y a) LS CATERPILLAR’ FORM No, SeNRATO401 rence sence awn ‘cra SEF GENERATORS severe Schematic : i Connection Diagrams: ° SR4 Generators VR3 & VR4 Voltage Regulators _ OptionsSEER Important Safety Information ‘basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situatons before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skils and tools to perform these functions property. ‘Most scents Invhing product operation, mielenance and pa are caused by flu to obser @ ( Improper operation, lubrication, maintenance or reps could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. of this product can be dangerous and Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons, ‘The hazards are identified by the "Safety Alert Symbol" and folowed by a “Signal Word such as WARNING’ as shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning, explaining the hazard, can be either writen or pictorally presented. Operations that may cause product damage are identified by NOTICE labels on the preduct and in this publication, Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The wamings in this publication and on the product are therefore not all inclusive. Ifa tool, procedure. work ‘method or operating technique not epectficaly recommended by Caterpillar is used, you must satisty yourself that itis safe for you and others. You should also ensure that the product wil not be damaged ‘or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustrations in this publication are on the basis of information | avalable atthe time it was written, The specifications, torques, pressures, measurements, adjustments, | ilustrations, and other items can change at any tme. These changes can affect the service gvven to the product. Obtain the complete and most current information before starting any job. Caterpillar | dealers have the most current information available. Fora fist of the most current publication form. | numbers avallable, see the Service Manual Contents Microtiche, REG 130F.e00000 Contents | 6 Generator Set Information 4 | ‘Main Stator (Armature) Connections And Voltage Sensing Leads © 12 Lead, Wye And Delta Connections ... A 5 10 Lead. Wye, Connection 5 6 Lead, Wye Connection 6 6 Lead, Delta Connection 6 4 Lead, Wye Connection 7 12 Lead, Single Phase Connection - 8 Main Revolving Field Connections Diode BIOGK 9 inde Block And Surge Suppressor 8 Three Diode Blocks And Surge Suppressor 10 Six Dodes And Two Surge Suppressors 10 \VR@ Voltage Regulator Sensing Lead Connections To Generator And Droop Transformer Selection Chart For Voltage Regulator " Seif Excited With Direct Connection To Generator 12 Solt Excited With Power Transformer For Four Lead Generator 3 Sel Excited With Power And Sensing Isolation Transformers 14 Petranent Magnet Excitation With Direct Connection To Generator 15 Permanent Magnet Excitation With Connections To Metering Potential Transformers 16 Perrnanent Magnet Excitation With Connections To An Isolation Transformer 7 \VR4 Voltage Regulator Sensing Lead Connections To Generator Self Excited With Direct Connection To Generator 18 ro Options \ ‘Manual Voltage Control With Self Excitation 19 ~ Manual Voltage Control With Power Transformer 20 © Manual Voltage Control With Permanent Magnet Exciter 21 Radio Frequeney interference (RFI Filter 2 Series Boost With VRS Voltage Regulator 23 Series Boost With V4 Voltage Regulator 24 Manual Control And Series Boost With Self Excitation 25 Oil Field $4 Generators Exciter Field Connections (Series or Parallel) And Voltage Sensing Leads 6 NOTE: A ‘C"in the lett margin is an indication of change from the forrner issue, Connection Diagrams 3 ContentsGenerator Set Information Sheet | Custonier Designation = te ole Engine Model Number <<< Engine Arrangement Number — <_< Engine Serial Number ————<—$<$_$_$_$?_J_$_$_ Generator Arrangement Number —————_—__<$__$_$_$_$_$_$_—— | Generator Serial Number Generator Frame Stee Voltage Rating KW Rating a PN @ 4 When servicing this generator, refer to the following diagrams. Excitation System: S.I Main Stator: Number of Leads Diagram Number Main Revolving Field: Diagram Number Voltage Regulator: Diagram Number —____— Options: Diagram Number e. ‘Connection Diagrams 4 Information Sheet oe el ae12 LEAD, WYE AND DELTA CONNECTION Cgk Wie COWECTION REGRATOR SES fz ‘DELTA CONNECTION ECRATOR fare eee arose 18 LEAD WYE CONNECTION 1 REGULATOR 10 SENSING Leaps 79 is rey WYE CONNECTION Bl Te ae N TIE TOGETHER ( OLTAGE| YU ¥ # Low [mn cere waral carstero RIGH [ot aoe oe 2 cain vie wera] cua ' @ Connection Diagrams 5 'SR4 Generator& LEAD WYE CONNECTION Fo fe lees J 1D i co accuaror ace SENN PED 5 Ec) — WYE CONNECTION REGULATOR SENSING (EADS Nor WerAceo [LI L213 N ON MEDIUM VOLTAGE U v W eens, we 13 (74.15.76) aie 6 LEAD DELTA CONNECTION or 22 GEN) Te Th eG ATOR ‘SENSING: 13 14 LEADS Z Oe) 2 1S a EN 1 DELTA CONNECTION REGULATOR | NOTE. eee REGULATOR SENSING u 2 “ LEAQS NOT INSTALLED ' ‘ON MEDIUM VOLTAGE MEE OG: v ¥ 2 22 24 GENERATORS (11,16) 12,74) (13,78) 3 TL 12 6 a ‘SR4 Generator Connection Diagrams e.4 LEAD WYE CONNECT ‘ON nH Paes REGULATOR 246] }--> SENSING 20_cen~ tEaDs. Note WYE , CONNECTION REGULATOR SENSING LEADS Nor INSTALLED | LI 2 Git " ‘ON MEDIUM VOLTAGE Uy GENERATORS 7 O Connection Diagrams 7 ‘SRA Generator12 LEAD SINGLE PHASE CONNECTION 5, al : u 12 1? VT 18 6 "Nee ni : v7 GENERATOR CONNECTION REG SENSE @ ul B N CONNECT LEADS U v ’ TOGETHER 224 (12,18) (11,17) (14,76,718,112) | (13,75,79, TLD) | 12 TL NOTE: FOR PARALLEL OPERATION, T8 LEAD GOES THROUGH WINDOW OF DROOP TRANSFORMER WITH VR-3 VOLTAGE REGULATOR, CONNECT JUMPER WIRE BETWEEN VOLTAGE REGULATOR TERMINALS 26 AND 28. WITH VR-4 VOLTAGE REGUALTOR, JUMPER WIRE IS NOT cset1art REQUIRED. e Connection Diagrams 8 SR4 Generatorcoarsaes cozr20P1 DIODE BLOCK L3 REVOLVING FIELD. U2 EXCITER ARMATURE CRI-6_ RECTIFIERS. CR7 SURGE SUPPRESSOR DIODE BLOCK AND SURGE SUPPRESSOR cRI-6 lz L3 REVOLVING FIELD (2 EXCITER ARMATURE Connection Diagrams CRI-6 RECTIFIERS ER7.8 SURGE SUPPRESSOR ‘SR4 GeneratorTHREE DIODE BLOCKS AND SURGE SUPPRESSOR CRI-6_ RECTIFIERS, be Beene saaettn CRT_SURGE SUPPRESSOR Gta ERE ON fr STATIC. DISCHARGE RESISTOR SIX DIODES AND TWO SURGE SUPPRESSORS L3 REVOLVING. FIELD. CRI-6 RECTIFIERS ER7.8 SURGE SUPPRESSOR (2 EXCITER ARMATURE RTS SU a, Rl STATIC. DISCHARGE RESISTOR Connection Diagrams 10 ‘SR4 GeneratorHOLVINDAY JDVLIOA HOS AGIND NOILOA1aS aug caigango nos aig 133810, ey ‘sabe a wolerra3e woleness ~ wi wouwTn538 wolTn934 008, 341208 osty\_dsulsad, “ony o vw sag Baa OST ween 7 Sou 70K ONT uo Segoe “NSH NHR osLiaKs 335 \VR3 Voltage Regulator csoizar1 ‘Connection DiagramsSELF EXCITED WITH DIRECT CONNECTION TO GENERATOR ney Game: 4 he INSTALLED. [REMOVE LINK 4-7) LEVEL GAIN VR3_ REGULATOR REGULATOR gp peaesy Fy aE Nore eh DROOP_ TRANSFORMER CTI AND OROOP RMEOSTAT AL MAY OR MAY NOT BE SUPPLIED Li EXCITER FIELD CTI DROOP TRANSFORMER RL DROOP RHEOSTAT Re REMOTE LEVEL AEOSTAT wie UeERS @ro.aniry 370061 Connection Diagrams 12 VR3 Voltage RegulatorSELF EXCITED WITH POWER TRANSFORMER, FOUR LEAD GEN Te OR 12 10K OHM ae L LST SGEN r em RI Sys om TL REMOTE LeveL 6 aN 1 HNSTALLED (REMOVE LINK 4-7) FROM (GENERATOR LEVEL GAIN REGULATOR SENSING LEADS VR3_ REGULATOR Sa eee od tH u NOTE y DROOP TRANSFORMER CT! AND BROOP RHEOSTAT AI MAY OR MAY NOT BE SUPPLED. Lt EXCITER FIELD. PT2 POWER TRANSFORMER ‘ Rl DROP RHEOSTAT (© TERMINAL NUMBERS. Re REMOTE LEVEL RHEOSTAT wine NUMBERS Cit DROOP TRANSFORMER POLARITY. cs705aP1 Connection Diagrams 13 ‘VRS Voltage RegulatorS.E. WITH PWR AND SENSING ISOLATION TRANS Ta oR 12 REGULATOR SENSING LEADS a 4d Note Tore IF INSTALLED REMOVE. Line LEVEL GAIN : VR3 REGULATOR ROOP TRANSFORMER CTI AND DROOP RHEOSTAT RI MAY OR MAY NOT BE SUPPLIED Li EXCITER FIELD Rl DROOP RHEOSTAT Re REMOTE LEVEL RHEOSTAT 'SOL. ISOLATION. TRANSFORMER o37056P1 © Tare ae 1K OHM. 4p CTI DROP. TRANSFORMER PT2 POWER TRANSFORMER : PT3PT4 SENSING TRANSFORMER © TERMIVAL NUMBERS © wine NUMBERS @ POLARITY Connection Diagrams 4 'VR3 Voltage RegulatorP.M. EXC WITH DIRECT CONN TO GENERATOR Ta oR 12 cn SEH = GEN FROM enna TOR REGULATOR 20_GEN| SENSING LEADS Tee 2 ,) eS eo U em fee me Sy 10K OHM lad a) REMOTE even IF RSTALLED. [REMOVE LINK 4-7 @@ LEVEL Gam VR3_ REGULATOR otk Rae Fuses TTR 20 22 24 26 28 FI Fe ° is cen} {nena} -{ Fuses + Fi u c Nore z — ‘OROOP TRANSFORMER CTL AND OROOP AHEOSTAT RL MAY OR MAY NOT BE SUPPLIED. (UL EXCITER FIELO, Us Py, EXCITER STATOR I OROKP FREOSTAT Fo REMOTE LEVEL REGSTAT ‘Connection Diagrams: Cipro Transr omen. © Tema. MrBERS O wine sareens fe PoaTY ¢37057°1 15 ‘VR3 Voltage RegulatorP.M. EXC W/CONN TQ METERING POT TRANS Ri OHM, tL REO oF (REMOTE LEVEL 1 lip INSTALLED TiREMOVE LINK LEVEL GAIN V3 REGULATOR REGULATOR SENSING CONNECT. TO. 120 VOLT SECONDARY METERING POTENTIAL TRANSFORMER SOE] HE 1g BT ot gt 2 EGE! 86 18 FY ON SEN TS PHASE. RELATION Wit DROOP TRANSFORMER TI |S IMPORTANT nore ° DROP TRANSFORMER CTi AND DROOP RHEOSTAT RI_MAY OR MAY NOT ae PT TrRay UBER couse) Connection Diagrams 18MANUAL CONTROL WITH POWER TRANSFORMER REGULATOR SENSING teaps YR3_ REGULATOR + Fi_ GEN] u c a io S46. Se are 00ST MODULE NSTALED SO---------4 ea) ray oT 006000 LL EXCITER BTL POWER emsosP) Fe Fi 25 24 46 45 44 43 a2 a1 21 20 FIELO TRANSFORMER MANUAL CONTROL © TERMINAL NUMBERS wie NUMBERS ‘Connection Diagrams 20 OptionsMANUAL CONTROL WITH P.M. EXCITER VAS REGULATOR REGULATOR SENSING 87654321 MANUAL CONTROL LL EXCITER FIELD ts “pw STATOR 9 TERMINAL NUMBERS aust WIRE NUMBERS Connection Diagrams 2 OptionsSENSING LEADS FROM GENERATOR cause7P RADIO INTERFERNCE FILTER 10 REGULATOR GENERATOR REGULATOR RFI RADIO INTERFERENCE SUPPRESSOR Connection Diagrams 22 OptionsSERIES BOOST WITH VRS VOLTAGE REGULATOR | ‘PA. vr3. REGULATOR 204K TK-R=12 - REGULATOR 2d FUSES SENSING KIK-R=12 LEADS 20 22 24 26 28 30 FIF2 99 R000 t I SERIES BOOST MODULE NOTE REMOVE LINK 6-7 FOR 50 HZ OPERATION L_EXCITER FIELD © TERMINAL NUMBERS SBT SERIES BOOST TRANSFORMER © WIRE NUMBERS cones ‘Connection Diagrams 23 OptionsSERIES BOOST WITH VR4 VOLTAGE REGULATOR ean aN secuaron Re REGULATOR een eens 2 aN eevee een aS ? €) fe oO ss A ul Fa 5 fhe he | sr 2 ! 5 ‘ SERES BOOST MODULE wore REMOVE LINK 6-7 FOR 50 HZ OPERATION LI EXCITER FIELD, SBT SERIES BOOST TRANSFORMER © TERMINAL NUMBERS WIRE NUMBERS Connection Diagrams 24 OptionsMANUAL CONT AND SERIES BOOST W/SELF EXC Ra REGULATOR RE REGULATOR SENSING teabs a FUSES, RIE 20 2 24 26 2a m0 FI Fe 000 5 ; | csr || 03 23456739 SERIES BOOST MODULE 9 29090 Fo FI 23 2046 45 a4 43 a2 at 2120 MANUAL CONTROL NOTE REMOVE LINK 6-7 FOR 50 HZ OPERATION LL EXCITER FIELD © TERMINAL NUMBERS ae SBT SERIES BOOST TRANSFORMER WIRE. NUMBERS Connection Diagrams - 25 OptionsEXC FLD CONN (SERIES AND PARALLEL) i 1 ul ‘agente! LA HONON CAD) 1 5 1 SERIES CORECTION (4 ON FIELD) Rs. REGULATOR 2 aeguaton RE Sexe i ruses fy RE 20 22 24 26 28 50 FI re 660 ul PARALLEL COMECTION + (3.5 OM FIELD) caries Connection Diagrams 26 - ‘SR4 Oil Field Generators