tb09500001e(generator paralel swgr)

8/11/2019 TB09500001E(Generator Paralel SWGR)

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CA08104001E For more information, visit: www.eaton.com/consultants

September 2011

Contents

40Cat Generator Paralleling Switchgear

Sheet 40001

CatGenerator

Paralleling

Switchgear

Cat

Generator Paralleling Switchgear

Introduction

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.0-2

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.0-4

Cat Switchgear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.1-1

Standard and Custom Configurable Products . . . . . . . . . . . . . . . . . . .

40.1-2

Cat Switchgear Control Technology Features. . . . . . . . . . . . . . . . . . . .

40.1-3

XLM Switchgear


40.2-1

Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.2-2

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.2-3

Technical DataXLM One-Line Diagrams . . . . . . . . . . . . . . . . . . . . . .

40.2-4

Functional Sequences of Operations. . . . . . . . . . . . . . . . . . . . . . . . . . .

40.2-10

EGP Switchgear


40.3-1

Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.3-2

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.3-3

Technical DataEGP One-Line Diagrams . . . . . . . . . . . . . . . . . . . . . . .

40.3-4

Functional Sequences of Operations. . . . . . . . . . . . . . . . . . . . . . . . . . .

40.3-12

Medium Voltage Systems


40.4-1

XLM Medium Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.4-4

EGP Medium Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.4-8

Custom Systems


40.5-1

Technical DataOne-Line Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.5-2

Specifications

See Eatons Product Specification Guide

, available on CD or on the Web.

CSI Format: . . . . . . . . . . . . . . . . . . . . . . . . . 1995 2010

Low Voltage XLMUL 1558 Switchgear . . . . . . . . . . . . . . . . Section 16426E Section 26 23 13.11

Low Voltage XLMUL 891 Switchboard . . . . . . . . . . . . . . . . Section 16429E Section 26 24 13.31

Medium Voltage XLMMetal-Clad Switchgear. . . . . . . . . . . . . . Section 16346E Section 26 13 26.13

Low Voltage EGPUL 1558 Switchgear . . . . . . . . . . . . . . . . Section 16426G Section 26 23 13.13

Low Voltage EGPUL 891 Switchboard . . . . . . . . . . . . . . . . Section 16429G Section 26 24 13.33

Medium Voltage EGPMetal-Clad Switchgear. . . . . . . . . . . . . . Section 16346G Section 26 13 26.16


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CA08104001E

September 2011

Cat Generator Paralleling Switchgear

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Introduction

General Description

002

Introduction

General Description

Cat

Generator Paralleling Switchgearis a product developed through a jointventure between Caterpillar and EatonCorporation. Caterpillar, an industryleader in electric generator sets, andEaton, an industry leader in Low andMedium Voltage Switchgear havecombined forces to create CatGenerator Paralleling Switchgear...the most reliable and feature richproduct available in the market today!

Cat Switchgear has been designedto integrate hand-in-glove withCaterpillars on-package, microproces-sor-based engine control. Exclusivelyfrom your Caterpillar dealer, you cannow get the markets best efficiency,reliability and dependability all in

one package.

Cat Switchgear combines the provenlow voltage Magnum DS power circuitbreaker and Magnum Switchgear withCat Switchgear control technology.Cat controls technology is for optimalpower generation and electricaldistribution system performance.It provides advanced, industry-leading, microprocessor-basedengine generator set controlprovided exclusively in Cat Switch-gear. Medium voltage systemscombine VCP-W breakers and VacCladMetal-Clad switchgear with the sameproven generator control technology.

Applications

Emergency/legally requiredstandby systems

Optional standby backup systems

Distributed generation

Peak shaving

Prime power

Reliable, flexible and powerful.Cat Switchgear is designed with themost critical power needs in mind:

Data center/data processing

Healthcare

Critical industrial/chemicalprocesses

Distributed generation/cogeneration

Water/wastewater treatment

Government/military

Banking/credit card processing

Landfill gas power

Cat Switchgear Features

Built-in redundancy

Reliability

Touchscreen interface

Simple, intuitive operation

Advanced communications

capabilities

Integrated digital technology

Advanced generator control andprotection

Detailed engine and electrical reports

Best-in-class footprint

XLM Medium Voltage


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Introduction

General Description

003

Standards

Low Voltage Cat Switchgear conformsto the following applicable standards:

NEMA

Standard SG-5

CSA

ANSI C37.20.1

ANSI C37.51

UL

Standard 1558

NFPA 110, NFPA 99 and NFPA 70

The switchgear uses Magnum DSBreakers that are designed to NEMAStandard SG-3; ANSI StandardsC37.13, C37.16, C37.17 and UL 1066.Optional switchboard constructionis available that is built to UL Standard891. These switchboards use MagnumSB Breakers for generator mains,utility mains and electrically operatedfeeders, and molded-case breakers fornon-switched feeders.

Medium Voltage Cat Switchgearconforms to the following applicablestandards:

NEMA SG-5

ANSI/IEEE C37.20.2

CSA-C22.2 No. 31-M89

EEMAC G8-3.2.

NFPA 70, 99, 110

The switchgear uses VCP-W vacuumcircuit breakers that are designedto meet or exceed all applicableIEEE/ANSI standards including C37.06.

Common ComponentsThroughout the Entire Facility

Cat Generator Paralleling Switchgearis built with Eatons industry-leadingMagnum DS low voltage drawoutswitchgear with Magnum DSbreakers and VacClad mediumvoltage switchgear with VCPWvacuum breakers. This allows theuse of common components on boththe normal power systems and thegenerator power systems. Commonand interchangeable breakers, relays,switchgear assembly parts, breakermaintenance procedures, and so on

can be used to help reduce the overalloperating cost and increase themaintainability of the entire facility.

Overview

Detailed Engine Data

Generator Set Control Screen


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Introduction

Definitions

004

Definitions

The terms and acronyms below arereferenced throughout this sectionon Generator Paralleling Switchgear.These definitions can help the readerfully understand the topics discussed.

Alternator

: A device for convertingmechanical energy into alternatingcurrent electrical energy. It mayalso be called an AC or synchronousgenerator.

ATS

: Automatic Transfer Switch.

Automatic Transfer Switch

: A switchdesigned to sense the loss of onepower source and automaticallytransfer the load to another sourceof power.

Closed-Transition Transfer

: A transferbetween sources that provides amomentary paralleling of both power

sources during a transfer in eitherdirection. This results in no interrup-tion of power to the loads during thetransfer. The closed transition transferis only possible when the sources areproperly synchronized and interfaced.

DGPS Distributed Generation PowerSystem

: Typically a local enginegenset and automation connectedto the utility system to peak shaveor export power.

EGP Switchgear (Engine GeneratorParalleling Switchgear)

: Parallelsmultiple engine/gensets to serve loadstransferred via downstream ATS units.

EGPT Switchgear

: Same as EGPexcept with a controlled emergencygenerator bus tie breaker betweensets of generators to segregate loadsor areas of the bus.

EMCP 3.S

: A Caterpillar microproces-sor module for switchgear control,rugged, industrially hardened,microprocessor-based synchronizerand load controller designed towork exclusively with Cat engine-generator sets.

EMCP Electronic Modular ControlPanel

: A Caterpillar microprocessormodule for engine/genset control.

Emergency Generator Bus Tie

: A bustie breaker used in EGP type systemsto segregate groups of generators and/

or loads. Emergency Generator BusTie breakers are used where criticalloads, required to be powered in10 seconds, exceed the capacity ofa single genset.

EPS Emergency Power System

:The emergency power sources andemergency distribution to down-stream loads.

EPSS Emergency Power System Sup-plier

: Supplier of all the components ofthe EPS, such as the Caterpillar dealer.

Emergency Standby PowerApplication

: Typical usage of 50 hoursper year with a maximum of 200 hours

per year. Generators can be appliedat their Standby rating with a typicalvariable load factor of 70%.

Emergency Tie Breaker

: A feederbreaker that is used to connect anEGP type system to a separate pieceof Normal (utility) switchgear.

Feeder Breaker Controls

: Automationcontrols to allow control of thedistribution feeder devices for loadshed/load add control and monitoring.

Generator

: A machine for convertingmechanical energy into electricalenergy. The electrical energy maybe direct current (DC) or alternating

current (AC).

Generator Bus Tie

: A bus tie used inXLM type systems for separating thegenerator bus and/or loads from thenormal utility fed bus and/or loads.

Generator Demand Priority

: Controlsthat automatically match the onlineengine generator capacity to theload to avoid unnecessary enginegenset operation when loads arelow. (Alternatively called Load SenseLoad Demand.)

Generator Tie Breaker

: A feederbreaker that is used to connect anXLM type system to a separate pieceof Normal (utility) switchgear.

Governor

: A device that regulatesprime mover speed by adjusting the

fuel input to maintain constant speed.

HMI Human Machine Interface

:Typically a touchscreen used bythe operator for interfacing with theparalleling generator system.

LM Switchgear (Load ManagementSwitchgear)

: A single generatorused in distributed generationpower systems. Includes automationcontrols that allow for the load tobe served simultaneously by bothutility and generator power sourceswhile managing how much eachsource contributes.

Load Shed/Load Add

: Automation

controls to control distribution devices(turn OFF and restore ON) when onlypartial emergency engine gensets areavailable for duty. Typically accom-plished by assigning Priority levels toeach controlled distribution device.

Master Controls

: All processors,HMI and programming to implementthe desired modes of operationof engine gensets in a parallelingswitchgear system.

NFPA 110Standard for Emergencyand Standby Power Systems

:Standard for the assembly, installationand performance of electrical power

systems to supply critical and essentialneeds during outages of the primarypower source.

NPS Normal Power System

: Theutility service entrance equipmentand distribution circuits to down-stream loads.

NPSS Normal Power System Supplier:Supplier of all the components of theNPS, such as the distribution equip-ment vendors authorized distributor.


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Introduction

Switchgear Selection007

Cat Switchgear Selector

Table 40.1-1. Cat Switchgear Selector

TabSection

VoltageRange

AvailableSwitchgearListings

ParallelMultiple

Gensets

ParallelWith

Utility

Standby

Application

Transfer

Switches

Modes of Operation ApplicationConsiderations

Emergency

(Standby)

SoftLoad

(ClosedTransition)

PeakShaving

LoadShed/

LoadAdd

Export

Transfer and Load Management Paralleling Switchgear (XLM)

40.2 208600V UL 1558UL 891

XLM product is used when genera-tors will be paralleled with a utility(even if utility breaker is not locatedin the same line-up as generatorbreakers). Allows closed transitiontransfer to/from utility, continuousparalleling with utility for peakshaving or exporting.

Emergency Generator Paralleling Switchgear (EGP)

40.3 208600V UL 1558

UL 891

EGP product is used to parallel

multiple gensets to a common buswhere interconnect with the utilityis not necessary. EGP systems aretypically used where there aredownstream Transfer Switches.

Medium Voltage Paralleling Switchgear

40.4 2.427 kV ANSI C37.20.2ANSI C37.20.3

Medium Voltage product is forapplications in excess of 600 Vac.Systems are available in any ofthe configurations above (XLM orEGP). Medium Voltage systems usevacuum circuit breakers for genera-tor and distribution switching.

Custom Paralleling Switchgear Products

40.5 20827 kV UL 1558UL 891ANSI C37.20.2ANSI C37.20.3

Custom Products are available tomeet the most demanding or uniquesystem requirements. (Ex., multipleutilities, multiple ties, special loadcontrol, custom sequence ofoperations, and so on)

G

XLM

GG

EGP

52

MV


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Introduction

Standard and Custom Configurable Products008

Standard ConfigurableProducts

Cat Switchgear is available in twostandard product configurations:

XLM(Emergency Transfer (Xfer)and Load Management)

EGP (Emergency GeneratorParalleling)

These configurations are availablefor both low voltage and mediumvoltage applications and representthe most typical paralleling switchgearconfigurations seen in the industry.Additionally, custom configurationsare available to meet the demandsof even the most unique andcomplicated systems.

XLM

XLM(Emergency Transfer (Xfer)and Load Management) switchgearis used when the Generators areparalleled with a normal utility(or multiple utility) power source(s).XLM switchgear allows closed transi-tion, soft-loading and unloading fromutility, and peak shaving capabilitywhere generators operate continu-ously in parallel with the utility.Typically, XLM switchgear eliminatesthe need for automatic transferswitches. Data centers, industrialprocess, and other critical processloads are prime candidates for XLMswitchgear. For detailed XLM product

description, specifications, layouts,and so on, refer to Section 40.2.

EGPEGP(Emergency Generator Parallel-ing) switchgear is used for parallelingmultiple generators that are notdirectly connected to a utility source.EGP switchgear is primarily used

in applications where downstreamautomatic transfer switches providethe switching between normal andemergency sources. This is what istypically required in medical facilities,hospitals, and water/wastewatertreatment facilities when multiplegenerator sets are paralleled.For detailed EGP product description,specifications, layouts, and so on, referto Section 40.3.

Medium Voltage Switchgear

Medium voltage switchgear isavailable in custom configurations,as well as standard configurationslisted in this section. Medium voltageCat Switchgear uses the same controltechnology and operator interface,and has all of the same features andfunctions as the low voltage systems.At the heart of all medium voltageCat Switchgear systems is EatonsVac-Clad metal-clad switchgear withtype VCP-W vacuum circuit breakers.For detailed medium voltage (5 and15 kV class) product descriptions,specifications, layouts, and so on, referto Section 40.4.

Custom Products

Custom switchgear is available tomeet the needs of the most demand-ing, unique or complicated systemconfigurations. Custom engineered

systems are available for specialsystem requirements such as: customsequences of operation, special loadcontrol requirements, multiple utilityand tie combinations, unique switch-gear locations or layouts, and so on.No matter how complicated or uniquethe system, Cat Switchgear has thepower and flexibility to handle it. Fordetailed custom product description,specifications, layouts, and so on, referto Section 40.5.

Cat C175 Genset


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Introduction

Cat Switchgear009

Cat Switchgear Control Technology Features

Figure 40.1-1. Cat Switchgear Automation ArchitectureHigh Redundancy Package

Features are common to all Low andMedium Voltage configurations.

Cat Switchgear uses the EMCP 3.S,an advanced, industry-leading,multifaceted, microprocessor-basedgenerator set control designed towork exclusively with Cat engine-generator sets.

Redundancy and Fault ToleranceCat Switchgear Control Technologyprovides maximum efficiency andreliability. With Cat Switchgear, singlepoints of failure are eliminated

because of the multiple levels ofredundancy and fault tolerance thatare built into the system:

1. True Distributed Processing.A separate automation controllerfor each power source ensuresthe system continues to operateeven if a single controller fails.This architecture allows the useof redundant Moving MasterTechnology.

2. Moving Master Technology.Master control functions, such asmodes of operation, load shedcontrols, generator demand prioritycontrols, and dead bus logic, andso on, reside in the Generator #1EMCP 3.S. If Generator #1 control-ler fails for any reason, the nextgenerator controller will assumemaster control functions withoutinterruption. Each generator con-troller is redundant to the first andcontains all the settings necessaryto assume master control func-tions. This technology ensures that

if a generator set is available, CatSwitchgear will automatically bringit to the bus.

3. Seamless and Bumpless Transfer.With Moving Master Technology,each EMCP 3.S controller monitorssystem status and data for eachgenerator. Should the EMCP 3.Sfunctioning as the Master controllerfail, the new Master already has allthe pertinent status and data toseamlessly assume the mastercontroller functions.

4. Distributed Manual Control. In thehighly unlikely case of a completeloss of system automation, distrib-uted manual control is available.

5. Redundant CommunicationProcessing.Two independentcommunication processors arebuilt into the EMCP 3.S to controlthe Ethernet Channels A and B.

6. Redundant Ethernet SupervisoryNetworks. Each EMCP 3.Scontroller contains dual Ethernetports and is connected to dual,independent Ethernet networks.

7. Instant Auto Switch. If the touch-screen fails, an Instant Autoswitch is provided to place alldigital controls in the Autoposition, protecting your facilityfrom power outages. A functionaltouchscreen is not required forcomplete automatic operation ofCat Switchgear.

Remote Operator Station

Ethernet

ATS

ATS

ATS

Modbus

CatATS

to SCADA or BMS

Cat SwitchgearFor systems with utility

interconnect (XLM Type)

Redundant 100 MHz Ethernet

EMCP 3.S(Master)

EMCP 3.S(Redundant

Master)

EMCP 3.S(Redundant

Master)

EMCP 3.S EMCP 3.S

Generator 1 Generator 2 Generator X Redundant Utility/ Tie Controllers

Utility ProtectiveRelay

RedundantEthernet I/O

Touchscreen

TouchscreenProcessor

EthernetSwitch A

EthernetSwitch B

Data Table Interface

Redundant Hardwired SignalsEmergency Start- ATS Run Request- Utility Fail"First Up Dead Bus" Logic


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Introduction

Cat Switchgear010

8. Remote Operator Stations.Theremote operator station functionscompletely independent of thelocal operator interface touch-screen. If the local operator inter-face touchscreen fails, it will notaffect the operation of the remotestation connected to the system.

9. Hardwired Emergency StartBackup.Each system is designedwith a hardwired emergency startbackup system installed in theevent of a catastrophic networkcommunications failure, utilityEMPC 3.S controller failure, ormaster I/O failures. The hard-wired emergency start backupsystem will initiate a generatorstart signal to ALL of the generatorEMCP 3.S controllers based onany ATS start signal or a UtilityFailure signal. This ensures that

the system is always alerted of autility outage or ATS Run Requestso generators can be started andpower can be restored.

10. Hardwired First Up Dead BusBackup. Each system is designedwith a hardwired hot bus backupsystem installed in the event of acatastrophic network communica-tions failure. This feature preventsmultiple units from closing to aDead Bus at the same time.Once the first generator breakercloses to the bus, a hardwired HotBus signal is passed to all EMCP

3.S controllers and Ethernet I/O.11. Best Source DC System. Control

power is protected against singlepoint of failure by the use of a24 Vdc Best Source DC system.Each engine battery and a stationbattery are connected to acommon DC bus. Each enginebattery and the station battery arefurnished with their own batterycharger. The entire system isprotected so that no individualbattery/charger fault will affectthe rest of the system.

12. Redundant Utility Fail Indication.

For systems with utility intercon-nections (XLM type systems), twoindependent utility failure signalsare present in each processor. Thisensures that the system is alwaysalerted of a utility outage sogenerators can be started andpower can be restored.

Touchscreen InterfaceCat Switchgear technology uses atouchscreen for operator interface,monitoring and control of the parallel-ing switchgear. The screens give theoperator an instantaneous, easily

understandable view of the entiresystem status. This feature is standardin all Cat Switchgear.

To access system controls, all youhave to do is touch the correspondingportion of the screen. The entireengine generator set can be controlledfrom one touchscreen. The easy-to-use touchscreen interface makesit possible to view, monitor andperform multiple functions including:

Metering

Engine data

Protective relay settings

Annunciators Adjust load shed controls and

generator demand priority

Synchronize and parallel

Set modes of operation

Voltage and frequency adjustments

With Cat Switchgear, its simple. Allthe critical information you need isdisplayed in a manner that is easy tounderstand. Graphics look exactly likethe meters and gauges on conventionalswitchgear. At a glance, users can easilysee how the system is performing and,based on real-time information canquickly do whats necessary to correct

or optimize system performance.

Generator Metering

Engine Data

Generator Control

Generator Annunciator

Automated Joint Commission Report


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Introduction

Cat Switchgear011

Table 40.1-2. PowerLynx Control Configuration Comparison

Cat SwitchgearControl TechnologyCat Switchgear offers two differentlevels of touchscreen operatorinterface. Each level gives differentoptions for trending, reporting, andlogging capabilities.

High Redundancy Package

19-inch color LCD TFT touchscreen

SAW (surface acoustic wave)LCD touchscreen technology forunsurpassed reliability

Historical trending of enginegenerator and electrical parameters

Unlimited alarm and event logging

Ability to save and archive trend andlogging data

Automated reporting capability

Alarm reports

Log reports Generator system reports

Joint commissioncompliant reports

Optional automatic transferswitch control

Moving master

Redundant control network

Features High Redundancy Standard

Redundancy and Fault Tolerance Features

True distributed processing Standard Standard

Best source 24 Vdc system Standard Standard

Moving master redundancy Standard Optional

Redundant control network Standard Optional

Redundant utility/tie automation processors Standard Optional

Redundant Ethernet I/O Standard Optional

Display Features and Options

Local touchscreen display 19-inch color 15-inch color

3-D generator view for engine data Standard Standard

Dynamic system overview one-line Standard Standard

Full redundant touchscreen Optional Optional

System tuning capabilities via touchscreen Standard Standard

Balance of plant monitoring or control Optional Optional

Individual genset unit display Optional Optional

Logging and Reporting Features

Historic trending Standard Not available

Real-time trend Standard Not availableAlarm and event logging Unlimited 100 events

Save/export alarm logs Standard Not available

Full feature remote monitoring/control Optional Optional

Automated reporting Standard Standard

Custom automated reporting(ex., Joint Commission Test Report, etc.)

Optional Not available

Connectivity to BMS or SCADA systems Optional Optional

ATS Monitoring and Control

Cat ATS monitoring and control Optional Optional

Cat ATS remote settingscapability via touchscreen

Optional Not available

Cat UPS monitoring only Optional Optional

Non-Cat ATS monitoring only Optional Optional

Non-Cat ATS monitoring and control Optional Not available

Non-Cat UPS monitoring only Optional Not available

Standard Package

15-inch color TFT touchscreen

High reliability resistive LCDtouchscreen technology

Limited alarm and event logging

Available moving master

Available redundant network

High-Speed Integrated Control SystemCat Switchgear uses a high-speedindustrially hardened network forsystem control. The high redundancypackage includes a redundant supervi-sory communication network. Thisensures that the loss of one or moreprocessors or a supervisory communi-cation network will not affect theintegrity of the switchgear automation.This feature ensures proper systemperformance under any condition.

Best-in-Class FootprintCat Switchgear technology usesless than one-third of the componentsof conventional generator parallelingswitchgear. This translates into lesswiring, a smaller footprint, highermean time between failures, andlower mean time to repair.

Integrated Digital TechnologyIntegrated with Cat on-package gensetcontrols, Cat controls have built-insynchronizer, power factor controllerand load sharing functions. CatSwitchgear products do not requireadditional discrete components,such as synchronizers, cross-currentcompensation devices, speed/voltagedrop controllers, load sharingmodules, and so on.


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Introduction

Cat Switchgear012

Cat Switchgear SystemAdvantagesCat Switchgear performs generatorprotective functions internal to theEMCP 3.S controller. With Cattechnology, you can monitor, process,compare, display and transmit datawith a high degree of precision andcontroland that control translatesinto high reliability and functionality.

EMCP 3.S technology provides CatSwitchgear with enhanced featuresthat set the standards for the industry.

Unequaled fault tolerance

World-leading operator interface

Sophisticated communications abilities

Superior connectivity

Additional Cat Switchgearadvantages include:

Less installation wiring

Smaller footprint provides betterutilization of available space

Detailed engine and electrical reports

Low cost redundancy

Enhanced performance

UL, NFPA, CSA and IEEE compliant

Higher mean time between failure

Lower mean time to repair

Advanced CommunicationsCapabilitiesCat Switchgear technology isequipped with exceptional remotecommunications technologies,enabling you to control and monitoryour engine generator sets fromanywhere at anytime. Whetherat home, in the office, or on theroad, you can access controls andinformation on a real-time basis andrespond immediately...even controlmultiple facilities from a singlecentralized site.

Whether on-site or off-site, the available remote communicationspackage gives you the identicalinterface and same capabilities asstanding in front of the generator orCat Switchgear. Although identical,

the remote communications runcompletely independent of theparalleling switchgear automation.This ensures remote communicationdevices or systems will not affectthe reliability of your Cat Switchgear.Figures 40.1-2and 40.1-3showexamples of remote communicationconnections to the Cat Switchgear.

Communications with BuildingManagement or SCADA Systems

Cat Switchgear can also easilycommunicate data to third partyBuilding Management, SCADA orother monitoring systems. For theseapplications, a Data Table Interfaceacts as a firewall between your CatSwitchgear system and the BuildingManagement or SCADA System. TheData Table Interface serves up therequested data to the third-partymonitoring system, but stays

completely independent of all criticalgenerator control automation. Thisensures remote communicationdevices or systems will not affectthe reliability of your Cat Switchgear.

Figure 40.1-2. On-Site RemoteEthernet Network with Multiple Users

Cat Switchgear

Ethernet Port

Switchgear PC- Dedicated Static

I.P. Address- Ethernet Port

Key Points:

1. Dedicated Ethernet LAN

or

2. Utilize customers' LANCoordinationwith network administrators may benecessary for connection and security issues.

3. Supports multiple clients.

End User PC- Full Control or View Only (depending on password)- Dedicated Static

I.P. Address

HUB or Switch

End User PC- Full Control or View Only

(depending on password)- Dedicated StaticI.P. Address

End User PC- Full Control or View Only (depending on password)- Dedicated Static

I.P. Address

Cat. 5 cable (up to approx. 300)


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Introduction

Cat Switchgear013

Figure 40.1-3. Off-Site Remote(TCP-IP) Web-Based Connection with Multiple Users (View Only)

On-Site

Your Company

Network

Off-Site

Cat Switchgear

Ethernet Port

Cat. 5 cable(up to approx. 300')

Switchgear PC

Remote Client- Web Browser



Remote Client

- Web Browser

VPN

TUNNEL

VPN TUNNEL

View Only

View Only

VPN Device

Firewall Device- VPN Access

Firewall Device- VPN Access

- 1 Web Server

- Ethernet Port

Provided withCat Switchgear


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014

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Sheet 40

XLM Switchgear

General Description015

XLM

XLM2 Switchgear

General DescriptionCat XLM SwitchgearGeneratorParalleling Switchgear for EmergencyTransfer (Xfer) and Load Managementcontrol of multiple engine generatorsets with one utility source. For

systems with multiple utility and/ortie breakers, please refer to theCustom Configurable SwitchgearSection 40.5. For medium voltageapplication, refer to Section 40.4.

Automatic transfer to emergencyupon utility failure

Automatic start, synchronize,parallel, and load share on a com-mon bus for emergency operation

Closed transition transfer back toutility upon stable return of power,with soft generator unloading

Closed transition Load ManagementMode with soft loading and unload-

ing of generator system

Closed transition transfer toEmergency Mode to facilitatemaintenance, or for storm threatavoidance with soft loading andunloading of generator system

Load shed/load add

Generator demand priority Cost-effective, technically superior

alternative to conventional ATSarrangement

Cat Switchgear brings the power andreliability of microprocessor technol-ogy to your generator switchgearapplication. Through the use of theoperator interface touchscreen displaywith easy-to-follow graphical represen-tations, the Cat Switchgear merges thefeatures of:

Power monitoring

Switchgear automation

Generator set control Optional remote communications

Figure 40.2-1. XLM2 Low Voltage Switchgear PR = Protective Relay.


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XLM Switchgear

Standard and Optional Equipment016

Equipment

Standard EquipmentXLM

Low voltage XLM systems useMagnum DS power circuit breakerswitchgear and Magnum power

circuit breakers. For completetechnical details on Magnum DSswitchgear, see Tab 20

Operator Interface Touchscreen(Choose one of the following):

19.00-inch surface acoustic waveLCD TFT color touchscreen withkey switch

15.00-inch resistive LCD TFT colortouchscreen

Direct data communication toCat microprocessor-based enginegenerator set control network

Full function 0.5% accuracy analogand digital AC metering for utility:

voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR

Full function 0.5% accuracy analogand digital AC metering for genera-tors: voltage 1-2, 2-3, 3-1; current 1, 2,3; frequency; power factor; kW; kVAR

Full function engine gauges; RPM,DC battery voltage, oil pressure,engine coolant temperature, enginehours, number of starts

Full function synchronizing and par-alleling controls with selection forautomatic or manual synchronizing

NFPA 110 engine/generator status,pre-alarm, lamp test button, shut-

down fault annunciation and 85 dBAalarm horn with silence button

Full function 0.5% accuracy analogand digital AC metering for system:voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR

System control functions for auto(standby for emergency), closedtransition to emergency and loadmanagement

Automatic load shed control withon-screen operator adjustments foressential, critical, and non-essentialloads. Manual load shed/load addcontrol

Automatic generator demand prior-ity with on-screen operator adjust-ments for automatic addition andremoval of generator to the load bus

System status and alarm annucia-tion with color display and 85 dbAalarm horn with silence button

Password secured settings andadjustments for generator and sys-tem setups and protective relaying

Alarm summary reports

Settings reports

Engine and generator load charts

3-D engine data (available withADEM 3 or ADEM 4 Governor)

UL 891, UL 1558 or CSA listedand labeled

NEMA 1 or NEMA 3R, deadfrontfreestanding construction

Copper bus, braced for 100 kA

Three-phase, four-wire, 100%neutral,1/4-inch x 2.00-inch copperground bus

Available in 600V, 480/277V or208/120V, 60 Hz

UL 1066 listed power circuitbreakers, 42200 kAIC, two-step

stored energy drawout mountedelectrically operated with long timeand instantaneous trip, and circuitbreaker control switch with lights

Continuous cross bus ratings upto 10,000A at 600 Vac

Mechanical lugs for incoming andoutgoing conductors

Top or bottom conduit entry

Plug together control connectionsacross shipping split

Optional EquipmentXLM

Distribution sections withelectrically operated drawoutUL 1066 circuit breakers

Circuit breaker trip functionsshorttime and/or ground fault (in additionto long time and instantaneous)

Steel barriers between switchboardor switchgear sections for compart-mentalization

Bus/cable barriers

Distribution sections with groupmounted UL 489 molded case circuitbreakers. (UL 891 construction only)

Also available in 150 kA (UL 891)or 200 kA (UL 1558) bus bracingconfigurations

Also available in 8000 and10,000A continuous cross busratings at 600 Vac

Also available with 4000, 5000 and6000A UL1066 breakers

Trip unit metering and communica-tions (Digitrip 520M, 520MC and 1150)

Also available in 5 kV, 15 kV and27 kV class configurations (seeSection 40.4)

Remote monitoring and control

Building Automation Systemor SCADA communicationsModbus or Ethernet

Remote notification

Historical data trending

Tie Breaker ApplicationMany systems require the use of tiebreakers to meet Code or system per-formance requirements. Tie breakerscan be used anywhere throughout theline-up to segment or isolate desiredsources, loads or sections of bus.

Generator Bus Tie

Generator Bus Ties can be used toseparate the normal electric servicesources from the generator sources.This can also allow separation of loadbreakers to either side of the generatorbus tie breaker in order to allowisolation of load banks, or dedicatedemergency loads. This separationalso may be required by NFPA orlocal codes.

Generator bus tie breakers can beapplied to serve several purposes.

1. Starting of large loadsthegenerator bus tie can be opened toallow multiple generators to beparalleled before being connectedto large load(s). Once multiplegenerators are paralleled, thegenerator bus tie can be closedto power the large loads.

2. Load banksthe generator bustie can allow the generators to beisolated from the normal utility fedbus. Having a distribution breakeror set of load take-off lugs on thegenerator side of the bus allowsthe generators to be load banktested without affecting anynormal utility fed loads.

3. Emergency standby systemswith automatic transfer switchesthe generator bus tie providesisolation between the normal andemergency buses. During a lossof utility power, the generator

bus tie can be opened to isolateall normal loads and allowrestoration of power to emergencyloads. Once emergency loads arerestored, the emergency bus tiecan be reclosed to restore powerto normal loads.

Note: See Page 40.2-8for an exampleof an XLM system with generator bustie breaker.


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40September 2011


Sheet 40

XLM Switchgear

Features017

Cat XLM Switchgear

Utility Metering

0.5% accuracy

Voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR;

synchroscope

Utility Protective Relaying

15automatic synchronizer

27/59under/overvoltage relay

81 O/Uunder/overfrequency relay

Multi-function utility grade,drawout with:

47phase sequence/phasefailure relay

32reverse direction relay,utility grade, drawout

32/51reverse directionovercurrent relay, utility grade,drawout

32/62reverse direction timingrelay, utility grade, drawout

86reverse power lockout relay,manual reset

25sync check relay

Generator Metering

0.5% accuracy

Voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR;synchroscope

Generator Protective Relaying



32reverse power relay

40loss of excitation(reverse VAR) relay

25sync check relay

Engine Gauges

RPM meter

Engine battery volt meter

Oil pressure gauge

Engine coolant temperature gauge

Engine Monitoring and Alarms

Low coolant temperature pre-alarm

High coolant temperature pre-alarmand shutdown

Low oil pressure pre-alarm andshutdown

Low fuel alarm (diesel only)

Low engine battery alarm

Overcrank shutdown

Overspeed shutdown

Engine/Generator Control

Automatic engine start

Adjustable engine cool-down timer

15automatic synchronizer

65microprocessor engine gover-nor load sharing and soft loadingcontrol

90VAR/PF and cross currentcompensation controller

System Metering

0.5% accuracy

Voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR

System Protective Relaying

27/59bus under/overvoltage relay

81 O/Ubus under/overfrequencyrelay

System Control

Automatic standby mode Emergency mode with closed

transition to normal

Closed transition to emergency mode

Load management mode

Automatic load shed control withbus underfrequency protection andone four-pole,10A,120 Vac, Form C,dry contact output for each loadshed level (1 level for eachgenerator in the system)

Automatic generator demandpriority control

Master shutdown button

Power Supply Automatic best DC source selector

24 Vdc station battery, sealed jar,4-hour, external 120 Vac emergencypower required for charger

Power from 24 Vdc engine crankingbatteries

Processor power supplies24 Vdc

Technology Communications

Automation networkhigh speed,high reliability, industrially hardened

Optional remote communicationsnetworkEthernet, modem

Optional communication to

building automation or SCADAsystems for general monitoringModbusRTU or Ethernet

Circuit Breakers

100% rated UL 1066 power circuitbreakers available 8006000A withtwo-step stored energy mechanism

42 kAIC standard (50200 kAoptional)

Some ratings are only availableunder certain UL ratings(UL 1558200 kA)

Drawout mounted (fixed optional)some ratings are only availableunder certain UL ratings.(UL 1558200 kA)

5 cycle closing

Electrically operated

Auxiliary and bell alarm contacts

Electronic trip unit with long time andinstantaneous trip functions (shorttime and ground fault optional)

Enclosure and Bussing

Available as UL 1558, UL 891 or CSAlisted and labeled

Optionally service entrance rated


Copper bus

100 kA bus bracing (150200 kAoptional)

Three-phase, four-wire, 100%neutral bus, 1/4-inch x 2.00-inchground bus

Also available in UL listed andlabeled medium voltage

Environment

0C to 50C

0 to 95% humidity, noncondensing

Seismic Qualification

Refer to Tab 1for information onseismic qualification for this andother Eaton products.


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XLM Switchgear

Technical Data018

XLM SwitchgearOne-Line Diagrams

Figure 40.2-2. Typical Electrical System with XLM1 Switchgear (One Generator Source, One Utility Source)(For Multiple Utility Sources, see Custom Configurable Switchgear Section 40.5) PR = Protective Relay.

Figure 40.2-3. XLM1 Low Voltage Switchgear Layout

4000A, 5000A and 6000A breakers available in 44.00-inch wide struc-ture. Contact your local Caterpillar Electric Power dealer for more details.

Low voltage switchgear for up to 3500 kW generator set ratingsat 480V is also available. Contact local Caterpillar Electric Power dealerfor more details.

66.00 (1676.4) with D1 (optional as shown).

Max.U

tility

Bkr.Size

GeneratorkW (480V)

Genera

tor

BreakerSize

Main

BusRating

Max.Feeder

BreakerSize Dimensions

Weight

Lbs(kg)

Min. Max.

Height Width Depth

800 0 532 800 1600 1600 99.00(2514.6)

44.00(1117.6)

72.00(1828.8)

3300(1498)

1600 533 1064 1600 1600 1600 3400(1544)

2000 1065 1330 2000 2000 2000 3600(1634)

3000 1331 2000 3000 3200 3200 78.00(1981.2)

3700(1680)

Conduit Space for 22.00-Inch (558.8 mm) Wide StructuresTop or Bottom Entry

StructureDepth

Rear Conduit Opening RecommendedNumber of 3.50 or4.00-Inch Conduits

Width Depth

66.00 (1676.4)72.00 (1828.8)78.00 (1981.2)84.00 (2133.6)

16.00 (406.4)16.00 (406.4)16.00 (406.4)16.00 (406.4)

19.30 (490.2)25.30 (642.6)31.30 (795.0)37.30 (947.4)

9121518

FRONT ELEVATION

SECT 1

CELL A

CELL B

CELL C

CELL D

R

MDS-CXX

52N1

52N1

CONTROLS

SECT 2

MDS-CXX

52G1

52G1

CONTROLS

O P E N C L O S E D

G R

SECT 3

MDS-CXX

52D1

DIST

CONTROLS

HORN

HORN

SI LENC E

TOU C HSC REEN

DISA B LE ENA B LE

86UCLOS

SR750

SYSTEM

CONTROLS

96.06(2440.0)

22.00(558.8)

22.00(558.8)

22.00(558.8)

66.00(1676.4)

HMI19

TOUCHSCREEN


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40September 2011


Sheet 40

XLM Switchgear

Technical Data019

Figure 40.2-4. Typical Electrical System with XLM2 Switchgear (Two Generator Sources, One Utility Source)(For Multiple Utility Sources, see Custom Configurable Switchgear Section 40.5) PR = Protective Relay.


FRONT ELEVATION

R

MDS-CXX

52N1

MDS-CXX

52G1

O P EN C L O SE D

G R

MDS-CXX

52D1HORNHORNSILENCETOUCHSCREENDISABLEENABLE

MDS-CXX

52D2

O P EN C L O SE D

G R

MDS-CXX

52G2

SECT 1

CELL A

CELL B

CELL C

CELL D

52N1

CONTROLS

SECT 2

52G2

CONTROLS

52G1

CONTROLS

SECT 3

DIST

CONTROLS

86UCLOS

SR750

SYSTEM

CONTROLS

96.06(2440.0)

22.00(558.8)

22.00(558.8)

22.00(558.8)

66.00(1676.4)

HMI19

TOUCHSCREEN

4000A, 5000A and 6000A breakers available in 44.00-inch wide structure.Contact your local Caterpillar Electric Power dealer for more details.


Max.Utility

Bkr.Size

GeneratorkW (480V)

Generator

BreakerSize

MainBusRating

Max.Feeder


Weig

ht

Lbs(kg)

Min. Max.

Height Width Depth

800 0 532 800 1600 1600 99.00(2514.6)

66.00(1676.4)

72.00(1828.8)

5000(2270)

1600 533 1064 1600 1600 1600 5200(2361)

2000 1065 1330 2000 2000 2000 5600(2542)

3000 1331 2000 3000 3200 3200 84.00(2133.6)

5800(2633)


StructureDepth


Width Depth

66.00 (1676.4)72.00 (1828.8)78.00 (1981.2)84.00 (2133.6)

16.00 (406.4)16.00 (406.4)16.00 (406.4)16.00 (406.4)

19.30 (490.2)25.30 (642.6)31.30 (795.0)37.30 (947.4)

9121518


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XLM Switchgear

Technical Data020

Figure 40.2-6. Typical Electrical System with XLM3 Switchgear (Three Generator Sources,One Utility Source)(For Multiple Utility Sources, see Custom Configurable Switchgear Section 40.5) PR = Protective Relay.


FRONT ELEVATION

SECT 1

CELL A

CELL B

CELL C

CELL D

R

MDS-CXX

52N1

CONTROLS52N1

SECT 2

MDS-CXX

52G1

CONTROLS52G2

O P E N C L O SE D

G R

SECT 4

MDS-CXX

52D1

CONTROLSDIST

HORNHORN

SILENCETOUCHSCREEN

DISABLEENABLE

MDS-CXX

52D2

CONTROLS52G1

O P E N C L O SE D

G R

MDS-CXX

52G2

SECT 3

MDS-CXX

52G3

O P E N C L O SE D

G R

MDS-CXX

52D3

CONTROLS52G3

96.06(2440.0)

22.00(558.8)

22.00(558.8)

22.00(558.8)

22.00(558.8)

88.00(2235.2)

86UCLOS

SR750SYSTEM

CONTROLS

HMI

19

TOUCHSCREEN



Max

.Utility

Bkr.

Size

GeneratorkW (480V)

Gen

erator

BreakerSize

Main

Bus

Rating

Max

.Feeder


Weight

Lbs(kg)

Min. Max.

Height Width Depth

800 0 532 800 1600 1600 99.00(2514.6)

88.00(2235.2)

72.00(1828.8)

7100(3223)

1600 533 1064 1600 1600 1600 7300(3314)

2000 1065 1330 2000 2000 2000 7700(3496)

3000 1331 2000 3000 3200 3200 84.00(2133.6)

7800(3541)


StructureDepth


Width Depth

66.00 (1676.4)72.00 (1828.8)78.00 (1981.2)84.00 (2133.6)

16.00 (406.4)16.00 (406.4)16.00 (406.4)16.00 (406.4)

19.30 (490.2)25.30 (642.6)31.30 (795.0)37.30 (947.4)

9121518


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40September 2011


Sheet 40

XLM Switchgear

Technical Data021

Figure 40.2-8. Typical Electrical System with XLM4 Switchgear (Four Generator Sources, One Utility Source)(For Multiple Utility Sources, see Custom Configurable Switchgear Section 40.5) PR = Protective Relay.


FRONT ELEVATION

SECT 1

CELL A

CELL B

CELL C

CELL D

R

MD S -C X X

52N1

CONTROLS52N1

SECT 2

MD S -C X X

52G1

CONTROLS52G2

O P E N C L O S E D

G R

SECT 4

MD S -C X X

52D1

CONTROLSDIST

CONTROLSSYSTEM

HORNHORN

S I LENC ETOUC H S C R EEN

DISABL EENA B LE

MD S -C X X

52D2

CONTROLS52G1

O P E N C L O S E D

G R

MD S -C X X

52G2

SECT 3

MD S -C X X

52G3

O P E N C L O S E D

G R

CONTROLS52G3

CONTROLS52G4

O P E N C L O S E D

G R

MD S -C X X

52G4

SECT 5

MD S -C X X

52D3

MD S -C X X

52D4

96.06(2440.0)

22.00(558.8)

22.00(558.8)

22.00(558.8)

22.00(558.8)

22.00(558.8)

88.00(2235.2)

86UCLOS

SR750

HMI

19

TOUCHSCREEN



Max.Utility

Bkr.S

ize

GeneratorkW (480V)

Generator

Break

erSize

Main

BusR

ating

Max.Feeder

Break

erSize Dimensions

Weigh

t

Lbs(k

g)

Min. Max. Height Width Depth

800 0 532 800 1600 1600 99.00(2514.6)

110.00(2794.0)

72.00(1828.8)

9100(4131)

1600 533 1064 1600 1600 1600 9300(4222)

2000 1065 1330 2000 2000 2000 9500(4313)

3000 1331 2000 3000 3200 3200 84.00(2133.6)

9800(4449)


StructureDepth


Width Depth

66.00 (1676.4)72.00 (1828.8)78.00 (1981.2)84.00 (2133.6)

16.00 (406.4)16.00 (406.4)16.00 (406.4)16.00 (406.4)

19.30 (490.2)25.30 (642.6)31.30 (795.0)37.30 (947.4)

9121518


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XLM Switchgear

Technical Data022

Figure 40.2-10. Typical Electrical System with XLMT4 Switchgear (Four Generator Sources, One Utility Source, One Generator Bus Tie Breaker)(For Multiple Utility Sources, see Custom Configurable Switchgear Section 40.5) PR = Protective Relay.

Figure 40.2-11. XLMT4 Low Voltage Switchgear Layout

FRONT ELEVATION

SECT 1

CELL A

CELL B

CELL C

CELL D

R

MD S -C X X

52N1

CONTROLS52N1

SECT 4

MD S -C X X

52G1

CONTROLS52G2

O P E N C L O S E D

G R

SECT 2

MDS-CXX

52D1

CONTROLSDIST

CONTROLSSYSTEM

HORNHORN

S ILENC ETOUCHSCREEN

D IS A B LEENA B LE

MD S -C X X

52D2

CONTROLS52G1

O P E N C L O S E D

G R

MD S -C X X

52G2

SECT 6

MD S -C X X

52G3

O P E N C L O S E D

G R

CONTROLS52G3

CONTROLS52G4

O P E N C L O S E D

G R

MD S -C X X

52G4

MD S -C X X

52D3

SECT 3

MD S -C X X

52D4

CONTROLS52T1

O P E N C L O S E D

G R

MD S -C X X

52T1

SECT 5

MDS-CXX

52D5

CONTROLSDIST

MDS-CXX

52D6

MDS-CXX

52D7

96.06(2440.0)

22.00(558.8)

22.00(558.8)

22.00(558.8)

22.00(558.8)

22.00(558.8)

22.00(558.8)

110.00(2794.0)

86UCLOS

SR750

HMI

19

TOUCHSCREEN

4000A, 5000A, and 6000A breakers available in 44.00-inch wide struc-ture. Contact your local Caterpillar Electric Power dealer for more details.

Low voltage switchgear for up to 3500 kW generator set ratingsat 480V is also available. Contact local Caterpillar Electric Power dea lerfor more details.

Max.

Utility

Bkr.Size

Generator

kW (480V)

Generato

r

BreakerS

ize

Main

BusRatin

g

Max.

Fee

der

BreakerS

ize Dimensions

Weight

Lbs(kg)Min. Max.

Height Width Depth

800 532 800 1600 800 99.00(2514.6)

132.00(3352.8)

72.00(1828.8)

9100(4131)

1600 1064 1600 1600 1600 78.00(1981.2)

9300(4222)

2000 1330 2000 2000 2000 84.00(2133.6)

9500(4313)

3000 2000 3000 3200 3200 9800(4449)


StructureDepth


Width Depth

66.00 (1676.4)72.00 (1828.8)78.00 (1981.2)84.00 (2133.6)

16.00 (406.4)16.00 (406.4)16.00 (406.4)16.00 (406.4)

19.30 (490.2)25.30 (642.6)31.30 (795.0)37.30 (947.4)

9121518


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40September 2011


Sheet 40

XLM Switchgear

Technical Data023

Table 40.2-1. Typical Control Circuit WiringLow Voltage Systems

All control wiring to be stranded copper unless specified otherwise. Conductor size may have to be increased for voltage drop over long distances. Recommend 20% spares of each size single conductor and one of each multi-conductor cable. Separate metallic conduits should be used for each Signal Type. Signal Level and DC Control Signal 30 Vdc wires may be combined in the

same conduit.

Note: Specific project and equipment requirements will determine exact number and type of control wiring required.

Function (Quantity)/Size/Type of Cable

SignalType

Description

Generator Control

Cat engine generator setcommunications

Diesel(1) x #16 AWG shieldedtwisted pair (Belden 8719)

Signal level Network communications for monitoringand display of engine data to switchgear

Gas(1) x #16 AWG shieldedtwisted quad

Signal level

Control panel discrete control interface (16) x 1/c #14 AWG (includes spares) DC control 30 Vdc Discrete control (start/stop, emergency stopand crank terminate, includes spares, etc.)

Best source 24 Vdc (4) x 1/c #10 AWG(2 x + 24 Vdc and 2 x24 Vdc)

DC control 30 Vdc 24 Vdc from generator battery system tosupplement switchgear 24 Vdc control voltage

Voltage regulation (VR) control (1) x #16 AWG twisted pair(Belden 8719)

Signal level Bipolar DC bias signal for voltage control

(3) x 1/c #14 AWG (additional forCDVR only)

DC control 0 Vdc

Speed control (governor) Type 2301A speed controller(2) x #16 AWG shieldedtwisted pair (2301A)

DC control 30 Vdc Bipolar DC bias signal for speed control

ADEMIII speed controller(1) x #16 AWG shielded twistedtriplet (Belden 8618)

Signal level

(Additional for pro act gov. only)

(3) x #14 AWG XHHW Cu

DC control 30 Vdc

Air fuel ratio (AFR) controller Gas only(1) x #16 AWG shieldedtwisted pair

Signal level For gas engines equipped with AFRcontroller only

Battery Systems

Power for 24 Vdc station battery charger (3) x 1/c #12 AWG(in master section)

AC control 120 Vac/20A emergency circuit for 24 Vdcbattery charger power

24 Vdc station batteries (4) x 1/c #10 AWG (2 x + 24 Vdc and2 x24 Vdc) (next to switchgear)

DC control 30 Vdc 24 Vdc supply to switchgear controls from24 Vdc battery system

24 Vdc station battery charger malfunction (2) x 1/c #14 AWG DC control 30 Vdc Alarms

Generator battery charger malfunction (2) x 1/c #14 AWG DC control 30 Vdc Alarms

Fuel Systems

Low fuel tank level (master fuel tank)Fuel tank rupture basin (master fuel tank)High fuel tank level (master fuel tank)Other fuel tank alarms (master fuel tank)

(2) x 1/c #14 AWG(2) x 1/c #14 AWG(2) x 1/c #14 AWG(2) x 1/c #14 AWG (each)

DC control 30 VdcDC control 30 VdcDC control 30 VdcDC control 30 Vdc

AlarmsAlarmsAlarmsAlarms

Low fuel tank level (day tank)

Fuel tank rupture basin (day tank)High fuel tank level (day tank)Other fuel tank alarms (day tank)

(2) x 1/c #14 AWG

(2) x 1/c #14 AWG(2) x 1/c #14 AWG(2) x 1/c #14 AWG (each)

DC control 30 Vdc

DC control 30 VdcDC control 30 VdcDC control 30 Vdc

Alarms

AlarmsAlarmsAlarms

Generator Protection Systems

Genset mounted CB statusGenerator differential CTs

(2) x 1/c #14 AWG(6) x 1/c #10 AWG (at gen.)

DC control 30 VdcAC control

Alarms87G relay alarm/shutdown

Generator RTD leads (1) x #14 AWG shielded twisted quadper reading (at generator)

DC control 30 Vdc Indication/alarms/shutdown

Engine thermo-couples (2) x 1/c #14 AWG thermo-couple wireper reading (at generator)

DC control 30 Vdc Indication/alarms/shutdown

Automatic Transfer Switch Interface (Per ATS)

Cat ATS monitoring and control (1) x #16 AWG shielded twisted pair(Belden 8471)

Signal Level Monitoring and control of ATS functions

Engine startDiscrete ATS positionATS load shed

(2) x 1/c #14 AWG(4) x 1/c #14 AWG(2) x 1/c #14 AWG

DC control 30 VdcDC control 30 VdcDC control 30 Vdc

Engine start requestNormal and emergency ATS statusload shed / load add

Miscellaneous (Optional)

Miscellaneous enclosure alarmsMiscellaneous aux. equipment alarmsSwitchgear 120 Vac space heaters

(2) x 1/c #14 AWG per required alarm(2) x 1/c #14 AWG per required alarm(3) x 1/c #10 AWG per 10 structures

DC control 30 VdcDC control 30 VdcAC control

Alarms/shutdownAlarms/shutdowns120 Vac for space heaters (single-phase/30A)

Remote monitoring/control PC (1) x 4 Pair #24 AWG UTP Cat. 5(Ethernet) or(1) 4 conductor fiberoptic cable (Belden I100466variesbased on Installation requirements)

Signal level Communication signal to remotemonitoring/control PC workstation or LAN

Building management/SCADA interface (1) x #18 AWG shielded twisted pair(Belden 3073)

Signal level Communication signal to buildingmanagement or SCADA system


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Functional Sequence of Operations024

XLM Functional Sequence of Operations

A. The EPS Automation shall be provided with thefollowing Modes of Operation:

1. Automatic/Standby Mode

a. The utility main breaker is closed serving utility

power to the generator/load bus.

b. The generator main breakers are open.

c. The automation is standing by to act in response to autility failure.

2. Emergency Mode (Standby)

a. Utility Failure

1. Utility protective relaying senses utility voltageor frequency out of tolerance.

2. The utility main breaker is opened.

3. A run request is sent to the generator plant.

4. The first generator up to voltage and frequencyis closed to the bus.

5. [With Generator Bus Tie Breaker]

The generator bus tie breaker is closed.6. The remaining generators are synchronized and

paralleled to the bus as they come up to voltageand frequency.

7. The system is now in Emergency Mode.

b. Utility Restoration and Exit from Emergency Mode

1. Utility protective relaying senses utility voltageand frequency within tolerance.

2. Following an adjustable time delay (which can beabbreviated by the operator) to ensure that theutility power source is stable, the generator plantis passively synchronized and paralleled to theutility source by closing the utility main breaker.

3. The generator plant is soft ramp unloaded until

the utility source is nominally serving the entiresystem load.

4. The generator breakers are opened.

5. The generators are allowed to run for theirprogrammed cool-down period.

6. The system is now back in Automatic/Standby Mode.

3. Transfer to Emergency Mode

a. Entry

1. The operator places the System Mode Selector Switchinto the Closed Transfer to Emergency position.


3. The first generator up to voltage and frequencyis closed to the bus at no load.

4. The remaining generators are synchronized andparalleled to the bus at no load as they come upto voltage and frequency.

5. When all generators are on the bus they are softramp loaded until the generator plant is nominallyserving the entire load on the bus and theutility main breaker is opened.

OR

5. [With Generator Bus Tie Breaker] When all generatorsare on the bus, they are paralleled across the genera-tor bus tie breaker. They are then soft ramp loadeduntil the generator plant is nominally serving all ofthe load on the bus and the utility main is opened.

6. The system is now running in Emergency Mode.

b. Exit from Emergency Mode

1. The operator removes the System Mode SelectorSwitch from Transfer to Emergency position andreturns it to the Auto position.

2. Following an adjustable time delay (which can beabbreviated by the operator), the generator plantis passively synchronized and paralleled to theutility source by closing the utility main breaker.

3. The generator plant is soft ramp unloaded untilthe utility source is nominally serving the entiresystem load.

4. The generator breakers are opened

OR

4. [With Generator Bus Tie Breaker] The generatorbus tie breaker is opened and then all of generatorbreakers are opened.


6. The system is now back in Automatic/Standby Mode.4. Load Management Mode

a. Entry

1. Select one of the modes of operation:

i. Import LimitThe user places the Import/Export toggle switch in the Import positionand places the Base Load/Utility Trackingtoggle switch in the Utility Tracking position.The user sets the Utility Import set point tothe desired amount of kW that they wantto import through the Utility Circuit Breakerduring Load Management Mode.

ii. Export LimitThe user places the Import/Exporttoggle switch in the Export position and placesthe Base Load/Utility Tracking toggle switch in the

Utility Tracking position. The user sets the UtilityExport Set point to the desired amount of kWthat they want to export through the UtilityCircuit Breaker during Load Management Mode.

iii. Base Load ImportThe user places theImport/Export toggle switch in the Importposition and places the Base Load/UtilityTracking toggle switch in the Base Load posi-tion. The user sets the Base Load set point tothe desired amount of kW that they want thegenerator plant to assume during Load Man-agement Mode. The controls shall not allowthe generator plant to export kW throughthe Utility Circuit Breaker and shall alwaysmaintain a nominal amount of Utility kWimported through the Utility Circuit Breaker.

iv. Base Load ExportThe user places theImport/Export toggle switch in the Exportposition and places the Base Load/UtilityTracking toggle switch in the Base Loadposition. The user sets the Base Load set pointto the desired amount of kW that they wantthe generator plant to assume during LoadManagement Mode. The controls shall allowthe generator plant to export kW through theUtility Circuit Breaker.


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2. The user places the System Mode SelectorSwitch in the Load Management position.


4. The generators are allowed to run for a five-minute warm-up time (which can be abbreviated

by the operator).

5. The generators are synchronized and paralleledto the bus at no load after completion of thewarm-up time.

6. When all generators are on the bus they are softramp loaded until the generator plant is nominallyserving the required amount of the load on thebus to meet the mode of operation selected.

7. The generator output is dynamically adjusted tomaintain the set point to meet the mode of opera-tion selected. If at any time the system is unableto maintain the set point then a Set pointExceeded alarm shall be sounded.

8. Should the utility fail at any time during Load

Management operation, the utility protectiverelays shall cause the utility main to open and belocked out, thus placing the system in EmergencyMode until the Utility is restored (as described inEmergency Mode exit).

b. Exit

1. The operator removes the System Mode SelectorSwitch from Load Management position andreturns it to the Auto position.

2. The generator plant is soft ramp unloaded untilthe utility source is nominally serving the entiresystem load and the generator main breakersare opened.



5. No Load Test Mode

a. Entrance into No Load Test Mode

1. The No Load Test Switch is placed in theON position.

2. All available generators are started.

3. All generators come up to voltage and frequencyand remain running disconnected from the bus.

4. The system is now in No Load Test Mode.

b. Exit from No Load Test Mode

1. The No Load Test Switch is placed in theOFF position.



6. Utility Fail Test Mode

a. Entrance into Utility Fail Test Mode

1. The Utility Fail Test Switch is placed in theON position.

2. Voltage sensing at the utility protective relay is

opened, which simulates a loss of utility.

3. The system enters into Emergency Modeas described in the Emergency Modesequence above.

b. Exit from Utility Fail Test Mode

1. The Utility Fail Test Switch is placed in theOFF position.

2. Voltage sensing at the utility protective relayis restored, which simulates the return ofutility power.

3. The system exits from Emergency Modeas described in the Emergency Modesequence above.

B. When the Generator Sets are carrying the facility load,the EPS Automation shall support two (2) sub-modes:Load Shed/Load Add, and Generator Demand Priority.

1. Load Shed Control

a. The System Controls shall include a Load ShedControl function to control the loads served by thegenerator plant.

b. The Load Shed Control shall have one Essential LoadShed Priority Level for each generator in the systemplus one Non-Essential Load Shed Priority Level(which is always shed in the Emergency Modeof operation).

c. The Load Shed Control shall control each of thedistribution circuit breakers that are shown on

the drawings. Distribution circuit breakers to becontrolled shall be electrically operated. Eachelectrically operated distribution circuit breakershall be field selectable to be assigned to any ofthe available Load Shed Priority Levels.

1. Provide the following controls for eachEssential Load Shed Priority Level

i. Shed Delay Timer, adjustable from0 to 1024 seconds

ii. Add Delay Timer, adjustable from0 to 1024 seconds

iii. Load Shed Override Selector (shed/auto/add)

iv. Status indicators to show whether the

Priority Level is Added or Shed

2. Provide the following controls for eachNon-Essential Load Shed Priority

i. Load Shed Override Selector (shed/auto/add)

ii. Status indicators to show whether thePriority Level is Added or Shed


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3. Additionally, the Load Shed Controls shall have:

i. Load Shed Control Switch (On/Off)

ii. User-settable Load Shed % (as a function ofon-line generator capacity)

iii. User-settable Load Shed Time Delay

iv. User-settable Load Add % (as a function ofon-line generator capacity)

v. User-settable Load Add Time Delay

vi. User-settable Bus Underfrequency set point

vii. User-settable Bus Underfrequency time delay

viii. Bus Underfrequency Reset Pushbutton

ix. Bus Underfrequency indicator

4. Conditional Load ShedUpon entrance intoEmergency Mode of operation, the Load ShedControl shall shed all Essential and Non-Essentialloads. As generators come to the bus, Essential

Priority Level loads shall be added conditionallybased on the number of generators on line.When the first generator comes to the bus,Priority Level 1 loads shall be added; Secondgenerator, priority 2, and so forth. After a timedelay that allows all operational generators tocome to the bus, Load Shed Mode shall shift toLoad Sensitive Mode.

5. Load Sensitive Load ShedAfter all generatorshave been given sufficient time to come to thebus, load shed shall shift to Load Sensitivemode. The system shall compare currentgenerator online capacity (in kW) to currentload requirements. If surplus capacity is greaterthan the calculated Load Add set point, after theLoad Add Time Delay the next Load Shed Priority

shall be added. This calculation shall continueuntil all Sheddable Loads are added, or untilsurplus capacity is less than the calculated LoadAdd set point. If surplus capacity is less than thecalculated Load Shed set point, after the LoadShed Time Delay the next Load Shed Priorityshall be shed. This calculation shall continue untilall Sheddable Loads are shed, or until surpluscapacity is greater than the calculated Load Shedset point. The Load Shed Control, in its automaticshedding and adding of loads, shall not overrideany manual load shed/add operation.

6. Should the load bus frequency fall below the userselected bus underfrequency set point for aperiod longer than the bus underfrequency time

delay, then all Priority Level loads shall be shedand load addition shall not resume until the oper-ator has depressed the Bus Underfrequency Resetbutton. The bus underfrequency protection shalloverride any manual load add operation.

NOTE: The following applies to systems with two ormore generators.

2. Generator Demand Priority Control

a. The System Controls shall include a GeneratorDemand Priority Control function to automaticallymatch the on-line generator capacity to the loads toavoid unnecessary operation of all the generatorswhen the loads are low.

b. The following controls shall be provided for eachgenerator:

1. User-settable Generator Priority Selector

2. Status indicator for the Generator Priority Selected

3. Status indicator for generator On-line or Off-line

c. The Generator Demand Priority Control shall havethe following controls:

1. Generator Demand Priority Control Switch (On/Off)

2. User-settable Generator Remove % (as a functionof a single generator capacity)

3. User-settable Generator Remove Delay

4. User-settable Generator Add % (as a function of asingle generator capacity)

5. User-settable Generator Add Delay

d. Upon entrance into Emergency or Load Managementmodes, all generators shall be started and paralleledto the bus. After the Remove Time Delay, generatorsshall be removed from the bus as a function of thegenerator percentage loading by the user selectedGenerator Remove time delay. Generators shallbe removed from the bus in descending priority.Should the generator percentage loading increaseto the user selected Generator Add limits for theuser selected Add Delay, the next generator shall

be started, synchronized and paralleled to the bus.Generators shall be added to the bus in ascendingpriority order. Should the generator plant ever reach95% loading, the next priority generator shall bestarted and added to the bus with no time delay.


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EGP Switchgear

General Description027

EGP

EGP Switchgear

General DescriptionCat Emergency GeneratorParalleling (EGP) Switchgear formultiple engine generator sets.

Automatic start, synchronize,

parallel and load/VAR share ona common bus

Main lugs output to feed down-stream emergency distribution

Optional emergency distributioncircuit breakers

Load shed/load add

Generator demand priority

For use with multiple downstreamAutomatic Transfer Switches

Cat Switchgear is designed tointegrate hand-in-glove withCat Automatic Transfer Switches.EGP Switchgear is optionallyavailable with direct communication

to Cat ATSs to provide fingertipcontrol and monitoring of all yourfacility ATSs from one convenientcentral location

Cat Switchgear brings the power andreliability of microprocessor technol-ogy to your generator switchgearapplication. Through the use of theoperator interface touchscreendisplay with easy-to-follow graphicalrepresentation, Cat Switchgearmerges the features of:

Power monitoring

Switchgear automation

Generator set control

Optional remote communications

Figure 40.3-1. EGP3 Low Voltage Switchgear (Three Generator Sources)


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Standard and Optional Equipment028

Equipment

Standard EquipmentEGP

Low voltage EGP systems useMagnum DS power circuit breakerswitchgear and Magnum power

circuit breakers. For completetechnical details on Magnum DSswitchgear, see Tab 20

Operator interface touchscreen(Choose one of the following):

High Redundancy Product,19.00-inch surface acoustic waveLCD TFT color touchscreen withkey switch

Standard product, 15-inchresistive LCD TFT colortouchscreen

Direct data communication to Catmicroprocessor-based engine gen-erator set control network (EMCP)

System overview screen withone line mimic diagram thatdepicts real-time metering, statusand control

Full function 0.5% accuracy analogand digital AC metering for genera-tors: voltage 1-2, 2-3, 3-1; current1, 2, 3; frequency; power factor;kW; kVAR

Full function engine gauges: RPM,DC battery voltage, oil pressure,engine coolant temperature,engine hours, number of starts

3-D engine data

Full function synchronizing and par-

alleling controls with selection forautomatic or manual synchronizing

NFPA 110 engine/generatorstatus, pre-alarm, lamp test button,shutdown fault annunciation and 85dBA alarm horn with silence button

Full function 0.5% accuracy analogand digital AC metering for system:voltage 1-2, 2-3, 3-1; current 1, 2, 3;frequency; power factor; kW; kVAR

System control functions forauto (standby for emergency), testwithout load and test with load

Automatic load shed control withon-screen operator adjustmentsfor essential (Life/Safety), criticaland non-essential loads. Manualload shed/load add control

Automatic generator demand

priority with on-screen operatoradjustments for automatic additionand removal of generator to theload bus

System status and alarm annuncia-tion with color display and 85 dbAalarm horn with silence button

Password secured settings andadjustments for generator andsystem setups and protectiverelaying

Alarm summary reports

Settings reports

Engine and generator load charts

Engine trend data

UL 891, UL 1558 or CSA listedand labeled


Copper bus, braced for 100 kA

Three-phase, four-wire, 100%neutral, 0.25-inch x 2.00-inch copperground bus

Available in 600V, 480/277V or208/120V, 60 Hz

UL 1066 listed power circuit breakers,42200 kAIC, two-step stored energydrawout mounted electricallyoperated with long time andinstantaneous trip, and circuit

breaker control switch with lights Continuous cross bus ratings up to

10,000A at 600 Vac

Mechanical lugs for incoming andoutgoing conductors

Top or bottom conduit entry

Plug together control connectionsacross shipping splits

Optional EquipmentEGP

Distribution sections withelectrically operated drawoutUL 1066 circuit breakers

Circuit breaker trip functionsshorttime and/or ground fault

(in addition to long time andinstantaneous)

Steel barriers between switchboardor switchgear sections for compart-mentalization

Bus/cable barriers

Distribution sections with groupmounted UL 489 molded case circuitbreakers (UL 891 construction only.)

Also available in 150 kA or 200 kAbus bracing configurations

Also available in 8000 and 10,000A

continuous cross bus ratings at600 Vac

Also available with 4000, 5000 and6000A UL 1066 breakers

Trip unit metering and communica-tions (Digitrip 520M, 520MCand 1150)

Also available in 5 kV, 15 kV and27 kV class configurations(See Section 40.4)

Remote monitoring and control

Building Automation Systemor SCADA communicationsModbus or Ethernet

Remote notification

Historical data trending

Communication to Cat ATS units

Automated Joint Commissionreport

Tie Breaker ApplicationMany systems require the use of tiebreakers to meet Code or system per-formance requirements. Tie breakerscan be used anywhere throughout theline-up to segment or isolate desiredsources, loads or sections of bus.

Emergency Generator Bus Tie

Certain NFPA Codes require all life

safety and critical loads (Priority 1loads) to be restored in a maximumof 10 seconds. If the total Priority 1load that must be restored in tenseconds exceeds the capacity ofa single generator, an emergencygenerator bus tie breaker should beused. This allows one generator oneach side of the tie to restore powerto Priority 1 loads in under 10 seconds.The system can then parallel allgenerators across the emergencygenerator bus tie breaker so the fullgenerator plant capacity is available.

Note: Priority 1 loads must be split to eitherside of the generator tie breaker. See Page40.3-9for an example of a system with anemergency generator bus tie breaker.


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Features029

Cat EGP Switchgear

Generator Metering

0.5% accuracy

Analog and digital voltage 1-2, 2-3,3-1; current 1, 2, 3; frequency; power

factor; kW; kVAR; synchroscope

Generator Protective Relaying



32reverse power relay

40loss of excitation(reverse VAR) relay

25synch check relay

Engine Gauges

RPM meter

Engine battery volt meter

Oil pressure gauge

Engine coolant temperature gauge

3-D engine data screens

Engine Monitoring and Alarms

Low coolant temperature pre-alarm

High coolant temperature pre-alarmand shutdown

Low oil pres

tb09500001e(generator paralel swgr)

Documents