number)
280-618 (Wago Part Number)
Low Voltage PT 154-3488 137-2493 128-5314 120-9772
Medium Voltage PT 149-3403 149-0590 136-5057 124-8474
Spare Parts Kits

Generator Kit 171-6719** 131-4254*
EMCP Kit 171-6721** 131-4254*
* = Wago Part
** = Allen Bradley Part
Regulator Protection
Depending on generator type and voltage regulator type, there must be some
resistance added to the circuit between the Current Transformer and the regulator.
These resistors will either limit the current or the voltage being supplied to the regulator.
The wiring diagrams are as follows.
CAT Control Panels
For more information see:
LEHX7085-01 Ð EMCP II Ð Electronic Modular Control Panel
LEHX7077 Ð EMCP II+ Ð Electronic Modular Control Panel
The Caterpillar family of control panels provides basic to complete generator set
monitoring. Control panels use a standard mounting and wire harness and are easily
upgraded to the next higher specification. The Electronic Modular Control Panels (EMCP
II and EMCP II+) are compatible with a complete line of local or remote annunciators,
and with remote communication and expansion modules.
Auto Start/Stop
This manual or auto start/stop electromechanical panel equipped with analog gauges
provides basic generator set metering, engine monitoring and protection, indicator
lights, and emergency stop shutdown. Optional protective and control devices are
available.
EMCP II and II+

The Electronic Modular Control Panel II and II+ equipped with high-tech electronics and
digital LCD readouts, provides the most complete generator set monitoring, metering,
control, and indication. A full range of optional protective devices, controls, and local
and remote annunciators are available. The EMCP II or II+ may be used for remote
generator set monitoring and control via a direct connection or modem. The EMCP II
and II+ use environmentally sealed, solid state, microprocessor-based modules.
Switchgear Conversion
An electromechanical panel equipped with analog gauges provides basic generator
set indicator lights, and emergency stop shutdown. Optional protective and control
devices are available.
The following page provides a table of all the standard features and options available
on these units. Materials and specifications are subject to change without notice.
Conversion Kits
Existing generators can be retrofitted with the EMCP II and II+ control panels. For this
information consult the following:
LEXX 7764 Field Installed EMCPII Control Panel
REHS 0076-01 Instructions for EMCP II+ Field Retrofit Onto EMCP II Equipped
Generator Sets
Electromechanical Panels EMCP Panels
(all gauges are analog) (all gauges are digital)
Switchgear Auto II II+
Conversion Start/Stop
Generator Metering
Voltmeter  S S S
Ammeter  S S S
Phase selector switch  S S S
Frequency  S S S
kW    S
kV•AR    S
kV•A    S
Power factor    S
Genset Monitoring
DC voltage S S S S
Coolant temperature S S S S
Oil Pressure S S S S
Hours run time S S S S
Rpm S S S S
Oil temperature    O
Controls
Start/stop control  Man/Auto Man/Auto Man/Auto
Emergency stop control S S S S
Lamp test S S S S
Cycle cranking (adjustable cranking times) S S S S
Voltage control  S S S
Cooldown timer   S S
Panel lights   S S
Load share module (shipped loose) O  O O
Alarm horn & silence switch (local)  O O O
Frequency control  O O O
Electronic isochronous governor  O O O
Ether starting aid control  O O O
Standard Indicating Lights
Low oil pressure shutdown S S S S
High coolant temperature shutdown S S S S
Overspeed shutdown S(1) S(1) S S
Overcrank shutdown S S S S
Emergency stop shutdown S(1) S(1) S S
Miscellaneous Protective Devices Select one only Select one or several (4)
Includes indicating light
Over/under frequency    S(2)
Overcurrent    S(2)
Reverse power    S(2)
Over/under AC voltage  O O S(2)
Low fuel level O O O O
Low coolant level O O O O
Ground (earth) fault Ð shutdown  O O O
Generator winding overtemp Ð prealarm O(3)  O O
Generator winding overtemp Ð shutdown O(3)  O O
Generator bearing overtemperature O(3)  O O
Low battery voltage   O O
Miscellaneous Controls Select on or more
Common alarm/shutdown volt free contact S O O O
Overload relay (kW level)    S
Computer communication data link   S S
Integral battery charger Ð 5 amp (non UL) O O O O
Automatic fuel transfer system control O O O O
JWH/space heater/battery charger disconnect O O O O
Generator running volt free contact  O O O
Remote annunciators (8 & 16 light panels)   O O
Enclosure
Vandal door S S S S
Dust proof (IP52 per IEC 34-5)   O O
(1) Combined emergency stop/overspeed light S = Standard
(2) Common indicating light with separate diagnostic codes for each function O = Optional
(3) Contact only provided Ð indicating light is not provided  = not available
(4) EMCP II and II+ alarm modules available in configurations of eight (8) lamps
Table of Contents – Transient Response
Page Number
Generator Set Transient Response 2
Inrush Current Data for Various Loads 7
Example Report
Test Report Terminology 11

particular purpose.
Caterpillar Inc
Generator Set Transient Response
Introduction
The transient response of a generator set refers to the frequency and voltage deviations
and the recovery time following a load change. Better response simply means smaller
frequency or voltage deviations and a shorter recovery time.
This note is a discussion of the first-order issues involved in transient response and the
options available to influence it. It applies mainly to 4 cycle diesel engines, because of
the issues differ with 2 cycle diesels or spark ignited engines.
Need for Good Response

The primary concern of the generator set purchaser is that it provides sufficient power for
their needs. The transient response characteristics are important in situations where quick
load changes may occur. In a standby installation, the generator set will be called on to
accept a block load, which may be the full rated load, in one or more steps. Block loads
will also occur where motors are suddenly loaded (the clutch on a blower may be
engaged, or a grinding mill is fed more material). The behavior of the generator set
when starting a motor can not be predicted by observing its block loading behavior.
When a motor is started, it demands power from the generator set at a very low power
factor. Besides the need for accepting load variations, loads like UPS systems or Variable
Frequency Drives impose sometimes severe restrictions on the maximum voltage and
frequency deviations.
A generator set is often required to demonstrate that it can recover from full load
applied in a single step. This could be a real requirement, but it is also a frequent
specification requirement which must be met even if it will not actually be experienced.
The most common standards cited are NFPA 99 and NFPA 110, which merely require that
the generator set not stall when full load is applied. In actual use, often only the most
critical parts of the load are applied in one step.
Typical Transient Response

The generator set transient response to a single block load or motor start consists of up to
three voltage dips and up to two frequency dips. Multiple loads applied at the same
time behave similarly to an equivalent single load. The response to multiple loads
applied staggered in time is a combination of responses to the individual loads.
Removal of loads typically cause single voltage and frequency rise.
The first dip is the generatorÕs reaction to the loadÕs instantaneous need for a lot of
current. The generator voltage dip is a function of the generator subtransient reactance
and the actual current required by the load. This voltage dip is so fast (and of such short
duration) that the resulting frequency dip is minor.
The second voltage dip is caused by a drop in engine speed (frequency drop) as the
engine slows down while developing the additional power required. The voltage drop is
created by the voltage regulator trying to unload the engine and is proportional to the
frequency drop when using a Volts per Hertz type regulator like the VR3. The VR3F with its
2 Volts per Hertz characteristic also behaves in this fashion. As the engine catches up
with the new load, it recovers to the original speed (frequency).
The third voltage dip is only present when a reduced voltage motor is used. The reduced
voltage motor starter brings the motor voltage to full voltage when the motor has
reached a certain speed (usually 60 to 80% of rated motor speed). The applied full
voltage is like a block load that demands an instantaneous jump in power. The genset
responds with another voltage and frequency dip while the engine catches up. Other
motor starters may also cause a third dip.
The relative size of the first voltage dip depends heavily on the generatorÕs subtransient
reactance. The second voltage dip depends on the amount of power the engine has
available and the inertia of the genset. The third voltage dip, if present, depends on the
percentage reduction of the reduced voltage starter. It also depends on the amount of
power the engine has available and the genset inertia. An inertial voltage sip like the first
dip may occur at the start of the third dip, but this is unusual. If there is sufficient power
available, this third dip is usually smaller than the second. If the third voltage dip is larger
than the second, the engine is probably near its limit in terms of power availability.
Generator manufacturers publish generator voltage dip curves where they show voltage
dip as a function of SKVA produce. These curves assume a constant generator speed.
When a generator is coupled to an engine, the speed drop, discussed previously, causes
the voltage dip to be greater than shown by the manufacturerÕs curves. Many transient
response performance specifications are written based on these generator
manufacturerÕs curves.
What Causes Transient Response Problems

A naturally aspirated (NA) engine pumps a fixed amount of air through the combustion
space per minute. If the fuel supplied is just the right amount for the available oxygen
(stoichiometric mixture), the engine will produce roughly its maximum output. If fuel flow
is reduced, less energy is released and engine output goes down. If fuel flow is
increased, there is insufficient oxygen to consume it, burning less efficient, the engine
smokes, and the excess liquid fuel absorbs some of the heat energy released which can
also reduce engine power output.
Maximum engine power is air flow limited. So, the way to increase power is to increase
air flow. Air flow is limited by engine displacement (the volume of a cylinder times the
number of cylinders), the speed of the engine in rpm, and by the density of the air (i.e. kg
of air per liter of air).
For a given engine displacement, more speed produces more air flow. But only certain
speeds (such as 720, 750, 900, 1000, 1200, 1500, and 1800 rpm) produce useful
frequencies for power generation (50 and 60 Hz). Therefor, the only practical way to
increase air flow is to increase the density of air entering the cylinders. This can be done
by increasing air pressure (usually by compression with a turbocharger) or reducing air
temperature. Compression increases air temperature, so it is often cooled by means of a
heat exchanger called an aftercooler using jacket water or radiator airflow. Turbo-
aftercooling (TA) an engine is a common and effective means of increasing engine
airflow and power output. If done properly, output can be doubled or even tripled
compared to a naturally aspirated engine of the same displacement.
The costs for the added output are a beefier engine structure, the added turbo charging
and aftercooling hardware, and slower response to large load changes. The governor
can increase the fuel in a fraction of a second, but at no-load, engine air flow is similar to
that of a naturally aspirated engine. Adding fuel increases exhaust temperature,
causing turbo acceleration and increased air flow, but reaching full turbo speed may
require several seconds. Meanwhile, the genset is slowing because its output is less than
the applied load. If speed falls far enough (typically 30% at 60 Hz or 25% at 50 Hz), the
genset may have trouble recovering. When engine output (rating) is increased by
turbocharging, the speed with which the engine responds to large load changes is
slowed down. This is the result of the turbo lag. The rate of a genset speed change
depends on the load applied and the inertia of the genset.
Initial deceleration rates for typical Caterpillar generator sets with full load applied range
from 50% per second (3600s) to 200% per second (3208s). Deceleration continues until
engine power increases enough to match the applied load. Further increases in engine
output return the engine to rated speed.
Transient Response Improvement
Engine Displacement
It is almost too obvious to mention, but a bigger engine will respond better to a given
load. There is no substitute for liters (or cubic inches).
Voltage Regulator
For years, Caterpillar has used a Volts per Hertz regulator. This means that as engine
speed falls when a load is added, the voltage regulator causes the generator output
voltage to fall by the same percentage. The lower voltage (to the load) reduces the
power that the load absorbs, thus unloading the engine as speed falls and minimizing the
speed dip. In spite of this, the latest round of rating increases has resulted in cases where
the speed dip is too great to allow recovery when a full load is applied. To overcome this
problem, we have developed a 2 volts per Hertz regulator, which means that the
voltage falls off twice as fast as the speed. The further reduction in voltage causes the
engine to be unloaded even faster and all but eliminates cases where recovery is
impossible. Exceptions include very highly rated engines with heavy turbos when the
load is applied immediately following a cold engine start.
Intuitively, the 2 V/Hz voltage regulator would seem to cause much higher voltage dip
during transients, which is also undesirable. However, analysis and tests demonstrate that
speed dip is improved so much that the voltage dip is far less than might be expected.
In many cases, the voltage dip is less than it would be of the V/Hz regulator was used.
Genets can now be equiped with a Digital Voltage Regulator (DVR). The DVR utilizes a
programmable microprocessor to control the engine. The programming can be set to
optimal parameters depending on the application. This will provide the best transient
response available from the individual genset. The DVR is also programmed to monitor
other engine functions. In case of overloading or other dangerous conditions, the DVR
will shut down the genset to prevent destroying of the mechanics of the genset.
Fuel / Air Ratio Control (FARC)

As mentioned earlier, excess fuel can cause smoke and reduce power. Highly rated
turbocharged engines have much more fuel flow available than can be used effectively
at no-load air flow, so they are subjected to over fueling when load is added. The FARC
is a device that senses air pressure from the turbocharger, and limits fuel flow to what
can be consumed by the available air flow. The air pressure acts on a diaphragm
balanced by a spring. A lever connected to the diaphragm prevents the governor from
fully opening the rack until sufficient air is available to burn it. While effective, the device
adds costs and complexity and is presently unavailable for certain governors such as the
popular Woodward 2301. Adjustment is critical, too much fuel limiting also reduces
power.
Waste Gate
Turbochargers can b made to run faster and therefore increase air flow by reducing the
area of the turbocharger turbine inlet nozzle. A smaller nozzle increases no-load air flow
and improves the ability of the engine to accept load. The difficulty is that the smaller
nozzle causes the turbocharger to run too fast at rated load. A waste gate is intended to
overcome this problem. It too is a diaphragm operated device that has no effect at low
loads. However, as the turbo accelerates and increases air pressure, the diaphragm
opens a valve allowing part of the exhaust gas to bypass the turbocharger preventing
turbo overspeeding. The difficulties with waste gates are added cost, complexity, and
reduced engine efficiency. One concept of minimizing performance penalties is to use
the waste gate to increase turbine nozzle area instead of bypassing gas, but this further
increases cost and complexity.
Genset Inertia
Since the engine deceleration rate is inversely proportional to the genset inertia when a
load is applied, frequency dip could be minimized by increasing inertia in proportion to
rating increases. The most obvious method is with a bigger flywheel, but this adds cost
and is likely to increase genset linear vibration.
Air Impingement
Over 20 years ago, experiments with a portable air compressor improved engine
response by injecting air from the air compressor through holes in the turbo compressor
housing to accelerate the turbo. Caterpillar has since used this principle to start gas
turbine engines and to substantially improve load acceptance on some 3500 and 3600
engines. Care must be taken to size and locate the holes to maximize response and
minimize opportunity for exciting compressor blades natural frequencies. A source of
plant air is required. Control systems can be very complex, especially in multi-engine
standby site where the first engine to start is unpredictable.
Reduced Inertia Turbos

Most of the reason for slow response at high engine ratings is the amount of time required
to accelerate the turbocharger. Since turbo acceleration torque is limited by safe
exhaust temperatures, improved response has been sought by reducing turbocharger
inertia. The compressor is already made of lightweight aluminum, so gains have been
make by replacing the steel turbine wheel by one made or ceramic material. In one
example, turbo inertia was reduced by about 40% and the rate of engine power
increase rose about 30%. Other technologies being considered include making a metal
turbine wheel lighter by a process similar to sintering.
Turbo inertia can also be reduced by replacing a large turbo by multiple smaller ones.
The transient response of the phase zero and phase one 3516 and 3512 prime engines
was improved by replacing the two turbos with four smaller turbos, effectively decreasing
the turbo inertia.
Tuned Manifolds
If development cost is secondary to performance, improved response is possible by
careful tuning of the length, volume, and shape of inlet and / or exhaust manifolds.
Opening and closing inlet and exhaust valves causes pressure pulsations in the
compressible manifold gases. If the manifolds are tuned, the pulsations can amplify
manifold pressure and increase air flow, although each engine speed might require a
different ÒoptimumÓ. Tuned inlet manifolds alone can yield up to a 25% reduction in
engine response time.
Inrush Current Data for Various Loads
Incandescent Lamps
Initial Inrush: 6 times nominal current.
Exponential Decay: time constant 1.0 second
Florescent Lamps
Magnetic Ballast: No inrush. Some waveform distortion for the first two cycles.
Electronic Ballast: Inrush Current: Up to 15 times normal peak.
Decay Time: 1 cycle.
D.C. SCR Drives

The D.C. SCR drives normally control the SCR conduction angle to bring the load on
slowly and therefore do not have any inrush current. During a normal start, the current
will rise to 0.5 to 2.0 times the rated as the motor is accelerated by the power factor will
be low until the motor approached rated speed. The current and power factor profile
will depend entirely on the settings of the motor speed and acceleration controls.
Inverter Drives
Inverter drives usually use a rectifier input to a D.C. bus with a large capacitor
connected. This capacitor must be brought up to full voltage as soon as the power is
switched on. Most drives use a delay circuit, which slowly charges the capacitor through
a resistor. This circuit usually limits the inrush current to 2 time rated peak current for
about 0.5 seconds.
Small drives (up to 2 H.P.) may not have this delay feature and therefore the peak inrush
current may be up to 30 times full load current for the first few (1 to 3) cycles.
Small D.C. Motors

Some small D.C. motors (up to 2 H.P.) are fed directly through a rectifier with no
capacitor on the D.C. side. These motors will have an inrush current of about 10 times full
load current with an exponential decay time constant of about 1 second.
UPS Systems
UPS (Uninterruptible Power Supply) systems vary widely depending on circuit design. The
larger units limit initial inrush currents to full load or less. Smaller units (up to 1 kW) may use
a rectifier input with a capacitor directly connected. These units will have peak inrush
currents of up to 30 times rated for the first few (1 to 3) cycles.
Office Equipment
Office buildings with large numbers of personal computers and office machines can
produce high amounts of inrush current when switched to a stand-by generator. These
devices use a rectifier input with a capacitor directly connected at the rectifier output.
The peak inrush current to these devices will be up to 30 times rated current for the first
few (1 to 3) cycles.
Effects of Generator Reactances

The relatively high substransient reactance of a generator, when compared to a utility
source, will reduce the peak inrush current when a drive or power supply is turned on, but
will also result in a much higher voltage drop.
Harmonic Currents
The level of harmonic currents produced by these drives vary widely with circuit design
and the components used in their construction. The following figures give a guide to the
approximate levels of typical units on the market at this time.
Incandescent Lamps: None

Florescent Lamps:
Magnetic Ballast
First 2 Cycles Ð 20% - 2nd harmonic
30% - 3rd harmonic
Steady State Ð 15% - 3rd harmonic
17% - Total harmonic
Electronic Ballast
First Cycle Ð 50% - 2nd harmonic
100% - 3rd harmonic
Steady State Ð 15% - 3rd harmonic
10% - 5th harmonic
8% - 7th harmonic
D.C. SCR Drives
Single phase units only -
10% - 3rd harmonic
10% - 5th harmonic
8% - 7th harmonic
Inverter Drives
Inrush Current - 50% - 2nd harmonic
50% - 3rd harmonic
Steady State - 15% - 3rd harmonic (Single phase only)
10% - 5th harmonic
8% - 7th harmonic
20% - Total harmonic (Single phase)
15% - Total harmonic (Three phase)
Small D.C. Motors fed directly from rectifier

Inrush Current and Steady State Ð
10% - 3rd harmonic (Single phase only)
10% - 5th harmonic
5% - 7th harmonic
UPS Systems (typically)

Steady State Ð 15% - 3rd harmonic (Single phase only)
12% - 5th harmonic
8% - 7th harmonic
Office Equipment
Inrush Current Ð 50% - 2nd harmonic
100% - 3rd harmonic
50% - 5th harmonic
Steady State Ð 50% - 3rd harmonic (Single phase only)
30% - 5th harmonic
20% - 7th harmonic
Transient Response and Motor Starting Analysis
Caterpillar has created a computer simulation program that will estimate the transient
response of a genset to a given load. This program was created by taking past
experimental data and creating empirically fit equations.
Please note that the calculated transient response is an estimate, it is NOT a

performance guarantee.
For further information about transient responses and to request the Transient Response
and Motor Starting Analysis for your particular genset, consult EDS 74.1 (LEKX4067).
The following list summarizes the generator set and load data required for transient
response and motor starting calculations. Please provide the generator set information
and supply the block load details. If no data is provided, the default values will be used.
If there are multiple loads, please provide data for all the loads.
Engine Model
Radiator Fan
Cold Start
Air Impingement
Governor Type
Governor Droop %
Fuel / Air Ratio Control
Voltage Regulator
Delta Knee Frequency Ð Hz
Slope 1
Slope 2
Minimum Voltage
Genset Ratings
Engine / Generator Speed
Engine Overload %
Power Factor
Altitude
Ambient Temperature
Type of Load
Motor
Motor Hp
Load Hp
Nameplate rpm
NEMA Motor Design Class
Load Inertia
Motor Starter
Ramp
Initial Load
Additional Step Loads (up to 8)
With this tool, a better estimate of what generator configuration will work for the
customers needs can be found.
The following page is an example of the output from the program.
Test Report Terminology
Air Impingement A method used to improve the response time of the
engine by forcing air through the turbo charger.
Altitude The elevation of the package generator set.
Ambient Temperature The temperature in degrees Fahrenheit of the
environment where the package generator set
operates.
Cold Start A load being applied to the generator before the
engine is at normal operating conditions
Corner (Freq. ÐHz below rated) The delta frequency below which a constant voltage
regulator changes to a volts per hertz regulator.
Date of analysis The date the analysis was run
Engine Model The engine used in the package generator set. For
example, 3516PH1-60S: 3516, phase 1, diesel engine, 60
Hz, standby
Engine overload setting The nominal percentage of power that the engine can
produce over the rated power.
Extra Inertia Extra generator set inertia (Nm2) added to minimize
speed change.
Fan Power The amount of power (kW) the engine is using to run
the cooling fan.
Field Response Accelerator A device used to shut regulator off faster on large load
dumps.
Final Load The amount of power (kW) the generator set is
producing after the load is applied.
Frequency Recovery Time (x% of The time it takes for the frequency to recover to x
Rated) percent of rated.
Fuel Type The type of fuel used in the engine, Diesel or Gas
Fuel-Air Ratio Controller Prevents overfueling and resultant power loss before
the turbo accelerates. (Not available on the
2301governor).
Full Load Bmep The internal pressure (psi) of the cylinder when
operating at full load.
Gen. Kg A constant used in modeling the generator.
Generator constant A constant used in modeling the generator.
Generator Efficiency at full load The efficiency of the generator at rated power.
Generator Frame Size The generator used in the package generator set.
Generator Set Inertia The inertia (Nm2) of the engine, the flywheel, the
coupling, and the generator.
Genset Ratings with fan Net power available from the generator set, assuming
a fan is part of the package.
Governor Constant A constant used in modeling the governor.
Governor Damping Factor The damping factor of the selected governor
Governor Type The governor used on the generator set.
Initial Load The amount of power (kW) the generator set is
producing before the load is applied.
Load Horsepower The horsepower the electric motor is required to
produce to operate the load.
Maximum Frequency Change The maximum value the frequency will vary from rated
frequency once the load is applied.
Maximum voltage change The maximum value the voltage will vary from rated
voltage when the load is applied.
Motor Horsepower The rated horsepower of the electric motor to be
started.
Motor Inertia The inertia (lb. ft2) of the electric motor to be started if
load type equals Motor or Both.
MotorÕs Load Inertia The inertia (lb. ft2) of the load on the electric motor.
Percent Speed Droop Percent permanent speed droop from NO-Load to Full-
Load.
Rated Genset Speed The operating speed of the engine in revolutions per
minute at rated load.
Speed Brk Intercept Anchor point of line defining where the engine Òsmokes
outÓ.
Turbo Limit Maximum Bmep available without turbo acceleration.
Turbo Rate Rate of power increase allowed by turbo acceleration
(Bmep/second).
Type of Load Ramp Ð A block or ramp load
Motor Ð The load is an electric motor.
Both - A block or ramp load and an electric motor are
being applied at the same time.
Volt Reg. (VR3, VR3F, VR4 , DVR) The voltage regulator used on the generator.
VR3 Ð V/Hz regulator, Standard Regulator
VR3F Ð 2V/Hz Cat Regulator
VR4 Ð V/Hz regulator,
DVR Ð Digital Voltage Regulator
Numerical value indicates the slope of the V/Hz
characteristic.
Voltage Recovery Time (x% of The time it takes for the voltage to recover to x percent
Rated) of rated.
Table of Contents – Wiring Diagrams
Page Number
3500 Shutoffs, Junction boxes & Diagrams 3
Lead Connection Diagrams
A. 10/12 Lead, Wye and Delta Connection 5
B. 6 Lead Wye / 6 Lead Delta Connection 6
C. 4 Lead Wye Connection 7
Connection Diagrams for Generators, VR3 & VR4 Voltage Regulators
A. Self Excited with Direct Connection to Generator 8
B. Self Excited with Power Transformer, Four Lead Generator 9
C. Self Excited with Power and Sensing Isolation Transformer 10
D. PM Excitation with Direct Connection to Generator 11
E. PM Excitation with Connection to Metering Pot. Transformer 12
F. PM Excitation with Connection to Isolation Transformer 13
G. Self Excited with Direct Connection to Generator 14
H. Manual Control with Self Excitation 15
I. Manual Control with PM Exciter 16
VR3 Voltage Regulator Wiring Diagrams (4/6 lead, Self Excited)
A. Schematics Ð 4/6 Pole Self-Excited Generators 18
B. VR3 with Power Transformer and Sensing 19
C. Manual Voltage Control Schematic with Power Transformer 20
D. Manual Voltage Control Schematic with Power Transformer 21
and Sensing.
E. Voltage Droop Transformer and Adjustment Rheostat for 22
Parallel Operation
VR3 Voltage Regulator Wiring Diagrams (10/12 lead, Self Excited)
A. Schematics Ð 10/12 Pole Self Ð Excited Generators 24
B. VR3 Ð Earlier One Fuse Version 25
C. Series Boost Schematic with Earlier One Fuse VR3 26
D. Series Boost Schematic with Current Two Fuse VR3 27
E. Manual Voltage control Schematic with Earlier 1 Fuse VR3 28
F. Manual Voltage Control Schematic with Current 2 fuse VR3 29
G. Voltage Droop Transformer and Adjustment Rheostat for 30
Parallel Operation
H. Single Phase Sensing 31
VR3F Flat Top Voltage Regulator Wiring Diagrams (4/6 lead, 10/12 lead,
SE)
A. VR3F (4/6 lead) with Power Transformer 33
B. VR3F with Power Transformer and Sensing 34
C. Schematics Ð 10/12 Lead Self Ð Excited Generators 35
D. Manual Voltage Control Ð 4/6 Lead SelfÐExcited Generator 36
with Power Transformer
E. 4/6 Lead SE Generators with Power Transformer and Sensing 37
Transformer
F. 10/12 Lead Self Ð Excited Generators 38
G. Voltage Droop Transformer and Adjustment Rheostat for 39
Parallel Operation for 4/6 Lead Generator
H. Voltage Droop Transformer and Adjustment Rheostat For 40
Parallel Operation for 10/12 lead generator
3500 EPG Technical Information Kit 3rd Edition Ð August 1998 Section 9 Ð Page 1
VR3 Voltage Regulator Wiring Diagrams (Permanent Magnet)
A. Medium Voltage Generator with Two PM Fuses 42
B. Medium Voltage Generator with Three PM Fuses 43
C. 4/6 Lead Generator with Two PM Fuses 44
D. 4/6 Lead Generator with Three PM Fuses 45
E. 10/12 Lead Generator with Two PM Fuses 46
F. 10/12 Lead Generator with Three PM Fuses 47
G. SR4 Generator with Sensing / Isolation Transformer and Two 48
PM Fuses
H. SR4 Generator with Manual Voltage Control and Two PM 49
Fuses
I. SR4 Generator with Manual Voltage Control and Three PM 50
Fuses
J. Voltage Droop Transformer and Adjustment Rheostat for 51
Parallel Operation
Digital Voltage Regulator Wiring Diagrams
A. 4/6 Lead 53
B. 4/6 Lead with Sensing Isolation Transformer 54
C. 10/12 Lead 55
D. 10/12 Lead with Sensing Isolation Transformer 56
E. 10/12 Lead with Self Excitation 57
F. Manual Control 58
G. Customer Options 59
H. Remote Communications 60

particular purpose.
Caterpillar Inc.
3500 Electrical Shutoffs
Reference # Shutoff Group Reference # Shutoff Group

LA Ð 0095 7W Ð 6954 PA Ð 2245 7W Ð 6954
LA Ð 0096 7W Ð 9361 PA Ð 2246 7W Ð 6954
LA Ð 0097 7W Ð 8054 PA Ð 2247 7W Ð 8054
LA Ð 0098 7W Ð 9362 PA Ð 2248 7W Ð 8054
LA Ð 1456 7W Ð 9362 PA Ð 2249 7W Ð 9361
LA Ð 1457 7W Ð 9361 PA Ð 2250 7W Ð 9361
LA Ð 1458 7W Ð 6954 PA Ð 2251 7W Ð 9362
LA Ð 1459 7W Ð 8054 PA Ð 2252 7W Ð 9362
Shutoff Groups Diagrams and Prints J – Box Group

7C Ð 5237 7W Ð 8552 ETS, OP, WT, OS (GS & Engine only) 7C - 5029
7C Ð 5275 2W Ð 4091 Speed Settings Chart
7W Ð 8053 7W Ð 8614 Wiring Diagram (Start & Prelube)
7W Ð 8054
7C Ð 2187 7W Ð 6798 ETS, OP, WT, OS (F/U/W Switchgear) 7C - 5029
7W Ð 6954 2W Ð 4091 Speed Settings Chart
7W Ð 8614 Wiring Diagram (Start & Prelube)
7W Ð 6349 7W Ð 3474 ETS, Fire Pump Wiring Diagram 7w Ð 3467
7W Ð 4386 Speed Switch Setting Chart
7C Ð 5239 7W Ð 9358 ETR, OP, WT, OS (GS & Engine only) 7C Ð 5030
7W Ð 9362 2W Ð 4091 Speed Settings Chart
7W Ð 8614 Wiring Diagram (Start & Prelube)
7C Ð 5238 7W Ð 6799 ETR, OP, WT, OS (F/U/W Switchgear) 7C - 5030
7W Ð 9361 7W Ð 8614 Wiring Diagram (Start & Prelube)
Table of Contents – Miscellaneous
Page Number
Media Reference Table 2
List of Commonly Used TLAs 7

Caterpillar Inc.
3500 EPG technical Information Kit 3rd Edition - January 1999 Section 10 Ð Page 1
Media Reference Table
The following table lists the current media releases for generators and their components.
3500 Generator Data Sheet 88-000272-00

3600 Generator Data Sheet 88-000273-00
Addendum to Generator Data Sheet for 88-000274-00
Marine Classification
3500 Series Engine with Electronic Unit LEKQ7455 1/97
Injection (EUI) option
3500B Engines Application & Installation LEBM7301 4/97
Guide
Application and Installation Instructions LEBX5048
CAT control Panels LEHX7045 1/97
Complete Guide to Electrical Insulation LEBQ4823 6/92
Testing
DVR Voltage Regulator SENR5833-01 5/96
Electrical Fundamentals LEHQ3210
EMCP II Ð Electronic Modular Control Panel LEHX7085-01 1/97
EMCP II for EUI Engines RENR1260 6/98
EMCP II for MUI Engines RENR1261 6/98
EMCP II+ Ð Electronic Modular Control Panel LEHX7077 1/97
EMCP II+ for EUI Engines RENR1259 7/98
EMCP II+ for MUI Engines SENR5832-01 7/97
Engine Division LEBQ8000 1/98
Advertising & Training Support Directory
Generator Sales Manual for High Voltage LEKX4400-03
Gen Sets
Generator Set Electrical Fundamentals LEHQ3210
Generator Set Sizing Guide LEBX5020
Generator Set Switchgear LEBX3298
Harmonic Wave Distortion Ð Cause and LEXX4343 9/94
Effects
On-Site Power Generation Book LEBX4457
Principles of Electric Set Governors, Parallel SEBD0515
Operation, Alternators, and Regulators
Spec Sheet Index LEXQ8096 1/98
SR4B Generators and Control Panels SEBU7050 3/97
Generator Set Drawings Drawing Booklet LEBX6693
Generator Set Application and Specification EDS 70.0.1 LEKX6073 1/96
Checklist
Generator Characteristics Terminology EDS 70.0.2 LEKX0776 10/90
Electrical Power Generation EDS 70.0.4 LEKX1365 11/91
Generator Technical Information Summary EDS 70.0.5 LEKX8524 10/88
Generator Quotation Worksheet EDS 70.0.6 LEKX5365 9/95
Caterpillar Generator Leads and the EDS 70.1 LEKX1353 11/91
National Electric Code
Understanding Static UPS Systems and EDS 70.3 LEKM7090 1/87
Generator Set Application Considerations
Considerations When Applying and Installing EDS 70.3.1 LEKX7368 10/87
Standby Generator Sets
Generator Winding and Pitch Harmonics EDS 70.4 LEKX3115 3/93
Generator Chart EDS 70.5 LEKX4030 2/94
SR4 Oilfield Brushless Generators EDS 71.0.6 LEKW5366 9/95
Effect of Temperature on Voltage Regulation EDS 71.4 LEKX3111 3/93
Remote Voltage Level Control for Caterpillar EDS 71.5 LEKX7087 2/87
Generators
Wiring of Wall and Floor Mounted Control EDS 72.3 LEKQ5146 2/85
Panels
Automatic Transfer Switch EDS 72.4.1 LEKX3108 3/93
Barber Colman ILS Module EDS 72.6 LEKX5364 9/95
Linear Vibration EDS 73.1 LEKQ4023 1/94
Ten-Second Automatic Start Stop EDS 74.0 LEKX7155 3/87
Transient Response EDS 74.1 LEKX4067 1/94
Generator Set Transient Response EDS 74.1.1 LEKX6072 1/96
Block Loading Transient Response EDS 74.2 LEKX4066 2/94
Grounding SR4 Generators EDS 75.0 LEKX3114 3/93
Currents Ð Circulating in Paralleled EDS 75.1 LEHX1423 11/91
Generators
Generator Sets Ð Parallel Operations EDS 75.3 LEHX1349
Caterpillar Zero Droop Voltage for Parallel EDS 75.5 LEKX8142 5/88
Operation
Brine Tank Load Test EDS 76.3 LEKQ3496 11/83
Synchronous Generators Ð NEMA Standards EDS 77.1 LEKX5360 5/95
Ambient Considerations when Applying EDS 78.4 LEKX3167 3/93
Generators
SR4B Generators and Control Panels Operation and SEBU6150-02 6/94
Maintenance
Manual
SR4B Generators and Control Panels Operation and SEBU6918 7/95
Maintenance
Manual
Customer Communication Module for 3500B OwnerÕs Manual SEBU6997 3/96
Engines
Customer Communication Module for EMCP OwnerÕs Manual SEBU6874-02 12/96
II
Generator Mounted Control Panel (EMCP II) Parts Book SEBP2265
for MUI engines
for PEEC engines
for EUI and Gas engines
Generator Mounted Control Panel (EMCP II+) Parts Book SEBP2534-01
for MUI engines
Generator Mounted Control Panel (EMCP II+) Parts Book SEBP2678
for PEEC engines
Caterpillar Automatic Transfer Switches for Parts Manual SEBP1258 2/96
Generator Sets
Digital Voltage Regulator Product News LEXX6512 9/96
Harmonic Wave Distortion Product News LEXX4343 9/94
Index Product News LEXQ8095 1/98
3500B Engines for Electrical Power Schematic SENR1004 10/96
Generation
3500B Engines for Electrical Power Schematic RENR1242 1/97
Generation (EPG) with EMCP
3500B Engines for Electrical Power Schematic RENR1243 1/97
Generation (EPG) with Switchgear
Conversion
3500B Engines for Electrical Power Schematic SENR1005 10/96
Generation (EPG) with Switchgear
Conversion
3500B Electronic Instrument Panel Service Manual SENR6587-01 10/96
Caterpillar Monitoring System Service Manual SENR6717 5/97
Caterpillar Switchgear Service Manual SENR8393 7/96
Electronic Modular Control Panel Service Manual SENR3535-01 1/91
Electronic Modular Control Panel (EMCP II) Service Manual SENR5809-03 2/97
for MUI
Electronic Modular Control Panel (EMCP II+) Service Manual SENR5832
for MUI
Electronic Modular Control Panel (EMCP II) Service Manual SENR5398 7/95
for EUI
Electronic Modular Control Panel (EMCP II+) Service Manual RENR1200
for EUI
Electronic Modular Control Panel (EMCP II) Service Manual SENR5394 9/96
for Gas
Electronic Modular Control Panel (EMCP II+) Service Manual RENR1201
for Gas
Floor Standing Switchgear Service Manual SENR7970 10/79
SR4 Electrical Set Generators Service Manual SENR7958 5/97
-----contains the following-----
Safety SENR2995
SR4 Generators
• SR4 Generator (Single Phase Half Wave) SENR7968
• SR4 Generator (Three Phase Full Wave) SENR2180
• SR4 Generator with VR3 or VR4 Voltage SENR3985
Regulator
• SRCV Generator SENR7962
• SRSE Generator SENR7964
• SRCR Generator SENR7966
Control Panels
• SR4 Control Panel (4W-8000) SENR4027
• SR4 Control Panel (9Y-1300) SENR3902
• SR4 Control Panel (9Y-1400) SENR3903
• SR4 Electronic Modular Control Panel SENR3535
• Electronic Modular Control Panel II(EMCP SENR5809
II)
• Electronic Modular Control Panel II(EMCP SENR5827
II) for Electronically Controlled Engines
• SR4 Generator Mounted Control Panel SENR5203
(4P-4780) for Spark Ignited (SI) Engines
Modules and Diagrams
• Connection Diagrams: SR4 & SR4B SENR4794
Generators, Voltage Regulators, Options
Voltage Regulators
• VR3 Voltage Regulator (4/6 Lead), Self SENR3904
Excited
Excited
• VR3f Flat Top Voltage Regulator (4/6 and SENR5205
10/12 Lead), Self Excited
• VR3 Voltage Regulator Permanent SENR5829
Magnet Excited SR4 Generators
• VR3F Voltage Regulator, Permanent SENR3905
Magnet Excited
• VR4 Voltage Regulator SENR3906
• Digital Voltage Regulator SENR5833
Rewind Data
• SR4 Rewind Data SENR2924
• SR4 Rewind Data SENR4941
• SR4 Rewind Data (3500 Engine Generator SENR5834
Sets)
Switch Gear
• Floor-Standing Switch Gear SENR7970
• Transfer Switches Operation & SEBU6234
Maintenance Manual
Maintenance
• Cleaning and Drying of Electrical Set SEHS9124
Generators
• SR4 Generators & Control Panels SEBU6150
Operations & Maintenance Manual
SR4B Electrical Set Generators Service Manual SENR8395
-----contains the following-----
Safety SENR2995
SR4B Generators
• SR4B Generator Service Manual SENR5359
Control Panels
• Electronic Modular control Panel II (EMCP SENR5809
II) for MUI Engines
II) for PEEC Engines
II) for EUI Engines
II) for Gas Engines
• Electronic Modular control Panel II+ SENR5832
(EMCP II+) for MUI Engines
• Electronic Modular control Panel II+ RENR1254
(EMCP II+) for PEEC Engines
• SR4B Generator Mounted Control Panel SENR5203
(4P-4780) for Spark Ignited (SI) Engines
• Generator Set Control Panel (130-3786) SENR8375
Modules & Diagrams
• Programmable Relay Control Module SENR6588
(PRCM)
• Connection Diagrams: SR4 & SR4B SENR4794
Generators, Voltage Regulators, Options
• Customer Communication Module for SEBU6874
EMCP II
Voltage Regulators
Excited
Excited
• VR3 Voltage Regulator, Permanent SENR3905
Magnet Excited
• VR3f Flat Top Voltage Regulator (4/6 and SENR5205
10/12 Lead), Self Excited
• VR3F Voltage Regulator, Permanent SENR5829
Magnet Excited
• VR4 Voltage Regulator SENR3906
• Digital Voltage Regulator SENR5833
Rewind Data
• SR4B Generator Rewind Data for 3500 SENR8319
Engine Generator Sets
• SR4 Generator Rewind Data SENR4941
Switch Gear
• Caterpillar Switchgear SENR8393
• Floor-Standing Switch gear SENR7970
• Transfer Switches Operation & SEBU6234
Maintenance Manual
Maintenance
• Cleaning and Drying of Electric Set SEHS9124
Generators
• SR4B Operation & Maintenance Manual SEBU6918
• SR4B Generator Set control Panel (130- SENU6918
3786)
SR4B Generators Service Manual SENR5359 7/95
Customer Communications Module Ð Software Manual JEBD3005
Getting Started
Customer Communications Module Software Software JERD2157
(includes
JEBD3005)
Alignment of Close Coupled Two Bearing Special Instructions REHS0177 11/97
Generators -- see also 3L-0415
Alignment of Single Bearing Generators Special Instructions SEHS7259-05 12/97
-- see also 3L-0414-02
Cleaning and Drying of Electric Generator Special Instructions SEHS9124 5/93
Sets
Technical Kit for Low Voltage Circuit Breakers Technical Kit LEBX3260 7/93
3500B Generator Set Engines Troubleshooting RENR2209 3/98
List of Commonly used TLAs
(Three Letter Acronyms)
Ñ -- Ñ Customer Wiring
A A mmeter
A/F A ir F uel Ratio
AB A dministration Building
AC A lternating C urrent
ACT A c t uator
ADEM A dvanced Diesel E ngine M anagement
ADS A ir D amper Position S witch
AFRC A ir F uel R atio C ontrol
AI A pplication I mplementation Ð Accommodation Invoice
AIF A uxiliary I nformation F ile
AIMS A (cluster) Ð I nformation M anagement S ystem
AIS A ssembly I nf. S ystem, Advance Inf. Services
ALM A l arm M odule
ALS A l arm S ilence Push Button
ALT A l t ernator
AMOCS A dvance M o dular C ooling S ystem (Radiator)
ANC A dvance N otification of C hange
ANS A dvance shipping N oticess
AOALT A dvance o n A l titude
AOCT A dvance o n Coolant T emperature
AOSS A dvance o n Steady S tate
APG A rizona P roving G round
API A merican P etroleum I nstitute
AQI A nnual Q uality I mprovement
AR A rming R elay
ASOS A ir S hut O ff S olenoid
ASSV A ir S tart S oleniod V alve
ASWC A ir S hielded W ater C ooled
ATAAC A ir T o A ir A fter C ooled
ATB A c T ransformer B ox
ATS A dvance Tech. S ystems, after test assembly
AUX A u x iliary Terminal Strip
AUXREL A u x iliary R e lay (Crank Termination)
AVL
AWG A merican W ire G auge
B/L B ill of L ading

B/M B ill of M aterial
BATT B a t t ery
BCF B attery C harger Malff unction
BCMS B attery C harger M alfunction S witch
BDE B ritish D epartment of E nvironment
BHP B rake H orsep p ower
BKW B rake K ilo W att (Engine output)
BMCM B ill of M aterial C onsist and Prices
BMDB B ill of M aterial D atabb ase
BMEP B rake M ean E ffective P ressure
BMMN B ill of M aterial In
n dicative Database
BMNO B ill of M aterial N o tes
BPT B usiness P lan T racking
BSAU B ritish S tandards A u tomobile Series
BSFC B rake S pecific F uel C onsumption
BSOC B rake S pecific O il C onsumption
BSSB B uilding S ervices S tandbby
BTDC B efore T op D ead C enter
BTM B rushless T orque M otor
BTRT B ottom of Top R ing Travel
C C ommon
C/R C hamfer/R R adius or Compression Ratio
CACO C at A mericas C o .
CAD C omputer A ided D esign
CAECAM C omputer A ided E ngineering C omputer A ided M anufacturing
CAM C omputer A ided M anufacturing
CAMPAR C omputer A ided M arketing P A R
CAP C ost A voidance P otential
CAPP C orp. A ccounts P arts P urchases
CAPS C orp. A ccounts P ayable S ystem
CARB C alifornia A ir R esources B oard
CAT PC C a t erpillar Engine P ower C onnection
CB C ircuit B reaker
CBSA C aterpillar B razil S outh A merica
CBT C omputer Based T raining
CCA C old C ranking A mp
CCAC C ombine C ircuit A fterc c ooler
CCR C ycle C r ank Module
CDIS C at. D lr. I nformation S ystem
CDM Engine C oold d own Timer M odule
CEOPS C orporate E ngine O rders P rocessing S ystem
CFA C harger F ailure A larm
CFEL C at. F ar E ast L imited
CGT C ollege G raduate Trainee
CIDB C ustomer I nformation D atab b ase
CIS C orporate I nformation S ervices
CLS C at. L ogistics Services
CMLS C orp. M ail L ist S ystem
CMM C ustomized M aintenance M anagement
CMOPS C orporate M achine O rders P rocessing S ystem
CMP C ustom M achined P roduct
COMPREX Air Injection System (C C o m p r e ssion)
COSA C aterpillar O verseas S A
CPC C onstant P ressure C ombustion
CPPD C oncurrent P roduct P rocess D evelopment
CPR C ompetitive P arts R eports
CPS C ycles P er S econd
CR C ompression R atio
CSA C anadian S tandards A ssociation
CSFC C alculated/Corrected Specific F uel C onsumption
CSM C ustom S hop M odification
CSM C aterpillar S hin-MM itsubishi
CSSI C ustomer S ervice S atisfaction I ndex
CSTG C at S ervice Technology G roup
CT C urrent Transformer
CTCO C aterpillar T ractor C o mpany
CTR C rank T ermination R elay
D D iode
D/N D ealer N et
DBS D ealer B usiness S ystem
DC D irect C urrent
DCAL D ealer C ustomer A cceptance L evel
DCS D ealer C hannel S ystems
DCTB D iscc ount Pricing Tab b le
DCV D C V oltmeter
DDS D ealer D ata S ystem
DDT D igital D iagnostic T ool
DF D eterioration F actor
DFA D esign F or A ssembly
DFM D esign F or M anufacturability
DFT D ealer F orecast T racking
DI D irect I njection
DISTA D irect I njection S eries T urbo A ftercooled
DIT D irect I njection T urbocharged
DITA D irect I njection T urbocharged A ftercooled
DITAAAAC D irect I njection, T urbo Cha a rged, A ir to A ir A fterc
c ooled
DITTA D irect I njection T win T urbo Charged A ftercooled
DLRTSO D eall err T ime S hare O ption
DMT D uring M achine T ime
DOLRS D ealer O n L ine R egistration S ystem
DOS D isc O perating S ystem
DPO D ealer P arts O rders
DPORS D ealer P arts O rders R eporting S ystem
DPSR D ata P rocessing S ervice R equest
DRF D ealer R epair F requency
DRS D iagnostic R eset S witch
DSDB D iscount S tandards D atab b ase
DSUO D ealer S olicited U ser O rder
DTF D ivision Topic F ailure
DTR D ealer T ransaction R eporting
DTS D ealer T erminal S ystem
DTSO D -TT ime S haring O ption
E&E E lectrical & E lectronic

E & E Eng E lectric & E lectronic E ngineering
E.O. E ngineering O rder
EC c Test Procedure
E lectronic
EC&SE E lectrical C omponents & S tandard E ngineering
ECAP E lectronic C ontrol A nalyzer and P rogrammer
ECE E conomic C ommission for E urope
ECLC E MCP C oolant L oss Sensor C onnector
ECLS E MCP C oolant L oss S ensor
ECM E lectronic C ontrol M odule
ECS E ngine C ontrol S witch
ECTS E MCP C oolant T emperature S ensor
EDAG E ngine D ivision A dministrative G roup Procedure
EDE E ngine D ivision E ngineering
EDI E lectronic D ata I nterchange
EDS E ngineering Data S ystem
EDSE E ngine D ivision S ervice E ngineering
EDT E ntering D ifferential T emperature
EEC E uropean E conomic C ommunity
EFL E ngine F ailure L ight
EG E lectronic G overnor (Speed Sensing)
EG-3C E lectronic G overnor Ð 3 1 LB. FT. C ompensated
EG-3P E lectric G overnor Ð 3 1 LB. FT. P roportional
EGA E lectronic G overnor A ctuator
EGC E lectronic G overnor C ontrol
EGR E xhaust G as R estrictor or Exhaust Gas Recirculation
EIA E ngine I nvestment A nalysis
EIMS E ngine I nformation M anagement S ystem
EIS E lectrical I nformation System
EKW E lectrical K ilo W att (Generator output)
EMCP E lectronic M odular C ontrol P anel
EMP E ngine/M M achine/Lift Truck P opulation
EOCC E MCP O il C oolant Sensor C onnector
EOCS E ngine O rder C ommunication S ystem
EOCS E ngine O rder C ommunication S ystem
EOD E ngine O rder D ivision
EOPS E MCP O il P ressure S ensor
EP Eng. E ast P eoria E n gineering
EPA E nvironmental P rotection A gency
EPG E lectric P ower G eneration
EPSR E ngine P roduct S upport R ep.
ERG E xhaust R ecirculation Gases
ES E mergency S top
ESC E xtended Service C overage
ESL E mergency S top L ight
ESO E ngine S hipping O rder
ESPB E mergency S top P ush Button
ESRS E ngine S pecification R eporting S ystem
ESS E lectronic S peed S witch
ET E ngine T est
ETDS E ngine T echnical Data S heets
ETE E ngine T est E valuation
ETR E nergize To R un
ETS E nergize To S hutdown
EUI E lectronic U nit I njector
EXC E x c avator
F F use
F/U/W F or U se W ith
FACM F a c toring Pricing Table
FARC F uel A ir R atio C ontrol
FCR F uel C ontrol R elay
FEA F inite E lement Analysis
FEL F amily E mission L imit
FHP
FIND F or I nformation, N ews & D ocuments
FL F l age Cooled (liner)
FLEX F l e x ible Scheduling System
FLS F ull L oad S tatic Fuel Setting
FLS/FTS F ull L oad S etting// F ull T orque S etting
FMEA F ailure M ode E ffects A nalysis
FMECA F ailure M ode E ffects & C riticality A nalysis
FON F leet O wners N et
FRACS F actory R eporting and A ccounting S ystem
FRB F uel R upture Basin
FRC F uel R atio C ontrol (Rack Limiter)
FS F uel S olenoid
FSOS F uel S hut O ff S olenoid
FTS F ull T orque S tatic Fuel Setting
GAV G as A dmission V alve

GFR G enset F ault R elay
GO G eneral O ffice
GOV G o v ernor
GRPTS G uidelines For R eusable P artt s
GS G overnor S witch
GSC G enset S tatus C ontrol
GSM G overnor S YNC M otor
GSOV G as S hut-o
o ff V alve
HEDC H ydraulic E xcavator Design C ontrol

HEPL H ydraulic E lectronic P ump & L ine
HEUI H ydraulic Actuated E U I
HHDE H eavy H eavy D uty E ngine
HI H igh I dle
HMSO H ydrom m echanical S hut O ff
HP H orsepower, Hewlitt-P P ackard
HPIT Governor
HYDRA-MECH H y d r a M e c h anical Governor
Hz H ertzz (CPS)
HZ Frequency Meter
IC Remote Start I nitiate C ontact

ICTB c ompany Pricing Factt ors for Sub
I nterc b sidiaries
ID I nside D iameter
IEC I nternational E lectro-Technical Commission
IHP
ILSC I n-ll ine S uper C harging
IMPCO I m p erial C o ., Carburetor
IMRM I mproved M ulti-R R ow M odule (Radiator)
IMS I nf. M anagement S ystem
IOUS I ndex of U nreliability S everity
IR I nfrarr ed
ISDB I nvoicing Standard D atab b ase
ISO International S tandards O rganization
IT I ntegrated Toolcarriers
IVDB v oicing D atab
I nv b ase
JIC J oint I ndustrial C ouncil

JIT J ust-ii n-TT ime (Juran Lingo)
JITD J ust-ii n-TT ime D elivery (Juran Lingo)
JWAC J acket W ater A fter C ooler
KE K e nworth
kW w att
K ilow
L L oad Leads
LCV L ow C revice V olume (Piston)
LDPO L ift Truck Dealer P arts O rders
LEUI L inear E U I (Linear Electronic Unit Injector)
LFB L ow F uel Basin
LFI L ow F uel Indicator
LFLAS L ow F uel L evel A larm S witch
LI L ow I dle
LTL L oose T op L oad (piston)
LVA L ow V oltage A larm
LWLAS L ow W ater L evel A larm S witch
LWLAS L ow W ater L evel A larm S witch
LWTAS L ow W ater T emperature A larm S witch
LWTI L ow W ater T emperature I ndicator
LWTL L ow W ater T emperature L ight
MAG M a g neto
MAN M a n uel
MASH M a chine S ales H istory
MCE M ajor C omponent E xchange
MCG M achine C lassification G uide
MCP M ajor C omponent P rice
MCS M aterial C ontrol S ystem, Marine Classification Society
MEPS M arine E ngine P arts & S ervice
MG M otor G rader
MHA M aterial H andling A rrangement
MHDE M edium H eavy D uty E ngine
MHI M itsubishi H eavy I ndustries
MIS M arketing I nformation S ystem
MISO M isc. I nterplant S hipping O rder
MIT M isc. I nterplant Transfer
MMIS M achine M arketing I nformation
MMS M ossville M anagement S ystem
MOD M achine O rder D ivision
MOL M edium O verll ap (camshaft)
MPDB M arket P rice D atab b ase
MPLT M aster L ist/Net P rice
MPNO M aster P rice N o tes
MPRT M aster P r ice Indicative Data
MPS M arine P ower S ystem
MPU M agnetic P icku up
MSHA M ine S afety & H ealth A dministration
MTBF M ean T ime B etween F ailures
MUI M echanical U nit Injector
N/F/U/W N ot F or U se W ith
NA N aturally A spirated
NACD N orth A merican C ommercial D ivision
NC N ormally C losed
NEG N e g ative
NPI N ew P roduct I ntroduction
NPR N umerical P art R ecord
NSFS N ew S croll F uel System
NTSA N ational T ransportation & S afety A dministration
OCI O verc c rank I ndicator

OCL O verc c rank L ight
OCT O verc c rank T imer
OD O utside D iameter
OEM O riginal E quipment M anufacturer
OHT O ff H ighway Truck
OIL O ffice I nformation L etter
OLPL O n-LL ine P rice L ist
OP O il P ressure
OPG O il P ressure G age
OPI Low O il P ressure I ndicator
OPL O il P ressure L ight
OPS3 O il P ressure S witch
OPT O verhaul P rotection for T rucks
OS O verss peed
OSI O verss peed I ndicator
OSL O verss peed L ight
OTO O n-TT ime-OO nly (Pricing)
OWS O il W ell S ervice
P.O. P urchase O rder

PA P ricing A rrangement
PABACS P a rts B ook A utomated C ompiling S ystem
PAN P roduct A ctivity N otice
PAR P erformance A nalysis R eport
PAT P roduct A cceptance T est
PATS P eoria A rea T elephone S ystem
PC P re-combustion C hamber, Personal Computer
PCI P roduct C ode I ndex (E&E Budget Term)
PCP P eak C ylinder P ressure
PDCC P ower D emand C ruise C ontrol
PE P aving E quipment
PEEC P rogrammable E lectronic E ngine C ontrol
PERG P roduct E valuation R eliability G rowth
PERG P rediction & E valuation of R eliability G rowth
PES P arts E xchange S ervice
PET P roduct E valuation T est
PF P ower F actor
PF P urchased F inished
PI P ersonal I nvolvement, People Involvement
PIC P rice I n C hassis
PIMS P roduct I nformation M anagement S ys., Parts Marketing Information
PINS P ercentage of I n dustry S ales
PIP P roduct I mprovement P rogram
PIR P roduct I nformation R eport
PIR P roduct I mprovement R equest
PIS P roduct I nformation S ystem
PIT P roblem I dentification T eam
PL P ipe L ayers
PLS P anel L ight Switch
PM P reventative M aintenance, Participative Management
PMIS P arts M arketing I nformation S ystem
PMS P roblem M onitor S ystem (Lafayette)
PMTPS P edal M ounted T hrottle P osition S ensor
PNPI P art N umber P rice I nquiry
POPS P ercentage o f P otential S ales, POPS-c = Cat
POS P o s itive
POT P o t ential (Average water temp. Ð Entering air_
PP P relube P ump
PPDB P arts P ricing D atabb ase
PPG P eoria P roving G rounds
PPL P lant P roblem L ist
PPMS P relube P ump M agnetic S witch
PPPS P relube P ump Oil P ressure S witch
PR P re-R R egulator
PRDB P roduct R eference D atab b ase
PRIDE P roduct R eliability I mprovement D efinition E ffort
PRL P iston R ing L iner
PRM P roduct R eliability M onitoring
PS P inion S olenoid
PS&EC P roduct S afety & E nvironmental C ontrol
PSA P art S tock A uthorization, Power Systems Associates, Product Support
Agreement
PSD P ower S ystems D istributors
PSG P ressure Compensated S imple G ov. (Woodward)
PSP P roduct S upport P rogram
PSR P arts S tock R ecommendation
PSSR P roduct S upport S ervice R epresentative
PWM P ulse W idth M odulated Speed Signal Converter
PWR P oww err
Q4 Q ueersome Quartet
QAR Q uality A lert R ecommendation
QFD Q uality F unction D eployment
QIR Q uality I mprovement R equest, Quality Inspection Report
QWS Q uote W riter S ystem
R/A R ocker A rm
RAN R emote A n nunciator (For NFPA 110 or NFPA 99)
REMAIN R e m a n ufactured
RFM R ental F leet M anagement
RMN m anufactured Pars In
R em n formation
ROI R eturn o n Investment
ROSS R etard o n Steady S tate
RPIR R equest For P roduct I mprovement R equest
RPL R everse P ower L ight
RPM R evolutions P er M inute
RPR R everse P ower R elay
RPTO
RR R un R elay
RTS R eady t o Ship
RTV R oom T emperature V ulcanizing
RWAC R aw W ater A fter C ooled
S/N S erial N umber

S/N S erial N umber
S/T S peed T iming (Sensor)
SAE S ociety of A utomotive E ngineers
SASV S tart A id S olenoid V alve
SATS S tart A id T emperature S witch
SCAC S eparate C ircuit A fterc c ooled
SCFS S c roll F uel S ystem
SCR S ilicon C ontrolled R ectifier
SCTE S ingle C ylinder T est E ngine
SD S hut-D D own
SDC S oftware D istribution C enter
SEA S elective E nforcement A udit
SEC S e c ond
SEGO S ervice E ngineering G eneral O ffice
SER S pecial E ngineering R equest
SG S mall G overnor
SG&A S elling G eneral & Administrative
SHP S h ipment P INS
SHTC Circuit Breaker S h unt Trip C oil
SI S park I gnited
SID S plit I njection D evice
SIEC S I E lectronic Engine Control (Lean Burn)
SIG S i g nal
SIMS S ervice I nformation & M anagement Sys.
SIRS S ervice I nformation R etrieval S ystem
SIS S ervice I nformation S ystem
SL S ynchronizing L ight
SLC S uper L ine C harged
SLM S ynchronizing L ight M odule
SLR S ynchronizing L ight R esistor
SM S tarting M otor
SM/TEN S ervice M agazine/TT ruck E ngine N ews
SMCS S ervice M anagement C ontrol S ystem
SMFS S leeve M etering F uel S ystem
SMMS S tarting M otor M agnetic Switch
SMR S tarting M otor R elay
SMU S ervice M eter U nits (Miles/Hours)
SOC S uggested O bjective C ost
SOD S ales O rder D ivision
SODB S hipping and O rder D atab b ase
SOF S oluble O rganic F ractions
SOHC S ingle O verh h ead C amshaft
SOI S tart o f Ignition
SOS S cheduled O il S ampling
SP S peed Adjust P otentiometer
SPAR S pecial P rice A ssistance R equest
SPC S tatistical P rocess C ontrol
SPD POT S p eed d Setting P o t entiometer
SPI S imilar P arts I ndex
SPL S imilar P arts L ist
SPM S ervice P rogram M odule
SPPS S et P oint P eak S having
SRCR S tatically R egulated Controlled R ectifier
SS S ynchronizing Switch
SSG Machine Shipments/SS ales/Inventory
SSI S hipments, S ales & I nventory
SSS S tart-SS top S witch
STDB S tandards T able D atab b ase
STTS S hunt T rip T erminal S trip
T Generator Line Leads

T&D T est a n d D evelopment
T&E T est a n d E valuation
TBAM A larm M odule Terminal Strip
TBC T hermal B arrier C oating
TC T echnical C enter
TD T ime D elay
TDC T op D ead C enter
TEAM T ruck E ngine A ccount M anager
TEBM T ruck E ngine B usiness M anager Ð Dealer Employee
TED T otal E stimated Demand
TEDM T ruck E ngine D istrict M anager Ð Cat Emp. (37)
TEMP T argeted E ngine M arketing P lan
TEN T ruck E ngine N ews
TEOC T ruck E ngine O wner/s C lub
TEPS T ruck E ng. P arts & S erv. Or Total Eng. Product Support
TERM T ruck E ngine R egional M anager Ð Cat Emp. (9)
TIB T echnical Information B ulletin
TIF T echnical Information F ile
TIR T otal I ndicator R eading or Tech. Information Release
TLA T hree L etter A cronym
TMI T echnical M arketing I nformation
TOA T rack O perations A nalysis
TOPP T ruck O wners P rotection P lan
TPA T ruck P erformance A nalysis
TPC T otal P lant C ost
TPS T hrottle P osition S ensor
TRG T ime R equirement G uide
TSC T ransfer Switch Position C ontact
TSODB T emporary S hipping And O rders D atab
b ase
TTL T ight T op L and (piston)
TTRT T op of T op R ing Travel
TTT T rack T ype T ractor
UCC U niform C ommercial C ode

UG U niversal G overnor
UTEPP U sed T ruck E ngine P rotection P lan
V AC V olimeter
VAR V oltage A djust R heostat
VI V iscosity I ndex
VMIS V ehicle M onitoring I nformation S ystem
VOP V alve O pening P ressure
VSL V ehicle S peed L imit
WDWRD W oodd w arr d Governor

WHAM W iebul H azard A nalysis M ethod
WHP W heel H P
WL W heel L oader
WSA W orld S ales A nalysis
WT W ater T emperature
WTG W ater T emperature G age
WTI High W ater T emperature I ndicator
WTL W heel T ractor L oader
WTS W heel T ractor S craper
XDUCER ducer
Transd
Z Z eener Diode

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3500 EPG

Technical Information Kit

Section 2 Ð Operating Characteristics

Section 3 Ð Application Notes

Section 4 Ð Generator Protection

Section 6 Ð Special Quotations

Section 7 Ð Voltage Regulators

Section 8 Ð Transient Response

Section 9 Ð Wiring Diagrams

The information contained in this publication is the property of Caterpillar Inc.

Generator information includes:

Rated Volts, Line Leads, Wires Per Lead

Line-to-neutral voltages for wye-connected generators can be calculated by dividing the

Number of Poles / Synchronous Speed

Overspeed Capability Ñ Percent

If the generator coils are connected in parallel for low voltage:

If the generator coils are connected in series for high voltage:

Transient reactance in ohms is:

Saturated Ñ Where applicable, figures are calculated at magnetic saturation.

Example: Generator base amps = 263 A

Asymmetrical refers to a current, which is not centered, or symmetrical, to a fixed reference

Rated current times that multiplier equals RMS symmetrical current:

Negative Sequence Reactance

236 x 1.732 236 x 1.732

RMS asymmetrical value is determined from:

Zero Sequence Reactance

For a generator at 60 Hz, 219 kV•A, 263 amperes and X0 of 0.0450:

Open Circuit Time Constant

Exciter Field ResistanceÑOhms, Exciter Voltage No Load, Rated Load and

Derate Altitude (m)

Typical European Altitude NEMA Design

See information on temperature rise.

Efficiency at 0.8 Power Factor

Heat Dissipated - Btu/min, kW

Mounting Flange Number

Waveform Deviation Factor

Telephone Influence Factor

Generator Chart Terminology

Connections Ð Leads, Wires, and Size

Stator Temp. Det. (Stator Temperature Detectors)

Package Restrict Codes

132-3667 690 Frame sizes Ð 2 Bearing

Sheet # 1- Generator general dimensions (Printed on the following pages)

SR4 A643 447 1212720 1212719 45034700 810 2340

These charts are for INTERNAL USE ONLY!!

The information contained in this publication is the property of Caterpillar Inc.

Frame Volts at 50 Hz thermal Ratings (EkW) 60 Hz thermal Ratings (EkW)

* Denotes that reports are available upon request

Frame Generator Engine Freq. Speed kW Torsional Notes

684 7C-3067 7W-8676 3508 50/60 1000/1200 N/A 8354

The information contained in this publication is the property of Caterpillar

LEHX1423 (EDS 75.1) Ð Currents Ð Circulating in Parallel Generators

i. Sensing isolation transformers (TX1 and TX2 in the diagram)

ii. Droop isolation transformer (TX3 in the diagram)

Shorting contacts must be provided across each Droop CT in the circuit to

2. For generators which utilize a Droop Isolation Transformer (TX3):

# of Wires per Phase 7500 8

• 130-8240 Ð Low voltage sensing isolation transformer (480:120) for SE to PM conversion.

• 123-6046 - 1Ω Power resistor