Cat Switchgear - Eaton Consulting Application Guide

Cat Generator Paralleling Switchgear 42.
0-1
June 2006 Home Index
Sheet 1815
Master TOC
Paralleling Switchgear
Cat Generator Contents
CatT Generator Paralleling Switchgear
Introduction
22
23
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.0-2
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.0-4
24
Standard and Custom Configurable Products . . . . . . . . . . . . . . . . . . . 42.1-1
PowerLynx Technology Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.1-2
XLM Switchgear 25
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.2-2 26
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.2-3
Technical Data — XLM One-Line Diagrams . . . . . . . . . . . . . . . . . . . . . 42.2-4
Functional Sequences of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.2-10
27
EGP Switchgear
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.3-1 28
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.3-2
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.3-3 29
Technical Data — EGP One-Line Diagrams . . . . . . . . . . . . . . . . . . . . . . 42.3-4
LM Switchgear
30
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.4-2 31
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.4-3
Technical Data — LM One-Line Diagrams . . . . . . . . . . . . . . . . . . . . . . . 42.4-4 32
Medium Voltage Systems
33
Technical Data — One-Line Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 42.5-3
Custom Configurable Systems 34
Technical Data — One-Line Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 42.6-2 35
Specifications
See Eaton’s Cutler-Hammer Product Specification Guide on enclosed CD-ROM:
1995 CSI Format:
36
Low Voltage XLM UL 1558 Switchgear. . . . . . . . . . . . . . . . . Section 16426E
Low Voltage XLM UL 891 Switchboard . . . . . . . . . . . . . . . . Section 16429E 37
Medium Voltage XLM Metal-Clad Switchgear . . . . . . . . . . Section 16346E
Low Voltage EGP UL 1558 Switchgear . . . . . . . . . . . . . . . . . Section 16426G
38
Low Voltage EGP UL 891 Switchboard . . . . . . . . . . . . . . . . . Section 16429G
Medium Voltage EGP Metal-Clad Switchgear. . . . . . . . . . . Section 16346G
Low Voltage LM UL 1558 Switchgear . . . . . . . . . . . . . . . . . . Section 16426X 39
Low Voltage LM UL 891 Switchboard . . . . . . . . . . . . . . . . . . Section 16429X
Medium Voltage LM Metal-Clad Switchgear . . . . . . . . . . . Section 16346X 40
2004 CSI Format:
Low Voltage XLM UL 1558 Switchgear. . . . . . . . . . . . . . Section 26 23 13.11
Low Voltage XLM UL 891 Switchboard . . . . . . . . . . . . . Section 26 24 13.31
41
Medium Voltage XLM Metal-Clad Switchgear . . . . . . . Section 26 13 13.31
Low Voltage EGP UL 1558 Switchgear . . . . . . . . . . . . . . Section 26 23 13.13 42
Low Voltage EGP UL 891 Switchboard . . . . . . . . . . . . . . Section 26 24 13.33
Medium Voltage EGP Metal-Clad Switchgear. . . . . . . . Section 26 13 13.33
Low Voltage LM UL 1558 Switchgear . . . . . . . . . . . . . . . Section 26 23 13.15
43
Low Voltage LM UL 891 Switchboard . . . . . . . . . . . . . . . Section 26 24 13.35
Medium Voltage LM Metal-Clad Switchgear . . . . . . . . Section 26 13 13.35
CA08104001E For more information visit: www.EatonElectrical.com

42.0-2 Cat Generator Paralleling Switchgear
Introduction Home TOC Index June 2006
Sheet 1816
General Description Master TOC
22 Introduction breaker switchgear and Magnum power ■ Data center/data processing.

circuit breakers with PowerLynxT ■ Healthcare.
CaterpillarT Generator Paralleling control technology. PowerLynx ■ Critical industrial/chemical
Switchgear is a product developed technology is for optimal power gener- processes.
23 through a joint venture between ation and electrical distribution system
performance. It provides advanced, ■ Distributed generation/co-generation.
Caterpillar and Eaton Corporation.
Caterpillar, an industry leader in industry-leading, microprocessor- ■ Water/wastewater treatment
24 electric generator sets, and Eaton, an based engine generator set control ■ Government/military.
industry leader in Low and Medium provided exclusively in Caterpillar ■ Banking/credit card processing.
Voltage Switchgear have combined Switchgear. Medium voltage systems
25 forces to create Caterpillar Generator combine VCP-W breakers and VacClad Caterpillar Switchgear Features
Paralleling Switchgear...the most Metal-Clad switchgear with the same
reliable and feature rich product proven PowerLynx technology. ■ Built-in redundancy.
26 available in the market today! ■ Reliability.
Applications ■ Touchscreen interface.
Caterpillar Switchgear has been
■ Emergency/legally required ■ Simple, intuitive operation.
27 designed to integrate hand-in-glove
standby systems.
with Caterpillar's on-package, ■ Advanced communications
microprocessor-based engine control. ■ Optional standby backup systems. capabilities.
28 Exclusively from your Caterpillar ■ Distributed generation. ■ Integrated digital technology.
dealer, you can now get the market’s ■ Peak shaving. ■ Advanced generator control and
best efficiency, reliability and protection.
■ Prime power.
29 dependability all in one package. ■ Detailed engine and electrical reports.
Reliable, flexible, and powerful. Cater-
Caterpillar Switchgear combines the ■ Best-in-class footprint.
pillar Switchgear is designed with the
30 proven Magnum DS power circuit
most critical power needs in mind:
31
32
33
34
35
36
37
38
39
40
41
42 XLM EGP LM
43
For more information visit: www.EatonElectrical.com CA08104001E

Cat Generator Paralleling Switchgear 42.0-3
June 2006 Home TOC Index
Introduction
Sheet 1817
Master TOC General Description
Standards
Low Voltage Caterpillar Switchgear
22
conforms to the following applicable
standards: 23
■ NEMAT Standard SG-5
■ CSAT
24
■ ANSI C37.20.1
■ ANSI C37.51
■ ULT Standard 1558 25
■ NFPA 110, NFPA 99 and NFPA 70
The Switchgear utilizes Magnum DS 26
Breakers that are designed to NEMA
Standard SG-3; ANSI Standards
C37.13, C37.16, C37.17 and UL 1066. 27
Optional switchboard construction is
available that is built to UL Standard
891. These switchboards utilize 28
Magnum SB UL1066 Breakers for
generator mains, utility mains Overview
and electrically operated feeders, 29
and molded-case breakers for
non-switched feeders.
30
Medium Voltage Caterpillar
Switchgear conforms to the following
applicable standards: 31
■ NEMA SG-5
■ ANSI/IEEE C37.20.2 32
■ CSA-C22.2 No. 31-M89
■ EEMAC G8-3.2.
■ NFPA 70, 99, 110. 33
The switchgear utilizes VCP-W vacuum
circuit breakers that are designed to 34
meet or exceed all applicable IEEE /
ANSI standards including C37.06.
35
Common Components
Throughout the Entire Facility 36
Caterpillar Generator Paralleling
Detailed Engine Data
Switchgear is built with Eaton's indus-
try-leading Magnum DS low voltage 37
drawout switchgear with Magnum DS
breakers and VacClad medium voltage
switchgear with VCPW vacuum 38
breakers. This now allows the use
of common components on both
the normal power systems and the 39
generator power systems. Common
and interchangeable breakers, relays,
switchgear assembly parts, breaker 40
maintenance procedures, etc. can
be used to help reduce the overall
operating cost and increase the 41
maintainability of the entire facility.
42
43
Generator Set Control Screen

Sheet 1818
Definitions Master TOC
22 Definitions Feeder Breaker Controls: Automation

controls to allow control of the
NPSS Normal Power System Supplier:
Supplier of all the components of the
The below terms and acronyms are distribution feeder devices for load NPS, such as the distribution equip-
referenced throughout this section shed/load add control and monitoring. ment vendor’s authorized distributor.
23 on Generator Paralleling Switchgear.
Generator: A machine for converting Paralleling: The procedure of connect-
These definitions can help the reader
mechanical energy into electrical energy. ing two or more generators, or other
fully understand the topics discussed.
The electrical energy may be direct power sources, of the same phase,
24 Alternator: A device for converting current (dc) or alternating current (ac). voltage and frequency characteristics
mechanical energy into alternating supplying the same load.
Generator Bus Tie: A bus tie used in
current electrical energy. It may also be
25 called an AC or synchronous generator.
XLM type systems for separating the Peak Shaving: Process by which
generator bus and/or loads from the utility customer minimizes utility
ATS: Automatic Transfer Switch. normal utility fed bus and/or loads. charges by either generating power
26 Automatic Transfer Switch: A switch Generator Demand Priority: Controls
and eliminating excessive demand
charges or by shedding load.
designed to sense the loss of one that automatically match the online
power source and automatically trans- engine generator capacity to the PowerLynx Technology: An advanced,
27 fer the load to another source of power. load to avoid unnecessary engine industry-leading microprocessor-
genset operation when loads are low. based engine generator set automa-
Closed-Transition Transfer: A transfer (Alternatively called Load Sense tion processor provided exclusively
28 between sources that provides a Load Demand.) in Caterpillar Switchgear.
momentary paralleling of both power
sources during a transfer in either Generator Tie Breaker: A feeder Prime Power Application: Unlimited
29 direction. This results in no interrup- breaker that is used to connect an hours of usage. Requires generators to
tion of power to the loads during the XLM type system to a separate piece be applied at their Prime Power rating
transfer. The closed transition transfer of Normal (utility) switchgear. with a typical load factor of 70%.
30 is only possible when the sources are
Governor: A device that regulates Processor: A specially configured
properly synchronized and interfaced.
prime mover speed by adjusting the logic controller with appropriate input-
DGPS Distributed Generation Power fuel input to maintain constant speed. output capability and programming.
31 System: Typically a local engine genset
HMI Human Machine Interface: SAW (Surface Acoustic Wave):
and automation connected to the utility
Typically a touchscreen used by A premium touchscreen sensing
system to peak shave or export power.
32 the operator for interfacing with the technology that offers maximum
EGP Switchgear (Engine Generator paralleling generator system. protection from wear or contaminants.
Paralleling Switchgear): Parallels
LM Switchgear (Load Management Station Battery: A power supply
33 multiple engine/gensets to serve loads
Switchgear): A single generator utilized for control of switchgear.
transferred via downstream ATS units.
used in distributed generation
power systems. Includes automation Synchronizer: A device which will syn-
EGPT Switchgear: Same as EGP except
34 with a controlled emergency generator controls which allow for the load to chronize an on-coming electric genera-
be served simultaneously by both tor set with the bus or another electric
bus tie breaker between sets of generators
utility and generator power sources generator set, and allows multiple power
to segregate loads or areas of the bus.
35 EMCP Electronic Modular Control
while managing how much each sources in be connected in parallel.
source contributes. Synchroscope: An instrument that
Panel: A Caterpillar microprocessor
Load Shed/Load Add: Automation provides a visual indication of proper
36 module for engine/genset control.
controls to control distribution devices time for closing of the breaker when
Emergency Generator Bus Tie: A bus (turn OFF and restore ON) when only synchronizing generators to connect
tie breaker used in EGP type systems to partial emergency engine gensets are them in parallel with another source.
37 segregate groups of generators and/or available for duty. Typically accom- TFT (Thin Film Transistor): A type
loads. Emergency Generator Bus Tie plished by assigning Priority levels to of touchscreen display technology
breakers are used where critical loads, each controlled distribution device.
38 used in HMI devices that offers high
required to be powered in 10 seconds,
Master Controls: All processors, levels of brightness and clarity.
exceed the capacity of a single genset.
HMI and programming to implement Utility Protection: A collection of protec-
39 EPS Emergency Power System : The
the desired modes of operation tive relays or a multifunction relay
emergency power sources and emer-
of engine gensets in a paralleling required by the utility to detect abnormal
gency distribution to down-stream loads.
switchgear system. conditions and open the utility breaker.
40 EPSS Emergency Power System Sup-
NFPA 110 — Standard for Emergency XLM Switchgear (Emergency
plier: Supplier of all the components of
and Standby Power Systems: Transfer [Xfer] and Load Management
the EPS, such as the Caterpillar dealer.
Standard for the assembly, installation Switchgear): Parallels multiple
41 Emergency Standby Power and performance of electrical power engine/gensets and the utility to serve
Application: Typical usage of 50 hours systems to supply critical and essential downstream loads. Typically does
per year with a maximum of 200 hours needs during outages of the primary not include downstream ATS units.
42 per year. Generators can be applied power source.
XLMT Switchgear: Same as XLM
at their Standby rating with a typical
NPS Normal Power System: The utility except with a controlled generator
variable load factor of 70%.
43 service entrance equipment and distri- bus tie breaker between the utility
Emergency Tie Breaker: A feeder bution circuits to downstream loads. bus and the engine genset bus.
breaker that is used to connect an
EGP type system to a separate piece
of Normal (utility) switchgear.

Introduction
Sheet 1819
Master TOC Standard and Custom Configurable Products
Standard Configurable EGP Medium Voltage Switchgear 22

Products EGP (Emergency Generator Parallel-
Medium voltage switchgear is
ing) switchgear is used for paralleling
available in any of the standard
Caterpillar Switchgear is available multiple generators that are not 23
configurations (XLM, EGP or LM) that
in three standard, product configura- directly connected to a utility source.
are described above. Medium voltage
tions: XLM (Emergency Transfer EGP switchgear is primarily used
Caterpillar Switchgear utilizes the same
(Xfer) and Load Management), EGP
(Emergency Generator Paralleling)
in applications where downstream
control technology, operator interface, 24
automatic transfer switches provide
and has all of the same features and
and LM (Load Management). These the switching between normal and
functions as the low voltage systems.
configurations are available for both emergency sources. This is what is
At the heart of all medium voltage 25
low voltage and medium voltage typically required in medical facilities,
Caterpillar Switchgear systems is
applications and represent the hospitals, and water/wastewater
Cutler-Hammer Vac-Clad Metal-Clad
most typical paralleling switchgear treatment facilities when multiple
Switchgear with type VCP-W vacuum 26
configurations seen in the industry. generator sets are paralleled.
circuit breakers. For detailed medium
Additional, custom configurations For detailed EGP product description,
voltage (5 and 15 kV class) product
are available to meet the demands specifications, layouts, etc., refer
descriptions, specifications, layouts, 27
of even the most unique and to Section 42.3.
etc., refer to Section 42.5.
complicated systems.
LM 28
XLM LM (Load Management) switchgear is Custom Configurable
XLM (Emergency Transfer (Xfer) a special product offering used for Products 29
and Load Management) switchgear Distributed Generation and Peak
is used when the Generators are Shaving applications. Load Manage- Custom configurable switchgear is
paralleled with a normal utility ment switchgear allows a single available to meet the needs of the
(or multiple utility) power source(s). generator to be paralleled with the most demanding, unique or compli- 30
XLM switchgear allows closed transi- utility. This arrangement can be used to cated system configurations. Custom
tion, soft-loading and unloading from reduce a facility’s demand for utility engineered systems are available for
utility, and peak shaving capability power (peak shaving), or to export special system requirements such 31
where generators operate continu- power onto the utility grid. The LM as: custom sequences of operation,
ously in parallel with the utility. switchgear product is ideal for retrofit special load control requirements,
Typically, XLM switchgear eliminates applications to provide more utilization multiple utility and tie combinations, 32
the need for automatic transfer of existing standby generator assets. unique switchgear locations or lay-
switches. Data centers, industrial In many cases, customers can take outs, etc. No matter how complicated
process, and other critical process advantage of special “limited interrupt- or unique the system, Caterpillar 33
loads are prime candidates for XLM ible” or “peak shaving” utility rates Switchgear has the power and flexibil-
switchgear. For detailed XLM product by using their existing generators to ity to handle it. For detailed custom
description, specifications, layouts, reduce their need for utility fed power. product description, specifications, 34
etc., refer to Section 42.2. For detailed LM product description, layouts, etc., refer to Section 42.6.
specifications, layouts, etc., refer to
Section 42.4. 35
36
37
38
39
40
41
42
43

Sheet 1820
PowerLynx Master TOC
22 PowerLynx Technology Features Touchscreen Interface

PowerLynx technology utilizes a
Features are common to all Low operate in a normal automatic
touchscreen for operator interface,
and Medium Voltage XLM (Emergency mode. An “Instant Auto” switch is
23 monitoring and control of the parallel-
Transfer (Xfer) and Load Management), provided to place all controls to
ing switchgear. The touchscreen
EGP (Emergency Generator Parallel- the Auto position, protecting your
gives the operator an instantaneous,
ing), LM (Load Management), and facility from power outages.
24 easy to understand view of the entire
Custom assembly configurations.
5. Each Remote operator station or system. This feature is standard in all
monitoring station operates com- Caterpillar Switchgear.
Redundancy and Fault Tolerance
25 PowerLynx technology provides
pletely independently of the local
To access system controls, all you
operator interface touchscreen.
maximum efficiency and reliability. have to do is touch the corresponding
If the local operator interface
With traditional engine generator con- portion of the screen. The entire
26 trol switchgear, if a single component
touchscreen fails, it will not affect
engine generator set can be controlled
the operation of any of the remote
shuts down, the entire system may not from one touchscreen. The easy-
stations connected to the system.
to-use touchscreen interface makes
27 operate. With PowerLynx technology,
single points of failure are eliminated 6. For systems with utility interconnec- it possible to view, monitor and
because of the levels of redundancy tions (XLM type systems), redun- perform multiple functions including:
dant utility failure signals are sent to
28 and fault tolerance built into the
each processor. This ensures that
■ Metering.
automation system: (Figure 42.1-1).
the system is always alerted of a ■ Engine data.
1. True distributed control processors utility outage so generators can be ■ Protective relay settings.
29 for each power source ensure the started and power can be restored. ■ Annunciators.
system continues to operate even if
7. In the highly unlikely case of a com- ■ Adjust load shed controls and
a single automation processor fails.
30 plete loss of system automation, dis- generator demand priority.
2. The main control network is tributed manual control is available. ■ Synchronize and parallel.
redundant. ■ Set modes of operation.
31 3. In the event of a failure of a master
8. Control power is protected against
■ Voltage and frequency adjustments.
single point of failure by the utili-
control processor, PowerLynx's zation of a 24 Vdc Best Source
32 “Moving Master” feature auto- DC system. Each Engine battery
matically transfers master control and a Station Battery are con-
functions to the next available nected to a common dc bus.
33 generator control processor. Each Engine battery and the
4. If the operator interface touch- Station Battery are furnished
screen fails, the system can still with their own battery charger.
34
Touchscreen
35 Remote Monitor/
Control PC e
36
d ATS
37 ATS
For systems with utility
Interconnect (XLM Type)
ATS b
38
Touchscreen
39 Processor
Gen. 1 ac Gen. 2 ac Gen. X ac Utility Tie Distribution
40 Typical ac Util.
Relay
Bus Power PowerLynx 3000
f Transducers
41 Generator Power Utility Power
Transducers
With PowerLynx technology, it’s simple.
Transducers All the critical information you need is
displayed in a manner that is easy to
42 Figure 42.1-1. PowerLynx Automation Redundancy and Fault Tolerance understand. Graphics look exactly like
1 Distributed Control — separate processors for each source. the meters and gauges on conventional
2 Redundant network connections. switchgear. At a glance, users can easily
43 3 Moving Master — Any of the source processors can assume the “Master” control functions see how the system is performing and,
for the switchgear. based on real-time information can
4 System continues to operate in fully automatic mode even without the operator touchscreen. quickly do what’s necessary to correct
5 Each remote PC work station works independently of the local touchscreen. or optimize system performance.
6 Redundant Utility Fail Indication.

Introduction
Sheet 1821
Master TOC PowerLynx
Table 42.1-1. PowerLynx Control Technology Comparison Integrated Digital Technology

Features PowerLynx PowerLynx PowerLynx Integrated with Caterpillar on-package
22
3000 2000 1000
genset controls, PowerLynx has
Redundancy and Fault Tolerance Features built-in synchronizer, power factor
True Distributed Processing Yes Yes Yes controller and load sharing functions.
23
Best Source 24 Vdc System Yes Yes Yes Caterpillar switchgear products
Moving Master Redundancy Yes Yes Yes
Redundant Control Network Yes Yes No
do not require additional discrete 24
Redundant Utility/Tie Automation Processors Yes Yes No components, such as synchronizers,
cross-current compensation devices,
Display Features and Options
Local Touchscreen Display 15" color 12" color 6" or 10" mono
speed/voltage droop controllers, 25
load sharing modules, etc.
3-D Generator View for Engine Data Yes Yes No
Dynamic System Overview Oneline Yes Yes Yes
Full Redundant Touchscreen Available Yes Yes Yes
Advanced Generator Protection 26
System Tuning Capabilities via Touchscreen Yes Yes Yes Caterpillar switchgear performs
Balance of Plant Monitoring or Control Yes No No generator protective functions inter-
Logging and Reporting Features nal to the PowerLynx processor. 27
Historic Trending Yes No No With PowerLynx technology, you can
Real-Time Trend Yes Limited Limited monitor, process, compare, display
Alarm and Event Logging Unlimited 500 events 500 events and transmit data with a high degree 28
Save / Export Alarm logs Yes No No of precision and control — and that
Full Feature Remote Monitoring/Control Available Yes Yes Yes control translates into high reliability
Automated Reporting Yes Yes Yes and functionality. 29
Custom Automated Reporting (JCAHO test report, etc.) Yes No No
Optional Connectivity Features to BMS or SCADA systems Yes Yes Yes PowerLynx technology provides
ATS Monitoring and Control Caterpillar switchgear with enhanced 30
Caterpillar ATS Monitoring and Control Yes No No features available from no other
Caterpillar ATS Remote Settings Capability via Touchscreen Yes No No manufacturer.
Caterpillar UPS Monitoring Only
Non-Caterpillar ATS Monitoring Only
Yes
Yes
No
Yes
No
No ■ Unequaled fault tolerance.
31
Non-Caterpillar UPS Monitoring Only Yes No No
■ World-leading operator interface.
PowerLynx Control Technology PowerLynx 1000 ■ Sophisticated communications abilities. 32

■ Superior connectivity.
Caterpillar Switchgear offers three ■ 6 or 10" monochrome TFT touchscreen.
different levels of touchscreen opera- ■ High reliability resistive LCD Caterpillar power systems protect 33
tor interface. Each level gives different touchscreen technology. your power every second of every day.
options for trending, reporting, and ■ Limited Alarm and Event logging. It is crucial to keep a power generation
logging capabilities. ■ Monochrome graphical interface.
or electrical distribution system 34
operating around-the-clock, especially
PowerLynx 3000 in applications that rely heavily on
High-Speed Integrated Control System
■ 15" color LCD TFT touchscreen. emergency/standby systems, such as: 35
■ SAW (surface acoustic wave) PowerLynx technology uses a high-
speed industrially hardened network ■ Hospitals/medical centers.
LCD touchscreen technology for
unsurpassed reliability. for system control. PowerLynx 3000 ■ Electrical, water and gas utilities. 36
and 2000 systems feature a redundant ■ Government institutions.
■ Historical trending of engine
supervisory communication network. ■ Data centers.
generator and electrical parameters.
■ Unlimited Alarm and Event logging.
This ensures that the loss of one or
■ Critical industrial/chemical processes.
37
more processors or a supervisory
■ Ability to Save and Archive Trend communication network will not Additional PowerLynx technology
and Logging data. affect the integrity of the switchgear 38
advantages include:
■ Automated reporting capability. automation. This essential feature
❑ Alarm reports ensures proper system performance ■ Less installation wiring.
❑ Log reports under any condition. ■ Smaller footprint provides better 39
❑ Generator system reports utilization of available space.
❑ JCAHO compliant reports
Best-in-Class Footprint ■ Detailed engine and electrical reports.
■ Optional Automatic Transfer PowerLynx technology uses less than ■ Low cost redundancy. 40
Switch Control. 1/3 of the components of conventional ■ Enhanced performance.
switchgear. This translates into less
■ Moving Master.
wiring, a smaller footprint, higher
■ UL, NFPA, CSA and IEEE compliant. 41
■ Redundant Network. mean time between failures, and lower Caterpillar Switchgear was designed
PowerLynx 2000 mean time to repair. with your critical power needs in mind.
42
■ 12" color TFT touchscreen.
■ High reliability resistive LCD
touchscreen technology. 43
■ Limited Alarm and Event logging.
■ Moving Master.
■ Redundant Network.

Sheet 1822
Advanced Communications Remote Communications Communications with Building

22 Capabilities PowerLynx makes it easy to remotely Management or SCADA Systems
view, or view and control your Genera- PowerLynx can also easily communi-
PowerLynx technology is equipped tor or Caterpillar Switchgear system. cate data to third party Building
23 with exceptional remote communica- Whether an on-site remote, or an off- Management, SCADA or other moni-
tions technologies, enabling you to site remote, the PowerLynx remote toring systems. For these applications,
control and monitor your engine gen- communications package gives you the a data concentrator processor acts as
24 erator sets from anywhere at anytime. identical interface and same capabili- a "firewall" between your Caterpillar
Whether at home, in the office, or on Switchgear system and the Building
ties as standing in front of the genera-
the road, you can access controls and Management or SCADA System.
tor or Caterpillar switchgear. Although
25 information on a real-time basis and
identical, the remote communications The data concentrator serves up the
respond immediately...even control requested data to the third party moni-
run completely independent of the
multiple facilities from a single toring system, but stays completely
paralleling switchgear automation.
26 centralized site.
This ensures remote communication independent of all critical generator
devices or systems will not affect the control automation. This ensures
reliability of your Caterpillar Switchgear. remote communication devices or
27 Figures 42.1-2 – 42.1-6 show examples systems will not affect the reliability
of remote communication connections of your Caterpillar Switchgear.
to the Caterpillar Switchgear.
28
Caterpillar Switchgear
29
30
Cat. 5 cable (up to approx. 300’)
31 Ethernet Port Ethernet Port
32
Key Points:
Switchgear PC 1. Single Ethernet (cross over) Cable End User PC
33 - Dedicated Static I.P. Address
- Ethernet Port
(approx. 300' standard, optional up to
5000' via Fiber Optics)
- Full Control or View Only
(depending on password)
2. Supports one client. - Dedicated Static I.P.
Address
34 - Ethernet Port
35 Figure 42.1-2. PowerLynx On-Site Remote — Ethernet Network with SINGLE User
36 End User PC
37 - Dedicated Static
I.P. Address
38
Caterpillar Switchgear End User PC
HUB or Switch - Full Control or View Only
39 (depending on password)
- Dedicated Static
I.P. Address
Cat. 5 cable (up to approx. 300’)
40 Ethernet Port
End User PC
41 Key Points:
- Dedicated Static
Switchgear PC I.P. Address
1. Dedicated Ethernet LAN
- Dedicated Static
42 I.P. Address or
- Ethernet Port
2. Utilize customers' LAN — Coordination
with network administrators may be
43 necessary for connection and security issues.
3. Supports multiple clients.
Figure 42.1-3. PowerLynx On-Site Remote — Ethernet Network with MULTIPLE Users

Introduction
Sheet 1823
Master TOC PowerLynx
22
End User PC
- 1 single point to point connection
- Full Control (depending on password)
23
Caterpillar Switchgear - 56k Modem
24
56k Modem 56k Modem

25
26
Key Point:
Switchgear PC
1. Standard Dial-up Analog Telephone Line
- 56k Modem with
phone line 27
28
Figure 42.1-4. PowerLynx Off-Site Remote — Dial-up Telephone Network
29
On-Site Off-Site 30
Provided with View Only Remote Client
- Web Browser
View Only
31
Your Company
Remote Client
Network - Web Browser
VPN Device 32
Caterpillar Switchgear VPN TUNNEL
33
Firewall Device
VP
- VPN Access
N
Ethernet Port
TU 34
N
N
Remote Client
Switchgear PC Cat. 5 cable - Web Browser EL
- 1 Web Server
- Ethernet Port
(up to approx. 300')
Remote Client 35
- Web Browser
Firewall Device 36
- VPN Access
37
Figure 42.1-5. PowerLynx Off-Site Remote — (TCP-IP) Web-Based Connection with MULTIPLE Users (View Only)
38
39
40
41
42
43

Sheet 1824
22
Provided by others
23
Remote Client
- VPN Client
24 Provided with - Terminal Services Client
- View only or Full Control
(Depending on password)
25
VPN Device
26 ISP Provider
Remote Client
VPN TUNNEL - VPN Client
- Terminal Services Client
Caterpillar Switchgear - View only or Full Control
27 (Depending on password)
HUB or Switch Firewall Device

28 Ethernet Port - VPN Access
Remote Client
Switchgear PC Equipment Center PC with
29 - Dedicated Static Microsoft Windows Terminal Server
- VPN Client
- Terminal Services Client
I.P. Address - View only or Full Control
- 1 Network Interface Card (Depending on password)
- Ethernet Port
30 - 1 Virus Protection
Cat. 5 cable - Configured as a VPN Server
(up to approx. 300')
31
32 Figure 42.1-6. PowerLynx Off-Site Remote — (TCP-IP) Connection with MULTIPLE Users
33
34
35
36
37
38
39
40
41
42
43

XLM Switchgear
Sheet 1825
XLM Product Description ■ Closed transition transfer to

22
Emergency Mode to facilitate
Caterpillar XLM Switchgear — maintenance, or for storm threat
Generator Paralleling Switchgear for avoidance with soft loading and
Emergency Transfer (Xfer) and Load unloading of generator system. 23
Management control of multiple ■ Load shed/add.
engine generator sets with one utility ■ Generator demand priority.
source. For systems with multiple 24
■ Cost-effective, technically superior
utility and/or tie breakers, please
alternative to conventional ATS
refer to the Custom Configurable
Switchgear Section 42.6.
arrangement. 25
Caterpillar Switchgear brings the
■ Automatic Transfer to Emergency
power and reliability of microproces-
upon Utility failure.
sor technology to your generator 26
■ Automatic start, synchronize, switchgear application. Through
parallel, and load share on a com- the use of the PowerLynx operator
mon bus for emergency operation. interface touchscreen display with 27
■ Closed transition transfer back to easy-to-follow graphical representa-
utility upon stable return of power, tions, the PowerLynx technology
with soft generator unloading. product merges the features of:
28
■ Closed transition Load Management
■ Power monitoring.
Mode with soft loading and unload- 29
ing of generator system. ■ Switchgear automation.
■ Generator set control.
■ Optional remote communications. 30
31
XLM2 Switchgear (PowerLynx 3000 Shown)
32
33
34
35
a 36
37
38
39
40
41
42
43
Figure 42.2-1. XLM2 Switchgear
1 PR = Protective Relay.

XLM Switchgear Home TOC Index June 2006
Sheet 1826
Standard and Optional Equipment Master TOC
22 Equipment ■ System status and alarm annucia- ■ PowerLynx remote software for
tion with color display and 85 dbA additional on-site monitoring and
alarm horn with silence button. control work stations.
Standard Equipment — XLM
■ Password secured settings and ■ PowerLynx remote software for
23 ■ Low voltage XLM systems utilize adjustments for generator and sys- off-site monitoring and control.
Magnum DS power circuit breaker tem setups and protective relaying. ■ Building Automation System
switchgear and Magnum power
■ Alarm summary reports. or SCADA communications —
24 circuit breakers. For complete
Modbus or Ethernet.
technical details on Magnum DS ■ Settings reports.
switchgear, see Section 20. ■ Engine and generator load charts. ■ Remote notification.
25 ■ Operator Interface Touchscreen ■ 3-D engine data. ■ Historical data trending.
(Choose one below): ■ UL 891 listed and labeled or UL 1558
❑ PowerLynx 3000, 15-inch listed and labeled. Tie Breaker Application
26 surface acoustic wave LCD TFT ■ NEMA 1, deadfront freestanding Many systems require the use of tie
color touchscreen construction. breakers to meet Code or system per-
formance requirements. Tie breakers
27 ❑ PowerLynx 2000, 12-inch resis- ■ IEEE 1547 compliant, when a compli-
can be used anywhere throughout the
tive LCD TFT color touchscreen ant utility protective relay is selected.
line-up to segment or isolate desired
❑ PowerLynx 1000, 6-inch resistive ■ UL or CSA listed. sources, loads or sections of bus.
28 LCD monochrome touchscreen ■ Copper bus, braced for 100 kA.
for XLM1, 10-inch resistive LCD ■ 3-phase, 4-wire, 100% neutral, Generator Bus Tie
monochrome touchscreen for 1/4-inch x 2-inch copper ground bus. Generator Bus Ties can be used to
29 XLM2-XLM4 separate the normal electric service
■ Available in 600 V, 480/277 V or
■ Direct data communication to 208/120 V, 60 Hz. sources from the generator sources.
Caterpillar microprocessor-based This can also allow separation of load
30 engine generator set control network.
■ UL 1066 listed power circuit breakers to either side of the generator
breakers, 100 kAIC, two-step stored bus tie breaker in order to allow isola-
■ Full function 0.5% accuracy analog energy drawout mounted electri- tion of load banks, or dedicated emer-
31 and digital ac metering for utility: cally operated with long time and gency loads. This separation also may
voltage 1-2, 2-3, 3-1; current 1, 2, 3; instantaneous trip, and circuit
frequency; power factor; kW; kvar. be required by NFPA or local Codes.
breaker control switch with lights.
32 ■ Full function 0.5% accuracy analog ■ Continuous cross bus ratings up Generator Bus Tie breakers can be
and digital ac metering for genera- to 6000 amperes at 600 Vac. applied to serve several purposes.
tors: voltage 1-2, 2-3, 3-1; current 1, 2,
■ Mechanical lugs for incoming and
33 3; frequency; power factor; kW; kvar.
outgoing conductors.
1. Starting of large loads — the
Generator Bus Tie can be opened
■ Full function engine gauges; RPM,
■ Top or bottom conduit entry. to allow multiple generators to be
dc battery voltage, oil pressure,
34 engine coolant temperature, engine ■ Plug together control connections paralleled before being connected
across shipping split. to large load(s). Once multiple
hours, number of starts.
generators are paralleled, the
■ Full function synchronizing and par-
35 alleling controls with selection for Optional Equipment — XLM
Generator Bus Tie can be closed
to power the large loads.
automatic or manual synchronizing.
■ Distribution sections with 2. Load banks — the Generator Bus
36 ■ NFPA 110 engine/generator status,
electrically operated drawout Tie can allow the generators to be
pre-alarm, lamp test button, shut-
down fault annunciation and 85 dBA UL 1066 circuit breakers. isolated from the normal utility fed
■ Circuit breaker trip functions — short bus. Having a distribution breaker
37 alarm horn with silence button.
time and/or ground fault (in addition or set of load take-off lugs on the
■ Full function 0.5% accuracy analog
to long time and instantaneous). generator side of the bus allows
and digital ac metering for system:
the generators to be load bank
38 voltage 1-2, 2-3, 3-1; current 1, 2, 3; ■ Steel barriers between switchboard
tested without affecting any
frequency; power factor; kW; kvar. or switchgear sections for compart-
mentalization. normal utility fed loads.
■ System control functions for auto
39 (standby for emergency), closed ■ Bus/cable barriers. 3. Emergency Standby systems with
transition to emergency and load ■ Distribution sections with group Automatic Transfer Switches —
management. mounted UL 489 molded case circuit the Generator Bus Tie provides
40 ■ Automatic load shed control with breakers. (UL 891 construction only). isolation between the Normal
on-screen operator adjustments ■ Also available in 150 kA or 200 kA and Emergency buses. During a
for essential (1 level of essential bus bracing configurations. loss of utility power, the Generator
41 for every generator in the system) Bus Tie can be opened to isolate
■ Also available in 8000 and 10,000
and 1 level of non-essential auto- all Normal loads and allow resto-
amperes continuous cross bus
matic or manual load shed/load ration of power to Emergency
42 add control.
ratings at 600 Vac.
loads. Once Emergency loads
■ Also available with 4000, 5000 and are restored, the Emergency
■ Automatic generator demand 6000 ampere UL1066 breakers. Bus Tie can be reclosed to
43 priority with on-screen operator
■ Trip unit metering and communica- restore power to Normal loads.
adjustments for automatic addition
tions (Digitrip 520M, 520MC and 1150).
and removal of generator to the Note: See Page 42.2-8 for an example
load bus. ■ Also available in 5 kV and 15 kV class of an XLM system with Generator Bus
configurations (See Section 42.5). Tie breaker.

XLM Switchgear
Sheet 1827
Master TOC Features
Caterpillar XLM Switchgear Engine Monitoring and Alarms ■ PowerLynx 1000, 6-inch or 10-inch
22
monochrome.
■ Low coolant temperature pre-alarm.
Utility Metering ■ Screen enable/disable key switch
■ High coolant temperature pre-alarm (PowerLynx 3000 only).
■ 0.5% accuracy. and shutdown. 23
■ Voltage 1-2, 2-3, 3-1; current 1, 2, 3; ■ Low oil pressure pre-alarm and Power Supply
frequency; power factor; kw; kvar; shutdown.
synchroscope. ■ Low fuel alarm (diesel only).
■ Automatic best dc source selector. 24
■ 24 Vdc station battery, sealed jar,
■ Low engine battery alarm. 4-hour, external 120 Vac emergency
Utility Protective Relaying
■ 27/59 — under/overvoltage relay.
■ Overcrank shutdown. power required for charger. 25
■ Overspeed shutdown. ■ Power from 24 Vdc engine cranking
■ 81 O/U — under/overfrequency relay. batteries.
■ Multi-function utility grade, Engine/Generator Control ■ Processor power supplies — 24 Vdc.
26
drawout with: ■ Automatic engine start.
❑ 47 — phase sequence/phase ■ Adjustable engine cooldown timer. Technology Communications 27
failure relay
■ 15 — automatic synchronizer. ■ Automation network — high speed,
❑ 32 — reverse direction relay, high reliability, industrially hardened.
■ 65 — microprocessor engine gover-
utility grade, drawout nor load sharing and soft loading ■ Optional remote communications 28
❑ 32/51 — reverse direction control. network — Ethernet, Modem.
overcurrent relay, utility grade, ■ 90 — var/PF and cross current ■ Optional communication to
drawout compensation controller. building automation or SCADA 29
❑ 32/62 — reverse direction timing systems for general monitoring —
relay, utility grade, drawout System Metering ModbusT RTU or Modbus TCP-IP.
■ 86 — reverse power lockout relay,
30
■ 0.5% accuracy.
manual reset. Circuit Breakers
■ Voltage 1-2, 2-3, 3-1; current 1, 2, 3;
■ 25 — synch check relay, (hardware frequency; power factor; kw; kvar ■ 100% Rated UL 1066 power circuit 31
redundant protective device). breakers available 800 – 6000 A with
System Protective Relaying two-step stored energy mechanism.
Generator Metering ■ 27/59 — bus under/overvoltage relay. ■ 100 kAIC standard (200 kA optional). 32
■ 0.5% accuracy. ■ 81 O/U — bus under/overfrequency
■ Drawout mounted (fixed optional).
■ Voltage 1-2, 2-3, 3-1; current 1, 2, 3; ■ 5 cycle closing.
frequency; power factor; kw; kvar;
relay. 33
■ 15 — auto synchronizer. ■ Electrically operated.
synchroscope. ■ Auxiliary and bell alarm contacts.
Generator Protective Relaying
System Control ■ Electronic trip unit with long time 34
■ Automatic standby mode. and instantaneous trip functions
■ 27/59 — under/overvoltage relay. (short time and ground fault
■ Emergency mode with closed 35
■ 81 O/U — under/overfrequency relay. transition to normal. optional).
■ 32 — reverse power relay. ■ Closed transition to emergency mode. Enclosure and Bussing
■ 40 — loss of excitation (reverse var) ■ Load management mode.
■ Available as UL 1558, UL 891 or CSA
36
relay.
■ Automatic load shed control with listed and labeled.
■ 25 — synch check relay (hardware bus underfrequency protection and
redundant protective device). one 4-pole,10 A,120 Vac, Form C, ■ Optionally service entrance rated. 37
dry contact output for each load ■ NEMA 1, deadfront freestanding
Engine Gauges shed level (1 level of essential for construction.
■ RPM meter. each generator in the system). ■ Copper bus. 38
■ Engine battery volt meter. ■ Automatic generator demand ■ 100 kA bus bracing (200 kA optional).
priority control.
■ Oil pressure gauge. ■ 3-phase, 4-wire, 100% neutral bus, 39
■ Engine coolant temperature gauge. ■ Master shutdown button. 1/4-inch x 2-inch ground bus.
■ Seismic qualified to exceed
Touchscreens the requirements of the Uniform 40
■ PowerLynx 3000, 15-inch SAW Building CodeT (UBC), California
LCD TFT color. Building Code (CBC) and IBC.
■ PowerLynx 2000, 12-inch LCD TFT ■ Also available in UL listed and 41
resistive color. labeled medium voltage.
Environment 42
■ 0°C to 50°C.
■ 0 to 95% humidity, non-condensing. 43

Sheet 1828
Technical Data Master TOC
22 XLM Switchgear — One-Line Diagrams
23
24
25
26
27
28
29
30
31
32
Figure 42.2-2. Typical Electrical System with XLM1 Switchgear (1-Generator Source, 1-Utility Source) —
(For Multiple Utility Sources, see Custom Configurable Switchgear Section 42.6)
33 1 PR = Protective Relay.
34 3 Generator Dimensions
Breaker Size
Breaker Size
Max. Feeder
Max. Utility
Bus Rating
Bkr. Size 1
Generator
kW (480 V)
Lbs. (kg)
35
Weight
Min. Max. Height Width Depth
Main
36 800 0 532 800 1600 1600 99.00 44.00 72.00 3300

(2514.6) (1117.6) (1828.8) (1498)
3
1600 533 1064 1600 1600 1600 3400
37 (1544)
2000 1065 1330 2000 2000 2000 3600
T (1634)
38 3000 1331 2000 3000 3200 3200 78.00 3700
(1981.2) (1680)
1 4000 A, 5000 A and 6000 A breakers available in 44" wide structure.
39 Contact your local Caterpillar Electric Power dealer for more details.
2 Low voltage switchgear for up to 3500 kW generator set ratings
at 480 V is also available. Contact local Caterpillar Electric Power
40 3
dealer for more details.
66.00 (1676.4) with D1.
Conduit Space for 22.00-Inch (558.8 mm) Wide Structures —
41 Top or Bottom Entry
Structure Rear Conduit Opening Recommended
Depth Width Depth Number of 3.5”
42 or 4” Conduits
22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9
72.00 (1828.8) 16.00 (406.4) 25.30 (642.6) 12
43 78.00 (1981.2) 16.00 (406.4) 31.30 (795.0) 15
84.00 (2133.6) 16.00 (406.4) 37.30 (947.4) 18
Figure 42.2-3. XLM1 Switchgear Layout

XLM Switchgear
Sheet 1829
Master TOC Technical Data
22
23
24
25
26
27
28
29
30
31
32
Figure 42.2-4. Typical Electrical System with XLM2 Switchgear (2-Generator Sources, 1-Utility Source) —
1 PR = Protective Relay. 33
Generator Dimensions
34
Breaker Size
Breaker Size
3
Max. Feeder
Max. Utility
Bus Rating
Bkr. Size 1
Generator
kW (480 V)
Lbs. (kg)
Weight
35
Main
Feeder
Breaker
Controls
800 0 532 800 1600 1600 99.00 66.00 72.00 5000 36
(2514.6) (1676.4) (1828.8) (2270)
1600 533 1064 1600 1600 1600 5200
(2361) 37
2000 1065 1330 2000 2000 2000 5600
T
(2542)
3000 1331 2000 3000 3200 3200 84.00 5800 38
(2133.6) (2633)
2
Contact your local Caterpillar Electric Power dealer for more details. 39
Low voltage switchgear for up to 3500 kW generator set ratings
40
Top or Bottom Entry
Structure Rear Conduit Opening Recommended 41
or 4” Conduits
66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9

42
22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 72.00 (1828.8) 16.00 (406.4) 25.30 (642.6) 12
78.00 (1981.2) 16.00 (406.4) 31.30 (795.0) 15
84.00 (2133.6) 16.00 (406.4) 37.30 (947.4) 18 43

Sheet 1830
22
23
24
25
26
27
28
29
30
31
32
34
Breaker Size
Breaker Size
Max. Feeder
Max. Utility
Bus Rating
Bkr. Size 1
Generator
kW (480 V)
35
Lbs. (kg)
Weight
Main
36 Feeder
Breaker 800 0 532 800 1600 1600 99.00 88.00 72.00 7100
Controls
(2514.6) (2235.2) (1828.8) (3223)
1600 533 1064 1600 1600 1600 7300
37 (3314)
2000 1065 1330 2000 2000 2000 7700
LY
LYNX
L
(3496)
38 T
3000 1331 2000 3000 3200 3200 84.00 7800

(2133.6) (3541)
1
Contact your local Caterpillar Electric Power dealer for more details.
40 dealer for more details.

42 or 4” Conduits
66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9

22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8)
72.00 (1828.8) 16.00 (406.4) 25.30 (642.6) 12
43 78.00 (1981.2) 16.00 (406.4) 31.30 (795.0) 15
84.00 (2133.6) 16.00 (406.4) 37.30 (947.4) 18

XLM Switchgear
Sheet 1831
22
23
24
25
26
27
28
29
30
31
32
1 PR = Protective Relay. 33
34
3 4 5 Generator Dimensions
Breaker Size
Breaker Size
Max. Feeder
Max. Utility
Bus Rating
Bkr. Size 1
Generator
kW (480 V)
Lbs. (kg)
35
Weight
Main
Feeder
Breaker
Controls
800 0 532 800 1600 1600 99.00 110.00 72.00 9100 36
(2514.6) (2794.0) (1828.8) (4131)
1600 533 1064 1600 1600 1600 9300
(4222) 37
T
2000 1065 1330 2000 2000 2000 9500
(4313)
3000 1331 2000 3000 3200 3200 84.00 9800
38
(2133.6) (4449)
Contact your local Caterpillar Electric Power dealer for more details. 39
dealer for more details. 40
Top or Bottom Entry 41
22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8)
or 4” Conduits
42
66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9
72.00 (1828.8) 16.00 (406.4) 25.30 (642.6) 12
78.00 (1981.2)
84.00 (2133.6)
16.00 (406.4)
16.00 (406.4)
31.30 (795.0)
37.30 (947.4)
15
18
43

Sheet 1832
22
23
24
25
26
27
28
29
30
31
32
Figure 42.2-10. Typical Electrical System with XLMT4 Switchgear (4-Generator Sources, 1-Utility Source, 1-Generator Bus Tie Breaker)
34 3 4 5 6
Breaker Size
Breaker Size
Max. Feeder
Max. Utility
Bus Rating
Bkr. Size 1
Generator
kW (480 V)
Lbs. (kg)
35
Weight
Main
2
Feeder Feeder
Breaker Breaker
Controls Controls
36 800 — 532 800 1600 800 99.00 132.00 72.00 9100
(2514.6) (3352.8) (1828.8) (4131)
3
Tie 1600 — 1064 1600 1600 1600 78.00 9300
37 L Breaker
Controls (1981.2) (4222)
2000 — 1330 2000 2000 2000 84.00 9500
(2133.6) (4313)
38 3000 — 2000 3000 3200 3200 9800
(4449)
1 4000 A, 5000 A, and 6000 A breakers available in 44" wide structure.
40 3
66.00 (1676.4) with D1.

41 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8)
Top or Bottom Entry

Depth Number of 3.5”
42 Width Depth
or 4” Conduits
66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9

43 72.00 (1828.8)
78.00 (1981.2)
16.00 (406.4)
16.00 (406.4)
25.30 (642.6)
31.30 (795.0)
12
15
84.00 (2133.6) 16.00 (406.4) 37.30 (947.4) 18
Figure 42.2-11. XLMT4 Switchgear Layout

XLM Switchgear
Sheet 1833
Table 42.2-1. Typical Control Circuit Wiring — Low Voltage Systems 1

Function (Quantity)/Size/ Signal Description 22
Type of Cable 2 Type 3
Generator Control
Caterpillar Engine Generator Set Diesel — (1) x #16 AWG Shielded Signal Level Network Communications for Monitoring
23
Communications Twisted Pair (Belden 8719) and Display of Engine Data to Switchgear
Gas — (1) x #16 AWG Shielded Signal Level
Twisted Quad 24
Control Panel Discrete Control Interface (16) x 1/c #14 AWG (Includes Spares) dc Control ≤ 30 Vdc Discrete Control (Start/Stop, Emergency Stop
and Crank Terminate, Includes Spares, etc.)
Best Source 24 Vdc (4) x 1/c #10 AWG dc Control ≤ 30 Vdc + / - 24 Vdc from Generator Battery System to
25
(2 x + 24 Vdc & 2 x – 24 Vdc) Supplement Switchgear 24 Vdc Control Voltage
Voltage Regulation (VR) Control (1) x #16 AWG Twisted pair Signal Level Bi-polar dc Bias Signal for Voltage Control
(Belden 8719) 26
(3) x 1/c #14 AWG (Additional for CDVR dc Control ≤ 30 Vdc
Only)
Speed Control (Governor) Type 2301A Speed Controller — dc Control ≤ 30 Vdc Bi-polar dc Bias Signal for Speed Control 27
(2) x #16 AWG Shielded
Twisted Pair (2301A)
ADEMIII Speed Controller — Signal Level 28
(1) x #16 AWG Shielded Twisted
Triplet (Belden 8618)
(Additional for Pro Act Gov. Only)
(3) x #14 AWG XHHW Cu
dc Control ≤ 30 Vdc 29
Air Fuel Ratio (AFR) Controller Gas Only — (1) x #16 AWG Shielded Signal Level For Gas Engines Equipped with AFR
Twisted Pair Controller Only
30
Battery Systems
Power for 24 Vdc Station Battery Charger (3) x 1/c #12 AWG ac Control 120 Vac/20 A Emergency Circuit for 24 Vdc
(in Master Section) Battery Charger Power 31
24 Vdc Station Batteries (4) x 1/c #10 AWG (2 x + 24 Vdc & dc Control ≤ 30 Vdc 24 Vdc Supply to Switchgear Controls from
2 x – 24 Vdc) (Next to Switchgear) 24 Vdc Battery System
24 Vdc Station Battery Charger Malfunction (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms 32
Generator Battery Charger Malfunction (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms
Fuel Systems
Low Fuel Tank Level (Master Fuel Tank) (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms
33
Fuel Tank Rupture Basin (Master Fuel Tank) (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms
High Fuel Tank Level (Master Fuel Tank) (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms
Other Fuel Tank Alarms (Master Fuel Tank) (2) x 1/c #14 AWG (Each) dc Control ≤ 30 Vdc Alarms 34
Low Fuel Tank Level (Day Tank) (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms
Fuel Tank Rupture Basin (Day Tank) (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms
High Fuel Tank Level (Day Tank) (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms 35
Other Fuel Tank Alarms (Day Tank) (2) x 1/c #14 AWG (Each) dc Control ≤ 30 Vdc Alarms
Generator Protection Systems
Genset Mounted CB Status
Generator Differential CTs
(2) x 1/c #14 AWG
(6) x 1/c #10 AWG (at Gen.)
dc Control ≤ 30 Vdc
ac Control
Alarms
87G Relay Alarm/Shutdown
36
Generator RTD Leads (1) x #14 AWG Shielded Twisted Quad dc Control ≤ 30 Vdc Indication/Alarms/Shutdown
per Reading (at Gen.)
37
Engine Thermo-Couples (2) x 1/c #14 AWG Thermo-Couple Wire dc Control ≤ 30 Vdc Indication/Alarms/Shutdown
Automatic Transfer Switch Interface (Per ATS) 38
Caterpillar ATS Monitoring and Control (1) x #16 AWG Shielded Twisted Pair Signal Level Monitoring and Control of ATS Functions
(Belden 8471)
Engine Start (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Engine Start Request 39
Discrete ATS Position (4) x 1/c #14 AWG dc Control ≤ 30 Vdc Normal and Emergency ATS Status
ATS Load Shed (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Load Shed / Load Add
Miscellaneous (Optional) 40
Miscellaneous Enclosure Alarms (2) x 1/c #14 AWG per Required Alarm dc Control ≤ 30 Vdc Alarms/Shutdown
Miscellaneous Aux. Equipment Alarms (2) x 1/c #14 AWG per Required Alarm dc Control ≤ 30 Vdc Alarms/Shutdowns
Switchgear 120 Vac Space Heaters (3) x 1/c #10 AWG per 10 Structures ac Control 120 Vac for Space Heaters (1-Phase/30 Ampere)
Remote Monitoring/Control PC (1) x 4 Pair #24 AWG UTP Cat. 5 Signal Level Communication Signal to Remote
41
(Ethernet) -— or — (1) 4 Conductor Monitoring/Control PC Workstation or LAN
Fiber Optic Cable (Belden I100466 —
Varies Based on Installation 42
Requirements)
Building Management / SCADA Interface (1) x #18 AWG Shielded Twisted Pair Signal Level Communication Signal to Building
(Belden 3073) Management or SCADA System 43
1 All control wiring to be stranded copper unless specified otherwise. Conductor size may have to be increased for Voltage Drop over long distances.
2 Recommend 20% spares of each size single conductor and (1) of each multi-conductor cable.
3 Separate metallic conduits should be used for each Signal Type. 'Signal Level' and 'dc Control Signal ≤ 30 Vdc' wires may be combined in the same conduit.
Note: Specific project and equipment requirements will determine exact number and type of control wiring required.

Sheet 1834
Functional Sequence of Operations Master TOC
22 XLM Functional Sequence of Operations 6. The system is now running in Emergency Mode.
b. Exit from Emergency Mode
A. The EPS Automation shall be provided with the
1. The operator removes the System Mode Selector
following Modes of Operation:
23 1. Automatic/Standby Mode
Switch from Transfer to Emergency position and
returns it to the Auto position.
a. The utility main breaker is closed serving utility 2. Following an adjustable time delay (which can be
24 power to the generator/load bus. abbreviated by the operator), the generator plant
b. The generator main breakers are open. is passively synchronized and paralleled to the
c. The automation is standing by to act in response to a utility source by closing the utility main breaker.
25 utility failure. 3. The generator plant is soft ramp unloaded until
2. Emergency Mode the utility source is nominally serving the entire
system load.
26 a. Utility Failure
4. The generator breakers are opened .
1. Utility protective relaying senses utility voltage
or frequency out of tolerance. OR
27
2. The utility main breaker is opened. 4. [With Generator Bus Tie Breaker] The generator
3. A run request is sent to the generator plant. bus tie breaker is opened and then all of generator
28 4. The first generator up to voltage and frequency
breakers are opened.
is closed to the bus. 5. The generators are allowed to run for their
programmed cooldown period.
29 5. [With Generator Bus Tie Breaker]
6. The system is now back in Automatic/Standby Mode.
The generator bus tie breaker is closed.
6. The remaining generators are synchronized and 4. Load Management Mode
30 paralleled to the bus as they come up to voltage a. Entry
and frequency. 1. Select one of the modes of operation:
7. The system is now in Emergency Mode.
31 i. Import Limit — The user places the Import/
b. Utility Restoration and Exit from Emergency Mode Export toggle switch in the Import position
1. Utility protective relaying senses utility voltage and places the Base Load/Utility Tracking
32 and frequency within tolerance. toggle switch in the Utility Tracking position.
The user sets the Utility Import Set point to
2. Following an adjustable time delay (which can be the desired amount of kW that they want
abbreviated by the operator) to ensure that the
33 utility power source is stable, the generator plant
to import through the Utility Circuit Breaker
during Load Management Mode.
is passively synchronized and paralleled to the
utility source by closing the utility main breaker. ii. Export Limit — The user places the Import/Export
34 toggle switch in the Export position and places
3. The generator plant is soft ramp unloaded until the Base Load/Utility Tracking toggle switch in the
the utility source is nominally serving the entire Utility Tracking position. The user sets the Utility
35 system load. Export Set point to the desired amount of kW
4. The generator breakers are opened. that they want to export through the Utility
5. The generators are allowed to run for their Circuit Breaker during Load Management Mode.
36 programmed cooldown period. iii. Base Load Import — The user places the
6. The system is now back in Automatic/Standby Mode. Import/Export toggle switch in the Import
position and places the Base Load/Utility
37 3. Transfer to Emergency Mode Tracking toggle switch in the Base Load posi-
a. Entry tion. The user sets the Base Load Set point to
the desired amount of kW that they want the
38 1. The operator places the System Mode Selector Switch
generator plant to assume during Load Man-
into the Closed Transfer to Emergency position.
agement Mode. The controls shall not allow
2. A run request is sent to the generator plant. the generator plant to export kW through
39 3. The first generator up to voltage and frequency the Utility Circuit Breaker and shall always
is closed to the bus at no load. maintain a nominal amount of Utility kW
40 4. The remaining generators are synchronized and imported through the Utility Circuit Breaker.
paralleled to the bus at no load as they come up iv. Base Load Export — The user places the
to voltage and frequency. Import/Export toggle switch in the Export
41 5. When all generators are on the bus they are soft position and places the Base Load/Utility
ramp loaded until the generator plant is serving Tracking toggle switch in the Base Load
nominally the entire load on the bus and the position. The user sets the Base Load Set
42 utility main breaker is opened. point to the desired amount of kW that they
want the generator plant to assume during
OR Load Management Mode. The controls shall
43 5. [With Generator Bus Tie Breaker] When all generators allow the generator plant to export kW
are on the bus, they are paralleled across the genera- through the Utility Circuit Breaker.
tor bus tie breaker. They are then soft ramp loaded
until the generator plant is serving nominally all of
the load on the bus and the utility main is opened.

XLM Switchgear
Sheet 1835
Master TOC Functional Sequence of Operations
2. The user places the System Mode Selector 6. Utility Fail Test Mode
Switch in the Load Management position. 22
a. Entrance into Utility Fail Test Mode
3. A run request is sent to the generator plant. 1. The Utility Fail Test Switch is placed in the
4. The generators are allowed to run for a five- ON position. 23
minute warm-up time (which can be abbreviated 2. Voltage sensing at the utility protective relay is
by the operator). opened, which simulates a loss of utility. 24
5. The generators are synchronized and paralleled 3. The system enters into Emergency Mode
to the bus at no load after completion of the as described in the “Emergency Mode”
warm-up time. sequence above. 25
6. When all generators are on the bus they are soft b. Exit from Utility Fail Test Mode
ramp loaded until the generator plant is serving
1. The Utility Fail Test Switch is placed in the 26
nominally the required amount of the load on the
bus to meet the mode of operation selected. OFF position.
7. The generator output is dynamically adjusted to 2. Voltage sensing at the utility protective relay 27
maintain the set point to meet the mode of opera- is restored, which simulates the return of
tion selected. If at any time the system is unable utility power.
to maintain the set point then a “Set point 3. The system exits from Emergency Mode
28
Exceeded” alarm shall be sounded. as described in the “Emergency Mode”
8. Should the utility fail at any time during Load sequence above. 29
Management operation, the utility protective B. When the Generator Sets are carrying the facility load,
relays shall cause the utility main to open and be the EPS Automation shall support two (2) sub-modes:
locked out, thus placing the system in Emergency Load Shed/Load Add, and Generator Demand Priority. 30
Mode until the Utility is restored (as described in
Emergency Mode exit). 1. Load Shed Control
a. The System Controls shall include a Load Shed
31
b. Exit
1. The operator removes the System Mode Selector Control function to control the loads served by the
Switch from Load Management position and generator plant. 32
returns it to the Auto position. b. The Load Shed Control shall have one Essential Load
Shed Priority Level for each generator in the system
2. The generator plant is soft ramp unloaded until plus one Non-Essential Load Shed Priority Level 33
the utility source is nominally serving the entire (which is always shed in the Emergency Mode
system load and the generator main breakers of operation).
are opened.
c. The Load Shed Control shall control each of the 34
3. The generators are allowed to run for their distribution circuit breakers that are shown on the
programmed cooldown period. drawings. Distribution circuit breakers to be con-
trolled shall be electrically operated. Each electrically 35
4. The system is now back in Automatic/Standby Mode. operated distribution circuit breaker shall be field
selectable to be assigned to any of the available
5. No Load Test Mode
Load Shed Priority Levels. 36
a. Entrance into No Load Test Mode 1. Provide the following controls for each
1. The No Load Test Switch is placed in the Essential Load Shed Priority Level 37
ON position.
i. Shed Delay Timer, adjustable from
2. All available generators are started. 0 to 1024 seconds
38
3. All generators come up to voltage and frequency ii. Add Delay Timer, adjustable from
and remain running disconnected from the bus. 0 to 1024 seconds
4. The system is now in No Load Test Mode. iii. Load Shed Override Selector (shed/auto//add)
39
b. Exit from No Load Test Mode iv. Status indicators to show whether the
1. The No Load Test Switch is placed in the Priority Level is Added or Shed 40
OFF position. 2. Provide the following controls for each
2. The generators are allowed to run for their Non-Essential Load Shed Priority 41
programmed cooldown period. i. Load Shed Override Selector (shed/auto//add)
3. The system is now back in Automatic/Standby Mode. ii. Status indicators to show whether the 42
Priority Level is Added or Shed
43

Sheet 1836
3. Additionally, the Load Shed Controls shall have: NOTE: The following applies to systems with two or
22 more generators.
i. Load Shed Control Switch (On/Off)
2. Generator Demand Priority Control
ii. User-settable Load Shed % (as a function of
23 on-line generator capacity) a. The System Controls shall include a Generator
Demand Priority Control function to automatically
iii. User-settable Load Shed Time Delay match the on-line generator capacity to the loads to
24 iv. User-settable Load Add % (as a function of
avoid unnecessary operation of all the generators
when the loads are low.
on-line generator capacity)
b. The following controls shall be provided for each
25 v. User-settable Load Add Time Delay generator:
vi. User-settable Bus Underfrequency set point 1. User-settable Generator Priority Selector
26 vii. User-settable Bus Underfrequency time delay 2. Status indicator for the Generator Priority Selected
viii. Bus Underfrequency Reset Pushbutton 3. Status indicator for generator On-line or Off-line
27 c. The Generator Demand Priority Control shall have
ix. Bus Underfrequency indicator
the following controls:
4. Conditional Load Shed — Upon entrance into
28 Emergency Mode of operation, the Load Shed
1. Generator Demand Priority Control Switch (On/Off)
Control shall shed all Essential and Non-Essential 2. User-settable Generator Remove % (as a function
loads. As generators come to the bus, Essential
29 Priority Level loads shall be added conditionally
of a single generator capacity)
based on the number of generators on line. 3. User-settable Generator Remove Delay

30 When the first generator comes to the bus, Prior- 4. User-settable Generator Add % (as a function of a
ity Level 1 loads shall be added; Second genera- single generator capacity)
tor, priority 2, etc. After a time delay that allows all
31 operational generators to come to the bus, Load 5. User-settable Generator Add Delay
Shed Mode shall shift to Load Sensitive Mode.
d. Upon entrance into Emergency or Load Management
5. Load Sensitive Load Shed — After all generators modes, all generators shall be started and paralleled
32 have been given sufficient time to come to the to the bus. After the Remove Time Delay, generators
bus, load shed shall shift to “Load Sensitive” shall be removed from the bus as a function of the
mode. The system shall compare current generator percentage loading by the user selected
33 generator on-line capacity (in kW) to current Generator Remove time delay. Generators shall
load requirements. If surplus capacity is greater be removed from the bus in descending priority.
than the calculated Load Add setpoint, after the Should the generator percentage loading increase
34 Load Add Time Delay the next Load Shed Priority to the user selected Generator Add limits for the
shall be added. This calculation shall continue user selected Add Delay, the next generator shall
until all Sheddable Loads are added, or until be started, synchronized and paralleled to the bus.
35 surplus capacity is less than the calculated Load Generators shall be added to the bus in ascending
Add setpoint. If surplus capacity is less than the priority order. Should the generator plant ever reach
calculated Load Shed setpoint, after the Load 95% loading, the next priority generator shall be
36 Shed Time Delay the next Load Shed Priority started and added to the bus with no time delay.
shall be shed. This calculation shall continue until
all Sheddable Loads are shed, or until surplus
37 capacity is greater than the calculated Load Shed
setpoint. The Load Shed Control, in its automatic
shedding and adding of loads, shall not override
38 any manual load shed/add operation.
6. Should the load bus frequency fall below the user
39 selected bus underfrequency setpoint for a period
longer than the bus underfrequency time delay,
then all Priority Level loads shall be shed and load
40 addition shall not resume until the operator has
depressed the Bus Underfrequency Reset button.
The bus underfrequency protection shall override
41 any manual load add operation.
42
43

EGP Switchgear
Sheet 1837
EGP Product Description 22

Caterpillar Emergency Generator Caterpillar Switchgear brings the
Paralleling (EGP) Switchgear for power and reliability of microproces-
multiple engine generator sets. sor technology to your generator 23
switchgear application. Through
■ Automatic start, synchronize, the use of the PowerLynx operator
parallel and load share on a interface touchscreen display with 24
common bus. easy-to-follow graphical representa-
■ Main lugs output to feed down- tion, the PowerLynx technology
stream emergency distribution. product merges the features of: 25
■ Optional emergency distribution
circuit breakers. ■ Power monitoring.
■ Load shed/add. ■ Switchgear automation. 26
■ Generator set control.
■ Generator demand priority.
■ Optional remote communications.
■ For use with multiple downstream 27
Automatic Transfer Switches.
■ Caterpillar switchgear is designed
to integrate hand-in-glove with 28
Caterpillar Automatic Transfer
Switches. EGP Switchgear is
optionally available with direct 29
communication to Caterpillar ATSs
to provide “fingertip” control and
monitoring of all your facility ATSs 30
from one convenient central location.
31
EGP Switchgear (PowerLynx 3000 Shown)
32
33
34
35
36
37
38
39
40
41
42
43
Figure 42.3-1. EGP3 Switchgear (3-Generator Sources)

EGP Switchgear Home TOC Index June 2006
Sheet 1838
22 Equipment ■ Automatic load shed control with ■ Distribution sections with group
on-screen operator adjustments mounted UL 489 molded case circuit
for essential (1 level of essential for breakers. (UL 891 construction only.)
Standard Equipment — EGP each generator in the system) and ■ Also available in 150 kA or 200 kA
23 ■ Low voltage EGP systems utilize 1 level of non-essential automatic or bus bracing configurations.
Magnum DS power circuit breaker manual load shed/load add control. ■ Also available in 8000 and 10,000
switchgear and Magnum power ■ Automatic generator demand amperes continuous cross bus
24 circuit breakers. For complete priority with on-screen operator ratings at 600 Vac.
technical details on Magnum DS adjustments for automatic addition
switchgear, see Section 20. ■ Also available with 4000, 5000 and
and removal of generator to the
25 ■ Operator interface touchscreen load bus.
6000 ampere UL 1066 breakers.
(Choose one below): ■ Trip unit metering and communica-
■ System status and alarm annuncia- tions (Digitrip 520M, 520MC
❑ PowerLynx 3000, 15-inch tion with color display and 85 dbA
26 surface acoustic wave LCD TFT alarm horn with silence button.
and 1150).
color touchscreen ■ Also available in 5 kV and 15 kV class
■ Password secured settings and configurations (See Section 42.5).
27 ❑ PowerLynx 2000, 12-inch resis- adjustments for generator and sys-
■ PowerLynx software for additional
tive LCD TFT color touchscreen tem setups and protective relaying.
on-site monitoring and control
❑ PowerLynx 1000, 6-inch resistive ■ Alarm summary reports. work stations.
28 LCD monochrome touchscreen ■ Settings reports. ■ PowerLynx software for off-site
for EGP2, 10-inch resistive ■ Engine and generator load charts. monitoring and control.
monochrome touchscreen
29 for EGP3-EGP5
■ Engine trend data. ■ Building Automation System
■ UL 891 listed and labeled or UL 1558 or SCADA communications —
■ Direct data communication to CAT listed and labeled. Modbus or Ethernet.
microprocessor-based engine gen-
30 erator set control network (EMCP). ■ NEMA 1, deadfront freestanding ■ Remote notification.
construction. ■ Historical data trending.
■ System overview screen with
■ UL or CSA listed. ■ Communication to Caterpillar
31 one line mimic diagram which
■ Copper bus, braced for 100 kA. ATS units.
depicts real-time metering, status
and control. ■ 3-phase, 4-wire, 100% neutral,
32 ■ Full function 0.5% accuracy analog 1/4-inch x 2-inch copper ground bus. Tie Breaker Application
and digital ac metering for genera- ■ Available in 600 V, 480/277 V or Many systems require the use of tie
tors: voltage 1-2, 2-3, 3-1; current 208/120 V, 60 Hz. breakers to meet Code or system per-
33 1, 2, 3; frequency; power factor; ■ UL 1066 listed power circuit breakers, formance requirements. Tie breakers
kW; kvar. 100 kAIC, two-step stored energy can be used anywhere throughout the
■ Full function engine gauges: RPM, drawout mounted electrically line-up to segment or isolate desired
34 dc battery voltage, oil pressure, operated with long time and sources, loads or sections of bus.
engine coolant temperature, instantaneous trip, and circuit
Emergency Generator Bus Tie
engine hours, number of starts. breaker control switch with lights.
35 ■ 3-D engine data. ■ Continuous cross bus ratings up to
Certain NFPA Codes require all Life
Safety and Critical loads (Priority 1
■ Full function synchronizing and par- 6000 amperes at 600 Vac.
loads) to be restored in a maximum
36 alleling controls with selection for ■ Mechanical lugs for incoming and of 10 seconds. If the total Priority 1
automatic or manual synchronizing. outgoing conductors. load that must be restored in ten
■ NFPA 110 engine/generator ■ Top or bottom conduit entry. seconds exceeds the capacity of
37 status, pre-alarm, lamp test button, ■ Plug together control connections a single generator, an Emergency
shutdown fault annunciation and 85 across shipping split. Generator Bus Tie breaker should be
dBA alarm horn with silence button. used. This allows one generator on
38 ■ Full function 0.5% accuracy analog Optional Equipment — EGP each side of the tie to restore power
and digital ac metering for system: to Priority 1 loads in under 10 seconds.
■ Distribution sections with The system can then parallel all
voltage 1-2, 2-3, 3-1; current 1, 2, 3;
39 frequency; power factor; kW; kvar.
electrically operated drawout generators across the Emergency
UL 1066 circuit breakers. Generator Bus Tie breaker so the full
■ System control functions for
■ Circuit breaker trip functions — generator plant capacity is available.
auto (standby for emergency), test
40 without load and test with load.
short time and/or ground fault
(in addition to long time and Note: Priority 1 loads must be split to either
instantaneous). side of the Generator Tie breaker. See Page
42.3-9 for an example of a system with an
41 ■ Steel barriers between switchboard Emergency Generator Bus Tie Breaker.
or switchgear sections for compart-
mentalization.
42 ■ Bus/cable barriers.
43

EGP Switchgear
Sheet 1839
Master TOC Features
Caterpillar EGP Switchgear System Metering Communications

22
■ 0.5% accuracy. ■ Automation network — high
Generator Metering ■ Analog and digital voltage 1-2, 2-3, speed, high reliability, industrially
■ 0.5% accuracy. 3-1; current 1, 2, 3; frequency; power hardened. 23
■ Analog and digital voltage 1-2, 2-3, factor; kW; kvar. ■ Optional remote communications
3-1; current 1, 2, 3; frequency; power network — Ethernet, Modem.
factor; kW; kvar; synchroscope. System Protective Relaying ■ Optional communication to 24
■ 27/59 — bus under/overvoltage relay. building automation or SCADA
Generator Protective Relaying ■ 81 O/U — bus under/overfrequency systems or general monitoring —
■ 27/59 — under/overvoltage relay. relay. Modbus RTU or Modbus TCP-IP. 25
■ 81 O/U — under/overfrequency relay. Circuit Breakers
■ 32 — reverse power relay.
System Control 26
■ Automatic standby mode. ■ 100% rated UL 1066 power circuit
■ 40 — loss of excitation (reverse var) breakers available 800 – 6000 A with
relay. ■ Emergency mode. two-step stored energy mechanism.
■ 25 — synch check relay (hardware ■ Test without load. 27
■ 100 kAIC standard (200 kAIC optional).
redundant protective device). ■ Test with load. ■ Drawout mounted (fixed optional).
Engine Gauges
■ Automatic load shed control with ■ 5 cycle closing. 28
bus underfrequency protection and
one 4-pole,10 A, 120 Vac, Form C, ■ Electrically operated.
■ RPM meter.
■ Engine battery volt meter. dry contact output for each load ■ Auxiliary and bell alarm contacts. 29
shed level (1 level of essential for ■ Electronic trip unit with long time
■ Oil pressure gauge.
each generator in the system). and instantaneous trip functions
■ Engine coolant temperature gauge.
■ Automatic generator demand (short time and ground fault 30
■ 3-D engine data screens priority control. optional).
(PowerLynx 2000 and 3000 only).
■ UL 1558, UL 891, or CSA listed
and labeled. Enclosure and Bussing 31
Engine Monitoring and Alarms ■ Available as UL 1558, UL 891 or
■ Master shutdown.
■ Low coolant temperature pre-alarm. CSA listed and labeled.
■ High coolant temperature pre-alarm Touchscreens ■ Optionally service entrance rated.
32
and shutdown. ■ NEMA 1, deadfront freestanding
■ PowerLynx 3000, 15-inch SAW LCD
■ Low oil pressure pre-alarm and TFT color. construction. 33
shutdown. ■ Copper bus.
■ PowerLynx 2000, 12-inch LCD TFT
■ Low fuel alarm (diesel only). resistive color. ■ 100 kA bus bracing (200 kA
■ Low and high engine battery alarm. ■ PowerLynx 1000, 6-inch or 10-inch optional). 34
■ Battery charger alarm. monochrome. ■ 3-phase, 4-wire, 100% neutral bus,
1/4-inch x 2-inch ground bus.
■ Overcrank shutdown. ■ Screen enable/disable key switch 35
■ Overspeed shutdown. (on PowerLynx 3000 systems). ■ Seismic qualified to exceed the
requirements of the Uniform
Engine/Generator Control Power Supply Building Code (UBC), California 36
■ Best dc source selector. Building Code (CBC) and IBC.
■ Automatic engine start.
■ Power from 24 Vdc engine cranking
■ Also available in UL listed and
■ Adjustable engine cooldown timer. labeled medium voltage. 37
■ 15 — automatic synchronizer. batteries.
■ 24 Vdc station battery, sealed jar,
■ 65 — microprocessor engine Environment
governor load sharing and soft 4-hour, external 120 Vac emergency
power required for charger. ■ 0°C to 50°C.
38
loading control.
■ Processor power supplies — 24 Vdc. ■ 0 to 95% humidity, non-condensing.
■ 90 — var/PF and cross current
compensation controller. 39
40
41
42
43

Sheet 1840
22 EGP2 Switchgear — One-Line Diagrams
23
24
25
26
27
28
29
30
31
32
33 Figure 42.3-2. Typical Electrical System with EGP2 Assembly and ATS Units (2-Generator Sources)
Breaker Size
Breaker Size
Max. Feeder
Bus Rating
Generator
kW (480 V)
Lbs. (kg)
Weight
35 Min. Max. Height Width Depth
Main
36 0 532 800 1600 1600 99.00 66.00 72.00 5000

(2514.6) (1676.4) (1828.8) (2270)
533 1064 1600 3200 3200 5100
37 (2315)
1065 1330 2000 4000 3200 5300
T
(2406)
38 1331 2000 3000 6000 3200 84.00 5500
(2133.6) (2497)
39 2
Contact your local caterpillar electric power dealer for more details.
40 3 66.00 (1676.4) with D1.

42 or 4” Conduits
22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9
72.00 (1828.8) 16.00 (406.4) 25.30 (642.6) 12
43 78.00 (1981.2) 16.00 (406.4) 31.30 (795.0) 15
84.00 (2133.6) 16.00 (406.4) 37.30 (947.4) 18
Figure 42.3-3. EGP2 Switchgear Layout

EGP Switchgear
Sheet 1841
22
23
24
25
26
27
28
29
30
31
32
33
Figure 42.3-4. Typical Electrical System with EGP3 Assembly and ATS Units (3-Generator Sources)
34
35
36
37
38
39
40
ATS Overview Screen ATS Control Screen 41
42
43

Sheet 1842
22
3
Configuration
Breaker Size
Max. Feeder
kW (480 V)
Bus Rating
Bkr. Size 2
23
Generator
Lbs. (kg)
Number
Weight
1
Main
24 Feeder
Breaker
Controls 0 532 800 3200 1600 99.00 66.00 84.00 7000 1
(2514.6) (1676.4) (2133.6) (3178)
25 533 1064 1600 5000 2000 7050 1
(3201)
533 1064 1600 4000 3200 88.00 7500 2
26 T
(2235.2) (3405)
1065 1330 2000 6000 2000 66.00 7100 1
(1676.4) (3223)
27 1065 1330 2000 4000 3200 88.00 7600 2
(2235.2) (3450)
1331 2000 3000 6000 2000 66.00 7200 1
28 (1676.4) (3269)
1331 2000 3000 6000 3200 88.00 7800 2
(2235.2) (3541)
29 1 4000 A, 5000 A and 6000 A breakers available in 44" wide structure.
30 at 480 V is also available. Contact local Caterpillar Electric Power
22.00 (558.8) 22.00 (558.8) 22.00 (558.8)
31 Conduit Space for 22.00-Inch (558.8 mm) Wide Structures —
Configuration 1 Top or Bottom Entry
32 3 4
or 4” Conduits
66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9

33 72.00 (1828.8) 16.00 (406.4) 25.30 (642.6) 12
Feeder 78.00 (1981.2) 16.00 (406.4) 31.30 (795.0) 15
Breaker 84.00 (2133.6) 16.00 (406.4) 37.30 (947.4) 18
34 Controls
35
L
LY
LYNX
T
36
37
38
39
40 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8)
Configuration 2
41
Figure 42.3-5. EGP3 Switchgear Layout
42
43

EGP Switchgear
Sheet 1843
22
23
G1 G2 G3 G4
EGP4 Switchgear Distribution

24
Revenue
Metering
PowerLynx HMI 25
Touchscreen
52G1 52G2 52G3 52G4
D1 D2 D3 D4
26
Main
Service
27
28
29
ATS1 N E
ATS2 N E ATS3 ATS4
N E
To Normal To Emergency
Circuits
N E
30
Distribution
Circuits
EDP1 EDP2 EDP3 EDP4

31
32
LP1 BP1 LP2 BP2 LP3 BP3 LP4 BP4
33
Figure 42.3-6. Typical Electrical System with EGP4 Assembly and ATS Units (4-Generator Sources) 34
35
36
37
38
39
40
41
42
43

Sheet 1844
22
4
Configuration
3 Generator Dimensions
Breaker Size
Max. Feeder
23 kW (480 V)
Bus Rating
Bkr. Size 2
Generator
Lbs. (kg)
Number
Weight
1
Main
24 Feeder
Breaker
Controls
0 532 800 3200 1600 99.00 88.00 78.00 7800 1
(2514.6) (2235.2) (1981.2) (3541)
25 533 1064 1600 5000 2000 7950 1
(3609)
LY
LYNX
L
26 T
533 1064 1600 4000 3200 110.0
(279.4)
84.00 9500 2
(2133.6) (4313)
1065 1330 2000 6000 2000 88.00 8000 1
(2235.2) (3632)
27 1065 1330 2000 4000 3200 110.0 9600 2
(279.4) (4358)
28 1331 2000 3000 6000 2000 88.00
(2235.2)
8200 1
(3723)
1331 2000 3000 6000 3200 110.0 9800 2
29 1
(279.4) (4449)
4000 A, 5000 A and 6000 A breakers available in 44" wide structure.
2
22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8)
Configuration 1
Top or Bottom Entry
3 4 5
32 Depth Width Depth Number of 3.5”
or 4” Conduits
66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9

33 Feeder
Breaker 72.00 (1828.8) 16.00 (406.4) 25.30 (642.6) 12
Controls
78.00 (1981.2) 16.00 (406.4) 31.30 (795.0) 15
84.00 (2133.6) 16.00 (406.4) 37.30 (947.4) 18
34
T
35
36
37
38
39
22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8)
Configuration 2
40 Figure 42.3-7. EGP4 Switchgear Layout
41
42
43

EGP Switchgear
Sheet 1845
22
Utility
Source
23
G1 G2 G3 G4
24
Revenue
Metering PowerLynx HMI
Touchscreen
25
52G1 52G2 52G3 52G4
Main
Service 26
Emergency Generator Bus Tie
Priority 1 Priority 1
27
D1 D2 Feeder Feeder D3 D4
28
~ ~ ~ 29
To Normal ~ ~
Distribution ~
To Emergency
Circuits
Circuits 30
ATS1 N E ATS2 N E ATS3 N E ATS4 N E
31
EDP1 EDP2 EDP3 EDP4
32
Optional Remote PC
with PowerLynx LP1 BP1 LP2 BP2 LP3 BP3 LP4 BP4
Software
33
Figure 42.3-8. Typical Electrical System with EGPT4 Switchgear (4-Generator Sources, 1-Emergency Generator Bus Tie Breaker) 34
35
36
37
38
39
40
41
42
43

Sheet 1846
22
3 4 5
Configuration
Breaker Size
Max. Feeder
23 kW (480 V)
Bus Rating
Bkr. Size 2
Generator
Lbs. (kg)
Number
Weight
1
Main
Feeder Feeder
24 Breaker
Controls
Breaker
Controls
0 532 800 3200 1600 99.00 110.00 78.00 7800 1

(2514.6) (2794.0) (1981.2) (3541)
25 T
Tie
Breaker 533 1064 1600 5000 2000 132.00 7950 1
Controls
(3352.8) (3609)
26 533 1064 1600 4000 3200 84.00 9500 2

(2133.6) (4313)
1065 1330 2000 6000 2000 110.00 8000 1
27 (2794.0) (3632)
1065 1330 2000 4000 3200 132.00 9600 2
(3352.8) (4358)
28 1331 2000 3000 6000 2000 110.00
(2794.0)
8200 1
(3722)
1331 2000 3000 6000 3200 132.00 9800 2
29 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8)
1
(3352.8) (4449)
Configuration 1 4000 A, 5000 A and 6000 A breakers available in 44" wide structure.
2
30 3 4 4 5

Feeder
Breaker
Feeder
Breaker
Top or Bottom Entry
Controls Controls
32 Depth Width Depth Number of 3.5”
or 4” Conduits
Tie
L
LY
LYNX
Breaker
66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9
33
T
Controls
72.00 (1828.8) 16.00 (406.4) 25.30 (642.6) 12
78.00 (1981.2) 16.00 (406.4) 31.30 (795.0) 15
84.00 (2133.6) 16.00 (406.4) 37.30 (947.4) 18
34
35
36
22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8)
37 Configuration 2
38 Figure 42.3-9. EGPT4 Switchgear Layout
39
40
41
42
43

EGP Switchgear
Sheet 1847

Generator Control
23
Twisted Quad 24
25
(Belden 8719) 26
Only)
30
Battery Systems
Fuel Systems
33
(2) x 1/c #14 AWG
(6) x 1/c #10 AWG (at Gen.)
ac Control
Alarms
36
37
(Belden 8471)
41
Requirements)

Sheet 1848
22 EGP Functional Sequence of Operations 4. Exit from No Load Test Mode

a. The No Load Test Switch is placed in the OFF position.
A. The EPS Automation shall be provided with the
following Modes of Operation: b. All generator breakers are opened.
23 c. The generators are allowed to run for their
1. Automatic/Standby Mode
programmed cool down period.
a. The automatic transfer switches are in the normal
24 position serving utility power to the loads.
d. The system is now back in Automatic/Standby Mode.
5. Utility Fail Test Mode
b. The generator mains are open.
25 c. The automation is standing by to act in response
a. Entrance into Utility Fail Test Mode
to a run request from associated Automatic 1. The Utility Fail Test Switch is placed in the
Transfer Switches. ON position.
26 2. Emergency Mode 2. A dry contact is sent to each ATS, which simulates
a loss of utility within the ATS controls.
a. Automatic Transfer Switch Run Request
27 1. Automatic transfer switches send system a 3. The system enters into Emergency Mode
run request. as described in the “Emergency Mode”
sequence above.
28 2. All available generators are started.
b. Exit from Utility Fail Test Mode
3. The first generator up to voltage and frequency is
1. The Utility Fail Test Switch is placed in the
29 closed to the bus.
OFF position.
4. Unsheddable loads and Load Shed Priority 1
2. A dry contact is removed from each ATS,
loads are powered in less than 10 seconds.
30 which simulates the return of utility within the
5. The remaining generators are synchronized and ATS controls.
paralleled to the bus as they come up to voltage
31 3. The system exits into Emergency Mode
and frequency.
as described in the “Emergency Mode”
6. As additional generators are paralleled to the sequence above.
32 emergency bus, Load Shed Priority levels are
B. When the Generator Sets are carrying the facility load,
added, powering their associated loads.
the EPS Automation shall support two (2) sub-modes:
7. The system is now in Emergency Mode. Load Shed/Load Add, and Generator Demand Priority.
33
b. Exit from Emergency Mode 1. Load Shed Control
1. Automatic transfer switches sense the a. The System Controls shall include a Load Shed
34 utility source is within acceptable operational Control function to control the loads served by the
tolerances for a time duration set at the automatic generator plant.
transfer switch.
35 b. The Load Shed Control shall have one Essential
2. As each automatic transfer switch transfers back Load Shed Priority Level for each generator in the
to utility power, it removes its run request from system plus one Non-Essential Load Shed Priority
36 the generator plant. Level (which is always shed in the Emergency
Mode of operation).
3. When the last automatic transfer switch has
c. The Load Shed Control shall control each of the
37 retransferred to the utility and all run requests
distribution circuit breakers that are shown on the
have been removed from the generator plant, all
generator main circuit breakers shall opened. drawings. Distribution circuit breakers to be con-
trolled shall be electrically operated. Each electrically
38 4. The generators are allowed to run for their operated distribution circuit breaker shall be field
programmed cool down period. selectable to be assigned to any of the available
Load Shed Priority Levels.
39 5. The system is now back in Automatic/Standby Mode.
1. Provide the following controls for each Essential
3. No Load Test Mode Load Shed Priority Level
40 a. Entrance into No Load Test Mode i. Shed Delay Timer, adjustable from
1. The No Load Test Switch is placed in the ON position. 0 to 1024 seconds
41 2. All available generators are started. ii. Add Delay Timer, adjustable from
0 to 1024 seconds
3. The first generator up to voltage and frequency
42 is closed to the bus. iii. Load Shed Override Selector (shed/auto/add)
4. The remaining generators are synchronized and iv. Status indicators to show whether the Priority
paralleled to the bus as they come up to voltage Level is added or Shed
43 and frequency.
5. The system is now in No Load Test Mode.

EGP Switchgear
Sheet 1849
Master TOC Functional Sequence of Operations
2. Provide the following controls for each NOTE: The following applies to systems with two or
Non-Essential Load Shed Priority more generators. 22
i. Load Shed Override Selector (shed/auto/add) 2. Generator Demand Priority Control
ii. Status indicators to show whether the a. The System Controls shall include a Generator 23
Priority Level is Added or Shed Demand Priority Control function to automatically
match the on-line generator capacity to the loads to
3. Additionally, the Load Shed Controls shall have: avoid unnecessary operation of all the generators 24
when the loads are low.
i. Load Shed Control Switch (On/Off)
b. The following controls shall be provided for each
ii. User-settable Load Shed % (as a function generator: 25
of on-line generator capacity) 1. User-settable Generator Priority Selector
iii. User-settable Load Shed Time Delay 2. Status indicator for the Generator Priority 26
iv. User-settable Load Add % (as a function of Selected
on-line generator capacity) 3. Status indicator for generator On-line or Off-line 27
v. User-settable Load Add Time Delay c. The Generator Demand Priority Control shall have
vi. User-settable Bus Under frequency Set point the following controls: 28
1. Generator Demand Priority Control Switch (On/Off)
vii. User-settable Bus Under frequency time delay
2. User-settable Generator Remove % (as a function 29
viii. Bus Under frequency Reset Pushbutton
of a single generator capacity)
ix. Bus Under frequency indicator
3. User-settable Generator Remove Delay
4. Conditional Load Shed — Upon entrance into
30
4. User-settable Generator Add % (as a function of a
Emergency Mode of operation, the Load Shed
single generator capacity)
Control shall shed all Essential and Non-Essential
loads. As generators come to the bus, Essential 5. User-settable Generator Add Delay
31
Priority Level loads shall be added conditionally
based on the number of generators on line. When d. Upon entrance into Emergency mode, all generators
the first generator comes to the bus, Priority Level shall be started and paralleled to the bus. After the 32
1 loads shall be added; Second generator, priority Remove Time Delay, generators shall be removed
2, etc. After a time delay that allows all opera- from the bus as a function of the generator percent-
tional generators to come to the bus, Load Shed age loading by the user selected Generator Remove 33
Mode shall shift to Load Sensitive Mode. time delay. Generators shall be removed from the
bus in descending priority. Should the generator
5. Load Sensitive Load Shed — After all generators percentage loading increase to the user selected 34
have been given sufficient time to come to the Generator Add limits for the user selected Add Delay,
bus, load shed shall shift to “Load Sensitive” the next generator will be started, synchronized and
mode. The system shall compare current paralleled to the bus. Generators shall be added 35
generator on-line capacity (in kW) to current to the bus in ascending priority order. Should the
load requirements. If surplus capacity is greater generator plant ever reach 95% loading, the next
than the calculated Load Add set point, after the priority generator shall be started and added to 36
Load Add Time Delay the next Load Shed Priority the bus with no time delay.
shall be added. This calculation will continue until
all Sheddable Loads are added, or until surplus 37
capacity is less than the calculated Load Add
setpoint. If surplus capacity is less than the
calculated Load Shed setpoint, after the Load 38
Shed Time Delay the next Load Shed Priority
shall be shed. This calculation shall continue until
all Sheddable Loads are shed, or until surplus 39
capacity is greater than the calculated Load Shed
setpoint. The Load Shed Control, in its automatic
shedding and adding of loads, shall not override 40
any manual load shed/add operation.
6. Should the load bus frequency fall below the user 41
selected bus underfrequency setpoint for a period
longer than the bus underfrequency time delay,
then all Priority Level loads shall be shed and load 42
addition shall not resume until the operator has
depressed the Bus Underfrequency Reset button.
The bus underfrequency protection shall override 43
any manual load add operation.

Home TOC Index June 2006
Sheet 1850
Master TOC
This page intentionally left blank.

22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43

LM Switchgear
Sheet 1851
LM Product Description 22
Caterpillar Load Management (LM) Caterpillar Switchgear brings the
Switchgear with PowerLynx utilizes a power and reliability of microproces-
single diesel or natural gas generator sor technology to your generator 23
set to operate in parallel with the utility switchgear application. Through
company for load management peak the use of the PowerLynx Operator
shaving. interface touchscreen display with 24
easy-to-follow graphical representa-
■ Standardized, simple, cost-effective tions, the PowerLynx technology
control switchgear for local or product merges the features of: 25
remotely initiated starting, stopping,
synchronizing, utility paralleling, ■ Power monitoring.
load management, and distributed ■ Switchgear automation. 26
generation. ■ Generator set control.
■ Available as:
■ Remote communications.
❑ Base Load Import/Export limit 27
❑ Utility set point import peak
shaving 28
29
LM Switchgear (PowerLynx 3000 Shown) 30
31
32
33
34
35
36
37
38
39
40
41
Figure 42.4-1. Application of LM Switchgear 42
43

LM Switchgear Home TOC Index June 2006
Sheet 1852
22 Equipment ■ System status and alarm annuncia- Optional Equipment — LM

tion with display and 85 dbA alarm
horn with silence button. ■ Circuit breaker trip functions:
Standard Equipment — LM short time, long time, ground fault
■ Password secured settings and trip and/or ground fault alarm.
23 ■ Low voltage LM systems utilize adjustments for generator and sys-
Magnum DS power circuit breaker tem setup and protective relaying. ■ Also available in 150 kA or 200 kA
switchgear and Magnum power bus bracing configurations.
■ UL 891 listed and labeled or UL 1558
24 circuit breakers. For complete
listed and labeled. ■ Also available with 4000 and
technical details on Magnum DS 5000 ampere main bus ratings
switchgear, see Section 20. ■ NEMA 1, deadfront freestanding and breakers.
25 ■ Operator Interface Touchscreen:
construction.
■ Also available in medium voltage
■ IEEE 1547 compliant, when a (See Section 42.5).
❑ PowerLynx 3000, 15-inch
compliant utility protective relay
surface acoustic wave LCD TFT ■ Operation via remote contact
26 color touchscreen
is selected.
closure, or manually initiated at unit.
■ UL or CSA listed.
❑ PowerLynx 2000, 12-inch resis- ■ Off-site frame relay — remote.
■ Copper bus, braced for 100 kA.
27 tive LCD TFT color touchscreen
■ 3-phase, 4-wire, 100% neutral,
■ Main bus compartment.
❑ PowerLynx 1000, 6-inch resistive ■ Trip unit metering and communica-
1/4-inch x 2-inch copper ground bus.
LCD monochrome touchscreen tions (Digitrip 520M, 520MC
28 ■ Direct data communication to
■ Available in 600 V, or 208/120 V, and 1150).
480/277 V, 60 Hz.
CAT microprocessor-based engine ■ PowerLynx software for additional
generator set control network. ■ UL 1066 listed power circuit on-site monitoring and control
29 ■ 0.5% accuracy ac metering for
breakers, 100 kAIC, two-step work stations.
stored energy drawout mounted
utility: average voltage; kW. electrically operated with long time ■ PowerLynx software for off-site
30 ■ 0.5% accuracy digital ac metering and instantaneous trip, local LCD monitoring control.
for generator: voltage 1-2, 2-3, 3-1; ammeter, and circuit breaker ■ Building Automation System
current 1, 2, 3; frequency; power control switch with lights. or SCADA communications —
31 factor; kW; kvar; kVA. ■ Continuous cross bus ratings up to Modbus or Ethernet.
■ Synchronizing and paralleling con- 3000 amperes at 600 Vac. ■ Remote notification.
trols for automatic synchronizing. ■ Mechanical lugs for incoming and ■ Historical data trending.
32 ■ NFPA 110 engine/generator status, outgoing conductors. ■ Redundant main processor.
pre-alarm and shutdown fault ■ Top or bottom conduit entry.
readout with 85 dbA alarm horn
33 with silence button.
■ System control functions for load
34 management.
35
36
37
38
39
40
41
42
43

LM Switchgear
Sheet 1853
Master TOC Features
Caterpillar LM Switchgear Engine Monitoring and Alarms Communications

22
■ Low coolant temperature pre-alarm. ■ Automation Network — high
Utility Metering ■ High coolant temperature pre-alarm speed, high reliability, industrially
■ 0.5% accuracy. and shutdown. hardened. 23
■ Average voltage: power factor, kW. ■ Low oil pressure pre-alarm and ■ Optional remote communications
shutdown. network, Ethernet or dial-up modem.
Protective Relaying ■ Low fuel alarm (diesel only). ■ Optional communication to 24
■ Low engine battery alarm. Building Automation or SCADA
■ 27/59 — under/overvoltage relay.
systems for general monitoring —
■ 81 O/U — under/overfrequency relay. ■ Overcrank shutdown. Modbus RTU or Modbus TCP-IP. 25
■ Multi-function, utility grade, ■ Overspeed shutdown.
drawout with: Circuit Breakers
❑ 32 — reverse direction relay, Engine/Generator Control ■ 100% rated UL 1066 power circuit
26
utility grade (import only) ■ Engine start function — automatic, breakers available 800 – 6000 A with
❑ 32/51 — reverse direction manual. two-step stored energy mechanism.
overcurrent relay, utility grade, ■ Adjustable engine cooldown timer.
27
■ 100 kAIC standard (200 kAIC optional).
(import only) ■ 15 — automatic synchronizer. ■ Drawout mounted (fixed optional).
❑ 32/62 — reverse direction timing ■ 65 — microprocessor engine ■ 5 cycle closing. 28
relay, utility grade, (import only) governor load sharing and soft ■ Electrically operated.
■ 86 — reverse power lockout relay, loading control.
manual reset, (import only). ■ 90 — var/PF and cross current
■ Auxiliary and bell alarm contacts. 29
compensation controller. ■ Electronic trip unit with long time
■ 25 — synch check relay (hardware and instantaneous trip functions
redundant protective device). (short time and ground fault optional). 30
■ 47 — phase sequence/phase failure System Control
relay, utility grade. ■ Load management mode (manually Enclosure and Bussing
initiated).
■ UL 1558 or UL 891 listed 31
Generator Set Metering ■ Emergency stop/master shutdown
and labeled.
■ 0.5% accuracy. button.
■ NEMA 1, deadfront freestanding 32
■ Voltage 1-2, 2-3, 3-1; current 1, 2, 3; construction.
frequency; power factor; kW; kvar; Touchscreens
■ Copper bus.
kVA. ■ PowerLynx 3000, 15-inch surface
acoustic wave LCD TFT color ■ 100 kA bus bracing (200 kA optional). 33
Generator Protective Relaying touchscreen. ■ 3-phase, 4-wire, 100% neutral bus,
1/4-inch x 2-inch ground bus.
■ 27/59 — under/overvoltage relay. ■ PowerLynx 2000, 12-inch resistive
■ Seismic qualified to exceed
34
■ 81 O/U — under/overfrequency relay. LCD TFT color touchscreen.
■ PowerLynx 1000, 6-inch resistive
the requirements of the Uniform
■ 32 — reverse power relay. Building Code (UBC), California
■ 40 — loss of excitation (reverse var)
LCD monochrome touchscreen.
Building Code (CBC) and IBC.
35
relay. Power Supply ■ Also available in UL listed and
■ 25 — synch check relay (hardware
■ Best dc source selector.
labeled medium voltage. 36
redundant protective device).
■ Power from 24 Vdc engine cranking Environment
batteries. 37
■ 0°C to 50°C.
■ 24 Vdc station battery sealed jar,
■ 0 to 95% humidity, non-condensing.
4-hour, external 120 Vac emergency
power required for charger. 38
■ Processor power supplies — 24 Vdc.
39
40
41
42
43

Sheet 1854
22 Caterpillar LM Switchgear — One-Line Diagrams
23
24
25
26
27
28
29
30
31
32
Figure 42.4-2. Application of LM Switchgear
33
34 Generator Dimensions
Breaker Size
Max. Feeder
Bus Rating
Bkr. Size 2
Generator
kW (480 V)
35 Lbs. (kg)
Weight
Main
36 0 532 800 1600 1600 99.00 22.00 72.00 1850

(2514.6) (558.8) (1828.8) (840)
533 1064 1600 1600 1600 1875
37 (851)
L
1065 1330 2000 2000 2000 1900
OUCH
(863)
38 1331 2000 3000 3200 3200 84.00 2100
(2133.6) (953)
40 dealer for more details.

Top or Bottom Entry
41
or 4” Conduits
42
22.00 (558.8) 66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9
72.00 (1828.8) 16.00 (406.4) 25.30 (642.6) 12
43 78.00 (1981.2)
84.00 (2133.6)
16.00 (406.4)
16.00 (406.4)
31.30 (795.0)
37.30 (947.4)
15
18
Figure 42.4-3. LM Switchgear Layout

LM Switchgear
Sheet 1855

Generator Control
23
Twisted Quad 24
25
(Belden 8719) 26
Only)
30
Battery Systems
Fuel Systems
33
(2) x 1/c #14 AWG
(6) x 1/c #10 AWG (at Gen.)
ac Control
Alarms
36
37
(Belden 8471)
41
Requirements)

Sheet 1856
Sequences of Operation Master TOC
22 LM Functional Sequences of Operation ix. When the generator is on the bus it shall be
soft ramp loaded until the generator plant is
A. The Distributed Generation Power System shall be serving nominally the required amount of
provided with the following Modes of Operation: the load on the bus to meet the mode of
23 operation selected.
1. Automatic Mode
x. The generator output is dynamically adjusted
a. The utility main breaker is closed serving utility
24 power to the generator/load bus.
to maintain the set point to meet the mode of
operation selected. If at any time the system is
b. The generator main breaker is open. unable to maintain the setpoint then a “Set
25 2. Load Management Mode point Exceeded” alarm shall be sounded.
a. Entry xi. Should the utility fail at any time during

Load Management operation and/or an ATS
26 1. Select one of the modes of operation: (Automatic Transfer Switch) calls on the gen-
i. Import Limit — The user places the Import/ erator for emergency operation during Load
Management operation, the utility protective
27 Export toggle switch in the Import position
relays shall cause the Paralleling Tie Circuit
and places the Base Load/Utility Tracking
toggle switch in the Utility Tracking position. Breaker to open and be locked out, thus
allowing existing Generator controls to enter
28 The user sets the Utility Import Set point to the
Emergency Mode and provide Emergency
desired amount of kW that they want to
import through the Paralleling Tie Circuit Power to critical loads.
29 Breaker during Load Management Mode. b. Exit
ii. Export Limit — The user places the Import/ 1. The operator removes the System Mode Selector
Export toggle switch in the Export position Switch from Load Management position and
30 and places the Base Load/Utility Tracking returns it to the Auto position.
toggle switch in the Utility Tracking position.
The user sets the Utility Export Set point to the 2. The generator plant is soft ramp unloaded
31 desired amount of kW that they want to export until the utility source is nominally serving the
through the Paralleling Tie Circuit Breaker entire system load and the generator main
during Load Management Mode. breakers are opened.
32
iii. Base Load Import — The user places the 3. The generator is allowed to run for it’s pro-
Import/Export toggle switch in the Import grammed cool down period.
33 position and places the Base Load/Utility 4. The system is now back in Automatic Mode.
Tracking toggle switch in the Base Load
position. The user sets the Base Load Set c. No Load Test Mode
34 point to the desired amount of kW that they 1. Entrance into No Load Test Mode
want the generator plant to assume during
Load Management Mode. The controls will 2. The No Load Test Switch is placed in the
35 not allow the generator plant to export kW ON position.
through the Paralleling Tie Circuit Breaker
3. The available generator is started.
and will always maintain a nominal amount
36 of Utility kW imported through the Paralleling 4. The generator ramps up to voltage and frequency
Tie Circuit Breaker. and remains running disconnected from the bus.
37 iv. Base Load Export — The user places the 5. The system is now in No Load Test Mode.
Import/Export toggle switch in the Export
position and places the Base Load/Utility 6. Exit from No Load Test Mode
38 Tracking toggle switch in the Base Load 7. The No Load Test Switch is placed in the
position. The user sets the Base Load Set OFF position.
point to the desired amount of kW that they
39 want the generator plant to assume during 8. The generator is allowed to run for it’s
Load Management Mode. The controls will programmed cool down period.
allow the generator plant to export kW
40 through the Paralleling Tie Circuit Breaker. 9. The system is now back in Automatic Mode.
v. The user places the System Mode Selector

41 Switch in the Load Management position.
vi. A run request is sent to the generator plant.
42 vii. The generator will be allowed to run for a
five-minute warm-up time (which can be
abbreviated by the operator).
43 viii. The generator will be synchronized and paral-
leled to the bus at no load after completion of
the warm-up time.

Sheet 1857
Medium Voltage Systems Recommended Protective Relaying ■ (32/51) Reverse Direction

22
Overcurrent Relay
One typical difference in the design of
■ (15/25) Automatic Synchronizer
Medium Voltage versus Low Voltage
Generator Paralleling Systems is the ■ (25) Manual Paralleling Synch
requirement for protective relays for Check Relay
23
proper system protection and coordi- ■ (86) Lock-out Relay
nation. The following is a listing of rec-
Distribution Breaker Relaying 24
ommended protective relay functions
for MV Generator Paralleling Systems ■ (50/51) Instantaneous/Time
with and without utility connections. Overcurrent 25
■ (86) Lock-out Relay
Generator Protective Relaying
■ (50/51) Instantaneous/Time Other Recommended Protective Functions 26
Overcurrent A. (87B) Switchgear Bus Differential
■ (51G) Ground Overcurrent Trip — Bus differential relays are high
Protection speed protective devices that are 27
Medium Voltage Systems ■ (27/59) Under/Overvoltage used to limit damage from faults
within the switchgear by quickly
The Caterpillar Generator Paralleling ■ (81O/U) Over/Underfrequency
Switchgear Systems described in ■ (32) Reverse Power Relay
isolating the faulted “zone.” 28
Differential relays measure the
Section 42.2 for XLM (Emergency ■ (40) Loss of Field (Reverse var) difference between the current
Transfer (Xfer) and Load Manage-
ment), Section 42.3 for EGP
■ (65) Engine Governor Load flowing into and the current 29
Sharing and Soft Loading Control flowing out of a given “zone.”
(Emergency Generator Paralleling), Systems with multiple utilities
and Section 42.4 for LM (Load ■ (87G) Generator Differential
Management) are also available Phase Fault and/or tie breakers will typically 30
have more than one bus differen-
for medium voltage systems. These ■ (15/25) Automatic Synchronizer
tial zone. In this configuration,
systems utilize the Eaton VacClad (25) Manual Paralleling Synch Check
switchgear with VCP-W vacuum circuit
■ during a differential fault, only 31
■ (90 PF) Var/Power Factor Controller breakers feeding in and out of
breakers and the same PowerLynx the faulted zone are tripped and
■ (86) Lock-out Relay
Control Technology, features and locked out. The other zone(s) 32
benefits described in Section 42.1. Utility Breaker Protective Relaying are unaffected and can continue
■ (50/51) Instantaneous/Time to operate.
Maximum Voltages Overcurrent 33
■ 4.76 kV, 8.25 kV, 15 kV B. Generator Neutral Grounding
■ (27/59) Under/Overvoltage Resistors — provide added
■ (81 O/U) Over/Underfrequency protection for generator windings
Interrupting Ratings
■ (47) Phase Sequence/Phase Failure by limiting the fault current during
34
■ 4.76 kV: ■ (32) Reverse Power Relay line to ground faults.
❑ 250 MVA (29 kA) 35
❑ 350 MVA (41 kA)
❑ 500 MVA (63 kA)
■ 8.25 kV
36
❑ 500 MVA (33 kA)
❑ 900 MVA (63 kA) 37
■ 15 kV
❑ 500 MVA (18 kA) 38
❑ 750 MVA (28 kA)
❑ 1000 MVA (37 kA)
39
❑ 1500 MVA (63 kA)
Continuous Current 40
Circuit Breakers
■ 1200, 2000 and 3000 A (5 and 15 kV) 41
Main Bus
■ 1200, 2000, 3000 and 4000 A 42
(5 and 15 kV)
For complete technical ratings,
layouts, and features of VacClad
43
Switchgear and VCP-W vacuum
circuit breakers, refer to Section 5.
Air/Cool System Screen

Medium Voltage Systems Home TOC Index June 2006
Sheet 1858
General Description Master TOC
Tie Breaker Application Generator Bus Tie breakers can be Emergency Generator Bus Tie
22 Many systems require the use of
applied to serve several purposes: Certain NFPA Codes require all Life
tie breakers to meet Code or system 1. Starting of large loads — the Safety and Critical loads (Priority 1
performance requirements. Tie loads) to be restored in a maximum of
23 breakers can be used anywhere
Generator Bus Tie can be opened
to allow multiple generators to be 10 seconds. If the total Priority 1 load
throughout the line-up to segment paralleled before being connected that must be restored in ten seconds
or isolate desired sources, loads exceeds the capacity of a single
24 or sections of bus.
to large load(s). Once multiple
generator, an Emergency Generator
generators are paralleled, the
Generator Bus Tie can be closed Bus Tie breaker should be used. This
Generator Bus Tie allows one generator on each side
25 Generator Bus Ties can be used to
to power the large loads.
of the tie to restore power to Priority 1
separate the normal electric service 2. Load banks — the Generator Bus loads in under ten seconds. The
sources from the generator sources. Tie can allow the generators to be system can then parallel all generators
26 This can also allow separation of load isolated from the normal utility fed across the Emergency Generator Bus
breakers to either side of the generator bus. Having a distribution breaker Tie breaker so the full generator plant
bus tie breaker in order to allow isola- or set of load take-off lugs on the capacity is available.
27 tion of load banks, or dedicated emer- generator side of the bus allows
Note: Priority 1 loads must be split to
gency loads. This separation also may the generators to be load bank
either side of the Emergency Generator
be required by NFPA or local Codes. tested without affecting any
28 normal utility fed loads.
Bus Tie breaker.
3. Emergency Standby systems with See Page 42.5-6 for an example of a

29 Automatic Transfer Switches — system with an Emergency Generator
the Generator Bus Tie provides Bus Tie Breaker.
isolation between the Normal and
30 Emergency buses. During a loss
of utility power, the Generator
Bus Tie can be opened to isolate
31 all Normal loads and allow resto-
ration of power to Emergency
loads. Once Emergency loads
32 are restored, the Emergency Bus
Tie can be reclosed to restore
power to Normal loads.
33
See Page 42.5-4 for an example of
an XLM system with Generator Bus
34 Tie breaker.
35
36
37
38
39
40
41
42
43

Sheet 1859
Caterpillar XLM Switchgear — One-Line Diagrams 22
23
24
25
26
27
28
29
30
31
Figure 42.5-1. Medium Voltage XLM1 Switchgear (1-Generator Source, 1-Utility Source) —
(For Multiple Utility Sources, see Custom Configurable Switchgear Section 42.6) 32
Note: 87B = Bus Differential Protection (if applicable).
33
34
Utility Relay Gen. Relay
35
Touch-
screen
36
37
38
36.00 36.00 36.00
(914.4) (914.4) (914.4)
39
108.00 (2743.2)
40
Figure 42.5-2. Medium Voltage XLM1 Switchgear Layout
Note: All structures are 96.25 inches (2444.8 mm) deep.
Note: See Figures 42.5-11 and 42.5-12 for typical distribution structure layouts.
41
Note: See Section 5 Medium Voltage Metal-Clad Switchgear for conduit space, weights, etc.
42
43

Sheet 1860
22
23
24
25
26
27
28
29
30
Figure 42.5-3. Medium Voltage XLMT3 Switchgear (3-Generator Sources, 1-Utility Source, 1-Generator Bus Tie Breaker) —
31 Note: 87B = Bus Differential Protection (if applicable).
32
SECT 1 SECT 2 SECT 3 SECT 4 SECT 5 SECT 6 SECT 7 SECT 8
33 VTN1 52D1 52ET1 VTB2 VTG1 VTG2 VTG3

Utility Relay Dist. Relay Tie Relay Gen. Relay Gen. Relay Gen. Relay
Cell A
34
Touch-
86
LOC K - O UT RELAY
G R UCLOS
CLOSE LOCKOUT
SWITCH
screen 86 G R
86 G R
86 G R
86 G R
86 G R
L OCKO UT AUTO LOC K - O UT RELAY LOC K - O UT RELAY LOC K - O UT RELAY
LOC K - O UT RELAY
95.00
LOC K - O UT RELAY
T RIP R ESET
T RIP R ESET T RIP R ESET T RIP R ESET
T RIP R ESET
T RIP R ESET
35 (2413.0)
86
LOC K - O UT RELAY
T RIP R ESET
G R
VTB1
36 Cell B
Dist. Relay
52N1 52D2 52G1 52G2 52G3
37
36.00 36.00 36.00 36.00 36.00 36.00 36.00 36.00
(914.4) (914.4) (914.4) (914.4) (914.4) (914.4) (914.4) (914.4)
38 288.00 (7315.2)
39
Figure 42.5-4. Medium Voltage XLMT3 Switchgear Layout
40 Note: See Figures 42.5-11 and 42.5-12 for typical distribution structure layouts.
41
42
43

Sheet 1861
22
23
24
25
26
27
28
29
30
31
Figure 42.5-5. Medium Voltage EGP3 Switchgear (3-Generator Sources)
32
33
34
Gen. Relay Gen. Relay Gen. Relay
Touch-
35
screen
36
37
38
36.00 36.00 36.00 36.00
(914.4) (914.4) (914.4) (914.4)
144.00 (3657.6)
39
Figure 42.5-6. Medium Voltage EGP3 Switchgear Layout

40
Note: See Figures 42.5-11 and 42.5-12 for typical distribution structure layouts. 41
42
43

Sheet 1862
22
23
24
25
26
27
28
29
30
31
Figure 42.5-7. Medium Voltage EGPT4 Switchgear (3-Generator Sources, 1-Emergency Generator Bus Tie)
32
33 SECT 1 SECT 2 SECT 3 SECT 4 SECT 5 SECT 6 SECT 7 SECT 8 SECT 9
34 Gen. Relay Gen. Relay Gen. Relay Gen. Relay

Dist. Relay Dist. Relay Dist. Relay
Cell A
Touch-
35 screen
95.00
(2413.0)
36
Cell B
Dist. Relay
37 Dist. Relay Tie Relay
38 36.00 36.00 36.00 36.00 36.00 36.00 36.00 36.00 36.00

(914.4) (914.4) (914.4) (914.4) (914.4) (914.4) (914.4) (914.4) (914.4)
324.00 (8229.6)
39
40 Figure 42.5-8. Medium Voltage EGPT4 Switchgear Layout

41 Note: See Section 5 Medium Voltage Metal-Clad Switchgear for conduit space, weights, etc.
42
43

Sheet 1863
22
23
24
25
26
27
28
29
30
Figure 42.5-9. Medium Voltage LM Switchgear (1-Generator Source Paralleled with Existing Normal Utility Source)
31
32
Gen. Relay
33
Touch-
screen 34
35
36
36.00
(914.4)
36.00
(914.4)
37
72.00 (1828.8)
38
Figure 42.5-10. Medium Voltage LM Switchgear Layout
39
Note: See Section 5 Medium Voltage Metal-Clad Switchgear for conduit space, weights, etc. 40
41
42
43

Sheet 1864
22 Typical Medium Voltage Distribution Section

Note: Single or double (as shown) distribution breaker sections can be added to XLM and EGP layouts as needed.
23
24
25
26
27
28
29
30
31
32
Figure 42.5-11. Typical Medium Voltage Distribution Section
33
34
35
Dist. Relay
36
37
38 Dist. Relay
39 36.00
(914.4)
40
Figure 42.5-12. Medium Voltage Distribution Section Layout
41 Note: See Section 5 Medium Voltage Metal-Clad Switchgear for conduit space, weights, etc.
42
43

Sheet 1865
Table 42.5-1. Typical Control Circuit Wiring — Medium Voltage Systems

Generator Control
23
Communications Twisted Pair (Belden 8719) and Display of Engine Data from EMCP to
Switchgear
Gas — (1) x #16 AWG Shielded
Twisted Quad
Signal Level
24
25
Voltage Regulation (VR) Control (1) x #16 AWG Twisted pair
(Belden 8719)
Signal Level Bi-polar dc Bias Signal for Voltage Control
26
Only)
Speed Control (Governor) Type 2301A Speed Controller — dc Control ≤ 30 Vdc Bi-polar dc Bias Signal for Speed Control
27
ADEMIII Speed Controller — Signal Level
28
(Additional for Pro Act Gov. Only) dc Control ≤ 30 Vdc
29
Twisted Pair Controller Only 30
Battery Systems
Power for 24 Vdc Station Battery Charger (3) x 1/c #12 AWG
(in Master Section)
ac Control 120 Vac/20 A Emergency Circuit for 24 Vdc
Battery Charger Power
31
24 Vdc Station Battery Charger Malfunction (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms
32
Power for 24 Vdc Battery Charger (3) x 1/c #10 AWG ac Control 120 Vac/40 A Emergency Circuit for 125 Vdc
battery charger power (circuit size varies with
charger ampacity requirements).
33
24 Vdc Batteries (4) x 1/c #10 AWG (2 x + 24 Vdc & dc Control ≤ 30 Vdc 125 Vdc Supply to from 125 Vdc batteries to
2 x – 24 Vdc) (Next to Switchgear) MV Breaker Controls (5 kV and 15 kV Only)
34
24 Vdc Battery Charger Malfunction (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms
Fuel Systems 35
High Fuel Tank Level (Master Fuel Tank) (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms 36
Other Fuel Tank Alarms (Master Fuel Tank) (2) x 1/c #14 AWG (Each) dc Control ≤ 30 Vdc Alarms
Fuel Tank Rupture Basin (Day Tank) (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms 37
High Fuel Tank Level (Day Tank) (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms
Generator Protection Systems 38
Genset Mounted CB Status (2) x 1/c #14 AWG dc Control ≤ 30 Vdc Alarms
Generator Differential CTs (6) x 1/c #10 AWG (at Gen.) ac Control 87G Relay Alarm/Shutdown
Generator RTD Leads (1) x #14 AWG Shielded Twisted Quad dc Control ≤ 30 Vdc Indication/Alarms/Shutdown 39
per Reading (at Gen.) 40
VT and CT Wires (4) x 1/c #10 AWG per AWG and ac Control Metering Input
(6) x 1/c #10 AWG (at Gen. Panel)
Neutral Grounding Resister (NGR) CT (2) x 1/c #10 AWG per NGR ac Control 51G Relay Alarm/Shutdown 41
(at Neutral Resistors)
2 Recommend 20% spares of each size single conductor and (1) of each multi-conductor cable. 42
43

Sheet 1866
Table 42.5-1. Typical Control Circuit Wiring — Medium Voltage Systems (Continued)
22 Function (Quantity)/Size/ Signal Description
Automatic Transfer Switch Interface (Per ATS)
23 CAT ATS Monitoring and Control (1) x #16 AWG Shielded Twisted Pair Signal Level Monitoring and Control of ATS Functions
(Belden 8471)
24 Engine Start
Discrete ATS Position
(2) x 1/c #14 AWG
(4) x 1/c #14 AWG dc Control ≤ 30 Vdc
Engine Start Request
Normal and Emergency ATS Status
Miscellaneous (Optional)
25 Miscellaneous Enclosure Alarms (2) x 1/c #14 AWG per Required Alarm dc Control ≤ 30 Vdc Alarms/Shutdown
26 Remote Monitoring/Control PC (1) x 4 Pair #24 AWG UTP CAT 5 Signal Level Communication Signal to Remote
27 Varies Based on Installation
Requirements)
28 (Belden 3073) Management or SCADA System
29 3 Separate metallic conduits should be used for each Signal Type. 'Signal Level' and 'dc Control Signal ≤ 30 Vdc' wires may be combined in the same conduit.
30
31
32
33
34
35
36
37
38
39
40
41
42
43

Custom Configurable Systems
Sheet 1867
Custom Configurable Systems Caterpillar Generator Paralleling

22
Switchgear has the power and
flexibility to handle even the most
unique or demanding configurations
and project requirements. If the 23
standard XLM (Emergency Transfer
(Xfer) and Load Management), EGP
(Emergency Generator Paralleling), 24
and LM (Load Management) configu-
rations do not fit the needs of your
specific project, Caterpillar Switch- 25
gear offers fully customized solutions.
In many cases, custom configurable 26
systems are based on standard XLM,
EGP or LM configurations with
additional requirements such as: 27
■ Multiple utility connections.
■ Multiple tie breakers. 28
■ Unique sequence of operations.
■ Special switchgear layout
requirements, etc. 29
Example Custom Overview Screen
Regardless what the project requires,
Caterpillar Switchgear can meet your 30
needs. Some examples of Custom
Configurable System one-line diagrams
and layouts are on the following pages. 31
32
33
34
35
36
Example Custom Overview Screen
37
38
39
40
41
42
43
Example Custom Oil/Fuel System Screen

Custom Configurable Systems Home TOC Index June 2006
Sheet 1868
22 One-Line Diagrams
23
24
25
26
52N2
27
Bus #1 Bus #2
28
29
30
31
32
33 Figure 42.6-1. Low Voltage Main-Tie-Generator-Tie-Main Switchgear (2-Utility Sources, 4-Generator Sources, 2-Generator Bus Tie Breakers)
1 PR = Protective Relay.
34
3 4 5 6 7
35
36
Feeder Feeder
Breaker Breaker
37 Controls Controls
38 L
LY
Tie
POWER YNX
Y
39
40
41
42
43 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8) 22.00 (558.8)
Figure 42.6-2. Low Voltage Main-Tie-Generator-Tie-Main Switchgear Layout

Sheet 1869
22
23
24
25
26
27
28
29
Figure 42.6-3. Medium Voltage Main-Tie-Generator-Tie-Main Switchgear (2-Utility Sources, 2-Generator Sources, 2-Generator Bus Tie Breakers)
30
SECT 10 SECT 11 31
VTN1 VTG1 VTG2 52T2 VTB3 52D3 VTN2
Utility Relay Dist. Relay Tie Relay Gen. Relay Gen. Relay Tie Relay Dist. Relay Utility Relay 32
Touch-
screen
33
CLO SE L OCKOUT CLO SE L OCKOU
T
SWITCH SWITCH
L OC KOUT AU TO L OC KOUT AU TO
Dist. Relay Dist. Relay

34
52N1 VTB1 52G2 52N2
36.00 36.00 36.00 36.00 36.00 36.00 36.00 36.00 36.00 36.00 36.00
35
(914.4) (914.4) (914.4) (914.4) (914.4) (914.4) (914.4) (914.4) (914.4) (914.4) (914.4)
396.00 (10,058.4) 36
Figure 42.6-4. Medium Voltage Main-Tie-Generator-Tie-Main Switchgear Layout 37

38
39
40
41
42
43

Custom Configurable Systems Home TOC Index June 2006
Sheet 1870
22
G1 G2 G3 G4
23 Utility Utility Utility

TX TX TX Gen
Synch &
24 Bus
Duct Parallel
Utility Utility Utility
Metering Metering Metering Gen
25 Synch &
Gen
Parallel
Synch &
Parallel
26 UF1
Utility
Tie UF6 Tie Tie Tie Tie
Prot.
EF1 EF6
27
To Other SWGR Assemblies #2 Thru #6
28
Closed
Transition of
Paralleling and
29 N1 E1 Utility, Plus
Soft Loading/
Unloading
30
SWGR#1
31 Load Shed/Load Add

E.O. Stored Energy Type
32
Figure 42.6-5. Large Critical Power System —Multiple Generators Closed Transition and Load Shed/Add LV Complex Utility
33 and Generator Paralleling System
34 MV Generators X = Number of Units
G1 G2 Gx
35 Utility
Utility Utility Tie Protection
Utility Tie Protection Typical
Gen Closed Transition
Closed Transition Generator
36 Paralleling and Breaker
Synch Paralleling and
Soft Load/Unload Soft Load/Unload
MV Generator Bus
37 Load Shed/Load Add
MV Gen Gen MV
Main Main Main Main
38 MV Bus A MV Bus B
Typical Synch & Paralleling

Closed Transition
39 MV Vacuum
Breaker Soft Loading/Unloading
Load Shed/Load Add
40 Typical
Secondary
Substations
No Load Shed/Load Add
41 Open Transition Main-Tie-Main
Transfer or Closed Transition
Secondary Momentary Overlap for
42 Main
LV Bus A
Main-Tie-Main
LV Bus B
Tie
43 Typical LV Breaker
Figure 42.6-6. Large Critical Power System — Multiple Generators Closed Transition (Active Synch) and Load Shed/Add MV Complex Utility
and Generator Paralleling System

Sheet 1871
22
MV Generators X = Number of Units
G1 G2 Gx 23
Utility
Gen Closed Transition 24
Synch Paralleling and
Paralleling and Breaker
MV Generator Bus
25
Load Shed/Load Add
MV Gen Gen MV
Main Main
Tie
Main Main 26
MV Bus A MV Bus B
Synch & Paralleling

Typical
MV Vacuum Closed Transition 27
Breaker Soft Loading/Unloading
Load Shed/Load Add
28
Typical
Secondary
Substations
29
Closed Transition
Secondary Soft Load/Unloading
Transfer
30
Main
LV Bus A LV Bus B
Typical
Tie 31
LV Breaker Load Shed/Load Add
32
Figure 42.6-7. Large Critical Power System — Multiple Generators MV/LV Closed Transition and MV/LV Load Shed/Add MV Complex Utility
33
MV Generators X = Number of Units 34

G1 G2 Gx
Utility 35
Gen Closed Transition
Paralleling and Breaker
Synch Paralleling and 36
MV Generator Bus
Gen
Load Shed/Load Add 37
MV Gen MV
Main Field Installed Main Main
Main
MV Bus A Cable by Contractor MV Bus B 38
Typical Synch & Paralleling
MV Vacuum Closed Transition
Breaker Soft Loading/Unloading 39
Load Shed/Load Add
Closed Transition Closed Transition 40

MV ATS MV ATS
Load Shed/ Load Shed/ 41

Load Add Load Add
Secondary
Main
LV Bus Typical Secondary Substations
42
Typical
LV Breaker 43
Figure 42.6-8. Large Critical Power System — Multiple Generators MV Only Closed Transition and MV/LV Load Shed/Add MV Complex Utility

Home TOC Index June 2006
Sheet 1872
Master TOC
Cat, Caterpillar, its respective logos and “Caterpillar

22 Yellow,” as well as corporate and product identity used
herein, are trademarks of Caterpillar and may not be
used without permission. PowerLynx is a registered
trademark of ISO, The Intelligent Switchgear Organiza-
23 tion. Caterpillar is a registered trademark of Caterpillar
Inc. CSA is a registered trademark of the Canadian
Standards Association. NEMA is the registered
trademark and service mark of the National Electrical
24 Manufacturers Association. Modbus is a registered
trademark of Modicon, a division of Schneider Electric
Industries SA. UL is a federally registered trademark of
Underwriters Laboratories Inc. Uniform Building Code
25 (UBC) is a trademark of the International Conference
of Building Officials (ICBO).
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43

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Cat Generator Paralleling Switchgear 42.

CA08104001E For more information visit: www.EatonElectrical.com

22 Introduction breaker switchgear and Magnum power ■ Data center/data processing.

For more information visit: www.EatonElectrical.com CA08104001E

Generator Set Control Screen

CA08104001E For more information visit: www.EatonElectrical.com

22 Definitions Feeder Breaker Controls: Automation

For more information visit: www.EatonElectrical.com CA08104001E

Standard Configurable EGP Medium Voltage Switchgear 22

CA08104001E For more information visit: www.EatonElectrical.com

22 PowerLynx Technology Features Touchscreen Interface

For more information visit: www.EatonElectrical.com CA08104001E

Table 42.1-1. PowerLynx Control Technology Comparison Integrated Digital Technology

PowerLynx Control Technology PowerLynx 1000 ■ Sophisticated communications abilities. 32

CA08104001E For more information visit: www.EatonElectrical.com

Advanced Communications Remote Communications Communications with Building

For more information visit: www.EatonElectrical.com CA08104001E

56k Modem 56k Modem

CA08104001E For more information visit: www.EatonElectrical.com

HUB or Switch Firewall Device

For more information visit: www.EatonElectrical.com CA08104001E

XLM Product Description ■ Closed transition transfer to

CA08104001E For more information visit: www.EatonElectrical.com

For more information visit: www.EatonElectrical.com CA08104001E

CA08104001E For more information visit: www.EatonElectrical.com

22 XLM Switchgear — One-Line Diagrams

36 800 0 532 800 1600 1600 99.00 44.00 72.00 3300

Figure 42.2-3. XLM1 Switchgear Layout

For more information visit: www.EatonElectrical.com CA08104001E

66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9

Figure 42.2-5. XLM2 Switchgear Layout

CA08104001E For more information visit: www.EatonElectrical.com

3000 1331 2000 3000 3200 3200 84.00 7800

Conduit Space for 22.00-Inch (558.8 mm) Wide Structures —

66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9

Figure 42.2-7. XLM3 Switchgear Layout

For more information visit: www.EatonElectrical.com CA08104001E

Figure 42.2-9. XLM4 Switchgear Layout

CA08104001E For more information visit: www.EatonElectrical.com

Conduit Space for 22.00-Inch (558.8 mm) Wide Structures —

Top or Bottom Entry

66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9

Figure 42.2-11. XLMT4 Switchgear Layout

For more information visit: www.EatonElectrical.com CA08104001E

Table 42.2-1. Typical Control Circuit Wiring — Low Voltage Systems 1

CA08104001E For more information visit: www.EatonElectrical.com

For more information visit: www.EatonElectrical.com CA08104001E

CA08104001E For more information visit: www.EatonElectrical.com

based on the number of generators on line. 3. User-settable Generator Remove Delay

For more information visit: www.EatonElectrical.com CA08104001E

EGP Product Description 22

Figure 42.3-1. EGP3 Switchgear (3-Generator Sources)

CA08104001E For more information visit: www.EatonElectrical.com

For more information visit: www.EatonElectrical.com CA08104001E

Caterpillar EGP Switchgear System Metering Communications

CA08104001E For more information visit: www.EatonElectrical.com

22 EGP2 Switchgear — One-Line Diagrams

36 0 532 800 1600 1600 99.00 66.00 72.00 5000

Conduit Space for 22.00-Inch (558.8 mm) Wide Structures —

Figure 42.3-3. EGP2 Switchgear Layout

For more information visit: www.EatonElectrical.com CA08104001E

ATS Overview Screen ATS Control Screen 41

CA08104001E For more information visit: www.EatonElectrical.com

66.00 (1676.4) 16.00 (406.4) 19.30 (490.2) 9