Introduction To Caterpillar Electric Power Products

The purpose of this presentation is to give prospective customers, new CAT employees and dealer personnel an overview of Caterpillars product offerings in the Electric Power Generation market. Note: This presentation is not intended to be a sales focused presentation with specific features and benefits, but more of a general description of Cat Electric Power products and their function.

Engine Division Investments 1996 1996

1997

1999

Griffin Georgia Plant

In June of 1999, the Electric Power group completed its acquisition of F. G. Wilson and CAT now owns 100% of this company. F. G. Wilsons blue and white line currently sells into some similar markets as CATs yellow line. We do not, however, see this as a problem because each tends to cover slightly different segments of the markets, and are serviced in much different fashions. F.G. Wilson produces the Olympian line of engine products with outputs ranging from 5-230 kW. MaK in Kiel, Germany, is also owned by Caterpillar. They are the producers of the 1000-10000 kW engines The CM line offerings (larger engines for electric power generation) are painted yellow. MaK products combined with the Olympian and traditional Cat yellow lines has given Caterpillar a strong presence in electric power generation world from 5 - 10000 kW. Perkins was acquired in February, 1998 by Caterpillar as a subsidiary operation. Perkins engines are sold as part of the Cat yellow line. Perkins is primarily a 4 family engine manufacturer ranging from 4 - 6 L engines. Perkins primary contribution to EPG are the smaller engines (<200 kW) used in many Olympian products. The assembly plant in Griffin, GA, is currently producing 3300, 3456, 3412, and 3500 series generator set packages and power modules.

Product Range

Standby Prime Continuous Cogeneration Distributed

Backup of a primary power source Primary source of power Normally the only power source with fixed load Electrical power and heat recovery Virtual power plants
3

This slides summarizes the product offerings available through Cat. The rating will be discussed later in greater detail

Caterpillar is the clear, undeniable leader in the global supply of electric power solutions for customer requirements encompassing 5KW to 20MW. Caterpillar has the most complete and comprehensive product line in the industry The pink represents turbine powered generator sets by Solar Turbines. The orange represents medium speed engines which include the Kiel product and the caterpillar 3600 generator sets. The green represents the high speed engines which are comprised of the Olympian gensets and Caterpillar 3500, 3400 and 3300 generator sets.

Olympian Product Line Overview

In this section, we will be covering the Olympian product offerings. We will discuss the different engines, generators, ratings, and control systems that are available for electric power generation.

Model Designation
D = Diesel G = Gas

D24LH2S --------- --Engine L = Lister P = Perkins U = Isuzu F = Ford H = High Speed, 3600 rpm S= Single Phase EPA Certification 1,3 = NonCert 2,4 = EPA Cert.

KW Rating at 60HZ Standby, p.f. = 1.0

Here is a breakdown of how the different generator set models are designated. As you can see, a lot of information can be extracted from the series of numbers and letters that are assigned to a particular model of generator set

Single Phase

The main thing to take away from the following graphs is the comprehensive power range that the Olympian diesel line covers. Single phase output is represented here.

Olympian also has a comprehensive line of diesel generator sets with three phase voltage output.

Spec Sheet Graph

Single Phase

The Olympian line has a large line of single phase gas generator sets.

There is also a large line of three phase gas generator sets.

Engines
Diesel
Lister (up to 20 kW) Perkins
Ford

Gas
Isuzu (up to 25 kW) Ford

Perkins

Lister and Isuzu engines are used for the smaller generator sets, while Perkins (CAT) and Ford engines are used for the larger engines.Lister sells about 8,000 engines per year, they are involved in engine development and have Good brand acceptance. Perkins sells about 25,000 engines per year,they are involved in Joint development programs with Cat and have a few Electronic engines - 1006TAG1 & 1306 Isuzu/Ford design high Quality engines, have good brand acceptance, are dependable suppliers, and have good working relationships w/ Cat. Through the Ford Gas Engine Replacement Program , new engines are now available for 30 through 100kW generator set ratings. They are the 4.2L V6(ESG642) and 6.8 L V10 (WSG1068).

Generators
The New Standard
Manufacturer: Leroy Somer Strong mechanical design Optimized engine compatibility Spectacular electrical performance The best performances of the market High efficiencies Low impedances Class F Insulation Quality/Standards - ISO 9001

The generators are 12 lead except small, single phase, 600V and HX/HQ rentals The bearings last for a minimum of 20,000 hours Insulation class refer to the generator sets ability to withstand heat for a specified period of time..Class F = 155 deg C, Class H = 180 deg C TIF (telephone influence factor) < 50low interference with nearby electronics and telephone equipment THD (total harmonic distortion) < 2% will not cause harmonics in surrounding equipment

Control Panels
LCP2 2001 2001K 4001 4001E Access 4000

These are the different control panel options. We will be discussing each one.The generator set can be easily upgraded from 2001 to 4001 to 4001E. Wiring looms have plugs in the case of the panel that allows interchangeability. All control panels (except LCP2) are laptop programmable

LCP2 Control Panel

Standard on Lister Generator sets
8 - 20 kw, Diesel

Remote Stop/Start Capability Shutdowns w/ warning lights Basic Controls Basic Metering

The LCP2 control panel is designed for automatic starting and stopping of the generator set with 2 wire, remote contacts as well as manual starting and stopping. The panel provides generator instrumentation for volts, amps, and a combined frequency meter and tachometer along with a battery condition voltmeter. The control system provides shutdown protection with individual indicating lamps on the panel for fail to start, high coolant temperature, low oil pressure, and overspeed. Optional instrumentation for lube oil pressure and coolant temperature is available. The LCP2 control panel has one additional protection control channel for options with an indicator lamp that can be programmed for either shutdown or alarm. The result is a fully automatic generator set controller.

2001K and 2001 Control Panel

2001K is Standard on Isuzu generator sets - 10 - 25 kW, Gas 2001 is Standard on larger Perkins diesel packages 4 preset shutdowns 1 programmable alarm/shutdown Additional circuits required for:
Battery charger Heaters Coolant, Oil, Generator, Battery 2001K

2001

The 2001K control panel is an automatic start/stop control and instrument panel for gas generator sets. The control panel provides for manual or automatic starting and stopping of the generator set and includes added operational and protection features. It is designed for remote control of the generator set with a 2-wire control signal from an automatic transfer switch equipped with volt-free, close-for-start contacts. The design provides for all engine and generator metering and operational protection functions required in most installations. The 2001 control panel is designed for automatic starting and stopping of the generator set with 2 wire remote, contacts as well as manual starting and stopping. The panel provides engine and generator instrumentation for volts, amps, combined frequency meter and tachometer, coolant temperature, lube oil pressure and battery condition voltmeter. The control system provides shutdown protection with individual indicating lamps on the panel for fail to start, high coolant temperature, low oil pressure, and overspeed. Optional instrumentation, alarms, and shutdowns are available. External wiring is required for coolant heater, oil heater, generator anti-condensation heater, or battery heater if so equipped.

4001 and 4001E Panels

Optional Allows for more shutdowns/alarms
Both have 4 preset shutdowns
4001

4001E advantages vs 4001

5 vs 1 Preset alarms 4 extra channels for programmable shutdown/alarm Can be used in NPFA110 installations

4001E

The 4001 and 4001E series control systems provide for automatic starting and stopping of the generator set from a remote signal as well as manual starting and stopping. This makes it appropriate for standby generating systems. On the 4001 and 4001E systems we have the same basic protections as that on the 2001 control system with the addition of an alarm protection for Low Battery Voltage. On 4001E series control systems there are additional alarms for Approaching Low Oil Pressure, Approaching High Engine Temperature, Battery Charger Failure, Not in Auto Mode and High Battery Voltage (Programmable Channel 1). Both systems have spare additional protection channels. The Preset Shutdowns with Individual Warning Lamps include: Fail to start, High coolant temperature, Low lube oil pressure, Overspeed

Access 4000 Control Panel

High End Option* Microprocessor digital controller Alphanumeric high resolution display Laptop/PC programmable
At factory At site

NFPA 110 Level 1 compliant Modular design 12 or 24 Volt

The Access 4000 series control panel is a microprocessor based autostart generator set control system. The design provides for high accuracy for all metering and protection functions, together with the obvious benefits of a large alphanumeric LCD. The use of an open protocol communication interface ensures compatibility with most building management or supervisory control systems.

Remote Communications
with Access4000 Panel Open protocol communication and monitoring
ModBus Or Modem Ethernet

Control through RS connection

MCM2 MCM3

Password protected operator levels Fault log memory

There are 2 ways by which the control system can be monitored and controlled: MCM2 enables remote connection of Access 4000 control system to a computer up to 3/4 mile away via RS232/485 LAN MCM3 enables remote connection of Access 4000 control system to a computer via Modem phone line

Access 4000 Annunciaton

MCM4 Remote Annunicator Interface Uses Pan 5/Pan 6 Annunciation Can be used on 4001/4001E Panels MCM5 Remote Annunciator Interface to 20 light remote annunciation MCM6 Optional 8 channel relay board

Remote Annunciation is controlled using the following interfaces: MCM4 - Interface to a 16 light (Pan5) or 8 light (Pan6) remote annunciator. Includes lamp test and alarm mute features. 3 different color notification options. Options include: Normal/run control switch (pan6), Emergency generator set stop button (pan7) MCM5 (optional on Access 4000) 20 light annunicator, NFPA110 level 1 compliance. MCM6 - is an optional 8 channel relay board that may be added to the Access 4000 remote annunciator (MCM5). Relays 1-8 will activate when channels 1-8 on the annunciator activate. It is possible to change the priority of the faults as they appear on the annunciator in the CONFIGURE/OUTPUTS menu. NOTE: If you change fault priorities then new labels will need to be fitted to the annunciator GenAccess is an open protocol software used with these interface. The operator has a choice of 4 display windows, mouse selectable control functions and the ability to define the display range parameter for each metering object.

Synchronizing Control Systems

Utilizes up-to-date microprocessor technology Common Operating Modes Include:
Automatic Utility failure (no paralleling) Automatic synchronizing of multiple gensets (up to 8) Automatic synchronizing of one genset with utility Automatic synchronizing of multiple gensets (up to 8) with the utility

6000 Series

The 6000 series control system incorporates a microprocessor based complete load control and engine management system and carries out all the functions necessary for engine control, synchronizing, real kW control systems against various fault conditions. To simplify the variations in control capability the most common operating modes have been designated as follows: 6100 Automatic Utility failure (no paralleling) 6200 Automatic synchronizing of multiple gensets (up to 8) 6300 Automatic synchronizing of one genset with utility 6400 - Automatic synchronizing of multiple gensets (up to 8) with the utility

Enclosures Options
Sound attenuated Fully Weatherproof Modular Design Fuel Tank Base available Steel body Solid Fit and Feel Spill Containment Basin

These weather resistive, factory installed, enclosures incorporate internally mounted silencers.They are matched for safety and aesthetic value on fabricated steel skidbases on diesel models. Optional UL listed tanks are available. They are designed on modular principles with many interchangeable components permitting on-site repair.

Additional Components

Skid Base

Fuel Tank Base

Single or Double Walled (UL2200)

Moving toward modular design fuel tank bases (away from integrated fuel tank bases)

Additional Components

Standard Lube Oil Drains

Bolted Key Latches

Double Exhaust Bellows

Standard Radiator Drains

Main Breaker w/ screw down terminals

Lifting Lug Holes 2

Additional Components include: Standard Lube Oil Drains Bolted Key Latches Double Exhaust Bellows Standard Radiator Drains Main Breaker w/ screw down terminals Lifting Lug Holes 2

Caterpillar Generators for 3300, 3400, 3500 and 3600

Kato is Caterpillars supplier of generators, they have been supplying the SR4 & SR4B Generators starting in 1998

SR4 Generator

This is a cutaway of an SR4 generator. The ball bearing, the exciter rotor, and the exciter stator are visible. This can be easily identified as an SR4 and not an SR4B because there are louvers on the back for cooling air to enter. The SR4B does not have louvers on the rear. The other visible sign is the screen at the front air exit. The next slide shows the SR4B and the louvers at the rear are replaced by an opening around the bottom half of the barrel and the SR4B will have thin sheet metal at the air exit with rectangular holes and not be a screen.

SR4B Generator

Since the back no longer has louvers for air entry, circuit breakers can be mounted on the back panel. All the air flow is coming up through the back bottom. Notice the grid work on the air exit cover to the front as well.

Stator Construction
SR4 SR4B

On the left is the conventional SR4 main stator lamination and the SR4B main stator lamination is on the right. The SR4B is said to be the square lamination design. The squared sides of the laminations do not impede performance and they are cost effective. The SR4B also has overall lower impedances than the SR4 designs. Impedance is resistance to frequency so, a it is better to have a lower impedance.

Generator Frame Size

The first 2 digits refer to diameter. The last digit refers to length.
360 family: 440 family: 490 family: 580 family: 590 family: 680 family: 690 family: 800 family: 820 family: 362 - 368 443 - 449 plus 450 498 - 499 (SR4B only) 582 - 589 (SR4 only) 592 - 598 (SR4B only) 681 - 689 (SR4 only) 691 - 697 (SR4B only) 804 - 809 822 - 828

Generator frame sizes and nomenclature can be confusing. The first two digits represent the diameter of the generator. The next digit represents the length. The 360 family is a relatively small diameter used with the 3304 & 3306 engines As for what engines are used the 450 is used with a 3456. The 580 was used for years on the old 3406 3412 engines. 680 was used with small 3500s, 690s on large 3500s with the SR4B. 800 and 820s very large 3500s. There are also some Kato generator frames not covered in this slide which are 2600 and 2800 frames for medium voltage sets.

Frame Size
368 443-444 445-450 490s 590s 690s 820s 100 600 1100 1600
113-125 ekW 160-200 ekW

230-400 ekW

450-500 ekW

500-900 ekW

800-1500 ekW

1750-2750 ekW

2100

2600

ekW at 60Hz 480V Standby

29

Generators of the same frame size are not necessarily identical. Both voltage and engine/generator mounting arrangements may be different. This illustrates the ratings of generator frame families at the time of preparation of this presentation.

Ratings
Prime - Typical Load Factor = 60% to 70%
Typical Hours per Year = no limit Typical Peak Demand = 100% of prime rating used occasionally. Typical Hours per Year < 500 hours Typical Peak Demand = 80% of standby rated Typical Hours per Year = no limit Typical Peak Demand = 100% of continuous used for Peak Shaving and Peak Sharing

Standby - Typical Load Factor = 60% or less

Continuous - Typical Load Factor = 70% to 100%

Load Management - A combination of the above three, usually

There are three main generators ratings, they are: prime , standby , continuous. Load management is a combination of the three. Load management ratings: If generator set is Paralleled with Utility during peak shaving/sharing <500 hrs/yr. = Prime >500 hrs/yr. = Continuous If generator set is Isolated from Utility during peak shaving/sharing <500 hrs/yr. = Standby >500 hrs/yr. = Prime Load management ratings are not included in the price list, a request has to be put in through the Cat dealer.

Caterpillar 3300,3400,3500 & 3600 Electric Power Products

This section will cover all electric power products whos engines are either 3300, 3400, 3500 or 3600. They are then shipped to Griffin for packaging packaging. All price list ratings are at 0.8 power factor and without a radiator fan

Caterpillar Diesel Electric Power Products

This section gives an overview of the diesel powered Cat products from Mossville and Lafayette, packaged in Griffin

3300 Specs - 60Hz

3300 Family 282 - 335 hp

Model 3306

Standby (ekW) 230/250

Prime (ekW) 210/225

Continuous (ekW) ---

Speed (rpm) 1800

Compression ratio 15

The 3306 @ 60hz is offered with wide range of factory designed and supported options. Is available as Turbocharged (TA) and Air-To-Air Aftercooled (ATAAC). Production of this engine has been moved from Mossville to Sagami but is still packaged in Griffin and Larne.

3300 Specs 50Hz

3300 Family 220 - 295 hp

Model 3306

Standby (ekW) 180-220 180-

Prime (ekW) 164-200 164-

Continuous Speed Compression (ekW) (rpm) ratio --1500 15

The 3306 @ 50hz generator set is also available as Turbocharged (TA) and as AirTo-Air Aftercooled (ATAAC). Production of this engine has also been moved from Mossville to Sagami but is still packaged in Griffin and Larne.

3400 Specs 60Hz

3400 Family 369 - 1073 hp

Model 3406 3412

Standby (ekW) 300-450 300500-800 500-

Prime (ekW) 275-410 275455-725 455-

Continuous (ekW) -----

Speed (rpm) 1800 1800

Compression ratio 14.5 14.5

The 3406 @ 60hz is available as Turbocharged (TA) and Air-To-Air Aftercooled (ATAAC) The 3412 @ 60hz is available as Turbocharged (TA), Twin TurbochargedAftercooled (TTA) and Series Turbocharged-Aftercooled (STA)

3400 Specs 50Hz

3400 Family 295 - 965 hp

Model 3406 3412

Standby (ekW) 240-400 240400-720 400-

Prime (ekW) 220-364 220364-580 364-

Continuous (ekW) -----

Speed (rpm) 1500 1500

Compression ratio 14.5 14.5

The 3406 @ 50hz is available as Turbocharged (TA) and Air-To-Air Aftercooled (ATAAC) The 3412 @ 50hz is available as Turbocharged (TA) Twin TurbochargedAftercooled (TTA), Series Turbocharged-Aftercooled (STA)

3456 Specs 60Hz

3456 Family 370 - 670 hp

Model 3456

Standby (ekW) 300-500 300-

Prime (ekW) 275-455 275-

Continuous (ekW) ---

Speed (rpm) 1800

Compression ratio 16.1

The 3456 @ 60hz is available Air-To-Air Aftercooled (ATAAC)

3456 Specs 50Hz

3456 Family 294 - 488 hp

Model 3456

Standby (ekW) 240-400 240-

Prime (ekW) 220-364 220-

Continuous (ekW) ---

Speed (rpm) 1500

Compression ratio 16.1

The 3456 @ 50hz is available Air-To-Air Aftercooled (ATAAC)

3500 Specs 60Hz

3500 Family 570 3017 hp C/R 13.5-14

Model 3508 3512 3516

Standby (ekW) 1000 1100-1500 11001750-2250 1750-

Prime (ekW) 425-910 425900-1360 9001250-1825 1250-

Continuous (ekW) 585-832 585890-1230 8901450-1640 1450-

Speed (rpm) 1200/1800 1200/1800 1200/1800

The 3500s @ 60hz are available as Turbocharged (TA) The 3516 @ 60hz are available with High Displacement (HD)

3500 Specs - 50Hz

3500 Family 791 - 2682 hp C/R 13.5-14

Model 3508 3512 3516

Standby (ekW) 720-880 7201000-1500 10001400-2000 1400-

Prime (ekW) 590-800 590775-1360 7751125-1825 1125-

Continuous (ekW) 650-725 650800-1056 8001200-1600 1200-

Speed (rpm) 1000/1500 1000/1500 1000/1500

The 3508 @ 50hz is available as Turbocharged (TA) The 3512 @ 50hz is available as Turbocharged (TA) and/or High Displacement (HD) The 3516 @ 50hz is available as Turbocharged (TA) and High Displacement (HD)

3600 Specs 60Hz

3600 Family 2212 - 7134 hp

Model 3606 3608 3612 3616

Standby (ekW) 2000 2660 4000 5320

Prime (ekW) 1820 2420 3640 4840

Continuous (ekW) 1650 2200 3300 4400

Speed (rpm) 900 900 900 900

Compression ratio 13 13 13 13

3600 generator sets are not sold as a standard package. The customer specifies the engine and the generator desired. The Kato brand generator is the most commonly used brand.They are available as Turbocharged (TA)

3600 Specs 50Hz

3600 Family 2950 - 9587 hp

Model 3606 3608 3612 3616

Standby (ekW) 2688 3575 5375 7150

Prime (ekW) 2425 3250 4850 6500

Continuous (ekW) 2200 2938 4400 5875

Speed (rpm) 1000 1000 1000 1000

Compression ratio 13 13 13 13

The 3600s @ 50hz are available as Turbocharged (TA)

Caterpillar Gas Electric Power Products

The ratings are based on Natural gas as fuel. Optional info: Natural gas ratings have been established on natural gas with net calorific Low Heat Value (LHV) of approximately 36.2 mJ/m3 (920 Btu/ft3)

G3400 Specs 60Hz

Model G3406 G3408 G3412

Standby (ekW) 150-275 150310-340 310480

Continuous (ekW) 150-225 150175-280 175250-425 250-

Speed (rpm) 1800 1800 1800

Compression A/C Temp ratio (oC) 9.4, 10.3 8.5,9.4 8.5,9.7, 11.5 32-54 3232-54 3232-54 32-

BHP 231-329 231255-405 255364-607 364-

The G3406 and G3408 @ 60hz are Turbocharged (TA). The G3412 is available as naturally aspirated(NA) or as Turbocharged (TA) Caterpillar robust digital ignition on most models Low emissions available Both high and low compression ratios available for greater fuel flexibility

G3400 Specs 50Hz

Model Continuous (ekW) G3406 G3408 G3412 125-185 125155-230 155225-395 225-

Speed (rpm) 1500 1500 1500

Compression A/C Temp ratio (oC) 11.6 8.5,9.7,11 11.4, 9.7, 8.5 32-54 3232-54 3232-54 32-

BHP 185-274 185225-337 225325-562 325-

The G3406, G3408 and G3412 @ 60hz are available as Naturally Aspirated (NA) or TA

G3500 Specs 60Hz

Model G3508 G3512 G3516 G3520

Continuous or Standby (ekW) 375-400 375365-600 365750-1400 7501600-2055 1600-

Speed (rpm) 1200 1200 1200/1800 1200/1800

Compression A/C Temp ratio (oC) 8 8,9,11 8,9,11 11.7/11.3 32-54 3232-54 3232-54 3232-54 32-

BHP 513-545 513791-861 791976-1148 9762166-2889 2166-

Continuous and standby generator sets have the same rating for 3500s and up. G3508 available in Low Emissions, G3512 available as Naturally Aspirated (NA), as Turbocharged (TA) or as Low Emissions(LE). G3516 available as Turbocharged (TA) or LE. G3520 in Low Emissions (LE) Features include State-of-the-art Electronic Ignition System Low emissions engines available for all models High temperature jacket water for ease of heat recovery systems Wide range of fuels, including digester and landfill gas G3524 and G3532 Tandem Configurations offered for ratings up to 2095 ekW

G3500 Specs 50Hz

Model G3508 G3512 G3516 G3520

Continuous or Standby (ekW) 480-510 480725-770 725975-1165 9751360-1950 1360-

Speed (rpm) 1500 1500 1500 1500

Compression A/C Temp ratio (oC) 8 8,9,11 8,9,11 11.7/11.3 32-54 3232-54 3232-54 3232-54 32-

BHP 513-545 513791-861 791976-1148 976979-2717 979-

G3508,3512, 3516, 3520 @ 50hz are also available as Low Emissions

G3600 Specs 60Hz

Model G3606 G3608 G3612 G3616

Continuous or Standby (ekW) 1155-1235 11551540-1640 15402310-2615 23103080-3480 3080-

Speed (rpm) 900 900 900 900

Compression ratio 9.2 9.2 9.2,10.5 9.2,10.5

BHP 1599-1704 15992130-2270 21303196-3615 31964259-4811 4259-

All 3600s @ 60hz are available only as Low Emissions packages Lower speeds Higher horsepower Lower emissions Minimum 45,000 hours between major overhauls

G3600 Specs 50Hz

Model G3606 G3608 G3612 G3616

Continuous or Standby (ekW) 1285-1370 12851715-1825 17152570-2900 25703425-3860 3425-

Speed (rpm) 1000 1000 1000 1000

Compression ratio 9.2 9.2 9.2, 10.5 9.2,10.5

BHP 1774-1893 17742368-2521 23682551-4009 25514732-5336 4732-

All 3600s @ 50hz are available only in Low Emissions packages

Caterpillar Motoren Kiel Engine Center Electric Power Product Overview

This section covers the electric power products that are manufactured over in Kiel, Germany by MAK; a Caterpillar owned subsidiary.

Caterpillar Program of CM Engines

CM 20 CM 25 CM 32 CM 43 GCM 34
340 mm 6100 kW rpm 720/750

Year
kW/Cyl

1990
190

1994
300

1992
480

1996
480

1998
900

2002
900

2000
380

Sold(02/03) 816 368 636 212 8 Every 2 years development of a new engine type since 1990

The total power manufactured since 1964: 12,800 MW Every 2 years development of a new engine type since 1990

CM 20 Series Technical Data

power output power output cylinders & arrangement (60Hz) 1083 1530ekW (50Hz) 1354 1913kVA 6, 8, or 9 - Inline

cylinder output 170/190kW/cyl bore stroke speed piston speed fuel 200mm 300mm 900/1000rpm 9.0/10.0m/s HFO (heavy fuel oil) LFO (light fuel oil) DFO (distillate fuel oil) 186/190 g/ekW

SFOC

The CM 20 gives a similar power output to the caterpillar 3500 family generator sets, which makes it tougher to sell especially in North America. The advantage of this particular model of engine is its ability to consume heavy fuels. These engines will be used primarily in locations where emissions regulations are less stringent. The main use of this engine is as a marine auxiliary engine

CM 25 Series Technical Data

power output power output cylinders & arrangement cylinder output bore stroke speed piston speed fuel (60Hz) 1800 2610 ekW (50Hz) 2250 2013 kVA 6, 8, or 9 - Inline 290 308 kW/cyl 255mm 400mm 720/750 rpm 9.6/10 m/s HFO (heavy fuel oil) DFO (distillate fuel oil) LFO (light fuel oil) 182/183 g/ekW

SFOC

The CM 25 gives a similar power output to the caterpillar 3500 family generator sets, which makes it tougher to sell especially in North America. The advantage of this particular model of engine is its ability to consume heavy fuels. These engines will be used primarily in locations where emissions regulations are less stringent. The main use of this engine is as a marine auxiliary engine

CM 32 Series Technical Data

power output power output cylinders & arrangement bore stroke speed piston speed fuel (60Hz) 2.8 7.5 eMW (50Hz) 3600-9600 kVA 6, 8, or 9 - Inline 12, 16 - Vee 320mm 420mm 600/720/750rpm 9.6/10.5/10.1 m/s HFO (heavy fuel oil) DFO (distillate fuel oil) LFO (light fuel oil) 181 g/ekW

cylinder output 480kW/cyl

SFOC

The CM32 Modular design and integral construction reduce the number of components by 40 percent over conventional designs. The engine block does not require cooling water.The engine offers excellent, proven performance on heavy fuel oil and has low specific fuel and lube oil consumption.The engine can be direct elastic mounted with the generator on a common concrete foundation block, constructed at the site. For offshore applications, a base frame aligns the engine and generator. Efficient combustion helps minimize exhaust emissions, even when burning heavy fuel. For example, NOx emissions from CM32 engines are better than IMO standards. Noise levels are low compared to engines of similar size.

CM 43 Series Technical Data

power output power output cylinders & arrangement bore stroke speed piston speed fuel (60Hz) 5.2 15.7 eMW (50Hz) 6750 - 20250kVA 6, 7, 8, or 9 - Inline 12 - Vee 430mm 610mm 500/514rpm 10.2/10.5m/s HFO (heavy fuel oil) DFO (distillate fuel oil) LFO (light fuel oil) 179g/ekW

cylinder output 900kW/cyl

SFOC

The 6,8,9 and 12 in line are currently available. A 16 cyl is expected to be available in 2006

G 16 CM 34 Technical Data
power output cylinders & arrangement cylinder output bore stroke speed fuel Fuel Cons 5.9 eMW 16 Vee 380 kW/cyl 340mm 420mm 720/750rpm Natural Gas Methane > 70 7700 BTU/ekW

45+ % Mechanical Efficiency

The Caterpillar medium-speed G16CM34 engine/generator set is built on the platform of the proven Cat CM32 diesel engine and the G3600 gas engine.The GCM34 meets market demand for continuous power with virtually no unscheduled downtime. The one-piece modular cast iron block is extremely rigid and strong. Modular componentry and integral construction add to a long, trouble-free life. A special cooling design of cylinder liner, cylinder head and piston protects critical components. Electronic ignition and combustion controls help conserve fuel, minimize emissions and keep the engine operating at peak capability under most ambient and loading conditions. Mechanical refinements contribute to the GCM34s efficiency. A few of these refinements include a long-stroke design, and an electronic-controlled gas admission valve on each cylinder.The G16CM34, the engine delivers the industrys lowest total maintenance cost through low oil consumption, long maintenance intervals and readily accessible service points.

G16CM34 Power Plant - Bramming, Denmark

Bramming Fjernvarme, municipal utility for Bramming, Denmark, is a pioneer in the energy field. The utility, which provides district heating for the village of Bramming (population 6,500 people), was the first to install a natural gas plant powered by a Cat G16CM34 engine. The G16CM34 engine provides a power output of 6.1 MW at 750 rpm and a world-class electrical efficiency of 43.4% (44.5% mechanical efficiency). Heat recovery efficiency levels reach 49%, with a combined total efficiency exceeding 92%.

G16CM 34 Gas CHP Plant

CUSTOMER: Town of Bramming

LOCATION: MODEL OF ENGINE:

(1) NUMBER OF ENGINES: TYPE OF FUEL: PLANT OUTPUT: Hot Water for District Heating SERVICING DEALER: PROJECT CONTRIBUTORS: Local EPC

Bramming, Denmark Bramming, G3612 (1), G3616 (1), G16CM34 3 Gas 15 MW Electric plus ENAMCO MOTORER A/S Caterpillar Supplied Equipment,

3616 & 16CM32 Nicaragua HFO Plant

CUSTOMER NAME: Corporacion Electrica Nicaraguensa S.A.

LOCATION: MODEL OF ENGINE: NUMBER OF ENGINES: TYPE OF FUEL: PLANT OUTPUT: SERVICING DEALER: SCOPE OF SUPPLY:

Puerto Sandino, Nicaragua, C.A. Sandino, 3616 and 16CM32 9 - 3616 and 4 - 16CM32 HFO 64 MW NICARAGUA MACHINERY CO. Caterpillar Turnkey

Solar Product Line Overview

www.solarturbines.com

A leading supplier in mid-range industrial gas turbines and gas turbine-driven generator sets from 1 to 20 MW, Solar Turbines designs and manufactures rugged, reliable products using quality systems certified to ISO 9001 standards. Solar offers complete solutions from engineering specification to asset management. A wholly owned subsidiary of Caterpillar Inc., Solar Turbines Incorporated has a fleet of more than 11,200 gas turbine units-with over 1,000,000,000 operating hours--installed in 90 nations.

Caterpillar Solutions - Solar Turbines

Product Rating Turbine/Package Details Product Rating Turbine/Package Details Saturn 20 1.2 MW Taurus 70 7.5 MW

Centaur 40 3.5 MW

Mars 90

9.4 MW

Centaur 50 4.6 MW

Mars 100 10.7 MW

Taurus 60 5.5 MW

Titan 130

14 MW

The slide shows an overview of the product line. Solar gas turbines and generators meet energy requirements in a variety of cogeneration, baseload, peak shaving, distributed power and standby duty applications. Solar gas turbines operate on a wide variety of fuels: natural gas distillates natural gas liquids (NGLs) liquefied petroleum gases (LPGs) hydrogen medium-Btu gas (coal-bed methane, landfill gas) Dual and tri-fuel systems can be configured for use with many models of Solar gas turbines.

Saturn 20
Saturn 20 PG - Available Power Saturn 20 PG - ISO Performance/Specifications Saturn 20 GS Power Heat Rate Exhaust Flow Exhaust Temperature Steam Production Axial Exhaust? SoLoNOx Available? Package Length Package Width Package Height Metric Metric 1 210 kWe 14795 kJ/kWhr 23 540 kg/hr 505C 4-17 tonnes/hr Yes No 5 766 mm 1 727 mm 2 134 mm 8 980 kg English English 1 210 kWe 14 025 Btu/kWhr 51 900 lb/hr 940F 8-37 klb/hr Yes No 18' 11" 5' 8" 7' 0" 19 800 lbs

www.solarturbines.com

Approximate Weight

The curves on the next few slides provide performance data for each continuous-duty Solar gas turbine generator set at full load under standard conditions (sea level, natural gas fuel, 60% relative humidity, zero inlet and exhaust losses). Power and efficiency ratings are nominal at the generator terminals. Features of the Saturn 20 . Industrial Gas Turbine Package . Compact, Integrated Package, Providing Ease of Installation . Factory Tested . Multiple Fuel Capability . Onskid Microprocessor-Control with Auto Sync Capability

Centaur 40
Centaur 40 PG - Available Power Centaur 40 PG - ISO Performance/Specifications Centaur 40 GS Power Heat Rate Exhaust Flow Exhaust Temperature Steam Production Axial Exhaust? SoLoNOx Available? Package Length Package Width Package Height Metric Metric 3 515 kWe 12 910 kJ/kW-hr 67 000 kg/hr 435C 8-48 tonnes/hr Yes Yes 8 750 mm 2 440 mm 2 130 mm 23 755 kg English English 3 515 kWe 12 240 Btu/kW-hr 147 720 lb/hr 820F 18-106 klb/hr Yes Yes 28' 9" 8' 0" 7' 0" 52 370 lbs

www.solarturbines.com

Approximate Weight

Features Industrial Gas Turbine Package Compact, Integrated Package, Providing Ease of Installation Factory Tested Dry, Low Emission ( SoLoNOx) Combustion Available Onskid Microprocessor-Control with Auto Sync Capability Multiple Fuel Capability

Centaur 50
Centaur 50 PG - Available Power Centaur 50 PG - ISO Performance/Specifications Centaur 50 GS Power Heat Rate Exhaust Flow Exhaust Temperature Steam Production Axial Exhaust? SoLoNOx Available? Package Length Package Width Package Height Approximate Weight Metric Metric 4 600 kWe 12 270 kJ/kW-hr 68 680 kg/hr 510C 11-49 tonnes/hr Yes Yes 8 750 mm 2 440 mm 2 130 mm 27 079 kg English English 4 600 kWe 11 630 Btu/kW-hr 151 410 lb/hr 950F 24-108 klb/hr Yes Yes 28' 9" 8' 0" 7' 0" 59 700 lbs

www.solarturbines.com

Features Industrial Gas Turbine Package Compact, Integrated Package, Providing Ease of Installation Factory Tested Dry, Low Emission ( SoLoNOx) Combustion Available Onskid Microprocessor-Control with Auto Sync Capability Multiple Fuel Capability Applications District Heating Centaur 50 Turbine Dual-Fuel, SoLoNOx, Cogeneration/District Heating, Germany District Heating Centaur 50 Turbine Generator Set, District Cogeneration, U.S.A.

Taurus 60
Taurus 60 PG -Available Power Taurus 60 PG - ISO Performance/Specifications Taurus 60 GS Power Heat Rate Exhaust Flow Exhaust Temperature Steam Production Axial Exhaust? SoLoNOx Available? Package Length Package Width Package Height Approximate Weight Metric Metric 5 500 kWe 11 840 kJ/kW-hr 78 820 kg/hr 510 C 12-57 tonnes/hr Yes Yes 8 750 mm 2 440 mm 2 130 mm 30 454 kg English English 5 500 kWe 11 225 Btu/kW-hr 173 770 lb/hr 950 F 26-125 klb/hr Yes Yes 28' 9" 8' 0" 7' 0" 67 140 lbs

www.solarturbines.com

Applications Institutional Cogeneration Taurus 60 Turbine Generator Set, Hospital Cogeneration, U.S.A. Peaking Power Taurus 60 Turbine Generator Sets, Rural Electric Coop, U.S.A

Taurus 60 Mobile Power Unit

www.solarturbines.com

Applications Rental: The Taurus 60 Mobile Power Unit is the prime choice if youre looking to produce reliable, low-cost, onsite peaking power. Designed as an onsite generator system to optimize service for seasonal or cyclical loads. At the core of the Mobile Power Unit is the 5.5 MW. Taurus 60 industrial gas turbine, with a population of more than 1085 units in the field. The Mobile Power Unit combines the features and benefits of the proven Taurus 60 industrial gas turbine with a mobile system that is easy to relocate and connect.

Taurus 70
Taurus 70 PG - Available Power Taurus 70 PG - ISO Performance/Specifications Taurus 70 GS Power Heat Rate Exhaust Flow Exhaust Temperature Steam Production Axial Exhaust? SoLoNOx Available? Package Length Package Width Package Height Approximate Weight Metric Metric 7 520 kWe 10 650 kJ/kW-hr 97 000 kg/hr 490C 14-69 tonnes/hr Yes Yes 10 950 mm 2 790 mm 2 630 mm 46 303 kg English English 7 520 kWe 10 100 Btu/kWhr 213 840 lb/hr 910F 31-153 klb/hr Yes Yes 35' 11" 9' 2" 8' 7-1/2" 102 080 lbs

www.solarturbines.com

Mars 90
Mars 90 PG - Available Power Mars 90 PG - ISO Performance/Specifications Mars 90 GS Power Heat Rate Exhaust Flow Exhaust Temperature Steam Production Metric Metric 9450 kWe 11 300 kJ/kW-hr 144 590 kg/hr 470C 19.6-103.6 tonnes/hr Yes Yes 14 520 mm 2790 mm 3660 mm 67 585 kg English English 9.4 MWe 10,710 Btu/kW-hr 318,760 lb/hr 870F 43.1-228.3 klb/hr

Axial Exhaust SoLoNOx Package Length Package Width Package Height

Yes Yes 47' 7 1/2" 9' 2" 12' 0" 149,000 lbs

www.solarturbines.com

Approximate Weight

Mars 100
Mars 100 PG - Available Power Mars 100 PG - ISO Performance Specifications Mars 100 GS Power Heat Rate Exhaust Flow Exhaust Temperature Steam Production Metric Metric 10 690 kWe 11 090 kJ/kW-hr 150 390 kg/hr 485C 22.1-107.7 tonnes/hr Yes Yes 14 520 mm 2790 mm 3660 mm 67 585 kg English English 10.7 MWe 10,520 Btu/kW-hr 331,550 lb/hr 910F 48.6- 237.3 klb/hr

Axial Exhaust SoLoNOx Package Length Package Width Package Height

Yes Yes 47' 7 1/2" 9' 2" 12' 0" 149,000 lbs

www.solarturbines.com

Approximate Weight

Applications: Institutional Cogeneration: Mars 100 Turbine Generator Set, Tri-Fuel, Paper Plant, Turkey Distributed Power: Two Mars 100 Turbine Generator Sets, CombinedCycle Utility Power, Australia

Titan 130
Titan 130 PG - Available Power Titan 130 PG - ISO Performance Specifications Titan 130 GS Power Heat Rate Exhaust Flow Exhaust Temperature Steam Production Metric Metric 13 500 kWe 10 810 kJ/kW-hr 179 800 kg/hr 490C 26.6-128.5 tonnes/hr Yes Yes 13 870 mm 3 050 mm 3 250 mm 79 061 kg English English 13 500 kWe 10 250 Btu/kW-hr 396 390 lb/hr 915F 58.6- 283.4 klb/hr

Axial Exhaust? SoLoNOx Available? Package Length Package Width Package Height

Yes Yes 45' 6" 10' 0" 10' 8" 174 300 lbs

www.solarturbines.com

Approximate Weight

Features . Industrial Gas Turbine Package . Compact, Integrated Package Providing Ease of Installation . Factory Tested . Dry, Low Emission ( SoLoNOx) Combustion Available . Onskid Microprocessor-Based Controls with Auto Sync Capability . Multiple Fuel Capability Applications: Peaking Power: Three Titan 130 Turbine Generator Sets, Municipal Power, U.S.A.

This slide shows how the gas turbine generator components are combined to generate electric power.

Power Modules & Rental Products

This sections covers Caterpillars power modules and the rental products offered through our dealers.

Power Modules
Standard, rental, & utility configurations

The three main configurations for a power module are: 1. Standard use 2. Rental 3. Utility

Modular DesignSide View

Switchgear and Controls Generator Engine Radiator Exhaust and Air Discharge Plenum

Day Tank with Automatic Fuel Transfer System Optional Trailer Undercarriage

This slide shows a schematic of a typical power module These are packaged and tested in Griffin, Georgia

CAT Rental Power

Mobile source of power Sound attenuated Multi-voltage Multi-purpose
power cooling (chiller) heating peak sharing/shaving

CAT Rental provides energy when you need it. A mobile source of power used to keep people comfortable and productive, to maintain process quality, to run an event or special project, to operate through a power outage or rebuild after a storm, you need equipment and service you can trust. The local Cat dealer is your link to a virtually unlimited rental fleet, with mobile power generators, temperature control equipment and much more for all your temporary needs. If the local dealer doesnt have just what you need, other Cat dealers do. There have more than 1,800 worldwide dealer locations. The dealer does the legwork, you get the equipment delivered, installed, fueled up and ready to run.

60 Hz XQ Product Line
Olympian
30 ekW 60 ekW 75 ekW 105 ekW

Medium XQ
300 ekW 400 ekW 500 ekW

Power Modules
600 ekW 750 ekW 1000 ekW 1250 ekW 1500 ekW 2000 ekW

Here is the current rental products offered by Caterpillar. XQ stands for Extra Quiet. The XQ1250 and XQ 500 are the newest in the product line

XQ500 - 3456
20 ISO Container
UL/CSA Approved Components Spill Containment

NEW!

Multi-Unit Paralleling Multi-

Tier I Certified

The XQ500 product defined by this specification uses an EPA certified 3456 engine generator set packaged into a 20 container purpose-built for the rental business. It has a similar look and feel to the XQ600 and XQ750 rental products.

XQ1250G G3516B

NEW!

40 ISO Container Spill Containment Methane Detector

1.0 & 0.5 g/bhp-hr NOx g/bhpUL/CSA Approved Components

Features: Utility Grade Switchgear Utility Grade Switchgear Sound Attenuated Container Sound Attenuated Container Spill Containment/ Water Ingress Prevention Spill Containment/ Water Ingress Prevention Compatible with After Treatment Systems Continuous Pre Continuous Pre--Lube System Lube System Crankcase Ventilation - Open Crankcase Breather System Vented To Radiator Discharge Vented To Radiator Discharge - Positive Crankcase Ventilation (Rental PM)

Georgia Co-Ops
Remote Utility Dispatched
SCADA compatible Auto Parallel Soft load and unload

Peak System Resource

Peak generation capacity

Sited at Substations
19 x 1.8 MW Diesel Units installed in 1994

Here are some rental applications: Remote Utility Dispatched SCADA (Supervisory Control And Data Acquisition) compatible remote data collection Auto Parallel governing is done by automatically by switchgear to parallel generator sets with utility Soft load and unload gradually increasing the amount of load on a generator set while also gradually decreasing the load on utility Peak System Resource Peak generation capacity Sited at Substations Worth mentioning is that 1MW can light about 40,000 homes!

Honduras
Site Controlled & Dispatched
Auto Parallel Soft load and unload

System Resource
Base generation capacity

Sited at Substations

20 x 1.5 MW Diesel Units installed in 1997

Site Controlled & Dispatched

Auto Parallel Soft load and unload

System Resource
Base generation capacity

Sited at Substations

The next section gives an overview of Caterpillars marketing strategy: System Solutions.

Product Bundling
High-End Electronics UPS

Growing in Depth

Switchgear
Automatic Transfer Switches

Small

Battery Charger Muffler Fuel Tank

Large

Caterpillars strategy is to provide our customers with a complete turnkey solution for power. Along with an established range of electric power generators, Caterpillar now offers a wide range of attachments that can be fully integrated to produce power at the push of a button or the turn of a key. This is known as a system solution

What is a system solution?

Genset Paralleling Switchgear Genset
ATS
CLEAN SOURCE
CS 600
On-line Temperature: OK Current: OK Voltage: OK Battery: OK

Non Critical Load

UPS

Utility Grid Power

Flywheel UPS

Critical Load

A basic system solution consists of genset(s), switchgear thats used to parallel with utility or other gensets and a transfer switch for switching between power source. All these components are now available through CAT

Mechanical Attachments
Exhaust systems
Mufflers
Industrial grade Residential grade Critical grade

Stainless Steel Flex Elbows Installation kits

Some of the mechanical attachments include Mufflers Stainless Steel Flex couplings Elbows Installation Kits

Electrical Attachments
Digital Voltage Regulators Starting & charging system Jacket Water Heater Circuit breakers Battery chargers etc.

Electrical Attachments Include: DVRs: used to control field excitation of the generator this is not optional (required) Battery Chargers: Used to charge up the starting battery set JWH: used to keep the jacket water warm in cold environments, for Space Heaters improve/lengthen generator set life for standby set These items are not made by CAT but are outsourced from suppliers who build these to CAT specs

EMCP II - Standard
Microprocessor based
Programmable

Highly accurate
True RMS sensing

Proven exceptionally reliable Expandable Remote communications and control

This is a picture of the Electronic Modular control panel (EMCP) II. The GSC It is the brain of the EMCP II system, it combines the AC Meter, Annunciator and ECM into one module. Also added was a Transformer box in the back of the panel for more accurate AC metering of all three phases. Lights for E-Stop, coolant level and fault lights were added. The EMCP II adds even more features than the EMCP I. If there was a need to program the EMCP I ECM, the technician had to remove a cover, push buttons and select a rotary switch to the proper position and then do the programming. All of these switches and pots are on the back of the panel and the display is in the front. The EMCP II GSC is programmed using the pushbuttons on the front of the panel. EMCP II was developed in 1994.

EMCP II - Improvements for Gas Operation

Purge Cycle
No gas or spark upon cranking Purges engine and stack Programmable: 0 to 20 seconds
Factory set at 5 seconds

Staged shutdown
GSOV closes first Ignition continues to combust remaining gas Gas and ignition are stopped immediately during Overspeed and Emergency shutdowns

The Purge Cycle is basically designed to perform the following functions Remove all gas and prevents spark upon cranking Purges engine and stack of any residue gas in the system, Programmable to purge for: 0 to 20 seconds Factory set at 5 seconds Staged shutdown Gas Shut off Valve (GSOV) closes first Ignition continues to combust remaining gas in the engine Gas and ignition are stopped immediately during Overspeed and Emergency shutdowns, these are controlled electronically and efficiently.

EMCP II+ - Optional

32 bit microprocessor Full power metering Built in protective relaying Expanded I/O Expanded communications / control

EMCP II+. The + or Plus has large displays on the top and bottom of the GSC. In the Plus one can read Kw, Kva, Power Factor, Kw hours, percent of load or percent Kw, etc. The AC metering can display separate phases or totals, average voltage, average frequency and total current. When the customer sees the total current of all three phases he may see the result of 500 Amps per phase which will show 1500 AMPs. This works very much like the EMCP II. The plus also has Protective Relay functions. Protective relays can be programmed for alarm or shutdown parameters such as over current or over voltage to provide industrial grade protection. It costs about $1000 to upgrade to the plus package which is reasonable since a watt meter alone is about $1000.

EMCP II+ P (Auto Paralleling) - Optional Simple, low cost paralleling Automatic Speed Matching Synchronizer Isochronous Load Sharing Modes of Synchronizing
Manual / Permissive Semi-Automatic Fully Automatic

Same as EMCP II+ except allows for automatic paralleling capability.

Control Panel - Options

Customer Communications Module (CCM) Relay Driver Module (RDM) Customer Interface Module (CIM) Manual Synchronizing Module Dust Proof Enclosure NFPA 99 / 110 / Custom Alarm Modules

CCM

The Customer Communications Module (CCM) is simply a translator box. It takes the Cat Data Link output out of the EMCP II and translates it into an RS232 protocol that will communicate with a computer if that computer has the CCM desktop software installed. This is the Customer Interface Module (CIM) and relay hardware. Instead of activating LEDs from the serial data link like the Annunciator, it receives the data link information to activates relays. So instead of turning LEDs on, it energizes relays on. The relays can then be used to activate various remote devices but should not be used for control logic.

Switchgear Conversion - Optional

Electronic configuration Standard control panel enclosure No AC metering Auto Start / stop Full engine protection Digital Engine gauges Simple 2 wire interface

The switch gear conversion option is used to replace an EMCP if you have a separate switchgear lineup for paralleling and monitoring your generator set. It gives you a less expensive option than having redundant control with an EMCP. Note, you need an electronically controlled engine for this to work (usually a 3500 model option).

Caterpillar UPS Solutions

er nt Ce lity ta bi Da elia R

Po Ind w e us r Q tria ua l lit y

Continuous Power
Commercial Industrial ISPs Telecom

Utilities Industrial Commercial

Data Centers ISPs

How Does The Cat UPS operate? Normal operation The Cat UPS continuously conditions utility power and regulates voltage while using a small amount of power to keep the flywheel fully charged. Abnormal power event When the Cat UPS senses a large utility disturbance or interruption, the flywheel seamlessly supplies power to the critical load and smoothly maintains normal operation during the excursion Prolonged event with generator set start option The flywheel supplies up to 120 seconds of ride-through, depending on the size of the critical load. At the same time, the system supplies 24 VDC power for generator set start-up, replacing or supplementing the conventional starting battery. Once the generator set has started, synchronized and walked in the critical load, generator set power recharges the flywheel. Caterpillars power quality system has numerous configurations from 150kVA to 900kVA, to suit your application requirements and your budget. Short-term power packages are ideal for short-duration events which constitute more than 98% of all power disturbances per a EPRI/DOE report. This system consists of a Cat UPS without a standby generator set. Continuous power packages protect against all power events, no matter how long or short. The system includes a completely integrated power system with a standby generator, automatic transfer switch and Cat UPS for uninterruptible, continuous power. These systems are available as pre-installed in enclosures for transportable or permanent outdoor installations. Redundant critical power packages enhance the reliability of new or existing UPS systems. The Cat UPS can easily be configured for N + 1 redundant as well as isolated redundant configurations. The concept of N+1 will be discussed later

Continuous Power Sequence

Utility Outage Transfer Switch Signals Gen Set
(adjustable)

UPS Syncs with Gen Set

(worst case)

Gen Set starts and output stabilizes

UPS walks in Gen Set

(adjustable)

On Gen Set, UPS recharges

t=0.0

t=2.0

t=7.5

t=9.0

t=12.0 2 sec of full power still available

Heres a typical continuous power solution sequence during a power disturbance. Upon a utility event the Cat UPS powers the critical load. If the event is over 2 seconds (selectable on transfer switch to assure it is indeed a long duration event), the gen set is started. Typically, within 7.5 seconds the gen set is at speed. The UPS then synchronizes with the gen set output by altering its output frequency at a maximum slew rate of 1 Hz/sec to match the output of the gen set and begins to walk on the gen set power (maximum time if completely out of phase is 1.5 secs). Once synchronized, the UPS will walk the gen set into the load. (in this example, 3 seconds), assuring no step load applied to gen set. In this example, at full load, 2 seconds of ride-through are still available from the flywheel. More time would be available if less power were required by critical load. The flywheel recharges from gen set power or utility power, whichever is available.

The CAT UPS Family

UPS 300 UPS 600

UPS 900

60 Hz, 480 volt

This is The CAT UPS Family for 60 Hz, 480 volt UPS 300 UPS 600 UPS 900

The CAT UPS Family

UPS 250 UPS 500

UPS 750

50 Hz, 400 volt

This is The CAT UPS Family for

50 Hz, 400 volt

UPS 250 UPS 500 UPS 750

Series 300 Power Stage

MMU Multi-module unit Multi-

This is the UPS 300 which has a 300KVA rating but at a 0.8 power factor. The UPS 300 has a larger cabinet and will accommodate standard (less expensive) cables. There is more room for the electrical contractor to make the interconnects. This unit cannot be expanded because it is a UPS 300 Stand Alone unit with a single flywheel. With a 300 Expandable, up to three more control cabinets (three more flywheels) can be added. In the bottom of the MMU Cabinet is a puck which contains a 600 pound forged flywheel. The flywheel spins at 7700 rpm. The MMU cabinet weighs about 2500 pounds. It takes about 3 KW to maintain the flywheel speed at 7700 rpm and another 2KW for the cooling fans and the vacuum pump (shown just above the puck on the right). The vacuum pump extracts air from the sealed puck to remove air and moisture to increase efficiency of the rotor and also protect the rotor.

Cat UPS Series 300

60 Hz 50 Hz

UPS 300 UPS 300E UPS 600 UPS 900

UPS 250i UPS 250iE UPS 500 UPS 750

UPS 250iE,UPS 300E, UPS 500 & UPS 600 are field upgradeable to larger sizes

UPS 250iE,UPS 300E, UPS 500 & UPS 600 are field upgradeable to larger sizes

CAT UPS 900

Optional N+1 redundant MMU not shown

This slide shows a UPS 900, there are three flywheels since each flywheel provides 300KVA. From left to right in the slide there are five cabinets. These are the I/O Cabinet, the System Cabinet, and the three flywheel cabinets called (MMU1 through MMU3). The UPS is available in a 300, 600, or 900, or a 300, 600 or 900 with n + 1 arrangement.If there were four fly wheel cabinets shown it would be a UPS 900 N+1 and the fourth wheel would not be used but rather be a backup. The Contactors and breakers are rated for 900KVA. There can be four flywheel cabinets but the fourth would ONLY be a back-up. No more than three can be used at a time. The software can alternate which wheels get used to balance their usages.A 900KVA traditional battery UPS would fill a 20 X 30 room full of batteries. With a traditional battery powered UPS there are also concerns of hydrogen gas as the batteries are charged and routine battery maintenance is also required.

CTS & CTG Transfer Switches

The newest Caterpillar Transfer switches are the CTS and CTG models. These, being a CAT prime product, do have Caterpillar part serial numbers and are serviceable through the Caterpillar system.

CTS Series Automatic Transfer Switch

Ratings of 40 to 4000 amps 2, 3, or 4 Poles NEMA 1, 3R, 4, 4X & 12 enclosures Available to 600 VAC, 50 or 60 Hz UL, CSA, IEC listed Contact transfer speed less than 100 msec The CTG Series transfer switch is similar
MX200 microprocessor panel

The CTS series transfer switch shown is rated from 40 to 4,000 amps, Two, three, or four pole, and several different styles of NEMA enclosures (that's the box you put it in) are available. The transfer switch can handle up to 600 volts, and are UL, CSA and IEC listed. These are in the Cat system and there is a service publication for the CTS and CTG switches. The CTS has an LED display.

CTG Series Automatic Transfer Switch

Ratings of 40 to 3000 amps 2, 3, or 4 Poles UL 1008 & IEC listed at 480 VAC CSA certified at 600 VAC Double throw, mechanically Interlocked Electrically operated, mechanically held Available as open (CTG) or delayed (CTGD) transition MX100 microprocessor panel

The CTG is less expensive and has different set-up features without the LCD display panel like the CTS. The CTG has adjusting pots instead of an LED display.

LM

XLM1

XLM2

EGP3

Caterpillar, Inc. purchased I & S Operations, Inc. (ISO) in October 2001. At acquisition ISO, was the # 3 domestic switchgear manufacturer. Operated as a wholly owned subsidiary of Caterpillar, Inc. Corporate headquarters and manufacturing facilities located in Alpharetta, GA. These are the switchgear options available through the Caterpillar

dealer

Emergency Generator Paralleling

EGP

Automatic start, synchronize, parallel and load share on a common bus Main lugs output to feed downstream emergency distribution switchboard Optional emergency distribution circuit breakers For use with multiple downstream Automatic Transfer Switches Control up to 4 generators

Automatic start, synchronize, parallel and load share on a common bus Main lugs output to feed downstream emergency distribution switchboard Optional emergency distribution circuit breakers For use with multiple downstream Automatic Transfer Switches Control up to 4 generators

XLM

Emergency Transfer and Load Management

Automatic transfer to Emergency upon Utility failure Automatic start, synchronize, parallel and load share on a common bus Closed transition transfer back to Utility upon stable return of power Closed transition to Load Management Mode Closed transition transfer to Emergency Mode

Automatic transfer to Emergency upon Utility failure Automatic start, synchronize, parallel and load share on a common bus Closed transition transfer back to Utility upon stable return of power Closed transition to Load Management Mode Closed transition transfer to Emergency Mode

LM

Load Management

Easy retrofit to existing Caterpillar standby generator set applications Standardized, simple, cost effective control switchgear Local or remotely initiated starting, stopping, synchronizing, paralleling, and load management

Easy retrofit to existing Caterpillar standby generator set applications Standardized, simple, cost effective control switchgear Local or remotely initiated starting, stopping, synchronizing, paralleling, and load management

Product Applications

Custom

Multiple Utilities More than 4 Generators 5kV & 15kV Medium Voltage Automatic transfer to Emergency upon Utility failure Automatic start, synchronize, parallel and load share on a common bus Closed transition transfer Load Management Mode

Multiple Utilities More than 4 Generators 5kV & 15kV Medium Voltage Automatic transfer to Emergency upon Utility failure Automatic start, synchronize, parallel and load share on a common bus Closed transition transfer Load Management Mode

Caterpillar Electric Power Installations

Here are a few situations in which Caterpillar electric power was used to produce power in a variety of applications and locations worldwide.

Cat Worldwide Installed EPG Capacity

North America 73,700 mW 128,500 Units Europe / AME 54,000 mW 116,300 units C & S America 11,100 mW 29,100 units Total mW: 163,000 Total EPG Units: 321,000 units

Asia 24,000 mW 47,400 units

As of 2001, the total amount of electric power supplied by Caterpillar generator sets was 163,000mW The total number of Units was 321,000 units

Reliable Electric Power Requirements

Margarita Island off Venezuela

Challenge:The failure of a major undersea cable threatened the tourism business on Margarita Island off Venezuela. Outcome: Power stayed on for 300,000 visitors, thanks to 34 Cat power modules supplying 44 MW of capacity. First rented by power supplier CMS Energy for peaking and for supplemental power during a main power plant upgrade, the units were pressed into extended emergency service.

Reliable Electric Power Requirements

Lucent Technologies Headquarters in New Jersey

Challenge: Lucent Technologies financial analysts conference. Reliable power and air conditioning were needed for a temporary 22,000-squarefoot building, plus six conference rooms and an atrium at the companys world headquarters in New Jersey. Outcome: Nine sound-attenuated power modules supplied 2.25 MW for computer systems, presentation and catering equipment, and extensive theatrical lighting. Nine mobile air conditioners supplied 360 tons of cooling.

Temperature Control

Timken Companys steel mill in Wooste Toyota, Georgetown, Ky

(left Picture) Challenge: Mid-summer heat challenged Toyota to keep work space cool at its assembly plant in Georgetown, Ky. Temperature control was essential for maintaining paint process quality and keeping team members comfortable. Outcome:Toyota found seasonal rental more cost-effective than adding permanent chillers. For six weeks, five mobile Cat chillers supplied 2,500 tons of cooling capacity, keeping the plant temperature at 79 F or lower. (right picture) Challenge:Time is precious during annual maintenance shutdowns at Timken Companys steel mill in Wooster, Ohio. Furnace repairs typically were delayed by two days to allow time for cool down. Outcome:Two 80-ton Cat mobile air conditioners cut furnace cooling time in half, enabling crews to begin fire brick replacement promptly, and allowing more curing time for cement holding new bricks in place.

Special Events

Special Olympics World Summer Games

Super Bowl XXXII in Miami, Fla

(left Picture) Challenge:The 10th Annual Special Olympics World Summer Games drew 450,000 competitors, coaches, family members, volunteers and spectators to events in Durham, Chapel Hill and Cary, N.C. Mobile power and cooling were needed for multiple purposes and numerous sites. Outcome: Some 8.5 MW of power supplied by the local Cat dealer served lighting, sound and TV equipment, food booths, vendor displays, hospitality tents, medical trailers, a Jumbotron video screen, and much more. (right picture) Challenge: Super Bowl XXXIII festivities in Miami, Fla., included parties, exhibits and numerous other events around the city. The Event Technical Services production company needed not just mobile power but help with the logistics of multiple events. Outcome:The local Cat dealer supplied sound-attenuated generators totaling 1.4 MW, plus more than 10,000 feet of cable. Numerous events, including the three-day NFL Players Party for football stars and fans, proceeded without a hitch.

Disaster Recovery

Hurricane Georges struck Puerto Rico in 1998

Challenge: After Hurricane Georges struck Puerto Rico in 1998, two Warner-Lambert pharmaceutical plants needed emergency power to resume production. Power modules were on hand in Chicago, but heavy transport aircraft were not available locally. Outcome:Through an air-freight company, the Cat network located a huge Russian-built Antonov AN 24 transport in Kiev, Ukraine, 5,400 miles away. The plane picked up three 1750 kW power modules at Chicagos OHare airport and air-lifted them to San Juan for ground transport to the plants.

Electric Power Potential Markets

There are many markets in which Caterpillar electric power products can be used to produce reliable, durable and adequate power. The next few slide give possible applications in which Cats electric power can be used

Reliable Electric Power Requirements

Hospitals and Critical Care

Commercial Services

Commercial Services include: Reliable power to protect Banks Reliable temperature control requirements for food storage Reliable Power for Buildings

Telecommunications
Cell Sites Fiber Systems Support Central Offices Data Centers 911 Support Centers Disaster Recovery

The telecommunications market includes: Cell Sites Fiber Systems Support Central Offices Data Centers 911 Support Centers Disaster Recovery power

Industrial and Manufacturing

Microprocessor Controls Power Quality Power Reliability Elimination Downtime

The industrial and manufacturing market opportunities include: Microprocessor Controls Power Quality Power Reliability elimination of downtime

Customer Support

Your Cat dealer offers a wide range of product support plans, from preventive maintenance programs to complete service agreements with monthly cost and performance guarantees. They can also help you prepare for a disaster, like a storm, fire or flood. Your dealer will help you plan for delivery of rental power to get you back into service quickly, no matter what may happen to your main power supply. You can also look to us for technical and financial planning. EPG Design Pro software package helps you specify the best generator set for your project; the Engine Investment Analysis software quickly calculates your life-cycle costs.

Product support is available after the sale. Caterpillar has over 1200 parts and service locations throughout the world, and this number is growing. Fast parts access is a must in the EPG business. Most dealers have a large stock of Caterpillar parts, but if they dont have the part available then it can be sent within 12 hours from the nearest Caterpillar warehouse worldwide.