Switchgear Operation: Power Module Training

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What It Does

Operational Modes
Standby Emergency Mode

Reliable Backup Power

Will accommodate up to 10 power modules in parallel to a common load bus
with load sharing and VAR sharing between the units.

Utility paralleling is not supported in this mode of operation.

Load Management Mode

Parallels only 1 power module to Utility to Provide Base-Loading, Import and

Export Power Control

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What it looks like in front

6 Proface HMI Touchscreen

Alarm Horn and Horn Silence Button

Circuit Breaker Control Switch

86 Lockout Device

SR 489 Generator
Multifunction Relay

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Circuit Breaker Position LED Indicators

Emergency Stop Pushbutton

SR 750 Utility Multifunction Relay

What it looks like inside

Lynx Block

Speed Brick

LSM

Timer
G1 PLC

TB-BS, TB-BC,
TB-PS, TB-PT

PTs

CTSBs

Instant
Auto SW

Programming
Port
Fuses

CPT
24VDC
Converter

ENG1-TB, TB-COMB,
TB-ACT, TB-MPU,
86-TB

Timer

Breaker

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Features and Benefits

HMI Touchscreen
Provides Single Point of Engine, Generator and Switchgear Data
Monitoring
Provides User-Friendly, Self-Explanatory System Configuration
Controls System
Provides both kW and kVAR Load Sharing for Efficient Generator
Performance and Lower Maintenance
Provides Automatic Generator Demand Control
Automatically starts and stops generators based on loading
demands
Configure which Units will Operate More Frequently
Interfaces with Previous Versions of Caterpillar Power Modules
Stores System Alarms and Shutdowns

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Test Demonstration Setup

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The general Field Interconnects

1.
2.
3.
4.

5.

Verify shore power connected to rear of switchgear.

An optional run request contact can be connected between terminals 39 and
41 on the ENG TB. This must be a dry, isolated contact.
An optional Utility Transfer Trip contact can be connected between terminals
39 and 42 on the ENG TB. This must be a dry, isolated contact.
Connect Utility Aux contact to terminals 28 and 29 on the ENG TB. This
contact must be open to allow the circuit breaker to close during Standby
mode and closed to allow circuit breaker to close during Load Management
mode.
Reference field interconnect drawings for connections necessary between
Power Modules.

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Field interconnects for Reverse Compatibility

Install jumper between terminals 6 and 7 on TB-RC to enable the
reverse compatibility option.
Interconnect all power modules for primary unit and first up logic
according to the following diagram

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Network Plug Connections

No additional Field interconnects are
required for single unit operation. Verify
that control network is terminated on
connector plugs in rear of enclosure.

Single Unit
operation

(Connect control network cable according to Information Drawing G05)

For multi-unit operation in Standby mode the control
network cable for each power module must be
interconnected. The control network is terminated in the
rear of each enclosure on screw type connector plugs. At
shipment the male plugs are connected to the female
plugs which are permanently attached to a bracket in the
rear of the switchgear. Each of the female plugs has a
terminating resistor installed in the plug housing. A
terminating resistor is required at each end of the network
for proper operation. DO NOT REMOVE THE FEMALE
CONNECTOR PLUGS FROM THE BRACKET.
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Female
Plug

Hardware Settings
Up to ten power modules may be connected
together for multi-unit operation in Standby
mode. The default hardware settings at
shipment will have all units configured for
unit #1. These settings must be changed for
multi-unit operation. The control network that
interconnects the units will not support
duplicate nodes so each PLC and HMI must
be set to a unique address. The Control
Network Address Table shows all available
address settings.
Determine unit numbers that will be used. Unit
numbers are not required to be consecutive
and do not have to start with #1. Each power
module must have a unique number and all
devices within the module must be set to the
appropriate node address.
Apply settings to all power modules before
turning on 24VDC control power.

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Unit

I/O Node HMI Node GRC Node

51

52

53

54

55

10

11

56

12

13

57

14

15

58

16

17

59

18

10

19

60

20

Powering Up 24VDC
The power module uses 24 VDC from the engine batteries for control
power. The battery charger is located in the rear of the switchgear and
can be accessed by removal of an access panel on the upper left
hand side of the enclosure. The AC supply to the battery charger is
fed through CB102, which is located in the switchgear. The 24 VDC
supply is fed through CB102A, which is located in the switchgear.

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Powering Up 24VDC
Verify CB 102 in the off position
Battery disconnect switch at genset is in the off position
CB102A and CB822A are in the off position. FU201, FU403, and
FU516 are not installed
Verify shore power voltage at CB 102
Close CB102
Turn battery disconnect switch at genset to the on position
Verify DC voltage at ENG1-TB-1 / ENG1-TB-2 and record value.
Install FU201, FU403, and FU516
Close CB102A
Verify DC voltage on both sides of FU516 / SYST-BS- and record value
Verify DC voltage at TS201+ / TS201- and record value
Close CB822A and verify Power Module DC lights work
For a complete Power Module Field Startup Procedure, See Appendix A
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Powering Up AC
Remove CT Shorting Block (CTSB) jumper screws from CTSB-G1 and CTSBMR
Insert AC sensing fuses -See W03 and A02 for locations & fuse sizes Apply 240VAC (60Hz) to Power Distribution Blocks (PDB) per W07 and record
values.
Close CB102 and verify BC102 DC output (27VDC)
Close CB807 and verify PM AC Light operation.
Close CB812 and verify Fuel Transfer Pump operation.
Close CB817 and verify Generator Space Heater operation.
Close CB822 and CB821. Verify 120VAC at receptacles.
CB827 is SPARE. Leave open.
Close CB832 and verify Switchgear Space Heater operation
Close CB807A and verify Vent Fan operation.
Close CB812A and verify Engine Jacket Water Heater #31.
Close CB817A and verify Engine Jacket Water Heater #32.
Verify that BC102 is charging the generator batteries.
For a complete Power Module Field Startup Procedure, See Appendix A
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PLC Verification
Verify LEDs on G1IO, GRCIO, TSP201, and G1LYNX are illuminated
Verify Modbus Plus LEDs on G1IO, GRCIO, and touch screen
flashing green at a rate of approximately 6 flashes/second.
Verify PLC run lights on G1IO and GRCIO are solid green.

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Touch Screen Configuration

Black lettering on white background
indicates ON

The touch screen is black and white so button and indicator

states are shown according to the following table.

White lettering on black background

indicates OFF
Important Note:
The power modules are designed for connection of up to 10
units. When the touch screen is first turned on, it will search
the network for all available units. Unless all ten units are
connected the touch screen will display an error
message such as the one below.

It may display multiple messages like this depending on

how many modules are connected. This does not
indicate a problem with the network. Touch the [x]
in the top right corner of the message box to close
the message window.

The Gen _ Setup Boxes may not appear when the systems starts up.
This does not indicate a problem with the network. Touch
the [Network Refresh] message box repeatedly as necessary until the
appropriate setup box appears.

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Touch Screen Configuration

Single unit operation
The touch screen will start on the GEN SELECT SCREEN.
A black GEN _ SETUP button will appear beside each unit
that is on the network. For single unit operation with the
default settings, only GEN 1 SETUP button should be visible.

Multi-Unit Operation
Selecting the appropriate GEN _ SETUP button will
open the SYSTEM SETUP screen

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Touch Screen Configuration

Selecting GEN 1 will open the GEN 1 SYSTEM SETUP SCREEN.
Ensure the correct Screen/PLC revision is shown
Examples: 4.02=Rev 2, 4.04=Rev4. New screen revisions are placed on the
power module website under your CAT Part number and uploaded to the
Touchscreen/PLC. Website information found at the end of this presentation.

Set the Time/Date

Touch the time/date itself and enter the time/date as appropriate. When finished,
touch [SET TIME/DATE] sections.

Select English or Metric values

Select mode of operation

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What You Can See

System Overview Screen

Plant Overview Screen

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What Else You Can See

Gen Demand Control Screen

Alarm Annunciator & Summary Screens
Engine Data & Monitoring Screens
Gen Control, Metering, Protectives, and Tuning Screens
Test Report Screen
System Control & Settings Screens

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After Setup is complete

Standby single unit operation
A START signal can be initiated from the touch screen MODE CONTROL screen or from the optional
hard wired RUN REQUEST connected to terminals 39 and 41 on the ENG TB.
(Utility Aux contact connected between terminals 28 and 29 on ENG TB must be open to allow the

generator circuit breaker to close.)

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Once the Generator is up to Speed and Voltage

The circuit breaker will close to a dead bus.
Generator will continue to run until the standby run request is turned
off on the touch screen and the hard wired run request is removed.
When both run requests are removed the generator circuit breaker
will immediately open and the generator will run for the programmed
cool down time.

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Standby Multi-unit unit operation

Start signal can be initiated the same way as Single Unit operation.
Each unit must receive its own start signal, including the Utility Aux
contact requirement.
First up (or dead bus) permission is controlled by the power module
that is configured for the lowest unit number. This will be referred to
as the Master Unit. The first Power Module Generator up to voltage
and frequency, as determined by the Master, is closed to the bus.
The remaining Power Module Generators are synchronized and
paralleled to the bus as they come up to voltage and frequency.
All on line generators will share load proportionally, kW and kVAR.
When both run requests are removed ALL generator circuit breakers
will immediately open and the generators will run for the programmed
cool down time.

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Standby Multi-unit Generator Demand Priority

Standby Multi-Unit Generator Demand
Priority controls function to
automatically match the on-line
generator capacity to the loads in
order to avoid unnecessary
operation of all the generators when
the plant loads are low. The removal
and addition of generators is based
on the On-line reserve capacity.

Generator Demand Priority Settings:

ADD % - A generator is added to the bus when
the on-line reserve capacity is less than ADD
% of a single generator.
REMOVE % - A generator is removed from the
bus when the on-line reserve capacity is
greater than REMOVE % of a single
generator.

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Total Generator Plant Capacity

Total Plant Load
On-line reserve capacity

Standby Multi-unit Generator Demand Priority

ADJUST REMOVE AND ADD %

AND TIME DELAYS

ADJUST GENERATOR
PRIORITY REQUEST

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Standby Multi-unit with Reverse Compatibility

The Reverse Compatibility option may be enabled to allow the Caterpillar power
module to operate in a standby mode with older style power modules.
A jumper must be installed between terminals 91 and 92 on the TBRC terminal block to
enable Reverse Compatibility (RC).
Start signal can be initiated the same as previously stated.
First up, or dead bus, permission is controlled by the Primary Unit relay logic.
The remaining Power Module Generators are synchronized and paralleled to the bus
as they come up to voltage and frequency.
Once the generator breaker is closed the PowerLynx speed and voltage control is
disabled. The load control is then done through Woodward load share lines and the
Var control can be manually adjusted by the raise and lower switch.
When both run request are removed the generator circuit breakers will immediately
open and the generators will run for the programmed cool down time.
Generator Demand Priority is not available when operating in Reverse Compatibility
mode.

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Operation in Load Management Mode

Load Management mode will accommodate single power module
operation in parallel with a utility source. There are three different
sub-modes: Baseload, Import, and Export (to be explained in the next
slide). Multiple units may be connected to the same bus in Load
Management mode but each unit will operate independently with the
utility. There will no kW or kVAR sharing between units.

TOUCH HERE TO
ADJUST THESE
PARAMETERS

TOUCH HERE TO
ENABLE OR DISABLE
LOAD MANAGEMENT
RUN

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TOUCH HERE TO CHOOSE

BETWEEN IMPORT, EXPORT
OR BASE LOAD

Load Management Modes of Operations

Base Load
Once the generator is in parallel with the utility it is soft ramp loaded to the Base
Load kW set point.
VAR/pf is controlled based on the kVAR/pf selector switch on the Settings Screen.
When selected for pf control the voltage regulator will be automatically adjusted to
maintain the power factor setting. When selected for VAR the voltage regulator
will be automatically adjusted to maintain the VAR setting.
TOUCH HERE TO ADJUST POWER FACTOR
OR kVAR SETTING

TOUCH HERE TO
CHOOSE
BETWEEN pf OR
kVAR MODE

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Load Management Modes of Operations

Import
Once the generator is in parallel with the utility the generator kW is dynamically adjusted to
maintain MAX UTILITY IMPORT kW set point. The generator output is limited by the generator
size setting. Utility kW is calculated based on the utility watt transducer input.
Var/PF is controlled based on the Var/PF selector switch on the Settings Screen. When selected
for PF control the voltage regulator will be automatically adjusted to maintain the power factor
setting. When selected for VAR the voltage regulator will be automatically adjusted to maintain
the Var setting.

Generator Size

Total Site Load

Generator Output

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Load Management Modes of Operations

Export
Once the generator is in parallel with the utility the generator kW is dynamically adjusted to
maintain MAX UTILITY EXPORT kW set point. The generator output is limited by the generator
size setting. Utility kW is calculated based on the utility watt transducer input.
Var/PF is controlled based on the Var/PF selector switch on the Settings Screen. When selected
for PF control the voltage regulator will be automatically adjusted to maintain the power factor
setting. When selected for VAR the voltage regulator will be automatically adjusted to maintain
the Var setting.

Generator Size

Generator Output
Total Site Load

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Operation in Load Management Mode

The Generators start by taking Load Management Mode switch to [ON]
or the optional hardwired Run Request (Utility Aux Contact open).
The generator will be allowed to run for a warm up period. This period
may be abbreviated by the operator by touching the IMM XFER
(Immediate Transfer) button.
Once the warm up period is complete, the generators are synchronized
and paralleled to the utility source.
The load and VAR/pf are then controlled based on the selected Load
Management mode of operation.
When both run request are removed the generator is soft ramp
unloaded. When the generator reaches the Disconnect setting the
circuit breaker will open and the generator will run for the programmed
cool down time.

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Summary

Layout of Equipment
Features
How to Power up the Module
Setting Up & Configuring the System
Different Modes of Operation
How to Start & Stop the Generators in each mode

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Thanks!

ISO Website Information

The Latest Revision of Caterpillar Power Module
Switchgear documents, drawings, and PLC & HMI
programs are available on the ISO website at:
www.catswitchgear.com
UserID: catpm
Password: caterpillar

ISO Product Support hotline:

1-866-883-3879
International Calls: (678) 746-5000
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