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Home My WebLink AboutSWP2703693 OPERATION & MAINTENANCE MANUAL I Strander Boulevard Stormwater Pump Station 7350 S. 163rd St Tukwila, WA 98055 City of Renton 09/ 30/ 2014 Contractor: Guy F. Atkinson Construction, LLC 707 S. Grady Way, Ste. 500 Renton, WA 98057 Engineer: Keith R. Woolley City of Renton Transportation 1055 S. Grady Way Renton, WA 98057 • TABLE OF CONTENTS System Tab Volume I FireAlarm System.....................................................................................A Flowmeter (Calibration Kit in blue nylon bag)..............................................B Genset Backup Power Supply.....................................................................0 LevelTransducer.......................................................................................D Pumps......................................................................................................E Valves......................................................................................................F Volume II Mechanical/HVAC......................................................................................A • Motor Control Center (MCC).......................................................................B Plumbing..................................................................................................0 • � �p RTA j ;Inc. 6917 166t" Ave E Sumner, WA 98390 Table of Contents vo4, uM6 Section 1: Specification Section 7-16.31(G); 2.01-Group I Technical Data Package a) Service disconnect switch b) Wiring Diagram Section 2: Specification Section 7-16.31(H); 2.03(P)-Group I Technical Data Package a) Load Bank Instruction Manual b) Wiring Diagram Section 3: Specification Section 7-16.31(3); 2.01-Group I Technical Data Package a) Electrical utility meter enclosure b) Wiring Diagram Section 4: Specification Section 7-16.31(M); 2.01-Group I Technical Data Package a) Pump Station Lighting A1, A2, A3 b) Wiring Diagram Section 5: Specification Section 7-16.31(N); 2.01-Group I Technical Data Package a) Mechanical Control Center b) Transient Voltage Surge Suppressor c) Powermonitor 3000 Display Module d) SMC Flex controller e) Arc Flash Protection f) Series B Ethernet Communications g) Reversing Contactor h) Electronic Digital 6-Digit Counter i) One line Diagrams j) Wiring Diagram Section 6: Specification Section 7-16.31(R ):2.01-Group I Technical Data • Package a) Smoke Detectors b) Intrusion Alarm Switch c) Keyed Switch Box dl) 'Wiring Diagram Section 7: Specification Section 7-16.31(R );2.02-Group I Technical Data Package a) Flood Switches b) Wastewater Level Float Switches c) Submersible Level Transmitter d) Wiring Diagram Section 8: Specification Section 7-16.31(R );2.03-Group I Technical Data Package a) Wall-Mounted Cooling Thermostat b) Wall-Mounted Heating Thermostat c) Wiring Diagram Section 9: Specification Section 7-16.31(T);2.01-Group I Technical Data Package a) Antenna b) Antenna Cable c) Wiring Diagram Section 10: Specification Section 8-20.3(13)A; Group 1 Technical Data Package a) Luminaire Poles b) Wiring Diagram and Location Map Section 11: Specification Section 9-29.10: Group I Technical Data Package a) Roadway Luminaires b) Bridge Mounted Light Fixtures c) Wiring Diagram SK-2/E & SK-4/E Fire Alarm Control Panel • Operating Instructions NORMAL-Only the GREEN A.C.POWER LED is on. PANEL KEY-The key to open the panel can be found at the All other LED's are off. following location: WHEN AUDIBLE DEVICES ARE SOUNDING - FORAN ALARM 1. Evacuate the protected area 2.Notify the monitoring service and/or the Fire Department immediately.Tell them briefly what happened and your current status. Phones: Fire Department Monitoring Service 3. If the Fire Department is responding, be prepared to provide directions to arriving firefighters. FORTROUBLE ONLY 1. Notify the monitoring service and/or Fire department if this panel is connected to either one,and tell them what is happening. 2.Silence audible devices by unlocking and opening the panel and pressing the ACKNOWLEDGE key for a minimum of one second.The yellow SYSTEM TROUBLE LED will remain on.Contact authorized service personnel immediately!(See Below). • WARNING! DO NOT ALLOW TROUBLE CONDITIONS TO REMAIN LOGGED IN THE SYSTEM. THE PROTECTION THE SYSTEM OFFERS HAS BEEN COMPROMISED, OR ELIMINATED WHEN A TROUBLE CONDITION EXISTS. To return to normal after an alarm Manual activation (Fire Drill or otherwise) 1. Do not enter the protected area until safe to do so. Notification Appliance Circuits (NACs) can be activated by 2.Clear all initiating devices. Smoke detectors will not reset activating a Manual Pull Station. if there is still smoke in the area. NOTE:You may want to disconnect municipal box by sliding 3.Reset the control panel(PRESS the RESET key) DISCONNECT switch,located on SK-4XTM module,to its disconnect position(to the right). If a DACT is Power failure or brownout connected, notify the monitoring service before If AC power drops too low or fails,the AC POWER LED will go out, conducting any fire drills or tests. the SYSTEM TROUBLE LED will turn on,the POWER TROUBLE LED will turn on and the panel buzzer and any other audible trouble Alarm Silencing devices will sound. Contact authorized service personnel Notification Appliance Circuits may be silenced by pressing the immediately.See below. ACKNOWLEDGE key and then the ALARM SILENCE key.The ALARM SILENCE LED will turn on.Subsequent alarms will reactivate circuits. Press the RESET key to clear the"silenced" SILENT condition. KNIGHT NOTE:Notification Appliance Circuits may be programmed as nonsilenceable. Also,Signal Silence Inhibit, if enabled,will prevent silencing of NACs for one minute after an alarm (see by Honeywell manual). In the event of trouble, contact the local To test the lamps and piezo sounder authorized Silent Knight Service Representative Press and release the RESET key and check all LEDs.Every LED should be on and the piezo should sound. Name: For more information,refer to the SK-2/E&SK-4/E Manual, Company: Document#52604. It is kept in the following location: • Address: THIS SHEETSHALLBE FRAMED ADJACENT TO Telephone Number: THE CONTROL PANEL Document#52607 Rev.A 08108/05 ECN OS-276 Premier[ow Voltaqe Z Systems by. E-SQUARED S�/STEMS, LLC 1-ire —Security—Card Access — CCTV/ STRANDER BLVD SW 27TH STREET EXTENSION TUKWILA, WASHINGTON FIRE ALARM SYSTEM Equipment Datasheets Battery and Voltage Calculations Certifications Prepared by: E-Squared Systems, LLC PO Box 731227 Puyallup, WA 98373 Ph: 253.284.3707 Fax: 253.284.3714 License: ESQUASL963BR is ZPremier Low Voltage Systems by. i&E- Aff—.547LhqA7A S�/STEMSc LLC —Security— Card IV Table of Contents Tab 1 ..................... Fire Alarm Control Panel Tab 2 ..................... Pull Stations Tab 3 ..................... Smoke Detectors Tab 4 ..................... Notification devices Tab 5 ..................... Transmitter Tab 6 ..................... Battery and Voltage Drop Calculations Tab 7 ..................... Certifications • Premier Low Voltage Systems by., 2 O-E E-SQ1-4QREO SySTEM-5� LLC. P ire —Security— Crd Access — CCTV • TAB 1 FIRE ALARM CONTROL PANEL • 2",* Gamewell Flex Series r FIRE CONTROL INSTRUMENTS GWF402 find GWF404 by Honeywell Two and Four Zone Conventional Description Fire Alarm Control Panels The Flex 402 is a two zone fire alarm control panel(FACP) and the Flex 404 is a four zone FACP. These control pan- els provide reliable fire signaling protection for small to medium-sized retail, office, multi-family, or other similar commercial or institutional buildings. The Initiating Device Circuits (IDCs) for the Flex Series panels are categorized as Class 2 Power-Limited and operate in Class B(Style B). Each panel is compatible with the following types of conventional input devices. • two-wire smoke detectors • water flow devices • four-wire smoke detectors• tamper switches GWF402IG(left)and GWF404(right) • pull stations Features In addition, each panel is compatible with other normally- open con devices. These devices include the System Listed under UL®Standard 864,9th Edition. Sensor i Series microprocessor-based detectors with • Flex 402:Two Class B(Style B)IDC zones,one Class B advanced features like drift compensation, maintenance (Style Y)NACs. • alert and freeze warning. • Flex 404:Four Class B(Style B)IDC zones,two Class B Note: For a listing of compatible devices, refer to the (Style Y)NACs. Device Compatibility Document P/N:52195. • Optional NAC Class A converter module(Flex 404). • Offers the following NAC synchronization and The outputs include one notification appliance circuit programmability features: (NAC) on the Flex 402 and two NACs on the Flex 404. — ADA compliant strobe synchronization. NACs are categorized as Class 2 Power-limited and oper- — ANSI audible signals as required by NFPA 72. ate in Class B (Style Y). Each FACP has a Form-C Alarm — Silence inhibit,auto-silence, non-silenceable. and Trouble relay and 24 VDC special applications resetta- — Selective Silence:mute horns, keep strobes lit. ble power. In addition,the Flex 404 has a Form-C Supervi- — Temporal or steady signal. sory relay and a special application non-resettable power Displays silent or audible walk test from front keypad. output. The FACP supervises wiring, AC voltage and bat- Zone disable,alarm verification selectable per zone. tery level. Includes the following controls: — Acknowledge — Silence The activation of a compatible smoke detector or any nor- — Alarm — Walk Test mally-open fire alarm initiating device will do the following: — Reset — Zone enable/disable • Activate the audible and the visual signaling devices. Contains the following LED indicators: • Illuminate an indicating LED. — Alarm — NAC fault • Sound the piezo sounder at the FACP. — Supervisory — System/Power Trouble • Activate the FACP alarm relay. — Maintenance — Walk Test • Operate any optional modules used to notify a remote — Trouble(one per zone) — Alarm Silence — AC — Charger/Battery/ station. — NAC/Zone Disable Earth Fault(on pcb) • Initiate an auxiliary control function. Provides alarm verification. • Uses a low AC voltage sense,automatic battery charger. • Hasa Piezo sounder for alarm,trouble,and supervisory. SIGNALING MCA i 3'•is a trademark of Honeywell International Inc. uL Approved } ' UL®is a registered trademark of Underwriter's Laboratories Inc. LISTED FDNY: S521 COA-#366-04E 7300 1703:0161 • IS® GAMEWELL-FCI T,"°"" 12 Clintonville Road,Northford,CT 06472-1610 USA•Tel:(203)484-7161 •Fax:(203)484-7118 Specifications are for information only,are not intended for installation purposes,and are subject to change without notice.No responsibility is assumed by Gamewell-FCI for their use. ©2013 Honeywell International Inc. All rights reserved. www.gamewell-fci.com 9021-60292 Rev.D page 1 of 2 Options Specifications Continued P P (Continued) CAC-4 Used to convert Class B(Style B)IDCs to Class A(Style D)and Class B(Style Y) Circuits(NAC)(Continued) NACs to Class A(Style Z). Operating Voltage: Maximum signaling current:2.5 A MountsinFACP.Flex404only. total(5.0 A Flex 404 with an optional XRM-24 Second 100VA transformer for maximum Maximum Line transformer). accessory power. Mounts in FACP. Flex 404 only. Impedance: 1.5 volt drop 4XTMF Transmitter module provides output for the Form-C Relays: Trouble,Alarm local energy municipal box transmitter and (Supervisory, Flex 404) alarm and trouble reverse polarity. Contact Ratings: 2 A @ 30 VAC(resistive) Mounts in FACP. Flex 402&Flex 404. Resettable: Operating voltage: nominal 24 VDC 4XZMF Zone relay module provides Form-C relays: Power: Class 2 Power-Limited circuitry Alarm Zones 1, 2, 3,4,System Alarm, Maximum Trouble. Mounts in FACP. Flex 404 only. Available Current: 500 mA 4XLMF LED interface module supports the Non-resettable: Operating voltage: nominal 24 VDC GWSAN-404 remote annunciator, Power: Class 2 Power-Limited circuitry supervises annunciator wiring for open Maximum conditions.Mounts in FACP. Flex 404 only. Available Current: 500 mA 411 UD Four input/channel,dual line, digital alarm Cabinet Dimensions: communicator/transmitter(DACT). Input/ Door: 15.3"x 14.7'x 0.3" channels are compatible with normally (39 x 37 x 1 cm) open relay contacts,are supervised and Backbox: 15.0"x 14.5'x 3.0" fully programmable. Interfaces with public (38 x 37 x 8 cm) switched telephone networks and compatible with most central station receiv- Ordering Information ers. Flex 404 only. GWF402 Flex 402 conventional FACP,2 zones, • GWSAN-404 Remote annunciator mounts in single-gang 120 VAC, red electrical box, provides LED indication of GWF404 Flex 404 conventional FACP,4 zones, Alarm Zones 1,2, 3,4;and System 120 VAC, red Trouble.Flex 404 only. 71252 EOL resistor,4.71K ohm,'/z watt 52194 Flex 402 and Flex 404 Installation& Specifications Operation Manual AC Power: 120 VAC, 50/60Hz,2.3 A Options: Battery: Max.charging circuit: 27.6 VDC@ CAC-4 Class A converter for initiating device 0.8A Max.charger capacity: 18 Ah cir- (Two 7Ah batteries fit inside the FACP). circuits and notification appliance Initiating Device: Alarm zones 1 &2 cults(cannot be used on Flex 402)). XRM-24 Transformer, expands NAC circuit (Flex 402/Flex 2 power from 3 to 5 amps. Circuits(IDC): Alarm zones 3&4(Flex 404 only) 4XTMF Transmitter module for remote station Operation: All zones Style B(Class B) output or municipal box connection. Power: Class 2 Power-Limited circuitry 4XZMF Relay module,four relays-by-zone, Operating alarm and trouble contacts,24VDC. Voltage: Nominal 20 VDC 4XLMF Remote annunciator driver,24 VDC, Alarm Current: 15 mA minimum supports GWSAN-404. Short Circuit 411 UD Four channel dual slave programmer Current: 40 mA maximum DACT, Form C relay and upload/ Standby Current: 4 mA download capability;with enclosure, Maximum Loop requires PRO-411. Resistance: 100 ohms PRO-411 Programmer, use with 411 LID, Notification: One NAC: Flex 402 411 UDAC. Two NACs:Flex 404 GWSAN-404 LED remote ann unciatorfor Flex404, Circuits(NAC): four alarms,one trouble Operation: Class B(Style Y) (requires 4XLMF). Power: Class 2 Power-Limited circuitry BB-17F Battery box, houses 2 batteries Operating Voltage: Nominal 24 VDC (7-18 Ah max.). • GAMEWELL-FCI \ 12 Clintonville Road,Northford,CT 06472-1610 USA-Tel:(203)484-7161 -Fax:(203)484-7118 9021-60292 Rev.D page 2 of 2 www.gamewell-fci.com P/em%e/•L0w V014,7ge Systems by. • 2 E S0LJA!?EL7 SYSTEMS, LLC Fire —Security — Card Access — CCTV TAB 2 PULL STATIONS • • Gamewell 3 SerigS gelqClorS FIRE CONMOL INSTRUM134T'S by Honeywell Description Intelligent Conventional Smoke Detector Series The System Sensor®,i3 Series smoke detectors represent a significant advancement in conventional detection.The i3 family is founded on three principles: installation ease, intelligence,and instant inspection. ^It 4 The i3 Series redefines installation ease with its plug-in design. This design allows an installer to pre-wire the bases included with the heads. The large wire entry port and the in-line terminals provide ample room to neatly route the wiring inside the base.The base accommodates 41 a variety of backbox mounting methods as well as direct mounting with drywall anchors. To complete the installa- tion,the i3 heads plug-in to the base. The i3 detectors offer a number of intelligent features to simplify testing and maintenance. Drift compensation and i3 smoothing algorithms are standard with the i3 line,to mini- mize nuisance alarms.When the i3 is connected to the fol- lowing,the 2-wire,i3 detectors are capable of generating a remote maintenance signal. Features • 2W-MOD Loop Test/Maintenance Module • i3 ready panel(MS-2 and MS-4)equipped with the i3 • Constructed of built-in remote maintenance signaling protocol and a built-in test switch. The remote maintenance signal indicates when the i3 • Provides drift compensation and smoothing algorithms. required cleaning and it is indicated via an LED located at • Contains a Stop-Drop`N Lock attachment to the base. the module and/or the panel. To read the sensitivity of i3 • Offers simplified sensitivity measurement. detectors, the SENS-RDR is a wireless device that dis- • Includes plug-in detector line-mounting base included. plays the sensitivity in terms of percent per foot obscura- • Has a large wire entry port. tion. • Installs with in-line terminals with SEMS screws. • Mounts to octagonal and single-gang backboxes,4" The i3 Series provide wide angle, red and green LED indi- (10.16 cm)square backboxes,or direct to ceiling. cators that allow you to instantly inspect the following • Designed with a removable detector cover and detector conditions: chamber to simplify cleaning. • normal standby • alarm • Equipped with a wide angle,dual color LED indication. • out-of-sensitivity • freeze trouble condition • Uses loop testing via EZ Walk feature. When the i3 is connected to the 2W-MOD Loop Test/Main- tenance Module or an i3 ready panel(i.e.,MS-2 and MS-4) with the i3 protocol,the EZ Walk loop test feature is avail- able on 2-wire i3 detectors.This feature verifies the initiat- ing loop wiring by providing the LED status indication at each detector. SIGNALING r & FM L� O LISTED GD APPROVED • S4011 3032010 7272-1653:0152 S5512 ISO NO] GAMEWELL-FCI ■ �■■ • 12 Clintonville Road,Northford,CT 06472-1610 USA•Tel:(203)484-7161 •Fax:(203)484-7118 Specifications are for information only,are not intended for installation purposes,and are subject to change without notice.No responsibility is assumed by Gamewell-FCI for their use. ©2013 by Honeywell International Inc. All rights reserved. www.gamewell-fci.com CS-2513 Rev.B page 1 of 2 Specifications Ordering Information Operating Voltage: 12/24 VDC(peak) Part Number Thermal Wiring Alarm Current Standby Current: 2-wire: 50 iA maximum average 2W-B No 2-wire 130 mA max. limited by 4-wire: 50 iA maximum average control panel Maximum Alarm 2WT-B Yes 2-wire 130 mA max. limited by Current: 2-wire: 130 mA limited by control panel control panel 4W-B No 4-wire 20 mA @ 12V, 23mA @24V 4-wire: 20 mA @ 12 V, 4WT-B Yes 4-wire 20 mA @ 12V, 23mA @24V 23 mA @ 24V 2WTA-B Yes 2-wire 130 mA max. limited by Alarm Contact control panel Ratings: 2-wire: n/a 2WTR-B Yes 2-wire 130 mA max. limited by 4-wire:0.5 A @ 30 V AC/DC control panel Operating 4WTA-B Yes 4-wire 35 mA Temperature Range: 4WTR-B Yes 4-wire 35 mA 2W-B and 4W-B: 32°F—120°F(0°C—49°C) 4WTAR-B Yes 4-wire 50 mA 2WT-B and 4WT-B: 32°F—100°F(0°C—37.8°C) 4WITAR-B Yes 4-wire 50 mA Operating Humidity Range: 0%to 95% RH non-condensing Part Number Description Thermal Sensor: 135°F(57.2°C)fixed 2W-MOD 2-wire loop test/maintenance Freeze Trouble: 2WT-B and 4WT-B only: module. 41°F(5°C) SENS-RDR Sensitivity: 2.5%/ft. nominal RT Removal/replacement tool Input Terminals: 14—22 AWG A77-AB2 Retrofit adapter bracket Dimensions CRRS-MODA Reversing relay/synchronization (including base): 5.3 inches(127 mm)diameter, module. 2.0 inches(51 mm)height CSENS-RDRA Sensitivity reader Weight: 6.3 oz.(178 grams) Mounting: 3.5-inch(8.8 cm)octagonal backbox 4-inch(10.16 cm)octagonal backbox. Single-gang back box 4-inch(10.16 cm)square backbox with plaster ring. Direct mount to ceiling. GAMEWELL-FCI • 12 Clintonville Road,Northford,CT 06472-1610 USA•Tel:(203)484-7161 •Fax:(203)484-7118 CS-2513 Rev. B page 2 of 2 www.gamewell-fci.com . Premier Low Voltage Systems by. v2 E-SOUf�REO SySTEM� LLC. Fire —Seu,t i L� — Card Access— CCTV • TAB 3 SMOKE DETECTORS • Gamewell M46=L Series INMILIOMENTS by Honeywell Conventional Fire Alarm Pull Stations Description The Gamewell-FCI M46-L Series is a cost-effective, fea- ture-packed series of non-coded manual fire alarm pull sta- tions. It was designed to meet multiple applications used by the installer and end-user. The M46-L Series features a P ILL DOWN variety of models including single-and dual-action versions. The M46-L Series provides conventional Fire Alarm Con- trol Panels (FACPs), such as the Flex 400 Series with an alarm initiating input signal. Its innovative design, durable Fu construction, and multiple mounting options make the M46-L Series simple to install, maintain, and operate. N146-L Series Operation Features The M46-L manual pull stations provide a textured finger- hold area that includes Braille text. In addition, the terms • PUSH-IN and PULL-DOWN are labeled on the station han- Compact, aesthetic design, highly visible color, dle, and down arrows are engraved to show the direction attractive contoured shape, and light textured finish. to operate the station handle. Meets with ADA 5 lb. maximum pull force. • Complies with UL®Standard 38,for manually acuated To activate the normally open alarm switch, push-in and signaling boxes. then pull down on the handle. When the handle is latched Easily operated(single-or dual-action),yet designed to in the down position, the word "ACTIVATED," appears in prevent false alarms when bumped, shaken, or jarred. bright yellow at the top of the handle. Push In/Pull Down handle latches in the down position To reset the station,do the following: to clearly indicate the station was operated. 1. Insert the key or hex(model dependent). • The word,"Activated,"appears in bright yellow on top of 2. Twist clockwise,one quarter-turn. the handle, indicating the station was operated,and the 3. Open the station's front cover, causing the spring- operation of the station loaded operation handle to return to its original • Operation handle engraved with white,down arrows to position. show the direction to pull the handle. 4. To reset the alarm switch to normal(non-alarm), • Braille text imprinted on the finger-hold area of the oper- manually position or close the station's front cover. ation handle and across the top of the handle The switch is automatically reset. • Multiple hex-and key-lock models available • U.S. patent pending hex-lock needs only a quarter- Construction turn to lock/unlock • Cover,backplate and operation handle are all molded of • Station can be opened for inspection&maintenance durable polycarbonate material. without initiating an alarm • Cover features white lettering and trim. • Product ID label is visible when opening the cover;label • Red color matches System Sensor's popular is made of a durable long-life material • The terms, "Normal"and"Activated,"are molded into SpectrAleO Horn/Strobe Series. the plastic adjacent to the alarm switch(located inside) SpectrAlert®is a trademark of Honeywell International Inc. An ISO 9000-2000 Company SIGNALING UL®is a registered trademark of Underwriter's Laboratories Inc. �L Lexan®is a registered trademark of GE Plastics,a subsidiary of General Electric Company. SLED GAMEWELL-FCI • 12 Clintonville Road,Northford,CT 06472-1610 USA•Tel:(203)484-7161 •Fax:(203)484-7118 Specifications are for information only,are not intended for installation purposes,and are subject to change without notice.No responsibility is assumed by Gamewell-FCI for their use. ©2008 by Honeywell International Inc. All rights reserved. www.gamewell-fci.com CS-2483 Rev.A page 1 of 2 i Engineer's Specifications Features (Continued) Manual Fire Alarm Stations shall be non-code, with a key- Four-position terminal strip molded into backplate. or hex-operated reset lock in order that they may be Terminal strip includes Phillips combination-head cap- tested. and so designed that after actual emergency oper- tive 8/32 screws for easy connection to Initiating Device ation, they cannot be restored to normal except by use of a Circuit(IDC). key or hex. An operated station shall automatically condi- Terminal screws backed-out at factory and shipped tion itself so as to be visually detected as activated ready to accept field wiring (up to 12 AWG/3.25 mm'). • Switch contacts are normally open. Manual stations shall be constructed of red colored Can be surface-mounted (with SB-1/0)or semi-flush LEXAN® (or polycarbonate equivalent) with clearly visible mounted. Semi-flush mount to a standard single-gang, operating instructions provided on the cover. The word, double-gang, or 4'(10.16 cm)square electrical box. FIRE. shall appear on the front of the stations in white let- Backplate is large enough to overlap a single-gang ters, 1.00 inches(2.54 cm)or larger. Stations shall be suit- backbox cutout by 1/2" (1.27 cm). able for the following: Optional trim ring (BG-TR). • surface mounting on matching backbox SB-1/0 Models packaged in attractive.. clear plastic(PVC), • semi-flush mounting on a standard single-gang,double- clamshell-style, packages. Packaging includes a cut- gang, or 4.0" (10.16 cm)square electrical box. away dust/paint cover in shape of pull station. The stations shall be installed in compliance with the Americans with Disabilities Act(ADA)or per national and local requirements. Manual stations shall be Listed with Underwriters' Laboratories. Specifications Ordering Information Electrical Specifications: Part Number Description Switch M46-SL Manual pull station, single with key. • Contact Ratings: Gold-plated. M46-DL Manual pull station, dual with key. rated 0.25 A @ 30 VAC or VDC. M46-OL Manual pull station,on door with key,no Auxiliary backbox. Contact Circuit: (Terminals 3&4, NBG-12LA) M46-OLB Manual pull station, on door with key rated to 3.0 @ 30 VAC or VDC. and backbox. SB-10 Surface backbox. Physical Specifications: Model Dimensions M46-L 5.5" H x 4.12"W x 1.4" D (13.97 H x 10.47 W x 3.5 D cm) SB-10 5.5" H x 4.3"W x 1.4" D (13.97 H x 10.47 W x 3.5 D cm) WP-10 6" H x 4.7"W x 2" D (15.24Hx 11.9 Wx5.08cm) • GAMEWELL-FCI 12 Clintonville Road, Northford,CT 06472-1610 USA•Tel:(203)484-7161 •Fax:(203)484-7118 CS-2483 Rev.A page 2 of 2 www.gamewell-fci.com Premier Low V01t,7ge Systems by. E-SQUARED SYSTEMS, LL_C. Fire —Security—Card Access— L, . TAB 4 • NOTIFICATION DEVICES • SYSTEM SENSORp� Outdoor Selectable- Output Horns, Strobes, and Horn Strobes for Wall Applications SPECTRIert SpectrAlertO Advance outdoor audible visible products 41 n v �► N c E are rich with features that cut installation times and maximize profits. Features SpectrAlert Advance offers the broadest line of outdoor horns, • Weatherproof per NEMA• 4X,IP56 strobes,and horn strobes in the industry.With white or red plastic housings,wall or ceiling mounting options,and plain or FIRE-printed • Listed to UL 1638(strobe)and UL 464(horn) devices,SpectrAlert Advance can meet virtually any application • Compatible with System Sensor synchronization protocol and requirement,including indoor,outdoor,wet,and dry applications in legacy SpectrAlert products temperatures from—40°F to 151°F. • Field-selectable candela settings: 15, 15r75,30,75,95, 110,115, Like the entire SpectrAlert Advance line,outdoor horns,strobes, 135, 150, 177,and 185 and horn strobes for wall applications include a variety of features • Automatic selection of 12-or 24-volt operation at 15 and that increase application flexibility and simplify installation.First, 15r75 candela field-selectable settings,including candela,automatic selection of • Rotary switch for horn tone and three volume selections 12-or 24-volt operation,horn tones,and three volume options enable • Horn rated at 88+dBA at 16 volts installers to easily adapt devices to meet requirements. • Rated from—40°F to 151°F Next,SpectrAlert Advance devices use a universal mounting plate • Universal mounting plate with an onboard shorting spring that for both wall and ceiling applications.This mounting plate includes tests wiring continuity before devices are installed an onboard shorting spring that ensures wiring continuity before • Plug-in design with minimal intrusion into the back box devices are installed,so installers can verify proper wiring without mounting the devices and exposing them to potential construction • Tamper-resistant construction damage.Once the plates are mounted,all SpectrAlert Advance • Listed for ceiling or wall mounting devices utilize a plug-in design with a single captured screw to speed installation and virtually eliminate costly ground faults. Outdoor devices ship with weatherproof plastic back boxes(metal back boxes are available separately)that accommodate in-and- Agency Listings out wiring for daisy chaining devices.Plastic back boxes feature removable side flanges and improved resistance to saltwater SMwNG corrosion.Knock-outs located on the back eliminate the need to drill U holes for screw-in mounting.Plastic and metal weatherproof back U� boxes come with 3/4-inch top and bottom conduit entries and 3A-inch • F M A "25-1653'88(horn strobes.br°bes) 54011(I.ISTEU strobes.horns) AM•OVED approved 7t251r 3'ea(horn sstrbey. knock-outs at the back.Ascrew-in NPT plug with an 0-ring gasket chime strobes) S3593(outdoor and alert strobes) 3C23572 MEA452-05-E 71351653::89(horns,chimes) for a watertight seal is included with each back box. SpectrAlert Advance Outdoor Horn, Strobe, and Horn Strobe Specifications • ArchitecVEngineer Specifications General SpectrAlert Advance outdoor horns,strobes,and horn strobes shall mount to a weatherproof back box.A universal mounting plate shall be used for mounting ceiling and wall products.The notification appliance circuit wiring shall terminate at the universal mounting plate. Also,SpectrAlert Advance products.when used with the Sync•Circuif'Module accessory,shall be powered from a non-coded notification appliance circuit output and shall operate on a nominal 12 or 24 volts.When used with the Sync•Circuit Module,12-volt-rated notification appliance circuit outputs shall operate between 9 and 17.5 volts;24-volt-rated notification appliance circuit outputs shall operate between 17 and 33 volts.Outdoor SpectrAlert Advance products shall operate between-40 and 151 degrees Fahrenheit from a regulated DC or full-wave rectified unfiltered power supply.Strobes and horn strobes shall have field-selectable candela settings including 15,15/75,30,75,95,110, 115,135, 150,177,and 185. Strove The strobe shall be a System Sensor SpectrAlert Advance Model listed to UL 1971 and shall be approved for fire protective service. The strobe shall be wired as a primary-signaling notification appliance and comply with the Americans with Disabilities Act requirements for visible signaling appliances,flashing at 1 Hz over the strobe's entire operating voltage range.The strobe light shall consist of a xenon flash tube and associated lens/reflector system.The strobe must be installed with its weatherproof back box in order to remain outdoor approved per UL.The strobe shall be suitable for use in wet environments. Horn Strobe Combination The horn strobe shall be a System Sensor SpectrAlert Advance Model listed to UL 1971 and UL 464 and shall be approved for fire protective service.The horn strobe shall be wired as a primary-signaling notification appliance and comply with the Americans with Disabilities Act requirements for visible signaling appliances,flashing at 1 Hz over the strobe's entire operating voltage range.The strobe light shall consist of a xenon flash tube and associated lens/reflector system.The horn shall have three audibility options and an option to switch between a temporal three pattern and a non-temporal(continuous)pattern.These options shall be set by a multiple position switch. On four-wire products,the strobe shall be powered independently of the sounder.The horn or horn strobe models shall operate on a coded or non-coded power supply.The horn strobe must be installed with its weatherproof back box in order to remain outdoor approved per UL. The horn strobe shall be suitable for use in wet environments. Physical/Electrical Specifications Operating Temperature -40°F to 151°F(-40°C to 66°C) Strobe Flash Rate 1 flash per second • Nominal Voltage Regulated 12 DC/FWR or regulated 24 DC/FWR1 Operating Voltage Rangez 8 to 17.5 V(12 V nominal)or 16 to 33 V(24 V nominal) Input Terminal Wire Gauge 12 to 18 AWG Wall-Mount Dimensions(including lens) 5.6-L x 4.7"W x 2.5-D(142 mm L x 119 mm W x 64 mm D) Horn Dimensions 5.6-L x 4.7-W x 1.3-D(142 mm L x 119 mm W x 33 mm D) Wall-Mount Weatherproof Back Box Dimensions(SA-WBB) 5.7"L x 5.1"W x 2.0"D(145 mm L x 130 mm W x 51 mm D) Notes: 1.Full Wave Rectified(FWR)voltage is a non-regulated,time-varying power source that is used on some power supply and panel outputs. 2.P,S,PC,and SC products will operate at 12 V nominal only for 15 and 15/75 cd. • AVDS01201 • UL Current Draw Data UL Max.Strobe Current Draw(mA RMS) UL Max.Horn Current • 8-17.5 Volts 16-33 Volts 8-17.5 Volts 16-33 Volts Candela DC FWR DC FWR Sound Pattem dB DC FWR DC FWR Standard 15 123 128 66 71 Temporal High 57 55 69 75 Candela 15/75 142 148 77 81 Temporal Medium 44 49 58 69 Range 30 NA NA 94 96 Temporal Low 38 44 44 48 75 NA NA 158 153 Non-Temporal High 57 56 69 75 95 NA NA 181 176 Non-Temporal Medium 42 50 60 69 110 NA NA 202 195 Non-Temporal Low 41 44 50 50 115 NA NA 210 205 Coded High 57 55 69 75 High 135 NA NA 228 207 Coded Medium 44 51 56 69 Candela 150 NA NA 246 220 Coded Low 40 46 52 50 Range 177 NA NA 281 251 185 NA NA 286 258 UIL Max.Current Draw(rnA RMS),2-Wire Horn Strobe,Standard Candela Range(15-115 cd) 8-17.5 Volts 16-33 Volts DC Input 15 15175 15 15l75 30 75 95 110 115 Temporal High 137 147 79 90 107 176 194 212 218 Temporal Medium 132 144 69 80 97 157 182 201 210 Temporal Low 132 143 66 77 93 154 179 198 207 Non-Temporal High 141 152 91 100 116 176 201 221 229 Non-Temporal Medium 133 145 75 85 102 163 187 207 216 Non-Temporal Low 131 144 68 79 96 156 182 201 210 FWR Input Temporal High 136 155 88 97 112 168 190 210 218 Temporal Medium 129 152 78 88 103 160 184 202 206 Temporal Low 129 151 76 86 101 160 184 194 201 Non-Temporal High 142 161 103 112 126 181 203 221 229 Non-Temporal Medium 134 155 85 95 110 166 189 208 216 Non-Temporal Low 132 154 80 90 105 161 184 202 211 UL Max.Current Draw(mA RMS),2-Wire Horn Strobe,High Candela Range(135-185 cd) 16-33 Volts 16-33 Volts DC Input 135 150 177 185 FWR Input 135 150 177 185 Temporal High 245 259 290 297 Temporal High 215 231 258 265 Temporal Medium 235 253 288 297 Temporal Medium 209 224 250 258 Temporal Low 232 251 282 292 Temporal Low 207 221 248 256 Non-Temporal High 255 270 303 309 Non-Temporal High 233 248 275 281 Non-Temporal Medium 242 259 293 299 Non-Temporal Medium 219 232 262 267 Non-Temporal Low 238 254 291 295 Non-Temporal Low 214 229 256 262 Candela Derating Horn Tones and Sound Output Data For K series products used at low temperatures,listed Horn and Horn Strobe Output candela ratings must be reduced in accordance with •8-.17.5 16-33 24-Volt Nominal this table. Switch Sound Volts Volts Reverberant Anechoic Strobe Output(cd) Position Pattern dB DC FWR DC FWR DC FWR DC FWR Listed Candela Candela rating at-40°F Temporal High 78 78 84 84 88 88 99 98 15 2 Temporal Medium 74 74 80 80 86 86 96 96 15175 Do not use below 32°F 3 Temporal Low 71 73 76 76 83 80 94 89 30 4 Non- High 75 44 Temporal 82 82 88 88 93 92 100 100 95 70 5 Non- Medium 78 78 85 85 90 90 98 98 110 110 Temporal 115 115 6 Non- Low 75 75 81 81 88 84 96 92 135 135 Temporal • 150 150 7t Coded High 82 82 88 88 93 92 101 101 177 177 St Coded Medium 78 78 85 85 90 90 97 98 185 1185 9t Coded Low 75 75 81 81 88 85 96 92 tSettings 7,8,and 9 are not available on 2-wire horn strobe. AVD601201 SpectrAlert Advance Diagrams . 4.7" 2.5" 5.6- O 0 Wall-Mount Horn Strobes ® ® Wall Plastic Weatherproof Back Box l� Wall-Mount Horn Strobe with Plastic Weatherproof Back Box SpectrAlert Advance Ordering Information i Model Description Wall Horn Strobes _ P2RK't 2-Wire Horn Strobe,Standard cd,Red,Outdoor(includes plastic weatherproof back box) P2RHK*t 2-Wire Horn Strobe,High cd,Red,Outdoor(includes plastic weatherproof back box) P2WK*t 2-Wire Horn Strobe,Standard cd,White,Outdoor(includes plastic weatherproof back box) P2WHK*t 2-Wire Horn Strobe,High cd,White,Outdoor(includes plastic weatherproof back box) P4RKt 4-Wire Horn Strobe,Standard cd,Red,Outdoor(includes plastic weatherproof back box) P4WK 4-Wire Horn Strobe,Standard cd,White,Outdoor(includes plastic weatherproof back box) P2RHK-120 2-Wire Horn Strobe,High cd,Red,Outdoor,120 V(includes plastic weatherproof back box) Wall Strobes SRK*t Strobe,Standard cd,Red,Outdoor(includes plastic weatherproof back box) SRHK*t Strobe,High cd,Red,Outdoor(includes plastic weatherproof back box) SWK*t Strobe,Standard cd,White,Outdoor(includes plastic weatherproof back box) SWHK*t Strobe,High cd,White,Outdoor(includes plastic weatherproof back box) Horns HRKt Horn,Red,Outdoor(includes plastic weatherproof back box) Accessories SA-WBB Red,Metal Weatherproof Back Box SA-WBBW White,Metal Weatherproof Back Box Notes: 'Add%P"to model number for plain housing(no"FIRE"marking on cover),e.g.,P2RK-P. t Add%R"to model number for weatherproof replacement device(no back box included),only for use with weatherproof outdoor flush mounting plate,WTP and WTPW. "Standard cd"refers to strobes that include 15.15l75.30,75.95,110.and 115 candela settings."High cd"refers to strobes that include 135,150,177,and 185 candela settings When replacing standard outdoor units both the device and back box must be replaced. SYSTEM ®,1018 System Sensor. l SENSOR hone Ohio Avenue Charles, Product prooanssub�em, ange ftouesUce.Vstrystemsensnet. Phone:BOO-SENSOR2•Fax:630 377-6495 nc rren!poc chn'o ma;:on,DS012inducing-elates,ve son ns daas eet. nvosa,zap•3112 SYSTEM SENSOR" _ F ,;�� F Indoor Selectable- E `jR Output Horns, Strobes, and Horn Strobes for - Wall Applications SpectrAlerp Advance audible visible notification products SPECTRIert are rich with features guaranteed to cut installation times p v a N c E and maximize profits. Features The SpectrAlert Advance series offers the most versatile and easy-to-use line of horns,strobes,and horn strobes in the industry. • • Plug-in design with minimal intrusion into the back box With white and red plastic housings,wall and ceiling mounting • Tamper-resistant construction options,and plain and FIRE-printed devices,SpectrAlert Advance • Automatic selection of 12-or 24-volt operation at can meet virtually any application requirement. 15 and 15175 candela • Field-selectable candela settings on wall units: 15, 15r/5, Like the entire SpectrAlert Advance product line,wall-mount horns, 30,75,95, 110, 115, 135, 150, 177,and 185 strobes,and horn strobes include a variety of features that increase their application versatility while simplifying installation.All devices • Horn rated at 88+dBA at 16 volts feature plug-in designs with minimal intrusion into the back box, • Rotary switch for horn tone and three volume selections making installations fast and foolproof while virtually eliminating • Universal mounting plate for wall units costly and time-consuming ground faults. • Mounting plate shorting spring checks wiring continuity before To further simplify installation and protect devices from construction device installation damage,SpectrAlert Advance utilizes a universal mounting plate • Electrically Compatible with legacy SpectrAlert devices with an onboard shorting spring,so installers can test wiring • Compatible with MDL3 sync module continuity before the device is installed. • Listed for ceiling or wall mounting Installers can also easily adapt devices to a suit a wide range of application requirements using field-selectable candela settings, automatic selection of 12-or 24-volt operation,and a rotary switch for horn tones with three volume selections. Agency Listings SIGNALING & <FM > MEA • approved 7125'1653.186(indoor strobes) LISTED APPROVED PP 7125-1653188(horn strobes, 54011(chimes,roe^ vDoes,horns) 3023572 MEA452-05-E chime strobes) S5512(strobes) 7135-1653.189(horns,chimes) SpectrAlert Advance Specifications Specifications SpectrAlert Advance horns,strobes,and horn strobes shall mount to a standard 4 x 4 x 1'/2-inch back box,4-inch octagon back box,or double-gang back box.Two-wire products shall also mount to a single-gang 2 x 4 x 17i8-inch back box.A universal mounting plate shall be used for mounting ceiling and wall products.The notification appliance circuit wiring shall terminate at the universal mounting plate. Also,SpectrAlert Advance products,when used with the Sync•Circuif'Module accessory,shall be powered from a non-coded notification appliance circuit output and shall operate on a nominal 12 or 24 volts.When used with the Sync•Circuit Module,12-volt-rated notification appliance circuit outputs shall operate between 8.5 and 17.5 volts;24-volt-rated notification appliance circuit outputs shall operate between 16.5 and 33 volts.Indoor SpectrAlert Advance products shall operate between 32 and 120 degrees Fahrenheit from a regulated DC or full- wave rectified unfiltered power supply.Strobes and horn strobes shall have field-selectable candela settings including 15,15/75,30,75,95: 110,115, 135,150,177,and 185. Strobe The strobe shall be a System Sensor SpectrAlert Advance Model listed to UL 1971 and shall be approved for fire protective service. The strobe shall be wired as a primary-signaling notification appliance and comply with the Americans with Disabilities Act requirements for visible signaling appliances,flashing at 1 Hz over the strobe's entire operating voltage range.The strobe light shall consist of a xenon flash tube and associated lens/reflector system. Horn Strobe Combination The horn strobe shall be a System Sensor SpectrAlert Advance Model listed to UL 1971 and UL 464 and shall be approved for fire protective service.The horn strobe shall be wired as a primary-signaling notification appliance and comply with the Americans with Disabilities Act requirements for visible signaling appliances,flashing at 1 Hz over the strobe's entire operating voltage range.The strobe light shall consist of a xenon flash tube and associated lens/reflector system.The horn shall have three audibility options and an option to switch between a temporal three pattern and a non-temporal(continuous)pattern.These options are set by a multiple position switch.On four-wire products,the strobe shall be powered independently of the sounder.The horn on horn strobe models shall operate on a coded or non-coded power supply. Synchronization Module The module shall be a System Sensor SynceCircuit model MDL3 listed to UL 464 and shall be approved for fire protective service.The module shall synchronize SpectrAlert strobes at 1 Hz and horns at temporal three.Also,while operating the strobes,the module shall silence the horns on horn strobe models over a single pair of wires.The module shall mount to a 411/16 x 411/16 x 21i8-inch back box.The module shall also control two Style Y(class B)circuits or one Style Z(class A)circuit.The module shall synchronize multiple zones.Daisy chaining two or more • synchronization modules together will synchronize all the zones they control.The module shall not operate on a coded power supply. Physical/Electrical Specifications Standard Operating Temperature 32°F to 120°F(0°C to 49°C) Humidity Range 10 to 93%non-condensing Strobe Flash Rate 1 flash per second Nominal Voltage Regulated 12 DC/FWR or regulated 24 DC/FWR' Operating Voltage Range 8 to 17.5 V(12 V nominal)or 16 to 33 V(24 V nominal) Operating Voltage Range MDL3 Sync Module 8.5 to 17.5 V(12 V nominal)or 16.5 to 33 V(24 V nominal) Input Terminal Wire Gauge 12 to 18 AWG Wall-Mount Dimensions(including lens) 5.6"L x 4.7"W x 2.5-D(142 mm L x 119 mm W x 64 mm D) Horn Dimensions 5.6-L x 4.7-W x 1.3-D(142 mm L x 119 mm W x 33 mm D) Wall-Mount Trim Ring Dimensions(sold as a 5 pack)(TR-HS) 5.7-L x 4.8"W x 0.35"D(145 mm L x 122 mm W x 9 mm D) Notes: 1.Full Wave Rectified(FWR)voltage is a non-regulated,time-varying power source that is used on some power supply and panel outputs. 2.P,S,PC,and SC products will operate at 12 V nominal only for 15 and 15/75 cd. • . UL Current Draw Data UL Max.Strobe Current Draw(mA RMS) UL Max.Horn Current Draw(mA RMS) 8-17.5 Volts 16-33 Volts 8-17.5 Volts 16-33 Volts Candela DC FWR DC FWR Sound Pattern dB DC FWR DC FWR Standard 15 123 128 66 71 Temporal High 57 55 69 75 Candela 15/75 142 148 77 81 Temporal Medium 44 49 58 69 Range 30 NA NA 94 96 Temporal Low 38 44 44 48 75 NA NA 158 153 Non-temporal High 57 56 69 75 95 NA NA 181 176 Non-temporal Medium 42 50 60 69 110 NA NA 202 195 Non-temporal Low 41 44 50 50 115 NA NA 210 205 Coded High 57 55 69 75 High 135 NA NA 228 207 Coded Medium 44 51 56 69 Candela 150 NA NA 246 220 Coded Low 40 46 52 50 Range 177 NA NA 281 251 185 NA NA 286 258 i UL Max,Current Draw(rnA RMS).2-Wire Horn Strobe.Standard Candela Range(15-115 cd) 8-17.5 Volts 16-33 Volts DC Input 15 15/75 15 15175 30 75 95 110 115 Temporal High 137 147 79 90 107 176 194 212 218 Temporal Medium 132 144 69 80 97 157 182 201 210 Temporal Low 132 143 66 77 93 154 179 198 207 Non-Temporal High 141 152 91 100 116 176 201 221 229 Non-Temporal Medium 133 145 75 85 102 163 187 207 216 Non-Temporal Low 131 144 68 79 96 156 182 201 210 FWR Input Temporal High 136 155 88 97 112 168 190 210 218 Temporal Medium 129 152 78 88 103 160 184 202 206 • Temporal Low 129 151 76 86 101 160 184 194 201 Non-Temporal High 142 161 103 112 126 181 203 221 229 Non-Temporal Medium 134 155 85 95 110 166 189 208 216 Non-Temporal Low 132 154 80 90 105 161 184 202 211 UL Max.Current Draw(mA RMS).2-Wire Horn Strobe,High Candela Range(135-185 cd) 16-33 Volts 16-3 Volts DC Input 135 150 177 185 FWR Input 135 150 177 185 Temporal High 245 259 290 297 Temporal High 215 231 258 265 Temporal Medium 235 253 288 297 Temporal Medium 209 224 250 258 Temporal Low 232 251 282 292 Temporal Low 207 221 248 256 Non-Temporal High 255 270 303 309 Non-Temporal High 233 248 275 281 Non-Temporal Medium 242 259 293 299 Non-Temporal Medium 219 232 262 267 Non-Temporal Low 238 254 291 295 Non-Temporal Low 214 229 256 262 Horn Tones and Sound Output Data StrobeHorn and Horn • .: 8--17.5 16-33 24-Volt Nominal Switch Volts Volts Reverberant Anechoic Position Sound Pattern dB DC FWR DC FWR DC FWR DC FWR 1 Temporal High 78 78 84 84 88 88 99 98 2 Temporal Medium 75 75 80 80 86 86 96 96 3 Temporal Low 71 71 76 76 83 80 94 89 4 Non-Temporal High 82 82 88 88 93 92 100 100 5 Non-Temporal Medium 78 78 85 85 90 90 98 98 6 Non-Temporal Low 73 74 81 81 88 84 96 92 7t Coded High 82 82 88 88 93 92 101 101 • 8t Coded Medium 78 78 85 85 90 90 97 98 9t Coded Low 74 75 81 81 88 85 96 92 tSettings 7,8,and 9 are not available on 2-wire horn strobes. SpectrAlert Advance Dimensions • 14 4.7" 2.5" Wall-mount horn strobes SpectrAlert Advance Ordering Information • DescriptionModel Description Model Wall Hom Strobes Wall Strobes(cont.) P2R 2-Wire Horn Strobe,Standard cd,Red SRH Strobe,High cd,Red P2R-P 2-Wire Horn Strobe,Standard cd,Red,Plain SRH-P Strobe,High cd,Red,Plain P2R-SP 2-Wire Horn Strobe,Standard cd,Red,"FUEGO" SRH-SP Strobe,High cd,Red,"FUEGO" P2RH 2-Wire Horn Strobe,High cd,Red SW Strobe,Standard cd,White P2RH-P 2-Wire Horn Strobe,High cd,Red,Plain SW-P Strobe,Standard cd,White,Plain P2W 2-Wire Horn Strobe,Standard cd,White SWH Strobe,High cd,White P2W-P 2-Wire Horn Strobe,Standard cd,White,Plain SWH-P Strobe,High cd,White,Plain P2WH 2-Wire Horn Strobe,High cd,White Home P2WH-P 2-Wire Horn Strobe,High cd,White,Plain HR Horn,Red P4R 4-Wire Horn Strobe,Standard cd,Red HW Horn,White P4R-P 4-Wire Horn Strobe,Standard cd,Red,Plain Accessories P4RH 4-Wire Horn Strobe,High cd,Red TR-HS Trim Ring,Wall,Red P4W 4-Wire Horn Strobe,Standard cd,White SBBR Indoor Surface Mount Back Box,Red Wall Strobes SBBW Indoor Surface Mount Back Box,White SR Strobe,Standard cd,Red SR-P Strobe,Standard cd,Red,Plain SR-SP Strobe,Standard cd,Red,"FUEGO" Notes: All-P models have a plain housing(no"FIRE"marking on cover) All-SP models have"FUEGO"marking on cover "Standard cd"refers to strobes that include 15,15/75,30,75,95,110,and 115 candela settings. "High cd"refers to strobes that include 135,150,177,and 185 candela settings. SYSTEM 3825 Ohio Avenue•St.Charles, IL 60174 02014 system sensor • ``` .7 �1/� Phone:BOG-SENSOR2•Fax:630-377-6495 Product specincatims sublet:to change wthout nonce.Visa systemsensw.,:am �� SENSOR y o current product in o mafion,DS102 1 he fates ve s on of his data sheet. www.systemsensor.com nvos,o2o,•,na ZPremier Low Volt,7qe Systems by. E-SQUfQREO SYSTEMS, LLC Fire —Security— Card Access — CCTV TAB S TRANSMITTER i CELLULAR ALARM TG-7FS COMMUNICATOR FOR 3G/4G NETWORKS TELGUARD COMMERCIAL FIRE PRODUCT FEATURES Meets UL 864 requirements for sole, primary or backup path communications. Provides RMR protection by leveraging technology that operates on 3G/4G networks. r- Supports listen-in, two-way voice verification over cellular. F Minimizes false alarms by providing dual paths for self-tests. Falls back to 2G (GSM) if a 3G/4G network isn't available. The Telguard TG-7FS is the ideal cellular alarm communications solution for commercial fire systems. The TG-7FS transmits alarm signals from the fire panel over the digital cellular network to the designated monitoring station. Compliant with the 2013 Edition of NFPA 72, the TG-7FS can serve as the sole communications path for the fire alarm system. It replaces all of the landlines currently dedicated to the master control unit. On i average, cellular monitoring costs the end user significantly less than a dedicated landline. For each landline replaced with a TG-7FS, the monthly communications bill decreases. By being able to signal failures to the central station within sixty minutes of an outage, the TG-7FS can be installed as the sole path for commercial fire installations. For existing installations, all landlines can be swapped for a single TG-7FS because of the new sixty minute supervision mode. The TG-7FS can also be installed as a backup path and upgraded to sole path at a later date. Telguard Online Telguard Cellular Service Advanced Reliability Telguard makes adopting cellular Telguard Cellular Service provides Features the ability to utilize easy with a secure Internet portal. nationwide digital cellular network multiple cellular technologies to The straightforward web interface coverage for all Telguard units. increase availability and reduce allows security dealers and central Telguard's Communication Center false alarms. stations to quickly and efficiently is JUL compliant and provides Automatic self-tests with central access Telguard based services 24/7. seamless connectivity between the station notification ensure the This advanced tool has multi-level alarm panel,the Telguard family cellular system is operating. user authorization and provides of products and the central station. Available relay output for tripping total account management of Telguard Technical Support provides • UL Listed Telguard cellular alarm a single point of contact for both the alarm control panel when a communicators. cellular service and Telguard product trouble condition occurs. questions. Add ATA CELLULAR ALARM TG-7FS COMMUNICATOR FOR 3G/4G NETWORKS TELGUARD Power • Transmit power:1.0W-2.OW Ea (maximum allowable). • Power Consumption: 60mA(Standby) �1 250mA(Transmission). - • Transformer: 12VAC, 800mA UL listed plug-in. Telguard technology allows full data reporting for unlimited point-to-point signal details and maximum transmitting power for Radio Transceiver superior in-building penetration. • 3G cellular radio. • GSM 850MHz: Class 4(2 watts). Telguard products are easy to install, economical, and UL Listed. • GSM 1900MHz: Class 10 watt). • UMTS WCDMA FDD 850/1900MHz. Accessories • Antenna:9"dipole with 2dBi gain, • ACD 12, ACD 35, ACD 50, ACD 100: 12 ft of cable and universal mounting 12/35/50/100 feet of low loss, high performance cable. bracket. • HGD-0: High gain directional antenna. • FCC part 15,22,24 and 68 compliant. • EXD-0: External antenna. Physical Details • TG-7FS: 7.5" H x 11.5"W x 3.5" D. • Shipping Weight: 8lbs. • Operating Environment: 0°C to+50°C;up to 95%humidity (non-condensing). UL Listings Standard Features Commercial Fire Commercial Burglary Residential 864 • Control units& 365 Police Station 985 • Household fire • Full data reporting. accessories for fire connected burglar warning systems • Automatic self-test(60 min.&daily alarm systems alarm units and systems • Power supply with battery harness. 1610 • Central station burglar • Locking, red metal enclosure. alarm units; • Two programmable supervisory Line security servcies trip outputs. --,1 the most current product specifications and UL Listings visit www.Teiguard.com. • Alarm format support for SIA2, Contact ID, pulse(3x1,4x2), modem Ile,&Illaz, DMP. �� U ` / • Telephone line monitor built-in, ` `Ic / E gSECURITY f is LISTED °•a �w ASSOCIATELECTRONICION with Standard Line Security. NFPA INTERNATIONAL Telguard,a Division of Telular Corporation•Cumberland Center IV•3225 Cumberland Blvd•Suite 300•Atlanta.GA 30339•USA 800-229-2326.Option 5•www.Telguard.com •Copyright s2012 Telular Corporation•All Rights Reserved Premier Low voltage Systems by. Z _-_- E-SQUF�REO Ste-/STEMS, LL C. Fire —Security— Card Access—CCTV T,9 B 6 • BATTERY AND VOLTAGE DROP CALCULATIONS • Garr��e�iweN System Current Draw • �� GWF402 Fire Alarm Control Panel by H-yw" Total Standby 0.080 A Total Alarm 0.404 A Standby Device Qt Draw Standby Qty rDraw"7' Alarm 1.System Main Circuit Board LO x 0.08000 0.08000 1 x 0.11200 0.11200 4XTMF x 0,00500 0 x 0.01100 411 x 0.07800 0 x 0.24000 411UD x 0.10000 0 x 0.30000 2.Resettable Power 2-Wire Detector Heads 1 x 0.00000 0.00000 1 x 0,00000 0.00000 4-Wire Detector Heads 0 x 0.00000 0 x 0.00000 EOLR-1 0 x 0.00000 0 x 0.00000 3.Notification Appliances P2R30 1 x 0,00000 0.00000 1 x 0.11600 0.11600 P2RK75 1 x 0,00000 0.00000 1 x 0.17600 0.17600 0 x 0.00000 0 x 0.00000 0 x 0.00000 0 x 0.00000 0 x 0.00000 0 x 000000 0 x 0,00000 0 x 0,00000 0 x 0.00000 0 x 0.00000 0 x 0.00000 0 x 0.00000 0 x 0,00000 0 x 0.00000 0 x 0.00000 0 x 0.00000 0 x 0.00000 0 x 0.00000 0 1 x 0.00000 0 x 0:00000 NAC#1 Totals(Max 2.5 Amps): 0,00000 0.29200 T131 Resettable Power 0 1 x 1 0,00000 0 x 0.00000 Total Standby 0.080 A Total Alarm 0.404 A Load: Load: • System Power Requirements Q Game+n� Y q by � GWF402 Fire Alarm Control Panel Protected Premises: STRANDER BLVD Date: 4/3/2014 Address: SW 27TH STREET EXTENSION City: TUKWILA State: WA Zip: Prepared By: E-SQUARED SYSTEMS LLC Phone: 253-284-3707 Address: PO BOX 731227 Email: City: PUYALLUP State: WA Zip: 98373 Secondary Load Requirements 2.34 Amp Hours Total Seconda Load from the calculation table below. Current Draw Time(hours) Total(AH) Secondary Standby Load x Re uired StandbyTime 0.080 A 24 hours 1.92 Secondary Alarm Load Re uired Alarm Time 0.404 A x 0.084 hours 0.03 Total Secondary Load 1.95 Derating factor x 1.20 Secondary Load Requirements 2.34 AH Battery Selection 7.00 Amp Hours Select batteries from the list below. 7.0 AH BAT-1270 Batter 12 volt Battery Distribution Chart Shows amp-hour distribution of your selections. I ■Spare Battery Capacity Secondary Alarm Load 1% ■Secondary Standby Load ■Secondary Alarm Load :Secondary Standby Load 33% Spare Battery Capacity 66 II i Spa B9 ,.Ca 4.66 Am Ho Se y S.. e.v Lo 2.30 Am p Ho S= A,. Lo 0 04 Am p Ho Notes: 1.Batteries will fit in the FACP cabinet. 2.Selected battery size meets secondary load requirements. 413t2014 , Pe neI FACP Circuit Device F0.r. X of Devices Current EOL NI P2WI5 HORN/STROBE 15CD X - 0 Ohms Per Foot X Total Wire Length Current VDC Voltage Mac HORWSTROBE 3000 X 1 - 0.116 3.19 60 X 0.309 = 0.049 23.951 P2W75 HORN STROBE 75CD X - 0 1000 P2RK WEATHERPROOF HORN/STROBE 11000 X 1 - 0.193 SW STROBE 15CD X - 0 12ga.2 cond = 1.69 D X 1 0 X - 0 14 ga,2 cond = 3.19 D X - 0 X - 0 X - 0 X - 0 Total Current 0.309 Panel FACP Premier Low Voltage Systems by. E SQUf�REO S�/STEMS, LLC. Fire —Security — Card Access —CCTV TAB 7 CERTIFICATIONS ; r'_ NATIONAL INSTITUTE FOR CERTIFIC ATION IN ENGINEEMNIGOLOW ® W UET o Providing Certification Programs Since 7 961 HE oT Kb\OVUN THAT Sandifer M Deer IS HEREBY AWARDED CERTIFICATION AT jG LEVEL III IN FIRE PROTECTION ENGINEERING TECHNOLOGY FIRE ALARM SYSTEMS P3ASFD UPON SUCCESSFUL DEMONSTRATION OF REQWSITE KNOWLEDGE, EXPFRIEN\9CE AND A4N ORK PERFORMANCE AS SET FORTH BY THr S H\ISTI"!I"B,ITF. Certification Valid through August I,2016 CERTIFICATION NUMBER 129796 nn y CHAIRMAN OF THE NICFT BOARD OF GOVERNORS A DIVISION OF THE NATIONAL SOCIETY OF PROFESSIONAL ENGINEERS Certificate of Completion 4 Sandifer M. Deer of r 9 E-S uared Systems, LLC q Y � 1. Has successfully completed a Recertification Training Program on the f. .. E3 Series Fire Alarm Control Panel ' !r Issue Date: 6/30/2011 Expires three years from above date �"FIRE C�NTNfSL Rt' iiY.INSTf:l.1t9EfiIi'S ��y by Honeywell Director of Training This certificate is Immediately rendered invalid should the employment of the recipient of this certificate ' f, ! with the above-named company be terminated for any reason.This certificate is rendered invalid should Z' • the Gamewell-M distributorship of the above named company be revoked for any reason. .Zv •�.�s. � +ar '� ��4;<'r! � ,�� x x ,�, ��t. x?,:..Y n'kZ1},�,� k'I"a-.�.a'.yy5, l} .;� „!+�n/.�yi$,Y.t-y ' ttiCta ,�A /�g1j�� ` "�+� .._� _` ,,. � � ' :,.��+ •"'^x�, St` .fx�y�R�iy:•�C`•A s'�A;e.tit�8 .�''}4�/�' �1[d a1 W'� cF,,,,ir � " '; �,�'�� .'" Su ,. 'rfd ;ik,1T �'rr.,�,j�,;1:• �,,y{' 1 ,:, .`�`f t,;t" .3 STRANDER BLVD np � a a H s J SW 27TH STREET EXTENSION �JX REVIEWED BY: �a SANDIFER M DEER N n NICET III m TUKWILA WASHINGTON #129796 FIRE ALARM SYSTEM INSTALLATION CONTRACTOR: g SCOPE OF WORK: E—SQUARED SYSTEMS LLC - INSTALLATION OF NEW LOW 10029 S. TACOMA WAY SUITE E7 �n VOLTAGE FIRE ALARM SYSTEM. LAKEWOOD, WA 98499PHONE: PHONE: 253-284-3707 FAX: 253-284-3714 ELECTRICAL LICENSE# ESQUASL963BRLn EXPIRES: 1 /26/ 1 4 r w li Q cn Ui Ll u- = J N s � � W > of O u� Li U SYMBOL MODEL DESCRIPTION MANUFACTURE BACK BOX OTY z NUMBER O Ln FIRE ALARM CONTROL E-SQUARED FACP GWF4O2 PANEL GAMEWELL-FCI TO SUPPLY 1 CABLE CONDUCTOR LIST N w O E-SQUARED CAM TYPE CAML IrPF �- Fi41GL COLDIM NDTES H C7 CELLULAR TRANSMITTER m(n W Z %TAR TG7GF504 PANEL TELGUARD 1 ?NEI = f TO SUPPLY PHOTOELECTRIC SMOKE 4 SO. BOX L w 3 OO 2W_B GAMEWELL-FCI SENSOR DOUBLE ACTION 4 S0. DEEP BOX Q Q � F� M46-L GAMEWELL-FCI SINGLE GANG'MUD RING 1 Q J cn Q CONVENTIONAL PULL STATION All G1�16 410u0 SOLD Q = 3 HORN/STROBE - 4 SO DEEP BOX Au CONDNIIS S U)K 3/4'LAIU5 OT IIIL NOTLO ON rUv15. of P2R WALL MOUNT SYSTEM SENSOR 1 n� N W F� p C H [L WP P2RK WEATHERPROOF HORN/STROBE SYSTEM SENSOR TOSSUUPPLVO 1 In MOUNT MANUAL PULL STATIONS SO ACTUATION LEVER IS AT +48" ABOVE FINISHED FLOOR. MOUNT HORN/STROBES AND STROBES WITH BOTTOM OF STROBE AT +80" ABOVE FINISHED FLOOR. • ENTIRE LENS MUST BE BETWEEN 80" & 96" AND NO LESS THAN 6" BELOW CLG. MOUNT ALL PANELS WITH TOP AT 6'-0" AFF. SET STROBE CANDELA OUTPUT AS SHOWN ON PLANS. JOB/734L FA-01 1 OF 4 n a mn ELECTRICAL NOTES: GENERAL NOTES: " • v; r 1) INSTALLATION SHALL COMPLY WITH NfPA 70, PARTICULARLY ARTICLE 1) NOTIFY E-SQUARED SYSTEMS OF ANY DESIGN QUESTIONS OR CHANGES W 3� 760, AND SHALL ALSO COMPLY WITH NFPA 72, AND ALL PRIOR TO INSTALLATION OR FABRICATION. COMPARE DRAWINGS WITH LOCAL ELECTRICAL CODES AND LOCAL JURISDICTION REQUIREMENTS. CURRENT CONTRACT DRAWINGS PRIOR TO INSTALLATION. y 4 Wao 2) CONDUIT INDICATED ON PRINTS IS DIAGRAMMATIC AND MAY 2) ANY ALTERATIONS OR VARIATIONS FROM DRAWINGS SHOULD BE REVIEWED BY: (r BE REROUTED PER FIELD REQUIREMENTS. APPROVED PRIOR TO WORK PROCEEDING AND DOCUMENTED ON THE SANDIFER M DEER 0"m AS BUILT DRAWINGS. VERIFY DEVICE LOCATIONS PRIOR TO INSTALLATION. I ,, xo 3) AC POWER SHALL NOT OCCUPY THE SAME CONDUIT AS FIRE NICET III w 0 PROTECTION CIRCUITS (MOST FIRE DETECTION CKT'S ARE NEC CLASS 3) 3) EFERENCE FACTORY OF FIRE CONTROL INSTRUCTIONMANUALS DURING INSTALLATION EQUIPMENT. #129796 a a 4) ALL SLC LOOP WIRING SHALL BE 2 CONDUCTOR #16, UNSHIELDED, LOW/MID CAPACITANCE FIRE ALARM CABLE OF THE PROPER RISER 4) DETECTORS SHALL NOT BE MOUNTED IN A DIRECT AIR STREAM. AND/OR PLENUM TYPE. DO NOT INSTALL DETECTORS WITHIN 3'-0" OF AIR SUPPLY DIFFUSERS. 5) CONVENTIONAL FIRE DETECTION INITIATING DEVICE CIRCUITS OR NOTIFICATION 5) USE ONLY U.L. LISTED DEVICES. APPLIANCE CIRCUITS SHALL NOT BE PARALLEL BRANCHED (TEE TAPPED) TO ENSURE SUPERVISION OF WIRING. ADDRESSABLE CLASS "A" FIRE DETECTION 6) DO NOT INSTALL DETECTOR HEADS UNTIL FINAL CLEANING HAS SIGNALING LINE CIRCUITS (SLC) SHALL NOT BE PARALLEL BRANCHED (TEE TAPPED) BEEN PERFORMED. TO ENSURE SUPERVISION OF WIRING. 7) FIELD DETERMINE INTERFACE REQUIREMENTS AND LOCATIONS OF 6) OBSERVE POLARITY OF ALL FIRE DETECTION WIRING. POLARITY SHALL BE EQUIPMENT SUPPLIED BY OTHER TRADES. ( i.e.. SPRINKLER DEVICES, HVAC MAINTAINED THROUGHOUT ENTIRE SYSTEM; WIRE SHALL BE MARKED AND UNITS, FIRE DAMPERS, ELEVATOR CONTROLS, & FAN CONTROLS.) IDENTIFIED WHERE SPLICED, AND AT ANY JUNCTION BOXES. 7) THE FIRE ALARM PANEL GROUND SHALL BE A SEPARATE CONTINUOUS GROUND WIRE BACK TO THE SOURCE GROUND; CONDUIT GROUND IS NOT AUDIBILITY REQUIREMENTS @ ACCEPTABLE PER MANUFACTURER'S SPECIFICATIONS. AUDIBILITY 8) ALL FIELD WIRING SHALL BE CHECKED FOR SHORTS, GROUNDS, & A SOUND LEVEL OF 75ciba OR 15ciba OVER AMBIENT SHALL BE REACHED IN ALL AREAS PROVIDED WITH PROPER END OF LINE RESISTOR (ELR) VALUES BEFORE SCHEDULING FIRE ALARM DEVICES PER SPECIFICATIONS AND NFPA-72. E-SQUARED FOR SYSTEM CHECK OUT. DOCUMENT CIRCUIT READINGS AND PRESENT TO E-SQUARED TECHNICIAN UPON INITIAL ARRIVAL ON o S SITE. PROVIDE E-SOUARED A MIN. OF 1 WEEK NOTICE PRIOR TO CHECK OUT. FIRE ALARM SYSTEMS SEQUENCE OF OPERATIONS _ 9) FIRE ALARM PANEL, AND ANY OTHER FIRE DETECTION EQUIPMENT REQUIRING 120VAC, SHALL BE SUPPLIED BY A DEDICATED CIRCUIT BREAKER SYSTEM INPUT OTHER (NON-FIRE DETECTION) EQUIPMENT SHALL NOT SHARE THE FIRE ALARM CIRCUIT(S). THIS BREAKER SHALL BE LOCKED AND CLEARLY MARKED "FIRE ALARM CIRCUIT CONTROL". 120VAC POWER BY OTHERS. 0 = REQUIRED RESPONSE J 0 = OVERRIDELj • 10) POWER SHALL NOT BE APPLIED TO THE FIRE ALARM PANEL UNLESS A C ; 0 4 n z n ~ REPRESENTATIVE FROM E-SQUARED IS PRESENT. a o z o a a } U Q 4 (.�U lA VJ 0 LL m N 11) WIRE NUTS ARE NOT ALLOWED. ALL SPLICES ARE TO BE TERMINATED `� ON TERMINAL STRIPS. ALARM 0 FCP X 12) ALL SLC, NOTIFICATION, AND SPEAKER WIRING SHALL BE STYLE 6 (CLASS A). W NO OUTPUT CIRCUITS, FROM FCP, OR RETURN CIRCUITS SHALL BE RUN IN TROUBLE 0 FCP X X X XLn THE SAME CONDUIT. VERTICAL SEPARATION OF CONDUITS SHALL BE AT LEAST 1 w FOOT AND HORIZONTAL SEPARATION SHALL BE AT LEAST 4 FEET. SUPV. 0 FCP X w x a w W w ACTIVATE FIRE i O O WATERFLOW BELL W U 7 TRANSMIT GEN ALM X ~ TO MONITORING } TRANSMIT WF ALM Ln TO MONITORING SET STROBE CANDELA OUTPUT AS SHOWN ON PLANS. TO MONITORING TROUBLE X X X X TO MONITORING C❑❑RDINATI❑N ITEMS TOMONTSUPv. TO MONITORING z o FCP BYPASS ON W THESE ARE TYPICALLY THE ITEMS THAT GET OVERLOOKED TO MONITORING N Z AND MAY LEAD TO DELAYS IN THE COMPLETION OF THE J>' X z FIRE ALARM SYSTEM AND PROJECT, m V) w = 1. SITE ELECTRICAL CONTRACTOR SHALL PROVIDE DEDICATED Ln w w 3 120VAC POWER CIRCUIT WITH BREAKER LOCK-OUT FOR ALL Q N FIRE ALARM EQUIPMENT. Q m f'-W r 2. ELECTRICAL FINAL SHALL BE COMPLETED PRIOR TO SCHEDULING V) N ~ L� 3 E-SQUARED FOR CHECK-OUT, UNLESS REQUIRED OTHERWISE BY AHJ Ln 3. NOTIFY E-SQUARED A MIN. OF 1 WEEK, PRIOR TO INSTALLATION OF ALL WIRING, DEVICES AND POWER, FOR SCHEDULING OF SYSTEM CHECK-OUT AND PROGRAMMING. E-SQUARED REQUIRES A MIN. OF 2 DAYS FOR CHECK-OUT AND • PROGRAMMING PRIOR TO SCHEDULING A FIRE ALARM FINAL. LARGER SYSTEMS WILL REQUIRE MORE TIME, FAILURE TO HAVE WORK JOB/734L COMPLETED WILL REQUIRE RESCHEDULING AND ADDITIONAL COSTS. NOTE: FIRE ALARM AND MNS SIGNALS SHALL ❑VERRIDE P,A, SYSTEM ❑PERATI❑N. FA-02 2OF 4 n n� mn • ;ri '^aN w� REVIEWED BY: SANDIFER M DEER " Inn" NICET III " wm" #129796 :n N1-2 75CD WP N1 F ZONE 2 N1-1 8 70CD Az o� Ni o� zoNE 1 k' A1,2 XTMR I FACP • Lo w �F-IRE ALARM PLAN -(TPLAN � r >1CALE111C11 ' NORTH ~ w w a cn w W CABLE CONDUCTOR LIST _ nAcurt rvcL wLc irrE w. cNx4 mwe Worts � J N i of lj LLw c � O v LL U N.L awfz sluuln�[souo ALL WN]IIRS-D E S/A"UI4E55 Oi"Ef1W5E NOTiD ON RA16. ZONE 2 F SYMBOL MODEL DESCRIPTION MANUFACTURE BACK BOX OlV O NUMBER FIRE ALARM CONTROL E-SOUARED N w ZONE 1 —AC CWF4O2 PANEL GAMEWELL-FCI TO SUPPLY I J> 0 SZ WP x z 2 y r CELLULAR TRANSMITTER E-SQUARED m N W = %TAR TG]GF504 TELCUARD TO SUPPLY WUl PANEL N 1-1 N 1-2 O PHOTOELECTRIC SMOKE 4 50 BOX A, 2W-B SENSOR GAMEWELL-FCI Q 30CD 75CD Z-i Ln a FACP XTMR F M46-L DOUBLE ACTION GAMEWELL-FCI 4 SO DEEP BOX Q Q J CONVENTIONAL PULL STATIGN SINGLE GANG MUD RING HORN/STROBE - 4 S0. DEEP BOX ~LAJ n O P2R WALL MOUNT SYSTEM SENSOR 1 Cn(X N f- 120VAC E-SQUARED w 3 TYPICAL FOR ALL �WP P2RK WEATHERPROOF HORN/STROBE SYSTEM SENSOR TO SUPPLY N PANELS FIRE ALARM RISER DIAGRAM MOUNT MANUAL PULL STATIONS SO ACTUATION LEVER IS AT +48" ABOVE FINISHED FLOOR. • MOUNT HORN/STROBES AND STROBES WITH BOTTOM OF STROBE AT +80" ABOVE FINISHED FLOOR. ENTIRE LENS MUST BE BETWEEN 80" k 96" AND NO LESS THAN 6" BELOW CLG. MOUNT ALL PANELS WITH TOP AT 6'-0" AFF. SET STROBE CANDELA OUTPUT AS SHOWN ON PLANS. JOB 0734L FA-03 3 OF 4 - - - - - -T REVIEWED BY: " SANDIFER M DEER m Control Panel Installation NICET III w d Telguard TG-7 Series #129796 usuiessne-1 e: - QUICK INSTALLATION GUIDE[SOLE PATH] 3.4 Control Board Components w a s S o -_ <H a - _ tr..._.�. Installation Summary There are seven steps m installing Tel uard property IF YOU DO NOT Figure 3-2 is a wiring diagram for wino the Flex 410 panel. P• 9 9 V P Y 8 mE 8m K P't PROCEED IN THE ORDER AND MANNER PRESCRIBED,YOU MAY NOT hone w 0 .�Fw-rise-N. N COMPLETE THE INSTALLATION IN THE TIME ALLOCATED. Connections m a i o --.+»-^ - STEP 1.REGISTER FOR CELLULAR SERVICE 9 R Register the unit online through www telguardonline.com,by completing the ,,,,�-,„„e•,� Online Regnstratlon Form at—Teiguard.com.Telular requires this Information T5 a; to reg aster and activate the unit (,�_ T4 :f rf .reomn.;E STEP 2:LOCATE UNIT AND MEASURE SIGNAL STRENGTH RSSI t rt Programmable NE-""�� r.�er- ( Output Relays rust ,, 1 y -11 wninmrg that let,-1has ad,-t,-,:,ar sn¢lal streng th.Pre m ss e LED/RSSI of Mode Toggle button one nine.LEDs will raw ndicale sgrel—Vth.Minimum recommended is 3(3 t4 .r rLewKr� Q �r'� 410 - w sold)Press the LEDIRSSI Made Toggle button a second time to exit RSSI rtlocle .€ 9 a� is- STEP 3:CONFIGURE ALARM PANEL FOR SOLE PATH CONNECTION .f Fire parcels are typically povided w8n two Telco connecnms.Bar use the TG-7 provdes a single tE -CRy Master Bov Elius 4 �_ connection.the pm i rust be set up acmrdagty Tne first meHad of i ln:u rWaleoon is to corAgure Ina Initiatl s Polarity-JJ ra� panel to disade tice second Telco mnnectan If nr�is nal an option due Io Panel Isnitations n is C Tt - Reversal • oanow.l puss—ro space both TIP and RING connections from I.Penal into the single jack of the o - � rc rrs Telguard The TG7 atcapable of pmvdug dal tone to both Telco oannectlons �aREA TTtwuAm 'v-e1Penp �' I STEP 4:PROGRAM,ACTIVATE&TRANSMIT PANEL ALARMS OVER THE T� NAC oonlTc-T o CELLULAR RADIO NETWORK v4 circuN Program the TG7 fo Sole Pam mrnmisiration You Trey do NIs by s ON Memory Location 831 w a value or 3,useg a MM1t-set(See programming guide m reverse).LE0 3 will be oR when ble, s: it successfiN Nexi,coon 1 the slam,gainers digital dialer a u[ro Telguard and venty that alarm «'fr' can be nelMd soot T Dana over cellWa r to the final stenar d to race A signals y tn,— alg O �r um o wo a a m vgre s mu t transmined A rvanon s onMmed when LEU tPA is ve �timma� Ac (NOTE:THE FIRST ALARM WILL ACTIVATE THE UNIT AT THE TELULAN COMMUNICATION CENTER,IT WILL NOT GO TO THE CENTRAL STATION,ALL SIGNALS AFTER THE FIRST ARE YYi 4 i ♦_ SENT TO THE CENTRAL STATICNI .E Connections �= N4A STEP 5:CONNECT SUPERVISORY TRIP OUTPUTS _I `fj Nexi,rot,will ware ragaeras supervrsory trip a,lpuls to the alan.i paaal sad tam test Q O Nay switch o STEP 6:CONNECT TRIP INPUT(OPTIONAL) ' Co..ctpr DpnonalN.You can w+re an edenal ralaY input to the mp ilqui lead and ground,and Zest Pnm ary Jr i z STEP 7:COMPLETE THE INSTALLATION Ac L Your last step wall be b anal,earm gnxmd one pemanennY mount the unit ��IIJJ�� - -- Battery I Connector ,I,I ua�u• Figure 3-2 Flex 410 Board Layout Refer to Section 3.4.1 for complete description o f control panel terminal comtections. (n to E— W I Li CELLULAR RADI❑ WIRING DIAGRAM — DETAIL—A V W 151321 3-3 Li _ Ln D 0 o FIRE ALARM PANEL — DETAIL B ® LO7. o5} Wo E- m In w wO PUSH Oa- ' z a - -c PULL oo nMMC� <.< f W L� 3 nH❑RN/STR❑BE - DETAIL C SM❑KE DETECT❑R — DETAIL D ®FIreHLm^Larms by Horteywell PULL STATI❑N — DETAIL E FA-04 4DF 4 Telguard® TELULAR CELLULAR SERVICE REGISTRATION REQUEST To activate your Telguard,fax this form to (678)945-1651 or complete the Registration Request at www.telguard.com You may also e-mail the form to cellservice@telular.com PLEASE PRINT LEGIBLY •ALL INFORMATION REQUIRED (INCOMPLETE REGISTRATION REQUEST WILL NOT BE PROCESSED) Telguard Digital Serial Number TELULAR USE ONLY-CONFIRMATION NUMBER: SUBSCRIBER INFORMATION O RESIDIDENTIAL ❑COMMERCIAL LAST NAME FIRST NAME MIDDLE INITIAL STREET ADDRESS CITY ST ZIP CODE DEALER INFORMATION DEALER ACCOUNT NUMBER DEALER COMPANY NAME DEALER STREET ADDRESS CITY ST ZIP CONTACT LAST NAME CONTACT FIRST NAME CONTACT PHONE CONTACT FAX CONTACT EMAIL CENTRAL STATION REPORTING TELGUARD WILL OBTAIN THE CENTRAL STATION RECEIVER AND SUBSCRIBER ACCOUNT NUMBERS FROM. PLEASE CHOOSE ONE: ❑ Alarm Panel OR (C/C)THE TELGUARD WILL OBTAIN CENTRAL STATION RECEIVER&ACCOUNT NUMBERS FROM THE ALARM PANEL ❑ Please use the following: (THE TELGUARD WILL TRANSMIT ALL ZONE INFORMATION TO THE CENTRAL STATION AND ACCOUNT NUMBER SPECIFIED BELOW) • PRIMARY RECEIVER NUMBER SECONDARY RECEIVER NUMBER CENTRAL STATION ACCOUNT CODE ALARM FORMAT-CHOOSE ONE FORMAT:YOU MAY CHOOSE TO TRAMSMIT PASS ONLY,FAIL ONLY,OR BOTH FORMAT COMPATIBILITY PASS FAIL BOTH PASS CODE FAIL CODE OTHER PASS/FAIL CID TGTG 8&TG 9 7 ❑ ❑ ❑ 603 358 / SIA2 TG-4,TG-7,TG-8& ❑ ❑ ❑ TX00 YC00 TG-9 Preset Codes Only DMP TG-4,TG-7,TG-8 ❑ ❑ ❑ SO4 S12 Preset Codes Only 3X1 (Double Rounded& TGA,TG-7&TG-8 ❑ ----- ----- 15 ----- ----- Nnn-FxtPndPdl 4X2 (Double Rounded& TG-4,TG-7&TG-8 ❑ ----- ----- 1515 ----- ----- Non-Fxtended) RADIONICS/BOSCH TG-4,TG-7&TG-8, "'(Ile,3a2) TG-9 ❑ ❑ ❑ 221 231 RATE PLAN SELECTION(SELECT ONE OF THE FOLLOWING) RESIDENTIAL PRIMARY/TG-1&TG-4 FIXED RATE 1 TEST SIGNAL AND NORMAL RESIDENTIAL ALARMS ❑ DAY OF MONTH(1 TO 28) MONTHLY TEST 10 SIGNALS(1 TEST&9 ALARMS PER MONTH) ❑ DAY OF MONTH(1 TO 28) WEEKLY TEST 20 SIGNALS(5 TESTS&15 ALARMS PER MONTH) ❑ DAY OF WEEK(MON-SUN) DAILY TEST 46 SIGNALS(31 TESTS&15 ALARMS PER MONTH) ❑ DAILY 5 MINUTE SUPERVISION ❑ 5 MINUTE ALER ACCEPTANCE aler acknowledges and accepts all Telular Terms and Conditions.Dealer authorizes the immediate registration of service. SIGNATURE PRINT NAME DATE 56042802 SILENT KNIGHT by Honeywell MODELS S K-2/E & S K-4/E FirE Alarm Control PanEls Instruction Manual Document 52604 10/18/2011 Rev: B2 Fire Alarm System Limitations While a fire alarm system may lower insurance rates, it is not a substitute for fire insurance! An automatic fire alarm system—typically made up of Heat detectors do not sense particles of combustion and smoke detectors, heat detectors,manual pull stations,audible alarm only when heat on their sensors increases at a predeter- warning devices,and a fire alarm control panel with remote mined rate or reaches a predetermined level. Rate-of-rise notification capability—can provide early warning of a develop- heat detectors may be subject to reduced sensitivity over time. ing fire. Such a system, however, does not assure protection For this reason,the rate-of-rise feature of each detector against property damage or loss of life resulting from a fire. should be tested at least once per year by a qualified fire pro- The Manufacturer recommends that smoke and/or heat detec- tection specialist. Heat detectors are designed to protect tors be located throughout a protected premise following the property, not life. recommendations of the National Fire Protection Association IMPORTANT! Smoke detectors must be installed in the Standard 72(NFPA 72), manufacturer's recommendations, same room as the control panel and in rooms used by the sys- State and local codes,and the recommendations contained in tem for the connection of alarm transmission wiring, communi- the Guides for Proper Use of System Smoke Detectors,which cations,signaling,and/or power. If detectors are not so are made available at no charge to all installing dealers. located,a developing fire may damage the alarm system,crip- These documents can be found at http://www.systemsen- pling its ability to report a fire. sor.com/html/applicat.html. A study by the Federal Emer- Audible warning devices such as bells may not alert people gency Management Agency(an agency of the United States if these devices are located on the other side of closed or government)indicated that smoke detectors may not go off in partly open doors or are located on another floor of a building. as many as 35%of all fires. While fire alarm systems are Any warning device may fail to alert people with a disability or designed to provide early warning against fire,they do not those who have recently consumed drugs,alcohol or medica- guarantee warning or protection against fire. A fire alarm sys- tion. Please note that: tem may not provide timely or adequate warning,or simply may not function,for a variety of reasons: Strobes can, under certain circumstances,cause seizures in people with conditions such as epilepsy. Smoke detectors may not sense fire where smoke cannot reach the detectors such as in chimneys,in or behind walls,on Studies have shown that certain people,even when they roofs,or on the other side of closed doors. Smoke detectors hear a fire alarm signal,do not respond or comprehend the also may not sense a fire on another level or floor of a building. meaning of the signal. It is the property owner's responsi- A second-floor detector,for example, may not sense a first- bility to conduct fire drills and other training exercise to floor or basement fire. make people aware of fire alarm signals and instruct them Particles of combustion or"smoke"from a developing fire on the proper reaction to alarm signals. may not reach the sensing chambers of smoke detectors In rare instances,the sounding of a warning device can because: cause temporary or permanent hearing loss. • Barriers such as closed or partially closed doors,walls,or A fire alarm system will not operate without any electrical chimneys may inhibit particle or smoke flow. power. If AC power fails,the system will operate from standby batteries only for a specified time and only if the batteries have • Smoke particles may become"cold,"stratify,and not reach been properly maintained and replaced regularly. the ceiling or upper walls where detectors are located. Equipment used in the system may not be technically com- • Smoke particles may be blown away from detectors by air patible with the control panel. It is essential to use only equip- outlets. ment listed for service with your control panel. • Smoke particles may be drawn into air returns before Telephone lines needed to transmit alarm signals from a reaching the detector. premise to a central monitoring station may be out of service The amount of"smoke"present may be insufficient to alarm or temporarily disabled. For added protection against tele- smoke detectors. Smoke detectors are designed to alarm at phone line failure, backup radio transmission systems are rec- various levels of smoke density. If such density levels are not ommended. created by a developing fire at the location of detectors,the The most common cause of fire alarm malfunction is inade- detectors will not go into alarm. quate maintenance. To keep the entire fire alarm system in Smoke detectors,even when working properly, have sensing excellent working order,ongoing maintenance is required per limitations. Detectors that have photoelectronic sensing the manufacturer's recommendations, and UL and NFPA stan- chambers tend to detect smoldering fires better than flaming dards. At a minimum,the requirements of NFPA 72 shall be fires,which have little visible smoke. Detectors that have ion- followed. Environments with large amounts of dust, dirt or izing-type sensing chambers tend to detect fast-flaming fires high air velocity require more frequent maintenance. A main- better than smoldering fires. Because fires develop in different tenance agreement should be arranged through the local man- ways and are often unpredictable in their growth, neither type ufacturer's representative. Maintenance should be scheduled of detector is necessarily best and a given type of detector monthly or as required by National and/or local fire codes and may not provide adequate warning of a fire. should be performed by authorized professional fire alarm • Smoke detectors cannot be expected to provide adequate installers only. Adequate written records of all inspections warning of fires caused by arson,children playing with should be kept. matches(especially in bedrooms),smoking in bed,and violent explosions(caused by escaping gas, improper storage of Limit-C 1-2-2007 flammable materials,etc.). 2 SK-2&SK-4 Series Manua!— P/N 52604:B2 10/18/2011 Installation Precautions Adherence to the following will aid in problem-free installation with long-term reliability. WARNING-Several different sources of power can be Like all solid state electronic devices,this system may connected to the fire alarm control panel. Disconnect all operate erratically or can be damaged when subjected to light- sources of power before servicing. Control unit and associ- ning induced transients. Although no system is completely ated equipment may be damaged by removing and/or insert- immune from lightning transients and interference, proper ing cards, modules, or interconnecting cables while the unit is grounding will reduce susceptibility.Overhead or outside aerial energized. Do not attempt to install,service,or operate this wiring is not recommended,due to an increased susceptibility unit until manuals are read and understood. to nearby lightning strikes. Consult with the Technical Ser- CAUTION-System Re-acceptance Test after Software vices Department if any problems are anticipated or encoun- Changes: To ensure proper system operation,this product tered. must be tested in accordance with NFPA 72 after any pro- Disconnect AC power and batteries prior to removing or gramming operation or change in site-specific software. Re- inserting circuit boards. Failure to do so can damage circuits. acceptance testing is required after any change,addition or Remove all electronic assemblies prior to any drilling,filing, deletion of system components,or after any modification, reaming,or punching of the enclosure.When possible, make repair or adjustment to system hardware or wiring.All compo- all cable entries from the sides or rear. Before making modifi- nents,circuits,system operations,or software functions known cations,verify that they will not interfere with battery,trans- to be affected by a change must be 100%tested. In addition, former,or printed circuit board location. to ensure that other operations are not inadvertently affected, at least 10%of initiating devices that are not directly affected Do not tighten screw terminals more than 9 in-lbs. Over- by the change, up to a maximum of 50 devices, must also be tightening may damage threads, resulting in reduced terminal tested and proper system operation verified. contact pressure and difficulty with screw terminal removal. This system meets NFPA requirements for operation at 0-490 This system contains static-sensitive components. C/32-120°F and at a relative humidity 93%±2% RH (non- Always ground yourself with a proper wrist strap before han- condensing)at 32°C±2°C(90oF±3°F). However,the useful dling any circuits so that static charges are removed from the life of the system's standby batteries and the electronic com- body. Use static suppressive packaging to protect electronic ponents may be adversely affected by extreme temperature assemblies removed from the unit. ranges and humidity. Therefore, it is recommended that this Follow the instructions in the installation,operating,and pro- system and its peripherals be installed in an environment with gramming manuals.These instructions must be followed to a normal room temperature of 15-270 C/60-80°F. avoid damage to the control panel and associated equipment. Verify that wire sizes are adequate for all initiating and indi- FACP operation and reliability depend upon proper installation. cating device loops. Most devices cannot tolerate more than a Precau-M-9-2005 10% I.R.drop from the specified device voltage. FCC Warning WARNING:This equipment generates, uses, and can Canadian Requirements radiate radio frequency energy and if not installed and This digital apparatus does not exceed the Class A limits used in accordance with the instruction manual may for radiation noise emissions from digital apparatus set cause interference to radio communications. It has been out in the Radio Interference Regulations of the Cana- tested and found to comply with the limits for class A dian Department of Communications. computing devices pursuant to Subpart B of Part 15 of FCC Rules,which is designed to provide reasonable Le present appareil numerique n'emet pas de bruits protection against such interference when devices are radioelectriques depassant les limites applicables aux operated in a commercial environment.Operation of this appareils numeriques de la classe A prescrites dans le equipment in a residential area is likely to cause interfer- Reglement sur le brouillage radioelectrique edicte par le ence, in which case the user will be required to correct ministere des Communications du Canada. the interference at his or her own expense. Silent Knight@ is a registered trademark of Honeywell International Inc. Echelon@ is a registered trademark and LonWorks- is a trademark of Echelon • Corporation. ARCNET@ is a registered trademark of Datapoint Corporation. Microsoft@ and Windows@ are registered trademarks of the Microsoft Corporation. ©2011. All rights reserved.Unauthorized use of this document is strictly prohibited. SK-2&SK-4 Series Manual P/N 52604:B2 10/18/2011 3 Software Downloads In order to supply the latest features and functionality in fire alarm and life safety technology to our customers,we make frequent upgrades to the embedded software in our products. To ensure that you are installing and programming the latest features,we strongly recommend that you download the most current version of software for each product prior to commissioning any system. Contact Technical Support with any questions about software and the appropriate version for a specific application. Documentation Feedback Your feedback helps us keep our documentation up-to-date and accurate. If you have any comments or suggestions about our online Help or printed manuals,you can email us. Please include the following information: -Product name and version number(if applicable) -Printed manual or online Help -Topic Title(for online Help) -Page number(for printed manual) -Brief description of content you think should be improved or corrected •Your suggestion for how to correct/improve documentation Send email messages to: FireSystems.TechPubs@honeywell.com Please note this email address is for documentation feedback only. If you have any technical issues,please contact Technical Services. • 4 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 Table of Contents Section 1: Product Description .............................................................................................10 1.1: Product Features..........................................................................................................................................10 1.2: Specifications...............................................................................................................................................11 1.3:Controls and Indicators................................................................................................................................12 1.4:Circuits.........................................................................................................................................................14 1.5:Components.................................................................................................................................................14 1.6:Optional Modules and Accessories.............................................................................................................14 Section2: Installation.............................................................................................................17 2.1: Backbox Mounting......................................................................................................................................17 2.2:Operating Power..........................................................................................................................................19 2.3: Input Circuits...............................................................................................................................................20 2.4: Output Circuits.............................................................................................................................................22 2.4.1:Notification Appliance Circuits.........................................................................................................22 2.4.2: Special Application DC Power Output Connections.........................................................................23 2.4.3:Relays................................................................................................................................................23 2.5:Power-limited Wiring Requirements...........................................................................................................24 2.6: Installation of Optional Modules.................................................................................................................25 2.6.1: CAC-4 Class A Converter Module(SK-4 only)...............................................................................25 Installation............................................................................................................................................25 Wiring NACs and IDCs for Class A....................................................................................................25 2.6.2:4XTMF,4XLMF and 4XZMF Option Modules...............................................................................26 4XTMF Transmitter Module Installation.............................................................................................27 4XZMF Zone Relay Module(SK-4 only)............................................................................................29 • 4XLMF LED Interface Module(SK-4 only).......................................................................................30 Section 3: Program Options via DIP Switch.........................................................................32 3.1: DIP Switch Settings.....................................................................................................................................33 3.1.1: SW DIP Switch Settings..................................................................................................................35 SilenceInhibit.......................................................................................................................................35 Auto-silence..........................................................................................................................................35 TemporalCoding..................................................................................................................................35 SelectiveSilence...................................................................................................................................35 TroubleReminder.................................................................................................................................35 ACTrouble Delay................................................................................................................................35 Autoresettable Supervisory..................................................................................................................35 IDCCombination Circuit.....................................................................................................................36 3.1.2: SW2 DIP Switch Settings..................................................................................................................36 IDCI Verification(SK4 only)............................................................................................................36 IDC 1 Supervisory(SK-4 only).............................................................................................................36 IDC1 Verification for SK-2 or IDC2 Verification for SK-4................................................................36 IDCI Supervisory for SK-2 or IDC2 Supervisory for SK-4................................................................37 IDC2 Verification for SK-2 or IDC3 Verification for SK-4................................................................37 IDC2 Supervisory for SK-2 or IDC3 Supervisory for SK-4................................................................37 IDC4 Verification(SK4 only).............................................................................................................37 IDC4 Supervisory(SK-4 only).............................................................................................................37 3.1.3: SW3 DIP Switch Settings..................................................................................................................37 NACI Nonsilenceable..........................................................................................................................37 NAC1 Disable......................................................................................................................................37 NAC2 Nonsilenceable(SK-4 only)......................................................................................................37 NAC2 Disable(SK-4 only)..................................................................................................................38 • Strobe Synchronization........................................................................................................................38 Nonsilenceable Watertlow for Combination Circuit............................................................................38 Spares...................................................................................................................................................38 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 5 Table of Contents Section 4: Operating Instructions.........................................................................................40 4.1: Switch Functions in Normal Mode..............................................................................................................40 4.1.1:ACK-Acknowledge.........................................................................................................................40 4.1.2: Silence................................................................................................................................................40 4.1.3:Zone Enable/Disable..........................................................................................................................40 4.1.4: Reset/(Lamp Test).............................................................................................................................40 4.1.5:Walktest.............................................................................................................................................41 4.2:Walktest........................................................................................................................................................41 4.3: Status LEDs..................................................................................................................................................42 4.4:Operation......................................................................................................................................................43 4.4.1:Fire Alarm Response.........................................................................................................................44 4.4.2:Fire Alarm Restoral...........................................................................................................................44 4.4.3: System Supervisory Condition Response..........................................................................................44 4.4.4: System Supervisory Restoral Response.............................................................................................44 4.4.5: Trouble Condition Response.............................................................................................................44 4.4.6: Trouble Condition Restoral...............................................................................................................45 Section 5: Power Supply Calculations .................................................................................46 5.1: Overview......................................................................................................................................................46 5.2: Calculating the AC Branch Circuit..............................................................................................................46 5.3: Calculating the System Current Draw.........................................................................................................47 5.3.1:Overview............................................................................................................................................47 5.3.2: How to Use Table 5.3 on page 48 to Calculate System Current Draw.............................................47 5.4: Calculating the Battery Size.........................................................................................................................48 5.4.1:NFPA Battery Requirements.............................................................................................................49 5.4.2: Selecting and Locating Batteries.......................................................................................................49 Appendix A: NFPA Standard-Specific Requirements .........................................................50 A.1:Central Station/Remote Station Transmitter:Connection to FACP Dry Contacts......................................50 • Index ........................................................................................................................................51 • 6 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 It is imperative that the installer understand the requirements of the Authority Having Jurisdiction (AHJ)and be familiar with the standards set forth by the following regulatory agencies: • Underwriters Laboratories Standards • NFPA 72 National Fire Alarm Code Before proceeding, the installer should be familiar with the following documents. noNFPA Standards NA® This Fire Alarm Control Panel complies with the following NFPA Standards: NFPA 72 National Fire Alarm Code for Local Fire Alarm Systems and Remote Station Fire Alarm Systems(requires an optional Remote Station Output Module) U Underwriters Laboratories Documents for Reference: UL 38 Manually Actuated Signaling Boxes UL 217 Smoke Detectors,Single and Multiple Station UL 228 Door Closers—Holders for Fire Protective Signaling Systems UL 268 Smoke Detectors for Fire Protective Signaling Systems UL 268A Smoke Detectors for Duct Applications UL 346 Waterflow Indicators for Fire Protective Signaling Systems UL 464 Audible Signaling Appliances UL 521 Heat Detectors for Fire Protective Signaling Systems UL 864 Standard for Control Units for Fire Protective Signaling Systems UL 1481 Power Supplies for Fire Protective Signaling Systems UL 1638 Visual Signaling Appliances UL 1971 Signaling Devices for Hearing Impaired Other: • NEC Article 250 Grounding NEC Article 300 Wiring Methods NEC Article 760 Fire Protective Signaling Systems Applicable Local and State Building Codes Requirements of the Local Authority Having Jurisdiction(LAHJ) Silent Knight Documents Silent Knight Device Compatibility DocumentDocument#52612 This product has been certified to comply with the requirements in the Standard for Control Units and Accessories for Fire Alarm Systems,UL 864,9th Edition. Operation of this product with products not tested for UL 864,9th Edition has not been evaluated. Such operation requires the approval of the local Authority Having Jurisdiction(AHJ). • SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 7 SK-2 Two Zone Main Circuit Board IDC(4.7 KQ,%watt ELR) • (supervised,power-limited) Zone 2 B- Trouble Relay(fail-safe) Zone 2 B+ 2 amps @ 30 VDC Zone 1 B- Zone 1 B+ (nonsupervised) NAC(4.7KW,%watt ELR) Common 2.5A max. Trouble(Normally Open) (supervised,power-limited) Normal(Normally Closed) B- B+ 24 VDC Special Application Alarm Relay Resettable Power 2 amps @ 30 VDC 500 mA max.(nonsupervised, (nonsupervised) Common power-limited) -24 VDC Normally Closed +24 VDC Normally Open EBW W � W + 0 O - N B. B- B+ e- B+ B- c TRBL NORM`S c NC No Reset NAC 1 ZONE 1 ZONE 2 TROUBLE ALARM (JP3 UnU O JP3-Cut to disable Ground Fault detection(only with J3 approval of AHJ) 1 FIRE ALARM SUPERVISORY TROUBLE MAINTENANCE J5 O �—J3 and J5 4XTMF Option FIRE ALARM rFIREALARMSUPERVISORY TROUeIE MAINTENANCE Module l l x Connectors O 0 AC NAC ZONE NAC SYSTEM POWER WAL, ALARNI 1�9 DISABLE DISABLE FAULT TROUBLE TROUBLE TEST SILENCE ACK ALARM RESET WAL: SILENCE ZONE TEST E-1 ENABLEIDISABLE 2t o �JP1 w o r o o TB8 z o EARTR®u+c 3 d J8 J7 � ❑❑ O 00 HOT NEUTEARTH BATTERY $W1 SW2 SW3 0 O rog L�220/240 20 VAC,2.3A or VAC, 1.15AJ7 Transformer arth P SW2 and SW3 Connector eutral Programming DIP Switches Note:Factory-installed cover Hot removed for illustration (supervised, purposes only! nonpower-limited) Module Placement Supervision(if installed) JP1 -cut to supervise module on J3&J5 J8 Battery Connector (supervised,nonpower-limited) Charger Fault LED 18 Amp Hour max. • Battery Fault LED Earth Fault LED 8 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 SK-4 Four Zone Main Circuit Board IDC(4.7 Ki2,%watt ELR)T133(supervised,power-limited) Zone 4 B- Zone 4 B+ Trouble Relay T135(fail-safe) Zone 3 B- 2A @ 30 VDC(nonsupervised) Zone 3 B+ Common Zone 2 B- Trouble(NormallyOpen) T13 (4. 2 watt ELR) Zone 2 B+ Normal Normally Closed 62 2.5A max.per NAC Zone 1 B ( ) (supervised,power-limited) Zone 1 B+ NAC 2 B- Alarm Relay T136 NAC 2 B+ 2A @ 30 VDC NAC 1 B- (nonsupervised) NAC 1 B+ Common 24 VDC Special Application Normally Closed Power TB1 Normally Open 500 mA per circuit (nonsupervised, power- Supv.Relay TB7 limited) 2A @ 30 VDC -Reset (nonsupervised) +Reset Common -No reset Normally Closed +Nonreset ,Normally Open W O O + + B+ B- B+ B- w B+ B- B+ B- B+ 6- B+ B- C TRBL NI C NC NO m C NC NO mO NOnreset Reset NAC 1 NAC 2 ZONE 1 ZONE 2 ZONE 3 ZONE 4 TROUBLE ALARM °i SUPV V V CLASS A 7 No(J P3 CONVERTER J10 JP3 Class A -Cut to disable Ground Converter Module Ground Fault J3 detection(only with ZONEI SUPERVISORY TROUBLE MAINTENANCE 1 J5 approval of AHJ) • ALARMFIRE SUPERVISORY TROUBLE MAINTENANCE O J3 and J5 Option Module ♦ SUPERVISORY TROUBLE MAINTENANCE Connectors s � © SUPERVISORY TROUBLE MAINTENANCE 0FIRE ALARM ILEICE DISABLE DISABLE FAULT TROUBLE TROUBLE TEST 5_ y— 0 a i SAACK M TEST RESET WALK N ❑ ZONE O N ❑ J4 J9 A 1 "W�J4 and J6 ❑ Jp2( �JP1 Js Option Module y ❑ t ❑A ❑ TB8 ` CM / Connectors m ® ® E A IO ® J8 EARTR a n cR❑ 3 V ❑° OJUL �° 00 BATTERY 0 y HOT NEUT EARTH $1/t/t $wz $yy3 E J7 Transformer SW1,SW2 and SW3 Connector Programming DIP Switches J9 Transformer Note:Factory-installed cover removed for illustration purposes (optional) onlyY 120 VAC,2.3A or Module Placement Supervision(if installed) 220/240 VAC, 1.15A JP1 -cut to supervise module on J3&J5 Hot J6 Battery JP2-cut to supervise module on J4 and J6 Neutral Connector • Earth (supervised, Charger Fault LED (supervised, nonpower-limited) Battery Fault LED nonpower-limited) 18 Amp Hour max. Earth Fault LED SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/201 1 9 Section 1 : Product Description The SK-2 is a two zone FACP(Fire Alarm Control Panel)and the SK-4 is a four zone FACP. The information in this manual refers to both the SK-2 and SK-4 unless otherwise specified. These control panels provide reliable fire signaling protection for small to medium sized commercial, industrial and institutional buildings. The FACP is compatible with System Sensor's i'detectors which are microprocessor-based conventional smoke detectors that can transmit a maintenance trouble signal to the FACP indicating the need for cleaning and a supervisory`freeze' signal when the ambient temperature falls below the detector rating(refer to System Sensor's i'Installation and Maintenance Instructions document 156-1800-00 for device specifications). In addition,the control panel is compatible with conventional input devices such as two-wire smoke detectors,four-wire smoke detectors,pull stations,waterflow devices,tamper switches and other normally-open contact devices. Refer to the Silent Knight Device Compatibility Document for a complete listing of compatible devices. Outputs include one NAC(Notification Appliance Circuit)on the SK-2 and two NACs on the SK- 4. Each FACP has a Form-C Alarm and Trouble relay and 24 VDC special application resettable power. In addition,the SK-4 has a Form-C Supervisory relay and a nonresettable special application power output.The FACP supervises wiring,AC voltage and battery level. Activation of a compatible smoke detector or any normally-open fire alarm initiating device will activate audible and visual signaling devices,illuminate an indicating LED,sound the piezo sounder at the FACP,activate the FACP alarm relay and operate an optional module used to notify a remote station or initiate a auxiliary control function. The SK-2E and SK-4E offer the same features as the SK-2 and SK-4 but allows connection to 220/240 VAC. 19 NOTE: Unless otherwise specified, the terms SK-2 and SK-4 are used in this manual to refer to the SK-2 and SK-2E as well as the SK-4 and SK-4E FACPs respectively. 1 .1 Product Features • Style B(Class B)IDC(Initiating Device Circuit) ✓ one zone programmable for combination supervisory and waterflow ✓ SK-2-two IDCs ✓ SK-4-four IDCs s)� • Style Y(Class B)NAC(Notification Appliance Circuit) ✓ SK-2-one NAC ✓ SK-4-two NACs ' • Form-C Alarm Relay • Form-C Trouble Relay • Form-C Supervisory Relay(SK-4 only) • 3.0 amps total system current standard for SK-2 and SK-4 • 6.0 amps total system current available for SK-4 with optional second transformer • Dress Panel DP-MS2/4 • Optional Trim Ring P/N:TR-1-R for semi-flush mounting the cabinet • Control Buttons ✓ ACK(Acknowledge) ✓ Alarm Silence • ✓ Reset ✓ Walktest 10 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 Specifications Product Description ✓ Zone Enable/Disable(one per zone) • LED Indicators ✓ Fire Alarm(one per zone) ✓ Supervisory(one per zone) ✓ Trouble(one per zone) ✓ Maintenance(one per zone) ✓ AC Power ✓ NAC Disable ✓ Zone Disable ✓ NAC Fault ✓ System Trouble ✓ Power Trouble ✓ Walktest ✓ Alarm Silence ✓ Earth Fault LED(on circuit board)lights if zero impedance between FACP and ground exist ✓ Battery Fault(on circuit board) ✓ Charger Fault(on circuit board) • Piezo sounder for alarm,trouble and supervisory • 24 volt operation • Low AC voltage sense • Alarm Verification • NACs Programmable for: • ✓ Silence Inhibit ✓ Auto-Silence ✓ Strobe Synchronization ✓ Selective Silence(horn-strobe mute) ✓ Temporal or Steady Signal ✓ Silenceable or Nonsilenceable • Automatic battery trickle charger • Silent or audible walktest capabilities • Optional NAC Class A converter module(SK-4 only) • Optional 4XTMF Transmitter Module(SK-2 and SK-4) • Optional 4XZMF Zone Relay Module(SK-4 only) • Optional 4XLMF Module for RZA-4XF Remote LED Annunciator(SK-4 only) 1 .2 Specifications AC Power - TB8 SK-2/SK-4: 120 VAC,50/60 Hz,2.3 amps SK-2E/SK-4E:240 VAC,50 Hz, 1.15 amps Wire size:minimum#14 AWG(2.0 mmz)with 600V insulation Battery (sealed lead acid only) -J8 Maximum Charging Circuit- Normal Flat Charge:27.6 VDC @ 0.8 amp • Maximum Charger Capacity: 18 Amp Hour battery(two 7 Amp Hour batteries can be housed in the FACP cabinet. Larger batteries require a separate battery box such as the BB-17F.) SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 1 1 Product Description Controls and Indicators Initiating Device Circuits -T133 Alarm Zones 1 &2(SK-2 and SK-4) • Alarm Zones 3&4(SK-4 only) Power-limited circuitry Operation:All zones Style B(Class B) Normal Operating Voltage:Nominal 20 VDC,Maximum 27 VDC Alarm Current: 15 mA minimum Short Circuit Current:40 mA maximum Maximum Loop Resistance: 100 ohms End-of-Line Resistor:4.7K-4 1/2 watt(Part#71252) Standby Current:4 mA Refer to the Silent Knight Device Compatibility Document for listed compatible devices Notification Appliance Circuit(s) -TB21 One NAC on SK-2,two NACs on SK-4 Operation: Style Y(Class B) Power-limited Circuitry Normal Operating Voltage:Nominal 24 VDC,Maximum 27 VDC Maximum Signaling Current:2.5 amps total with standard transformer. 5.0 amps total(2.5 amp maximum per NAC)with optional transformer on SK-4 only Maximum Line Impedance: 1.5 volt drop end-of-line End-of-Line Resistor:4.7KQ 1/2 watt(Part#71252) Refer to the Silent Knight Device Compatibility Document for compatible listed devices Form-C Relays Trouble Relay T135(fail-safe) Alarm Relay T136 Supervisory Relay T137(SK-4 only) • Relay Contact Ratings:2 amps @ 30 VDC(resistive) Resettable Special Application Power -TB1 Operating Voltage:Nominal 24 VDC Maximum Available Current: 500 mA -appropriate for powering 4-wire smoke detectors (see Footnote 1.) Power-limited Circuitry Refer to the Silent Knight Device Compatibility Document for compatible listed devices Nonresettable Special Application Power-TB1 (SK-4 only) Operating Voltage:Nominal 24 VDC Maximum Available Current: 500 mA(see footnote 1 on page 12.) Power-limited Circuitry Refer to the Silent Knight Device Compatibility Document for compatible listed devices 1 .3 Controls and Indicators Front Panel Membrane Buttons • Acknowledge • Alarm Silence • Reset 1. Total current for resettable power and one Notification Appliance Circuit must not exceed • 3.0 amps for the SK-2. Total current for nonresettable power,resettable power and two Notification Appliance Circuits must not exceed 6.0 amps for the SK-4(requires optional second transformer). 12 SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 Controls and Indicators Product Description • Walktest • Zone Enable/Disable-Zone 1 • Zone Enable/Disable-Zone 2 • Zone Enable/Disable-Zone 3 (SK-4 only) • Zone Enable/Disable-Zone 4(SK-4 only) LED Indicators • Fire Alarm Zone 1 -red LED • Fire Alarm Zone 2-red LED • Fire Alarm Zone 3-red LED(SK-4 only) • Fire Alarm Zone 4-red LED(SK4 only) • Supervisory Zone 1 -yellow LED • Supervisory Zone 2-yellow LED • Supervisory Zone 3-yellow LED(SK4 only) • Supervisory Zone 4-yellow LED(SK-4 only) • Trouble Zone 1 -yellow LED • Trouble Zone 2-yellow LED • Trouble Zone 3-yellow LED(SK-4 only) • Trouble Zone 4-yellow LED(SK4 only) • Maintenance Zone 1 -yellow LED • Maintenance Zone 2-yellow LED • Maintenance Zone 3-yellow LED(SK4 only) • Maintenance Zone 4-yellow LED(SK-4 only) • AC Power-green LED • NAC Disable-yellow LED • Zone Disable-yellow LED • NAC Fault-yellow LED • System Trouble-yellow LED • Power Trouble-yellow LED • Walktest-yellow LED • Alarm Silence-yellow LED • Earth Fault-yellow LED(on main circuit board)lights if zero impedance between FACP and ground exists • Battery Fault-yellow LED(on main circuit board) • Charger Fault-yellow LED(on main circuit board) Local Piezo Sounder A piezo sounder provides separate and distinct sounds for alarm,trouble,maintenance and supervisory conditions as follows: • Alarm-on steady • Trouble-pulse 1 second on and I second off • Maintenance-pulse'h second on and second off • Supervisory-pulse''/z second on and second off • SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 13 Product Description Circuits 1 .4 Circuits Input Circuits Two input IDCs(Initiating Device Circuits)on the SK-2 and four IDCs on the SK-4 provide Style B(Class B)configurations. All IDCs accept i'detectors as well as conventional two-wire smoke detectors,four-wire smoke detectors and normally-open contact devices. Output Circuits • 24 VDC resettable special application power output-500 mA • 24 VDC nonresettable special application power output(SK-4 only)-500 mA • 24 volt battery charger(up to 18 Amp Hour batteries) Notification Appliance Circuits One NAC(Notification Appliance Circuit)Style Y(Class B)on the SK-2 Two NACs Style Y(Class B)on the SK-4 Relays Alarm Relay Trouble Relay(fail-safe) Supervisory Relay(SK-4 only) Form-C contacts rated 2.0 amps @ 30 VDC(resistive) 1 .5 Components Main Circuit Board The main circuit board contains the system's CPU,power supply,other primary components and • wiring interface connectors. Optional modules plug in and are mounted to the main circuit board. Cabinet The backbox measures 14.5"(36.8 cm)x 15.218"(38.65 cm)x 2.875"(7.3 cm)and provides space for two batteries(up to 7 Amp Hours). Also included is a dress panel which mounts inside the cabinet. Transformer Assembly One 100VA transformer is provided standard with the FACR An optional second 100VA transformer is available for the SK-4 to provide maximum accessory power. Batteries The cabinet provides space for two 7 Amp Hour batteries(larger batteries up to 18 Amp Hour, require use of a UL listed battery box such as the 1313-17F). Batteries must be ordered separately. 1 .6 Optional Modules and Accessories CAC-4 Class A Converter Module (SK-4 only) The CAC-4 Module can be used to convert the Style B(Class B)Initiating Device Circuits to Style D(Class A)and Style Y(Class B)Notification Appliance Circuits to Style Z(Class A). The module connects to JI on the SK-4 main circuit board. 4XTMF Transmitter Module (SK-2 and SK-4) The 4XTMF provides a supervised output for local energy municipal box transmitter and alarm and • trouble reverse polarity. It includes a disable switch and disable trouble LED. A module jumper option allows the reverse polarity circuit to open with a system trouble condition if no alarm 14 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 Optional Modules and Accessories Product Description condition exists. The 4XTMF mounts to the SK-2 main circuit board option module connectors J3 &J5 or the SK-4 main circuit board,occupying one of the two sets of option module connectors J3 . &J5orJ4&J6. 4XLMF LED Interface Module (SK-4 only) The LED Interface Module supports the RZA-4XF Remote Annunciator module. Annunciator wiring is supervised for open conditions by this module. The 4XLMF mounts to the SK-4 main circuit board option module connectors J3 and J5 only. RZA-4XF Remote Annunciator (SK-4 only) The Remote Annunciator mounts on a standard single-gang electrical box and provides LED indication of the following: • Alarm Zone 1 (red LED) • Alarm Zone 2(red LED) • Alarm Zone 3(red LED) • Alarm Zone 4(red LED) • System Trouble(yellow LED) A Local Trouble Sounder and Silence Switch are also provided. All LED wiring is supervised for open conditions. Any open condition will cause the System Trouble LED to illuminate. Slide-in paper labels permit an easy change of zone information. NOTE: The RZA-4XF Remote Annunciator requires the use of the LED Interface Module (4XLMF). 4XZMF Zone Relay Module (SK-4 only) . The Zone Relay Module provides Form-C relay contacts for the following: • Alarm Zone 1 • Alarm Zone 2 • Alarm Zone 3 • Alarm Zone 4 • System Alarm • System Trouble As a jumper option,the first four relays described above can be made silenceable. The 4XZMF mounts to the SK-4 main circuit board,occupying one of the two sets of option module connectors. Dress Panel DP-MS2/4 A dress panel DP-MS2/4 is optional. The dress panel restricts access to the system wiring while allowing access to the membrane switch panel. Battery Box The BB-17F battery box may be used to house two batteries greater than 7 Amp Hour to a maximum of 18 Amp Hour. The battery box mounts directly below the control panel cabinet, centered to the main circuit board. The BB-17F is red and is provided with knockouts. 411 and 411UD Digital Alarm Communicator/Transmitter The three input/channel 411 and the four input/channel 41IUD are dual line,digital alarm communicator/transmitters which can be used as slave communicators with the SK4 FACR The inputs/channels are compatible with normally open relay contacts,require ELRs(End-of-Line Resistors),are supervised and are fully programmable. The communicators interface with the • public switched telephone network and are compatible with most central station receivers. Power supplied must be 12 or 24 volts,filtered and nonresettable. The communicators are mounted in a small metal enclosure,providing a variety of mounting options. Refer to the 411 or 41IUD manual for additional information. SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 15 Notes • 16 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 Section 2: Installation 10 The cabinet can be surface mounted or semi-flush mounted using the optional Trim Ring P/N: TR-1-R. The door is removable during the installation period by opening and lifting if off the hinges. The cabinet mounts using two key slots at the top of the backbox and two additional 0.250" diameter holes located at the bottom. Carefully unpack the system and check for shipping damage. Select a location for the cabinet that is in a clean,dry,vibration-free area where extreme temperatures are not encountered. The area should be readily accessible with sufficient room to easily install and maintain the control panel. Locate the top of the cabinet approximately five feet above the floor with the hinge mounting on the left. Determine the number of conductors required for the devices to be installed and determine the appropriate knockouts. All wiring must be in accordance with the National and/or Local codes for fire alarm systems and power supplies. 2.1 Backbox Mounting l. Mark and predrill holes for the top two keyhole mounting bolts. 2. Install two upper fasteners in the wall with the screw heads protruding approximately'/<". 3. Using the upper keyholes,mount the backbox over the two screws. 4. Mark the lower two holes,remove the backbox from the wall and drill the mounting holes. 5. Mount the backbox,install the remaining fasteners and tighten all screws. Top • 2.875"(7.3 cm) O O O O O 1 Depth=3.000" Backbox= 14.5" 10 (7.62 cm) (36.8 cm) 1. cm ° 2.7" 9.1"(23.1 cm) (6.86cm 0 0 ° O 10.375" (26.35 cm) Height=15.000" Pem Studs (38.10 cm) 0 '001/ o ° 0 E 3 Backbox Mounting Holes a N N E Bottom O 0 — 1.125"(2.868 cm) • Figure 2.1 Backbox Mounting Dimensions SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 17 Installation Backbox Mounting Top O O O O O Depth t 2.875"(7.3 cm) Depth=3.05" Door= 14.677"(37.28 cm) (7.75cm) Ol Door= 15.342" (38.97 cm) O Bottom 0 O • Depth=4.75" I (12.065 cm) I Battery Box=8.5" (21.59 cm) 3 a U q E Battery Box= 14.5" (37.384 cm) Figure 2.2 Backbox and Battery Box When using batteries larger than 7 Amp Hour(up to 18 Amp Hour),the 1313-17F battery box(or UL-listed equivalent)must be installed. To install the BB-17F: 1. Mount the FACP cabinet to the wall. 2. Remove knockouts on the bottom of the FACP cabinet and top of the BB-17F. 3. Using conduit,hang the BB-17F from the FACP cabinet making sure there is at least''/z"of • clearance between the two cabinets. 4. Anchor the BB-17F to the wall. 18 SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 Operating Power Installation 2.2 Operating Power JLWARNING: DISCONNECT POWER SEVERAL DIFFERENT SOURCES OF POWER CAN BE CONNECTED TO THIS PANEL. DISCONNECT ALL SOURCES OF POWER BEFORE SERVICING. THE PANEL AND ASSOCIATED EQUIPMENT MAY BE DAMAGED BY REMOVING AND/OR INSERTING CARDS, MODULES OR INTERCONNECTING CABLES WHILE THIS UNIT IS ENERGIZED. Primary Power Source (AC) and Earth Ground Connections AC power connections are made inside the control panel cabinet. The primary power source for the panel is 120 VAC, 50/60 Hz,2.3 amps for the SK-2/SK-4 or 240 VAC,50 HZ, 1.15 amps for the SK-2E/SK-4E. Run a pair of wires(with ground conductor)from the protected premises main breaker box to T138 of the main circuit board. As per the National Electrical Code,use 14 AWG (2.00 mm', 1.6 mm O.D.)or heavier gauge wire with 600V insulation. No other equipment may be connected to this circuit. In addition,this circuit must be provided with overcurrent protection and may not contain any power disconnect devices. A separate Earth Ground connection must be made to ensure proper panel operation and lightning and transient protection. Connect the Earth Ground wire[minimum 14 AWG(2.00 mm2)]to the transformer mounting stud. Do not use conduit for the Earth Ground connection since this does not provide reliable protection. Secondary Power Source (Batteries) Observe polarity when connecting the battery. Connect the battery cable to J8 on the main circuit board using the plug-in connector and cable provided. The battery charger is current-limited and capable of charging sealed lead acid batteries. The charger shuts off when the system is in alarm. WARNING: BATTERIES CONTAIN SULFURIC ACID . BATTERY CONTAINS SULFURIC ACID WHICH CAN CAUSE SEVERE BURNS TO THE SKIN AND EYES AND CAN DESTROY FABRICS. IF CONTACT IS MADE WITH SULFURIC ACID, IMMEDIATELY FLUSH THE SKIN OR EYES WITH WATER FOR 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION. Optional second transformer 8 shown installed 0 o Standard transformer o 0 c 0 J* Oo Earth ground wire show O - connected to transformer E mounting stud N 3 0 a v E • Figure 2.3 Operating Power Connections SK-2&SK-4 Series Manual— PM 52604:B2 10/18/2011 19 Installation Input Circuits 2.3 Input Circuits The SK-2 has two IDCs(Initiating Device Circuits)and the SK-4 has four IDCs. Each circuit is compatible with System Sensor's i3 smoke detectors which generate a maintenance signal when the detector becomes dirty and a separate supervisory `freeze' signal when ambient temperature falls below the detector rating. The maximum loop resistance limit for each IDC is 100 ohms. The field wiring for each zone is supervised for opens,shorts and ground faults(zero impedance to ground). All conditions are visually and audibly annunciated. Each circuit is configured for Style B(Class B)operation and will accept I3 smoke detectors,any normally-open contact devices as well as conventional 2-wire or 4-wire,24 VDC smoke detectors. In addition,Zone 1 (IDC 1)on the SK-2 and Zone 2(IDC2)on the SK-4 can be programmed as combination supervisory and waterflow zones. Refer to the Silent Knight Device Compatibility Document for a list of compatible devices. SK-4 Initiating Device Circuits can be converted to Style D(Class A)by installing the optional Class A Converter module. Refer to"CAC-4 Class A Converter Module(SK-4 only)"on page 25. Class B Initiating Device Circuits(supervised and power-limited) 4.7 K0,'%watt resistor P/N:71252 UL listed Power Supervision Relay - (refer to Device Compatibility Document for list of compatible relays) UL listed compatible UL listed compatible 4-wire smoke detector C 2-wire smoke detectors • manual pull stations • • • heat detectors 1 Dummy load all unused circuits-4.7 KQ,'/z watt resistor Resettable 24 VDC (P/N:71245) 4-wire smoke detector power (500 mA maximum) E 3 ti v v y E O _ 1mmr-� J EQ ,r0 0OC OO + - + - ry B+ B- B+ B- B+ B- B+ B- B+ B- B+ B- Nonreset Reset NAC 1 NAC 2 ZONE 1 ZONE 2 ZONE 3 ZONE 4 Note:Zones 3&4 on SK-4 only Figure 2.4 IDC Connections • 20 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/201 I Input Circuits Installation Combination Waterflow/Supervisory Zone . A combination Waterflow/Supervisory circuit allows an FACP to distinguish between an Alarm switch(waterflow device)and a Supervisory switch(tamper)installed on the same circuit. The following figure illustrates the wiring of Zone 2 as a Style B(Class B)Waterflow/Supervisory circuit.Note that only Zone 1 on the SK-2 and Zone 2 on the SK-4 can be configured in this manner. Class B Initiating Device Circuits(supervised and power-limited) 4.7 KQ,%watt resistor P/N:71252 Supervisory Switch (tamper) ) ) Supervisory Switch (tamper) • • In-Line-Resistor 1.2 KU '/2 watt resistor P/N 75579 Alarm Switch (waterflow) Dummy load all unused circuits-4.7 Kn,'/:watt resistor(P/N:71245) . Note:Zones 3&4 on SK-4 only N X B+ B- B+ B- B+ B- B+ B- E ZONE 1 ZONE 2 ZONE 3 ZONE 4 Figure 2.5 Style B Combination Circuit on Zone 2 of the SK-4 Requirements for the Combination Waterflow/Supervisory circuit are as follows: ✓ The Waterflow Alarm Switch(es)must connect to the FACP Initiating Device Circuit before the In-Line Resistor as shown in Figure 2.5 ✓ The Waterflow Supervisory Switch(es)must connect to the FACP Initiating Device Circuit after the In-Line Resistor as shown in Figure 2.5 ✓ Program the FACP Initiating Device Circuit#1 on the SK-2 or Circuit#2 on the SK-4 as a Combination circuit by placing SW 1 DIP switch 8 to the ON position as described in"SW 1 DIP Switch Settings"on page 35 ✓ Waterflow Alarm Switch activation causes the panel to latch into alarm until the alarm condition is cleared and the FACP is reset ✓ Supervisory Switch activation causes the panel to track the supervisory condition,that is, the panel will clear when the supervisory condition is cleared(if FACP is programmed for • Autoresettable Supervisory) SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 21 Installation Output Circuits 2.4 Output Circuits 2.4.1 Notification Appliance Circuits • The SK-2 provides one Style Y(Class B)NAC(Notification Appliance Circuit)while the SK-4 provides two Style Y(Class B)NACs. Each circuit is capable of providing a maximum of 2.5 amps of current. Total current drawn from these as well as other DC power outputs cannot exceed 3.0 amps for the SK-2 or 6.0 amps for the SK-4 with the optional second transformer installed (refer to battery calculations section).Each circuit is supervised and power-limited. Refer to the Silent Knight Device Compatibility Document for a listing of compatible notification appliances. The SK-4 NACs can be converted to Style Z(Class A)by installing the optional Class A Converter module. Refer to"CAC-4 Class A Converter Module(SK-4 only)"on page 25. Class B Notification Appliance Circuits(supervised and power-limited) 4.7 KQ,'/z watt resistor P/N:71252 Polarized Bell Polarized Bell Polarized Strobe Polarized Horn-Strobe Polarized Horn Polarized Horn • Dummy load any unused circuits(P/N:71245) ir Notification Appliance Circuit 3 polarity shown in alarm condition co U0 a N y B+ B- B+ B- E NAC 1 NAC 2 Figure 2.6 NAC Connections • 22 SK-2&SK-4 Series Manua[- P/N 52604:132 10/18/2011 Output Circuits Installation 2.4.2 Special Application DC Power Output Connections • Resettable 24 VDC special application power is available on both the SK-2 and SK-4 control panels. Nonresettable 24 VDC special application power is available only on the SK-4. Nonresettable Power(500 mA)-SK-40nly 4-Wire Smoke Detector Power(500 mA) 24 VDC filtered,nonresettable special application power 24 VDC filtered,resettable special application power for can be obtained from 4-wire smoke detectors can be obtained from these these terminals(power-limited) terminals(power-limited) i 3 v Figure 2.7 Special Application Power 2.4.3 Relays The SK-2 and SK-4 control panels provide an alarm and fail-safe trouble relay and the SK-4 also provides a supervisory relay. Each Form-C relay is rated for 2 amps @ 30VDC(resistive). • Note that relay connections may be power-limited or nonpower-limited,provided that 0.25" minimum spacing is maintained between conductors of power-limited and nonpower-limited circuits. Note: Relay contacts are shown with TROUBLE ALARM SUPV power applied to the panel and no active C TRBL NORM C NC NO C NC NO troubles,alarms or supervisories. 3 The Trouble Relay is a fail-safe relay which will transfer on any trouble or total MJ03 Ll m power failure. Cn co co v Figure 2.8 Relay Terminals • SK-2&SK-4 Series Manual P/N 52604:132 10/18/2011 23 Installation Power-limited Wiring Requirements 2.5 Power-limited Wiring Requirements Power-limited and nonpower-limited circuit wiring must remain separated in the cabinet. All • power-limited circuit wiring must remain at least 0.25"(6.35 mm)away from any nonpower- limited circuit wiring. Furthermore,all power-limited and nonpower-limited circuit wiring must enter and exit the cabinet through different knockouts and/or conduits. A typical wiring diagram for the SK-4 is illustrated below. Power-limited Circuits Nonpower-limited Circuits '00/ 1 0 a 0 x 0 A,A Aa m + - + ®! - O NO NO m O NC NO m A� - A- A� A- A� - A- A- ®Nonreset Resen A A. dAg O -- NAC 1 NAC] ZONE 1 ZZONE 2 ZONE] ZONE d 6=�9 CAC-4 Power-limited Circuits OO Riff ' • 4XLMF 00 OSILENCE TEST "a �e �m � m u�9 Qi 1112 �I JP7 BE bbb � ®®®A4XTMF 0 C? sA Non power-limited Circuit O O E 3 N 3 n y E AC Power Figure 2.9 Typical UL Power-limited Wiring Requirements • 24 SK-2&SK-4 Series Manual— PM 52604:B2 10/18/2011 Installation of Optional Modules Installation 2.6 Installation of Optional Modules QCAUTION: DISCONNECT POWER REMOVE ALL POWER(AC AND DC) BEFORE INSTALLING OR REMOVING MODULES OR WIRING. 2.6.1 CAC-4 Class A Converter Module (SK-4 only) Installation The CAC-4 Module can be used to convert the four Style B(Class B)Initiating Device Circuits to Style D(Class A)and the two Style Y(Class B)Notification Appliance Circuits to Style Z(Class A). The module plugs into connector J1 which is located at the top right of the SK-4 main circuit board. Install the three supplied standoffs in the holes on the main circuit board as indicated in the following figure. Carefully align the connector on the CAC-4 with J1 on the FACP main circuit board and press the module securely into place. Make certain the pins are properly aligned to prevent bending or breaking of any connector pins. m - A+ A- A+ A- A+ A- A+ A- A+ A- A+ A- CLASS A CLASS A CLASS A CLASS A CLASS A CLASS A NAC 1 NAC 2 ZONE 1 ZONE 2 ZONE 3 ZONE 4 CAC-4 Module • Secure to Standoffs Secure to Standoff H O + + " B- B+ B- B+ B- B+ B- B+ B- B+ B- C CLNCNOwC NC NO wONonreset Reset AC 1 NAC 2 ZONE 1 ZONE 2 ZONE 3 ZONE 4 ° SUPV 0j CLASS ® 0P3 CONVERTER J1 Connector 3 : o E SK-4 Main Circuit Board Figure 2.10 CAC-4 Module Installation Wiring NACs and IDCs for Class A Wire the Style Z(Class A)Notification Appliance Circuits using T132 of the SK-4 and TB 1 of the CAC-4 module. Wire the Style D(Class A)Initiating Device Circuits using T133 of the SK-4 and TB 1 of the CAC-4. Make certain to observe polarity when connecting the devices to the circuits. The B+and A+terminals must comprise the feed and return for the positive side of a device and the B-and A-terminals must comprise the feed and return for the negative side of a device. To configure any of the zones for Class B when the CAC4 is installed,simply wire to the B+and B- input on the FACP terminal(s)and install the End-of-Line Resistor after the last device on the • SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 25 Installation Installation of Optional Modules circuit. Do not wire to the corresponding A+and A-terminals on the CAC-4 module. Note that Zone 1 IDC on the SK-2 and Zone 2 IDC on the SK-4 can be configured as a combination waterflow/supervisory circuit as illustrated in the following figure. Class B(Style B) IMPORTANT! All Class A IDC-4.7 KQ devices must be (Style D)IDC %watt ELR within 20 feet of the Combo Waterflow& resistor Class A portion of Supervisory P/N:71252 the circuit and 20Kf2, '%watt ELR Class A (supervised and wiring must be in resistor P/N:75477 (Style D)IDC power-limited) conduit. (supervised and (supervised and power-limited) power-limited) Class A(Style Z)NAC Tamper (supervised and power-limited) Smoke Smoke WHorn i � ' Tamper pull Station ' Pull Station • 1 ' 1 • � ' 1.2 KQ '/2 watt In-Line Heat Waterflow 1 Heat resistor P/N:75579 Dummy load all unused • Circuit polarities circuits-4.7 KQ shown in alarm /2 watt ELR resistor condition (P/N:71245) O W � o� 6 c� CU0 (JI J' SK-4 Circuit Board + A + 6 � 9 XV ® A+ A- A+ A- A+ A- A+ A- A+ A- A+ A- CLASS A CLASS A CLASS A CLASS A CLASS A CLASS A NAC 1 NAC 2 ZONE 1 ZONE 2 ZONE 3 ZONE 4 CAC-4 Class A Converter Module 7 E Figure 2.11 Wiring NACs and IDCs for Class A Operation 2.6.2 4XTMF, 4XLMF and 4XZMF Option Modules SK4: The 4XLMF LED Interface Module can only be plugged into connectors J3 and J5 on the SK-4 main circuit board. The 4XTMF and 4XZMF modules can be plugged into connectors J3 and J5 or J4 and J6 on the SK-4 main circuit board. A combination of any two of the three modules can be installed. SK-2: Only the 4XTMF module can be plugged into connectors J3&J5 on the SK-2 main circuit • board. (No other option modules can be installed on the SK-2). 26 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 Installation of Optional Modules Installation The following steps must be followed when installing each of these modules: 1. Remove all power(AC and DC)from the FACP before installing the modules. 2. Cut jumper JP (for connectors J3 and J5)and/or JP2(for connectors J4 and J6)on the main circuit board to allow the control panel to supervise the placement of any installed option module. 3. Install the two supplied metal standoffs in the locations indicated. These standoffs provide the required earth ground protection. 4. Carefully plug the connectors on the option module into connectors J3 and J5 or J4 and J6 on the FACP main circuit board,being careful not to bend any pins. 5. Secure the option module to the standoff on the main circuit board with the supplied screws. 6. When the installation has been completed,connect the wiring to the modules as indicated in the following sections. 7. Test system for proper operation. O r �s r dt O O + - + - B+ B- B+ B- B+ B- B+ B- B+ B- B+ B- C TRBL NORM C NC NO m C NC NO-'O Nomesel Reset NAC 1 NAC 2 ZONE 1 ZONE 2 ZONE 3 ZONE 4 TROUBLE ALARM SUPV O CLASS OP3 CONVERTER® O J3 Standoffs J3 (when using SUPERVISORY TROUBLE NTENANCE J3&J5 JS OSUPERVISORY TRWBLE NTENANCE44 J5 SUPERVISORY TROUBLE MAINTENANCE n 01 • Y O SUPERVISORY TROUBLE MAINTENANCE O ° Standoffs p ° (when using J4 J4&J6 ° JP2 J6 J6 E y ° T88 . ° Ew®*N® � o a �' JB q P £ O O rot NEUT EARTHBATTERY OO JP2 Jumper JP1 Jumper Cut to install module on J4&J6 Cut to install module on J3&J5 Figure 2.12 4X Option Module Connection to SK-4 4XTMF Transmitter Module Installation The 4XTMF provides a supervised output for a local energy municipal box transmitter in addition to alarm and trouble reverse polarity. A jumper option allows the reverse polarity circuit to open with a system trouble condition if no alarm condition exists. A disable switch allows disabling of the transmitter output during testing to prevent accidental calling of the monitoring service. Local Energy Municipal Box Service (NFPA 72 Auxiliary Fire Alarm Systems): Supervisory Current: 5.0 mA • Trip Current: 350 mA(subtracted from notification appliance power) Coil Voltage:3.65 VDC SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 27 Installation Installation of Optional Modules Maximum Coil Resistance: 14.6 ohms Maximum allowable wire resistance between panel and trip coil: 3 ohms Municipal Box wiring can leave the building Remote Station Service(NFPA 72 Remote Station Fire Alarm Systems)-Intended for connection to a polarity reversal circuit or a Remote Station receiving unit having compatible ratings: Maximum load for each circuit: 10 mA Reverse polarity output voltage: 24 VDC Remote Alarm and Remote Trouble wiring can leave the building Before installing the module,place the disconnect switch to the down(disconnect)position to prevent accidental activation of the municipal box. Note that a Disconnect LED will illuminate after the module is installed in the FACP. In addition,the System Trouble LED will turn on to indicate the Disconnect condition. Note:4XTMF Module is not suitable for transmitting reverse polarity supervisory signal. Polarities are shown for module activation T61 Remote Alarm(power-limited)` 2- 3+ — }Remote Trouble(power-limited)' q_ 5 No connection 6+ TBL Jumper 7- }Municipal Box(nonpower- ' limited)' Wiring from these terminals • Emil can exit the protected premises. Dummy load terminals 6 and 7 Disconnect ® (4.7kQ,'/.watt resistor)if Switch E Municipal Box is not connected. shown in [J2 3 disconnect E position a Disconnect LED Connect to: •SK-4 Connectors J3&J5 or J4&J6 •SK-2 Connectors J3&J5. Figure 2.13 4XTMF Transmitter Module • 28 SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 Installation of Optional Modules Installation 4XZMF Zone Relay Module (SK-4 only) The 4XZMF provides four zone alarm,one system alarm and one system trouble Form-C relays. Nonpower-limited and power-limited wiring must have a minimum distance of 0.25",wire to wire. If this module is used to drive nonpower-limited and power-limited circuits,follow the instructions below: Relay#1 through#4 will activate with Output#1 through#4 and remain latched. - ® no 1 - NO ® 2 - NC} Relay#1 ® 3 - C ® 5 _ NCO} Relay#2 ® 6 - C ® 8 _ NC} Relay#3 ® 9 - C ® 10 - NO} Relay#4 ® 11 - NC ® 12 - C ® 13 - NO ® 14 - NC} Alarm ® 15 - C ® 16 - NO} Trouble E ® 17 - NC 3 ® 18 - C T • Use Disable Switch to disconnect the relays 1. Skip a set of dry contacts to maintain the 0.25"required space between power-limited and nonpower-limited circuits. The wiring of this module must follow the requirements as specified in"Power-limited Wiring Requirements"on page 24. OR 2. If this module is needed to drive power-limited and nonpower-limited relays that are next to each other,refer to the following illustration which shows a typical connection: NO 1!� oRelay#1 { NC power-limited circuit C Y Rela #2 { NCpower-limited circuit C NO no connection } nonpower-limited circuit Relay#3 { NC C ® E 3 Relay#4 { NOC ® nonpower-limited circuit E N C Figure 2.14 4XZMF Zone Relay Module • SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 29 Installation Installation of Optional Modules 4XLMF LED Interface Module (SK-4 only) The 4XLMF supports the RZA-4XF Remote Annunciator module. The wiring of this module must follow the requirements as specified in"Power-limited Wiring Requirements"on page 24. Important: The 4XLMF module can only be installed on connectors J3 and J5 of the SK-4 main circuit board. 4XLB O —+24 VDC m-09 ® 2 —Out#1 ® 3 —Out#2 m b9 ® 4 —Out#3 m� ® 5 —Out#4 6 —System Trouble —Sound CD ® 8 —Resound Connect to corresponding terminals of ° o RZA-4XF Remote Annunciator 3 of X 7 4XLMF Module Note:Make wiring connections with system power off. Maximum wire impedance is 50 ohms per wiring connection. --------- --------------- 0 2 =E 3 4 5 SYSTEM TROUBLE 6 7 E ��ESOUND —8 x TONE�1e a SILENCE N O E o 3 FIRE ALARM ANNUNCIATOR ____ C Single-gang Box Side View Front View of RZA-4XF Figure 2.15 4XLMF LED Interface Module • 10 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 Notes • • SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 31 Section 3: Program Options via DIP Switch This section describes the programming options available via DIP switch settings. The FACP can be field programmed using option DIP switches SW 1,SW2,and SW3 which are located in the hot_ tom right side of the main circuit board. A factory-installed dip switch cover,which prevents acci- dental programming,must first be removed. Once programming is complete,the cover must be reinstalled. Refer to the following illustration for switch locations and DIP switch placement in the ON and OFF positions. To remove dip switch cover,remove the two screws,pull upper arm (A)partially from hole, then unhook the screws— App- bottom side of cover o o �A� (B)from circuit board e. & e. 8- B. a B. e. a e. a C NOAF LA Nam C NC ND edge. Replace when O Nl---I Reset J NAC 1 NAC 2 ZONE 1 ZONE 2 ZONE 3 ZONE d T FSL E ALARM SUP o C RTER IIIIIIIIIIIIIIIII programming is �1 O complete. eRER,.�oR. ,Ro°e°E eawrER,RE d 0 8 o O s� • C< E • ° d Switches 1 through 7 00 0 , • 0 3: shown in OFF position pT REui eppiR BATTERY SW1 S SW 0 E Switch 8 shown in ON position SW1 SW2 SW3 Figure 3.1 Field Programming DIP Switches i 32 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 DIP Switch Settings Program Options via DIP Switch 3.1 DIP Switch Settings The following tables list the programmable features for the SK-2 and SK-4. Placing a DIP switch in the ON position will select the feature while placing the DIP switch in the OFF position will deselect the feature. The exceptions to this rule are SW3 DIP switches 5&6. These two switches are used to select the Notification Appliance Circuit synchronization feature.A detailed description of each feature is presented in the following pages. Important: When any programmable feature is changed by repositioning a DIP switch,the FACP Reset button must be pressed to ensure that the control panel can read the new switch position. Switch Number DIP Switch Number DIP Switch ON 1 Silence Inhibit 2 Auto-silence 3 Temporal Coding 4 Selective Silence(if sync.enabled) SW1 5 Trouble Reminder 6 AC Trouble Delay 7 Autoresettable Supervisory 8 IDC Combination Waterflow/Supervisory Circuit 1 not used 2 not used • 3 IDC1 Verification 4 IDC1 Supervisory SW2 5 IDC2 Verification 6 IDC2 Supervisory 7 not used 8 not used 1 NAC1 Nonsilenceable 2 NAC1 Disable 3 not used 4 not used Switch 5 Switch 6 5&6 No Synchronization OFF OFF SW3 used to select strobe System Sensor Synchronization ON OFF synchronization feature as shown to the right Gentex Synchronization OFF ON Wheelock Synchronization ON ON 7 Nonsilenceable Waterflow for Combination Circuit (only if SW1 switch 8 is ON) 8 spare Table 3.1 SK-2 DIP Switch Settings SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 33 Program Options via DIP Switch DIP Switch Settings Switch Number DIP Switch Number DIP Switch ON 1 Silence Inhibit 2 Auto-silence 3 Temporal Coding 4 Selective Silence(if sync.enabled) SW1 5 Trouble Reminder 6 AC Trouble Delay 7 Autoresettable Supervisory 8 IDC Combination Waterflow/Supervisory Circuit 1 IDC1 Verification 2 IDC1 Supervisory 3 IDC2 Verification 4 IDC2 Supervisory SW2 5 IDC3 Verification 6 IDC3 Supervisory 7 IDC4 Verification 8 IDC4 Supervisory 1 NAC1 Nonsilenceable 2 NAC1 Disable • 3 NAC2 Nonsilenceable 4 NAC2 Disable Switch 5 Switch 6 5&6 No Synchronization OFF OFF SW3 used to select strobe synchronization feature as System Sensor Synchronization ON OFF shown to the right Gentex Synchronization OFF ON Wheelock Synchronization ON ON Nonsilenceable Waterflow for 7 Combination Circuit (only if SW1 switch 8 is ON) 8 spare Table 3.2 SK-4 DIP Switch Settings • 34 SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 DIP Switch Settings Program Options via DIP Switch 3.1.1 SW1 DIP Switch Settings Silence Inhibit Switch 1,placed in the ON position,selects the Silence Inhibit feature. This feature prevents the silencing or resetting of the NACs(Notification Appliance Circuits)for a period of one minute after initiation of an alarm. Placing switch 1 to the OFF position deselects the Silence Inhibit fea- ture. The factory default setting is switch 1 OFF for no Silence Inhibit. Auto-silence Switch 2,placed in the ON position,selects the Auto-silence feature. This feature automatically silences all NACs,programmed for silenceable operation,twenty minutes after alarm activation. A new activation on another zone will resound the NACs. The factory default setting is switch 2 OFF for no Auto-silence. Temporal Coding Switch 3,placed in the ON position,selects the Temporal Coding feature. This feature causes the NACs to pulse,'/2 second on,'/z second off,%second on, %second off,'/2 second on, 1'/2 seconds off,continually repeating this pattern while activated. The factory default setting is switch 3 OFF for no Temporal Coding,which will cause the NACs to sound a steady signal when activated. Note that Temporal Coding is disabled if Strobe Synchronization is enabled. Selective Silence Switch 4,placed in the ON position,selects the Selective Silence feature. This feature allows the use of various manufacturer's horn strobe mute protocols. When Selective Silence is enabled and the Synchronization feature is selected(refer to"Strobe Synchronization"on page 38),pressing the Silence button will turn off all silenceable audible devices while leaving on the visual devices,such • as strobes. The factory default setting is switch 4 OFF for no Selective Silence. NOTE: Enabling Selective Silence but not Synchronization will cause audible and visual devices to be turned off when the Silence button is pressed. Trouble Reminder Switch 5,placed in the ON position,selects the Trouble Reminder feature. This feature causes the FACP piezo to sound every 15 seconds for alarms and every two minutes for troubles after the alarms or troubles have been silenced. In addition,the piezo will resound 24 hours after a trouble has been silenced but not cleared. The factory default setting is switch 5 OFF for Trouble Reminder disabled. AC Trouble Delay Switch 6,placed in the ON position,selects the AC Trouble Delay feature. This feature allows the FACP to delay trouble activation for two hours following an AC loss or brownout condition. The factory default setting is switch 6 OFF for no AC Trouble Delay. Autoresettable Supervisory Switch 7,placed in the ON position,selects the Autoresettable Supervisory feature. This feature causes the IDCs(Initiating Device Circuits),programmed as supervisory circuits,to automatically reset(nonlatching)after the alarm condition has been cleared. The factory default setting is switch 7 OFF for no Autoresettable Supervisory. • SK-2&SK-4 Series Manual— PM 52604:132 10/18/2011 35 Program Options via DIP Switch DIP Switch Settings IDC Combination Circuit Switch 8,placed in the ON position,sets IDC#1 on the SK-2 or IDC#2 on the SK-4 as a combina- tion circuit. A combination zone can be used for monitoring supervisory devices such as valve tamper switches and alarm devices such as waterflow switches. Supervisory conditions,which latch via software,can be silenced by pressing the Acknowledge and then Silence buttons. The fac- tory default setting is switch 8 OFF for no Combination circuit. 3.1.2 SW2 DIP Switch Settings IDC1 Verification (SK-4 only) Switch 1 only on the SK4,placed in the ON position,selects the Verification feature for IDC(Ini- tiating Device Circuit)#1. When Verification is selected the following events will occur when a smoke detector activates: 1. FACP removes power from all zones for 6 seconds,resetting all smoke detectors. 2. Power is reapplied and a 17 second retard period begins,allowing detectors to stabilize. 3. During the 23 second reset/retard periods of steps 1 &2,subsequent alarms by the same zone are ignored. 4. Alarms detected on any other zone during the retard period will cause the FACP to immediately process the alarm. 5. A 60 second confirmation period follows the reset/retard period. If an alarm occurs during the confirmation period,on the zone which initiated verification,the FACP will immediately process the alarm. If no alarm is detected during this confirmation period,the FACP returns to normal condition. Important! Circuits selected for verification must have only smoke detectors installed 0 sec. 6 sec. 23 sec. 83 sec. • Detector Alarm RESET RETARD CONFIRMATION Verification (Reset/Retard+ Confirmation) Detector Goes Into Alarm Alarm Ignored Control Panel Processes Alarm if Same Detector is Still in AlarmDet —� Zoe tor During Fist Different) Control Panel Immediately Processes Alarm Zone During First Detector's L _ — _ _ _ — — — — — — — — — — — — — — — Verification Period i The factory default setting is switch 1 OFF for no IDC1 Verification. IDC1 Supervisory (SK-4 only) Switch 2 only on the SK-4,placed in the ON position,programs IDC#1 as a Supervisory circuit. A supervisory zone can be used for monitoring supervisory devices such as sprinkler tamper switches. A supervisory activation will pulse the piezo sounder at a'/2 second rate and flash the zone supervi- sory LED at the same rate. The factory default setting is switch 2 OFF for no IDC 1 Supervisory. IDC1 Verification for SK-2 or IDC2 Verification for SK-4 Switch 3,placed in the ON position,selects the Verification feature for IDC#1 on the SK-2 or IDC #2 on the SK-4. The factory default setting is switch 3 OFF for no Verification. Refer to IDC 1 Ver- • ification(SK-4 only)for a description of this feature. 36 SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 DIP Switch Settings Program Options via DIP Switch IDC1 Supervisory for SK-2 or IDC2 Supervisory for SK-4 Switch 4,placed in the ON position,programs IDC#1 on the SK-2 or IDC#2 on the SK-4 as a Supervisory circuit. A supervisory zone can be used for monitoring supervisory devices such as sprinkler tamper switches. A supervisory activation will pulse the piezo sounder at a'h second rate and flash the zone supervisory LED at the same rate. The factory default setting is switch 2 OFF for no Supervisory. IDC2 Verification for SK-2 or IDC3 Verification for SK-4 Switch 5,placed in the ON position,selects the Verification feature for IDC#2 on the SK-2 or IDC #3 on the SK-4. The factory default setting is switch 5 OFF for no Verification. Refer to"IDC 1 Verification(SK-4 only)"on page 36 for a description of this feature. IDC2 Supervisory for SK-2 or IDC3 Supervisory for SK-4 Switch 6,placed in the ON position,programs IDC#2 on the SK-2 or IDC#3 on the SK-4 as a Supervisory circuit. A supervisory zone can be used for monitoring supervisory devices such as sprinkler tamper switches. A supervisory activation will pulse the piezo sounder at a'/z second rate and flash the zone supervisory LED at the same rate. The factory default setting is switch 6 OFF for no Supervisory. IDC4 Verification (SK-4 only) Switch 7 only on the SK-4,placed in the ON position,selects the Verification feature for IDC#4. The factory default setting is switch 7 OFF for no IDC4 Verification. Refer to"IDC 1 Verification (SK-4 only)"on page 36 for a description of this feature. IDC4 Supervisory (SK-4 only) Switch 8 only on the SK-4,placed in the ON position,programs IDC#4 as a Supervisory circuit. A supervisory zone can be used for monitoring supervisory devices such as sprinkler tamper switches. • A supervisory activation will pulse the piezo sounder at a''/z second rate and flash the zone supervi- sory LED at the same rate. The factory default setting is switch 8 OFF for no IDC4 Supervisory. 3.1.3 SW3 DIP Switch Settings NAC1 Nonsilenceable Switch 1,placed in the ON position,programs NAC#1 as a nonsilenceable circuit. Selecting this feature will prevent the notification appliances on NAC#1 from being silenced by the Autosilence feature or by pressing the Alarm Silence button. The factory default setting is switch 1 OFF for silenceable circuit. NAC1 Disable Switch 2,placed in the ON position,will disable NAC#1,preventing the notification appliances from activating. This feature may be used during maintenance or while testing the system to pre- vent building evacuation. The FACP will indicate an NAC disabled fault and system trouble while this feature is selected. The factory default setting is switch 2 OFF for NAC1 enabled. NAC2 Nonsilenceable (SK-4 only) Switch 3 only on the SK-4,placed in the ON position,programs NAC#2 as a nonsilenceable cir- cuit. Selecting this feature will prevent the notification appliances on NAC#2 from being silenced by the Autosilence feature or by pressing the Alarm Silence button. The factory default setting is switch 3 OFF for silenceable circuit. • SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 37 Program Options via DIP Switch DIP Switch Settings NAC2 Disable (SK-4 only) Switch 4 only on the SK-4,placed in the ON position,will disable NAC#2,preventing the notifi- cation appliances from activating. This feature may be used during maintenance or while testing the system to prevent building evacuation. The FACP will indicate an NAC disabled fault and sys- tem trouble while this feature is selected. The factory default setting is switch 4 OFF for NAC2 enabled. Strobe Synchronization Switches 5 and 6 are used to program the Synchronization feature. This feature controls the activa- tion of notification appliances in such a way that all devices will turn on and off at exactly the same time, This is particularly critical when activating strobes which must be synchronized to avoid ran- dom activation and a potential hazard or confusion. The FACP can be programmed to operate with a variety of manufacturer's devices. The following table lists the required switch settings to accomplish synchronization: Synchronization Feature Switch 5 Switch 6 No Synchronization OFF OFF System Sensor Synchronization ON OFF Gentex Synchronization OFF ON Wheelock Synchronization ON ON The factory default setting is switches 5 and 6 OFF for No Synchronization. ■Maximum Number of Strobes for Synchronization The total current draw for each Notification Appliance Circuit cannot exceed 2.5 amps.Refer to the manufacturer's documentation supplied with the strobes to determine the maximum current draw . for each strobe and ensure that the circuit maximum is not exceeded. To ensure proper strobe and circuit operation,there is also a limit to the number of strobes that can be attached to each circuit. Following is a list of the strobes that have been tested with this FACP and the maximum number that can be connected to each NAC. Make sure that the NAC maximum current is not exceeded: ✓ System Sensor:40 Strobes ✓ Wheelock:25 Strobes ✓ Gentex:23 Strobes Nonsilenceable Waterflow for Combination Circuit If SW 1 switch 8 is set to the ON position to select a Combination Waterflow/Supervisory Circuit (refer to"IDC Combination Circuit"on page 36)and SW3 switch 7 is set to the ON position to select the Nonsilenceable Waterflow for the Combination Circuit option,the following conditions will occur: • SK-2-NACs become nonsilenceable upon acitvation of IDC#1 (Combination Circuit) • SK-4-NACs become nonsilenceable upon activation of IDC#2(Combination Circuit) Notes: 1. If initial alarm activations are from IDCs other than the Combination Circuit,the NACs will be either silenceable or nonsilenceable,depending on the setting of SW3 switches 1 and 3(refer to"NAC 1 Nonsilenceable"on page 37 and"NAC2 Nonsilenceable(SK-4 only)"on page 37). 2. If alarm activation is from the Combination Circuit programmed for nonsilenceable,all NACs will be nonsilenceable regardless of subsequent IDC activations. Spares Switch 8 is a spare switch and has no function at this time. The switch should therefore be left in the factory default setting of OFF. 38 SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 Notes i SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 39 Section 4: Operating Instructions The SK-2 and SK-4 have two modes of operation which are Normal and Walktest modes. Upon initial power-up,the system will be in Normal Mode. This section discusses operation of the control panel in the Normal Mode. 4.1 Switch Functions in Normal Mode 4.1.1 ACK - Acknowledge The Acknowledge button,which is located on the FACP membrane switch panel,silences the system piezo sounder and changes all flashing system LEDs to on steady. Pressing the Acknowledge button will have no effect on the Notification Appliance Circuits. To activate,press and hold the Acknowledge button for a minimum of one second. 4.1.2 Silence Pressing the Silence button,which is located on the FACP membrane switch panel,silences the system piezo sounder,turns off the silenceable Notification Appliance Circuits and turns on the Alarm Silence LED. The Silence button will be ignored for nonsilenceable waterflows and NACs. Upon the occurrence of a subsequent event(alarm or trouble),Silence is overridden and the control panel will respond to the new event. To activate,press the Silence button for a minimum of one second. IFNOTE: If Silence Inhibit has been enabled, NACs cannot be silenced for one minute following initiation of an alarm. 4.1 .3 Zone Enable/Disable To disable a zone,press the corresponding Zone Enable/Disable button. The Zone Disable and system Trouble LEDs will blink,as well as the Trouble LED for the disabled zone. To enable the zone,press the Zone Enable/Disable button a second time. 4.1.4 Reset/(Lamp Test) The system Reset button,which is located on the FACP membrane switch panel,resets the system and any smoke detectors. Each press of the Reset button will cause the following: ✓ Clear all status LEDs ✓ Turn off the Notification Appliance Circuits ✓ Reset all zones by temporarily removing power ✓ Silence the onboard piezo sounder ✓ Restore all system relays to normal ✓ Temporarily remove power from the resettable power output ItNOTE: If Silence Inhibit is active,a panel reset cannot occur for one minute. Any alarm,supervisory or trouble condition that exists after a system reset will resound the system, reactivating appropriate system activity. Any zones that were disabled before the reset will be disabled after the reset. Lamp Test When the Reset button is pressed and then released,the FACP will perform a Lamp Test. All panel LEDs will be turned on and the piezo will sound for approximately two seconds. 40 SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 11"(,lkw�� Operating Instructions 4.1 .5 Walktest The Walktest button,which is located on the FACP membrane switch panel,allows a panel walktest to be performed. Pressing and holding the Walktest button for a minimum of two seconds causes the FACP to enter audible walktest. Pressing the Walktest button and then the Silence button and holding both for a minimum of two seconds will cause the panel to enter silent walktest. Walktest can be exited by pressing and holding the Walktest button for a minimum of three seconds or by pressing the Reset button. Refer to"Walktest"for a complete description of this feature. 4.2 Walktest Walktest allows the testing of all control panel IDCs(input zones). An audible or silent walktest may be performed. QWARNING: NO FIRE PROTECTION IT IS IMPORTANT TO NOTE THAT WHILE THE FACP IS IN WALKTEST MODE, THE CONTROL PANEL IS IN AN OFF-NORMAL CONDITION AND DOES NOT PROVIDE FIRE PROTECTION. It should also be noted that the trouble relay will be activated while the control panel is in Walktest mode. Placing the control panel into Walktest mode will only be possible if the system has no active alarms. Prior to initiating a walktest,check to make certain that all system faults have been cleared. Upon entering Walktest mode,the following conditions should occur: • Trouble relay will activate • Alarm relay will be disabled • Supervision relay will be disabled(SK-4 only) • Piezo sounder will be disabled • 1'smoke detectors will enter their own test mode causing their LEDs to flash twice every five seconds(refer to the i3 specification document) • All alarm conditions will be displayed as they occur by blinking zone alarm LED • All zone troubles will be displayed as they occur by blinking zone trouble LED During walktest,the FACP zone LEDs will blink for the first activation on a zone. Subsequent activations on the same zone will cause the corresponding zone LED to blink the number of alarms on the zone since the start of the test,followed by a two second pause and then a repeat of the sequence. Note that following a zone activation,a 6 second reset for conventional and 60 second reset for I' detectors is initiated. No new alarms or troubles will be detected during this reset period. Disabled zones will not respond during Walktest. A zone may be disabled while in Walktest mode, should a faulty device be detected. This allows the user to return the system to Normal mode, enabling all other zones while preventing the faulty zone from triggering a false alarm. Audible Walktest To perform an audible Walktest,press and hold the Walktest button for a minimum of two seconds. The Trouble and Walktest LEDs will blink at a'/4 second rate. While testing input devices,the first initiating device activated on a zone will cause the NACs to sound for four seconds. Subsequent device activations on the same zone will cause the NACs to turn on for one second. Any smoke detectors that are activated will automatically be reset by the panel. Zone faults(open circuits)will cause the NACs to remain on steadily until the fault is cleared. SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 41 Operating Instructions Status LEDs During an audible walktest,if a device remains latched in alarm(such as a Pull Station that is not reset after activation),subsequent testing of devices on the same zone will not trigger the NACs. Be certain to reset or clear each device after testing. Silent Walktest To perform a silent Walktest,press the Walktest button,then press the Alarm Silence button and hold both for a minimum of two seconds. The Trouble,Walktest and Alarm Silence LEDs will blink at a'/4 second rate. A silent walktest will not activate the control panel Notification Appliance Circuits. All alarm and trouble conditions must be observed using the LEDs at the control panel as described in the previous sections. Exiting Walktest Mode Walktest mode can be exited by pressing and holding the Walktest button for a minimum of three seconds or by pressing the Reset button. The time-out feature will cause the control panel to automatically exit Walktest mode if no button presses have occurred for one hour. 4.3 Status LEDs AC Power LED A green LED that remains on while the AC power supply is within correct limits. If this indicator fails to light under normal conditions,service the system immediately. NAC Disable LED A yellow LED that blinks to indicate that a Notification Appliance Circuit has been disabled using the main circuit board DIP switches. The LED will turn on steady when the Acknowledge or Alarm Silence button is pressed. Zone Disable LED A yellow LED that blinks to indicate that one or more alarm zones have been disabled using the Zone Enable/Disable buttons. The disabled zone's trouble LED will also be on. The Zone Disable LED will turn on steady when the Acknowledge or Alarm Silence button is pressed. NAC Fault LED A yellow LED that blinks to indicate that an NAC trouble condition exists in the system. The LED turns on steady when the Acknowledge or Alarm Silence button is pressed. System Trouble LED A yellow LED that blinks to indicate that a system fault or abnormal condition exists and that the fire alarm system may be inoperative. It turns on steady when the Acknowledge or Alarm Silence button is pressed. Power Trouble LED A yellow LED that blinks to indicate an AC power,battery or charger trouble condition. It turns on steady when the Acknowledge or Alarm Silence button is pressed. Walktest LED A yellow LED that blinks to indicate that the control panel is in Walktest mode. The Acknowledge and Alarm Silence buttons do not affect the Walktest LED. Alarm Silence LED A yellow LED that turns on to indicate that an Alarm condition exists in the system but the Notification Appliance Circuits and the local piezo sounder have been silenced. 42 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 Operation Operating Instructions Zone Fire Alarm LED A red LED for each zone that blinks to indicate that an alarm exists on the corresponding zone. It turns on steady when the Acknowledge or Alarm Silence button is pressed. Zone Supervisory LED A yellow LED for each zone that blinks if the zone has been programmed for supervisory and a supervisory condition exists on the corresponding zone. It turns on steady when the Acknowledge or Alarm Silence button is pressed. Note that an i3 smoke detector freeze condition is displayed as a supervisory condition. The zone does not have to be programmed as a supervisory for this to occur. Zone Trouble LED A yellow LED for each zone that blinks to indicate that a trouble exists on the corresponding zone. It turns on steady when the Acknowledge or Alarm Silence button is pressed. Zone Maintenance LED A yellow LED for each zone that blinks to indicate that a I3 smoke detector on the corresponding zone is dirty or in need of maintenance. It turns on steady when the Acknowledge or Alarm Silence button is pressed. Earth Fault LED (on main circuit board) A yellow LED that blinks to indicate a ground fault condition on the system. A ground fault occurs when zero impedance between the FACP and earth ground exists. The LED turns on steady when the Acknowledge or Alarm Silence button is pressed. Battery Fault LED (on main circuit board) A yellow LED that blinks to indicate a low battery or no battery condition on the FACP. It turns on steady when the Acknowledge or Alarm Silence button is pressed. Charger Fault LED (on main circuit board) A yellow LED that blinks to indicate a battery charger fault. It turns on steady when the Acknowledge or Alarm Silence button is pressed. 4.4 Operation Normal mode is the standard mode of operation. In this mode,the panel continuously monitors system status. When no alarm or trouble conditions exist,the control panel will be in the following state: • all LEDs will be off(except the AC Power LED) • the Notification Appliance Circuits will be off • all relays are in their normal state • the onboard piezo sounder will be off • i3 smoke detectors will be polled for maintenance and freeze conditions on initial entry into Normal mode. Thereafter,each device will be polled every hour for freeze and every four hours for maintenance conditions All alarm and system trouble conditions are annunciated on the control panel's LEDs. NOTE: To ensure that the system is functioning properly,the FACP will perform a freeze check five minutes after the panel is reset,followed by a maintenance check. If there is no freeze or maintenance condition,the panel will continue to monitor for freeze conditions every hour and maintenance conditions every four hours. SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 43 Operating Instructions Operation 4.4.1 Fire Alarm Response The control panel will,upon detection of an alarm condition,cause the following: • Latch the alarm condition-requires panel reset to clear alarm condition • Blink the Zone Alarm LED one second On and one second Off • Turn on remote annunciator alarm LED and piezo sounder • Turn the Notification Appliance Circuit(s)on • Turn the FACP piezo sounder on steady • Turn on the alarm relay • Start the Silence Inhibit,Auto-silence and Trouble Reminder functions if enabled 4.4.2 Fire Alarm Restoral The control panel returns to normal after all alarms have been cleared and a system reset button has been pressed(pull stations have been reset,smoke detectors have reset and no smoke is present, waterflow has stopped). The control panel will perform the following upon restoral of all active alarms: • Turn off the FACP Zone Alarm LED • Turn off remote annunciator alarm LED and piezo sounder • Turn off the Notification Appliance Circuit(s) • Turn off the FACP piezo sounder • Turn off the alarm relay • i3 smoke detectors will be polled for maintenance and freeze conditions on initial entry into Normal mode. Thereafter,each device will be polled every hour for freeze and every four hours for maintenance conditions 4.4.3 System Supervisory Condition Response Zones can be programmed for supervisory in applications where a waterflow sensing device has been employed and a sprinkler tamper switch is to be monitored. An I'detector in a`freeze' condition(detected abnormally low ambient temperature)will also generate a supervisory condition on its alarm zone(refer to the I3 specification sheet for temperature threshold).Any supervisory condition will cause the control panel to perform the following functions: • Blink the FACP Zone Supervisory LED'h second On and'/z second Off • Pulse the piezo sounder''/2 second On and'h second Off • Turn on the supervisory relay(SK-4 only) 4.4.4 System Supervisory Restoral Response When the supervisory condition has been cleared,the control panel will perform the following: • Turn off the FACP Zone Supervisory LED • Turn off the piezo sounder • Turn off the supervisory relay(SK-4 only) 4.4.5 Trouble Condition Response The control panel,upon detection of one or more trouble conditions,well perform the following: • Blink the FACP System Trouble LED one second On and one second Off • Blink the FACP Zone Trouble LED one second On and one second Off • Turn on remote annunciator Trouble LED and pulse the piezo sounder 44 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 Operation Operating Instructions • Pulse the FACP piezo sounder one second On and one second Off • Transfer fail-safe Trouble relay • Additional LEDs will turn on or blink according to the specific trouble ✓ NAC Disable LED if NAC has been disabled ✓ Zone Disable LED if a zone has been disabled ✓ NAC Fault LED if a fault is detected on an NAC ✓ Power Trouble LED if an AC,battery or charger fault is detected ✓ AC Power LED will turn off if AC fail or brownout occurs ✓ Alarm Silence LED if Silence button is pressed after an alarm or trouble ✓ Walktest LED if Walktest mode is entered ✓ Zone Maintenance LED if a I3 smoke detector needs servicing ✓ Earth Fault LED if a ground fault occurs(zero impedance to ground) ✓ Battery Fault LED if low or no battery condition occurs ✓ Charger Fault LED if a charger trouble occurs 4.4.6 Trouble Condition Restoral The control panel performs the following upon restoral of all trouble conditions: • Turn off the FACP System Trouble LED • Turn off the FACP Zone Trouble LED • Turn off the remote annunciator Trouble LED and piezo sounder • Turn off the piezo sounder • Transfer the fail-safe Trouble relay • Turn off additional LEDs corresponding to specific troubles SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 45 Section 5: Power Supply Calculations 5.1 Overview 40 This section contains instructions and tables for calculating power supply currents in alarm and standby conditions. This is a four-step process,consisting of the following: 1. Calculating the total amount of AC branch circuit current required to operate the system 2. Calculating the power supply load current for non-fire and fire alarm conditions and calculating the secondary(battery)load 3. Calculating the size of batteries required to support the system if an AC power loss occurs 4. Selecting the proper batteries for your system 5.2 Calculating the AC Branch Circuit The control panel requires connection to a separate,dedicated AC branch circuit,which must be labeled FIRE ALARM. This branch circuit must connect to the line side of the main power feed of the protected premises. No other non-fire alarm equipment may be powered from the fire alarm branch circuit. The branch circuit wire must run continuously,without any disconnect devices, from the power source to the control panel. Overcurrent protection for this circuit must comply with Article 760 of the National Electrical Codes as well as local codes. Use 14 AWG(2.00 min 2) wire with 600 volt insulation for this branch circuit. Use Table 5.1 ,to determine the total amount of current,in AC amperes(A),that must be supplied to the system. Device Type Number of Current Draw Total Current per Devices (AC amps) Device SK-2/SK-4 2.3 or 1 X or = SK-2E/SK-4E 1.15 [ ] X = [ ] X Sum Column for AC Branch Current Required = Table 5.1 120/240 VAC Branch Circuit Requirements 46 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 Calculating the Svs7em Current Dram, Power Supply Calculations 5.3 Calculating the System Current Draw 5.3.1 Overview The control panel must be able to power all internal and external devices continuously during the non-fire alarm condition. To calculate the non-fire alarm load on the system power supply when primary power is applied,use Calculation Column 1 in Table 5.3 on page 48. The control panel must support a larger load current during a fire alarm condition. To calculate the fire alarm load on the power supply,use Calculation Column 2 in Table 5.3 on page 48. The secondary power source (batteries)must be able to power the system during a primary power loss. To calculate the non-fire alarm load on the secondary power source,use Calculation Column 3 in Table 5.3 on page 48. When calculating current draw and the battery size,note the following: • `Primary'refers to the main power source for the control panel • `Secondary' refers to the control panel's backup batteries • All currents are given in amperes(A). Table 5.2 shows how to convert milliamperes and microamperes to full amperes. To convert... Multiply Example Milliamperes(mA)to mA x 0.001 3 mA x 0.001 =0.003A amperes(A) Microamperes(pA)to pA x 0.000001 300 pA x 0.000001 =0.0003 A amperes(A) Table 5.2 Converting to Full Amperes 5.3.2 How to Use Table 5.3 on page 48 to Calculate System Current Draw Use Table 5.3 on page 48 to calculate current draws as follows: 1. Enter the quantity of devices in all three columns. 2. Enter the current draw where required. Refer to the Silent Knight Device Compatibility Document for compatible devices and their current draw. 3. Calculate the current draws for each in all columns. 4. Sum the total current for each column. 5. Copy the totals from Column 2 and Column 3 to Table 5.4 on page 49. Following are the types of current that can be entered into Table 5.3 on page 48: ✓ Calculation Column 1 -The primary supply current load that the control panel must support during a non-fire alarm condition,with AC power applied. ✓ Calculation Column 2-The primary supply current load that the control panel must support during a fire alarm condition,with AC power applied. ✓ Calculation Column 3-The standby current drawn from the batteries in a non-fire alarm condition during a loss of AC power. SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 47 Power Supply Calculations Calculating the Battery Size Table 5.3 contains three columns for calculating current draws. For each column,calculate the current and enter the total(in amperes)in the bottom row. When finished,copy the totals from Calculation Column 2 and Calculation Column 3 to Table 5.4 on page 49. 40 Calculation Column 1 Calculation Column 2 Calculation Column 3 Device Type Primary,Non-Fire Alarm Current Primary,Fire Alarm Current Secondary,Non-Fire Alarm (amps) (amps) Current (amps) Qty X[current Total pty X[current draw] Total (sty X[current Total draw]= = draw]= Main Circuit Board 1 0. 1 0. 1 0. SK-2 X[0.080]= X[0.112]'= X[0.080]= or SK-4 X[0.085]= X[0.175]= X[0.0851= CAC-4 [ ] X[0.001]= [ ] X[0.001]= X[0.001]= 4XTMF [ ] X[0.005]= [ ] X[0.011].= X[0.005]= 4XZMF [ ] X[0.004]= [ ] X[0.008]= X[0.004]= 4XLMF/RZA-4XF [ ] X[0.004]= [ ] X[0.019]= X[0.004]= pair 1 pair max. 2-wire Detector [ ] X[ ]t= [ ] X[ ]= X1 1= Heads 4-wire Detector [ ] X[ ]$_ [ ] X[ ]= X1 1= Heads Power Supervision [ ] X[0.025]= [ ] X[0.0251= X[0.025]= Relays NAC#1tt [ ] X[ ]= • NAC#2 [ 1 X[ ]= Current Draw from TB1 (nonalarmtl) Sum each Primary Non-Alarm= Primary Alarm= Secondary Alarm= column**"for totals Table 5.3 System Current Draw Calculations If using the Reverse Polarity Alarm output, add 0.005 amps; if using the Reverse Polarity Trouble output, add another 0.005 amps. t Refer to the Device Compatibility Document for standby current. $ Refer to the Device Compatibility Document for standby current. ** Must use compatible listed Power Supervision Relay. tt Current limitation of Terminal T62 circuits is 2.50 amps per NAC(SK4 requires optional transformer for max. current) $$The total standby current must include both the resettable(T131 Terminals 3&4)and nonresettable for SK-4 only(T131 Terminals 1 &2)power. Caution must be taken to ensure that current drawn from these outputs during alarm does not exceed maximum ratings specified. Current limitations of T131, Terminals 1 &2=0.500 amps,filtered, 24 VDC+/-5%, 120 Hz ripple @ 10 mVRMs, nonresettable power and T131,Terminals 3&4 = 0.500 amps,filtered, 24 VDC+/-5%, 120 Hz ripple @ 10mVRMs, resettable power. ***Total current draw listed above cannot exceed 3.0 amps with only standard transformer installed or,for the SK- 4,6.0 amps with both the standard and optional transformers installed. 5.4 Calculating the Battery Size Use Table 5.4 to calculate the total Standby and Alarm load in ampere hours(AH). This total load determines the battery size(in AH),required to support the control panel under the loss of AC power. Complete Table 5.4 as follows: 48 SK-2&SK-4 Series Manual- P/N 52604:132 10/18/2011 Calculating the Battery Size Power Supply Calculations 1. Enter the totals from Table 5.3 on page 48,Calculation Columns 2 and 3 where shown. 2. Enter the NFPA Standby and Alarm times(refer to`NFPA Requirements' below). 3. Calculate the ampere hours for Standby and Alarm,then sum the Standby and Alarm ampere hours. 4. Multiply the sum by the derating factor of 1.2 to calculate the proper battery size(in AH). 5. Write the ampere hour requirements on the Protected Premises label located inside the cabinet door. Secondary Standby Load Required Standby Time (total from Table 5.3 Calculation (24 or 60 hours) Column 3) [ ] X[ ] = AH Primary Alarm Load Required Alarm Time (total from Table 5.3 Calculation (for 5 min.,enter 0.084, Column 2) for 10 min.,enter 0.168) [ ] X[ ] = AH Sum of Standby and Alarm Ampere Hours = AH Multiply by the Derating Factor X 1.2 Battery Size,Total Ampere Hours Required = AH Table 5.4 Total Secondary Power Requirements at 24 VDC 5.4.1 NFPA Battery Requirements • NFPA 72 Local,Central and Proprietary Fire Alarm Systems require 24 hours of standby power followed by 5 minutes in alarm • NFPA 72 Auxiliary and Remote Station require 60 hours of standby followed by 5 minutes in alarm. Batteries installed in a system powered by a generator need to provide at least 4 hours of standby power 5.4.2 Selecting and Locating Batteries Select batteries that meet or exceed the total ampere hours calculated in Table 5.4. The control panel can charge batteries in the 7 AH to 18 AH range. The control panel cabinet is capable of housing batteries up to 7 AH. Batteries larger than 7 AH require the BB-17F or other UL listed external battery cabinet. SK-2&SK-4 Series Manual— P/N 52604:132 10/18/2011 49 I Appendix A: NFPA Standard-Specific Requirements The SK-2 and SK-4 have been designed for use in commercial,industrial,and institutional applications and meet the requirements for service under the National Fire Protection Association (NFPA)Standards outlined in this Appendix. The minimum system components required for compliance with the appropriate NFPA standard are listed below: SK-2/SK-4 Control Panel Contains the main control board,cabinet(backbox and door),main power supply transformer,and power supply. Batteries Refer to"Power Supply Calculations"on page 46,for Standby Power Requirements. Initiating Devices Connected to one of the control panel's Initiating Device Circuits. Notification Appliances Connected to the control panel's Notification Appliance Circuits via a control module. A.1 Central Station/Remote Station Transmitter: Connection to FACP Dry Contacts The dry contacts of the FACP programmable relays can be used to trip a UL-864 Listed Central Station/Remote Station Transmitter. The FACP contacts must be supervised by the Central Station/Remote Station Transmitter module using End-of-Line Resistors(ELRs)with a value determined by the Transmitter manufacturer. Power is also provided by the Central Station/Remote Station Transmitter manufacturer. Refer to the Central Station/Remote Station Transmitter manufacturer's manual for details. Typical Central Station/Remote Station Transmitter Module Typical Input Zone Triggers O O O O O O O O O O O O O O O O —�_j z 'Note: The Trouble Relay is a N fail-safe relay. With power applied to the FACP and no Ea troubles in the panel,the wiring should be connected to the C 2 Q U) and TRBL contacts as indicated in the illustration. HC O E B. B- B+ B- B+ B- B+ B- C TRBL NORM C NC NO m C NC NO 3 ZONE 1 ZONE 2 ZONE 3 ZONE 4 TROUBLE ALARM °' sUPJ E cJP3 i a �----i.7 U---�J6 U---- J E FACP Main Circuit Board Figure A.1 FACP Dry Contacts Connection to Central Station/Remote Station Transmitter �0 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 Index Numerics B 2 Zone Main Circuit Board 8 backbox 4 Zone Main Circuit Board 9 dimensions 14, 17 411 15 mounting 17 41IUD 15 battery 14, 19 4XLMF precautions 19 installation 26,30 rating 11 see also LED Interface Module 15 battery box 15 see also LED interface module 30 mounting 18 specifications 30 battery calculations 48 wiring to RZA-4XF 30 battery connector 8, 9 4XTMF Battery Fault LED 43 installation 26, 27 BB-17F 18 operation 27 see also battery box 15 see also Transmitter Module 14 buttons 12 see also transmitter module 27 see also control buttons 10 specifications 27 4XZMF C installation 26, 29 see also Zone Relay Module 15 cabinet see also zone relay module 29 dimensions 17, 18 mounting 17 specifications 29 see also backbox 14 A installation CA nlation 25 AC power 19 see also Class A Converter Module 9, 14 AC Power LED 42 charger 14 AC power rating 11 charger capacity 11 AC power requirements 46 Charger Fault LED 43 AC trouble delay 35 circuits 10 accessories 14 Class A 14, 20, 25 ACK Class A Converter Module 9, 14 see also Acknowledge 10 installation 25 Acknowledge 10, 12 Class B 10, 12, 14, 20 Acknowledge button 40 coding alarm NACs 35 piezo pulse rate 13 combination circuit 10, 21 alarm relay 8, 9, 10, 14, 23 see also waterflow/tamper 36 contact rating 12 combination waterflow/supervisory 10, 20, 21 Alarm Silence 10, 12 requirements 21 Alarm Silence LED 42 wiring 21 alarm verification 36, 37 compatibility timing graph 36 see also device compatibility 10 annunciator,remote control buttons 10 see also RZA-4XF 30 controls 12 applications 10 cover 32 audible Walktest 41 current autoresettable supervisory 35 maximum system 12 auto-silence 35 nonresettable power 23 auxiliary power 23 resettable power 23 see also system current 10 total output 22 current requirements for system 47, 48 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 51 D-L Index p short circuit current 12 description 10 standby current 12 device compatibility 10 wiring 20 Digital Alarm Communicator/Transmitter indicators 12 see also 411 &411UD 15 see also LED 11 dimensions Initiating Device Circuit 8, 9, 10, 12, 14, 20 backbox 14, 17 Class A 25 dip switch cover 32 In-Line resistor DIP switch options IDC combination circuit 21 see also programming 32 installation 17 DIP switch settings 33 4XLMF 26 see also programming 32 4XTMF 26, 27 disable 4XZMF 26 see also zone enable/disable 11 CAC-4 25 disable NAC 37 Class A Converter Module 25 dress panel 10, 15 option modules 25, 26 E J Earth Fault LED 43 J3 and J5 earth ground 19 option module connectors 26 enable J4 and J6 see also zone enable/disable 11 option module connectors 26 End-of-Line resistor JP1 jumper IDC 12, 20, 21 placement supervision 27 NAC 12, 22 JP2 placement supervision 27 F L fail-safe trouble relay 23 Lamp Test 40 fail-safe relay LED 11, 13 see also trouble relay 14 AC Power 11, 13, 42 features 10 Alarm Silence 11, 13, 42 fire alarm response 44 Battery Fault 11, 13, 43 fire alarm restora144 Charger Fault 11, 13, 43 Form-C 15, 29 Earth Fault 11, 13, 43 see also relay 10, 14 Fire Alarm 11, 13 freeze 20 main circuit board 8, 9 freeze signal Maintenance 11, 13 1, see also smoke detector monitoring 10 NAC Disable 42 NAC Fault 11,, 13,, 42 Power Trouble 11, 13, 42 G Supervisory 11, 13 Gentex synchronization 38 System Trouble 11, 13,42 ground fault 20, 43, 45 Trouble 11, 13 disable 8, 9 Walktest 11, 13, 42 Zone Disable 11, 13, 42 I Zone Fire Alarm 43 Zone Maintenance 43 B detectors 14, 20 Zone Supervisory 43 IDC 9, 10, 12, 14, 20 Zone Trouble 43 alarm current 12 LED Interface Module 15 compatibility 20 installation 26 End-of Line resistor 21 see also 4XLMF 30 End-of-Line resistor 12, 20 maximum loop resistance 12, 20 see also Initiating Device Circuit 8 52 SK-2&SK-4 Series Manual- P/N 52604:132 10/18/2011 Index ASS M see also 4XTMF 28 main circuit board power 12, 19, 23 see also 2 Zone 8 maximum system 12 see also 4 Zone 9 primary 19 maintenance 20 secondary piezo pulse rate 13 see also battery 19 maintenance signal see also resettable and nonresettable power see also smoke detector monitoring 10 9 modes of operation power supply calculations 46 see also normal and walktest 40 Power Trouble LED 42 mounting power-limited wiring 24 cabinet 17 programming 32, 33 municipal box 27 chart 33 municipal box transmitter DIP switches 32 see also 4XTMF 14 feature chart 33 supervisory 36 N programming DIP switches 32 NAC 9, 10, 12, 14, 22 R coding 35 current 22 relay 8, 9, 10, 14, 15, 23, 29 disable 37 contact rating 12, 23 End-of-Line resistor 12, 22 Remote Annunciator maximum current 12 see also RZA-4XF 15 nonsilenceable 37 remote station service 28 see also Notification Appliance Circuit 8 Reset 10 wiring 22 Reset button 40 NAC Disable LED 42 resettable power 8, 9, 10, 12, 14, 23 NAC Fault LED 42 current 23 nonpower-limited wiring 24 maximum current 12 nonresettable power 9, 10, 12, 14, 23 reverse polarity circuit current 23 see also 4XTMF 14 maximum current 12 RZA-4XF nonsilenceable NAC 37 see also Remote Annunciator 15 normal mode 40 see also remote annunciator 30 Notification Appliance Circuit 8, 9, 10, 12, 14, wiring to RXLMF 30 22 Class A 25 S selective silence 35 0 silence operating instructions 40 selective 35 operation 43 Silence button 40 option modules 14 silence inhibit 35 connector 8, 9 silent walktest 42 connectors 26 sounder 11, 13 installation 25, 26 status LEDs 42 placement supervision 27 strobe synchronization see also synchronization 38 P strobes maximum quantity 38 piezo 13 Style B 12, 14, 20 alarm 13 see also Class B 10 maintenance 13 Style D 14, 20, 25 see also sounder 11 Style Y 12, 14 supervisory 13 see also Class B 10 trouble 13 Style Z 14, 25 polarity reversal circuit supervision SK-2&SK-4 Series Manual- PM 52604:132 10/18/2011 53 T—Z Index option module placement 27 CAC-4 25 supervisory Class A Converter Module 25 piezo pulse rate 13 Class A IDC 26 see also programming supervisory 36, 37 Class A NAC 26 supervisory relay 9, 10, 14, 23 combination waterflow/supervisory 21 contact rating 12 IDC 20 supervisory response 44 NAC 22 supervisory restoral 44 nonpower-limited 24 switch functions 40 power-limited 24 synchronization UL requirements 24 Gentex 38 see also strobe synchronization 38 Z System Sensor 38 Wheelock 38 Zone 1 20 system current 10 Zone Disable LED 42 system current calculations 47 Zone Enable/Disable 11, 13 System Sensor synchronization 38 Zone Fire Alarm LED 43 System Trouble LED 42 Zone Maintenance LED 43 zone relay module 15 see also 4XZMF 29 T Zone Supervisory LED 43 temporal coding 35 Zone Trouble LED 43 transformer assembly 14 rating 14 Transmitter Module 14 transmitter module see also 4XTMF 27 trouble piezo pulse rate 13 trouble relay 8, 9, 10, 14, 23 contact rating 12 fail-safe 23 trouble reminder 35 trouble response 44 trouble restoral 45 V UL wiring requirements 24 V verification alarm timing graph 36 see also alarm verification 36 w Walktest 10, 13 Walktest LED 42 Walktest mode 40, 41 audible 41 exiting 42 silent 42 waterflow/tamper circuit 36 I Wheelock synchronization 38 is wiring 54 SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 i Manufacturer Warranties and Limitation of Liability Manufacturer Warranties. Subject to the limitations set forth herein, Manufacturer warrants that the Products manufactured by it in its Northford, Connecticut facility and sold by it to its authorized Distributors shall be free, under normal use and service, from defects in material and workmanship for a period of thirty six months (36) months from the date of manufacture (effective Jan. 1, 2009). The Products manufactured and sold by Manufacturer are date stamped at the time of production. Manufacturer does not warrant Products that are not manufactured by it in its Northford, Connecticut facility but assigns to its Distributor, to the extent possible, any warranty offered by the manufacturer of such product. This warranty shall be void if a Product is altered, serviced or repaired by anyone other than Manufacturer or its authorized Distributors. This warranty shall also be void if there is a failure to maintain the Products and the systems in which they operate in proper working conditions. MANUFACTURER MAKES NO FURTHER WARRANTIES, AND DISCLAIMS ANY AND ALL OTHER WARRANTIES, EITHER EXPRESSED OR IMPLIED, WITH RESPECT TO THE PRODUCTS, TRADEMARKS, PROGRAMS AND SERVICES RENDERED BY MANUFACTURER INCLUDING WITHOUT LIMITATION, INFRINGEMENT, TITLE, MERCHANTABILITY, OR FITNESS FOR ANY PARTICULAR PURPOSE. MANUFACTURER SHALL NOT BE LIABLE FOR ANY PERSONAL INJURY OR DEATH WHICH MAY ARISE IN THE COURSE OF, OR AS A RESULT OF, PERSONAL, COMMERCIAL OR INDUSTRIAL USES OF ITS PRODUCTS. This document constitutes the only warranty made by Manufacturer with respect to its products and replaces all previous warranties and is the only warranty made by Manufacturer. No increase or alteration, written or verbal, of the obligation of this warranty is authorized. Manufacturer does not represent that its products will prevent any loss by fire or otherwise. Warranty Claims. Manufacturer shall replace or repair, at Manufacturer's discretion, each part returned by its authorized Distributor and acknowledged by Manufacturer to be defective, provided that such part shall have been returned to Manufacturer with all charges prepaid and the authorized Distributor has completed Manufacturer's Return Material Authorization form. The replacement part shall come from Manufacturer's stock and may be new or refurbished. THE FOREGOING IS DISTRIBUTOR'S SOLE AND EXCLUSIVE REMEDY IN THE EVENT OF A WARRANTY CLAIM, Warn-HL-08-2009.fm SK-2&SK-4 Series Manual— P/N 52604:B2 10/18/2011 55 3 SILENT KNIGHT by Honeywell 12 Clintonville Road Northford,CT 06472-1610 USA 203-484-7161 Fax:203-484-7118 www.silentknight.com ©2011 Honeywell International Inc. INSTALLATION AND MA114TENANCE INSTRUCTIONS SYSTEM 00 � 3) series SENSOR 3825 Ohio Avenue,St. Charles,Illinois 60174 Photoelectric Smoke Detector 1-800-SENSOR2,FAX:630-377-6495 Models: 2W-B,2WT-13,4W-B,4WT-B www.systemsensor.com ELECTRICAL SPECIFICATIONS 2-WIRE 4-WIRE System Voltage-Nominal: 12/24 12/24 Volts Non-polarized Min.: 8.5 8.5 Volts Max.: 35 35 Volts Max.Ripple Voltage: 30 30%peak to peak of applied voltage Max.Standby Current: - 50 50 µA average Peak Standby Current: 100 —µA Max.Alarm Current: 130 20 mA 12 Volt Systems (For 2W-B and 2WT-B,panel must limit current) 130 23 mA 24 Volt Systems Alarm Contact Ratings: — 0.5 Amp @ 30 V AC/DC Alarm Reset Time: 0.3 0.3 sec Max.Start-up Capacitance: 0.1 —µF Latching Alarm:Reset by momentary power interruption Maximum Initial Start-up Time: 45 15 sec Alarm Verification* Start-up Time: 15 15 sec *Assumes the panel's alarm verification reset time is 10 seconds or less.Should the alarm verification reset exceed 10 seconds,use the maximum initial start-up time. PHYSICAL SPECIFICATIONS Heat Sensor(Model 2WT-B and 4WT-B): 135°F(57.2°C) Freeze Trouble(Model 2WT-B and 4WT-B): 41°F(5°C) Operating Temperature Range: 2W-B and 4W-B: 32 to 120°F(0 to 49°C) 2WT-B and 4WT-B: 32 to 100°F(0 to 37.8°C) Operating Humidity Range: 0 to 95%RH ron-condensing Storage Temperature Range: -4 to 158*F(-20 to 70°C) .Diameter(including base): 5.3 inches Height(including base): 2.0 inches Weight: 6.3 oz. BEFORE INSTALLING Please read thoroughly System Sensor manual A05-1003,Applications Guide Installation of the 2W-B,2WT-B,4W-B,and 4WT-B detectors is simplified by for System Smoke Detectors,which provides detailed information on detector the use of a mounting base that may be pre-wired to the system,allowing the spacing, placement, zoning,wiring, and special applications. Copies of this detector to be easily installed or removed.The mounting base installation is manual are available from System Sensor at no charge. further simplified by the incorporation of features compatible with drywall fasteners. NOTICE:This manual shall be left with the owner/user of this equipment. Two LEDs on the detector provide a local visual indication of the detector's status: IMPORTANT.This detector must be tested and maintained regularly following TABLE is DETECTOR LED MODES NFPA 72 requirements.At a minimum,cleaning should be performed annually. Green LED Red LED GENERAL DESCRIPTION Models 2W-B and 2WT-B are 2-wire photoelectric smoke detectors; models Power up Blink 10 sec Blink 10 sec 4W-B and 4WT-B are 4-wire photoelectric smoke detectors. All models in- Normal(standby) Blink 5 sec — corporate a state-of-the-art optical sensing chamber and an advanced micro- Out of sensitivity — Blink 5 sec processor.The microprocessor allows the detector to automatically adjust its Freeze Trouble — Blink 10 sec sensitivity back to the factory setting when it becomes more sensitive due to Alarm — Solid contaminants settling in its chamber. In order for this feature to work prop- erly,the chamber must never be opened while power is applied to the smoke detector.This includes cleaning,maintenance or screen replacement.Should After an initial power-up delay,the red and green LEDs will blink synchro- it become necessary, the screen/sensing chamber is field replaceable. Mod- nously once every ten seconds.It will take approximately 80 seconds for the els 2WT-B and 4WT-B also feature a restorable, built-in, fixed temperature detector to finish the power-up cycle(see Table 2). (1357)thermal detector and are also capable of sensing a freeze condition if TABLE 2:POWER-UP SEQUENCE FOR LED STATUS INDICATION* the temperature is below 41°F. Condition Duration All i3 Series detectors are designed to provide open area protection.Two-wire Initial LED Status Indication 80 seconds models must be used with compatible UL Listed panels only. Initial LED Status Indication 4 minutes When used with an i3 Series compatible control panel or the i3 Series 2W (if excessive electrical noise is present) MOD2 module(refer to installation manual D500-46-00),the 2W-B and 2WT-B are capable of generating a"maintenance needed"signal.The 2W-MOD2 can *Refer to Electrical Specifications for start-up time in conjunction with panel indicate a need for cleaning,replacement,or a freeze condition(2WT-B only) alarm verification. at the control panel or module. D100-96-00 1 I56-1800-012R NOTE:If,during power-up,the detector determines there is excessive electri- • In wet or excessively humid areas,or Next to bathrooms with showers. cal noise in the system such as those caused by improper grounding of the . In dusty,dirty,or insect-infested areas. system or the conduit,both LEDs will blink for up to 4 minutes before display Near fresh air inlets or returns or excessively drafty areas.Air condition- ing detector status(see Table 2). • ers, heaters, fans, and fresh air intakes and returns can drive smoke away from the detector. . After power-up has completed and the detector is functioning normally within Consult NFPA 72,the local Authority Having Jurisdiction (AHJ), and/or sp- its listed sensitivity range,the green LED blinks once every five seconds.If the plicable codes for specific information regarding the spacing and placement detector is in need of maintenance because its sensitivity has shifted outside of smoke detectors. the listed limits,the red LED blinks once every five seconds.When the detec- tor is in the alarm mode,the red LED latches on.The LED indication must not ACAUTION be used in lieu of the tests specified under Testing.In a freeze trouble condi- Smoke detectors are not to be used with detector guards unless the combina- tion,the red LED will blink once every 10 seconds(refer to Table 1). tion has been evaluated and found suitable for that purpose. To measure the detector's sensitivity,the i3 Series Model SENS-RDR Infrared Sensitivity Reader tool should be used. (See Figure 4.) WIRING INSTALLATION GUIDELINES Models 2W-13 and 2WT-B also include an output that allows an optional Model All wiring must be installed in compliance with the National Electrical Code, RA10OZ Remote Annunciator to be connected. applicable state and local codes, and any special requirements of the local Authority Having Jurisdiction. MOUNTING Proper wire gauges should be used. The conductors used to connect smoke Each il Series detector is supplied with a-mounting base that can be mounted: detectors to the alarm control panel and accessory devices should be color- coded to reduce the likelihood of wiring errors. Improper connections can 1. To a single gang box,or prevent a system from responding properly in the event of a fire. 2. To a 31/2-inch or 4-inch octagonal box,or 3. To a 4-inch square box with a plaster ring,or The screw terminals in the mounting base will accept 14-22 gauge wire.For 4. Direct mount or to ceiling using drywall fasteners(Figure 2). best system performance,all wiring should be installed in separate grounded FIGURE 1-MOUNTING OF DETECTOR conduit;do not mix fire alarm system wiring in the same conduit as any other electrical wiring. Twisted pair may be used to provide additional protection against extraneous electrical interference. O Wire connections are made by stripping approximately 1/4-inch of insulation from the end of the feed wire,inserting it into the proper base terminal,and tightening the screw to secure the wire in place. TWO-WIRE COMPATIBILITY System Sensor two-wire smoke detectors are marked with a compatibility identifier located on the label on the back of the product.For two-wire models 2W-B and 2WT-B,connect detectors only to compatible alarm control panels r� as identified by System Sensor's compatibility chart.This chart contains the current list of detectors and UL Listed compatible control units.A copy of this S0121-00 list is available from System Sensor upon request. The i3 Series heads and bases are keyed so that a 2-wire head will only mount to a 2-wire base, and a 4-wire head will only mount to a 4-wire base. The WIRING DIAGRAMS heads and bases are clearly identified as either 2-wire or 4-wire.When mount- FIGURE 3A:WIRING DIAGRAM,2W-B AND 2WT-B ing the i3 Series,ensure that the head is mounted to the correct base. TAMPER-RESISTANT FEATURE 2-WIRE, EOL The i3 Series detectors include a tamper-resistant feature that prevents removal ZONE - RESISTOR from the mounting base without the use of a tool.To engage the tamper-re- sistant feature,cut the small plastic tab located on the mounting base(Figure �a'°°Z RA'°°Z 2),and then install the detector.To remove the detector from the base once it has been made tamper resistant,use a small screwdriver to depress the square tamper release tab, located on the skirt of the mounting base, and turn the 00000 00000 2-WIRE � 3"' =' detector counterclockwise. _Z 0 2 D 9 D CONTROL z O z a a Z O z a a FIGURE 2:TAMPER-RESISTANT FEATURE PANEL g ' S a * ' 2W-B or 2W-B or DIRECT MOUNT 2WT-B 2WT-B HOLES ® S0133-01 • • FIGURE 3B:WIRING DIAGRAM,4W-B AND 4WT-B AUX OR YRESISTO� L SMOKE Av POWER - R-il IDC + SNAP OFF TAB FOR TAMPER LOCK STORTAMPER 00000 RELEASE TAB ,S0226-00 a-WIRE - -z oCONTROL � ozoo DO NOT INSTALL DETECTORS IN THE FOLLOWING AREAS: PANEL S a• In or near areas where particles of combustion are normally present4W-B or such as kitchens;in garages(vehicle exhaust);near furnaces,hot water 4WT-B heaters,or gas space heaters. o134-01 • In very cold or very hot areas. DI00-96-00 2. I56-1800-012R 2-WIRE 13 DETECTOR WiRED!W4 STYLE D CONFIGURATION: B.SMOKE ENTRY TEST Hold a smoldering punk stick or cotton wick at the side of the detector and ACAUTION gently blow the smoke through the detector until it alarms. Any 2-wire i3 smoke detector (2W-B, 2WT-B, 2WTA-B, or 2WTR-B) wired C.DIRECT HEAT METHOD(MODELS 2WT-B AND 4WT-B ONLY) • in the Style D initiating device circuit (IDC) configuration requires the use Using a 1000-1500 watt hair dryer,direct the heat toward either of the thermis- of a 2W-MOD2 module. This is because fire alarm control panels vary by tors.Hold the heat source about 12 inches from the detector to avoid damage manufacturer on the implementation of Style D circuits. Therefore,the only to the plastic. way to insure proper operation of 2-wire i3 smoke detectors (2W-B, 2WT-B, 2WTA B,or 2WTR-B)on Style D IDC's is to use a 2W-MOD2 module.Refer to NOTE:For the above tests,the detector will reset only after the power source the 2W-MOD2 installation manual,document D500-46-00,for Style D wiring has been momentarily interrupted. diagrams. The 2W-MOD2 installation manual may be downloaded from the If a detector fails any of the above test methods,its wiring should be checked System Sensor web site at www.systemsensor.com. and it should be cleaned as outlined in the Maintenance section.If the detec- tor still fails,it should be replaced. INSTALLATION Notify the proper authorities when the system is back in service. AWARNING LOOP VERIFICATION(MODELS 2W-B AND 2WT-B ONLY) Remove power from alarm control unit or initiating device circuits before in- Loop verification is provided by the EZ Walk loop test feature. This feature stalling detectors. is for use with i3 Series compatible control panels or the i3 Series 2W-MOD2 module only. The EZ Walk loop test verifies the initiating loop wiring and NOTE: To install units so that corresponding LEDs are lined up, refer to the provides visual status indication at each detector. "Green LED"indicator on the base. 1. Ensure proper wiring and power is applied.Wait approximately six min- 1. Wire the mounting base screw terminals per Figure 3a or Figure 3b, as utes before performing EZ Walk test. applicable. 2. Place control panel or module in EZ Walk Test mode(refer to panel man- 2. Place detector on the base and rotate clockwise.The detector will drop ufacturer's manual or 2W-MOD2 manual D500-46-00). into the base and lock into place with a"click". 3. Observe the LEDs on each detector: 3. After all detectors have been installed,apply power to the alarm control unit. TABLE 3:EZ WALK TEST DETECTOR MODES 4. Test each detector as described in Testing. Green LED Red LED 5. Reset all the detectors at the alarm control unit. 6. Notify the proper authorities that the system is in operation. Proper Operation Double blink 5 sec — ACAUTION Out of Sensitivity — Double Blink 5 sec Dust covers are an effective way to limit the entry of dust into the smoke detec- Freeze Condition — Double Blink 10 sec for sensing chamber.However,they may not completely prevent airborne dust • particles from entering the detector. Therefore, System Sensor recommends NOTE:The EZ Walk loop test must not be used instead of alarm the removal of detectors before beginning construction or other dust produc- testing. ing activity.When returning the system to service,be sure to remove the dust covers from any detectors that were left in place during construction. MAINTENANCE NOTE:Before performing maintenance on the detector,notify the proper au- TESTING thorities that maintenance is being performed and the system will be tem- Detectors must be tested after installation and following maintenance. porarily out of service.Disable the zone or system undergoing maintenance NOTE:Before testing,notify the proper authorities that maintenance is being to prevent any unwanted alarms. Power must be removed from the detector performed and the system will be temporarily out of service.Disable the zone before performing maintenance of any kind. or system undergoing maintenance to prevent any unwanted alarms. 1. Remove the detector cover by turning counterclockwise.(See Figure 6.) Ensure proper wiring and power is applied.After power up,allow 80 seconds 2. Vacuum the cover or use canned air to remove any dust or debris. for the detector to stabilize before testing. 3. Remove the top half of the screen/sensing chamber by lifting straight up Test i3 Series detectors as follows: (Figure 5). 4. Vacuum or use canned air to remove any dust or particles that are pres- A.TEST SWITCH ent on both chamber halves. 1. An opening for the recessed test switch is located on the detector hous- 5. Replace the top half of the screen/sensing chamber by aligning the arrow ing(See Figure 4). on the screen/sensing chamber with the arrow on the housing. Press 2. Insert a small screwdriver or allen wrench (0.18-max.) into the test down firmly until the screen/sensing chamber is fully seated. switch opening;push and hold. 6. Replace the detector cover by placing it over the screen/sensing chamber 3. If the detector is within the listed sensitivity limits, the detector's red and turning it clockwise until it snaps into place. LED should light within five seconds. 7. Reinstall the detector and test.(See the Testing section.) FIGURE 4:RECESSED TEST SWITCH OPENING AND SEN84M POSITION g, Notify the proper authorities when the system is back in service. POSITION SENS-RDR _ ATAN ANGLE ON THE OVALAREA OR AT THE CHAMBER OPENING BY THE WORD*PAINT" LED PUSH RECESSED DIAMET WITHA 0.18'MAX. RECESSED TEST SWITCH DIAMETER TOOL S0135-00 D100-96-00 3 I56-1800-012R FIGURE 5:REMOVING/Ra;P1_1V'!%!•G SCREEN/SENSING CHAMBER r-REMOVABLE DETECTOR COVER - �-SCREEN/SENSING CHAMBER (TOP HALF) DETECTOR HOUSING S0136-00 - Please refer to insert for the Limitations of Fire Alarm Systems THREE-YEAR LIMITED WARRANTY System Sensor warrants its enclosed smoke detector to be free from defects in materials Department,RA u 3825 Ohio Avenue,St.Charles,IL 60174.Please include a and workmanship under normal use and service for a period of three years from date note describing the malfunction and suspected cause of failure.The Company shall not of manufacture.System Sensor makes no other express warranty for this smoke detec- be obligated to repair or replace units which are found to be defective because of damage, tor.No agent,representative,dealer,or employee of the Company has the authority to unreasonable use,modifications,or alterations occurring after the date of manufacture. increase or alter the obligations or limitations of this Warranty.The Company's obligation In no case shall the Company be liable for any consequential or incidental damages for of this Warranty shall be limited to the repair or replacement of any part of the smoke breach of this or any other Warranty,expressed or implied whatsoever,even if the loss detector which is found to be defective in materials or workmanship under normal use or damage is caused by the Company's negligence or fault.Some states do not allow the and service during the three year period commencing with the date of manufacture. exclusion or limitation of incidental or consequential damages,so the above limitation After phoning System Sensor's toll free number 800-SENSOR2 (736-7672) for a Return or exclusion may not apply to you.This Warranty gives you specific legal rights,and you Authorization number, send defective units postage prepaid to:System Sensor, Repair may also have other rights which vary from state to state. FCC STATEMENT This device complies with part 15 of the FCC Rules.Operation is subject to the following two conditions:(1)This device may not cause harmful interference,and(2)this device must accept any interference received,including interference that may cause undesired operation. Note: This equipment has been tested and found to comply with the limits for a Class B digital device,pursuant to Part 15 of the FCC Rules.These limits are designed to provide reasonable protection against harmful interference in a residential installation.This equipment generates, uses and can radiate radio frequency energy and,if not installed and used in accordance with the instructions,may cause harmful interference to radio communications.However,there is no guarantee that interference will not occur in a particular instal- lation. If this equipment does cause harmful interference to radio or television reception,which can be determined by turning the equipment off and on,the user is encouraged to try to correct the interference by one or more of the following measures: -Reorient or relocate the receiving antenna. -Increase the separation between the equipment and receiver. -Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. -Consult the dealer or an experienced radio/TV technician for help. D100-96-00 4 I56-1800-012R 02012 System Sensor SILENT 3 KNIGHT i by Honeywell DEVICE Compatibility DocumF.nt i Document 52612 5/14/2013 Rev:F Table of Contents Control Panel Circuit Specifications...............................................................................................................................3 is CompatibleTwo-Wire Smoke Detectors........................................................................................................................3 VariousManufacturers ............................................................................................................................................3 Maximum Number of Detectors per Zone......................................................................................................................4 SystemSensor..........................................................................................................................................................4 Four-Wire Smoke Detectors/Devices..............................................................................................................................5 NotificationAppliances..................................................................................................................................................6 SystemSensor-24VDC..........................................................................................................................................6 System Sensor SpectrAlert Advance.......................................................................................................................7 Gentex-24VDC......................................................................................................................................................7 Cooper-Wheelock-24VDC....................................................................................................................................8 Cooper-Wheelock Exceder Series...........................................................................................................................9 DoorHolders...................................................................................................................................................................9 Relays............................................................................................................................................................................10 2 Silent Knight Device Compatibility Document— PM 52612Y 5/14/2013 Control Panel Circuit Specifications SK-2/SK-2E,SK4/SK4E SK-5UD/SK-5UDE Initiating Device Circuit Voltage: 17.3-24.6 Initiating Device Circuit Voltage: 17.18-20.48 Max Detector Circuit Standby Current:2.OmA/circuit Max Detector Circuit Standby Current:2.OmA/circuit Compatibility Identifier:"A" Compatibility Identifier:"A" NAC Power: Full Wave Rectified (Special Application) NAC Power: Full Wave Rectified (Special Application) ECS-550(HV) Maximum signaling current for special application power: NAC Power: Filtered(Special Application, Regulated) 2.0 amps Nominal operating voltage:24 VDC Maximum signaling current for regulated power:200 mA Compatible Two-Wire Smoke Detectors Various Manufacturers Model Detector Detector Base Base Standby ID Type Model ID Current(uA) System Sensor 2W-B A Photoelectric I N/A N/A 120 System Sensor 2WT-B A Photoelectric I N/A N/A 120 System Sensor 1100/D A Ionization N/A N/A 100 System Sensor 1151 A Ion B401 /6110LP/B116LP A 120 System Sensor 1400 A Ion N/A N/A 100 System Sensor 1451 A Ion B401 B/B406B/B110LP/ A 120 B116LP System Sensor 1451 DH A Ion DH-400 A 120 System Sensor 1800 A Ion N/A N/A 120 System Sensor 1851 B A Ion 13101 B/B107B A 120 System Sensor 1851 DH A Ion DH1851 DC A 120 System Sensor 2151 A Photo B401/6110LP/B116LP A 120 System Sensor 2300T A Photo/Therm. N/A N/A 120 System Sensor 2400 A Photo N/A N/A 120 System Sensor 2400AIT A Photo/Iso.Therm./Horn N/A N/A 120 System Sensor 2400AT A Photo/Therm./Horn N/A N/A 120 System Sensor 2400TH A Photo/Therm. N/A N/A 120 System Sensor 2451 A Photo 6401 B/B406B/DH-400/ A 120 B110LP/B116LP System Sensor 2451 TH A Photo/Therm. B401 B/B406B/B110LP/ A 120 B116LP System Sensor 2800 A Photo N/A N/A 120 System Sensor 2800TH A Photo/Therm. N/A N/A 120 System Sensor 2851 B A Photo B101 B/B107B A 120 System Sensor 2851 BTH A Photo/Therm. B101 B/13107B A 120 System Sensor 2851 DH A Photo DH2851 DC A 120 System Sensor 2100/D/S A Photoelectric N/A N/A 120 System Sensor 2100T/D/S A Photoelectric N/A N/A 120 System Sensor DH1OOP A Photoelectric N/A N/A 100 System Sensor DH100LP A Photoelectric N/A N/A 120 System Sensor 2WTA-B A Photoelectric N/A N/A 100 System Sensor 2WTAR-B A Photoelectric N/A N/A 100 Silent Knight Device Compatibility Document—P/N 52612:F 5/14/2013 3 Maximum Number of Detectors per Zone When using two-wire smoke detectors containing supplementary relays or indicators,the operation of more than one detector per zone cannot be ensured. System Sensor Base SK-2 Model Number SK-4 Model „SK-5UD/E 2W-B N/A 16 2Wr-B N/A 16 1100/D N/A 20 1151 B401 /B110LP/B116LP 16/16/1 1400 N/A 20 1451 B401 B/B406B 16/1 B110LP/B116LP 16/1 1451 DH DH-400 16 1800 N/A N/A 1851 B B101 B N/A 1851B B107B N/A 1851DH DH1851DC 16 2100/D/S N/A 16 • 2100T/D/S N/A 16 2151 B401/B110LP/B116LP 16/16/1 2300T N/A 16 2400 N/A 16 2400AIT N/A 1 2400AT N/A 1 2400TH N/A 16 2451 B401 B/B406B 16/1 B110LP/B116LP 16/1 2451 DH-400 16 2451 TH B401 B/B406B 16/1 B110LP/B116LP 16/1 2800 N/A N/A 2800TH N/A N/A 2851 B B101 B N/A 2851E B107B N/A 2851BTH B101B N/A 2851BTH B107B N/A 2851 DH DH2851 DC 16 DH100P N/A 16 • DH100LP N/A 16 4 Silent Knight Device Compatibility Document—PM 52612T 5/14/2013 Base SK-2 Model Number Model SK-4 • SK-5UD/E 2WTA-B N/A 20 2WTAR-B N/A 1 Four-Wire Smoke Detectors/Devices Smoke Detector/Base Detector Type Max Standby Alarm Current Current(mA) (mA) Fenwal CPD-7021 (w/70-201000-005 Base) Ionization 0.10 Fenwal PSD-7125 Photoelectric 0.10 Fenwal PSD-7126(w/70-201000-005 Base) Photoelectric 0.10 Fire-Lite BLP-12-4W Base ' Gentex 824 Photoelectric 0.50 Gentex 824T Photoelectric 0.50 Gentex 824CP Photoelectric 0.50 ' Gentex 824CPT Photoelectric 0.50 Hochiki HSC-4R Base ' Hochiki SPB-24 Projected Beam 0.25 System Sensor B112LP Base 0.12 36 System Sensor 13114LP Base ' System Sensor B404B Base System Sensor DH100ACDC Photoelectric 0.15 0.70 • System Sensor DH100ACDCLP Photoelectric 0.15 0.70 System Sensor DH100ACDCLWP Photoelectric 0.15 0.70 System Sensor DH400ACDCI Ionization Duct 25 95 System Sensor DH400ACDCP Photoelectric Duct 25 95 System Sensor 1112/24/D Ionization 0.05 50 System Sensor 1424 Ionization 0.10 41 System Sensor 1451 (w/1340213/13112LP Base) Ionization 0.10 39 System Sensor 2112/24ATR Photoelectric 0.50 60/70 System Sensor 2112124AITR Photoelectric 0.50 60/70 System Sensor 2112/24/D Photoelectric 0.05 50 System Sensor 2112/24R Photoelectric 0.50 60/70 System Sensor 2112/24TR Photoelectric 0.50 60/70 System Sensor 2112/24T/D Photoelectric w/135°Thermal 0.05 50 System Sensor 2112/24TSRB Photoelectric w/135'Thermal 15 45 Supervisory Relay System Sensor 2312/24TB Photoelectric 0.12 50 System Sensor 2424 Photoelectric 0.10 41 System Sensor 2424TH Photoelectric 0.10 41 System Sensor 2451 Photoelectric 0.10 39 System Sensor 2451TH(with B402I3/B112LP Base) Photoelectric 0.10 39 System Sensor 2W-MOD Loop Test/Maintence Mod. 30 50 System Sensor 4W-B(24 Volt) Photoelectric 13 .05 23 System Sensor4WT-B(24 Volt) Photoelectric 13 w/Therm .05 23 System Sensor 4WTA-B(24 Volt) 13 Photo w/Therm/Sounder .05 35 Silent Knight Device Compatibility Document-P/N 52612Y 5/14/2013 5 Smoke Detector/Base Detector Type Max Standby Alarm Current Current(mA) (mA) • System Sensor 4WTR-B(24 Volt) 13 Photo w/Therm/Relay 05 35 System Sensor 4WTAR-B(24 Volt) 13 Photo w/ .05 50 Therm/Sounder/Relay System Sensor 4WITAR-B(24 Volt) 13 Photo w/ .05 50 IsolatedTherm/Sounder/Relay System Sensor 2W-MOD2 13 Loop Test/Maintence Mod. .05 System Sensor RRS-MOD 13 Reversing Relay/Sync .05 Module System Sensor 6424 Projected Beam 10 28.4 System Sensor Beam 1224(S) Projected Beam 17 38.5 Contact manufacturer for current draws Notification Appliances Control panels with Notification circuits supplied by Special Application power must use appliances listed in this table. • Refer to manufacturer's installation instructions for more information. • Contact manufacturer for current draws or additional options System Sensor - 24VDC Use only 24VDC devices with 24 volt control panels. MODEL NUMBER&NOMENCLATURE(System Sensor) CH12/24 Electronic Chime/Sounder • CH2415, CH241575,CH2475,CH24110 SpectrAlert Chime with Strobe MA-12/24D Electronic Sounder MA12/24EH Multi Alert Horn with Mechanical Tone MAEH24LO,MAEH24LOC,MAEH24LOLA,MAEH24M,MAEH24MC,MAEH2415ADA, MAEH2475ADA, MAEH241575ADA, MAEH24110ADA, MAEH2415ADAS, MAEH241575ADAS Multi Alert Horn with Mechanical Tone/Strobe MASS24D, MASS241-0, MASS24M Electronic Sounder/Strobe MASS24LOC, MASS24MC Electronic Ceiling Sounder/Strobe MASS24LOLA Electronic Sounder/Strobe with Fuego lens MASS2415ADA, MASS2475ADA, MASS24110ADA, MASS241575ADA Sounder/Signaling Strobe MASS2415ADAS, MASS241575ADAS Sounder/Signaling Strobe w/Synch.Ckt. MDL/MDLW Sync Modules for use with SpectraAlert series P2415, P241575,P2430, P2475, P24110 SpectrAlert Horn/Strobe PA400R, PA400W, PA400B Sounder PC24115, PC24177 SpectrAlert Ceiling Mount Horn/Strobe PS24LO Add-on Strobe RP2415ADA, RP241575ADA. RP2475ADA, RP24110ADA Retrofit Strobe Plate S2415,S241575,S2430,S2475, S24110 SpectrAlert Strobe SC24115,SC24177 SpectrAlert Ceiling Mount Strobe SP100W24LOC, SP100W24MC Ceiling Speaker/Strobe, 8 round grille SP101 R24LO, SP101 R24M Speaker/Strobe, 5 square grille SP2C24115,SP2C24177 SpectrAlert Ceiling Mount Speaker Strobe SP2C2415,SP2C2430, SP2C2415/75,SP2C2475, SP2C24110 SpectrAlert Speaker Strobe S1224MC, P1224MC, SP1224MC SpectrAlert Strobe SS24, SS241-0, SS24M, Strobe 6 Silent Knight Device Compatibility Document-P/N 52612:F 5/14/2013 MODEL NUMBER&NOMENCLATURE(System Sensor) SSM24-6,SSM24-8,SSM24-10 Alarm Bell SS24LOC,SS24LOBC(beige),SS24MC Ceiling Strobe SS2415ADA,SS2475ADA,SS24110ADA,SS241575ADA Signaling Strobe SS2415ADAS,SS241575ADAS Signaling Strobe with Synch.Circuit V4R2415ADA,V4R2475ADA,V4R24110ADA,V4R241575ADA Speaker/Signaling Strobe SPH-15R,SC2415,SC241575,SC2430,SC2475,SC2495, PC2415,PC242575,PC2430, PC2475 PC2495,SP2C2415,SP2C242575,SP2C495 System Sensor SpectrAlert Advance System Sensor Spectralert Advance chimes,chime strobes,horns,horn strobes and strobes base models:CHR,CHW, CHSR,CHSW,HR,HW, MDL3R,MDL3W,P2R,P2W, P2RH,P2WH,P4R,P4W,P4RH, P4WH,POR,POW, PC2RH,PC2WH,PC4R, PC4W,PC4RH,PC4WH, SCR, SCW, SCRH, SCWH, SR, SW, SRH, SWH, SW-ALERT, SWH-ALERT,MHR,MHW followed by suffixes denoting application(K=outdoor),market(A=Canada)and/or markings(P=Plain, SP=Spanish,FR=French,B=Bi-lingual and PG=Portugese): Gentex - 24VDC Use only 24VDC devices with 24 volt control panels. MODEL NUMBER&NOMENCLATURE(Gentex) GEC-24-15,GEC-24-30,GEC-24-60,GEC-24-75,GEC-24-110,GEC-24-15/75W Horn/Strobe GES-24-15,GES-24-30,GES-24-60,GES-24-75,GES-24-110,GES-24-15175W Strobe GMH-24 Electro-Mechanical Horn GMS-24-15,GMS-24-15-1,GMS-24-110,GMS-24-110-1,GMS-24-1575-1,GMS-24-3075, GMS24-30W,GMS24-60W Electro-Mechanical Horn with Strobe GOT-24 Multi-Tone Horn GOS-24-15-1,GOS-24-110-1,GOS-24-1575-1,GOS-24-3075-1 Multi-Tone Horn/Strobe GXS-4RH,GXS-4BH,GXS4RL,GXS-4BL Strobes GXS-4-15,GXS-4-15-1,GXS-4-1575,GXS-4-30,GXS-4-60,GXS-4-110,GXS-4-110-1, GXS-4-3075 Strobe GX-90-4 Horn GX-90S-4BH,GX-90S-4BL,GX-90S-4RL,GX-90S-4RH,GX-90S-4-15,GX-90S-4-15-1, GX-90S-4-110,GX-90S-4-110-1,GX-90S-4-1575 Horn with Strobe HG124 Electronic Horn HS24-15,HS24-15/75,HS24-30, HS24-60,HS24-110, HS24-110W,HS24-75W,HS24-60W, HS24-30W, Multi-Tone Horn/Strobe SHG-24L,SHG-24H,SHG24-15,SHG24-15-1,SHG 24-60,SHG24-110,SHG24-110-1, SHG24-1575,SHG24-30,SHG24-60,SHG24-3075 Electronic Horn with Strobe SPK4-15,SPK4-15-1,SPK4-1575,SPK4-110,SPK4-110-1,SPK4-24-3075 Speaker with Strobe SPK8-15,SPK8-15-1,SPK8-1575,SPK8-110,SPK8-110-1 B,SPK8-24-3075 Speaker with Strobe SPKE4,SPKE4-15-1,SPKE4-15/75,SPKE4-15/75-C SPKE4-30/75,SPKE4-60,SPKE4-110-1, SPKE4-60W,SPKE4-30W Speaker with Strobe SPKE8,SPKE8-15-1,SPKE8-15/75,SPKE8-15/75-C,SPKE8-30/75,SPKE8-60,SPKE8-110-1, SPKE8-1575W,SPKE8-30W Speaker with Strobe ST24-15,ST24-15/75,ST24-30,ST24-60,ST24-110,ST24-75W,ST24-11OW,ST24-30W Strobe WGMS-24-75 Weatherproof Electro-Mechanical Horn with Strobe Silent Knight Device Compatibility Document-PM 52612T 5/14/2013 7 Cooper-Wheelock - 24VDC Use only 24VDC devices with 24 volt control panels. MODEL NUMBER&NOMENCLATURE(Cooper-Wheelock) 7002T-24 Horn with Strobe AES-DLI-WM-24-VF-R,AES-ELI-WM-24-VF-R Multi-Tone Signals AES-DL1-LSM-24,AES-EL1-LSM-24 Horn Strobe AH-24,AH-24WP Horn AMT-12/24 Multi-Tone Horn AMT-24-IS-VFR,AMT-24-LS-VFR,AMT-24-LSM-VFR,AMT-241575-FR Multi-Tone Horn Strobe AS-2415,AS-2430,AS-2430C,AS-2475,AS-24110,AS-241575 Audible Strobe AS-2415W,AS-2430W,AS-2475W,AS-24110W,AS-241575W Horn/Strobe AS-24MCW-FR/FW,AS-24MCC-FR/FW Multi-Candela Appliance ASWP-2475W-FR/FW Weatherproof Audible Strobe CH-CFI-IS-24-CFW,CH-CF1-LS-24-CFW,CH-CFI-MS-24-CFW Chime CH-DF1-IS-24-VFR,CH-DF1-LS-24-VFR,CH-DFI-LSM-24-VFR,CH-DF1-MS-24-VFR Chime CH70-24-R/W,CH90-24-R/W Chime CH70-2415W,CH70-2430,CH70-2475,CH70-241575 Chime with Strobe CH70-24MCW-FR/FW Multi-Candela Appliance CH90-2475C,CH90-24100C Chime with Strobe DSM-12/24 Dual Synchronization Module EH-DLI-WM-24-VF-R, EH-EL1-WM-24-VF-R Electronic Horn Strobes HSW-24-HFR,HSPW-24-HFR,HS2W-HFR Strobe IS-24-VFR, IS1-24-VFR, IS3-24-VFR Strobe ISP-24-VFR Strobe LS-24-VFR,LS1-24-VFR, LS1M-24-VFR LS3-24-VFR,LS3M-24-VFR Strobe LSM-24-VFR Strobe LSP-24-HFR,LSPM-24-VFR Strobe MB-G6-24-R Motor Bell,6"gong MB-GI0-24-R Motor Bell, 10"gong MBS-G6-24-R Motor Bell/Strobe,6"gong MBS-G10-24-R Motor Bell/Strobe, 10"gong MIZ-24 Mini Piezo Horn MIZ-24-HSW-HFR,MIZ-24-IS-VFR,MIZ-24-LS-VFR,MIZ-24-LSM-VFR,MIZ-24-MS-VFR, MIZ-24-WM-VFR,MIZ-TC24-R,MIZ-TC24-W Mini-Horns Strobe MS-24-VFR,MS1-24-VFR,MS3-24-VFR Strobe MSP-24-HFR Strobe MT-12/24-R MultiTone MT-24-WM,MT-24-WM-VFR MultiTone Strobe 117cd MT-24-IS-VFR,MT-24-LS-VFR,MT-24-LSM-VFR,MT-24-MS-VFR MultiTone Strobe MT-24-SL-VFR,MT-24-SLM-VFR Multi-tone/Strobe MT4-24-IS-VFR,MT4-24-LS-VFR,MT4-24-LSM-VFR,MT4-24-MS-VFR MultiTone Strobe NS-2415W-FR, NS-2430W-FR,NS-2475W-FR, NS-24110W-FR,NS-241575W-FR Horn Strobe NS4-2415W-FR,NS4-2430W-FR,NS4-2475W-FR,NS4-24110W-FR,NS4-241575W-FR, NS4-24MCW- FR,NS-24MCW-FW, NS-24MCW-FR Horn Strobe RS-1230, RS-2415, RS-2430, RS-2475,RS-24110,RS-241575 Strobe RS-2415W,RS-241575W Strobe RSS-2415W,RSS-2415/75W, RSS-2430W,RSS-2475W, RSS-24110W Strobe 8 Silent Knight Device Compatibility Document-P/N 52612:F 5/14/2013 MODEL NUMBER&NOMENCLATURE(Cooper-Wheelock) • RSS-24MCW-FR/FW Strobe RSS-2415-CR-FW, RSS-2430-CR-FW, RSS-2475-CR-FW RSS-24100-CR-FW Strobe RSS-24150-CR-FW,RSS-24177-CR-FW Strobe RSSP-24MCW-FR/FW strobe RSSP-2415W, RSSP-2415/75W, RSSP-2430W,RSSP-24185W Strobe SCM-24-R Synchronized Controller Module SHW-24-HFR,SH2W-24-HFR,SHPW-24-HFR Strobe SL-24-VFR,SL1-24-VFR,SL3-24-VFR,SLP-24-VFR Strobe SLM-24-VFR,SL1 M-24-VFR,SL3M-24-VFR,SLPM-24-VFR Strobe SM-12/24 Synchronization Module SR-2415,SR-241575 Synchronized Strobe WMT-24-FR,WM1T-24-FR,WM3T-24-FR Strobes AS-24MCC-FW,CH90-24-MCC-FW, E90-24MCC-FW,ET90-24MCC-FW, HS-24-RNV MIZ-24S-R/W, RSS-24MCC-FW,NH-12/24R/W ZNH-R,ZNH-W,ZNS-MCC-FR,ZNS-MCC-FW,ZNS-MCCH-FR,ZNS-MCCH-FW,ZNS-MCW-FR ZNS-MCW-FW,ZNS-MCWH-FR,ZNS-MCWH-FW,ZRS-MCC-FR,ZRS-MCC-FW,ZRS-MCCH-FR ZRS-MCCH-FW,ZRS-MCW-FR,ZRS-MCW-FW,ZRS-MCWH-FR,ZRS-MCWH-FW AMT-241575W-FR,AMT-241575W-FW,AS-241575W-FR,AS-241575W-FW,CH90-24MCC-FR CH90-24MCC-FW,CSX10-24-R,CSXG10-24-R,DSM-12/24-R,HS-24-R,HS-24-W HS4-241575W-FR,HS4-241575W-FW, HS4-24MCW-FR,HS4-24MCW-FW,HS4-24MCWH-FR HS4-24MCWH-FW,MT-24MCW-FR,MT-24MCW-FW, MT4-115-R,MT4-115-W, • MT4-115-WH-VFR,MTWP-2475W-FR, M7WP-2475W-FW,NS-24MCW-FR,NS-24MCW-FW RSS-121575W-FR, RSS-121575W-FW,RSS-241575W-FR,RSS-241575W-FW,RSS-2415C-FR RSS-2415C-FW,RSS-2475W-FR, RSS-2475W-FW, RSS-24MCC-FR,RSS-24MCC-FW, RSS-24MCCH-FR,RSS-24MCCH-FW,RSS-24MCCHR-FR,RSS-24MCCHR-FW,RSS-24MCCR-FR RSS-24MCCR-FW,RSSP-241575W-FR, RSSP-241575W-FW, RSSWP-2475W-FR, RSSWP-2475W-FW Cooper-Wheelock Exceder Series HSR, HSW,STR,STW, HNR, HNW, HSRC,HSWC,STRC, STWC,HNRC,HNWC Silent Knight certifies the Exceder product line for synch compatibility based on documentation provided by Underwriters Laboratories. Silent Knight requires that the current draw data from legacy products(RSS,AS,NS,ZRS,and ZNS series)be used for the purpose of determining the number of devices allowed per circuit. Door Holders MANUFACTURER MODEL TYPE Current (mA) Edwards DH150A Floor Mount 96 Edwards DH154A Flush Mount 96 Edwards DH158A Surface Mount 96 Rixon Firemark FM-980 Floor Mount,single 68 Rixon Firemark FM-996 Surface Wiring 68 Rixon Firemark FM-998 Concealed Wiring 68 Silent Knight Device Compatibility Document-PM 52612:F 5/14/2013 9 Relays MANUFACTURER MODEL Current(mA) Air Products&Controls, LTD MR-101/C 15 M R-201/C 35 PAM-1 15 PAM-2 15 PAM-SD 15 System Sensor A77-716B 20 PR-1 15 PR-2 30 PR-3 30 EOLR-1 30 R-10T 23 R-14T 23 R-20T 40 R-24T 40 R-10E 23 R-14E 23 R-20E 40 R-24E 40 10 Silent Knight Device Compatibility Document P/N 526121 5/14/2013 T' ELGUARD Teiguard TG-7 Series Quil (-.,% k Installation Guide SECURITY SIGNALING COMPANY CONFIDENTIAL For use by TELGUARD*customers only. LISTED LISTED Distribution to other parties strictly prohibited June 22,2012 56044203 INCOMING System Status LEDs(RSSI Mode) Te I g u a rd T G-7 Series TELCO _ 0 - 0 0 0 D 0 o QUICK INSTALLATION GUIDE [BACKUP MODE] D D D D D D D D ° RSSI IEFn: NONE 1 Pe : '� m ] ix E AT K j- Installation Summary 'sgw;aeml . a <.na >no ,+ >.w .aE >ae as ® R There are seven steps in installing Telguard properly. IF YOU DO NOT ® m m Acceptable RSSI Range PROCEED IN THE ORDER AND MANNER PRESCRIBED, YOU MAY System Status LEDs(Normal Mode) NOT COMPLETE THE INSTALLATION IN THE TIME ALLOCATED. RJ31X ■ «F or AcmA ED Ow ACTIVATION D GN ;OTIV.tlFO ----- STEP 1: REGISTER FOR CELLULAR SERVICE ° ELA'"Me "`m"T'°"°EMED Register the unit online through www.teiguardonline.com, by completing the ■ OFF NoTSDU"E Online Registration Form at www.Teiguard.com. Telular requires this -D_FLASHING T11WM.E: ANTENNA FLASH*Ac LOWSASSINc V SYSTEM iFIASH—L—SATTER1 information to activate the unit. TROUBLE f LASH.LFC LINE FAULT rusH.Nu No SERVICE Battery wire should J s FLASH=RFc RADIO FAILURE beat from/.IDDh TONE FAIL STEP 2: LOCATE UNIT AND MEASURE SIGNAL STRENGTH (RSSI) bean from AC wh r Fuses PRF R'A PRE --- -- ------ __- _-_- PANEL PANEL D""oo"LRM 1 First,you will be confirming that Telguard has adequate cellular signal strength. Press the «F COMM ■ WARNING: 1 D ON ANELONHDONIRACNVRI LED/RSSI Mode Toggle button one time, LEDs will now indicate signal strength. Minimum «TALE .ES.NTDNPHDNE z° J D """I"` R "°° recommended is 2 (2 on solid and the third flashing). Press the LED/RSSI Mode Toggle poavlccT RRIOR ❑ s..Nm sFm� ■ OFF aM TMc '° ° button a second time to exit RSSI mode, i 5 0 D W TMC COMM D o wRA n FDR RESroNSE A COVITIDM—ED a Fow LED D ;OF G 1F aE STEP 3: TRANSMIT PANEL ALARMS OVER THE TELCO CONNECTION s' fif eDMm.,;_ o RADIO STATUS DoN AD°NLALLINc Y fY P programmed properly. P P t1 sIM TOEa.R�N;,--, J Next,you will verity that the alarm panel is ro rammedThis step Is important to ven "'tits+ TELcuARo D FLASHING RA1000MMDNICATING that the alarm panel is programmed with valid account code and central station information D FLASHING L vSIONENARLED before transmitting signals through the cellular network. tlf g 3 Digital TG-7 E,ER g g g r S SECON°51 ' t STEP 4: PROGRAM ACTIVATE $TRANSMIT PANEL ALARMS OVER THE IF Battery Connector NOT USED ■ OFF NOT used , sST CELLULAR RADIO NETWORK IN C) 't':� � T. FF—I SNo? NOT USED ■ «F NDTDSED Next, ou will be connectn the alarm anel's di ital dialer out ut to Tel uard and veri In that �� i Y 9 P 9 P 9 verifying tff s i ei t0,_ a POVERLED ■ m, "D"°TD°""E°TED-LINT alarm signals can be reliably sent through Telguard over cellular to the central station digital -1 L - D ON 11COANEDTEDTOUNIT receiver. The incoming Telco line is not connected to Telguard during this step.A minimum of two alarm signals must be transmitted.Activation is confirmed when LED 1 is illuminated. EARTH Alarm Panel (NOTE:THE FIRST ALARM WILL ACTIVATE THE UNIT AT THE TELULAR COMMUNICATION _ Ban ryl GROUND r CENTER,IT WILL NOT GO TO THE CENTRAL STATION,ALL SIGNALS AFTER THE FIRST ARE CAUTION:MAY yO �O ��p SENT TO THE CENTRAL STATION)CONNECTIONS MAY RESULT G,P G"Q IN DAMAGE TO UNIT. AC r0 r0 OQ T 11.V ROOMA) tiTC tiF �9 WWW Te!guard.com STEP 5: CONNECT SUPERVISORY TRIP OUTPUTS REFER TO INSTALLATION AND OPERATING DESTRUCTIONS TO ETERNAL MANUAL THIS DEVICE COMPLIES TRIP INPUT ,L Next,you will wire Telguard's supervisory trip outputs to the alarm panel and then test. -- WITH FCC RULE PART 15 — STEP 6: CONNECT TRIP INPUT (OPTIONAL) Optionally,you can wire an external relay input to the trip input lead and ground,and test. IS STEP 7: COMPLETE THE INSTALLATION Your last step will be to attach earth ground,reconnect Telco,and permanently mount the unit. 6044203 • TELGUARD TeIguard TG-7 Series Installation and Operating Guide for models TG-7, • -and TG-7FS r w .a� i SECURITY COMPANY CONFIDENTIAL SIGHALMG (R) For use by TELGUARD"customers only. Distribution to other parties strictly prohibited. Jun 01,2012 LISTED LISTED Important • The registration form must be completed before leaving for the job site to install the Telguard product. There are two ways to register a Telguard: • Register online at www.telcivardonline.com (preferred method), • Send the electronic registration form at www.telguard.com, Foreword Dealers purchase Telguard®cellular communicators for the quality, features and total value they represent.The Telguard TG-7 models (part#s TG7G0004,TG7GC004,TG7GFSO4 and TG7GA004)are UL Listed for Household Burglary systems, Household Fire systems, Commercial Burglary and depending on the model,Commercial Fire systems.The Telguard TG-7 models may be used in Household Burglary/Fire systems and Retail or Commercial Burglary/Fire systems as the sole, primary or secondary communication path. Technical Support Technical support for all Telguard products is available: Monday -Saturday 8am -8pm ET Toll Free: 800-229-2326, option 9 About this Manual • This manual assumes that you have basic security system installation skills such as measuring voltages, stripping wire, properly connecting wires together, connecting wires to terminals, and checking phone lines. It also assumes that you have a familiarity with the proper installation and programming tasks related to various alarm panels. The material and instructions covered in this manual have been carefully checked for accuracy and are presumed to be reliable. However,Telular assumes no responsibility for inaccuracies and reserves the right to modify and revise this manual without notice. It is our goal at Telular to always supply accurate and reliable documentation. If a discrepancy is found in this documentation, please mail or fax a photocopy of the corrected material to: Telular Corporation Telguard Technical Services 2727 Paces Ferry Road SE Suite 1-800 Atlanta,GA USA 30339 Fax:678-945-1651 • 56044103 i 0 2011 Telular Corporation • Repair and Warranty If trouble is experienced with the Telguard Cellular Alarm Communicator please contact Telguard Technical Support for trouble shooting, repair and(or)warranty information.The dealer or end user should not attempt any repair to the Telguard Cellular Alarm Communicator. Repair of this equipment should only be referred to qualified technical personnel. Telular will repair or replace(our option) inoperative units for up to two years from date of manufacture.This excludes damage due to lightning or installer error.Unauthorized modifications void this warranty. Not responsible for incidental or consequential damages. Liability is limited to price of unit. This is the exclusive warranty and no other warranties will be honored,whether expressed or implied. An RMA must be assigned before returning product to: Telular Corporation Attention: Repair Depot 294 W Palatine Rd Wheeling,IL 60090 Note:RMA number must be on the outside of box or product will not be accepted. Future Testing and Limitations on Use The Telguard TG-7 Series is part of an advanced design alarm communication system. It does not offer guaranteed protection against burglary and fire. Any alarm communication system is subject to compromise or failure. The Telguard unit will not work without power. Electrically powered devices will not work if the • power supply is off for any reason, however briefly. The cellular radio network, needed to transmit alarm signals from protected premises to a central monitoring station, may be inoperable or temporarily out of service. Cellular radio networks are also subject to compromise by sophisticated methods of attack. This equipment, like any other electrical device, is subject to component failure. Although this equipment is designed to be long lasting,the electrical components could fail at any time. Due to these limitations,we recommend that if the automatic self-test feature is not enabled, other arrangements be made with the user to test the system at least once every three months. Moreover, arrangements should also be made for on-site inspection/test by a licensed alarm installer at least once each year. Terms and Conditions for Use of Telular Product These Terms and Conditions are a legal contract between you and Telular Corporation for the title to and use of the Product. BY RETAINING AND USING THE PRODUCT YOU AGREE TO THE TERMS AND CONDITIONS INCLUDING WARRANTY DISCLAIMERS, LIMITATIONS OF LIABILITY AND INDEMNIFICATION PROVISIONS BELOW. IF YOU DO NOT AGREE TO THE TERMS AND CONDITIONS, DO NOT USE THE PRODUCT AND IMMEDIATELY RETURN THE UNUSED PRODUCT FOR A COMPLETE REFUND. You agree to accept sole responsibility for any misuse of the Product by you;and, in addition,any negligent or illegal act or omission of your or your agents, contractors, servants,employees,or other users of the Product so long as the Product was obtained from you, in the use and operation of the Product. • 56044103 ii 0 2011 Telular Corporation INDEMNIFICATION OF TELULAR CORPORATION ("TELULAR") YOU SHALL INDEMNIFY, DEFEND AND HOLD HARMLESS TELULAR FOR ANY OF THE COST,INCLUDING REASONABLE ATTORNEYS' FEES,AND FROM CLAIMS ARISING OUT OF YOU,YOUR CLIENTS'OR OTHER THIRD PARTIES' USE OR OPERATION OF THE PRODUCT:(i) FOR MISUSE OR IN A MANNER NOT CONTEMPLATED BY YOU AND TELULAR OR INCONSISTENT WITH THE PROVISIONS OF THIS MANUAL; (ii)IN AN ILLEGAL MANNER OR AGAINST PUBLIC POLICY; (iii)IN A MANNER SPECIFICALLY UNAUTHORIZED IN THIS MANUAL;(iv)IN A MANNER HARMFUL OR DANGEROUS TO THIRD PARTIES;(v) FROM CLAIMS BY ANYONE RESPECTING PROBLEMS, ERRORS OR MISTAKES OF THE PRODUCT;OR(vi)COMBINATION OF THE PRODUCT WITH MATERIAL, MODIFICATION OF THE PRODUCT OR USE OF THE PRODUCT IN AN ENVIRONMENT NOT PROVIDED, OR PERMITTED, BY TELULAR IN WRITING. THE PARTIES SHALL GIVE EACH OTHER PROMPT NOTICE OF ANY SUCH COST OR CLAIMS AND COOPERATE, EACH WITH THE OTHER,TO EFFECTUATE THIS INDEMNIFICATION, DEFENSE AND HOLD HARMLESS. WARRANTY and LIMITATIONS TELULAR WILL REPAIR OR REPLACE(OUR OPTION)INOPERATIVE UNITS FOR UP TO TWO YEARS FROM DATE OF MANUFACTURE. EXCLUDES DAMAGE DUE TO LIGHTNING OR INSTALLER ERROR AS WELL AS UNITS THAT INCORPORATE MATERIAL, OR USED IN A MANNER OR ENVIRONMENT, NOT SPECIFICALLY AUTHORIZED IN THIS MANUAL. UNAUTHORIZED MODIFICATIONS VOID THIS WARRANTY. NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. LIABILITY`LIMITED TO PRICE OF UNIT. THIS IS THE EXCLUSIVE WARRANTY, IN LIEU OF ALL OTHER WARRANTIES INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY, TITLE, DELIVERY,INFRINGEMENT OR FITNESS FOR A PARTICULAR PURPOSE AND NO OTHER WARRANTIES WILL BE HONORED,WHETHER EXPRESSED OR IMPLIED. • • 56044103 iii ®2011 Telular Corporation • Table of • Important Note I Foreword I Table of Contents Iv General Description and Operation i Features 2 Operating Mode 2 Multiple Alarm Format Support 2 Complete Supervision of Communication Path 2 Link Supervision and Standard Line Security 3 Complete Power Supervision 4 Telguard Automatic Self-test Report 4 Telguard Remote Query Capability 5 • Programmable Supervisory Trip Output(STC)Relays 5 Diagnostic and Status LEDs 5 Two Way Voice 5 UL and ULC Listings 6 Getting Ready 6 Dealer Account Establishment 6 Subscriber Account Registration 6 Pre-Installation Checklist 6 Installation 7 Summary 7 Step 1:Register the Telguard Unit 7 Step 2:Locate Unit and Measure Signal Strength(RSSI) 7 Step 3: Verify Panel sends alarms over the Telco Connection for Back-up Path g Step 4:Program,Activate& Transmit Alarms over Cellular Network g Step 5:Connect Supervisory Trip Outputs 13 Step 6:Connect and Test the Trip Input(optional) 14 • Step 7:Connect the tamper switch(mandatory for Commercial Burglary Installations in Canada) 15 56044103 iv 0 2011 Telular Corporation Step 8: Complete the Telguard Installation Appendix 1—Connection Guide 16 Wiring Diagrams 16 Tamper Switch Installation for ULC Commercial Burglary Applications 21 Jack Assignments 22 Main Terminal Strip Pin Assignments 22 DC Terminal Strip Pin Assignments 22 A/C Terminal Strip Pin Assignments 22 Compatible Alarm Panels 23 Appendix 2—Troubleshooting Guide 24 LED Indicator Guide—Normal Operating Mode 24 LED Indicator Guide—RSSI Mode 25 Troubleshooting Quick Reference Table 26 Appendix 3—Commercial Fire Sole Path Communicator Installation 27 Configuring the TG-7FS 27 Configuring a Sole Path at the Panel 27 Appendix 4—Compliance for UL Listed Installations 29 is Appendix S—Detailed Specifications 31 Dialer to Interface Electronics 31 Power 31 Digital Cellular Radio 31 Telco Interface 31 Appendix 6—Accessories 32 • 56044103 v 0 2011 Telular Corporation General Description and Operation • The Telguard® TG-7 series is a line of digital cellular radio alarm transmission devices used to provide the following three methods of communications for alarm panels via a cellular network: • Sole path (Cellular Transmission Only) • Primary path (Cellular Primary& Telco Backup) • Back-up path (Telco Primary&Cellular Backup) Depending on the TG-7 series and configuration (determined at time of installation),the alarm panel will use the PSTN line or cellular as sole, primary or back-up (secondary)transmission path to deliver alarm messages. When it is configured as a backup, it will provide transparent access from the alarm panel to the central station.When transmitting an alarm signal using the cellular path,the Telguard obtains its data from the alarm panel by way of a Telco line interface. The Telguard will obtain all alarm signal information including monitoring station phone number,account number and all zones for every alarm transmission.The Telguard handshakes with the alarm panel causing it to transmit the alarm data. The Telguard encodes the alarm data and transmits to the Telular Communication Center(TCC) over the digital cellular network. The TCC performs a function similar to a central station receiver and issues the transmission acknowledgement when the last message in the transmission is received.After decoding and reformatting, the alarm signal is routed to the appropriate alarm company monitoring station for action. In a cellular back up alarm installation,the incoming Telco line is connected from the premises' RJ-31xjack to the Telguard and then from the Telguard's RJ-45jack to the alarm panel in the normal fashion. Two programmable System Trouble Condition (STC)relays provide supervisory trip outputs for connection to the alarm panel's trip zone input terminals in order to provide a Telguard trouble signal to the alarm panel. Additionally, automatic self-test and remote query signals are transmitted exclusively over the cellular network with all Telco line and cellular monitoring, switching and supervisory functions built in. No extra modules are • required.The Telguard TG-7 series has its own power supply which keeps the Telguard battery charged. The UL Listed equipment at the TCC plays a key role in the operation of every Telguard. All Telguards utilize the TCC due to the panel alarm signal format encoding and decoding requirements used in packet-data transmissions over the digital cellular network. The TCC also manages the real-time databases for cellular accounts and a complete history of every Telguard's operating conditions. These conditions include programming setup information,cellular alarm transmission information, supervisory trouble information, remote query information, and automatic self test information. The TG-7 Series is offered in several models designed and configured to meet various applications and UL requirements as listed below. MODEL APPLICATION UL LISTINGS TG-7(standard unit) Commercial, Industrial, Retail & UL 365, UL 985, UL 1023, UL 1610, Financial Markets 5545, C1023, 5304 TG-7A(attack resistant enclosure Retail &Financial Markets UL 365, UL 985, UL 1023, UL 1610, unit) S545, C1023, 5304 and UL Bank, Safe&Vault applications TG-7FS (fire unit) Fire Systems UL 365, UL 985, UL 1023, UL 1610, S545, C1023, 5304 and UL 864 • 56044103 1 O 2011 Telular Corporation Features This section summarizes the key features of the Telguard TG-7 series. • Operating Mode The Telguard is a digital cellular Data/SMS transmission device that is installed at the protected premises to provide alarm transmission for security systems. The Telguard TG-7 series transmits alarm signals over the nationwide digital cellular network if the telephone line or data network has been disrupted,compromised or when there is no wire line service available. Multiple Alarm Format Support The Telguard TG-7 series supports multiple alarm communication formats. Note:The Telguard unit's default program setting is for auto detection of the panel alarm format. Auto Format Detect feature allows the Telguard to adapt to receive any listed format. If the alarm panel's format is changed for whatever reason,the Telguard will adjust to accept the new format. In order for the alarm panel to be compatible with the Telguard,the alarm panel must be programmed to transmit alarm messages to the central station using one of the following non-extended formats: • Pulse Formats: 0 3+1 pulse; 10pps, Double Round, 1400 Hz ack 0 3+1 pulse;20pps, Double Round, 2300 Hz ack 0 3+1 pulse;40pps, Double Round, 2300 Hz ack 0 4+2 pulse; 10pps, Double Round, 1400 Hz ack 0 4+2 pulse;20pps, Double Round, 2300 Hz ack 0 4+2 pulse;40pps, Double Round,2300 Hz ack • • Contact ID • Modem IIe or IIIa2 • SIA2(SIA-DC-03 level 2 release at 300 baud) • Sonitrol • DMP Hexadecimal account numbers can be used with 3+1 or 4+2 formats,as well as Contact ID and Modem (4 or 10 digits for Contact ID,4 digits for Modem). Complete Supervision of Communication Path The Telguard TG-7 series continuously supervises both the Telco and cellular communication paths. If either communication path becomes inoperative,the Telguard generates a relay trip output that can be connected to a zone input of the host alarm panel and/or used to control remote annunciation devices. Line Fault Condition (LFC) The Telguard monitors voltage on the incoming Telco line. If an inoperative Telco line is identified, (voltage below—20vdc, on hook)a Telco line fault condition (LFC) is declared. The System Trouble Condition LED(STC LED)will flash 3 times and the STC relay will trip after a programmable period of time. Upon Telco restoral,the relay and STC LED are returned to normal. NOTE:When the Telguard is configured as the Sole communications path,the Line Fault Condition(LFC) is disabled. • 56044103 2 m 2011 Telular Corporation No Service Condition (NSC) The Telguard declares a no service condition(NSC)when 1 of the following occurs. • 0 The Telguard device is unable to register with the cellular network. • The Telguard device has registered with the cellular network and the measured "receive"cellular radio signal strength at the protected premises drops to-114 dBm or less. NSC is programmable to trip the supervisory relay output(STC relay)after a delay of either 30 seconds, 1 minute, 3 minutes, 10 minutes,20 minutes, 30 minutes,45 minutes, 60 minutes or 1440 minutes(24 hours). The STC LED will flash 4 times immediately after losing cellular service and independent of the STC assertion and programmed assertion delay. NSC restoral occurs immediately after cellular service has been acquired. Radio Failure Condition (RFC) Radio communications failure condition(RFC) is declared when the Telguard is unable to transmit over the cellular network even with acceptable signal strength.When RFC is declared,the STC LED will flash 5 times and the STC relay will trip. Restoral of this condition occurs when a message is received from the TCC. Panel Presence Failure Condition (PPFC) Panel presence failure condition (PPFC) is declared when the Telguard is unable to detect the presence of the alarm panel. PPFC is indicated by the STC LED flashing 7 times.A supervisory report is generated and sent to the TCC for Central Station delivery upon detection of PPFC. Restoral of this condition occurs when the alarm panel is detected as present for the selected delay time. NOTE:The factory default for PPFC is Disabled and needs to be Enabled for its use. • Control Failure to Communicate (CFC) The Control Failure to Communicate(CFC)feature is an option that allows the Telguard unit to monitor the number of communication attempts the alarm panel makes over Telco before the Telguard becomes the main path of communication.This feature works by monitoring the alarm panel from the time it goes off-hook, and attempts to communicate,to on-hook status,and comes off-hook again. Each change in state by the alarm panel from off-hook to on-hook to off-hook again is considered an attempt. If this continually happens for a specified number of times within a specific time period,then the Telguard seizes the line and takes over as the main communication path for the alarm panel. If the Telguard goes into CFC,then it will not allow the panel to communicate via Telco again until the panel has been on-hook for 10 consecutive minutes. Note that the CFC condition causes the Telguard to redirect communications to the cellular channel, but it is not indicated on the STC LED, nor does it cause either of the external relays to be tripped. NOTE:The factory default for CFC is Disabled and needs to be Enabled for its use.When the TG7 is configured as the Sole Path,the CFC function is not applicable. Link Supervision and Standard Line Security In some high security commercial burglary applications,the communication path needs to be monitored periodically.TG-7 models support those applications when Link Supervision feature is enabled.When this feature is enabled,TG-7 models also meet the requirements for Standard Line Security(equivalent to previously known AA Grade security)when used with a UL Listed compatible alarm panel. Once the TG-7 model is provisioned with the Link Supervision option,the TCC constantly monitors the cellular path and sends a specific message to the central station if the path is broken or a compromise attempt is made.After the initial account activation is done, the installer must verify the Link Supervision by turning off the device and making sure an alarm with the specific code is delivered. • WARNING: Standard Line Security has only been evaluated between the TG-7 and the TCC. It is the responsibility of the installer to verify Standard Line Security from the Listed alarm panel to the Listed 56044103 3 0 2011 Telular Corporation receiver through the TG-7 models as marked on the alarm panel and as indicated in the manufacturer's installation instructions. Please note that Link Supervision is supported by all TG-7 models. However,only TG-7FS model has the UL • Listing for Commercial Fire applications. Complete Power Supervision The Telguard supervises and reports status of the backup battery and AC power source.The Telguard has an integrated control and power module which also keeps the Telguard battery charged.This battery charger function is also supervised. Low/Missing Battery Condition (LBC) The Telguard checks the backup battery voltage on initial power-up and every 60 seconds thereafter. If the battery voltage is less than 11.6 volts, it changes from'good'to'bad'state and a LBC is declared whereby the STC LED blinks twice,and the STC relay trips. When the battery voltage increases to 12.1 volts,the STC LED and STC relay restore.The Telguard also indicates Low/missing Battery Condition(LBC)when the battery charger fails. AC Failure Condition (ACFC) AC failure condition(ACFC) is detected immediately when the AC power drops below 102 VAC. When this condition is detected,the STC LED blinks once,the AC Power LED turns off,and the STC trip output is activated after 2 hours. When AC power returns to normal (>_106 VAC),the AC Power LED turns on immediately and the STC trip output restores after 60 seconds. Dial Tone Failure (DTF) The Telguard continuously monitors the 30V supply circuit that provides dial tone to the alarm panel.A Dial Tone • Failure(DTF) is declared when the 30V supply drops to 20V or less while the alarm panel is on-hook.The STC LED will flash 6 times and the STC relay can be programmed to trip. Note:This condition will require contacting Telguard Technical Support for resolution. Catastrophic Failure (CF) Catastrophic Failure (CF) is any condition that causes the Telguard to stop functioning at all levels. The most common CF is AC power failure followed by a complete discharge of the backup battery.The STC1 and STC2 trip outputs are activated and the visible indication is loss of all LED activity. Total loss of power to the Telguard does not prevent transmission of alarm messages from the alarm panel "through"the Telguard and out over an operative phone line. Telguard Automatic Self-test Report The automatic self-test signal is programmed to a daily,weekly or monthly schedule as prescribed when the Telguard is registered. The central station receives the automatic self-test report in the same format that the alarm panel normally uses for communication over the Telco line. The `self-test code and testing frequency are set during registration,and can accommodate any code the Central Station expects.The TCC captures all current and historical data pertaining to the operation of the Telguard when it processes the automatic self-test signal. This data contains current operational status(C.O.S.)of the Telguard such as "All OK", "AC fail condition", "low/missing battery condition", or any combination of these as well as the current signal strength. In addition, the data also contains historical data for supervisory events that occurred since the last self-test or remote query report signal was transmitted. This data includes the number of occurrences of AC fail conditions, low battery conditions, line fault conditions,communications failure conditions and no cellular service conditions.This • 56044103 4 0 2011 Telular Corporation additional information is available by contacting Telguard Technical Support or by visiting www.teiguardonline.com(dealer log-in credentials required). • Telguard Remote Query Capability Although the Telguard has the capability for a daily,weekly, or monthly automatic self-test, a separate feature is provided for determining the current operational status of every Telguard. This feature is called Remote Query and is used to provide real-time operational status for the Telguard on-demand.It is useful in resolving STC events that are reported by the alarm panel to the central station. The Remote Query is available via www.teiguardonline.com. The Remote Query causes the Telguard to upload current operational status data and historical data,just as the automatic self-test described above, except that the query signal is controlled by the one who initiates it. The query signal is held in the Telguard database at the TCC for review and is not forwarded on to the central station. Programmable Supervisory Trip Output (STC) Relays The Telguard has two supervisory relay trip outputs(STC1 normally open and STC2 normally closed) and both are energized in a powered-up state when no system troubles exist. This enables a supervisory trouble code to be transmitted to the central station when connected to an alarm panel's 24-hour instant input zone.The STC relays are programmable, using a standard touch-tone telephone (or butt-set)or during registration on www.telguardonline.com,to meet virtually any installation requirement. The following supervisory features or combination of features are programmable to trip the STC relays in order to meet a variety of installation requirements: • Trips on AC fail condition (ACFC) • Trips on low or missing battery condition (LBC) • Trips on no service condition (NSC) • Trips on line fault condition (LFC) • Trips on radio failure condition(RFC) • • Trips on dial tone failure (DTF) The following system trouble features are embedded in the Telguard for tripping the STC relays and cannot be changed: • Tripped when unit is not activated at the TCC • Trips on catastrophic failure(CF) if all power is lost • Trips on transmit-disable command from the TCC. This radio command disables only the Telguard transmitter and would be used,for example, to shut down the Telguard unit due to a runaway dialer. Note: For ULC Commercial Burglary installation, STC1 shall be connected to the panel's 24hr zone and shall be designated only as Low Battery Condition.Other failure conditions shall be triggered through STC2 and shall be treated as general trouble condition. Diagnostic and Status LEDs Six active LEDs are provided as a useful aid during installation and give installers an immediate visual indication of system status.The LEDs serve as indicators for activation, system trouble conditions,AC power,and communication indicators.They can also be used to provide a signal strength indication, similar to the signal strength bars on a cellular phone.See the installation section for details. Two Way Voice TG-7 supports 2-Way Voice feature when installed with a control panel that is UL listed for this feature. • Note:Currently,the two-way voice feature is available solely for panels configured for Contact ID. 56044103 5 C)2011 Telular Corporation UL and ULC Listings The TG-7 series meets the requirements for all Household Burglary, Household Fire, Commercial Burglary,and • Commercial Fire installations. The chart on Page 1 shows the various models and their associated UL and ULC Listings. Note:The alarm panel must also be UL or ULC Listed for the appropriate categories above. Getting Ready The Telguard can only be activated when all the necessary accounting information has been entered into the customer database located at the TCC (i.e.the unit has been registered).The database includes information about the customer account, unit location, and system test plan information. Dealer Account Establishment A Dealer Account must be established prior to registration of any Telguard unit. This can be accomplished by visiting www.telguardonline.com and completing the necessary information under"Dealer Signup".This is a one- time event and an acknowledgment from Telguard Customer Service will include a Dealer Account Number that will be used for all Telguard Digital registrations. Telguards are available for registration and activation once the Dealer Account has been established. Subscriber Account Registration A completed Registration Form is required by Telular to register the Telguard prior to leaving for thejob site. There are two ways to register a Telguard: • Register online at www.tellquardonline.com (preferred method), • • Send the electronic registration form at www.telular.com/telguard. Pre-Installation Checklist Before attempting to connect the Telguard to the alarm panel, please make sure you have all the proper parts before you go to thejob site. The following items are shipped with each Telguard: • Telguard Cellular Communicator • UL Listed plug-in transformer • 9 inch dipole Antenna • 12-foot antenna cable with mounting bracket • 7 foot RJ 45 plug-to-plug cord • 20-inch battery cable assembly with connector plug • Enclosure key lock • Pluggable screw terminal blocks(2,3,6 position) • Telguard Installation and Operating Instructions Manual • Quick Install Guide • Registration Form • Tamper switch (applicable to TG-7 units sold in Canada) Note:The Telguard registration must be completed in advance to avoid installation delays You must also have certain installation test tools: • A standard telephone or lineman's butt-set is required for programming the Telguard. • Screws and a screwdriver will be required to attach the Telguard and antenna to the wall. • • In order to connect the STC relay outputs and trip input to the alarm panel,solid or stranded electrical wire will be required.The terminal strips can accommodate solid or stranded wire from 14 to 22 gauge in size. 56044103 6 0 2011 Telular Corporation Installation • Summary The following are steps necessary to install the Telguard properly. NOTE: IF YOU DO NOT PROCEED IN THE ORDER AND MANNER PRESCRIBED,YOU MAY NOT COMPLETE THE INSTALLATION IN THE TIME DESIRED. These steps are summarized below and explained in detail in the remainder of this manual. 1. Register for Telguard service 2. Locate unit and measure signal strength 3. Transmit an alarm over the Telco connection 4. Program,activate and transmit alarm panel alarm messages over cellular connection 5. Connect supervisory trip outputs 6. Connect trip input(optional) 7. Connect the tamper switch (mandatory for Commercial Burglary Installations in Canada) 8. Complete installation Note: Step 3 not necessary for Sole Path installations. This seven step installation approach provides the alarm installer with the easiest and fastest method of properly installing a Telguard. Please follow the instructions carefully and if you should need assistance or have any questions, please call Telguard Technical Support at 1-800-229-2326 extension 9. Note:Dealer Account Establishment and Telguard Registration must be complete prior to Installation (see Section 3). Step 1: Register the Telguard Unit • Installation Tip: Register for Telguard service prior to leaving for the job site to avoid a second trip. There are two ways to register a Telguard: • Register online at www.tellouardonline.com (preferred method), • Send the electronic registration form at www.telauard.com, Step 2: Locate Unit and Measure Signal Strength (RSSI) Locate Unit Temporarily place the Telguard unit near the alarm panel. Permanent mounting should only be done after determining the optimum cellular reception location. Connect Backup Battery and AC Power Transformer To apply power to the Telguard, attach a battery to the battery connectorjack using the supplied battery cable. If the need for a different size cable arises,the Telguard provides an alternate screw-in terminal connection for the battery. Backup battery must be sized appropriately to meet installation requirements. Connect the Telguard AC power transformer(see A3.2 for acceptable UL Listed transformers)to AC terminals using stranded copper insulated wire following wire gauge and length recommendations below: Recommended Wire Size Length Not to Exceed 18ga 20ft • 16ga 40ft 56044103 7 0 2011 Telular Corporation Connect Antenna and Temporarily Place Unit The Telguard unit is supplied with an antenna.In most cases the antenna can be mounted directly to the unit.If necessary,the antenna may be moved to a better signal location using optional cable and bracket accessories. • The performance of the antenna may be affected by the wall or materials contained within the wall chosen for mounting. These effects may not be clearly identified by RSSI monitoring alone. The wall materials may have a more pronounced effect on the antenna transmit band performance. Do not install the Telguard in an area where the general public could reasonably be within 20cm (8 inches)of the antenna. NOTE:Optimum RF performance can usually be found at the highest point within a building with the fewest number of walls between the Telguard unit's antenna and the outside of the premises. NOTE:To avoid interference with other electronic devices operating in the area,avoid mounting the Telguard unit's antenna near other electronic devices. NOTE:The Telguard unit's dipole antenna is designed for indoor installations only. These considerations should be coupled with the best RSSI indication obtainable.Care should be taken to ensure that a large metal object such as a refrigerator or a metal cabinet is not located on the opposite side of the wall. If moving the Telguard to a different location is not practical,you may need to get an extension cable and remote the antenna in order to receive adequate radio signal strength. Pick a high,visually secure spot using the guidelines below. Tips for Improved Radio Signal Reception • The higher the antenna the better. Start in the drop ceiling above the unit and proceed from there, up to the roof if necessary. • Remember,the antenna should be as inconspicuous as possible for greatest visual security. • Try to keep the antenna away from sources of RF interference, including pumps,compressors, ovens, etc., or where metal objects can shield it or otherwise block the cellular radio RF signal. • Place the antenna perpendicular to the ground,either right side up or upside down. Do not mount the • antenna horizontally. Measure Received Signal Strength (RSSI) for Best Antenna Placement Measure the received signal strength by pressing the RSSI button.This switches the LEDs to signal strength mode. Now,slowly move the unit or remote antenna to achieve maximum signal strength. Pick a spot where the most LEDs(up to four) are illuminated. LED Function Table—View RSSI Mode(RSSI button) RSSI Value Illuminated LEDs RF dBm NO SVC LED 5 = slow flash, LED 4-2 = off n/a 1 LED 5 = on, LED 4-2 = off _< -111 dBm LED 5 = on, LED 4 = slow flash 11/z >_-110 dl3m LED 3-2 = off 2 LED 5-4 = on, LED 3-2 = off >_ -100 dBm LED 5-4 = on, LED 3 = slow flash 2112 >_LED 2 = off -90 dBm (Minimum signal strength with Telco) 3 LED 5-3 = on, LED 2 = off >-80 dBm (Minimum signal strength as Sole-Path) 31/2 LED 5-3 = on, LED 2 = slow flash >_-70 dBm 044103 8 0 2011 Telular Corporation 4 LED 5-2 = on >_-60 dBm If you cannot obtain a signal strength reading of 21/2 (TWO LEDS ON SOLID AND THE THIRD LED ON SLOW FLASH),you will need to move the unit and/or remote the antenna higher,or switch to a special antenna as described below. Antenna Options Antenna issues are unlikely unless the premises are located in a fringe network coverage area, in a building below ground level, or in a metal structure..Telular offers a variety of high quality low-loss antenna cables as well as high gain antennas listed in Appendix 6 Step 3: Verify Panel sends alarms over the Telco Connection for Back-up Path Connect alarm panel and Telco line to the Telguard. Plug the modular jack of the alarm panel into J16(black jack)of the Telguard and the incoming Telco connection into J17(grayjack).Trip a zone on the alarm panel and transmit over the Telco line. This step is important to verify the panel is programmed with a valid account code and central station information before transmitting signals through the cellular network. Step 4: Program, Activate & Transmit Alarms over Cellular Network Confirm that the Telguard enables the alarm panel to transmit alarm events over the cellular radio network. The Telguard will confirm activation with the TCC if the registration form was submitted prior to installation. Make sure that there is no Telco connection for the panel to use, and trip a zone on the alarm panel. During processing of the first alarm signal over the cellular network the Telguard will transmit all programming parameters along with the information (central station number and account code)from the alarm panel.Once this information is received,the TCC will transmit a message back indicating that the unit is activated. Once this message is received the LEDs on the unit will begin operating in normal mode;Activation LED 1 will be on. • The initial alarm is to confirm registration and activate the Telguard.This alarm will NOT be transmitted to the central station. Special LED Indications during Activation If the Telguard fails the activation process, it will be displayed on the LEDs. • If LED 1 and LED 4 are flashing,the Telguard has failed activation.The serial number is not in the database at the TCC.Clear the fault(see note below)and call Telguard Technical Support to verify proper registration before resending an alarm signal. • If LEDs 1-5 are flashing,there is an activation error.The activation message was NOT received at the TCC. Clear the fault(see note below)and retry transmitting an alarm signal. If the Telguard fails a second time to activate, check signal strength.If signal strength is OK,then call Telguard Technical Support for further assistance. NOTE:In order to clear the faults listed above,the RSSI button must be pressed twice.After the issue has been resolved and the unit cleared, STEPS 3 AND 4 MUST BE REPEATED OR THE TELGUARD wILL NOT TRANSMIT ANY SIGNALS. • 56044103 9 0 2011 Telular Corporation System Status LEDs Table System Status LEDs Activation Indications LED 1-5 FLASHING Failed Activation —Signal Too Weak a LED 1 &LED 4 FLASHING Activation Error—Call Telguard Technical Support LED 1 ON Activation Successful System Trouble Condition,STC(LED 2)Table Status LED 2 Indication 1 FLASH ACFC -A/C Low or Missing 2 FLASH LBC—Low Battery and/or Battery Charger Failure 3 FLASH LFC—Line Fault 4 FLASH NSC—No Service 5 FLASH RFC—Radio Failure 6 FLASH DTF—Dial Tone Failure 7 FLASH PPFC—Panel Presence Failure Condition Setup & Programming the Operating Parameters in the Telguard When the Telguard is received from the factory and is powered up for the first time, it is immediately ready ! for activation, provided the default settings are what you want.The STC LED 2 will flash to indicate any failure conditions.The yellow LED 3 will be on (Telco primary) and both of the STC relays will be tripped.If changes are required to the default settings,the Telguard can be locally programmed using a line-mans butt-set connected to T&R Test Points or a POTS phone connected to J16(where the alarm panel is normally connected). Command Key Sequences for POTS Pro ra ming Table Key Sequence Description ###* Enters the programming Mode #* Begins programming * Saves and stores changes Telguard Programming Steps 1. Make sure the Telguard has finished initialization and is idle. 2. Connect a POTS phone or lineman's butt set on the alarm panel jack(J16). 3. Take the POTS phone off hook or put the butt set in talk mode. You should hear dial tone. 4. Dial###*,and you should hear two(2)beeps. 5. Dial#*,and you should hear two(2)beeps. 6. Dial the memory location number(8XX)to be changed;you should hear two(2)beeps. 7. Enter the data value;you should hear two(2)beeps. 8. After the last data value is entered,dial*;you should hear two(2)beeps.Hang up to terminate POTS session. • 56044103 10 0 2011 Telular Corporation • Recheck signal strength. You need RSSI = 2Y2 (TWO LEDS ON SOLID AND THE THIRD LED FLASHING)for adequate signal transmission. Also, check antenna connector and make sure it is seated correctly. • Call Telguard Technical Support, 1-800-229-2326 option 9. • Verify Audio Connectivity (optional) The TG-7 supports transmit and receive audio, if used with a listen-in alarm panel, and configured with the voice feature at the TCC. If the audio capability is being used, it is important to verify proper voice communication.To do this,configure the alarm panel as appropriate, and trip an alarm.Once this is done,verify correct listen-in functionality with the central station personnel. Step 5: Connect Supervisory Trip Outputs Connect and test the supervisory trip outputs to the alarm panel. Enabling of a local alarm or strobe light may be desirable when a trip is declared. The STC trip output can be used directly to activate a local signaling device, provided that the trip output is not needed to trip the host control/communicator at the same time. If both a local signal and a control trip input are required,then external relays are needed to provide additional uncommitted contacts. NOTE:UL Listed installation of the TG-7 series will at a minimum have the trip output to the alarm panel to indicate low A/C (ACFC) and low battery(LBC)conditions. Note: For ULC Commercial Burglary installation, STC1 shall be connected to the panel's 24hr zone and shall be designated as Low Battery Condition.Other failure conditions shall be triggered through STC2 and shall be treated as general trouble condition. • Decide on a STC Trip Output Strategy The Telguard provides the alarm panel with two supervisory trip outputs for reporting a Telguard system trouble code to the central station. The supervisory trip outputs are programmable via a touch-tone telephone or butt- set to suit various installation requirements. The programming options for these supervisory trip outputs can be any combination of the following: • Always Off: Disables all relay supervisory functions • ACFC:Trips 2 hours(programmable for up to 24 hours)after loss of AC power. Restores 60 seconds after AC power is restored • LBC:Trips within 60 seconds on low battery condition. Restores when battery voltage>_ 12.1 vdc • LFC:Trips after 60 seconds on Telco line fault condition. Restores 60 seconds after Telco line restores • NSC:Trips after specified delay time(determined by POTS programming value 852)on no service condition due to loss of RF signal strength. Restores after RF signal strength is available • RFC:Trips on radio failure to communicate with the TCC • DTF:Trips on an internal failure in the dial tone circuitry within the TG-7 Use the butt-set programming instructions outlined in the previous step to program the STC trip output strategy. Reprogram Alarm Panel to Send Proper Code If necessary, reprogram the alarm panel to send proper alarm code when tripped by the Telguard's supervisory output. Program zone restoral as desired. Check Proper Operation of Telguard Supervisory Output Check for proper operation of each programmed supervisory output by causing it to trip the alarm panel and making sure the proper LED illuminates and that the proper trouble code is reported to the central station. Skip the testing of any supervisory functions that have not been enabled. Note that the yellow LED 3 starts to flash when the alarm panel goes off-hook to report the alarm signal over cellular. 56044103 13 0 2011 Telular Corporation • Low Battery Condition (LBC): Disconnect the battery and during the next 60 seconds check to see that the STC LED 2 flashes 2 times indicating that the battery is missing. Check to see that the alarm panel indicates the STC trouble code on the STC LED. Reconnect the battery and check during the next 60 seconds to see • that the STC LED 2 goes off, indicating the missing battery condition has been restored. • Line Fault Condition (LFC): Disconnect Telco cable at J17. LED 2 flashes 3 times and after 60 seconds the panel transmits the STC trouble code(over cellular)to the central station indicating the incoming Telco line is disconnected. Reconnect Telco cable and check to see that the STC LED 2 goes off in 30/60-seconds indicating Telco line restored. • No Service Condition (NSC): Disconnect the antenna from the Telguard. Check to see that the STC LED 2 flashes 4 times and in 60 seconds and the alarm panel transmits the STC trouble code over the Telco line indicating loss of RF signal strength. Reconnect the antenna and check to see that the STC LED 2 goes off within 30/60 seconds indicating RF signal strength resorted. Note:The Received Signal Strength (RSSI) must be less than -114 dBm in order to cause a NSC condition. If the Telguard is located in a high signal strength area (close to a cellular tower), it is possible for the signal strength to be greater than -114 dBm even with the antenna disconnected. • AC Fail Condition (ACFC): Disconnect the 12VAC, 10VA transformer and check to see that the AC POWER LED goes out and the STC LED 2 flashes once indicating that AC power is missing. Reconnect the AC transformer and check to see that the AC POWER LED goes on and the STC LED 2 goes off indicating that AC power has been restored. No transmissions will be sent to the central station. The AC power must be off, continuously,for 2 hours before the STC relay causes the alarm panel to send a trouble code. Verify the STC History The POTS command 858 was designed to display STC history for troubleshooting purposes.This feature increases in-field efficiency by eliminating the need for installers to call Telular for STC report data. To access the STC history, enter the POTS programming mode as described in Step 4 above. Enter the POTS command 858, and wait for the confirmation tone(2 beeps). Enter"Y to start the history display.The STC LED will light for 3 seconds, and then each STC in the history log will be displayed as a series of flashes of the STC • LED.At the end of the history,the STC LED will again light for 3 seconds, denoting the end of the history log. After the STC history is displayed,the STC LED will return to normal operation.To cancel the history playback at any time, use the POTS command 858 with a parameter value of"0". The STC history log can be cleared by using the POTS command 858 with a parameter value of"2".The STC history log is also cleared when the Telguard is reset or power cycled. Step 6: Connect and Test the Trip Input (optional) In addition to the interface to the alarm panel, a single trip input may be connected to the terminal block of the Telguard.When the input is tripped,an alarm message is sent to the central station via the TCC.This allows an external relay, separate from the alarm panel,to be connected to the Telguard in order to provide independent sensor input for other functions, such as tamper detection. The trip input is connected to the external relay by wiring the external relay to the TRIP IN terminal (pin 6)of the terminal block, and the other side to either the TRIP GND terminal of the same block(pin 5) or to the chassis ground on the Telguard circuit board. Note that trip inputs are normally wired such that there is a 2.2kQ resistor in parallel with the external relay,so that a tamper condition (i.e.a cut wire)can be detected. The functionality of the trip input can be customized at installation time using an ordinary phone set or a lineman's butt-set, in a similar manner to other Telguard programming options.The relevant POTS programming commands are: 56044103 14 0 2011 Telular Corporation Mem Loc. Field Default Setting Value 1 =Telco Primary/Cellular Backup 831 Mode of operation 01 2 = Cellular Primary/Telco Backup 3 = Cell ONLY (Sole Service, no Telco hook- up) 01 =42 pulse,40pps 2300 hz 02 =42 pulse,20pps 2300 hz 03 =42 pulse, 10pps 1400 hz 04 = 3x1 pulse,40pps,2300 hz 05 = 3x1 pulse, 20pps,2300 hz 833 C/C Reporting Format 09 06 = 3x1 pulse, 10pps,21400 hz 07 = Modem IIe or IIIa 08 = Contact ID 09 = Auto Format Detect 10 = Sonitrol 11 = SIA2(300 Baud) 12 = DMP 845 Manual Battery Test N/A Initiates the on-demand battery test. Enter the SUM TOTAL of the events that you wish to trip the STC relay by ADDING STC1 Trip Output the corresponding values: 850 Reporting Normally 04(only 00 = STC Trip Input Not Used LFC) 01 = AC Failure 08 = NSC Open 63 = ALL 02 = Low Battery 16 = RFC • 04 = LFC 32 = DTF Enter the SUM TOTAL of the events that you wish to trip the STC relay by ADDING STC2 Trip Output the corresponding values: 851 Reporting Normally 59(All 00 = STC Trip Input Not Used Open but LFC) 01 = AC Failure 08 = NSC 63 = ALL 02 = Low Battery 16 = RFC 04 = LFC 32 = DTF STC Trip Delay for 1=30 seconds* 6=30 minutes NSC/LFC* 2=60seconds* 7=45 minutes 852 *LFC delay can only be 2 3=3 minutes 8=60 minutes 30/60 seconds 4=10 minutes 9=24 hours 5=20 minutes 0 = terminate STC history display mode 858 STC History N/A 1 = start STC history display mode 2 = clear STC history 861 CFC Number of Events 0 0 = disabled 2 = 4 attempts 1 = 2 attempts 3 = 8 attempts 1 = 30 seconds 3 = 70 seconds 862 CFC Between Events 1 5 = 90 seconds 2 = 60 seconds 4 = 80 seconds 6 = 99 seconds 868 PPFC Delay 0 0 = disabled, 1 = 10 seconds,2=20 seconds, ... 15=150 seconds 56044103 11 ©2011 Telular Corporation Mem Loc. Field Default Setting Value 872 AC Failure Delay 02 0-24 hours,default = 2 hours 873 Trip Input Reporting 0 0= no report 1 = report trip 874 Trip Input Restoral 0 0 = no report Reporting 1 = report restoral 875 Trip Input Swinger 0 0= swinger function disabled Function 1 = swinger function enabled 899 Factory Default Unit N/A Resets all settings to factory defaults. Example: To change the Telguard factory default for STC 1 Trip Output reporting from only LFC to include all system trouble conditions the installer would perform steps 1-5 from the Telguard Programming Steps listed above. Then press 850, the Telguard will respond with 1 beep, then press 63, the Telguard will respond with 2 beeps, then press *,you will hear 2 beeps then hang up(this will change STC 1 trip output to report all system trouble conditions). The Telguard will automatically transmit a message to update the Telular Communication Center. Notice to Users,Installers,Authorities having Jurisdiction,and other involved parties: This product incorporates field-programmable software.In order for the product to comply with the requirements in the Standard for Control Units and Accessories for Fire Alarm Systems, UL864,the following programming settings must be limited to specific values or not used as indicated below. Memory Permitted in UL Possible Settings Settings Permitted • Location 864? (Y/N) by UL Yes 1=30seconds 1=30seconds 852 2=60 seconds* 2=60 seconds STC Trip Delay 3=3 minutes 3=3minutes for NSC/LFC* 4=10 minutes 5=20 minutes *LFC delay can 6=30 minutes only be 30/60 7=45 minutes seconds 8=60 minutes 9=24 hours 872 AC Failure Yes 0—Immediate 1-1 Hour Delay 1—24:from 1 Hour to 24 2 -2 Hours hours 3—3 Hours Verify Alarm Signal Transmissions over Cellular Before beginning this step, make sure that the Telco line from the TG-7jack J17(gray connector)that goes to the RJ-31x Jack at the premise for Back-up Communication is disconnected. Trip several alarms on the alarm panel and verify that the central station received them by calling the central station operator. Use a lineman's butt-set in MONITOR MODE connected to Telguard's "T" and "R"test pins to "listen"to communications between the alarm panel and the Telguard. If you are having problems getting reliable alarm signal transmissions, additional adjustments may be necessary. 56044103 12 0 2011 Telular Corporation • Scheme 1: Telco Connection through the Alarm Panel (Backup or Primary Mode) Used when the TG-7 unit is working in a system that involves a Telco connection. In this case, both the Telco and the TG-7 connections are being monitored by the Alarm Panel. It is the alarm panel that makes the decision of which communication path to use for signal delivery. REMOTE ANTENNA INCOMING TELCO I • R T • 0D re 0 0 7 Sri"„6„d,z o RJ31 X Lea 5 o 40 so Na u..e 6 0 "Uasd 7 17 ® Porer LED 8 0 LED Moos To 19:Butlon SIM TELGUARD • Digital TG-7 Alarm Panel R Battery wire should be at least h inch apart from AC wires SA, STC2 9 ?b C��O N.C.) v v T FFFF' (N�) Connector ? OGP O O -� 10,�, r0,�, I / I" 1 5 Iff• TAMPER �Gp /4, EARTH SWITCH o, q —FQ� GROUND \J Battery AC 6(IOMAI Connector TRIP INPUT Note Note:When using this scheme, the use of the primary or secondary dialer to connect to Telco is what determines whether the TG-7 is meant to work as a back-up or primary communicator. 56044103 17 ®2011 Telular Corporation Scheme 2: Telco Connection through the Telguard (Backup or Primary Mode) Used when the TG-7 unit is working in a system that involves a Telco connection. In this case,the Telco is connected through the Telguard unit,and it is the TG-7 that monitors the Telco and cellular connection. It is the TG-7 that makes the decision of which communication path to use for signal delivery. REMOTE ANTENNA INCOMING TELCO 4 ® R T ® D T U Q ' a RJ31X system s ae e z o LEDs 3 a as so Na Used 6 a Not used 7 a ® Vo D LED 6 a LED Mode 7oggk Burson SIM _ _ • TELGUARD Alarm Panel Digital TG-7 _ —� Battery wire should ( � ) be at least%inch 1P I STC2 apart from AC wires C'. 00 I _ I (N.C.) AV Avg Otis I - STC1 Battery Qp �G 9 9 T (N.O.) Connector ��O t FFF 4 a t0i 2 TAMPER ro1� ro��/1 ` EARTH SWITCH Qj Qj GROUND Note Battery AC BooMA) Connector TRIP INPUT Note.When using this scheme,the programming of the TG-7 is what determines whether the TG-7 is meant to work as a back-up or primary communicator. 56044103 18 ®2011 Telular Corporation Mem Loc. Field Default Setting 873 Trip Input Reporting 0 0 = no report 1 = report trip • 874 Trip Input Restoral Reporting 0 0 = no report 1 = report restoral 875 Trip Input Swinger Function 0 0 = swinger function disabled 1 = swinger function enabled When the trip input functionality is being used,closing the trip contact will cause the Telguard to send a message to the TCC,which in turn will cause the TCC to send a message to the central station.If the Telguard is configured to report restorals,the contact opening will also be reported. The message that is sent from the TCC to the central station is configurable in Telguard Online, or by a Telguard Customer Service Representative.The Telguard will automatically be configured with a unit template that allows configuration of the trip input feature, including the message that is sent to the central station.There is a default event configured for each alarm format, so that if the Telguard is configured with the butt-set to send trip input events to the TCC, a default notification will be sent to the central station. For UL installations, burglary zones shall not be connected to the Trip Input. Swinger Function The swinger function is designed to reduce the incidence of excessive messaging and alarms due to faulty equipment or installation.If enabled,the swinger function will discontinue sending trip input messages to the TCC once 10 trip events are detected within a 10 minute period.The Telguard will resume sending trip input messages to the TCC after a 10 minute period without trip events. • Step 7: Connect the tamper switch (mandatory for Commercial Burglary Installations in Canada) When installing TG-7 for Commercial Burglary Applications in Canada, a tamper switch needs to installed on the enclosure of TG-7.One tamper switch and a bracket are provided with all TG-7A models as well as all TG-7 models sold in Canada.The tamper switch needs to be connected to a zone on the panel and shall designate the zone as Tamper Protection. All Canadian Installations shall also meet the installation requirements of CAN/ULC-5302 standard for Installation and Classification of Burglar Alarm Systems for Financial and Commercial Premises, Safes and Vaults. Step 8: Complete the Telguard Installation The last step is to permanently mount the Telguard. 1. Attach earth ground to the grounding screw located on lower right-hand corner of printed circuit board assembly and permanently mount the Telguard enclosure. 2. Install mounting screws. 3. Slide the enclosure onto these screws. 4. Close the enclosure door and lock it S6044103 15 O 2011 Telular Corporation Appendix Connection Guide Wiring Diagrams The following wiring diagrams are for the Telguard TG-7 series used for: • Back-up path (Telco Primary&Cellular Back-up) • Primary path (Cellular Primary& Telco Back-up) • Sole path (Cellular Transmission Only) { 56044103 16 0 2011 Telular Corporation Scheme 3: No Telco connection (Cellular Only Mode) Used when the TG-7 unit is working in a system that does not involve a Telco connection. In this case,the Alarm Panel is connected directly to the TG-7,and there is no other connection for communication. REMOTE ANTENNA O O to snrea sucu: z o LEDs 3 0 ao so Not Uaed 6 0 Nat used 7 0 • ® Po LEDDMode B O LED Made SIM ❑ Togpb eunon TELGUARD Digital TG-7 Alarm Panel i R Battery wire should e be at least%inch S� 01 STC2 apart from AC wires C, IN.'I �4y ?4ti OHO t T�' I FFFT SN o) Connector �% OG% 9�y 9�}- O ®®®!��,a s t ®s t ® TAMPER /4, /1. + EARTH SNATCH Qj Cj GROUND Note Battery AC Connector (12V 800MA) TRIP INPUT Note:Since there is no Telco connection, there is a single connection for communication—between the Alarm Panel and the TG-7. • 56044103 19 0 2011 Telular Corporation Installation Using Conduit 0 0 0 0 COVER 0 0 ® 8IN. 0 o 8 IN. > • — 6 IN. FRONT VIEW SIDE VIEW • LISTED PULL BOX WITH LISTED OUTLET BOX AND RECEPTACLE LISTED PULL BOX WALL LISTED TRANSFORMER LISTED OUTLET BOX AND RECEPTACLE ULTPDE.VSD 56044103 20 O 2011 Telular Corporation Tamper Switch Installation for ULC Commercial Burglary Applications For all ULC Commercial Burglary Installations,a Tamper switch must be installed on TG-7 enclosure.The wiring from Tamper Switch to the panel shall be in a rigid or flexible metal conduit along with other wiring from TG-7 to the Panel. REMOTE ANTENNA INCOMING TELCO l�J 4RJ O sv.pn LEDs 5 O 4a 5 13 TAMPER No U.W 7 0 a a 8 SWITCH ® de Paver LED 8 O LEDED Toggle Mo Mode0 SIM 9b non a TELGUARD Digital TG-7 Alann Panel Battery wire should R be at least%inch I apart from AC wires Ilk STC2 T.a ?' C' O AON.C) 1"r STC1 Battery (NO) Connector ' GP 9p,FFF' � � 9 'P`O 1 2�' ��'l ./4 - - - ' EARTH GROUND � l Battery AC fl00MA) Connector 10 TRIP INPUT Note 56044103 21 ©2011 Telular Corporation Jack Assignments Jack Connects To Pin Assignment Function Status LED Reference 1 = Brown R1 Incoming 2 = Blue STC LED 2 will flash 3 J17(Gray) Telco RJ-45 4 = Green R(Ring) Connects Telco line to times when Telco 5 = Red T(Tip) TG-7 series. jack. voltage is lost. 7 = Orange 8 = Gray T1 1 = Brown Rl If PPFC is ENABLED, Digital Dialer 2 = Blue Connects alarm panel to STC LED 2 will flash 7 input/output 4 = Green R(Ring) TG-7 series for J16(Black) times when alarm of host 5 = Red T(Tip) transmitting alarms to alarm panel. 7 = Orange central station. panel is not detected and PPF enabled. 8 = Gray Tl Main Terminal Strip Pin Assignments Status Terminal Definition Connects To Function LED Strip Pin Referen ce Supervisory Relay Trip 24-hour trip Enables transmission of programmed 1 STC2 output for programmable zone input supervisory trouble code(see diagram or STC LED 2 STC2 trouble conditions. on alarm installation section). 2 Normally Closed. panel. Supervisory Relay Trip 24-hour trip Enables transmission of programmed 3 STC1 output for programmable zone input STC LED • supervisory trouble code(see diagram or 4 STC1 trouble conditions. on alarm installation section). 2 Normally Open. panel. 5 GND Trip Ground External trip Allows an external relay to trigger an alarm relay. signal. 6 PWR Trip Input External trip Allows an external relay to trigger an alarm relay. signal. DC Terminal Strip Pin Assignments Terminal Strip Pin Definition Connects To Function Note 1 GND DC Power 2 DC input NOT used NOT used These pins are not used in TG-7 models. A/C Terminal Strip Pin Assignments Terminal Definition Connects To Function Status LED Reference Strip Pin 1 AC AC power 120 VAC 60Hz Provides primary AC Power LED ON when AC is normal. 2 AC input. un-switched operational power to AC power LED OFF 12 VAC circuit. the Telguard and And 10VA. battery charging STC LED 2 circuit. Flashes 1 time when AC is low. 56044103 22 0 2011 Telular Corporation Compatible Alarm Panels Any UL Listed alarm panel that supports one of the following formats is compatible and may be used with the TG-7 series: • Pulse Formats: 0 3+1 pulse; 10pps, Double Round, 1400 Hz ack 0 3+1 pulse;20pps, Double Round,2300 Hz ack 0 3+1 pulse;40pps, Double Round, 2300 Hz ack 0 4+2 pulse; 10pps, Double Round, 1400 Hz ack o 4+2 pulse;20pps, Double Round,2300 Hz ack 0 4+2 pulse;40pps, Double Round,2300 Hz ack • Contact ID • Modem IIe or IIIaz • SIA2(SIA-DC-03 level 2 release at 300 baud) • Sonitrol • DMP The installer should verify compatibility at the time of installation. 56044103 23 m 2011 Telular Corporation This section provides a summary of all LED indications and their meanings, as well as the expected behavior of the Telguard under various exception conditions. LED Indicator Guide — Normal Operating Mode LED Symbol Color Showing Indication Solid On Unit is activated at the message center and enabled LED 1 Activation Green Off Unit not activated at message center(and disabled) Flash* Unit is disabled Off ALL Oil 1 1 Flash* System Trouble Condition—Low/Missing AC Power 2 Flashes* System Trouble Condition—Low/Missing Battery Condition LED 2 STC AND/OR Battery Charger Failure (System Trouble Red 3 Flashes* System Trouble Condition—LFC Condition) 4 Flashes* System Trouble Condition—NSC 5 Flashes* System Trouble Condition—RFC 6 Flashes* System Trouble Condition—DTF 7 Flashes* System Trouble Condition—PPFC Off Alarm panel idle(Telguard is primary or Sole Path) LED 3 MODE Yellow Flash*(1 sec) Alarm panel off-hook to transmit signals over cellular. On Alarm panel idle(Telguard is backup) Solid On The Telguard is waiting for acknowledgement from the TCC LED 4 Off Idle state Acknowledgeme Red When flashing with LED 1, unit has failed activation due to the nt Flash* programming of the panel, CALL TELGUARD TECHNICAL SUPPORT Off Telguard initialized On Telguard initializing with cellular network Flash (1 sec) Radio receiving message LED 5 Radio Green Flash (2 sec) Radio sending message Flash (2 flashes every Link Supervision Mode 6 sec.) LED 6 Not used LED 7 Not used LED 8 AC Power Red Solid On AC power connected to unit Note:*means that the LED will continuously flash. • 56044103 24 0 2011 Telular Corporation LED Indicator Guide - RSSI Mode RSSI Value LED's Lighted RF dBm NO SVC LED 5 = slow flash, LED 4-2 = off n/a 1 LED 5 = on, LED 4-2 = off <_ -111 dBm 11/2 LED 5 = on, LED 4 = slow flash >_-110 dBm LED 3-2 = off 2 LED 5-4 = on, LED 3-2 = off >_-100 dBm 21h LED 5-4 = on, LED 3 = slow flash >_-90 dBm(Minimum signal strength required LED 2 = off when Telco is involved) 3 LED 5-3 = on, LED 2 = off >_-80 dBm (Minimum signal strength when used as a Sole Path) 31/2 LED 5-3 = on, LED 2 = slow flash >_-70 dBm 4 LED 5-2 = on >_-60 dBm • 56044103 25 V 2011 Telular Corporation Troubleshooting Quick Reference Table Telguard Event LED Indication Relay Radio Message Internal Action Output STC ACFC AC LED off.STC LED 2 flashes Optional None Switch to standby battery if Telguard continuously 1 time. present,monitor battery, System monitor AC for restoral. Trouble LBC STC LED 2 flashes cont.2 times. Optional None Wait for LBC restoral,charge Conditions battery. LFC STC LED 2 flashes cont.3 times. Optional None Transmit alarm via radio if necessary.When Telco is restored,remove LFC condition. NSC STC LED 2 flashes cont.4 times. Optional None Continue to validate signal strength,NSC will restore when signal returns. RFC STC LED 2 flashes cont.5 times. Optional None Wait for RFC restoral. DTF-Dial STC LED 2 flashes cont.6 times. Yes Yes Internal 30V supply circuit Tone Failure failure. PPFC STC LED 2 flashes cont.7 times. No Yes Wait for PPF restoral. Not Activated Activation LED 1 off. Yes None The Telguard will not function until the first signal is sent through the Telguard to activate the unit Automatic Self-Test Radio LED 5 flashes during None Yes(Self-test) Send Self-test information to transmit. central station via TCC,return to ready state. Telguard Remote Query— Radio LED 5 flashes during None Yes(Status Send Status data to the TCC Communication Center transmit. data) for review customer service. Activated by Customer • Service. Telguard Enable and Radio LED 5 flashes during None Configuration The Telguard sends setup Configuration Upload— transmit. Data(Setup configuration to the TCC and data) switches to READY state to begin operation. Disable TX— Radio LED 5 flashes when Yes Yes(Status TX capability is disabled until Communication Center transmitting. data) further notice. The Telguard initiated. can still receive radio signals from the TCC. Note:If several trouble conditions are present,the STC LED will flash all of the indications in sequence. 56044103 26 m 2011 Telular Corporation Appendix Commercial FireSole Path Communicator Installation The 2010 edition of NFPA 72 allows the TG-7FS to be utilized as the sole path for fire communications. By following Telular's installation guidelines,the installer can provide the best conditions for a stable,sole path connection. In order to ensure that the cellular path to be used for signaling has the highest reliability possible, it is necessary to confirm two additional conditions, beyond what is outlined in the TG-7 Installation Guide. Configuring the TG-7FS 1. Insure Optimal Signal Strength Installation instructions for the Telguard TG-7 series indicate that a signal strength of-90dBm is sufficient.While this is suitable for"normal" use, i.e.daily,weekly or monthly supervision,an additional level of signal integrity will minimize the false alarms supervision failures caused by interference and atmospheric fading. Because of this, a signal strength of-80dBm,as indicated by at least 3 illuminated LEDs(LEDs 3,4 and 5), is the recommended minimum for TG-7FS units installed as sole path communicators. 2. Configure as Cell-Only By default,the TG-7FS is configured as Telco Primary with Cellular Backup.If the unit is being used as Cell-only(with the telco jack unused)then registration through www.telguardonline.com will allow the installer to choose this mode of operation. If a device needs to be reprogrammed locally,the POTS command interface should be used to set the mode of operation (memory location 831)to Cell Only(value 3), by performing the following steps: 1. connect a POTS phone to J16 2. dial "###*", listen for two beeps 3. dial 4 ", listen for two beeps• 4. dial "831", and listen for two beeps 5. dial 3, and listen for two beeps 6. dial "*", listen for two beeps and then hang up. To provide optimal signal conditions to the Telguard communicator, it may be necessary to boost the signal strength by installing an external antenna.Telular provides a variety of antenna options as accessories;consult your local distributor for more information. Configuring a Sole Path at the Panel Fire panels are typically provided with two Telco connections, in order to provide multiple reporting paths.With the TG-7FS configured as a sole path communicator,one of these Telco connections is no longer necessary for UL 864 compliance. However,the panel will continue to supervise that line unless changes are made at installation time. There are two methods for removing supervision alarms at the panel caused by disconnecting the second Telco connection. Either method can be used. 1. Disabling the Second Telco Connection Most fire panels have a configuration mechanism to disable the second Telco connection.Once the second Telco connection is disabled,the panel will no longer supervise the connection.This is the preferred method of removing supervision alarms at the panel caused by removal of the second Telco connection. 2. Connecting the Telco Connections Together • 56044103 27 0 2011 Telular Corporation The Telguard communicator is capable of providing dial tone to both Telco connections, if the Telco connections are connected together, such that "TIP" is connected to"TIP", and "RING" is connected to"RING".The two connections will receive dial tone in much the same way that multiple extensions in a household are connected together.If this method is used,the installer must take care to ensure that dual path reporting is not enabled on the panel, or else simultaneous alarm reports from the two Telco connections may interfere with each other. TIP1 HT1 HR1 n RING1 C7 TIP2 HT2 0 HR2 0 ~ RING2 • • 56044103 28 ©2011 Telular Corporation • Appendix 4 - Compliance for UL Listed Installations UL Installation Requirements Summary Household Household Household Central Central Police Bank,Safe Commercial Commercial Burglary Fire Burg/Fire Station Station Connect and Vault Fire Fire& Combination Burg Burg Burg Central Grade A Station Bur TG-7 TG-7 or TG-7 or TG-7A TG-7A TG-7A TG-7A TG-7FS TG-7A Telguard Model TG7FS TG-7FS 0 0 0 Y Y Y Y+ 0 Y UL Listed Bell and Bell Housinci** 0 0 0 0 0 0 Y Y Y AC transformer lines in flexible conduit. Y Y Y Y Y Y Y Y Y AC transformer plugged into un-switched outlet. 0 0 0 0 0 0 Y Y Y AC transformer plugged into dedicated branch circuit. 0 - - N N N N N N PBX connection to RJ31X jack. 0 0 0 Y Y Y Y 0 Y Enclosure Tamper Switch connected to 24-hour circuit. 0 0 0 0 Y Y Y Y Y Antenna cable in flexible conduit concealed or covered by motion detector. 0 O O Y Y Y Y 0 Y Attack resistant enclosure(APC- 32S). 24 hrs.Use 24 hrs.Wse 24 hrs Use 24 hrs.Use 24 hrs.Use 24 hrs. 72 hrs.Use 24 hrs.Use 24 hrs Use 12V.Battery 7ah. 7ah. 7ah:- 7ah. 7ah. Use 7ah. 7ah 7ah. 7ah. backup re uirement. •Must be connected to olorm panel UL Listed for Bonk and Vault ••Use Mercantile Listed bell and bell housing O=Optional(Not Required) Y=Yes(Required) N=No(Not Allowed) 56044103 29 ®2011 Telular Corporation • ULC Installation Requirements Summary Household Burglary Household Fire Household Commercial Burg Burg/Fire Combination TG-7 TG-7 TG-7 TG-7 Telguard Model 0 0 0 0 UL Listed Bell and Bell Housing** 0 0 0 0 AC transformer lines in flexible conduit. Y Y Y Y AC transformer plugged into un-switched outlet. 0 0 0 0 AC transformer plugged into dedicated branch circuit. - N PBX connection to R131X jack. 0 0 0 Y Enclosure Tamper Switch connected to 24-hour circuit. 0 0 0 0 Antenna cable in flexible conduit concealed or covered by motion detector. 0 0 0 0 Attack resistant enclosure (APC-32S). 24 hrs.Use 7ah. 24 hrs.Use 7ah. 24 hrs Use 7ah. 24 hrs.Use 7ah. 12V.Battery backup requirement. O=Optional(Not Required) Y=Yes(Required) N=No(Not Allowed) 56044103 30 0 2011 Telular Corporation Appendix 5 - Detailed Specifications • Dialer to Interface Electronics The patented integrated interface by Telular Corporation,allows digital dialers to dial into the cellular radio network. • Line voltage: -30 Vdc into standard telephone device when on-hook. • Dial tone: Precision 350 + 440Hz +/- 1%. 10 digits dial out capability. • Mode: Loop start only. 25mA +/- 10%off-hook. • Protected by U.S. Patents:4,658,096;4,775,997;4,922,517;4,737,975;4,868,519; 5,134,644. Power • Maximum AC current draw: • 125mA(battery charged) • 350mA(battery charging) • Battery Supply: • Maximum full charge DC voltage = 13.8V +/-0.2V. • Battery charging system:Constant current, Electronic short circuit protection • Maximum charging current of 240mA • Transformer Supplied: 12 VAC 10VA, UL, plug-in;acceptable transformers: • Hon-Kwang part number: A12083CEC • GlobTek part number: WA1E800J00-N-GTGTAB • Tri-Mag part number:WTD-1208-C Digital Cellular Radio • The Telguard TG-7 radio supports GSM/GPRS and UMTS (WCDMA)cellular protocols. It is equipped with an integrated radio transceiver conforming to all the requirements of the GPRS/EDGE: 3GPP Release 99 and GERAN Feature Package#1 and WCDMA: Release 5. The TG-7 transceiver is FCC compliant, meeting all of the requirements of Part 22 and 24 testing. It is also compliant to the Industry of Canada ICES-003 and PTCRB requirements. • Frequency range: ➢ GSM 850/1900MHz, ➢ UMTS WCDMA FDD 850/1900MHz • Antenna Port:TNC connector(female), 50-ohm • Receiver Sensitivity: ➢ WCDMA band 2 -107dBm, band 5 -108dBm ➢ GSM -90 dBm to -106 dBm • Transmit Power: ➢ EGSM 850MHz:Class 4(2 watts) ➢ GSM 1900MHz:Class 1 (1 watt) ➢ WCDMA 850/1900MHz Class 3 (0.250 watts) • FCC ID: N7NSL8080 • IC ID:2417C-SL8080 • Supplied Antenna: Dipole • Physical Size: 11.4"x 7.75"x 3.3"(TG7GA004 12.5"x 12.5"x 4.25") • Shipping weight: 5 lbs. (TG7GA004 14 lbs.) • Operating Environment: 0 C to +49 C;0-95%humidity(non-condensing). Telco Interface • Ringer equivalence: 0.3B REN 56044103 31 C 2011 Telular Corporation Appendix 6 - Acces ACD-12 12 feet of antenna cable and mounting bracket • ACD-35 35 feet of low loss high performance antenna cable and mounting bracket ACD-50 50 feet of low loss high performance antenna cable and mounting bracket ACD-100 100 feet of low loss high performance antenna cable and mounting bracket HGD-0 High Gain Directional Antenna EXD-0 External Omni-Directional Antenna • 56044103 32 0 2011 Telular Corporation System Status LEDs(Normal Mode)_ T e i g u a rd T G-7 Series System Status LEDs(RSSI Model ■ OFF TN"°ACTIVATION --a - ---- TEo QUICK INSTALLATION GUIDE [SOLE PATH] ■ ■ ■ ■ ■ ■ ■ D D D .LA- -TNAPb10FN�ED D , ,« ■ ■ ■ ■ D D D D D a, ■ ■ D D D D D D ■ OFF xo TRouaLE. --- Installation Summary o D D D D ClD D ,D FLASNNFG TRouaLF. Rr - - - _ _ ._ _. . � Rss11xN1 NONE 1 } }•A , _ }y, . ry '-ASN•NC EOVM41111NG w SYSTEM ,Fus„:F There are seven steps in installing Telguard properly. IF YOU DO NOT —__,-__-`-__. --_ _...-_... - -+--- w0 TROUBLE xD ;;' .F�1N•x1C No 1TONE PROCEED IN THE ORDER AND MANNER PRESCRIBED, YOU MAY NOT svc sN•OF c RAo,o FuwRE LASH'PPF TN FPR S FAR TFU., . ES FCIL Acceptable RSSI Range ■ IF _ EE°".NGnx IPRFN,R,I COMPLETE THE INSTALLATION IN THE TIME ALLOCATED. � PANEL COMM D ON - AxEt OM�IOON IBACNUPI ° FLAS"'"° PANEL OF— STEP 1: REGISTER FOR CELLULAR SERVICE ■ OFF DLE TMCCOMM D ON RM�°R RESPOe1E Register the unit online through www.teiguardonline.com, by completing the J D FLAS11NG AGTNATIONDENIEO Online Registration Form at www.Teiguard.com. Telular requires this information ■ IF IDLE to register and activate the unit. RADIO STATUS D oN RApp IxnlAl¢IMG D F—HiNG RAGOCGxAAIUDONIN STEP 2: LOCATE UNIT AND MEASURE SIGNAL STRENGTH (RSSI) D FL.SxxFG sARx SUPE"„Spx ExABLED ANTENNA RASnE1EVER,SSECGNDI, First,you will be confirming that Telguard has adequate cellular signal strength.Press the LED/RSSI Mode Toggle button one time, LEDs will now indicate signal strength.Minimum recommended is 3(3 Battery wire should NOT USED ■ OFF NGTGSED be at least'/.inch on solid). Press the LED/RSSI Mode Toggle button a second time to exit RSSI mode. apart f_AC cores NOT USED ■ OFF NOT USED STEP 3: CONFIGURE ALARM PANEL FOR SOLE PATH CONNECTION WARNING: - m OFF AC NOT coN«Ec ION VCLTACE '' POWER LED ■ ° "°T°""'T Fire panels are typically provided with two Telco connections. Because the TG-7 provides a single RRESSMTGNFNIOFIE t° D ON ONNFCTED TO UNR LNlE1. ,„xm1Mb._ "" connection,the panel must be set up accordingly.The first method of installation is to configure the DMCCNFIECT MICR I.E.3 D °EE""`"0 A D panel to disable the second Telco connection. If this is not an option due to panel limitations,it is '° OPTIONAL CONNECTION: possible to splice both TIP and RING connections from the panel into the single jack of the (rVV® PwF LED D ALARM PANEL INTO HE T THE relguard. The TG-7 is capable of providing dial tone to both Telco connections. ALARM PANEL SPLICED INTO THEM }F SI ED 4PM n SIM T.Ey.e.m"TELGUARD - Alarm Panel TG-71FS STEP 4: PROGRAM, ACTIVATE &TRANSMIT PANEL ALARMS OVER THE -- -- -- -._ Digital TG-7 rF�c CELLULAR RADIO NETWORK It Battery Oo P-ogram the TG-7 for Sole Path communication.You may do this by setting Memory Location 831 - sres cGn°`�« rF� Fq�:, R to a value of 3,using a butt-set.(See programming guide on reverse). LED 3 will be off when idle, FF[ �ST�1 00 if successful Next,connect the alarm panel's digital dialer output to Telguard and verify that alarm I (IN ' • '<Fq N signals can be reliably sent through Telguard over cellular to the central station digital receiver. A o ■ �'4• T ■l minimum of two alarm signals must be transmitted.Activation is confirmed when LED 1 is - - - -_ —., illuminated. (NOTE:THE FIRST ALARM WILL ACTIVATE THE UNIT AT THE TELULAR COMMUNICATION EARTH Alarm Panel CENTER,IT WILL NOT GO TO THE CENTRAL STATION,ALL SIGNALS AFTER THE FIRST ARE OpbOaten l GROUND r SENT TO THE CENTRAL STATION) CAUTION:INCORRECT -0 CONNECTIONS MA V RESULT F(C GR G'P OO IN DAMAGE TO UNIT AC 0. 1p 1 AC woFnnl tiF tiF % STEP 5: CONNECT SUPERVISORY TRIP OUTPUTS w Telgua Next,you will wire Telguard's supervisory trip Outputs to the alarm panel and then test. T REFERR TO INSTALLATIONATION AND l._.._� OPERATING INSTRUCTIONS TO EXTERNAL MANUAL T IS DEVICE FCC TRIP INPUT STEP 6: CONNECT TRIP INPUT(OPTIONAL) VNTN FCC RULE PART 15 __ _-„- -_- Optionally,you can wire an external relay input to the trip input lead and ground,and test. STEP 7: COMPLETE THE INSTALLATION Your last step will be to attach earth ground,and permanently mount the unit. 56044203 Setup & Programming the Operating Parameters in the Telguard TG-7 models When*the Telguard is received from the factory, registered and is powered up for the first time, it is ready for activation, provided the default settings are what you want.The STC LED #2 will flash to indicate any failure conditions. The Mode LED#3 will be on and the STC 1 and STC 2 relays will be tripped. The Telguard can be programmed using a line-mans butt- set connected to T& R Test Points. TO PROGRAM THE Telguard TG-7 A. Put the line-mans butt-set in talk mode. B. Dial"###',*, you will hear 2 beeps. C. Press#, *, this will put the Telguard into a Master Access programming mode, 2 beeps. D. Enter changes required. The syntax for programming a specific memory location is as follows: MEMORY LOCATION (3-digits),will respond with 2 beeps,then VALUE,will respond with 2 beeps. E.Then press*, you will hear 2 beeps then hang up. This saves the change and exits the programming mode. Mem Loc. Field Default Value Setting 831 Mode of operation 01 1=Telco Primary/Cellular Backup 2=Cellular Primary/Telco Backup 3=Cell Only 01 =4x2 pulse,40pps,2300 hz 02=4x2 pulse,20pps,2300 hz 03=4x2 pulse, 1Opps, 1400 hz 833 C/C Reporting Format 09 04=30 pulse,40pps,22 00 hz 05=30 pulse,20pps,2300 hz 06=30 pulse, 10pps, 1400 hz 07=Radionics Ile or Isla 08=Contact ID 09=Auto Format Detect 11 =SIA2(300 Baud) 12=DMP 845 Manual Battery Test N/A Initiates the on-demand battery test STC1 Trip Output Enter the SUM TOTAL of the events that you wish to trip the STC relay by ADDING the corresponding values: 850 Reporting 04 00=Not UsPd 01 =AC Failure 02=Low Battery 04=LFC 08=NSC Normally Open (LFC only) 16=RFC 32=DTF 63=ALL STC2 Trip Output Enter the SUM TOTAL of the events that you wish to trip the STC relay by ADDING the corresponding values: 851 Reporting 59 Normally Closed (all except LFC) 00=Not Used 01 =AC Failure 02=Low Battery 04=LFC 08=NSC 16=RFC 32=DTF 63=ALL 852 STC Trip Delay for NSC 2(60 sec) 1=30 seconds 4=10 minutes 7=45 minutes 2=60 seconds 5=20 minutes 8=60 minutes 3=3 minutes 6=30 minutes 9=24 hours 858 STC History N/A 0=terminate STC history display mode 1 =start STC history display mode 2=clear STC history 861 CFC Number of Events 0(disabled) 0=disabled 2=4 attempts 1 =2 attempts 3=8 attempts 862 CFC Between Events 1 (30 sec) 1 =30 seconds 3=70 seconds 5=90 seconds 2=60 seconds 4=80 seconds 6=99 seconds 868 PPF Delay 0(disabled) 0=disabled, 1 =10 seconds, 2=20 seconds. _ 15=150 seconds 872 AC Failure Delay 02(2 hours) 0-24 hours 873 Trip Input Reporting 0(no report) 0=no report 1 =report trip 874 Trip Input Restoral Reporting 0(no report) 0=no report 1 =report restoral 875 Trip Input Swinger Function 0(disabled) 0=swinger function disabled 1 =swinger function enablers 899 Factory Default Unit N/A Resets all settings to factory defaults NOTE: SPECIAL LED INDICATIONS DURING ACTIVATION If the Telguard fails to confirm activation it will be displayed on the LEDS: System Status LEDs Activation Indications LEDs 1-5 FLASHING FAILED ACTIVATION—SIGNAL TOO WEAK LED#1 &LED#4 FLASHING ACTIVATION ERROR—CALL TECH SUPPORT LED#1 ON ACTIVATION SUCCESSFUL LED#1 OFF NOT ACTIVATED.NEED TO CONNECT PANEL AND TRIP ZONE On either a FAIJI&ACTIVATION or ACTIVATION ERROR,the unit MUST BE RESET BY PRESSI HE RSSI BUTTON TWICE.The activation message MUST BE RESENT or the UARD will •not transmit s through the cellular network. Repeat step 4 above. KROHNE Calibration Certificate - Kalibrierzertifikat - Certificat d'etalonnage DIN 55 350-18-4.2.2 Customer/Kunde/Client Customer Order/Bestellnummer/Commande Client Product/Produkt/Produit Type/Typ/Type OPTIFLUX 4000 DN 500 mm/20 inch Sales Order/VK-Auftrag/Commande de vente 701001029 P 2 Serial Number/Seriennummer/Numero de serie S12310257 Tag Number/Tagnummer/Repere Calibration Method/Kali briermethode/Methode d'etalonnage The flow sensor has been calibrated against a fixed-volume tank.The calibration certificate of this tank registers the traceability to national standards,which establishes the physical units of measurements according to the International System of Units(SI). Die Prufung des Durchflussmessgerats erfolgt im Vergleich zu einem Messbehalter. Die Kalibrierung des Messbehalters ist rilckfuhrbar auf Nationale Standards. Die physikalischen Einheiten sind nach dem SI-System definiert. Le capteur de mesure a ete etalonne avec un reservoir a volume fixe. Le certificat d'etalonnage de cet etalon prouve la tragabilite aux etalons nationaux qui utilisent des unites de mesures physiques selon le Systeme International (SI). Test Equipment Data/Kalibrierstanddaten/Donnees du banc d'etalonnage Serial Number/Seriennummer/Numero de serie PSTC4 Calibration fluid/Kalibrierfliissigkeit/Fluide d'etalonnage Water/Wasser/Eau Uncertainty/Unsicherheit/Incertitude Calibration Results/Kalibrier Resultats/Resultats d'etalonnage Flow Rate Set Flow rate Deviation Durchflussmenge Gewahlte Durchfluss Abweichung Debit Debit regle Ecart (%) (m3/h) (%) 101.56 1435.7706 +0.04 22.15 313.1382 -0.08 Calibration Data/Kalibrierdaten/Donnees d'etalonnage GK : 3.6326 GKh GKI : 7.3357 GK070: 0.0000 Date/Datum/Date: 2012-03-21 Signature/Unterschrift/Signature OP NFLUX COMPACT f LOWML ILIA AMBIENT f MPERATURE: -40...+65'C (-4Q..+150F) A+ HAZARDOUS (CLASSIFIFD' IOCATIONS: t CLASS I, DIVISJCN 2, CROLPS A,B,C,D A CLASS 11, DIVISION 2, CROUPS F,3 A- >w CLASS III, DIVISION 2. a I OPTIFLUX a300 C-DIV2 0 © U ; B I COMPACT FLONMETER NOTES z� , (CONVERTER IDENTIF,CA ION C I r 10 The OPTIFLIJX a300 C-OIV2 compact fiowmeter must not be connected to any device tha: uses or grnrra rs z? r CG300x1abcl C_ T w I � voltages in excess of 250 V. The mains supply line must have o suitable switch incorporated to safely disconnect Lo I the power snppl'ed to the signal converter e�ectrorics. he switch must be installed in a non-hazardous area. D 7 to I SIGNA_ CONVERTER 1-OUSING (2) The installation must be in accordance with the NATIONAL F.L.F.CTRICAL CODE®, NFPA 70, Article 500 to 510 or D- r MTH INTRINSICALLY SAFE ANSI ASA - RP 12,06.01. -- i INTERNAL ELECTRODE CIRCUITS _ ® The OP.IFLUX a300 C-CIV2 mus: be cornectec to a suitable ground per NFPA. 70. Article 50'. The resistance of the ground path must be less then otim. 1 LA+ [CXi] O Wren mounted n o Division 2 a,ea, the electronics co..,npertment (front compartment with window cover) must be Nam- considered cs an exolos'onproof enclosure per Division ' requirements. The termlrcl compartmert (-ea- compartment) i y l con be considered a Livision 2 enclosure and mus! be corrected accordirgly. � PE � � IS The "o" in the type name idenf"es the type o4 primary head (a _ 1, 2, 4, 5 or 6, e.g. OPTIFLUX 4300 C-DIV a ' ® The "atic" in the converter ident'fication "CG300xlabc" designates the 1/0 configuration. 1 ------------------ ----_---------------------------------------------..-_ HAzABUpU5 (aAssinrDl LOCATIONS OPTIFLUX REMOTE FLOWMETER SYSTFM HAZARDOUS (CLASSIFIED) LOCA?IONS: CLASS I, DIVISION 2, GROUPS A,B,C,D AMBIENT TEMPERATURE: -40-+65'C (-40...+1507) AMBIENT TEMPERATURE -40...+65 C (-40-+150-F) CLASS I, DIVISION 2, GROUPS A,B,C,D I CLASS 11, DIVISION 2, GROUPS F,G CLASS 11, DIVISION Y. GROUPSE,G CLASS III, DIVISION 2. A+ I I CONDUIT GROUND BONDING WIRE i CLASS III, DIVISION 2. r AWG14 (2.5mm ) A A- 1 l IFC 300 F'-DIV2 ur Q a 140 { y - OPTIFLUX a000-DIV2 B I REMOTE SIGNAL CONVERTER > 30 4 } I I REMOTE PRIMARY HEAD t J B- i ((ONVf'R1ER IDENTIFfCA?ION ; w 3 - 1 ( -t--- —'-- ` r 3 w s I CC30Ox1 obc) ® ih$ ? ll/I V1 z `� E X I C i ; fY 20 \i 1 � C- u i [E X I] %z v 1 ELECTRODE CIRCUIT 7 , a z r CABLE DS 300 ' ---_.__----_---( u, () w c' - 'I p z r r I l SIGNA. CONVERTER HOUSING r w N � r t � �i NON-tNCENDIVE APPARATUS f WTH INTRINSICALLY SAFE I Z z i WITH INTRINSICALLY SAFE ELECTRODE CIRCUITS I-$$ 9 , ELECTRODE CIRCUITS L/L1 j I 1 i d i i z-r $ t'. Z Nam._ y l T8 7 7 $i i r yZ PE O I CONDUIT FIELD CON. Z g g b 2 0 l CIRCUIT CABLE z 4 (#) WITH -BOQTSTRAP � ea•Y � 40 � NOTES: 30 4 ' �Us m 3 �w I �7 Qt The IcC 300 F-DIV2 remote signal converter must not be connecter to any device which uses or generates voltages u 1 ) I u 0 in excess of 250 V. ? 2 z ® j To CIRCUIT 1 ® 1he insta'ilation must be in accordance with the NATIONAL ELECTRICAL CODE , NFPA 70, Article 500 to 510 and 1 CABLE BTS 300 i W ANSI SA - RP 12.06.01. w Cu a12 ® The IPC 300 F-DIV2 must be connected to a suitable ground per NFPA 70, Article 501. The resistance of the ground R. Drown Appr.v" )cle N"o Dncrbuun path must be less than 1 ohm. CONTROL DRAWING FOR ® when mounting the IFC 300 F•-DIV2 it a Division 2 area, the electronics compartment must be considered as on Aw. 07.13.04 -r.t.. OPTIFLUX USA DIV2 SYSTEMS x _ !t exploslust be enclosure per Division 1 rncuiremenls. The terminal compartment can be considered a Division 2 enclosure -�� 1 � Art.no and must De connected accordingly. D Es � The "a" in the type name identifies the type of prima-y head (a 1, 2, 4, 5 or 6, e.g. OPTIFLUX 5000-DIV2) C 20.12.06 J.K 20.12.D KRC3HNE Holland DrarMq na pe�T �p o e 1 14.7.05 M.L. It.aa:.u.:• A110lnclt: 8.30702.61 A i• 6 The "abc" in the converter identification "CG300xtabc" designates the 1/0 configuration. 77.1.C5 M.L- NaufacMrirq'cc"�l of IGonc: ,Bond a! 1 0 • �r 010 x • OPTIFLUX 4000 ,. Electromagnetic flow sensor • The documentation is only complete when used in combination with the relevant documentation for the converter. ©KROHNE 04/2010-7309852300-QS OPTIFLUX 4000 R03 en KR O H N E CONTENTS 111 1 Safety instructions 3 • 2 Installation 4 2.1 Scope of delivery...............................................................................................................4 2.2 Nameplates ...................................................................................................................... 5 2.3 Storage ............................................................................................................................. 5 2.4 Transport.......................................................................................................................... 5 2.5 Installation conditions...................................................................................................... 6 2.5.1 Inlet and outlet........................................................................................................................6 2.5.2 Mounting position....................................................................................................................6 2.5.3 Flange deviation......................................................................................................................7 2.5.4 T-section ................................................................................................................................. 7 2.5.5 Vibration .................................................................................................................................. 7 2.5.6 Magnetic field..........................................................................................................................8 2.5.7 Bends ......................................................................................................................................8 2.5.8 Open discharge .......................................................................................................................9 2.5.9 Control valve ...........................................................................................................................9 2.5.10 Air venting .............................................................................................................................9 2.5.11 Pump................................................................................................................................... 10 2.5.12 Temperatures ..................................................................................................................... 10 2.5.13 Vacuum load........................................................................................................................ 11 2.6 Mounting......................................................................................................................... 12 2.6.1 Torques and pressures......................................................................................................... 12 • 3 Electrical connections 15 3.1 Safety instructions.......................................................................................................... 15 3.2 Grounding ....................................................................................................................... 15 3.3 Virtual reference for IFC 300 (C. W and F version) ........................................................ 17 3.4 Connection diagrams ..................................................................................................... 17 4 Technical data 18 4.1 Dimensions and weights ................................................................................................ 18 5 Notes 22 • 2 www.krohne.com 04/2010-7309852300-QS OPTIFLUX 4000 R03 en SAFETY INSTRUCTIONS Warnings and symbols used A DANGER! This information refers to the immediate danger when working with electricity. A DANGER! These warnings must be observed without fail. Even partial disregard of this warning can lead to serious health problems and even death. There is also the risk of seriously damaging the device or parts of the operators plant. WARNING! A! Disregarding this safety warning, even if only in part,poses the risk of serious health problems. There is also the risk of damaging the device or parts of the operators plant. CAUT/ rd Disregaarding these Instructions can result in damage to the device or to parts of the operator's Qs plant. INFORMATION! 1 These instructions contain important information for the handling of the device. HANDLING • This symbol designates all instructions for actions to be carried out by the operator in the specified sequence. RESULT This symbol refers to all important consequences of the previous actions. Safety instructions for the operator CAUTION! Installation, assembly, start-up and maintenance may only be performed by appropriately Q trained personnel. The regional occupational health and safety directives must always be observed. ® LEGAL NOTICE. The responsibility as to the suitability and intended use of this device rests solely with the user. The supplier assumes no responsibility in the event of improper use by the customer. Improper installation and operation may lead to loss of warranty. In addition, the "Terms and Conditions of Sale"apply. They appear on the back of the invoice and form the basis of the purchase contract. /NFORMA TION! i • Further information can be found on the supplied CD-ROM in the manual, on the data sheet, in special manuals, certificates and on the manufacturer's website. • If you need to return the device to the manufacturer or supplier,please fill out the form contained on the CD-ROM and send it with the device. Unfortunately, the manufacturer cannot repair or inspect the device without the completed form. • 04/2010-7309852300-OS OPTIFLUX 4000 R03 en www.krohne.com 3 INSTALLATION , _ V a, _ . 00 2.1 Scope of delivery 0 o 0 Remote version ® Compact version with IFC 300 signal converter Q Compact version with IFC 100(01 signal converter Compact version with IFC 100(45°)signal converter T k I • Figure 2-1:Scope of delivery 1Q Ordered flowmeter (2) Product documentation Q3 Factory calibration report 4Q CD-ROM with product documentation Q5 Grounding rings(optionally) © Cable(remote versions only) • 4 www.krohne.com 04/2010-7309852300-QS OPTIFLUX 4000 R03 en INSTALLATION 2.2 Nameplates 3_1 INFORMA T/ON! Look at the device nameplate to ensure that the device is delivered according to your order. Check for the correct supply voltage printed on the nameplate. 2.3 Storage • Store the device in a dry and dust-free location. • Avoid lasting direct exposure to the sun. • Store the device in its original packing. 2.4 Transport L Figure 2-2:Transport • 04/2010-7309852300-OS OPTI FLUX 4000 R03 en www.krohne.com 5 p INSTALLATION 06d 2.5 Installation conditions 2.5.1 Inlet and outlet � ) 02 Figure 2-3:Recommended inlet and outlet sections 1� >_5DN 2) >_2DN 2.5.2 Mounting position Figure 2-4:Mounting position • 6 www.krohne.com 04/2010-7309852300-OS OPTIFLUX 4000 R03 en INSTALLATION r 2.5.3 Flange deviation CAUTION! QMax.permissible deviation of pipe flange faces: Lmax-Lmin—<0.5mm/0.02" 1� Figure 2-5:Flange deviation Amax Amin 2.5.4 T-section • D ► Figure 2-6:Distance after T-sections 1T >_10DN 2.5.5 Vibration Figure 2-7:Avoid vibrations 04/2010-7309852300-OS OPTIFLUX 4000 R03 en www.krohne.com 7 INSTALLATION • 2.5.6 Magnetic field Figure 2-8:Avoid magnetic fields 2.5.7 Bends l� Figure 2-9:Installation in bending pipes Figure 2-10:Installation in bending pipes • 8 www.krohne.com 04/2010-7309852300-OS OPTI FLUX 4000 R03 en 4000 INSTALLATION 2.5.8 Open discharge Figure 2-11:Installation before an open discharge 2.5.9 Control valve Figure 2-12:Installation before control valve 2.5.10 Air venting 10 Figure 2-13:Air venting 1Q >_5m (2) Airventilation point • 04/2010-7309852300-OS OPTI FLUX 4000 R03 en www.krohne.com 9 p INSTALLATION 2.5.11 Pump i Figure 2-14:Installation after pump 2.5.12 Temperatures A0CAUTION! Protect the device from direct sunlight. Temperature range Process ['Cl Ambient PC1 Process [°F1 Ambient [°F1 min. max. min. max. min. max. min. max. PTFE Separate flow sensor -40 180 -40 65 -40 356 -40 149 • s Compact with IFC 300 -40 140 -40 65 -40 284 -40 149 �c Compact with IFC 100 -40 140 -40 65 -40 284 -40 149 ' PFA Separate flow sensor -40 180 -40 65 -40 356 -40 149 Compact with IFC 300 -40 140 -40 65 -40 284 -40 149 Compact with IFC 100 -40 140 -40 65 -40 284 -40 149 ETFE Separate flow sensor -40 120 -40 65 -40 248 -40 149 Compact with IFC 300 -40 120 -40 65 -40 248 -40 149 Compact with IFC 100 -40 120 -40 65 -40 248 -40 149 Hard rubber Separate flow sensor O -5 80 -40 65 23 176 -40 149 Compact with IFC 300 O -5 80 -40 65 23 176 -40 149 Compact with IFC 100 p -5 80 -40 65 23 176 -40 149 PU Separate flow sensor -5 65 -40 65 23 149 -40 149 Compact with IFC 300 -5 65 -40 65 23 149 -40 149 Compact with IFC 100 -5 65 -40 65 23 149 -40 149 • Q Hard rubber liner is available for Ex-versions only 10 www.krohne.com 04/2010-7309852300-OS OPTIFLUX 4000 R03 en __ .._ - UkkavINSTALLATION 2.5.13 Vacuum load Diameter Max. Vacuum load in mbar abs. at a process temperature of pressure [mm] [bar] 40°C 60°C 70°C 80°C 90°C 100°C 120°C 140°C 180°C Liner in PTFE DN10...20 50 0 0 10 0 0 0 500 750 1000 DN200...300 50 500 750 1000 1000 11000 1000 1000 1000 1000 DN350...600 50 800 1000 1000 1000 1 1000 1000 1000 1000 1000 Liner in PFA DN2.5...150 50 0 0 1 0 1 0 0 1 0 0 1 0 0 Liner in ETFE DN200...2000 150 100 100 1 100 1 100 100 1 100 100 1 - - Liner in Hard rubber DN200...300 150 250 400 1 400 1 400 - - - - - DN350...3000 150 500 600 600 600 - - - - - Liner in PU DN200...1800 1500 500 600 - - - - - • Diameter Max. Vacuum load in psia at a process temperature of pressure [inches] [psi] 104°F 140°F 158°F 176°F 194°F 212°F 248°F 284°F 356°F Liner in PTFE 3/8...3/4" 725 10 1 0 0 10 0 0 7.3 10.9 14.5 8...12" 725 7.3 10.9 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14...24" 725 11.6 14.5 14.5 14.5 1 14.5 14.5 14.5 14.5 14.5 Liner in PFA 1/10...6" 725 0 0 1 0 1 0 0 0 1 0 1 0 1 0 Liner in ETFE 8...72" 2176 1.5 1.5 1.5 1.5 1.5 T.5 1.5 - - Liner in Hard rubber 111118...12" 2176 3.6 5.8 5.8 5.8 - 14...120" 2176 7.3 8.7 8.7 8.7 - - - - - Liner in PU 8...72" 21756 7.3 8.7 - - - - - - • 04/2010-7309852300-QS OPTIFLUX 4000 R03 en www.krohne.com 11 INSTALLATION , OPTIFLUX4000 : 2.6 Mounting 2.6.1 Torques and pressures / Figure 2-15:Tightening of bolts Tightening of bolts 10 Step 1:Apply approx. 50% of max. torque given in table. (2 Step 2:Apply approx. 80% of max. torque given in table. (3 Step 3:Apply 100% of max. torque given in table. • • 12 www.krohne.com 04/2010-7309852300-QS OPTIFLUX 4000 R03 en INSTALLATION Nominal size Pressure Botts Max.torque[Nm] DN [mm] rating PFA, PTFE, ETFE PU, hard rubber 2.5 PN 40 4xM12 32 - 4 PN 40 4 x M 12 32 - 6 PN 40 4 X M 12 32 - 10 PN 40 4xM12 7.6 4.6 15 PN 40 4xM12 9.3 5:7 20 PN 40 4 x M 12 16 9.6 25 PN 40 4-M 12 22 11 32 PN 40 4xM16 37 19 40 PN 40 4 x M 16 43 25 50 PN 40 4 x M 16 55 31 65 PN 16 4xM16 51 2 65 PN 40 8 x M 16 38 21 -80 PN 10 8 x M 16 - _ 471 25 100 PN 16 8 x M 16 39 30 125 PN16 8 x M 161 53 40 150 PN 16 8 x M 20 68 47 200 PN 10 8 x M 20 84 68 200 PN 16 12 x M 20 68 45 250 PN 10 12 x M 20 78 65—' 250 PN 16 12 x M 24 116 78 300 PN 10 12 x M 20 - 88 76 300 PN 16 12 x M 24 144 ! 105 1 3501 PN 10 1 16 x M 201 97 �75 400 PN 10 16 x M 24 139 104 450 PN 10 20 x M 24; 127 li 93 500 PN 10 20 x M 24 149 107 600 PN 10 20 x M 271 205 138 700 PN 10 20 x M 27 238 163 800 PN 10 24 x M 30 328 219 900 PN 10 28 x M 30 - 205 1000 PN 10 28 x M 35 - 261 • 04/2010-7309852300-QS OPTIFLUX 4000 R03 en www.krohne.com 13 p INSTALLATION l Nominal size Flange class Bolts Max.torque[Nml [inch] [lbl ' � PFA, PTFE, ETFE, PU, hard rubber 1/10 150 4 x 1/2" 32 1/6 150 4 x 1/2" 32 -1/4 150 4 x 1/2" 32 - 3/8 150 4 x 3.5 3.6 1/2 150� — — 4x 1/2" 3.5 3.6 3/4 150 ! 4 x 1/2" 4.8 4.8 1 150L- ,, 4 x 1/2" _ 6.7 4.4 1 112 150 4 x 1/2" 13 12 ' 2 150 4 x 5/8" 24 23 3 150 4 x 5/8" 43 39 4 150 8 x 5/8" 34 31 6 150 8 x 3/4" 61 51 j 8 150 8 x 3/4" 86 69 10 150 12 x 7/8" 97 79 12 150 i 12 x 7/8" 119 104 14 150 12 x 1" 133 93 16 150 16x1" 130 91 18 150 ' 16 8 199 143 20 150 : 20 x 1 1/8" 182 12 24 150 20 x 1 1/4" 265 180 28 150 28 x 1 1/4" 242 161 32 150 28 x 1 1/2" 380 259 36 150 32 x 1 1/2" - 269 40 150 36 x 1 1/2" 269 14 www.krohne.com 04/2010-7309852300-QS OPTI FLUX 4000 R03 en ELECTRICAL CONNECTIONS 19 3.1 Safety instructions A DANGER! All work on the electrical connections may only be carried out with the power disconnected. Take note of the voltage data on the nameplate! A DANGER! Observe the national regulations for electrical installations! ADANGER! For devices used in hazardous areas, additional safety notes apply,please refer to the Ex documentation. WARNING! A! Observe without fail the local occupational health and safety regulations.Any work done on the electrical components of the measuring device may only be carried out by properly trained specialists. F1_1 /NFORMA TION! Look at the device nameplate to ensure that the device is delivered according to your order. Check for the correct supply voltage printed on the nameplate. • 3.2 Grounding ADANGER! The device must be grounded in accordance with regulations in order to protect personnel against electric shocks. 10 Figure 3-1:Grounding 1� Metal pipelines,not internally coated.Grounding without grounding rings. © Metal pipelines with internal coating and non-conductive pipelines.Grounding with grounding rings. • 04/2010-7309852300-OS OPTIFLUX 4000 R03 en www.krohne.com 15 ® ELECTRICAL CONNECTIONS 0 0 0 Figure 3-2:Different types of grounding rings 1� Grounding ring number 1 © Grounding ring number 2 a3 Grounding ring number 3 Grounding ring number 1: • 3 mm/0.1" thick (tantalum: 0.5 mm/0.1") Grounding ring number 2: • 3 mm/0.1" thick • Prevents damage to the flanges during transport and installation • Especially for flow sensors with PTFE liner Grounding ring number 3: • • 3 mm /0.1" thick • With cylindrical neck (length 30 mm/ 1.25" for DN10...150/3/8...6") • Prevents damage to the liner when abrasive liquids are used • 16 www.krohne.com 04/2010-7309852300-Os OPTIFLUX 4000 R03 en ELECTRICAL CONNECTIONS 3.3 Virtual reference for IFC 300 (C, W and F version) Figure 3-3:Virtual reference Possible if: • >_ DN10 • Electrical conductivity>_200 NS/cm • Electrode cable max. 50m. 3.4 Connection diagrams • � /NFORMA TION! The connection diagrams can be found in the documentation of the converter. 04/2010-7309852300-QS OPTI FLUX 4000 R03 en www.krohne.com 17 ® TECHNICAL DATA - OPTIFLUX40Wil 4.1 Dimensions and weights • Remote version b c a=77 mm/3.1" b=139mm/5.5" tT -- a c=106mm/4.2" oho Total height=H+a H - -r--- ({ �j- L W t Compact version with b C a=155 mm/6.1" IFC300 b=230mm/9.1" 10 a c=260mm/10.2" Total height=H+a 00 L W Compact version with C b a=82 mm/3.2" IFC100(01 b=161mm/6.3" a t-"00- 10c=257mm/10.1"Total height=H+a Compact version with b C a= 186 mm/7.3" IFC 100(45°) b=161 mm/6.3" a c=184mm/2.7"(D Total height= H +a 0 0 --- --- o�o- H Q The value may vary depending on the used cable glands. INFORMA T/ON! 1 All data given in the following tables are based on standard versions of the sensor only. • Especially for smaller nominal sizes of the sensor, the converter can be bigger than the sensor. • Note that for other pressure ratings than mentioned, the dimensions maybe different. • For full information on converter dimensions see relevant documentation. 18 www.krohne.com 04/2010-7309852300-Os OPTIFLUX 4000 R03 en TECHNICAL DATA EN 1092-1 Nominal size Dimensions[mml Approx. -DN PN [bar] L H W weight [kg] DIN ISO 2.5 40 130 142 90 3 4 40 1301 - 142 90 3 6 40 130 - 142 90 3 10 40 130 Cl - I 106 90 6 15 40 130 10 200 106 95 6 20 40 150j 200 158 105 7 251 40 150 200 140 115 4 32 40 150 200 157 140 5 40 40 150 200 166 150 5 50 40 200 200 186 165 9 65 16 200 200 200 185 9 80 40 200 200 209 1 200 12 100 16 250 250 237 220 15 125 16 250 250 2661 250 19 i • 150i 16 � 300 300 300 285 27 200 10i, 350 350 361 340 34 1 2501 10 400 450 408 395 48 300 10 500 500 458 445 58 3501 10 500 550 510 _ 505 78 400 10 600 600 568 565 101 450i 10 600 - 618 615 111 500 , 10 600 - 671 670 1301 600 10 600 - 781 780 165, 700 10 700 _ 898 895 248 800 10 800 - 1012 1015 331 900 10 900 1114 1115 430 1000 10 1000 - 1225 1230 507 1200 6 1200 1417 1405 555 1400 6 1400 - 1619 1630 765 1600 6 1600 - 1819 1830 1035I 1800 6 1800 - 2027 2045 1470 2000 6 2000 2259 22651 18601 C 150 mm for construction according to order code VN03. • 002010-7309852300-QS OPTIFLUX 4000 R03 en www.krohne.com 19 ® TECHNICAL DATA OPTIFLUX4000 150 lb flanges • Nominal size Dimensions [inches] Approx.weight [lb] ASME PN [psi] L H W 1/10" 284 5.12 5.59 3.50 6 1/8" 284 5.12 5.59 3.50 6 '/4" 284 5.12 5.59 3.50 6 3/8" 284 5.12 10 5.08 3.50 12 '/2" 284 5.12 10 5.08 3.50 12 3/4" 284 - 5.91 5.28 3.88 18 1" 284 5.91 5.39 4.25 7 1 '/4" 284 5.91 5.98 4.62 7 1 '/z" 284 5.91 6.10 5.00 11 2" 284 7.87 7.05 5.98 18 3" 284 7.87 8.03 7.50 26 4" 284 9.84 9.49 9.00 40 5" 284 9.84 10.55 10.0 49 6" 284 11.81 11.69 11.0 64 8" 284 13.78 14.25 13.5 95 10" 284 15.75 16.3 16.0 143 12" 284 19.69 18.78 19.0 207 . 14" 284 27.56 20.67 21.0 284 16" 284 31.50 22.95 23.5 364 18" 284 31.50 24.72 25.0 410 - 20" - 284 31.50 26.97 27.5 492 284"24 31.501 31.38 32.0_ 675 1T 5.91"for construction according to order code VN03 - re Q Pressures at 20°C/68°F. 0 • For higher temperatures, the pressure and temperature ratings areas per ASME B 16.5(up to 24'Y or ASME B 16.47 t>24'7. • Dimensions for other sizes on request. • 20 www.krohne.com 04/2010-7309852300-QS OPTIFLUX 4000 R03 en TECHNICAL DATA p 300 lb flanges Nominal size Dimensions[inches] Approx.weight [lb] ASME PN [psi] L H W 1/10" 741 5.12 5.59 3.75 6 1/8" 741 5.12 5.59 3.75 6 741 5.12 5.59 3.75 6 3/8" 741 5.12 10 5.24 3.75 15 741 5.12 tO 5.24 3.75 15 W, 741 5.91 5.67 4.62 201 1 741 5.91 5.71 4.87 11 1 ''/2" 741 7.87 6.65 6.13 13 2" 741 9.84 7.32 6.50 22 3" 741 9.84 8.43 8.25 31 4' j 741 111 10.00 10.0 � 44 6" 741 12.60 12.44 12.5 73 741 15.75 15.04 15.0 157 10" 741 19.69 17.05 17.5 247 12• - 741 23.627 20.00 20.5 375 14" 741 27.56 21.65 23.0 474 • 16• 741 31.50 23.98 25.5 639 20" 741 31.50 28.46 30.5 937 24" 741 31.50 33.39 36.0 I 1345 1� 5.91"for construction according to order code VN03 A CAUTION! • Pressures at20°C/68°F. • For higher temperatures, the pressure and temperature ratings are as per ASME B 16.5(up to 24.J or ASME B 16.47/>24 V. • Dimensions for other sizes on request. • 04/2010-7309852300-OS OPTI FLUX 4000 R03 en www.krohne.com 21 NOTES 22 www.krohne.com 04/2010-7309852300-QS OPTI FLUX 4000 R03 en NOTES p i 04/2010-7309852300-OS OPTI FLUX 4000 R03 en www.krohne.com 23 • I i KROHNE product overview • Electromagnetic flowmeters • Variable area flowmeters • Ultrasonic flowmeters 0 • Mass flowmeters 0 • Vortex flowmeters 3 • Flow controllers v • Level meters L s • Temperature meters • Pressure meters v • Analysis products • Measuring systems for the oil and gas industry 0 • Measuring systems for sea-going tankers x J LL_ H a 0 0 Head Office KROHNE Messtechnik GmbH N Ludwig-Kroh ne-Str. 5 • D-47058 Duisburg (Germany) 0 Tel.:+49 (0)203 301 0 3 Fax:+49 (0)203 301 10389 0 Z infofdkrohne.de & The current list of all KROHNE contacts and addresses can be found at:Y KR�HNE 0 www.krohne.com • F + 2.49T • IFC 300 Quick Start Signal converter for electromagnetic flowmeters Electronic Revision: ER 3.3.xx (SW.REV. 3.3x) The documentation is only complete when used in combination with the relevant documentation for the sensor. ©KROHNE 08/2010-4000070303-QS IFC 300 ROb en KROHNE CONTENTS 1 Safety instructions 4 2 Installation 5 2.1 Intended use..................................................................................................................... 5 2.2 Scope of delivery............................................................................................................... 5 2.3 Storage ............................................................................................................................. 6 2.4 Transport.......................................................................................................................... 6 2.5 Installation specifications ................................................................................................ 6 2.6 Mounting of the compact version..................................................................................... 7 2.7 Mounting the field housing, remote version.................................................................... 7 2.7.1 Pipe mounting.........................................................................................................................7 2.7.2 Wall mounting.........................................................................................................................8 2.7.3 Mounting plate, field housing .................................................................................................9 2.7.4 Turning the display of the field housing version .................................................................. 10 2.8 Mounting the wall-mounted housing, remote version .................................................. 11 2.8.1 Pipe mounting....................................................................................................................... 11 2.8.2 Wall mounting....................................................................................................................... 12 2.8.3 Mounting plate, wall-mounted housing ............................................................................... 13 3 Electrical connections 14 3.1 Safety instructions.......................................................................................................... 14 • 3.2 Important notes on electrical connection...................................................................... 14 3.3 Electrical cables for remote device versions, notes...................................................... 15 3.3.1 Notes on signal cables A and B............................................................................................ 15 3.3.2 Notes on field current cable C.............................................................................................. 15 3.3.3 Requirements for signal cables provided by the customer................................................. 16 3.4 Preparing the signal and field current cables (except TIDALFLUX) ............................. 17 3.4.1 Signal cable A (type DS 3001, construction........................................................................... 17 3.4.2 Preparing signal cable A, connection to signal converter................................................... 18 3.4.3 Length of signal cable A........................................................................................................ 20 3.4.4 Signal cable B (type BTS 300), construction.........................................................................21 3.4.5 Preparing signal cable B, connection to signal converter...................................................21 3.4.6 Length of signal cable B ....................................................................................................... 24 3.4.7 Preparing field current cable C, connection to signal converter......................................... 25 3.4.8 Preparing signal cable A, connection to measuring sensor................................................27 I 3.4.9 Preparing signal cable B, connection to measuring sensor................................................ 28 3.4.10 Preparing field current cable C, connection to measuring sensor ...................................29 3.5 Connecting the signal and field current cables (except TIDALFLUX) ........................... 30 3.5.1 Connecting the signal and field current cables, field housing ............................................31 3.5.2 Connecting the signal and field current cables, wall-mounted housing.............................32 3.5.3 Connecting the signal and field current cables, 19" rack-mounted housing (28 TE)..........33 3.5.4 Connecting the signal and field current cables, 19" rack-mounted housing (21 TE)..........34 3.5.5 Connection diagram for measuring sensor, field housing ..................................................35 3.5.6 Connection diagram for measuring sensor, wall-mounted housing...................................36 3.5.7 Connection diagram for measuring sensor, 19" rack-mounted housing (28 TE)................37 3.5.8 Connection diagram for measuring sensor, 19" rack-mounted housing (21 TE)................38 2 www.krohne.com 08/2010-4000070303-Q5 IFC 300 R06 en CONTENTS ■ • 3.6 Preparing and connecting the signal and field current cables (only TIDALFLUX) ....... 39 3.6.1 Cable lengths........................................................................................................................39 3.6.2 Signal cable A (type DS 300), construction...........................................................................40 3.6.3 Preparing signal cable A, connection to signal converter...................................................41 3.6.4 Prepare signal cable A, connect to measuring sensor........................................................42 3.6.5 Signal cable B (type BTS 300), construction.........................................................................43 3.6.6 Preparing signal cable B, connection to signal converter...................................................43 3.6.7 Preparing signal cable B, connection to measuring sensor................................................45 3.6.8 Preparing field current cable C, connection to signal converter.........................................46 3.6.9 Preparing field current cable C, connection to measuring sensor .....................................47 3.6.10 Interface cable ....................................................................................................................49 3.6.11 Connection of cables........................................................................................................... 50 3.7 Grounding the measuring sensor.................................................................................. 51 3.7.1 Classical method................................................................................................................... 51 3.7.2 Virtual reference (not valid for TIDALFLUX 4000 & OPTIFLUX 7300 C)............................... 52 3.8 Power supply connection ............................................................................................... 52 3.9 Inputs and outputs, overview ......................................................................................... 55 3.9.1 Combinations of the inputs/outputs 0/0s) ........................................................................... 55 3.9.2 Description of the CG number.............................................................................................. 56 3.9.3 Fixed, non-alterable input/output versions.......................................................................... 57 3.9.4 Alterable input/output versions............................................................................................ 59 3.10 Electrical connection of the inputs and outputs .......................................................... 60 3.10.1 Field housing, electrical connection of the inputs and outputs.........................................60 3.10.2 Wall-mounted housing, electrical connection of the inputs and outputs..........................61 • 3.10.3 19" rack-mounted housing (28 TE1, electrical connection of the inputs and outputs....... 62 3.10.4 19" rack-mounted housing (21 TE), electrical connection of the inputs and outputs....... 63 3.10.5 Laying electrical cables correctly.......................................................................................63 4 Start-up 64 4.1 Switching on the power.................................................................................................. 64 4.2 Starting the signal converter ......................................................................................... 64 5 Notes 65 08/2010-4000070303-OS IFC 300 R06 en www.krohne.com 3 p SAFETY INSTRUCTIONS : Warnings and symbols used • A DANGER! This information refers to the immediate danger when working with electricity. A DANGER! These warnings must be observed without fail. Even partial disregard of this warning can lead to serious health problems and even death. There is also the risk of seriously damaging the device or parts of the operators plant. WARNING! A* Disregarding this safety warning, even if only in part,poses the risk of serious health problems. There is also the risk of damaging the device or parts of the operators plant. CAUTION! QDisregarding these instructions can result in damage to the device or to parts of the operator's ° plant. /NFORMA T/ON! These instructions contain important information for the handling of the device. HANDLING • • This symbol designates all instructions for actions to be carried out by the operator in the specified sequence. RESULT This symbol refers to all important consequences of the previous actions. Safety instructions for the operator CAUTION! Installation, assembly, start-up and maintenance may only be performed by appropriately Q trained personnel. The regional occupational health and safety directives must always be observed. ® LEGAL NOTICE! The responsibility as to the suitability and intended use of this device rests solely with the user. The supplier assumes no responsibility in the event of improper use by the customer. Improper installation and operation may lead to loss of warranty. In addition, the 'Terms and Conditions of Sale"apply. They appear on the back of the invoice and form the basis of the purchase contract. /NFORMA TION! 3_1 • Further information can be found on the supplied CD-ROM in the manual, on the data sheet, in special manuals, certificates and on the manufacturers website. • If you need to return the device to the manufacturer or supplier,please fill out the form contained on the CD-ROM and send it with the device. Unfortunately, the manufacturer cannot repair or inspect the device without the completed form. 4 www.krohne.com 98/2010-4000070303-QS IFC 300 R06 en I INSTALLATION p 2.1 Intended use The electromagnetic flowmeters are designed exclusively to measure the flow and conductivity of electrically conductive, liquid media. ADANGER! For devices used in hazardous areas, additional safety notes apply,please refer to the Ex documentation. AWARNING! If the device is not used according to the operating conditions/refer to chapter 'Technical datal, the intended protection could be affected. 2.2 Scope of delivery /NFORMA TION! Inspect the cartons carefully for damage or signs of rough handling. Report damage to the carrier and to the local office of the manufacturer. a /NFORMA TION! Check the packing list to check ifyou received completely all thatyou ordered. INFO Look at t e device Look at the device nameplate to ensure that the device is delivered according to your order. Check for the correct supply voltage printed on the nameplate. 10 a O Figure 2-1:Scope of delivery 1) Device in the version as ordered 2� Documentation(calibration report,Quick Start,CD-Rom with product documentation for measuring sensor and signal converter) �3 Signal cable(only for remote version) • 0812010-4000070303-aS IFC 300 R06 en www.krohne.com 5 INSTALLATION Possible scope of delivery for signal converter/ measuring sensor • Measuring sensor Measuring sensor+ signal converter IFC 300 Compact Remote field Remote wall- Remote rack-mounted housing mounted housing housing l R 128 TE) or (21 TE) 0PTIFLUX 1000 OPTIFLUX 1300 C OPTIFLUX 1300 F OPTIFLUX 1300 W OPTIFLUX 1300 R 0PTIFLUX 2000 OPTIFLUX 2300 C OPTIFLUX 2300 F OPTIFLUX 2300 W OPTIFLUX 2300 R OPTIFLUX 4000 OPTIFLUX 4300 C OPTIFLUX 4300 F OPTIFLUX 4300 W OPTIFLUX 4300 R OPTIFLUX 5000 OPTIFLUX 5300 C OPTIFLUX 5300 F OPTIFLUX 5300 W OPTIFLUX 5300 R — ........... OPTIFLUX 6000 j OPTIFLUX 6300 C CPTIFLUX 630o F OPTIFLUX 6300 W OPTIFLUX 6300 R OPTIFLUX 7000 OPTIFLUX 7300 C - WATERFLUX 3000 WATERFLUX 3300 C WATERFLUX 3300 F WATERFLUX 330O W WATERFLUX 3300 R TIDALFLUX 4000 - TIDALFLUX 4300 F - - 2.3 Storage • Store the device in a dry, dust-free location. • Avoid continuous direct sunlight. • Store the device in its original packing. • Storage temperature: -50...+70°C/-58...+158°F 2.4 Transport Signal converter • No special requirements. Compact version • Do not lift the device by the signal converter housing. • Do not use lifting chains. • To transport flange devices, use lifting straps. Wrap these around both process connections. 2.5 Installation specifications INFORMA T/ON! The following precautions must be taken to ensure reliable installation. • Make sure that there is adequate space to the sides. • Protect the signal converter from direct sunlight and install a sun shade if necessary. • Signal converters installed in control cabinets require adequate cooling, e.g. by fan or heat exchanger. • Do not expose the signal converter to intense vibration. The flowmeters are tested for a vibration level in accordance with IEC 68-2-3. • 6 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en " INSTALLATION p 2.6 Mounting of the compact version INFORMA TION! .- The signal converter is mounted directly on the measuring sensor For installation of the flowmeter, please observe the instructions in the supplied product documentation for the measuring sensor 2.7 Mounting the field housing, remote version �-� INFORMA T/ON! 1 Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. 2.7.1 Pipe mounting � r 02 • r Figure 2-2:Pipe mounting of the field housing 1) Fix the signal converter to the pipe. �2 Fasten the signal converter using standard U-bolts and washers. 3� Tighten the nuts. • 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 7 19 INSTALLATION 2.7.2 Wall mounting ...... 1 `^•i 10 Figure 2-3:Wall mounting of the field housing 1) Prepare the holes with the aid of the mounting plate. For further information refer to Mounting plate, field housing on page 9. �2 Use the mounting material and tools in compliance with the applicable occupational health and safety directives. 03 Fasten the housing securely to the wall. Mounting multiple devices next to each other o ; o 1 f o O O o O O ' II ` o o , O a I a b O O O O a O O 0 a>_600mm/23.6" b>_250mm/9.8" ----. 8 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en INSTALLATION 2.7.3 Mounting plate, field housing � a c b O Dimensions in mm and inch [mm] [inch] a 60 2.4 b 100 3.9 c 09 00.41 0812010-4000070303-OS IFC 300 R06 en www.krohne.com 9 INSTALLATION 2.7.4 Turning the display of the field housing version All O T 0000 TV l Figure 2-4:Turning the display of the field housing version The display of the field housing version can be turned in 90' increments. 1� Unscrew the cover from the display and operation control unit. (2 Using a suitable tool, pull out the two metal puller devices to the left and right of the display. 03 Pull out the display between the two metal puller devices and rotate it to the required position. 4� Slide the display and then the metal puller devices back into the housing. 05 Re-fit the cover and tighten it by hand. A CAUTION! The ribbon cable of the display must not be folded or twisted repeatedly. INFORMA TION! Each time a housing cover is opened, the thread should be cleaned and greased. Use only resin- free and acid-free grease. Ensure that the housing gasket is properly fitted, clean and undamaged. • 10 www.krohne.com 08/2010-4000070303-O5 IFC 300 R06 en INSTALLATION p • 2.8 Mountingthe wall-mounted housing, remote version 9 /NFORMA TION! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. 2.8.1 Pipe mounting I ° U 0 Q Figure 2-5:Pipe mounting of the wall-mounted housing • (1) Fasten the mounting plate to the pipe with standard U-bolts, washers and fastening nuts. 02 Screw the signal converter to the mounting plate with the nuts and washers. 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 11 INSTALLATION , 2.8.2 Wall mounting • • • — NgNP\\\N " NU IAZI Q 0 0 Figure 2-6:Wall mounting of the wall-mounted housing Prepare the holes with the aid of the mounting plate. For further information refer to Mounting plate, wall-mounted housing on page 13. �2 Fasten the mounting plate securely to the wall. 3� Screw the signal converter to the mounting plate with the nuts and washers. Mounting multiple devices next to each other a a •I 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o 0 0 o o 0 D o o 0 0 o a>_240mm/9.4" • 12 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en Mlffgkllll INSTALLATION • 2.8.3 Mounting plate, wall-mounted housing ►a-., c b ► o O O o o id h e o 0 1f 99 Dimensions in mm and inch [mm] [inch] 00.4 b 64 -- - --- - 2.5 - - - 0.6 d b 0.2 f 4 - 0.2 OIL- h 98 3.85 • 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 13 © ELECTRICAL CONNECTIONS 3.1 Safety instructions • A DANGER! All work on the electrical connections may only be carried out with the power disconnected. Take note of the voltage data on the nameplate! A DANGER! Observe the national regulations for electrical installations! ADANGER! For devices used in hazardous areas, additional safety notes apply;please refer to the Ex documentation. WARNING! Ae! Observe without fail the local occupational health and safety regulations. Any work done on the electrical components of the measuring device may only be carried out by properly trained specialists. /NFORMA TION! lLook at the device nameplate to ensure that the device is delivered according to your order. Check for the correct supply voltage printed on the nameplate. • 3.2 Important notes on electrical connection ADANGER! Electrical connection is carried out in conformity with the VDE 0100 directive "Regulations for electrical power installations with line voltages up to 1000 V"or equivalent national regulations. CAUTION! Q0Use suitable cable entries for the various electrical cables. • The sensor and converter are configured together in the factory. For this reason,please connect the devices in pairs. Ensure that the sensor constant GK/GKL [see type plates]are identically set. • if delivered separately or when installing devices that were not configured together, set the converter to the DN size and GK/GKL of the sensor. • 14 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS 3.3 Electrical cables for remote device versions, notes 3.3.1 Notes on signal cables A and B /NFORMA TION! 1 The signal cables A (type DS 300J with double shield and B(type BTS 300Y with triple shield ensure proper transmission of measured values. Observe the following notes: • Lay the signal cable with fastening elements. • It is permissible to lay the signal cable in water or in the ground. • The insulating material is flame-retardant to EN 50625-2-1, IEC 60322-1. • The signal cable does not contain any halogens and is unplasticized, and remains flexible at Low temperatures. • The connection of the inner shield is carried out via the stranded drain wire (1). • The connection of the outer shield is carried out via the shield (60) or the stranded drain wire (6), depending on the housing version. Observe the following notes. • The signal cable type B cannot be used with options with "virtual reference"! 3.3.2 Notes on field current cable C • ADANGER! All versions except T/DALFLUX.• A non-shielded three-wire copper cable is sufficient for the field current cable. if you nevertheless use shielded cables, the shield must NOT be connected in the housing of the signal converter. Only TIDALFLUX.• A shielded two-wire copper cable is used as the field current cable. The shielding MUST be connected in the housing of the measuring sensor and signal converter. INFORMA T/ON! The field current cable is not part of the scope of delivery. • 08/2010-4000070303-OS IFC 300 R06 en www.krohne.com 15 ELECTRICAL CONNECTIONS 3.3.3 Requirements for signal cables provided by the customer INFORMA TION! If the signal cable was not ordered, it is to be provided by the customer. The following requirements regarding the electrical values of the signal cable must be observed: Electrical safety • To EN 60811 (Low Voltage Directive) or equivalent national regulations. Capacitance of the insulated conductors • Insulated conductor/ insulated conductor < 50 pF/m • Insulated conductor/shield < 150 pF/m Insulation resistance Riso ' 100 Gf2 x km ' Umax < 24 V Imax < 100 mA Test voltages • Insulated conductor/ inner shield 500 V • Insulated conductor/ insulated conductor 1000 V • • Insulated conductor/outer shield 1000 V Twisting of the insulated conductors • At least 10 twists per meter, important for screening magnetic fields. 16 www.krohne.com 08/2010-4000070303-as IFC 300 R06 en a �� ELECTRICAL CONNECTIONS El • 3.4 Preparing signal and field current cables p g the nal g es (except TIDALFLUX) /NFORMA T/ON! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. The electrical connection of the outer shield is different for the various housing variants. Please observe the corresponding instructions. 3.4.1 Signal cable A (type DS 3001, construction • Signal cable A is a double-shielded cable for signal transmission between the measuring sensor and signal converter. • Bending radius: >_ 50 mm/2" ® O 10 Figure 3-1:Construction of signal cable A 1� Stranded drain wire(11 for the inner shield (101, 1.0 mm2 Cu/AWG 17(not insulated,bare) (2) Insulated wire(2),0.5 mm2 Cu/AWG 20 (3 Insulated wire(3),0.5 mm2 Cu/AWG 20 4) Outer sheath �5 Insulation layers © Stranded drain wire(6)for the outer shield(601 • 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 17 IN ELECTRICAL CONNECTIONS ; 3.4.2 Preparing signal cable A, connection to signal converter Field housing INFORMA TION! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • The outside shield (60) is connected in the field housing directly via the shield and a clip. • Bending radius: >_ 50 mm/2" Required materials: • PVC insulation tubing, 02.5 mm/0.1" • Heat-shrinkable tubing • Wire end ferrule to DIN 46 228: E 1.5-8 for the stranded drain wire (1) • 2x wire end ferrules to DIN 46 228: E 0.5-8 for the insulated conductors (2, 3) a _ b (6) (1) I 2 c (601 s— Figure 3-2:Signal cable A,preparation for field housing a=80mm/3.15" b=10mm/0.39" T Strip the conductor to dimension a. 3 Trim the outer shield to dimension b and pull it over the outer sheath. (2 Cut off the inner shield (10) and the stranded drain wire (6). Make sure not to damage the stranded drain wire (1). (3 Slide an insulating tube over the stranded drain wire (1). 40 Crimp the wire end ferrules onto the conductors (2, 31 and stranded drain wire. 5� Pull the heat-shrinkable tubing over the prepared signal cable. 18 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS El SWall mounted housing /NFORMA T/ON! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • The connection of the outer shield (60) is carried out in the wall-mounted housing via the stranded drain wire (6). • Bending radius: >_ 50 mm/2" Required materials • Push-on connector 6.3 mm/0.25", insulation to DIN 46245 for conductor 0 = 0.5...1 mm2/ AWG 20...17 • PVC insulation tubing, 02.5 mm/0.1" • Heat-shrinkable tubing • Wire end ferrule to DIN 46 228: E 1.5-8 for the stranded drain wire (1) • 2x wire end ferrules to DIN 46 228: E 0.5-8 for the insulated conductors (2, 3) a 6) © O Figure 3-3:Signal cable A,preparation for wall-mounted housing a=80mm/3.15" 1) Strip the conductor to dimension a. 2� Cut off the inner shield (10) and the outer shield (60). Make sure not to damage the stranded drain wires (1) and (6). (3 Slide the insulation tubing over the stranded drain wires. 4� Crimp the push-on connector onto the stranded drain wire (6). (5) Crimp the wire end ferrules onto the conductors (2, 31 and stranded drain wire (1). © Pull the heat-shrinkable tubing over the prepared signal cable. • 08/2010-4000070303-QS IFC 300 RO6 en www.krohne.com 19 ELECTRICAL CONNECTIONS " 3.4.3 Length of signal cable A INFORMA T/ON! For temperatures of the medium above 150°C1300'F, a special signal cable and a ZD intermediate socket are necessary. These are available including the changed electrical connection diagrams. Measuring sensor Nominal size Min. electrical Curve for signal I ,---- conductivity cable A DN [mm] [inch] i [NS/cm] -- OPTIFLUX 1000 F 10...150 3/8...6 5 Al OPTIFLUX 2000 F 25...150 1...6 20 Al 200...2000 8-80 20 A2 0PTIFLUX 4000 F 2.5...150 1/10...6 1 Al 200...2000 8...80 1 A2 OPTIFLUX 5000 F 2.5...100 1/10...4 1 Al 150...250 6...10 1 A2 OPTIFLUX 6000 F 2.5...150 1/10...6 1 Al WATERFLUX 3000 F 25...600 1...24 20 Al 1D 600 1800 A2 Al 100 300 i 10 �— LLJ30 1 5 10 100 1000 6000 O Figure 3-4:Maximum length of signal cable A 1� Maximum length of signal cable A between the measuring sensor and signal converter[m] 2� Maximum length of signal cable A between the measuring sensor and signal converter[ft] �3 Electrical conductivity of the medium being measured[µS/cm] • 20 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en > s .. 11111 ELECTRICAL CONNECTIONS i 3.4.4 Signal cable B (type BTS 3001, construction • Signal cable B is a triple-shielded cable for signal transmission between the measuring sensor and signal converter. • Bending radius: >_ 50 mm /2" 4 05 10 (20) � 20 O (30) Figure 3-5:Construction of signal cable B 0 Stranded drain wire for the inner shield(10), 1.0 mm2 Cu/AWG 17(not insulated,bare) (2) Insulated wire(2),0.5 mm2 Cu/AWG 20 with stranded drain wire(20)of shield Z Insulated wire(3),0.5 mm2 Cu/AWG 20 with stranded drain wire(30)of shield (4) Outer sheath (5) Insulation layers © Stranded drain wire(6)for the outer shield(601,0.5 mm2 Cu/AWG 20(not insulated,bare] 3.4.5 Preparing signal cable B, connection to signal converter Field housing /NFORMA TION! 114-1 Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • The outside shield (60) is connected in the field housing directly via the shield and a clip. • Bending radius: >_ 50 mm/2" Required materials • PVC insulation tubing, 02.0...2.5 mm /0.08...0.1" • Heat-shrinkable tubing • Wire end ferrule to DIN 46 228: E 1.5-8 for the stranded drain wire (11 • 4 wire end ferrules to DIN 46 228: E 0.5-8 for the insulated conductors 2 and 3 and the stranded drain wires (20, 30) • 08/2010-4000070303-0S IFC 300 R06 en www.krohne.com 21 ELECTRICAL CONNECTIONS " a ►� (6) 111 C 1201 I60) (301 \_>WqC 3 4 i 1 (60) (20) i (30) Figure 3-6:Signal cable B,preparation for field housing a=80mm/3.15" b=10mm/0.39" © Strip the conductor to dimension a. Trim the outer shield to dimension b and pull it over the outer sheath. Cut off the inner shield 1101, the stranded drain wire (6) and the shields of the insulated con- ductors. Make sure not to damage the stranded drain wires (1, 20, 30). 0 Slide the insulation tubing over the stranded drain wires (1, 20, 30). (5) Crimp the wire end ferrules onto the conductors and stranded drain wires. © Pull the heat-shrinkable tubing over the prepared signal cable. • 22 www.krohne.com 08/2010-4000070303-QS IFC 300 RO6 en ELECTRICAL CONNECTIONS El Wall-mounted housing /NFORMA T/ON! 1 Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • The connection of the outer shield (601 is carried out in the wall-mounted housing via the stranded drain wire (6). • Bending radius: >_ 50 mm /2" Required materials: • Push-on connector 6.3 mm/0.25", insulation to DIN 46245 for conductor 0 = 0.5...1 mm2/ AWG 20...17 • PVC insulation tubing, 02.5 mm/0.1" • Heat-shrinkable tubing • Wire end ferrule to DIN 46 228: E 1.5-8 for the stranded drain wire (1) • 4 wire end ferrules to DIN 46 228: E 0.5-8 for insulated conductors 2 and 3 and the stranded drain wires (20, 301 a • (6) (1 (20) (30) I (6) � (11 i (20) (30) Figure 3-7:Signal cable B,preparation for wall-mounted housing a=80mm/3.15" 1) Strip the conductor to dimension a. Cut off the inner shield (101,the outer shield (601 and the shields for the conductor(2,3). Make sure not to damage the stranded drain wires (1, 6, 20, 30). Slide the insulation tubing over the stranded drain wires. (4) Crimp the push-on connector onto the stranded drain wire (6). • 0 Crimp the wire end ferrules onto the conductors and stranded drain wires (1, 20, 30). © Pull the heat-shrinkable tubing over the prepared signal cable. 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 23 ELECTRICAL CONNECTIONS . 3.4.6 Length of signal cable B • INFORMA TION! For temperatures of the medium above 150°C/300°F, a special signal cable and a ZD intermediate socket are necessary. These are available including the changed electrical connection diagrams. Measuring sensor Nominal size Min. electrical Curve for signal - - conductivity cable B DN [mm] [inch] [NS/cm] 0PTIFLUX 1000 F 10...150 3/8...6 5 B2 OPTIFLUX 2000 F 25...150 1...6 20 B3 200...2000 8...80 20 B4 OPT]FLUX 4000 F 2.5...6 1/10...1/6 10 B1 10...150 3/8...6 1 B3 200...2000 8...80 1 B4 OPTIFLUX 5000 F 2.5 1/10 10 B1 4...15 1/6...1/2 5 B2 25-100 1...4 1 B3 150...250 6...10 1 B4 OPTIFLUX 6000 F 2.5...15 1/10...1/2 10 B1 25...150 1...6 1 B3 WATERFLUX 3000 F 25...600 1...24 20 i B1 10 — 600 _ 1800 B4 83 82 40 B1 100 __ ( 1300 10 130 1 5 10 100 1000 6000 (3) Figure 3-8:Maximum length of signal cable B 1� Maximum length of signal cable B between the measuring sensor and signal converter[m] 2� Maximum length of signal cable B between the measuring sensor and signal converter[ft] 3� Electrical conductivity of the medium being measured [µ5/cm] 24 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS 3.4.7 Preparing field current cable C, connection to signal converter ADANGER! A non-shielded three-wire copper cable is sufficient for the field current cable. lfyou nevertheless use shielded cables, the shield must NOTbe connected in the housing of the signal converter. /NFORMA TION! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • Field current cable C is not part of the scope of delivery. • Bending radius: >_ 50 mm/2" Required materials: • Shielded 3-wire copper cable with suitable heat-shrinkable tubing • DIN 46 228 wire end ferrules: size according to the cable being used Length and cross-section of field current cable C Length Cross-section AF (Cu) [m] [ftl [mm21 [AWGI 0...150 0...492 3x0.75Cu 1Q 3x18 ' 150...300 492...984 3 x 1.50 Cu C 3 x 14 300...600 984...1968 3 x 2.50 Cu 1) 3 x 12 C Cu=copper cross-section • 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 25 ELECTRICAL CONNECTIONS In the wall-mounted housing version the connection terminals are designed for the following cable cross-sections: • Flexible cable<_ 1.5 mm2/AWG 14 • Solid cable <_2.5 mm2/AWG 12 tO 7; ® a O � ► 4 Figure 3-9:Field current cable C,preparation for the signal converter a=80mm/MY 1) Strip the conductor to dimension a. (2) Remove any shield that is present. 03 Pull a shrinkable tube over the prepared cable. 4� Crimp the wire end ferrules onto the conductors 7, 8 and 9. 26 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS El 3.4.8 Preparing signal cable A, connection to measuring sensor INFORMATION! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • The outer shield (601 is connected in the terminal compartment of the measuring sensor directly via the shield and a clip. • Bending radius: >_ 50 mm /2" Required materials • PVC insulating tube, 02.0...2.5 mm /0.08...0.1" • Heat-shrinkable tubing • Wire end ferrule to DIN 46 228: E 1.5-8 for the stranded drain wire (1) • 2 wire end ferrules to DIN 46 228: E 0.5-8 for the insulated conductors (2, 3) b — (6) (1) o iba) (1) (601 2 w000� 3 Figure 3-10:Preparing signal cable A,connection to measuring sensor a=50mm/2" b=10mm/0.39" (J) Strip the conductor to dimension a. Trim the outer shield (60) to dimension b and pull it over the outer sheath. Remove the stranded drain wire (6) of the outer shield and the inner shield (10). Make sure not to damage the stranded drain wire (1) of the inner shield. (4) Slide an insulating tube over the stranded drain wire (11. ($) Crimp the wire end ferrules onto conductors 2 and 3 and the stranded drain wire (1). © Pull the heat-shrinkable tubing over the prepared signal cable. • 08/2010-4000070303-QS IFC 300 R06 en wwwArohne.com 27 ELECTRICAL CONNECTIONS 3.4.9 Preparing signal cable B, connection to measuring sensor aINFORMA T/ON! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • The outer shield (60) is connected in the terminal compartment of the measuring sensor directly via the shield and a clip. • Bending radius: >_ 50 mm /2" Required materials • PVC insulation tubing, 02.0...2.5 mm /0.08...0.1" • Heat-shrinkable tubing • Wire end ferrule to DIN 46 228: E 1.5-8 for the stranded drain wire (1) • 2x wire end ferrules to DIN 46 228: E 0.5-8 for the insulated conductors (2, 3) i0 a ► b (6) (1) 02 r �(20) 40 (601 `� 30 111 (60) J 50 2 3 Figure 3-11:Preparing signal cable B,connection to measuring sensor a=50mm/2" b=10mm/0.39" 1) Strip the conductor to dimension a. 02 Trim the outer shield (60) to dimension b and pull it over the outer sheath. �3 Remove the stranded drain wire (6) of the outer shield and the shields and stranded drain wires of the insulated conductors (2, 31. Remove the inner shield (10). Be sure not to damage the stranded drain wire (1). 4� Slide an insulating tube over the stranded drain wire (1). �5 Crimp the wire end ferrules onto conductors 2 and 3 and the stranded drain wire (1). © Pull the heat-shrinkable tubing over the prepared signal cable. • 28 www.krohne.com O8/2010-4000070303-05 IFC 300 RO6 en ELECTRICAL CONNECTIONS El 3.4.10 Preparingfield current cable C, connection to measuring sensor 9 /NFORMA TION! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • The field current cable is not included in delivery. • The shield for field current cable C can be connected to the measuring sensor. • Bending radius: >_ 50 mm/2" Required materials • Heat-shrinkable tubing • 3 wire end ferrules to DIN 46 228: size according to the cable being used 10 © a Figure 3-12:Field current cable C,preparation for the measuring sensor a=50mm/2" 1) Strip the conductor to dimension a. (2 Remove any shield that is present. (3 Pull a shrinkable tube over the prepared cable. 40 Crimp the wire end ferrules onto the conductors 7, 8 and 9. • 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 29 ELECTRICAL CONNECTIONS 3.5 Connecting the signal and field current cables (except TIDALFLUX) A DANGER! Cables may only be connected when the power is switched off. A DANGER! The device must be grounded in accordance with regulations in order to protect personnel against electric shocks. DANGER! EX For devices used in hazardous areas, additional safety notes apply,please refer to the Ex documentation. WA Obseserverve without A! Observe fail the local occupational health and safety regulations. Any work done on the electrical components of the measuring device may only be carried out by properly trained specialists. i 30 www krohne_com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS 3.5.1 Connecting the signal and field current cables, field housing • The outer shield of signal cable A and/or B is connected electrically with the housing via the clip of the strain relief. • If a shielded field current cable is used, the shield must NOT be connected in the housing of the signal converter. • Bending radius: >_ 50 mm/2" OO OO ■ 6 i0O � 10 OO 03 4 Figure 3-13:Electrical connection of the signal and field current cables,field housing 1) Remove the locking screw and open the housing cover. �2 Pass the prepared signal and field current cables through the cable entries and connect the corresponding stranded drain wires and conductors. �3 Secure the field current cable using the clip. Any shield that is present must NOT be connect- ed. 4� Secure the signal cable using the clip. This also connects the outer shield to the housing. (5 Close the housing cover and secure it with the locking screw. INFORMATION! Each time a housing cover is opened, the thread should be cleaned and greased. Use only resin- free and acid-free grease. Ensure that the housing gasket is properly fitted, clean and undamaged. 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 31 1 ELECTRICAL CONNECTIONS 3.5.2 Connectingthe signal and field current cables wall-mounted housing 9 9 • The outer shield of signal cable A and/or B is connected via the stranded drain wire. • If a shielded field current cable is used, the shield must NOT be connected in the housing of the signal converter. • Bending radius: >_ 50 mm/2" 30 3 2 20 1 O 9 8 7 0 0 0 0 ♦ G G G i i i J i a t(4) Figure 3-14:Electrical connection of the signal and field current cables,wall-mounted housing 9) Open the housing cover. 0 Pass the prepared signal cable through the cable entry and connect the corresponding strand- ed drain wires and conductors. 3I Connect the stranded drain wire of the outer shield. 4) Pass the prepared field current cable through the cable entry and connect the corresponding conductor. Any shield that is present must NOT be connected. Tighten the screw connections of the cable entry and close the housing cover. /NFORMA TION! 1-14-1 Ensure that the housing gasket is properly fitted, clean and undamaged. 32 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en 1 Fri �l ELECTRICAL CONNECTIONS 3.5.3 Connecting the signal and field current cables, 19" rack-mounted housing (28 TE) f11 p• 1Q i — 3 000o (s) (1) 2 3 8 9 , (S) 7 , Figure 3-15:Connection signal cable A and field current cable 11) Signal cable A Shield and insulated wires 2 and 3 (3 Field current cable (1) (2o) �--L •.©. 1Q i i 3 (301 v / (S) � (1) 2 3 � 3� 8 9 ' 4 6 8 10 12 14 16 18 20 22 24 26 28 30 1 32 0 bM M a M M M M M M� �, M M M1 b, 0 (S) (20) (30); 7 Figure 3-16:Connection signal cable B and field current cable 1� Signal cable B T Shield and insulated wires 2 and 3 �3 Field current cable 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 33 ELECTRICAL CONNECTIONS 3.5.4 Connecting the signal and field current cables, 19" rack-mounted housing (21 TE) F X1 '' 10 3 I o X1 f i 0 2-- 4/ 6 dim = m d �(1) -2--3-J -- -- i � 7 8 9 X2 _ i z �� z 16 18 20 0 Figure 3-17:Connection signal cable A and field current cable 1� Signal cable A T Shield and insulated wires 2 and 3 � Field current cable X2� xjF, ., (1) (20) T (b) (30) T (20) (30) xi Lz' m m z O �2 4 b O d:m = m A: d i '(1) _2 3_ 7 8 9 i I z m m m z C 16 18 20 O d --------- d Figure 3-18:Connection signal cable B and field current cable 1Q Signal cable B ® Shield and insulated wires 2 and 3 (2) Field current cable • 34 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS 3.5.5 Connection diagram for measuring sensor, field housing QDANGER! The device must be grounded in accordance with regulations in order to protect personnel against electric shocks. • If a shielded field current cable is used, the shield must NOT be connected in the housing of the signal converter. • The outer shield of signal cable A or B in the signal converter housing is connected via the strain relief terminal. • Bending radius of signal and field current cable: >_ 50 mm /2" • The following illustration is schematic. The positions of the electrical connection terminals may vary depending on the housing version. 4 40 30 3 2 20 1 9 8 7 30 3 2 20 1 9 8 7 1 110) (10) T I (60) O® ® (60) 0 i ® 4) ® 3 2 1 W98 —� O -'� 3 2 1 Figure 3-19:Connection diagram for measuring sensor,field housing 1� Electrical terminal compartment in housing of the signal converter for signal and field current cable. (2 Signal cable A 3Z Signal cable B 4) Field current cable C 5� Connection box of measuring sensor © Functional ground FE i 08/2010-4000070303-OS IFC 300 R06 en www.krohne.com 35 11 ELECTRICAL CONNECTIONS 3.5.6 Connection diagram for measuring sensor, wall-mounted housing 9 9 9 A DANGER! The device must be grounded in accordance with regulations in order to protect personnel against electric shocks. • If a shielded field current cable is used, the shield must NOT be connected in the housing of the signal converter. • The outer shield of the signal cable is connected in the signal converter housing via the stranded drain wire. • Bending radius of signal and field current cable: >_ 50 mm/2" • The following illustration is schematic. The positions of the electrical connection terminals may vary depending on the housing version. 4 1401301 3 2 20 1 1 9 8 7 4 40 30 3 1 2 20 1 1 9 8 7 (1) (101 10 (10) 1601 (6) (60) (6) © o 0 o r ® o 4 3 2 1 4 9 8 7 © 3 2 1 9 8 7 Figure 3-20:Connection diagram for measuring sensor,wall-mounted housing 1� Electrical terminal compartment in housing of the signal converter for signal and field current cable. © Signal cable A (3 Signal cable B 4� Field current cable C ® Connection box of measuring sensor © Functional ground FE 0 36 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en m°� ELECTRICAL CONNECTIONS 3.5.7 Connection diagram for measuring sensor, 19" rack-mounted housing (28 TO QDANGER! `j The device must be grounded in accordance with regulations in order to protect personnel + against electric shocks. • If a shielded field current cable is used, the shield must NOT be connected in the housing of the signal converter. • The outer shield of the signal cable is connected in the signal converter housing via the stranded drain wire. • Bending radius of signal and field current cable: >_ 50 mm/2" • The following illustration is schematic. The positions of the electrical connection terminals may vary depending on the housing version. j 24 22 20 j 20 32 32 32'I 24 24 22 2220 20 32 32 32 z z z d b z d ', d z z d z d b z d (10) 1 (10) 1 (60),= _: 6 1601,- .: 6 02 ® 30 O® ® O® c 3 2 1 Figure 3-21:Connection diagram for measuring sensor, 19"rack-mounted housing(28 TE) 1� Electrical terminal compartment in housing of the signal converter for signal and field current cable. (2) Signal cable A (3 Signal cable B 44) Field current cable C (5) Connection box of measuring sensor © Functional ground FE 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 37 ELECTRICAL CONNECTIONS 5p � � 3.5.8 Connection diagram for measuring sensor, 19" rack-mounted housing (21 TE) ADANGER! The device must be grounded in accordance with regulations in order to protect personnel against electric shocks. • If a shielded field current cable is used, the shield must NOT be connected in the housing of the signal converter. • The outer shield of the signal cable is connected in the signal converter housing via the stranded drain wire. • Bending radius of signal and field current cable: >_ 50 mm/2" • The following illustration is schematic. The positions of the electrical connection terminals may vary depending on the housing version. 6 4 2 16 18 20 6 6 4 4 2 16 18 20 X1 d d d z z z X1 z d d z d z I z z [30l [20l 1� [601 O 01 e [60] O 0 3 2 1 7 8 9 -� O 4 3 2 1 7 8 9 i Figure 3-22:Connection diagram for measuring sensor, 19"rack-mounted housing(21 TE) 1� Electrical terminal compartment in housing of the signal converter for signal and field current cable. 2� Signal cable A a3 Signal cable B 40 Field current cable C �5 Connection box of measuring sensor © Functional ground FE 38 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS El 3.6 Prepgrin and connectingthe si nal and field current cables onl TIDALFLUX) 9 Y QDANGER! Cables may only be connected when the power is switched off. A DANGER! The device must be grounded in accordance with regulations in order to protect personnel against electric shocks. DANGER! EX For devices used in hazardous areas, additional safety notes apply,please refer to the Ex documentation. WARNING! Observe without fail the local occupational health and safety regulations. Any work done on the e! electrical components of the measuring device may only be carried out by properly trained specialists. 3.6.1 Cable lengths CAUTION! Q° The maximum allowed distance between the flow sensor and the converter is determined by thAe shortest cable length. Interface cable: maximum length is 600 m/ 1968 ft. Type B (BTS) signal cable: maximum length is 600 m/ 1968 ft. Type A(DS) signal cable: maximum length depends on the conductivity of the fluid: Electrical conductivity Maximum length [PS/cm] [m] [ft] 50 120 394 100 200 656 200 400 1312 >_400 600 1968 Field current cable: The cross section of the cable determines the maximum length: Cross section Maximum length [mm21 [AWG] [m] [ft] 2 x 0.75 2 x 18 150 492 2 x 1.5 2 x 14 300 984 2 x 2.5 2 x 12 600 1968 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 39 ELECTRICAL CONNECTIONS 3.6.2 YP Si nal cable A (type DS 300), construction 9 • Signal cable A is a double-shielded cable for signal transmission between the measuring sensor and signal converter. • Bending radius: >_ 50 mm/2" ® O O Oz Figure 3-23:Construction of signal cable A 10 Stranded drain wire(1)for the inner shield(101, 1.0 mm2 Cu/AWG 17(not insulated,bare) (2) Insulated wire(2),0.5 mm2 Cu/AWG 20 03 Insulated wire(31,0.5 mm2 Cu/AWG 20 4� Outer sheath (5) Insulation layers © Stranded drain wire(6)for the outer shield(60) 40 www.krohne.com 08/2010-4000070303-Q5 IFC 300 R06 en �t ELECTRICAL CONNECTIONS p 3.6.3 Preparing signal cable A, connection to signal converter Field housing INFORMA T/ON! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • The outside shield (60) is connected in the field housing directly via the shield and a clip. • Bending radius: >_ 50 mm /2" Required materials: • PVC insulating tube, 02.5 mm/0.1" • Heat-shrinkable tubing • Wire end ferrule to DIN 46 228: E 1.5-8 for the stranded drain wire (1) • 2 wire end ferrules to DIN 46 228: E 0.5-8 for the insulated conductors (2, 3) a _ b 1 � � 5 (601 Figure 3-24:Signal cable A,preparation for field housing a=80mm/3.15" b=10mm/0.39" Strip the conductor to dimension a. Trim the outer shield to dimension b and pull it over the outer sheath. 0 Cut off the inner shield (10) and the stranded drain wire (6). Be sure not to damage the strand- ed drain wire (1). Slide an insulating tube over the stranded drain wire (1). 0 Crimp the wire end ferrules onto the conductors (2, 3) and stranded drain wire. Pull the heat-shrinkable tubing over the prepared signal cable. 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 41 p ELECTRICAL CONNECTIONS 3.6.4 Prepare signal cable A, connect to measuring sensor /NFORMA TION/ Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. Required materials • PVC insulation tubing, 02.0...2.5 mm/0.08...0.1" • Heat-shrinkable tubing • Wire end ferrule to DIN 46 228: E 1.5-8 for the twisted stranded drain wires (1) and (6) • 2x wire end ferrules to DIN 46 228: E 0.5-8 for the insulated conductors (2, 3) O a (6) (1) (60) b (1)+(6) (3 2 3 Figure 3-25:Prepare signal cable A,connect to measuring sensor a=50mm/2" /� 1� Strip the conductor to dimension a. 2� Cut the outer shields (60) and (10). Make sure not to damage the stranded drain wires (1) and (6). �3 Twist the stranded drain wires (6) of the outer shield and the drain wire (1) of the inner shield (10). 4� Slide an insulating tube over the stranded drain wires (1) and (6). 5� Crimp the wire end ferrules onto conductors 2 and 3 and the stranded drain wires (1) and (6). © Pull the heat-shrinkable tubing over the prepared signal cable. 42 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS 19 3.6.5 Signal cable B (type BTS 300), construction • Signal cable B is a triple-shielded cable for signal transmission between the measuring sensor and signal converter. • Bending radius: >_ 50 mm /2" O O o (201 il O [30) Figure 3-26:Construction of signal cable B 1� Stranded drain wire for the inner shield(10). 1.0 mm2 Cu/AWG 17(not insulated,bare) 0 Insulated wire(2),0.5 mm2 Cu/AWG 20 with stranded drain wire(201 of shield (3) Insulated wire(3),0.5 mm2 Cu/AWG 20 with stranded drain wire(30)of shield (4) Outer sheath S Insulation layers © Stranded drain wire(6)for the outer shield(601,0.5 mm2 Cu/AWG 20(not insulated,bare) 3.6.6 Preparing signal cable B, connection to signal converter Field housing IN T/ON! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • The outside shield (60) is connected in the field housing directly via the shield and a clip. • Bending radius: >_50 mm/2" Required materials • PVC insulating tube, 02.0...2.5 mm /0.08...0.1" • Heat-shrinkable tubing • Wire end ferrule to DIN 46 228: E 1.5-8 for the stranded drain wire (1) • 4 wire end ferrules to DIN 46 228: E 0.5-8 for the insulated conductors 2 and 3 and the stranded drain wires (20, 30) 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 43 ELECTRICAL CONNECTIONS 0 a b (b) (tl 02 (20) — (601 (301 11) (601 (20) —: _— (30) Figure 3-27:Signal cable B,preparation for field housing a=80mm/3.15" b=10mm/0.39" /v 1� Strip the conductor to dimension a. Trim the outer shield to dimension b and pull it over the outer sheath. (3 Cut off the inner shield (10), the stranded drain wire (6) and the shields of the insulated con- ductors. Make sure not to damage the stranded drain wires (1, 20, 30). 4� Slide the insulation tubing over the stranded drain wires (1, 20, 30). (5) Crimp the wire end ferrules onto the conductors and stranded drain wires. © Pull the heat-shrinkable tubing over the prepared signal cable. 44 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS a 3.6.7 Preparing signal cable B, connection to measuring sensor aINFORMA T/ON! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. Required materials • PVC insulation tubing, 02.0...2.5 mm/0.08...0.1" • Heat-shrinkable tubing • Wire end ferrule to DIN 46 228: E 1.5-8 for the twisted stranded drain wires (1) and (6) • 2x wire end ferrules to DIN 46 228: E 0.5-8 for the insulated conductors (2, 3) T a (6) 11) (20) 0 (30) (60) (1)+(6) 0 . 2 3 Figure 3-28:Preparing signal cable B,connection to measuring sensor a=50mm/2" 10 Strip the conductor to dimension a. Cut the outer shields (601, (10), the shields around the insulated conductors (2, 31 and the stranded drain wires (20, 301 . Make sure not to damage the stranded drain wires (1) and (6). 3I Twist the stranded drain wires (6) of the outer shield and the drain wire (1) of the inner shield (10). 4� Slide an insulating tube over the stranded drain wires (1) and (6). (5) Crimp the wire end ferrules onto conductors 2 and 3 and the stranded drain wires (1) en (6). © Pull the heat-shrinkable tubing over the prepared signal cable. 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 45 p ELECTRICAL CONNECTIONS 3.6.8 Preparing field current cable C, connection to signal converter A DANGER! A shielded two-wire copper cable is used as the field current cable. The shielding MUST be connected in the housing of the measuring sensor and signal converter. aINFORMA T/ON! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • Field current cable C is not part of the scope of delivery. • Bending radius: >_ 50 mm/2" Required materials: • Shielded 2-wire copper cable, with fitted heat-shrinkable tubing • DIN 46 228 wire end ferrules: size according to the cable being used a b � 2 Figure 3-29:Preparation of field current cable C a=80mm/3.15" b=10mm/0.4" 1) Strip the conductor to dimension a. (2) Trim the outer shield to dimension b and pull it over the outer sheath. 3Z Crimp wire end ferrules onto both conductors. 40 Pull a shrinkable tube over the prepared cable. 46 www.kFohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS 3.6.9 Preparing field current cable C, connection to measuring sensor /NFORMA TION! Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. • The field current cable is not part of the scope of delivery. • The shield is connected in the terminal compartment of the converter directly via the shield and a clip. • The shield is connected in the sensor via the special cable gland. • Bending radius: >_50 mm/2" Required materials • Shielded 2-wire insulated copper cable • Insulating tube, size according to the cable being used • Heat-shrinkable tubing • DIN 46 228 wire end ferrules: size according to the cable being used a t� bf � Figure 3-30:Preparation of field current cable C a=125mm/5" b=10mm/0.4" 10 Strip the conductor to dimension a. Trim the outer shield to dimension b and pull it over the outer sheath. 3� Crimp wire end ferrules onto both conductors. • 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 47 ELECTRICAL CONNECTIONS At flow converter side: Connecting shielding under clamp in connection box of converter 10 20 Figure 3-31:Clamping of shields 1Q Field current cable Signal cable At flow sensor side: Connecting shielding via special cable gland 2mm/3/32., � 1 3 4 5� ► � s �UfjV i Figure 3-32:Connecting the shield within the cable gland 1Q Wires (2) Isolation S3 Shielding ® Isolation ® Feed cable through dome nut and clamping insert and fold shielding over clamping insert.Make sure that the braided shield overlaps the 0-ring by 2 mm/3/32". © Push clamping insert into body. ® Tighten the dome nut. • 48 www.krohne.com 08/2010-4000070303-OS IFC 300 R06 en ELECTRICAL CONNECTIONS p 3.6.10 Interface cable The data interface cable is a shielded, 3 x 1.5 mm2 LIYCY cable. The standard length 10 m / 32.8 ft is included in the delivery. Preparing the interface cable a 1� 1 0 Figure 3-33:Preparing the interface cable a=100mm/4" b=10mm/0.4" 10 Strip the conductor to dimension a. Trim the outer shield to dimension b and pull it over the outer sheath. �3 Crimp the wire end ferrules onto the conductors 1, 2 and 3. Connect the shielding at both sides of the cable via the special cable gland. Connecting shielding via special cable gland 1 3 4 2mm/3/32" �rrrrr. Figure 3-34:Connecting the shield within the cable gland 1) Wires 2Z Isolation 3I Shielding 4) Isolation 5) Feed cable through dome nut and clamping insert and fold shielding over clamping insert.Make sure that the braided shield overlaps the 0-ring by 2 mm/3/32". © Push clamping insert into body. ® Tighten the dome nut. 08/2010-4000070303-CS IFC 300 R06 en www.krohne.com 49 © ELECTRICAL CONNECTIONS g 3.6.11 Connection of cables 10 O Figure 3-35:Electrical connection T Unscrew the cover to reach the connectors © Unscrew the cover to reach the connectors Field current cable 4O Interface cable 0 Signal cable IDS or BTS) Connection diagram 7 8 1 202 3 30E C D I - 101112 7 8 A B C D E 1 L2L3 - Figure 3-36:Connection diagram Q Protective Earth connection(PEI ® Mains power neutral IN) Q Mains power live IL) (4) Field current cable ® Interface cable © Signal cable.Shown is the BTS cable.In case of IDS cable,do not use connectors 20 and 30. ® Connect housing to PE 50 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS Flow sensors with protection class IP 68 can not be opened anymore. The cables are factory connected and labeled as follows. 1 2 3 4 Mains Teem nab 1-i? E\efRN�a\s 1.es 23, COI s 'rer i ' naffs 7-8 1 ��terface (errt�lna O Figure 3-37:Labeled cables for IP 68 versions (D Mains power(10=blank, 11 =blue, 12=black) Field current(7=white,8=green) (3) Data interface(black wires,C=marked"1", D=marked"2",E=marked"31 (4) Electrodes(1 =blank,2=white,3=red) 3.7 Grounding the measuring sensor 3.7.1 Classical method CAUTION! QThere should be no difference in potential between the measuring sensor and the housing or ° protective earth of the signal converter! • The measuring sensor must be properly grounded. • The grounding cable should not transmit any interference voltages. • Do not use the grounding cable to connect more than one device to ground at the same time. • In hazardous areas, grounding is used at the same time for equipotential bonding. Additional grounding instructions are provided in the separate Ex documentation, which are only supplied together with hazardous-duty equipment. • The measuring sensors are connected to ground by means of a functional grounding conductor FE. • Special grounding instructions for the various measuring sensors are provided in the separate documentation for the measuring sensor. • The documentation for the measuring sensor also contain descriptions on how to use grounding rings and how to install the measuring sensor in metal or plastic pipes or in pipes which are coated on the inside. 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 51 El ELECTRICAL CONNECTIONS 3.7.2 Virtual reference (not valid for TIDALFLUX 4000 & OPTIFLUX 7300 C) For pipelines which are electrically insulated on the inside (e.g. have an inner liner or are made completely out of plastic), it is also possible to measure without additional grounding rings or electrodes. The signal converter's input amplifier records the potentials of both measuring electrodes and a patented method is used to create a voltage which corresponds to the potential of the ungrounded medium. This voltage is then the reference potential for signal processing. That means there are no interfering potential differences between the reference potential and the measuring electrodes during signal processing. Ungrounded use is also possible for systems with voltages and currents in the pipelines, e. g. electrolysis and galvanic systems. INFORMA T/ON! 1 /f there is a virtual reference with wall housing, voltage is permitted between PE/FE of the converter and the measuring sensor! Thresholds for measuring operation with the virtual reference Size >_ DN 10/>_3/8" Electrical conductivity >_200 pS/cm Signal cable use only A(type DS 300) Signal cable length <50 m/<_ 150 ft 3.8 Power supply connection A DANGER! The device must be grounded in accordance with regulations in order to protect personnel against electric shocks. ADANGER! For devices used in hazardous areas, additional safety notes apply,please refer to the Ex documentation. • The protection category depends on the housing versions (IP65...67 to IEC 529/ EN 60529 or N E M A4/4X/6). • The housings of the devices, which are designed to protect the electronic equipment from dust and moisture, should be kept well closed at all times. Creepage distances and clearances are dimensioned to VIDE 0110 and IEC 664 for pollution severity 2. Supply circuits are designed for overvoltage category III and the output circuits for overvoltage category II. • Fuse protection (IN <_ 16 A) for the infeed power circuit, as well as a separator (switch, circuit breaker) to isolate the signal converter must be provided close to the device. The separator must conform to IEC 60947-1 and IEC 60947-3 and must be marked as the separator for this device. 52 www.krohne.com 08/2010-4000070303-Q5 IFC 300 R06 en ELECTRICAL CONNECTIONS El 100...230 VAC (tolerance range: -15%/+10%) • Note the power supply voltage and frequency (50...60 Hz) on the nameplate. • The protective ground terminal PE of the power supply must be connected to the separate U- clamp terminal in the terminal compartment of the signal converter For 19" rack-mounted housing please refer to the connection diagrams. /NFORMA TION! 240 VAC+5%is included in the tolerance range. 12...24 VDC (tolerance range: -55%/+30%) • Note the data on the nameplate! • When connecting to functional extra-low voltages, provide a facility for protective separation (PELV) (acc. to VDE 0100/VDE 0106 and/or IEC 364/ IEC 536 or relevant national regulations). INFORMA T/ON! 12 VDC- 10%is included in the tolerance range. 24 VAC/DC (tolerance range:AC: -15%/+10%; DC: -25%/+30%) • AC: Note the power supply voltage and frequency (50...60 Hz) on the nameplate. • DC: When connecting to functional extra-low voltages, provide a facility for protective separation (PELV) (acc. to VDE 0100/VDE 0106 and/or IEC 364/ IEC 536 or relevant national regulations). /NFORMA T/ON! 12 V is not included in the tolerance range. 08/2010-4000070303-aS IFC 300 R06 en www.krohne.com 53 p ELECTRICAL CONNECTIONS Power supply connection (excluding 19" rack-mounted housing) 11) PE O N L - I01 � 0 V 0 FE 4- L- L+ L((23))- FE -;�- I_N L 11) 100...230 VAC(-15%/+10%),22 VA (2) 24 VDC(-55%/+30%), 12 W (3 24 VAC/DC(AC:-15%/+10%;DC:-25%/+30%),22 VA or 12 W Power supply connection for 19" rack-mounted housing (28 TO M L(L+1 eo PE IFEI 0000 Power supply connection for 19" rack-mounted housing (21 TO X2 X2- X' Sur z „ 28 30 32 d N L (L-) (L+) I 414 INFORMA TION! lFor safety reasons the manufacturer has connected the 28d contacts internally to the 28z, 30z and 32z contacts. You are advised to also connect contacts 28z, 30z and 32z to the external protective conductor. A CAUTION! The protective conductor contacts must not be used to loop through the PE connection. 10 54 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS p • 3.9 Inputs and outputs, overview p p 3.9.1 Combinations of the inputs/outputs (1/0s) This signal converter is available with various input/output combinations. Basic version • Has 1 current output, 1 pulse output and 2 status outputs/limit switches. • The pulse output can be set as status output/limit switch and one of the status outputs as a control input. Ex i version • Depending on the task, the device can be configured with various output modules. • Current outputs can be active or passive. • Optionally available also with Foundation Fieldbus and Profibus PA Modular version • Depending on the task, the device can be configured with various output modules. Bus systems • The device allows intrinsically safe and non intrinsically safe bus interfaces in combination with additional modules. • For connection and operation of bus systems, please note the separate documentation. Ex option • For hazardous areas, all of the input/output variants for the housing designs C and F with terminal compartment in the Ex d (pressure-resistant casing) or Ex e (increased safety) versions can be delivered. • Please refer to the separate instructions for connection and operation of the Ex-devices. 08/2010-4000070303-aS IFC 300 R06 en www.krohne.com 55 © ELECTRICAL CONNECTIONS 3.9.2 Description of the CG number CG 3 T ® oo ® © ® Figure 3-38:Marking(CG number)of the electronics module and input/output variants 1� ID number:0 ® ID number:0=standard;9=special Q3 Power supply option/measuring sensor option 4Q Display(language versions) ® Input/output version(1/0) © 1st optional module for connection terminal A ® 2nd optional module for connection terminal B The last 3 digits of the CG number(®,©and©) indicate the assignment of the terminal connections. Please see the following examples. Examples for CG number CG 300 11 100 100...230 VAC &standard display; basic I/0: la or Ip&Sp/Cp&Sp& PP/Sp CG 300 11 7FK 100...230 VAC&standard display; modular 1/0: la & PN/SN and optional module PN/SN & CN CG 300 81 4EB 24 VDC & standard display; modular 1/0: la & Pa/Sa and optional module PP/Sp& Ip Description of abbreviations and CG identifier for possible optional modules on terminals A and B Abbreviation Identifier for CG No. Description la A Active current output IP B Passive current output Pa/Sa C Active pulse,frequency,status output or limit switch (changeable) Pp/SP E Passive pulse,frequency,status output or limit switch (changeable) PN/SN F Passive pulse,frequency,status output or limit switch according to NAMUR(changeable) Ca G Active control input CP K Passive control input CN H Active control input to NAMUR Signal converter monitors cable breaks and short circuits acc.to EN 60947-5-6. Errors indicated on LC display. Error messages possible via status output. Ilna P Active current input IInP R Passive current input 8 No additional module installed - 0 No further module possible 56 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS 3.9.3 Fixed, non-alterable input/output versions This signal converter is available with various input/output combinations. • The grey boxes in the tables denote unassigned or unused connection terminals. • In the table, only the final digits of the CG no. are depicted. • Connection terminal A+ is only operable in the basic input/output version. CG no. Connection terminals A+ A A- B B- C- D D- Basic I/Os (standard) 1 0 0 IP+ HART passive 1Q Sp/Cp passive (2) Sppassive PP/Sp passive la+HART®active 1D Ex i 10s (option) 2 0 0 la+HART active PN/SN NAMUR 3 0 0 IP+ HART®passive PN/SN NAMUR 2 1 0 la active PN/SN NAMUR la+HART®active PN/SN NAMUR Cp passive (2) 3 1 0 la active PN/SN NAMUR Ip+HART®passive PN/SN NAMUR (2)Cp passive (2) 2 2 0 Ip passive PN/SN NAMUR la+ HART®active PN/SN NAMUR Cp passive (P 3 2 0 I passive P /S R PN/SN 2 P P N N NAMUR Ip+HART passive NAMUR Cp passive (2) 2 3 0 1Ina active PN/SN NAMUR la+HART active PN/SN NAMUR O Cp passive 3 3 0 1Ina active PN/SN NAMUR Ip+HART passive PN/SN NAMUR Cp passive 2 4 0 11np passive PN/SN NAMUR la+HART active PN/SN NAMUR (2) Cp passive (2) 340 Ilnp passive PN/SN NAMUR Ip+ HART passive PN/SN NAMUR (2) Cp passive 08/2010-4000070303-05 IFC 300 R06 en www.krohne.com 57 ELECTRICAL CONNECTIONS "" CG no. Connection terminals A+ A A- B B- C C- D D- PROFIBUS PA (Ex i) (option) D 0 0 PA+ PA- PA+ PA- FISCO Device FISCO Device D 1 0 la active PN/SN NAMUR PA+ PA- PA+ PA- Cp passive © FISCO Device FISCO Device D 2 0 Ip passive PN/SN NAMUR PA+ PA- PA+ PA- Cp passive © FISCO Device FISCO Device D 3 0 1Ina active PN/SN NAMUR PA+ PA- PA+ PA- Cp passive ® FISCO Device FISCO Device D L 0 IInp passive PN/SN NAMUR PA+ PA- PA+ PA- Cp passive (2) FISCO Device FISCO Device FOUNDATION Fieldbus (Ex i) (option) E 0 0 V/D+ V/D- V/D+ V/D- FISCO Device FISCO Device EI 10 Ia active PN/SN NAMUR V/D+ V/D- V/D+ V/D- Cp passive OO FISCO Device FISCO Device E 2 0 Ip passive PN/SN NAMUR V/D+ I V/D- V/D+ V/D- Cp passive ® FISCO Device FISCO Device E 3 0 1Ina active PN/SN NAMUR V/D+ V/D- V/D+ V/D- j Cp passive ® FISCO Device FISCO Device E 4 0 IInp passive PN/SN NAMUR V/D+ V/D- V/D+ V/D- Cp passive (2) FISCO Device FISCO Device 1� function changed by reconnecting (2) changeable 58 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en ELECTRICAL CONNECTIONS 3.9.4 Alterable input/output versions This signal converter is available with various input/output combinations. • The grey boxes in the tables denote unassigned or unused connection terminals. • In the table, only the final digits of the CG no. are depicted. • Term. _ (connection) terminal CG no. Connection terminals A+ A A- B B- C C- D D- Modular 10s (option) 4__ max.2 optional modules for term.A+B la+HART®active Pa/Sa active 9Q 8__ max.2 optional modules for term.A+B IP+HART®passive Pa/Sa active 1Q 6__ max. 2 optional modules for term.A+ B la+HART®active PP/SP passive 1O B__ max. 2 optional modules for term.A+ B IP+HART®passive PP/Sp passive 1O 7__ max. 2 optional modules for term.A+ B la+HART®active PN/SN NAMUR Q C__ max. 2 optional modules for term.A+B IP+HART®passive PN/SN NAMUR Q PROFIBUS PA (option) D max.2 optional modules for term.A+ B PA+(2) PA-(2) PA+(11 FOUNDATION Fieldbus (option) E__ max.2 optional modules for term.A+B V/D+(2) V/D- (2) V/D+(1) V/D-(1) PROFIBUS DP (option) -- � F_0 1 optional module for or RxD/TxD- RxD/TxD- Terminati i RxD/TxD- RxD/TxD- term.A on P P(2) N(2) on N P(1) NO) Modbus (Option) G__ © max. 2 optional modules for term.A+B Common Sign. B Sign.A (D1) (DO) H__ a max. 2 optional modules for term.A+ B Common Sign. B Sign.A (D1) (DO) (1) changeable ® not activated bus terminator Q activated bus terminator 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 59 ELECTRICAL CONNECTIONS 1 3.10 Electrical connection of the inputs and outputs /NFORMA TION! 1-14-1 Assembly materials and tools are not part of the delivery. Use the assembly materials and tools in compliance with the applicable occupational health and safety directives. 3.10.1 Field housing, electrical connection of the inputs and outputs A DANGER! All work on the electrical connections may only be carried out with the power disconnected. Take note of the voltage data on the nameplate! • For frequencies above 100 Hz, shielded cables are to be used in order to reduce radiation from electrical interferences (EMC). • Terminal A+ is only operable in the basic version. --- i .. .. .. .. .. .. .. .. .. A A- A+B B- C C- D D- 10 OO 03 F, Figure 3-39:Terminal compartment for inputs and outputs in field housing 1) Open the housing cover (2 Push the prepared cable through the cable entry and connect the necessary conductors. (3 Connect the shield if necessary. • Close the cover of the terminal compartment. • Close the housing cover. /NFORMA TION! Each time a housing cover is opened, the thread should be cleaned andgreased. Use only resin- free and acid-free grease. Ensure that the housing gasket is properly fitted, clean and undamaged. 60 wvvw.krohne.com 08/2010-4000070303-QS IFC 300 R06 en 'r ELECTRICAL CONNECTIONS 3.10.2 Wall-mounted housing, electrical connection of the inputs and outputs A DANGER! All work on the electrical connections may only be carried out with the power disconnected. Take note of the voltage data on the nameplate! • For frequencies above 100 Hz, shielded cables are to be used in order to reduce radiation from electrical interferences (EMC). The shield must be electrically connected using 6.3 mm/0.25" push-on connectors (insulation to DIN 46245) in the 1/0 terminal compartment. • Terminal A+ is only operable in the basic version. � rJ O A A- A+ B B- C C- D D- ti n_ TT � tot Figure 3-40:Connection of inputs and outputs in wall-mounted housing 10 Open the housing cover (2) Push the prepared cables through the cable entry and connect them to the supplied connector plugs 4). �3 Connect the shield if necessary. 4� Route the connector plugs with the clamped conductors into the sockets provided for that pur- pose. 5� Close the housing cover. a /NFORMA TION! 3 Ensure that the housing gasket is properly fitted, clean and undamaged. 08/2010-4000070303-DS IFC 300 R06 en www.krohne.com 61 ,111 ELECTRICAL CONNECTIONS 3.10.3 19" rack-mounted housing (28 TE), electrical connection of the inputs and outputs A DANGER! All work on the electrical connections may only be carried out with the power disconnected. Take note of the voltage data on the nameplate! • For frequencies above 100 Hz, shielded cables are to be used in order to reduce effects from electrical interferences (EMC). • Terminal A+ is only operable in the basic version. S1 S2 0000 D- D A+ A- A b2 12 14 b0 = i s m = = m = b 00 C- C B- B Figure 3-41:Terminal compartment for inputs and outputs in rack-mounted housing (E Shielding • Connect the conductor to the multipolar plug according to the illustration. • The signal cable shield is connected to the Pin S. • Press the plug into the connector. 62 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en 11 ELECTRICAL CONNECTIONS F 3.10.4 19" rack-mounted housing (21 TE), electrical connection of the inputs and outputs A DANGER. All work on the electrical connections may only be carried out with the power disconnected. Take note of the voltage data on the nameplate! • For frequencies above 100 Hz, shielded cables are to be used in order to reduce effects from electrical interferences (EMC). • Terminal A+ is only operable in the basic version. x2 xi X2 D D- B B- z M M = z 2 4 6 10 12 14 dm m m = = M d A+ A A- A+ CC- 3-42:Terminal compartment for inputs and outputs in rack-mounted housing Connect the conductor to the multipolar plug according to the illustration. • Press the plug into the connector. 3.10.5 Laying electrical cables correctly 03 O O Figure 3-43:Protect housing from dust and water /� 1� Lay the cable in a loop just before the housing. �2 Tighten the screw connection of the cable entry securely. (3 Never mount the housing with the cable entries facing upwards. 4� Seal cable entries that are not needed with a plug. 08/2010-4000070303-Qs IFC 300 R06 en www krohne com 63 START-UP 4.1 Switching on the power Before connecting to power, please check that the system has been correctly installed. This includes: • The device must be mechanically safe and mounted in compliance with the regulations. • The power connections must have been made in compliance with the regulations. • The electrical terminal compartments must be secured and the covers have been screwed on. • Check that the electrical operating data of the power supply are correct. • Switching on the power. 4.2 Starting the signal converter The measuring device, consisting of the measuring sensor and the signal converter, is supplied ready for operation.All operating data have been set at the factory in accordance with your order specifications. When the power is switched on, a self test is carried out. After that the device immediately begins measuring, and the current values are displayed. . : A - .. : x3 + 12345.6 x/y + 123 .45 y12.3 °Y +1234.56 z3 Figure 4-1:Displays in measuring mode(examples for 2 or 3 measured values) x,y and z denote the units of the measured values displayed It is possible to change between the two measured value windows, the trend display and the list with the status messages by pressing the keys T and �. 64 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en NOTES F-4- 08/2010-4000070303-QS IFC 300 R06 en www.krohne.com 65 NOTES o 66 www.krohne.com 08/2010-4000070303-QS IFC 300 R06 en NOTES 08/2010-4000070303-OS IFC 300 R06 en www.krohne.com 67 • i ram. l - KROHNE product overview • Electromagnetic flowmeters • Variable area flowmeters • Ultrasonic flowmeters • Mass flowmeters v • Vortex flowmeters • Flow controllers r • Level meters 3 • Temperature meters C s • Pressure meters 0 • Analysis products • Measuring systems for the oil and gas industry 0 • Measuring systems for sea-going tankers 0 0 M U LL d Head Office KROHNE Messtechnik GmbH gLudwig-Krohn e-Str. 5 D-47058 Duisburg (Germany) 0 Tel.:+49 (0)203 301 0 0 Fax:+49 (0)203 301 10389 Z info(dkrohne.de & The current list of all KROHNE contacts and addresses can be found at: KR�E"�NE Y o www.krohne.com 1/23/2015 KROHNE Group—Terms and Conditions I KROHNE Group KROHNE Group Terms and,Conditions KROHNE Group —Terms and Conditions Standard Terms and Conditions of Sale and Delivery of the KROHNE Group 1.General 1.1 These Standard Terms and Conditions of Sale and Delivery shall apply to all deliveries and other services provided by any company of the KROHNE Group("Seller').Buyer's Terms and Conditions are only applicable in whole or in part,if expressly accepted by Seiler in writing per letter,telecopy or email. 1.2 In case certain provisions of these Standard Terms and Conditions of Sale and Delivery will be regarded as invalid,the validity of the remaining provisions of these Standard Terms and Conditions of Sale and Delivery and of the Sales Contract shall not be affected.Buyer and Seller will replace the invalid provisions by such valid provisions being legally permitted and corresponding as close as possible to the legal and economic sense and purpose of the invalid provisions. 1.3 Waiving any special notice,the Buyer authorizes the Seller to use personal data to the extent permitted by any applicable statutory law governing the protection of personal data and necessary for the implementation of the Sales Contract and to disclose such personal data to the Seller's personnel involved in the implementation of the Sales Contract. 2.Offers,extent of delivery and conclusion of contract 2.1 All offers are subject to alteration. 2.2 The Sales Contract takes effect when the Seller's written order confirmation is dispatched(per mail,telecopy or email).The order confirmation of Seller shall also be valid without hand-written signature.Further alterations of the Sales Contract require the Seller's written confirmation per letter,telecopy or email.In case the delivery had to take place without prior written order confirmation.the Sales Contract takes effect upon the delivery.Confirmed orders cannot be put on Hold or cancelled without Seller's written approval. 2.3 The order confirmation shall govern the extent of the deliveries to be performed according to the Sales Contract. • Any information regarding the quality or characteristics of the product outside the order confirmation,e.g.in advertising material,shall be without any legal significance.The Seller reserves the right to after the construction, the choice of material,the specification and the design even after dispatch of the order confirmation to the extent that such alterations are not in contradiction to the order confirmation. 2.4 Any documents relating to the offer or the order confirmation,such as sketches,drawings,dimensions and weights shall not be binding unless they are expressly specified in writing to be binding. 2.5 In case of material changes in the financial condition of the Buyer compared to the financial condition at the moment of dispatch of the order confirmation,Seiler shall be entitled to refuse the deliver until the Buyer has obtained corresponding security. 3.Prices and payment conditions 3.1 The prices are free carrier,ex works(FCA)excluding packaging and other costs for handling and transportation.The packaging shall be calculated at prime cost and cannot be returned.If applicable the prices are increased by the value added or sales tax as required by law. 3.2 In case of a material and unforeseeable alteration of the product costs not under control of the Seller,the Seller reserves the right to agree with the Buyer on a price deviating from the order confirmation. 3.3 In case of changes required by the Buyer after dispatch of the order confirmation,any potential additional costs will be invoiced to the Buyer. 3.4 Any payments shall be effected within 30 days after the date of invoice without any deduction. 3.5 Upon delayed payment.the Buyer is due to pay interest from the due date at a rate of 8%p.a.The interest payable on default amounts to 8%p.a.about the basis interest rate.The Seller's right to raise further claims caused by default of the Buyer shall remain unaffected. 3.6 Bills of exchange and cheques do not count as payment until they are cashed.Discount,bank and other charges shall be bome by the Buyer. 3.7 The Buyer shall not have the right of retention of payments.An off-set of counterclaims is only permitted insofar as these counterclaims are acknowledged by the Seller as existing and due or have been finally determined as legally binding. • 4.Delivery terms,acceptance and dispatch 4.1 The Seller will endeavour to comply with the confirmed delivery time.The statements regarding delivery times are made according to best discretion without being binding unless the delivery date has been agreed upon in the http://Ivohne.cotTVerVterms-and-conditions/print.htr l 1/6 1/23120 1 5 KROHNE Group—Terms and Conditions I KROHNE Group order confirmation as a fixed day. i4.2 The delivery time commences after technical and commercial clarification of the order and submittal of required approvals with the dispatch of the order confirmation.If the Buyer does not fulfil its material contractual and payment obligations the delivery time shall be extended reasonably.Compliance with the delivery time has been reached when the Buyer has been notified within the agreed delivery time of the readiness of the order for shipment.Any alterations of the order demanded by the Buyer within that delivery time shall interrupt or extend the delivery time accordingly. 4.3 Unforeseeable events entitle the Seller to defer delivery for so long as the impediment persists plus an appropriate additional period.Unforeseeable events are such circumstances as those which cannot be avoided by reasonable care due to circumstances,in particular cases,such as war,currency and economical or other sovereign measures,civil disturbance,natural events,fire,strikes,lockouts,non-supply of materials arising through no fault of the Seller,traffic obstructions,operation interruptions,and other events of force majeure,through which the fulfilment of the Sales Contract is endangered,made substantially more difficult or rendered impossible.In such cases,the Seller is entitled to withdraw from the Contract without any obligation to pay damages.The Buyer may demand a statement from the Seller as to whether the Seller will withdraw or deliver within an appropriate period.If no statement is given by the Seller,the Buyer may withdraw from the Sales Contract.The Buyer may not refuse partial deliveries or partial fulfilment. 4.4 If deliveries are delayed for other reasons.the Buyer shall grant an appropriate extension of time in writing. Upon expiration of such an extension without the goods being shipped by the Seller,the Buyer is entitled to cancel those supplies,which have not been shipped or declared ready for shipment prior to the expiration of such an extension.In case the deliveries,which have already been partially performed,are of no practical interest to the Buyer,he shall be entitled to withdraw from the entire Sales Contract. 4.5 Claims of the Buyer for damages are in all cases of delayed delivery or order fulfilment excluded.This shall not apply if the Seller is liable for wilful actions or gross negligence. 4.6 In case that no fixed dates for acceptance have been agreed upon,the Buyer is committed to accept the delivered goods within 8 days after completion. 4.7 If the Buyer has submitted an"open purchase order',he is committed to accept the ordered products-in case of several different products all products-within 12 months after the date of order.Sec.4.5 shall apply correspondingly. • 4.8 If the Buyer does not accept the goods at the agreed date,he shall nevertheless be obliged to pay the purchase price.Notwithstanding any further legal rights,the Seller shall be entitled to arrange for storage of the goods at the expense and risk of the Buyer or to dispose otherwise about the goods and to perform a delivery to the Buyer at the next possible date.The Seller will charge the minimum of a%%of the order value per month for storage. 4.9 The goods will be shipped ex works at the expense and risk of the Buyer.If not otherwise agreed upon,using his best judgment,the Seller determines the carrier and the method of shipment.The Seller will only,at the expense of the Buyer,insure against transport damages,theft or loss if expressly required by the Buyer. 5.Rights to use of the Buyer for software 5.1 The following terms of Sec.5 shall apply exclusively to the provision of standard software for a limited or unlimited period as a part of or in connection with related hardware(such software hereinafter referred to as "Software"),as well as to the entire Supplies,to the extent that a breach of contract has its cause in the Software. The General Standard Terms and Conditions of Sale and Delivery shall apply to those matters as far as not specifically covered in the Sec.5.The Seller does not assume any obligation to perform software services by virtue these terms in Sec.5.Such services require a separate agreement. 5.2 Firmware is not"Software"within the meaning of Sec.5.To the extent that Software is provided to the Buyer,for which the Seller is only derived rights to use(third party software),the provisions of this Sec.5 shall be amended and superseded by the conditions of use agreed between the Seller and its licensor.To the extent that the Buyer is provided with open source Software,the provisions of this Sec.5 shall be amended and superseded by the conditions of use underlying the open source Software.The superseding conditions of use will be announced or published online to the Buyer. 5.3 The Seller supplies a copy of the Software in digital form on a data medium or online to the Buyer.The delivery of documentation has to be agreed upon in writing.If documentation is supplied,the term"Software"as used hereinafter shall also include the documentation. The Supplier shall also be entitled to provide the documentation only online,if the Software is supplied on a data medium.The Buyer is obligated to install the Software by himself, to check the efficiency and give notification of defects without undue delay.In case a license key is needed for the use of the Software,it will be transferred to the Buyer by digital form.The license key is personalized and shall only be used by the Buyer for the use of the acquired Software.An assignment of the license key is only allowed under the terms of Sec.5.10. • 5.4 The Seller grants the Buyer the non-exclusive right to use the Software.The right is limited to the agreement period of time,the absence of such agreement,the right to use shall be unlimited in time. 5.5 The Buyer shall use the Software solely on the hardware referred to in the contract documents,in the absence of such reference,the use shall be limited to the respective hardware supplied together with the Software.The use of http://ITohne.corrVen/terms-and-conditions/print.html 216 1/23/2015 KROHNE Group—Terms and Conditions I KROHNE Group the Software on any other device shall require the express prior written consent of the Seller and shall,if used on a more powerful device.entitle the Seller to claim an appropriate additional remuneration:this does not apply, however,to the extent and for the period..in which the Buyer uses a temporary substitute device within the agreed scope of use,because of a defect in the agreed device. 5.6 Where the contract documents refer to more than one device,the Buyer shall not use the Software provided on more than one of these devices simultaneously(Single License),to the extent that it has not been granted a Multiple License pursuant to Sec.5.11 below.Where more than one workplace exists for a specific device where the Software can be used independently,the Single License shall apply to only one workplace. 5.7 The Software shall exclusively be provided in machine readable format(object code). 5.8 The Buyer shall be entitled to make only one copy of the Software and solely so for back-up purposes(back-up copy).Any other duplication on the part of the Buyer shall be allowed only subject to a Multiple License pursuant to Sec.5.11 below.Any assignment,rent or lease of the Software to a third party is not allowed. 5.9 Sales as provided for in Sec.69(e)(decompilation)of the German Copyright Act,the Buyer shall not be entitled to modify,decompile,translate.or isolate parts of the Software.The Buyer shall not remove alphanumeric or other identifiers from the data medium and shall transfer such identifiers unchanged to any back-up copy. 5.10 In the case of rights to use provided for an unlimited period of time.in detail the following is valid:The Seller grants the Buyer the right-which shall be revocable for good cause-to assign the right to use granted to him to a third party.The Buyer to whom the Software has not been provided for commercial resale shall pass on the right to use the Software only together with the device he has bought in combination with the Software from the Seller.If the right to use is transferred to a third party,the Buyer shall ensure that the right to use granted to the third party does not exceed the scope of rights to the Software granted to the Buyer under this Agreement,and the Buyer shall ensure that the third party shall be obliged to comply with at least the same obligations as are imposed herein. When doing so,the Buyer may not retain copies of the Software.The Buyer shall not be entitled to grant sublicenses.Where the Buyer provides the Software to a third party,the Buyer shall ensure that any existing export requirements are observed and shall hold the Seller harmless in this respect. 5.11 The use of the Software on more than one device or simultaneously at more than one workplace shall require a separate agreement on the right to use.The same shall apply if the Software is used in networks even if the Software is not copied for this purpose.With regard to situations named above(hereinafter referred to as"Multiple License"),the following provisions of the Sec.5.11 shall apply in addition to and with priority of the provisions of this Sec.5.1 to 5.10: • a)Multiple Licenses requires that the Seller expressly confirms in writing the number of admissible copies that Buyer may make of the Software provided in the number of devices and/or workplaces where the Software may be used.Sec.5.10 second sentence shall be applicable to Multiple Licenses provided that they may be transferred by the Buyer to third parties only if transferred in the totality and together with all devices,on which the use of the Software is allowed. b)The Buyer shall observe the duplication rules provided by the Seller together with the Multiple License.The Buyer shall keep records on the whereabouts of all copies made and submit them to the Seller upon request. 6.Passing of risk 6.1 The risk shall pass on to the Buyer upon acceptance of the goods,or on the day the acceptance is rejected without reason,or in case of passivity of the Buyer after expiration of the terms stated in Sec.4.6 and 4.7 above,or after expiration of a separately agreed term for acceptance.In case the parties have agreed on shipment of the goods to the Buyer or a third party,the risk shall pass on to the Buyer upon transfer of the goods to a forwarding agent(carrier,railway etc.).In any case,the risk shall pass on to the Buyer in the moment he starts using the goods. If the Seller agrees to take back the goods for reasons the Seller is not responsible for,the risk shall remain with the Buyer until receipt of the goods by the Seller. 6.2 If the Software is provided via electronic communication media(e.g.via the internet),the risk shall pass when the Software leaves the sphere of influence of the Seller(e.g.when making a download). 7.Retention of title 7.1 The goods shall remain in the property of the Seller until settlement of all claims.on whatever legal basis,even if payment has been made in respect of specially designated claims.With regard to a running account of the Buyer, the property to which the Seller has reserved title shall be the security for the outstanding balance on account. 7.2 The Buyer is not entitled to pledge or transfer as security any goods being subject to retention of title.The Buyer shall immediately inform the Seller about attachments or seizures or other disposals by third parties. 7.3 In the event of the goods becoming part of or being converted into other products,the retention of title shall extend to the complete new product.In case of the goods becoming parts of or being converted into products of third parties,the Seller shall acquire the co-ownership of the new product in such percentage corresponding to the • relation between the value of the Sellers products to the other products used by the Buyer in the moment of the Seller's goods becoming parts of or being converted into such other products.The Buyer shall be entitled to sell the goods being subject to retention of title within the ordinary course of business to third parties.In case the Buyer sells the goods without receiving simultaneously the complete purchase price against transfer of the goods,he shall be http://Wohne.comlen/terrris-and-conditions/print.html 3/6 1/23/2015 KROHNE Group—Terms and Conditions I KROHNE Group committed to agree with his customer on retention of title according to these General Terms and Conditions of Sale and Delivery.The Buyer herewith already assigns his claims and other rights based of such sale and agreement on retention of title to the Seller.At the Sellers request,the Buyer is obliged to disclose the assignment to his customers and to provide the Seller with the appropriate information and documents being necessary for the enforcement of his rights against such customers. 7.4 In case the retention of title will be qualified as invalid in the country to which the goods have been forwarded, such securityfor the purchase price claim of the Seller shall be deemed to have been agreed upon,which can be validly stipulated in the respective country and which corresponds as close as possible to the retention of title from the economical point of view.The Buyer shall be committed to take and perform all steps and measures insofar as actually or legally necessary. 8.Warranties 8.1 Seller warrants that under normal use and service its products will function in accordance with the current product specifications if installed and operated in accordance with the accompanying installation manuals;but the Buyer is solely responsible for determining the suitability of the products for the Buyer's use.The Buyer shall examine the goods immediately after receipt with responsible care;defects discovered shall be reported to the Seller within a preclusive period of 2 weeks in writing.Not recognizable defects shall be reported in writing to the Seller within 2 weeks after discovery. 8.2 In case of a justified immediate notification of defects,a warranty will be granted either by repairing the goods (rectification of defects)or replacement of default parts(subsequent delivery).Instead the Seller shall also be entitled to compensate the decrease in value when obeying the interest of the Buyer appropriately. 8.3 The Seller adheres to the basic principle that functionally adequate spare parts for each device or each important accessory part will be kept available for a period of 3 years after delivery of the last production run for the device.This regulation only applies to spare parts which are under normal operating conditions subjects to wear and tear. 8.4 In case the Seller does not comply to rectify defects or to replace defective parts or the rectification or replacement fail,the Buyer shall be entitled to reduce the remuneration or,at his option.to rescind the contract. 8.5 As regards spare parts,parts being subject to wear and tear or parts being designated to become a part of or to be converted into other products,the Buyer is committed to examine such parts and give notification of defects within the time period set forth in Sec.8.1.With regard to defects which could have been noticed before installation • or conversion,any warranty claims are excluded after installation and conversion. 8.6 In case the Buyer requests examination of the delivered goods by the Seller and alleges a defect for which the Seller would be responsible according to Sec.8.2 above,the Buyer shall be committed to bear the associated costs in case it turns out that the delivered goods are free from such defect. 8.7 Other or further claims of the Buyer based on defects including claims for damages.also with respect to consequential damages..are excluded unless otherwise expressly set forth in these Standard Terms and Conditions of Sale and Delivery.The disclaimer shall not apply in the case of injury to life.limb or health and in the case of violation of a material contractual obligation(cardinal obligation),whereby,however,in the case of violation of a cardinal obligation due to slight negligence,the Seller's liability shall be limited to such loss or damage foreseeable and typical for this type of contract,which shall in no way include indirect losses(e.g.loss of profit).In case of non- compliance with a guarantee,which has to be expressly designated and confirmed in the order confirmation as guarantee,claims for damages can only be enforced,if it was intended that the guarantee given to the Buyer should apply precisely to damage of the kind that has occurred. 8.8 The Seller's liability is expired,if the goods delivered have been dismantled by a third parry or altered by the incorporation of parts produced elsewhere and the cause of the damages is connected with such alterations.The Seller's liability is also expired,if the Buyer does not duly observe the Seller's instruction for handling the goods (installation&operation instructions). 8.9 The warranty period shall last for a period of 12 months from start-up or 18 months after passing the risk, whichever comes first. 8.10 In the case of Software provided for an unlimited period of time(Sec.5),the following provisions shall apply additionally. 8.10.1 Software is considered to be defective only if the Buyer can prove that there are reproducible deviations from the specifications.A Defect shall not be deemed to exist if it does not manifest itself in the latest version supplied to the Buyer,and the use thereof by Buyer can reasonably be required.No Defects are such functional mall performances,which follow from the hardware and Software environment provided by the Buyer or other causes be allocated to the Buyer's risk sphere. 8.10.2 Notification of Defects shall be given in writing without undue delay.Defects and the relevant data processing environment shall be described as precisely as possible therein. • 8.10.3 Claims based on Defects do not exist in the cases of any of the following: -insignificant deviations from the agreed characteristics. http://Wohne.corrVen/terms-and-conditions/print.html 4/6 1/23/2015 KROHNE Group—Terms and Conditions I KROHNE Group only minor impairment of usability, • damage from faulty or negligent handling, damage from particular external influences not assumed under the contract, -modifications made by the Buyer or third parties and any consequences resulting therefrom, -Software extensions made by the Buyer or a third party through the use of an interface provided by the Seller, -incompatibility of the Software provided with the data processing environment of the Buyer. 8.10.4 Unless the Seller chooses otherwise,the Seller will correct the Defect in the Software as follows:The Seller will provide a replacement by way of an update or an upgrade of the Software if available to the Seller or obtainable with reasonable efforts by the Seller.If the Buyer has been granted a Multiple License,it may make a corresponding number of copies of the update,or,as the case may be,upgrade.Unfit an update,or,as the case may be,upgrade is provided,the Seller will make available to the Buyer an interim solution by passing the Defect,provided that this does not result in unreasonable expenditures and that the Buyer would otherwise,due to the Defect,be unable to complete work that cannot be delayed.If the data medium or documentation supplied proves to be defective,the Buyer's right shall be limited to demanding that the Seller replace it with a non-defective version.The Seller shall have the right to choose whether it corrects the Defect at the location of the Buyer or at its own location.If the Seller chooses to correct the Defect at the Buyer's location,the Buyer shall assure that the required hardware and Software as well as the required operating conditions(including the required computing time)and qualified operating personnel are available.The Buyer shall submit to the Seller the documents and information available to it and required for Defect correction. 8.10.5 For Software provided for a limited period of time only,Sec.8.10 shall apply mutatis mutan dis.Sec.8.4 shall apply except that the right of rescission shall be replaced by the right to termination without notice. 9.General limitation on liability 9.1 Unless otherwise expressly set forth in these Standard Terms and Conditions of Sale and Delivery,the Seller is only liable for damages,whatever their legal basis is,in case that they are based on a wilful action or gross negligence. 9.2 This limitation on liability does not apply in the event the Buyer raises claims relating to personal injury or damages to property according to the Product Liability Law based on a defect of the delivered goods. • 9.3 Any advice given by the Seller,in particular regarding the application of the delivered goods,shall only commit the Seller if given or confirmed in writing. 10.Copyright 10.1 The Seller retains the property and copyright in drawings,sketches,cost estimates and the documents attached to any offers or order confirmation.The Buyer may only be entitled to use them to the agreed purpose and may not reproduce or disclose them to third parties without the prior written consent of the Seller.At the Seller's request,such documents and any duplicates have to be rendered to the Seller. 10.2 The technology and the knowledge patented or not,used in the materials and services,all the rights of technical intellectual properties relating to the products and services,remain the exclusive property of KROHNE. Only is conceded to the customer a right of user of the materials on a purely non-exclusive basis. 10.3 With regard to the delivered Software,the Seller is not aware that the use of the Software will violate any third party's industrial property rights.The Seller assumes no liability for Software free from third parties'industrial property rights and copyrights,excluding industrial property rights in the Federal Republic of Germany.This shall also apply,if the Buyer uses the Software outside the Federal Republic of Germany,irrespectively of whether or not the Seller has been informed by the Buyer in advance thereof.lt the use violates industrial property rights,the Seller is allowed at his own option either to after the Software to a reasonable scope for the Buyer so it is excluded from the extent of protection or to obtain the right for the Buyer to use the Software in an unlimited way without paying additional costs.In case of other defects of title the terms in Sec.8.10 above shall apply. 11.Disposal of the products 11.1 The Buyer shall be committed at the end of the use of the delivered products to take care of the proper disposal according to the legal and statutory provisions and requirements applicable as of the end of the use of the delivered products.The Buyer shall hold harmless the Seller of any applicable statutory recovery obligations and requirements,in particular from any applicable obligations and requirements pursuant to§10 subset.2 of the German Code on the Circulation,the Recovery and the environmentally sound Disposal of Electrical and Electronic Equipment(German WEEE Code)as well as from any claims of third parties connected therewith. 11.2 In case the Buyer will pass on the delivered products to users other than private households the Buyer shall be obligated to contractually commit such users to take care of the proper disposal of the delivered products according • to the statutory and legal provisions and requirements applicable when the use of the delivered products has ended at his expense and shall further be obligated in case the delivered products are again passed to another user to agree on a respective commitment with such user.If the Buyer failed to agree on such commitment,he shall be committed to recover the delivered products at his expense afterthe use of the delivered products has ended and http://ITohne.corTVentterms-and-concibons/prinLhtrri 516 1/2 3120 1 5 KROHNE Group—Terms and Conditions I KROHNE Group to dispose them property according to the statutory and legal provisions and requirements applicable as of the end of the use of the delivered products. 11.3 The claim of the Seller to take care of the disposal respectively to hold harmless Buyer pursuant to this subsec. 11 shall not be time barred until the end of two years after the final end of the use of the delivered products. 12.Place of performance,jurisdiction and applicable law 12.1 Place of performance for Seller's delivery is ex works of the appropriate KROHNE factory. 12.2 The place of jurisdiction is Duisburg.The Seller shall also to be entitled to bring proceedings against the Buyer at his place of residence. 12.3 All legal relations between the Seller and the Buyer shall be governed by German law as applicable for legal relations of domestic contracting parties.The United Nations'Convention on the International Sale of Goods dated April 11,1980 shall be excluded. February 2011 Download Terms&Conditions(PDF) (February 2011) • • http://Wohne.can/en/terms-and-conditions/print.htrri 616 CmTERPILLAR8Mayy 2001 SEBUa06 ■ Operation and Maintenance Manual C6.6 Generator Set SDA1-Up (Generator Set) N6D1-Up (Generator Set) • 01658146 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe • basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING" or"CAUTION". The Safety Alert"WARNING" label is shown below. i ' • The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar • is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. AWARNING When replacement parts are required for this product Caterpillar recommends using Caterpil- lar replacement parts or parts with equivalent specifications including, but not limited to, phys- ical dimensions, type, strength and material. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death. • SEBU8139-01 3 ■ Table of Contents Table of Contents Maintenance Interval Schedule (Standby Generator Sets) .................................................................... 72 Foreword ................................................................. 4 Reference Information Section Safety Section Engine Ratings ................................................... 104 Safety Messages .................................................... 6 Customer Service ............................................... 106 Additional Messages............................................. 18 Reference Materials............................................ 108 General Hazard Information ................................. 25 Index Section BurnPrevention .................................................... 28 Index .................................................................... 111 Fire Prevention and Explosion Prevention ............ 28 Crushing Prevention and Cutting Prevention ........ 31 Before Starting Engine .......................................... 31 Engine Starting ..................................................... 31 Engine Stopping ................................................... 32 Electrical System .................................................. 32 • Generator Isolating for Maintenance .................... 33 Product Information Section General Information .............................................. 34 ModelViews ......................................................... 35 Product Identification Information ........................ 36 Operation Section Lifting and Storage................................................ 45 Installation ............................................................. 47 Features and Controls .......................................... 48 Engine Starting ..................................................... 58 Engine Operation .................................................. 60 Engine Stopping ................................................... 61 Cold Weather Operation ....................................... 62 Maintenance Section • Refill Capacities .................................................... 65 Maintenance Interval Schedule (Prime Power Generator Sets) .................................................. 70 4 SEBU8139-01 Foreword Foreword Use fuel consumption or service hours to determine • intervals. Calendar intervals shown (daily, annually, Literature Information etc.) may be used instead of service meter intervals if they provide more convenient schedules and This manual contains safety, operation instructions, approximate the indicated service meter reading. lubrication and maintenance information. This Recommended service should be performed at the manual should be stored in or near the engine area appropriate intervals as indicated in the Maintenance in a literature holder or literature storage area. Read, Interval Schedule. The actual operating environment study and keep it with the literature and engine of the engine also governs the Maintenance Interval information. Schedule. Therefore, under extremely severe, English is the primary language for all Caterpillar dusty, wet or freezing cold operating conditions, publications. The English used facilitates translation more frequent lubrication and maintenance than is and consistency in electronic media delivery. specified in the Maintenance Interval Schedule may be necessary. Some photographs or illustrations in this manual The maintenance schedule items are organized for show details or attachments that may be different a preventive maintenance management program. If from your engine. Guards and covers may have the preventive maintenance program is followed, a been removed for illustrative purposes. Continuing periodic tune-up is not required. The implementation improvement and advancement of product design of a preventive maintenance management program may have caused changes to your engine which are should minimize operating costs through cost not included in this manual. Whenever a question avoidances resulting from reductions in unscheduled arises regarding your engine, or this manual, please downtime and failures. consult with your Caterpillar dealer for the latest available information. Maintenance Intervals Safety Perform maintenance on items at multiples of the • This safety section lists basic safety precautions. original requirement. Each level and/or individual items in each level should be shifted ahead or back In addition, this section identifies hazardous, depending upon your specific maintenance practices, warning situations. Read and understand the basic operation and application. We recommend that precautions listed in the safety section before the maintenance schedules be reproduced and operating or performing lubrication, maintenance and displayed near the engine as a convenient reminder. repair on this product. We also recommend that a maintenance record be Operation maintained as part of the engine's permanent record. See the section in the Operation and Maintenance Operating techniques outlined in this manual are Manual, "Maintenance Records" for information basic. They assist with developing the skills and regarding documents that are generally accepted techniques required to operate the engine more as proof of maintenance or repair. Your authorized efficiently and economically. Skill and techniques Caterpillar dealer can assist you in adjusting your develop as the operator gains knowledge of the maintenance schedule to meet the needs of your engine and its capabilities. operating environment. The operation section is a reference for operators. Overhaul Photographs and illustrations guide the operator through procedures of inspecting, starting, operating Major engine overhaul details are not covered in the and stopping the engine. This section also includes a Operation and Maintenance Manual except for the discussion of electronic diagnostic information. interval and the maintenance items in that interval. Major repairs are best left to trained personnel or Maintenance an authorized Caterpillar dealer. Your Caterpillar dealer offers a variety of options regarding overhaul The maintenance section is a guide to engine care. programs. If you experience a major engine failure, The illustrated, step-by-step instructions are grouped there are also numerous after failure overhaul options • by fuel consumption, service hours and/or calendar available from your Caterpillar dealer. Consult with time maintenance intervals. Items in the maintenance your dealer for information regarding these options. schedule are referenced to detailed instructions that follow. SEBU8139-01 5 Foreword • California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. • • 6 SEBU8139-01 Safety Section Safety Messages Safety Section i02439277 Safety Messages SMCS Code: 1000, 7405 There may be several specific safety messages on your generator set. The exact location and a description of the safety messages are reviewed in this section. Please become familiar with all safety messages. Ensure that all of the safety messages are legible. Clean the safety messages or replace the safety messages if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the safety messages. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety messages. The safety messages that are loosened could drop off of the engine. Replace any safety message that is damaged or missing. If a safety message is attached to a part • of the engine that is replaced, install a new safety message on the replacement part. Your Caterpillar dealer can provide new safety messages. M MINIM! 1� Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Man- ual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. Illustrations 1 through 4 show one type of enclosed generator set. 0 SEBU8139-01 7 Safety Section Safety Messages • 1 m i Q *71 2 • Illustration 1 g01218859 2 3 w AUTO 5 • Illustration 2 g01219063 8 SEBU8139-01 Safety Section Safety Messages • I Vim' a® 0 0 10 0 Illustration 3 g01232868 View of the inside of the enclosure • • a �© m o a 00 Ij o mo O O Illustration 4 g01222980 Illustrations 5 through 7 show another type of enclosed generator set. • SEBU8139-01 9 Safety Section Safety Messages • � .e7 1 2 • Illustration 5 g01221813 • 10 SEBU8139-01 Safety Section Safety Messages • auro 3 4 — 0 0 � 1 � EFlIMETITT 6 • ` 5 Q Illustration 6 g01221851 • SEBU8139-01 11 Safety Section Safety Messages 1A• 3 2 4 2 ❑m �t� ■ 0 it 0 • 5 Illustration 7 g01222038 2 � , r^� 0 0 0 0 • Illustration 8 g01232868 View of the inside of the enclosure Illustrations 9 and 10 show an open generator set. 12 SEBU8139-01 Safety Section Safety Messages • O c o 0 0 . 0 o 0 O O 0 0 o .00•o O 0 Illustration 9 901222927 • SEBU8139-01 13 Safety Section Safety Messages • n, ( 1 AUTO 2 3 4 O L • ooa ® ® ■ 1 _ a 5 m W Illustration 10 g01222960 Illustration 11 shows the control panel and the distribution panel. • 14 SEBU8139-01 Safety Section Safety Messages • I � 4 3 ' auro � + ' o o 7 03Oo0 6 I 0 0 ® o Illustration 11 g01223013 • • SEBU8139-01 15 Safety Section Safety Messages • Hot Fluid Under Pressure (1) Hot Surface (2) This safety message is located on the top of the This safety message is located on top of the enclosure by the radiator cap access cover on enclosure, the sides of the enclosure and the sides of enclosed generator sets. This safety message is the generator on enclosed generator sets. This safety located toward the top of the radiator by the filler neck message is located on the sides of the radiator and on open generator sets. the sides of the generator on open generator sets. MY&I: ri - g 9 E2L: "I g00930639 g01085603 Pressurized system! Hot coolant can cause seri- Hot surface! Do not touch! • ous burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Op- eration and Maintenance Manual before perform- ing any cooling system maintenance. 0 16 SEBU8139-01 Safety Section Safety Messages Electrocution (3) Automatic Starting (4) • This safety message is located on the sides of the This safety message is located on the sides of the enclosure on enclosed generator sets. This safety enclosure on enclosed generator sets. This safety message is located on the sides of the terminal box message is located on the sides of the terminal box on open generator sets. This safety message is also on open generator sets. This safety message is also located on the enclosure for the control panel and located on the enclosure for the control panel and the distribution panel on open generator sets and the distribution panel on open generator sets and enclosed generator sets. enclosed generator sets. 229-5047 AUTO g00928349 g01154070 DANGER: Shock/Electrocution Hazard-Do not op- When the engine is in the AUTOMATIC mode, the • erate this equipment or work on this equipment engine can start at any moment.To avoid personal unless you have read and understand the instruc- injury, always remain clear of the the engine when tions and warnings in the Operation and Mainte- the engine is in the AUTOMATIC mode. nance Manual. Failure to follow the instructions or heed the warnings will result in serious injury or death. Do not connect generator to a utility electrical dis- tribution system unless it is isolated from the sys- tem. Electrical feedback into the distribution sys- tem can occur and could cause personal injury or death. Open and secure main distribution system switch, or if the connection is permanent, install a double throw transfer switch to prevent electrical feed- back. Some generators are specifically approved by a utility to run in parallel with the distribution system and isolation may not be required. Always check with your utility as to the applicable circum- stances. • SEBU8139-01 17 Safety Section Safety Messages • Lifting the Generator Set (5) Universal Warning (6) This safety message is located on the sides of the This safety message is located on the door for access enclosure toward the bottom of the enclosure on to the control panel on enclosed generator sets. This enclosed generator sets. This safety message is safety message is located on the enclosure for the located on the sides of the base on open generator control panel and the distribution panel on open sets. generator sets and enclosed generator sets. AWARNINPt , 0 • 228-3581 g00934493 221-3M Do not operate or work on this equipment unless • you have read and understand the instructions g00928085 and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury T ' ' or death. Crushing Hazard! Improper lifting could cause se- rious injury or death. Follow the lifting instruc- tions in the Operation and Maintenance Manual for safe lifting procedures. • 18 SEBU8139-01 Safety Section Additional Messages Electrical Shock (7) S The safety message for electrical shock is located on the enclosure for the control panel and the distribution panel on open generator sets and enclosed generator sets. 1 � g01120247 WARNING! Shock/Electrocution Hazard! Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to fol- • low the instructions or heed the warnings could cause serious injury or death. 102482102 Additional Messages SMCS Code: 1000; 7405 There are several specific messages on these machines. The exact location of the messages and the description of the messages are reviewed in this section. Please become familiarized with all messages. Make sure that all of the messages are legible. Clean the messages or replace the messages if the words or images are unreadable. When you clean the messages, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the messages. Loose adhesive will allow the messages to fall. Replace any message that is damaged, or missing. If a message is attached to a part that is replaced, • install a message on the replacement part. Any Caterpillar dealer can provide new messages. SEBU8139-01 19 Safety Section Additional Messages zIn cow 1 • 2 Illustration 12 g01233415 This illustration shows one type of enclosed generator set. • 20 SEBU8139-01 Safety Section Additional Messages • 1 ® ® IN 3 • Y�F1 Irr1 Illustration 13 g01233280 This illustration shows another type of enclosed generator set. • SEBU8139-01 21 Safety Section Additional Messages • O . oo, 0 ® ® ■ - o E2 LC 1 1 1 1 4 Illustration 14 g01233028 This illustration shows an open generator set. • 22 SEBU8139-01 Safety Section Additional Messages • MAX.LIFT LUG LOAD 1025 kg 7 0 0 0 0 � 0 m 0 0 0 O 0 0 o O 0 0 0 O 0 o _ 0 0 0 0 0 0 0 0 � o 0 ®0 0 � 0 m 0 0 0 a o 0 0 6 5 7 • MAX.LIFT LUG LOAD 1025 kg CLS:S� Illustration 15 g01239884 Typical example of a fuel tank Lifting point (1) Illustration 16 g01034418 Lift the package from this point. Refer to the following topic: 3,000 Kg • Operation and Maintenance Manual, "Product (6,600 LBS) Lifting" Rating for lifting equipment(2) • This message is located on the side of the enclosure 2721641 near the bottom of the enclosure. Illustration 17 g01233472 SEBU8139-01 23 Safety Section Additional Messages • The lifting equipment that is used for lifting this type The lifting equipment that is used for lifting this type of generator set must be rated for a total weight of of generator set must be rated for a total weight of 3000 kg (6,600 lb). 3000 kg (6,600 lb). Rating for lifting equipment (3) Fuel tank vent (5) This message is located on the side of the enclosure This message is located on the fuel tank by the vent. near the bottom of the enclosure. ATTENTION THIS GENERATOR TANK HAS BEEN PRESSURE TESTED AT 3-5 PSI FOR WELD INTEGRITY.HOWEVER,IT HAS NOT BEEN DESIGNED AS A PRESSURE VESSEL AND MUST BE VENTED FROM SUPPLIED OPENINGS. THIS TANK WAS DESIGNED,MANUFACTURED AND INTENDED FOR DIESEL FUEL ONLY. THIS TANK WAS INTENDED FOR STATIONARY USE ONLY. MAX.LOAD CAPACITY 1180 KG. FUEL TANK CAPACITY 557 LITRES. 4,000 Kg WHEN FILLING THE TANK VIA A PUMP,THE OVERFLOW FITTING OF THIS ATMOSPHERIC DAY TANK MUST BE (8,800 LBS) PLUMBED IN A CONTINUOUS DOWNWARD PATH TOWARDS THE MAIN TANK WITHOUT DOWNSIZING TO PREVENT A POTENTIAL FUEL SPILLAGE. TO PREVENT FUEL AND COMPARTMENT CONTAMINATION,IT IS RECOMMENDED TO USE A 100- MESH FUEL STRAINER FOR INCOMING FUEL. 288-7968 772 2643 Illustration 20 g01239683 Illustration 18 g01233040 This generator tank has been pressure tested at The lifting equipment that is used for lifting this type 20.6 kPa (3 psi) to 34.5 kPa (5 psi) for weld integrity. of generator set must be rated for a total weight of However, it has not been designed as a pressure 4000 kg (8,800 lb). vessel and must be vented from supplied openings. This tank was designed, manufactured and intended Rating for lifting equipment (4) for diesel fuel only. This tank was intended for stationary use only. Maximum load capacity 1180 kg This message is located on the side of open (2601 lb) Fuel tank capacity 557 L (147 US gal). generator sets on the base. When filling the via a pump, the overflow fitting of this atmospheric day tank must be plumbed in a continuous downward path toward the main fuel tank without downsizing to prevent a potential fuel spillage. To prevent fuel and compartment contamination, it is recommended to use a 100 mesh fuel strainer for incoming fuel. <5. 3,000 Kg (6,600 LBS) • m.,na Illustration 19 g01233043 24 SEBU8139-01 Safety Section Additional Messages This generator tank has been pressure tested at • 20.6 kPa (3 psi) to 34.5 kPa (5 psi) for weld integrity. However, it has not been designed as a pressure ATTENTION vessel and must be vented from supplied openings. This tank was designed, manufactured and intended THIS GENERATOR TANK HAS BEEN PRESSURE TESTED for diesel fuel only. This tank was intended for AT 3-5 PSI FOR WELD INTEGRITY.HOWEVER,IT HAS stationary use only. Maximum load capacity 2250 kg NOT BEEN DESIGNED AS A PRESSURE VESSEL AND (4960 lb). Fuel tank capacity 1485 L (392 US gal). MUST BE VENTED FROM SUPPLIED OPENINGS. When filling the via a um the overflow fitting of THIS TANK WAS DESIGNED,MANUFACTURED AND 9 pump, 9 INTENDED FOR DIESEL FUEL ONLY. this atmospheric day tank must be plumbed In a THIS TANK WAS INTENDED FOR STATIONARY USE continuous downward path toward the main fuel tank ONLY. without downsizingto prevent potential fuels e.Ills MAX. LOAD CAPACITY 2250 KG. a P P spillage. FUEL TANK CAPACITY 757 LITRES. To prevent fuel and compartment Contamination, It Is WHEN FILLING THE TANK VIA PUMP,THE OVERFLOW recommended to use a 100 mesh fuel strainer for FITTING OF THIS ATMOSPHERIC DAY TANK MUST BE PLUMBED IN A CONTINUOUS DOWNWARD PATH incoming fuel. TOWARDS THE MAIN TANK WITHOUT DOWNSIZING TO PREVENT A POTENTIAL FUEL SPILLAGE. Size Of fuel tank Vent (6) TO PREVENT FUEL AND COMPARTMENT CONTAMINATION,IT IS RECOMMENDED TO USE A 100- MESH FUEL STRAINER FOR INCOMING FUEL. This message Is located On the fuel tank by the Vent. Illustration 21 g01239658 This generator tank has been pressure tested at 20.6 kPa (3 psi) to 34.5 kPa (5 psi) for weld integrity. This tank requires Emergency Relief However, it has not been designed as a pressure vessel and must be vented from supplied openings, not less than: This tank was designed, manufactured and intended for diesel fuel only. This tank was intended for 37900 cubic ft./hr. stationary use only. Maximum load capacity 2250 kg (4960 lb). Fuel tank capacity 757 L (200 US gal). When filling the via a pump, the overflow fitting of this atmospheric day tank must be plumbed in a continuous downward path toward the main fuel tank g01239936 without downsizing to prevent a potential fuel spillage. Illustration 23 To prevent fuel and compartment contamination, it is recommended to use a 100 mesh fuel strainer for This tank requires emergency relief not less than incoming fuel. 37900 cubic feet per hour. ATTENTION THIS GENERATOR TANK HAS BEEN PRESSURE TESTED This tank requires Emergency Relief AT 3-5 PSI FOR WELD INTEGRITY.HOWEVER,IT HAS NOT BEEN DESIGNED AS A PRESSURE VESSEL AND not less than: MUST BE VENTED FROM SUPPLIED OPENINGS. THIS TANK WAS DESIGNED,MANUFACTURED AND INTENDED FOR DIESEL FUEL ONLY. 544H5 CUBIC ft./hr. THIS TANK WAS INTENDED FOR STATIONARY USE ONLY. MAX.LOAD CAPACITY 2250 KG. FUEL TANK CAPACITY 1485 LITRES. WHEN FILLING THE TANK VIA A PUMP,THE OVERFLOW FITTING OF THIS ATMOSPHERIC DAY TANK MUST BE PLUMBED IN A CONTINUOUS DOWNWARD PATH Illustration 24 g01239912 TOWARDS THE MAIN TANK WITHOUT DOWNSIZING TO PREVENT A POTENTIAL FUEL SPILLAGE, TO PREVENT FUEL AND COMPARTMENT This tank requires emergency relief not less than • CONTAMINATION,IT IS RECOMMENDED TO USE A 100- 54485 cubic feet per hour. MESH FUEL STRAINER FOR INCOMING FUEL. 288-7967 Illustration 22 g01239678 SEBU8139-01 25 Safety Section General Hazard Information • This tank requires Emergency Relief not less than: MAX. LIFT LUG LOAD 80525 cubic ft./hr. 1025 kg Illustration 25 g01239873 Illustration 28 g01239958 This tank requires emergency relief not less than Maximum lift lug load 1025 kg (2260 Ib) 80525 cubic feet per hour. Maximum Lift Lug Load (7) i02344741 This message is located on the fuel tank by the lifting General Hazard Information points. SMCS Code: 1000; 7405 MAX. LIFT LUG LOAD 623 kg c ' Al Illustration 26 g01239953 g00104545 Illustration 29 Maximum lift lug load 623 kg (1373 lb) Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer. Attach the warning tags to the engine and to each operator control station. When it is appropriate, MAX. LIFT LUG LOAD disconnect the starting controls. 1000 kg Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced. Engine exhaust contains products of combustion • which may be harmful to your health. Always start the Illustration 27 g01239955 engine and operate the engine in a well ventilated area. If the engine is in an enclosed area, vent the Maximum lift lug load 1000 kg (2205 lb) engine exhaust to the outside. 26 SEBU8139-01 Safety Section General Hazard Information Cautiously remove the following parts. To help • Disconnect the batteries when maintenance • prevent spraying or splashing of pressurized fluids, is performed or when the electrical system is hold a rag over the part that is being removed. serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks. • Filler caps • Do not attempt any repairs that are not understood. • Grease fittings Use the proper tools. Replace any equipment that is damaged or repair the equipment. • Pressure taps • Breathers Pressurized Air and Water • Drain plugs Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in Use caution when cover plates are removed. personal injury. Gradually loosen, but do not remove the last two When pressurized air and/or pressurized water is bolts or nuts that are located at opposite ends of used for cleaning, wear protective clothing, protective the cover plate or the device. Before removing the last two bolts or nuts, pry the cover loose in order to shoes, and eye protection. Eye protection includes goggles or a protective face shield. relieve any spring pressure or other pressure. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi). Fluid Penetration Pressure can be trapped in the hydraulic circuit long • after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to AO� escape rapidly if the pressure is not relieved correctly. Do not remove any hydraulic components or parts until pressure has been relieved or personal injury Illustration 30 9oo�ozozo may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved • Wear a hard hat, protective glasses, and other or personal injury may occur. Refer to the OEM protective equipment, as required. information for any procedures that are required to relieve the hydraulic pressure. • When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent damage to hearing. • Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine. • Ensure that all protective guards and all covers are secured in place on the engine. (0 0 woo—Vow • Never put maintenance fluids into glass containers. Glass containers can break. • Use all cleaning solutions with care. • Report all necessary repairs. illustration 31 g00687600 • Unless other instructions are provided, perform the maintenance under the following conditions: • The engine is stopped. Ensure that the engine cannot be started. SEBU8139-01 27 Safety Section General Hazard Information • Always use a board or cardboard when you check Use caution. Avoid inhaling dust that might be for a leak. Leaking fluid that is under pressure can generated when you handle components that contain penetrate body tissue. Fluid penetration can cause asbestos fibers. Inhaling this dust can be hazardous serious injury and possible death. A pin hole leak can to your health. The components that may contain cause severe injury. If fluid is injected into your skin, asbestos fibers are brake pads, brake bands, lining you must get treatment immediately. Seek treatment material, clutch plates, and some gaskets. The from a doctor that is familiar with this type of injury. asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal Containing Fluid Spillage handling is not hazardous unless airborne dust that contains asbestos is generated. Care must be taken in order to ensure that fluids If dust that may contain asbestos is present, there are contained during performance of inspection, maintenance, testing, adjusting and repair of the are several guidelines that should be followed: engine. Prepare to collect the fluid with suitable . Never use compressed air for cleaning. containers before opening any compartment or disassembling any component that contains fluids. . Avoid brushing materials that contain asbestos. Refer to Special Publication, NENG2500, "Dealer . Avoid grinding materials that contain asbestos. Service Tool Catalog" for the following items: • Tools that are suitable for collecting fluids and • Use a wet method in order to clean up asbestos equipment that is suitable for collecting fluids materials. • Tools that are suitable for containing fluids and • A vacuum cleaner that is equipped with a high equipment that is suitable for containing fluids efficiency particulate air filter (HEPA) can also be used. Obey all local regulations for the disposal of liquids. . Use exhaust ventilation on permanent machining Asbestos Information jobs. • Wear an approved respirator if there is no other -«j�. way to control the dust. L`;r •� y ~ tit?'ji Comply with applicable rules and regulations for the work place. In the United States, use Occupational Safety and Health Administration ;1� =' r••'`'�"�-""'%�,l' (OSHA) requirements. These OSHA requirements can be found in "29 CFR 1910,1001 Obey environmental regulations for the disposal � X• of asbestos. • Stay away from areas that might have asbestos particles in the air. Illustration 32 g00702022 Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free. Caterpillar recommends the use of only genuine Caterpillar replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris. • 28 SEBU8139-01 Safety Section Burn Prevention Dispose of Waste Properly Any contact with hot coolant or with steam can cause • severe burns. Allow cooling system components to cool before the cooling system is drained. Check the coolant level after the engine has stopped and the engine has been allowed to cool. Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch with a bare hand. Remove the filler cap slowly in order to relieve pressure. Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth. Illustration 33 g00706404 Oils Improperly disposing of waste can threaten the Hot oil and hot lubricating components can cause environment. Potentially harmful fluids should be personal injury. Do not allow hot oil to contact the disposed of according to local regulations. skin. Also, do not allow hot components to contact Always use leakproof containers when you drain the skin. fluids. Do not pour waste onto the ground, down a drain, or into any source of water. Batteries Electrolyte is an acid. Electrolyte can cause personal 102344742 injury. Do not allow electrolyte to contact the skin or • Burn Prevention the eyes.Always wear protective glasses for servicing batteries. Wash hands after touching the batteries SMCS Code: 1000; 7405 and connectors. Use of gloves is recommended. Do not touch any part of an operating engine. i02328452 Allow the engine to cool before any maintenance is performed on the engine. Fire Prevention and Explosion Prevention SMCS Code: 1000; 7405 Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu- el spray may cause a fire hazard. Failure to fol- low these inspection,maintenance and service in- / structions may cause personal injury or death. After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines. Allow the pressure to be purged in the air system, in the hydraulic system, in the lubrication system, or in the cooling system before any lines, fittings or related items are disconnected. Illustration 34 g00704000 Coolant All fuels, most lubricants, and some coolant mixtures • are flammable. When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. SEBU8139-01 29 Safety Section Fire Prevention and Explosion Prevention • Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause ` a fire. Fire may cause personal injury and property Contact with high pressure fuel may cause fluid damage. penetration and burn hazards. High pressure fu- A flash fire may result if the covers for the engine el spray may cause a fire hazard. Failure to fol- crankcase are removed within fifteen minutes after low these inspection,maintenance and service in- an emergency shutdown. structions may cause personal injury or death. Determine whether the engine will be operated in an After the engine has stopped, you must wait for 60 environment that allows combustible gases to be seconds in order to allow the fuel pressure to be drawn into the air inlet system. These gases could purged from the high pressure fuel lines before any cause the engine to overspeed. Personal injury, service or repair is performed on the engine fuel lines. property damage, or engine damage could result. Inspect all lines and hoses for wear or for If the application involves the presence of combustible deterioration. The hoses must be properly routed. gases, consult your Caterpillar dealer for additional The lines and hoses must have adequate support information about suitable protection devices. and secure clamps. Tighten all connections to the recommended torque. Leaks can cause fires. Remove all flammable materials such as fuel, oil, and debris from the engine. Do not allow any flammable Oil filters and fuel filters must be properly installed. materials to accumulate on the engine. The filter housings must be tightened to the proper torque. Store fuels and lubricants in properly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers. Do not smoke in areas that are used for • storing flammable materials. Do not expose the engine to any flame. Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be installed correctly. • Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting. Wiring must be kept in good condition. All electrical wires must be properly routed and securely attached. Check all electrical wires daily. Repair any wires g00704059 that are loose or frayed before you operate the Illustration 35 engine. Clean all electrical connections and tighten Use caution when you are refueling an engine. Do all electrical connections. not smoke while you are refueling an engine. Do not Eliminate all wiring that is unattached or unnecessary. refuel an engine near open flames or sparks. Always Do not use any wires or cables that are smaller than stop the engine before refueling. the recommended gauge. Do not bypass any fuses and/or circuit breakers. Arcing or sparking could cause a fire. Secure • connections, recommended wiring, and properly maintained battery cables will help to prevent arcing or sparking. 30 SEBU8139-01 Safety Section Fire Prevention and Explosion Prevention Do not store ether cylinders in living areas or in the • engine compartment. Do not store ether cylinders in direct sunlight or in temperatures above 49 °C (120 OF). Keep ether cylinders away from open flames or sparks. Dispose of used ether cylinders properly. Do not puncture an ether cylinder. Keep ether cylinders away from unauthorized personnel. Do not spray ether into an engine if the engine is equipped with a thermal starting aid for cold weather starting. Lines, Tubes and Hoses P Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged. Repair any lines that are loose or damaged. Leaks Illustration 36 g00704135 can cause fires. Consult your Caterpillar dealer for Gases from a battery can explode. Keep any open repair or for replacement parts. flames or sparks away from the top of a battery. Do Check lines, tubes and hoses carefully. Do not use not smoke in battery charging areas. your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections Never check the battery charge by placing a metal to the recommended torque. • object across the terminal posts. Use a voltmeter or a hydrometer. Replace the parts if any of the following conditions Improper jumper cable connections can cause are present: an explosion that can result in injury. Refer to . High pressure fuel line or lines are removed. the Operation Section of this manual for specific instructions. • End fittings are damaged or leaking. Do not charge a frozen battery. This may cause an . Outer coverings are chafed or cut. explosion. The batteries must be kept clean. The covers • Wires are exposed. (if equipped) must be kept on the cells. Use the . Outer coverings are ballooning. recommended cables, connections, and battery box covers when the engine is operated. . Flexible part of the hoses are kinked. Fire Extinguisher • Outer covers have embedded armoring. Make sure that a fire extinguisher is available. Be • End fittings are displaced. familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire Make sure that all clamps, guards, and heat shields extinguisher regularly. Obey the recommendations are installed correctly. During engine operation, this on the instruction plate. will help to prevent vibration, rubbing against other parts, and excessive heat. Ether Ether is flammable and poisonous. • Use ether in well ventilated areas. Do not smoke while you are replacing an ether cylinder or while you are using an ether spray. SEBU8139-01 31 Safety Section Crushing Prevention and Cutting Prevention • i01359666 All protective guards and all protective covers must Crushing Prevention and be installed if the engine must be started in order g to perform service procedures. To help prevent an Cutting Prevention accident that is caused by parts in rotation, work around the parts carefully. SMCS Code: 1000; 7405 Do not bypass the automatic shutoff circuits. Do not Support the component properly when work beneath disable the automatic shutoff circuits. The circuits are the component is performed. provided in order to help prevent personal injury. The circuits are also provided in order to help prevent Unless other maintenance instructions are provided, engine damage. never attempt adjustments while the engine is running. See the Service Manual for repairs and for adjustments. Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance i02344744 is performed. After the maintenance is performed, reinstall the guards. Engine Starting Keep objects away from moving fan blades. The fan SMCS Code: 1000 blades will throw objects or cut objects. When objects are struck, wear protective glasses in order to avoid injury to the eyes. Do not use aerosol types of starting aids such as Chips or other debris may fly off objects when objects ether. Such use could result in an explosion and are struck. Before objects are struck, ensure that no personal injury. 0 one will be injured by flying debris. If a warning tag is attached to the engine start switch or to the controls DO NOT start the engine or move i01805780 the controls. Consult with the person that attached Before Starting Engine the warning tag before the engine is started. SMCS Code: 1000 All protective guards and all protective covers must be installed if the engine must be started in order NOTICE to perform service procedures. To help prevent an For initial start-up of a new or rebuilt engine, and for accident that is caused by parts in rotation, work start-up of an engine that has been serviced, make around the parts carefully. provision to shut the engine off should an overspeed Start the engine from the operator's compartment or occur. This may be accomplished by shutting off the from the engine start switch. air and/or fuel supply to the engine. Always start the engine according to the procedure Overspeed shutdown should occur automatically. that is described in the Operation and Maintenance If automatic shutdown does not occur, press the Manual, "Engine Starting" topic in the Operation emergency stop button in order to cut the fuel and/or Section. Knowing the correct procedure will help to air to the engine. prevent major damage to the engine components. Knowing the procedure will also help to prevent Inspect the engine for potential hazards. personal injury. Before starting the engine, ensure that no one is on, To ensure that the jacket water heater(if equipped) underneath, or close to the engine. Ensure that the and/or the lube oil heater (if equipped) is working area is free of personnel. correctly, check the water temperature gauge and/or the oil temperature gauge during the heater If equipped, ensure that the lighting system for the operation. • engine is suitable for the conditions. Ensure that all lights work properly, if equipped. Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside. 32 SEBU8139-01 Safety Section Engine Stopping Note: The engine is equipped with a device for cold Grounding Practices • starting. If the engine will be operated in very cold conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with 8 g the correct type of starting aid for your region of operation. e ° ° •° 1 These engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake 0 0 air in order to improve starting. 0 0 i02328530 Engine Stopping SMCS Code: 1000 To avoid overheating of the engine and accelerated ° wear of the engine components, stop the engine according to this Operation and Maintenance Manual, "Engine Stopping"topic (Operation Section). Use the Emergency Stop Button (if equipped) Illustration 37 g01162916 ONLY in an emergency situation. DO NOT use the Emergency Stop Button for normal engine stopping. Typical example After an emergency stop, DO NOT start the engine (2)Starting motor to engine block until the problem that caused the emergency stop ( )Ground to starting motor has been corrected. (3)Ground to battery On the initial start-up of a new engine or an engine a a that has been serviced, make provisions to stop the ° engine if an overspeed condition occurs. s 0 0 To stop an electronic controlled engine, cut the power 4 to the engine and/or the air supply to the engine. 0 0 0 0 i02234878 ° Electrical System SMCS Code: 1000; 1400 Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit pi 5 is operating. A spark can cause the combustible ° gases that are produced by some batteries to ignite. — + To help prevent sparks from igniting combustible gases that are produced by some batteries, the Illustration 38 g01162918 negative"-" cable should be connected last from the external power source to the negative "-" terminal Typical example of the starting motor. If the starting motor is not ( Ground to engine equipped with a negative "-" terminal, connect the (5))Ground to battery cable to the engine block. Correct grounding for the engine electrical system Check the electrical wires daily for wires that is necessary for optimum engine performance • are loose or frayed. Tighten all loose electrical and reliability. Incorrect grounding will result in connections before the engine is started. Repair all uncontrolled electrical circuit paths and in unreliable frayed electrical wires before the engine is started. electrical circuit paths. See the Operation and Maintenance Manual for specific starting instructions. SEBU8139-01 33 Safety Section Generator Isolating for Maintenance • Uncontrolled electrical circuit paths can result in 4. Lock out the circuit breaker. Attach a "DO NOT damage to the crankshaft bearing journal surfaces OPERATE" or similar warning tag to the circuit and to aluminum components. breaker. Refer to the electrical diagram. Verify that all points of possible reverse power flow have Engines that are installed without engine-to-frame been locked out. ground straps can be damaged by electrical discharge. 5. For the following circuitry, remove the transformer's fuses: To ensure that the engine and the engine electrical systems function correctly, an engine-to-frame • power ground strap with a direct path to the battery must be used. This path may be provided by way of a direct • sensing engine ground to the frame. • control The connections for the grounds should be tight and free of corrosion. The engine alternator must be 6. Attach a "DO NOT OPERATE" or similar warning grounded to the negative "=' battery terminal with tag to the generator excitation controls. a wire that is adequate to handle the full charging current of the alternator. 7. Remove the cover of the generator's terminal box. The power supply connections and the ground 8. Use an audio/visual proximity tester in order to connections for the engine electronics should always verify that the generator is de-energized. This be from the isolator to the battery. tester must be insulated for the proper voltage rating. Follow all guidelines in order to verify that the tester is operational. io14a997o Generator Isolating for 9. Determine that the generator is in a de-energized • condition. Add ground straps to the conductors Maintenance or terminals. During the entire work period, these ground straps must remain connected to the SMCS Code: 4450 conductors and to the terminals. When you service an electric power generation set or when you repair an electric power generation set, follow the procedure below: 1. Stop the engine. Illustration 39 goo104545 2. Attach a "DO NOT OPERATE" or similar warning • tag to the engine prime mover starting circuit. Disconnect the engine starting circuit. 3. Disconnect the generator from the distribution system. ■ 34 SEBU8139-01 Product Information Section General Information Product Information Section General Information 4 5 / \ i02276735 2 \ " 1 Welding on Engines with 3 Electronic Controls s SMCS Code: 1000 NOTICE Because the strength of the frame may decrease, some manufacturers do not recommend welding onto a chassis frame or rail. Consult the OEM of the equip- ment or your Caterpillar dealer regarding welding on I a chassis frame or rail. \ 11 10 9 8 7 Proper welding procedures are necessary in order to avoid damage to the engine's ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the component. If removal of the component Illustration ao g01075639 • is not possible, the following procedure must be followed when you weld on a unit that is equipped Use the example above. The current flow from the welder to the ground clamp of the welder will not cause damage to any with a Caterpillar Electronic Engine. The following associated components. procedure is considered to be the safest procedure to (1) Engine weld on a component. This procedure should provide (2)Welding electrode a minimum risk of damage to electronic components. (3)Keyswitch in the OFF position (4)Battery disconnect switch in the open position (5)Disconnected battery cables NOTICE (6) Battery Do not ground the welder to electrical components (7) Electrical/Electronic component such as the ECM or sensors. Improper grounding can (8)Minimum distance between the component that is being welded cause damage to the drive train bearings, hydraulic and any electrical/electronic component components, electrical components, and other com- (1 The component that is being welded com p p ( 0)Current path of the welder ponents. (11)Ground clamp for the welder Clamp the ground cable from the welder to the com- 4. Connect the welding ground cable directly to the ponent that will be welded. Place the clamp as close part that will be welded. Place the ground cable as as possible to the weld. This will help reduce the pos- close as possible to the weld in order to reduce the sibility of damage. possibility of welding current damage to bearings, hydraulic components, electrical components, and 1. Stop the engine. Turn the switched power to the ground straps. OFF position. Note: If electrical/electronic components are used 2. Disconnect the negative battery cable from the as a ground for the welder, or electrical/electronic g ry components are located between the welder ground battery. If a battery disconnect switch is provided, and the weld, current flow from the welder could open the switch. severely damage the component. 3. Disconnect the J1/P1 and J2/P2 connectors from 5. Protect the wiring harness from welding debris • the ECM. Move the harness to a position that will and spatter not allow the harness to accidentally move back and make contact with any of the ECM pins. 6. Use standard welding practices to weld the materials. SEBU8139-01 35 Product Information Section Model Views Model Views 02450263 Model View Illustrations SMCS Code: 1000 The following model views display typical features of the generator sets that are described in this manual. The operator should become familiar with the locations of these items. Due to individual applications, your generator set may appear different from the illustrations. 1 2 3 4 5 6 % 8 e i e O 0 e 0 0 a 0 o 1 9 0 13 12 11 10 Illustration 41 g01223275 (1)Radiator filler cap (6)Air Cleaner (11)Manual sump pump for engine oil drain (2)Secondary fuel filter (7)Generator terminal box (12)Engine oil level gauge(dipstick) (3)Primary fuel filter/water separator (8)Control panel (13)Engine oil filler (4) Breather canister (9) Distribution panel (5)Engine Control Module(ECM) (10)Engine oil filter • 36 SEBU8139-01 Product Information Section Product Identification Information Product Identification Serial Number Plate (1) • Information The engine serial number plate is located on the left side of the cylinder block to the rear of the front engine mounting. i02299510 Engine Identification Caterpiller dealers need all of these numbers in order to determine the components that were included with SMCS Code: 1000 the engine. This permits accurate identification of replacement part numbers. The engines are identified by a serial number. This number is shown on a serial number plate that is mounted on the left hand side of the engine block. An example of an engine number is REU090001 H. WERPILLAR GAT° TPLNol RE Type of engine O O U Built in the United Kingdom 0900001 Engine Serial Number LIST No SERIAL No TYPE H Year of Manufacture Caterpillar dealers need these numbers in order to 43 g01159926 determine the components that were included with Illustration the engine. This permits accurate identification of Serial numbbee r plate replacement part numbers. • Emissions Certification Film i02461803 Note: This information is pertinent in the United Plate Locations and Film States, in Canada and in Europe. Locations A typical example is shown. SMCS Code: 1000 1 I O [ ° ODC21 ° • Illustration 42 g01144128 Location of the serial number plate SEBU8139-01 37 Product Information Section Product Identification Information CATERPILLAR INC. IMPORTANT ENGINE INFORMATION 2000 JDM00001 Y�rl ENGINE MODEL:3116 - DISPLACEMENT:6.61- - VALVE LASH: 0.38mm INTAKE 0.64mm EXHAUST MAXIMUM MAXIMUM MAXIMUM MAX.FUEL RATE MAXIMUM EXHAUSTENGINE ENGINE ADVERTISED RATED LOYJ IDLE INITIAL TIMING EMISSION FAMILY WI(HP) SPEED(RPM) SPEED(RPM) (m1A'/STROM) DEGREES STOC CONTRDL SYSTEM XGPXL066MRB 164(220) 2600 875 104 "1 EM.DI.TC SPL CAG THIS 3116 ENGINE CONFORMS TO DIRECTIVE 97AT1ffC FOR NON-ROAD ENGINES. EC TYPE APPROVAL NO.MRL'97r6SM'0001'00 THIS 3116 ENGNECDWOFNST02000 U.S.EPA AND CALIFORNIA REGULATIONS LARGE NON-ROAD COMPRESSR)NAGMT10N ENGINES. THIS ENGINE IS CERTIFIED TO OPERATE ON COMMERICMLLY AVAILABLE DIESEL FUEL. GATE OF MANUFACTURE MONTH:OB 7E-fia10 ei FMT:3500 The EPA/EU Emissions Certification Film (if applicable) is located either on the side, the top, or the front of the engine. p�� CATERPILLAR INC. INFORMATION IMPORTANTE SUR LE MOTEUR VGA MODELE MOTEUR:3116 -DEBIT:6.6 I -JEU SOUPAPES:0,38 mm ADMISSIDN:8.64 mm ECHAPPEMENT KM(NPR MAXI MAXI MAXI DEBIT DX MAXI CALM# FAMRIE MAXI REGIME REGIME APUIS.MAX, IIMT1Al O MJ. DISPOSITF OE MOTEURS: PIAILIES: NOMINAL(trim): RALENTI(trMmJ: (MnL1ISTROKE)(PISTON): (OEGR(S)VIVANTPMH): ANTI-POLLUANT: XCPXLO66MRB 164,220) 2000 675 104 iIS FM.DI,TCSPL,CAC CF MOmM 3116 EST CONFORME AUX DIRECTIVES 970KC POUR LIS MTELIRS NON ROUTIERS. NO APPROBATION TYPE EC eML'97168M'0W'SO CE MOTEUR 3116 EST CONFDRME AUX REGLEMENTATIONS 21M DE UAGENCE AMEr9CAINE DE PROTECTION OE LENWROMNEINENT(EPA)El DE LA CAL"RNN POUR LES GROS MOTEURS NON ROUTIERS A COMPRESSION-CONTACT. CE MOTEUR EST NOMOLOCUE POUR FONCTIONNER NEC LE CM9LRANT DIESEL DU COMMERCE. DATE Of FABMCA110N IMOISI N Etiquette dlomologalioR Anti-P01101101 L'outocollont d'homologotion du dispositif antipollution EPA/EU (selon #quipement) est situ# soil sur le cbt# du moteur, soil Sur le dessus du moteur, soil Sur le devont du moteur. Illustration 44 g00776690 This information is pertinent in the United States and in Canada. • 38 SEBU8139-01 Product Information Section Product Identification Information • IMPORTANT ENGINE INFORMATION GAT' Manufacturer Perkins Engines Co. LTD Engine Type Engine Family: 5PKXL04.4RH2 List: Displacement: 4.4 E Refer to Factory Reset if List: RH37881 11 Manufacturer setting I Applicable EPA Advertised kw:86. el1*97/68FA* ❑ 2372/2500 ❑ Family Max Fuel Rate: 85.0 mm3/stk Values Init. Timing:0 DEGATDC idle RPM **** 2001/63*0247*00 ® 2372/2500 ❑ Settings are to be made with engine at normal operating temperature ❑ with transmission in neutral. This engine conforms to 2004 U.S. EPA non - road and California off- road Regulations for large C.I. engines ❑ 171 and is certified to operate on commercially available diesel fuel. Emission Control System Valve Lash Cold (inch): Engine Label Use Service Tool **** ** ECM Exhaust 0.*** Inlet 0.*** to verify current Hanger No. position (**) Label No. 3181 A08 1 engine settings Illustration 45 g01159950 Typical example 102293163 Generator Lead Connections Personal injury or death can result from high volt- • SMCS Code: 4450 age. When power generation equipment must be in op- eration to make tests and/or adjustments, high DANGER: Shock/Electrocution Hazard-Do not op- voltage and current are present. erate this equipment or work on this equipment unless you have read and understand the instruc- Improper test equipment can fail and present a tions and warnings in the Operation and Mainte- high voltage shock hazard to its user. nance Manual. Failure to follow the instructions or heed the warnings will result in serious injury or Make sure the testing equipment is designed for death. and correctly operated for high voltage and cur- rent tests being made. When servicing or repairing electric power gener- ation equipment: • Make sure the unit is off-line (disconnected from utility and/or other generators power service) , and either locked out or tagged DO NOT OPERATE. • Remove all fuses. • Make sure the generator engine is stopped. • Make sure all batteries are disconnected. • Make sure all capacitors are discharged. • Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, sta- tor and the generator is discharged. SEBU8139-01 39 Product Information Section Product Identification Information • There are some cases when the neutral wire is not grounded. An ungrounded generator neutral lead is Accidental engine starting can cause injury or acceptable when the possibility of grounds to the death to personnel working on the equipment. phase leads has been eliminated. An example of such measures are ground fault protective circuits. To avoid accidental engine starting, disconnect Ground fault protection requires the entire group the battery cable from the negative(—) battery ter- of distribution circuits to be treated as a system. minal. Completely tape all metal surfaces of the The owner should contact a certified consultant if disconnected battery cable end in order to prevent a new distribution system is being developed. The contact with other metal surfaces which could ac- owner should also contact a certified consultant if an tivate the engine electrical system. existing system should be modified for the ground fault protection. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is Single Units being worked on. Each unit should be connected to a common ground. Grounding the Frame In a three-phase, four-wire system, the neutral wire should be grounded according to local wiring codes. In any generator set installation, the frame of the generator must be positively connected to an earth Be sure to check your local wiring codes. ground. This connection is the first connection that is made at the installation. This connection Connection Diagrams is the last connection that should be removed. If the generator set is on flexible mounting pads, the ground connection must be flexible in order to avoid possible breakage in later operation. 2 • Ground connection cable or straps should have at least the current carrying capacity of the largest line lead to the connected load. Joints in cables or straps must be clean, free of electrical resistance, and protected from possible oxidation. Bolted ground connection joints eventually oxidize. The joints are frequent sources of radio frequency interference (RFI). Joints that are silver soldered and bolted are preferred. Neutral Connections FJ The generators with a Wye Configuration usually have the neutral ground when the generator is installed. Grounding the neutral is for preventing damage to equipment. If the neutral wire is grounded and one of the phase Illustration 46 g01148000 leads becomes grounded, the excessive current The generator lead connections are located in the terminal box on will open a load circuit breaker. Also, the excessive the generator or in the enclosure for the control panel. current will cause the generator voltage to collapse. (1)Terminal Box on the Generator The result depends on the following items: electrical (2)Enclosure for the Control Panel characteristics of the generator, type of fault, and trip The generator lead connections are located in the rating of the circuit breaker. An undervoltage device terminal box on the generator or in the enclosure for may be required in order to provide an adequate the control panel. short circuit protection. • Change the position of the wire terminals in order to modify the connection. The code for the winding is specified on the nameplate. 40 SEBU8139-01 Product Information Section Product Identification Information Wiring Code A for Three-Phase R 438 LS voltage sensing — 0 => (T3) /220 V => • Configuration (T2) L1(U) Wiring Code B for Single-Phase Configuration or Three-Phase T1 n Configuration L1(V) N T4 T10 T12 T1 T12 T5 T6 T7 T11 T9 T6 T2 T9 T4 T3 710 L3(W) T3 T8 L2(V) L3(W) TS 72 L2(V) Illustration 47 goo952030 L L T11 T8 T6 •T11 T5 Illustration 49 g00952097 T12 N T10 T4 T11 T5 T9 L3(W) L L3(W) T3 TS T3 L2(V) O T9 T2 T10 T7 L1(U) L T8 T4 L2(V) T1 T12 T2 Illustration 48 g00952058 T7 T6 L1(U) Factory connection for"A"wiring code T1 Table 1 L-L Voltage for Wiring Code A Illustration 50 g00952196 Winding 50 Hz 60 Hz Factory connection for"B"wiring code 6 190-208 190-240 7 220-230 - • 8 - 190-208 R 230 voltage sensing —0 => (T8)/ 110 V=> (T11) SEBU8139-01 41 Product Information Section Product Identification Information • Table 2 L-L Voltage for Wiring Code B Winding 50 Hz 60 Hz T11 6 110-120 120 T 12 N 7 120-130 - T10 8 - 110-120 T9 O(W) R 230 voltage sensing —0 => (T8)/ 110 V=> (T11) T6 T3 R 438 LS voltage sensing —0 => (T3) / 110 V => T8 L2(v) (T2) T5 T2 Wiring Code D for Three-Phase Configuration T7 L1(u) T4 T1 L1(U) T1 Illustration 52 g00952365 Factory connection for"D"wiring code T4 Table 3 T7 L-L Voltage for Wiring Code D • N Winding 50 Hz 60 Hz T 10 6 380-415 380-480 T12 7 440-460 - T9 T11 8 - 380-416 T5 TB T3 T6 T2 R 230 voltage sensing —0 => (T8)/ 110 V=> (T11) R 438 LS voltage sensing — 0 => (T3) / 380 V => L3(W) L2(V) (T2) Illustration 51 goo952201 • 42 SEBU8139-01 Product Information Section Product Identification Information Wiring Code F for Single-Phase R 230 voltage sensing —0 => (T8)/ 110 V=> (T11) • Configuration or Three-Phase Configuration R 438 LS voltage sensing —0 => (T3)/220 V => (T2) Wiring Code FF for Single-Phase Configuration L1(U) T12 T1 T2 T6 T8 T12 T9 T4 T6 T7 T5 T3 T11 T9 T3 T10 L T1 T4 T7 T10 L L3(W) L2(V) L T11 T8 T5 T2 L M M Illustration 55 g00952416 Voltage LM equals one half of voltage LL. Illustration 53 go0952381 Voltage LM equals one half of voltage LL. T11 T4 • T11 T7 N O T3 T6 T9 L T9 O(W) T10 T5 T3 T8 T6� T8 T10 L2(V) T2 T4 T2 T12 �T, T7 T12 L1(U) T1 Illustration 56 g00952430 Factory connection for"FF"wiring code Illustration 54 g00952390 Table 5 Factory connection for"F"wiring code L-L Voltage for Wiring Code FF Table 4 Winding 50 Hz 60 Hz L-L Voltage for Wiring Code F 6 220-240 220-240 Winding 50 Hz 60 Hz 7 250-260 - • 6 220-240 220-240 8 200 1 220-240 7 250-260 - 8 200 220-240 R 230 voltage sensing —0 => (T1)/ 110 V=> (T4) SEBU8139-01 43 Product Information Section Product Identification Information • R 438 LS voltage sensing —0 => (T1 0)/220 V=> Table 7 (T1) Voltage at 50/60 Hz Connect Output 1000 Series Generators, Single Phase L-L L-M L L M with 4 Leads, Winding Dedicated Type M or Type M1 110 - T1 -T3 115 - T2 - T4 T1 -T3 T2 - T4 120 R 230 voltage sensing —0 => (T1)/ 110 V=> (T2) Ti T2 T3 T4 2000/3000 SeriesConnections for Exciter Field t M L Connection for Series Arrangement (SHUNT) WHT 00952989 BLU Illustration 57 g BLK O O O Wiring diagram for a connection in series Table 6 O 5+ R 230 Voltage at Connect. Output 50/60 Hz s- R 448 • L-L L-M L L M + + RED 220 110 T3 115 230 115 T1 T4 T2-T3 g01147977 Illustration 59 240 120 (WHT)White (BLU)Blue R 230 voltage sensing —0 => (T1)/ 110 V=> (T2) (BLK)Black (RED) Red Connection for Parallel Arrangement (AREP excitation and PMG excitation) T3 T4 T1 T2 WHT MB � �Illustration 58g00953002R 438 Wiring diagram for a parallel connection • Illustration 60 g01147978 (WHT)White (BLU)Blue (BLK)Black (RED) Red 44 SEBU8139-01 Product Information Section Product Identification Information R 791 T Interference Suppression . A B F F/F TBILK T1 Ti D 1 T1 T BLK T T2 2 T9 BILK T3 T3 T3 BLU N N WHT 7Z�— Illustration 61 g00953025 Connect the interference suppression,as shown.The letters in the circles represent the wiring codes for the generators. (BLK) Black (BLU) Blue (WHT)White (A)Wiring code"A" (B)Wiring code"B" (D)Wiring code "D" (F)Wiring code"F" (FF)Wiring code"FF" • • SEBU8139-01 45 ■ Operation Section Lifting and Storage Operation Section The lifting labels are located on the lifting eyes. These labels designate the proper lifting locations for the generator set. Some generator sets may be lifted at the base of the generator set and other generator Lifting and Storage sets may have a single lifting point on top of the generator set. 02472970 Engine Lifting with a Fuel Tank Product Lifting Do not lift the unit with fuel in the fuel tank. SMCS Code: 1000, 1404, 7002 Lifting of Generator Sets NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remem- ber that the capacity of an eyebolt is less as the angle between the supporting members and the object be- comes less than 90 degrees. When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight. • Use a hoist to remove heavy components. Use an adjustable lifting beam, if necessary. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted. Some removals require lifting the fixtures in order to obtain proper balance and safety. Consult your Caterpillar dealer for information regarding fixtures for proper lifting of your complete package. Lifting eyes are designed and installed for the specific arrangement. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure that proper lifting devices are provided. Consult your Caterpillar dealer for information regarding fixtures for proper engine lifting. On some enclosed generator sets, It may be necessary to remove a top panel of the enclosure in order to access the lifting eye. • Illustration 62 g01034418 46 SEBU8139-01 Operation Section Lifting and Storage 102283885 • Product Storage SMCS Code: 1000, 1404; 7002 If the engine will not be started for several weeks, the lubricating oil will drain from the cylinder walls and from the piston rings. Rust can form on the cylinder liner surface, which will increase engine wear which can reduce engine service life. To help prevent excessive engine wear, use the following guidelines: • Complete all of the lubrication recommendations that are listed in this Operation and Maintenance Manual, "Maintenance Interval Schedule" (Maintenance Section). • If freezing temperatures are expected, check the cooling system for adequate protection against freezing. See this Operation and Maintenance Manual, "Refill Capacities and Recommendations" (Maintenance Section). If an engine is out of operation and if use of the engine is not planned, special precautions should be made. • If the engine will be stored for more than one month, a complete protection procedure is recommended. Your Caterpillar dealer will have instructions for preparing the engine for extended storage periods. For more detailed information on engine storage, see Special Instruction, SEHS9031, "Storage Procedure for Caterpillar Products". Generator Storage Store the generator set in a dry area in order to minimize condensation on the windings. Use space heaters to keep the windings dry, when possible. Wrap the genset in plastic with bags of desiccant for extended storage. Test the insulation of the generator when the generator is removed from storage. Refer to this Operation and Maintenance Manual, "Insulation - Test". Dry the generator if the insulation is not acceptable. refer to this Operation and Maintenance Manual, "Generator - Dry". • SEBU8139-01 47 Operation Section Installation Installation Location The location of the generator must comply with all i02290564 local regulations. The location of the generator must Generator Set Installation also comply with all special industrial regulations. Locate the generator in an area that meets the SMCS Code: 7002 following requirements: • Clean Receiving Inspection • Dry If the generator is received during cold weather, allow the unit to reach room temperature before you • Well ventilated remove the protective packing material. Warming the generator to room temperature will prevent the • Easily accessible for inspection and maintenance following problems: Do not obstruct air inlet openings. Do not obstruct • Water condensation on cold surfaces discharge openings. Coolant flow must reach these openings. If the generator is exposed to harsh • Early failures due to wet windings environmental conditions, the generator can be modified in the field in order to add filters and • Early failures due to wet insulating materials space heaters. In addition, a more rigid periodic maintenance schedule should be established. Unpacking Remote Fuel Tanks and Auxiliary Moving the Generator Fuel Tanks • Connect the generator to a remote fuel tank or an ' auxiliary fuel tank, if necessary. The tank should have Improper lift rigging can allow unit to tumble caus- good clean fuel and there should be provisions for ing injury and damage. draining water and sediment from the fuel tank. Refer to this Operation and Maintenance Manual, "Fuel Tank Water and Sediment- Drain". NOTICE Do not use the engine lifting eyes to remove the en- Connect the tank to the fuel supply fitting and the fuel gine and generator together. return fitting on the generator set. Unpack the equipment with care in order to avoid Electrical Measurements scratching painted surfaces. Move the unit to the Measure the insulation resistance of each winding mounting location. The unit can be moved by either if the generator was exposed to the following of the following methods: conditions: • Attach an overhead crane to the lifting eye that is . Rapid changes in temperature installed on the generator package. • Use a lift truck in order to lift the generator. • Freezing The hoist and the hoist cables should have a rating • Wet climate during shipment that is greater than the weight of the generator. . Wet climate during storage When the unit is moved, ensure that the generator is completely supported by the lift truck's fork tines. Refer to this Operation and Maintenance Manual, Also ensure that the generator is balanced on the "Insulation -Test". lift truck's fork tines. Slide the fork tines beneath the attached skid in order to lift the generator. Note: These tests should be conducted prior to any • power connections or control connections that are being made. 48 SEBU8139-01 Operation Section Features and Controls Features and Controls i02353372 Control Panel SMCS Code: 7451 This section describes basic operation of the control panel. For more information, refer to Systems Operation/Testing and Adjusting, RENR7902, "EMCP 3". 4 5 6 7 1 8 MAIN MENU g 2 EVENT LOGS 10 ENGINE OVERVIEW � 11 • • 12 13 14 3 j 15 16 Illustration 63 g01045431 (1)Display Screen (7)Lamp Test Key (13)Scroll Right Key (2)AC Overview Key (8) Run Key (14)Enter Key (3)Engine Overview (9)Auto Key (15)Scroll Down Key (4)Yellow Warning Lamp (10)Stop Key (16)Scroll Left Key (5)Red Shutdown Lamp (11)Scroll Up Key (6)Alarm Acknowledge/Silence Key (12)Escape Key Navigation Keys Alarm Acknowledge/Silence — Pressing the key for Alarm Acknowledge/Silence (6) will cause the AC Overview — The key for AC Overview (2) output for the horn relay to turn off. This will silence will navigate the display to the first screen of AC the horn. Pressing the key will also cause any yellow information. The AC information contains various AC or red flashing lights to turn off or pressing the key parameters that summarize the electrical operation will cause the lights to illuminate depending on of the generator set. the active status of the alarms. The key for Alarm Acknowledge/Silence may also be configured to send • Engine Overview —The Key for Engine Overview a signal for global alarm silence on the J1939 Data (3) will navigate the display to the first screen of Link which will silence horns on annunciators. engine information. The engine information contains various engine parameters that summarize the operation of the generator set. SEBU8139-01 49 Operation Section Features and Controls • Lamp Test — Pressing and holding the Lamp Test Down — The Down Key (15) is used in order to Key (7) will cause all of the LED indicators and the navigate through the various menus and monitoring display screen pixels to illuminate until the key is screens. The Down Key is also used during the released. programming of setpoints. The Down Key is used in order to decrement "0" through "9" when the data is RUN — Pressing the "RUN" Key (8) will cause the entered into the system. The Down Key is used in engine to enter the "RUN" mode. order to move downward through the list for selecting an item for the setpoint. AUTO — Pressing the "AUTO" Key (9) will cause the engine to enter the "AUTO" mode. Scroll Left Key — The Scroll Left Key (16) is used during setpoint adjustment. The Scroll Left Key is STOP — Pressing the "STOP" Key (10)will cause the used to choose the digit that is edited when the data engine to enter the "STOP" mode. is entered into the system. The Scroll Left Key is also used during certain adjustments to setpoints in Scroll Up Key —The"Scroll Up Key" (11) is used to order to select a check box or the Scroll left key is navigate through the various menus or the screens used to unselect a check box. If a box has a check for monitoring. The Scroll Up Key is also used during mark inside the box, pressing the Scroll Left Key will entering setpoints. When data is entered, the Scroll cause the check mark to disappear. This will disable Up Key is used in order to increment the digits 0 the function. If the box does not have a check mark through 9. If the setpoint requires selection from a list, inside the box, pressing the Scroll Left Key will cause the Scroll Up Key is used to navigate through the list. a check mark to appear. This will enable the function. Escape —The Escape Key(12)is used for navigating Alarm Indicators through the menus. Use the escape Key in order to navigate through the menus and the submenus. Yellow Warning Lamp —A flashing yellow lamp Each keystroke causes the user to move upward indicates that there are active warnings that have not through the menus. The Escape Key is also used been acknowledged. A solid yellow lamp indicates in order to cancel out the screens that are used to that there are active warnings that have not been enter the data for the setpoints. If the Escape Key is acknowledged. If there are any active warnings, the pressed during the programming of setpoints, none yellow lamp will change from flashing yellow to solid of the changes that have been made on the screen yellow after the key for Alarm Acknowledge/Silence will be saved to the memory. (6 ) is pressed. If there are no longer any active Scroll Right Key —The Scroll Right Key (13) is used warnings, the yellow lamp will turn off after the Key during setpoint adjustment. The Scroll Right Key is for Alarm Acknowledge/Silence (6 ) is pressed. used to edit the digits when data is being entered into Red Shutdown Lamp — A flashing red lamp the system. The Scroll Right Key is also used during indicates that there are active shutdown conditions certain setpoint adjustments in order to select a that have not been acknowledged. A solid red lamp check box or the Scroll Right Key is used to unselect indicates that there are acknowledged shutdown a check box. If a box has a check mark that is inside conditions that are active. If there are any active the box, pressing the Scroll Right Key will cause shutdown conditions the red lamp will change from the check mark to disappear. This will disable the flashing red to solid red after the key for Alarm function. If the box does not have a check mark inside Acknowledge/Silence (6 ) is pressed. Any condition the box, pressing the Scroll Right Key will cause a that has caused a shutdown condition must be check mark to appear. This will enable the function. manually reset. If there are no longer any active Enter — The Enter Key (14) is used in order to shutdown conditions, the red lamp will turn off. navigate forward in the menus and the submenus. The Enter Key is also used during the programming Basic Operation of setpoints in order to save changes to the setpoints. Pressing the Enter Key during the programming of Engine Starting Sequence the setpoints causes the changes to the setpoints to be saved to memory. 1. The EMCP 3 receives an engine start signal. The signal will be one of three. • • The operator presses the "RUN" Key. • The control is in "AUTO" and the remote initiate input becomes active. 50 SEBU8139-01 Operation Section Features and Controls • The operator presses the"AUTO" Key and a Viewing Events • start command is sent via the RS-485 SCADA Data Link. Information from the EMCP 3 is displayed on the display screen (1). The arrow keys on the keypad are 2. The EMCP 3 checks the system before the crank used in order to navigate through the main menu. cycle begins. The EMCP 3 checks that no system Press the UP key (11) or the DOWN key (15) in order faults are present. The EMCP 3 checks that all to highlight the main menu options. previous shutdown faults have been reset. The EMCP 3 also checks that the engine is not already Press the "Enter" key (14) in order to select one of running. If the engine is equipped with prelube, the main menu options. The arrow keys are used in the EMCP 3 checks the status of the prelube. If order to view one of the setpoints. the prelube is not complete, the EMCP 3 will not crank the engine. The EMCP 3 will power up to the screen with the main menu. If the EMCP 3 is already powered up, 3. The EMCP 3 begins the crank cycle. press the "Escape" key (12) in order to return to the main menu. 4. The EMCP 3 cranks the engine until the cycle crank time reaches the setpoint for total crank The event monitoring system uses the following time or until the engine starts. terms to describe the status of an Event: 5. The EMCP 3 deactivates the starting motor PRESENT —The condition that caused the event is relay (SMR)when the engine speed reaches the present and the condition is affecting the behavior setpoint for crank terminate speed. of the system. Engine Stopping Procedure ACTIVE —The event was previously present but the condition is no longer present. The condition has 1. The EMCP 3 will receive an engine stop signal. been recorded by the event monitoring system and The signal will be one of three. the event monitoring system needs to be reset before • the engine can be restarted. • The operator presses the "STOP" Key. INACTIVE —The event was active at some time but • The control is in "AUTO" and the remote initiate the event is no longer active. The condition is not input becomes inactive. affecting the behavior of the system. • The operator presses the "AUTO" Key and a Perform the following steps in order to view one of stop command is sent via the RS-485 SCADA the events. Data Link. 1. From the main menu, highlight"Event Log". 2. After receiving the signal to stop, the EMCP 3 checks that there are no present system faults. 2. Press the "ENTER" key (14). 3. The EMCP 3 begins the cooldown period. In 3. Select an ECM and press the"ENTER" key (14). order to bypass the cooldown period, hold down the "STOP" Key. "PRESS ENTER TO BYPASS 4. In order to scroll through the Events, use the "UP" PRESS ESCAPE TO CONTINUE"will be shown and "DOWN" keys. on the display. Press the Enter Key in order to bypass the cooldown period or press the Escape 5. Press"ENTER" after highlighting an event in order Key in order to continue the cooldown period. to see additional information such as SPN, FMI, time and the date of the first occurrence, time 4. After the cooldown period, the EMCP 3 initiates a and date of the last occurrence, engine hours at engine shutdown by turning off the fuel supply. the first occurrence, and engine hours at the last occurrence. a. The EMCP 3 deactivates the fuel control relay (FCR), which will stop the engine. Resetting Events A flashing red shutdown lamp indicates that there • is an engine shutdown event that has not been acknowledged. The red shutdown lamp will change from flashing red to solid red when the Alarm Acknowledge/Silence key is pressed. Use the following procedure in order to reset the event. SEBU8139-01 51 Operation Section Features and Controls • 1. Press the STOP Key (10). Enter the "EVENT i LOG" option from the main menu. 2. Select an ECM from the list. Personal injury or death can result from high volt- age. 3. Scroll through the events in order to highlight the When power generation equipment must be in op- active events. eration to make tests and/or adjustments, high 4. Make sure that the condition that caused the event voltage and current are present. is no longer present. Improper test equipment can fail and present a 5. Press the Enter Key. high voltage shock hazard to its user. 6. "RESET' will be highlighted if the condition is no Make sure the testing equipment is designed for longer present and the control is in "STOP". and correctly operated for high voltage and cur- rent tests being made. 7. Press the Enter Key again. When servicing or repairing electric power gener- The fault will be cleared and the red shutdown ation equipment: lamp will be turned off, if there are no other active . Make sure the unit is off-line (disconnected shutdown conditions. from utility and/or other generators power 8. Press the Escape Key 3 times in order to get back service) , and either locked out or tagged DO to the main menu. NOT OPERATE. • Remove all fuses. 02398069 Voltage Regulators • Make sure the generator engine is stopped. • • Make sure all batteries are disconnected. SMCS Code: 4467 • Make sure all capacitors are discharged. Failure to do so could result in personal injury or DANGER: Shock/Electrocution Hazard-Do not op- death. Make sure residual voltage in the rotor,sta- erate this equipment or work on this equipment for and the generator is discharged. unless you have read and understand the instruc- tions and warnings in the Operation and Mainte- nance Manual. Failure to follow the instructions or i heed the warnings will result in serious injury or death. Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (—) battery ter- minal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could ac- tivate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. The voltage regulator is located in the enclosure • for the control panel or in the terminal box on the generator. 52 SEBU8139-01 Operation Section Features and Controls The voltage regulator is powered by two auxiliary R23O Adjustments • windings. These windings are independent from the circuit for detection of voltage. The first winding Table 8 is labelled as "X1" and "X2". This winding has a R230 Regulator voltage that is proportional with the output voltage of the generator. The second winding is labelled as Voltage regulation ±0.5% 121" and '22". This winding has a voltage that is Voltage detection range 85 to 139 V(50/60 Hz) proportional to the current of the stator. The voltage from the power supply is rectified and filtered before Rapid response time for a 500 ms being used by the regulator monitoring transistor. transient voltage variation This principle ensures that regulation is not affected amplitude of±20% by interference that is generated by the load. Voltage setting "P1" These voltage regulators may have an optional Stability setting "PZ remote potentiometer for voltage adjustment. This 8 Amp Fuse for protection 10 amperes for 10 seconds potentiometer is 450 ohms 0.5 W minimum. The of the power supply adjustment range is 5%. The voltage range is 50 or 60 Hz selection with jumper"ST3"(1). limited by the internal potentiometer"P2". Remove "ST4" in order to connect the potentiometer. A 1000 Underspeed protection and adjustment of frequency ohm potentiometer can also be used to extend the threshold via potentiometer TY adjustment range. (1) The engine speed setting must be changed in order to change the frequency of the generator set. 1 2 • Illustration 64 g01148000 The voltage regulator is located in the terminal box on the generator or in the enclosure for the control panel. (1)Terminal Box on the Generator (2)Enclosure for the Control Panel • SEBU8139-01 53 Operation Section Features and Controls • Voltage sensing 4x05.8x50rn 75 mm -T csj> E wi0 W W E E O 0 mot' r— r r C. Slow-blow c i-« fuse 250 V 8 A r 1 Voltage zP 1 Stability P2 s Exciter Under- fie speed CP 3 l d ST3Frequency is ST4J 50 Hz 60 Hz ST4 Voltage adjustment via remote potentiometer Illustration 65 goo952495 R230 Voltage Regulator with components Use the following procedure to adjust the R230 voltage regulator. 1. Make sure that the ST3 wire is connected for 50 White Hz applications. Remove the ST3 wire for 60 Blue Hz applications. Also, the engine speed must be changed from the factory setting in order to change the frequency of the generator. O 5+ 2. Turn potentiometer P1 to the full counterclockwise 6_ position. • , 3. Turn the potentiometer ST4 to the middle of the total rotation for the potentiometer ,if equipped. goos52510 Run the generator at the rated speed. If the Illustration 66 voltage does not increase, the field may need to R230 connections be energized. Refer to the"Special Use" section. 54 SEBU8139-01 Operation Section Features and Controls 4. Turn potentiometer P1 until the rated output • voltage is obtained. 5. Adjust the stability with potentiometer P2. ST5 With LAM& W/O LAMJk] 5+ EXciter Field 6- Response Time 6. The sealed potentiometer P3 is set at the factory ST2 normalr, fast -1 110V T11 for 50 Hz or 60 Hz. ST10 LAM 15%&.L Supply T8 R438 and R448 Adjustments LAM 25%.LU ST3 50 Hz 60 Hz F1Sl ow-blow fuse 250V 10 A NOTICE to ST9 must be closed for AREP excitation. Table 9 b r R438 and R448 Automatic Voltage Regulators _P5 z1 X1 Maximum current for short 3 x In for 10 seconds CIfCUIt E Standard power supply Two auxiliary windings �P4� • u L3 • 11 (W) Supply for shunt max 48 VAC at 50/60 Hz CP3— Rated overload current 8 amperes for 10 seconds Stabil Electronic protection for Excitation ceiling current 02) overload and short circuit for 10 seconds and return voltage opening on voltage sensing to approximately 1 ampere THE GENERATOR STG ST9 n s000 MUST BE STOPPED s,00 Qu� 1 r60 1n AREP IN ORDER TO RESET Droop PMc THE PROTECTION. ST1 n L2(V) Fuse"F1"on input side "X1"and "X2" Single-phase T I' 340-520V Detection S1_ S2 Opt on Fuse"F2"on output side "E+"and "E-" ,7o-2sov Voltage sensing 5 VAC that is isolated by 3-ph detection the transformer ss-,4ov Terminals for 0 to 110 VAC 95 to 140 ACV R731 Option Terminals for 0 to 220 VAC 170 to 260 ACV ST4 Extfor ernal potentiometer adjus mee Terminals for 0 to 380 VAC 340 to 520 VAC Voltage regulation t1% Illustration 67 g01144712 Rapid response time or normal response time from the location of jumper"ST2" Voltage adjustment via potentiometer"P2"(other voltages via the step down transformer) Underspeed protection and adjustment of frequency threshold via potentiometer"P4" Maximum adjustment for excitation via potentiometer "P5" (4.5 to 10 amperes) 50 or 60 Hz selection with jumper"ST3"(1). (1) The engine speed setting must be changed in order to change the frequency of the generator set. • SEBU8139-01 55 Operation Section Features and Controls • ST5 With LnM n W/O7�Fl 5+ Exciter field 6 ST2 normal rapi Response time n F, ux.windings Red ST3 50Hz 60Hz Black Frequency Green Yellow 4 x 5.8 x100 125 mm /F2 2 o gop fuse E vE E I ii X2 'n T 1■1 Z1 x1 ceiling Z2 + 41 I E+ Under 1■1 L3 speed I I Q (W) � � • 1■1 11 MPA 22 38 StabilityEJ t SPA OVoltage • ST1 s"tEP n ST9 AREP � Single phase PMG detection �P1� Quadrature 3 phase detection a droop L2(V) T.I. 340-520V R731 Option Optbn St——S2 170-260V 95-140V ST4 External potentiometer o for Voltage adjustment Illustration 68 g00952512 • 56 SEBU8139-01 Operation Section Features and Controls 11.Turn potentiometer(P4) slowly counterclockwise • until there is a significant voltage drop. The White voltage drop should be approximately 15 %. Blue 12.Vary the frequency of both parts between 48 Hz or Black O 58 Hz according to the operating frequency. Check the change in the voltage that was previously O 5+ observed. Use the following procedure in order to run the + + R 6 . generator set in parallel operation. ed 1. Preset the unit for parallel operation by connecting the current transformer to S1 and S2 of the g00952515 connector J2. Set potentiometer P1 for quadrature Illustration 69 droop in the center position. Apply the rated load. R438 connections The voltage should drop for 2% to 3%. Switch the positions of the two incoming secondary wires of Use the following procedure to adjust the R438 the current transformer if the voltage increases. voltage regulator. 2. The no-load voltages should be identical for all the 1. Remove wire ST4. generators that are operating in parallel. Connect the generators in parallel. Try to obtain a 0 kW 2. Connect an analog voltmeter that is calibrated for power exchange by adjusting the speed of the 50 VDC on terminal E+ and terminal E-. generator. Try to minimize the circulating currents between generators by altering the voltage setting 3. Connect a voltmeter that is calibrated for 300 VAC with potentiometer P2 or Rhe on one of the to 500 VAC or 1000 VAC. generators. 4. Make sure that the ST3 wire is positioned on the Note: Do not change the voltage settings after desired frequency. Also, the engine speed must this step. be changed from the factory setting in order to change the frequency of the generator. 3. Apply the available load. The setting is correct only if a reactive load is available. Equalize the 5. Turn potentiometer(P2)to a full counterclockwise Kilowatts or divide the rated power of the units position. proportionally by altering the speed. Equalize or divide the currents by altering the quadrature 6. Turn potentiometer (P4) to a full clockwise droop potentiometer. position. 7. Turn potentiometer(P3)counterclockwise to about R438 and R448 Adjustment for 1/3 of the total rotation for the potentiometer. Maximum Excitation 8. Start the engine and set the engine speed to a frequency of 48 Hz for 50 Hz or 58 Hz for 60 Hz. Max.exa�atWn Depending on manshequoncy r%. ST3 9. Adjust the output voltage to the correct value - ! ! x2� 1 with potentiometer P2. This voltage should be Ps' Mk= MHz z1 x1 the rated voltage UN for single operation or .;; zz UN plus 2% to 4% for parallel operation. Use P3, R438 E* i (�E;oahm:" potentiometer P3 to make adjustments if the _ e- A voltage oscillates. Adjust potentiometer P3 in both ov 1aacoc directions while you observe the voltage between ; 110v E+and E-. The voltage between E+ and E-should 380V be approximately 10 VDC. The best response times are obtained at the limit of the instability. Vohage • Try cutting or replacing the wire ST2 if no stable position can be obtained. illustration 70 goo9szeoo 10.Check the LAM operation. ST5 must be closed. SEBU8139-01 57 Operation Section Features and Controls • The factory setting corresponds to an excitation Special Use current that is required to obtain a three-phase short circuit current of 3 X IN at 50 Hz for industrial power, unless this is specified otherwise. The maximum level of excitation may be reduced by X2 AREP/ PMG a static method. The static method is safer for the generator and the network. Use the following steps Z1 /---�1 to reduce the maximum excitation level. X1 Z2 • 1. Disconnect the power supply wires X1, X2, Z1 E+ and Z2. 2. Disconnect sensing leads OV, 110V, 220V and 380V on the generator. 3. Connect the main power supply 200V-240V, as Illustration 71 g00952821 shown. X1,X2:120V The exciter is switched off by disconnecting the 4. Install a 10 Amp DC ammeter in series with the power supply to the voltage regulator. The connection exciter field. is identical for resetting the internal protection for the voltage regulator. 5. Turn potentiometer P5 to a full counterclockwise position and activate the power supply. If there is no output current from the voltage regulator, turn potentiometer P2 clockwise until the ammeter (aoo v 10 A) Diode ode indicates a stable current. i 1� Z; DO, -AI�]101 }i+'. • 6. Switch off the power supply. Switch on the power �,t... 0 Bottery J supply. Turn potentiometer P5 until the required X1 r , B Volts maximum current is obtained. The maximum Z2 current must not be greater than 10 Amperes. E+ ---- 10 ohms E- — — Use the following steps in order to check the internal Exciter field protection. 1. Open switch D. The excitation current should increase up to the preset maximum value and Illustration 72 go0ss2a30 the excitation current should remain at the preset maximum value for approximately 10 seconds. Use a 12 VDC power source in order to energize the The current will decrease to less than 1 Amp. field, if necessary. Refer to the following table. 2. Open switch A in order to reset the internal Table 10 protection. Applications B Volts Time Note: The voltage must be adjusted after the Voltage build up 12 (1 A) 1 -2 seconds maximum excitation current has been set. De-energized parallel 12 (1 A) 1 -2 seconds operation Standby parallel 24 (2A) 5- 10 seconds operation Battery starting 48 (4A) 5- 10 seconds Voltage that is sustained 48 (4A) 5- 10 seconds at overload • 58 SEBU8139-01 Operation Section Engine Starting Engine Starting i02344933 • Starting with Jump Start i02322203 Cables Starting the Engine SMCS Code: 1000; 1401; 1402; 1900 SMCS Code: 1000, 1450 Note: Do not adjust the engine speed control during ' • start-up. The electronic control module (ECM) will Improper jump start cable connections can cause control the engine speed during start-up. an explosion resulting in personal injury. Starting the Engine Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump start 1. Disengage any equipment that is driven by the cable ends to contact each other or the engine. engine. If the installation is not equipped with a backup 2. Turn the keyswitch to the RUN position. Leave the battery system, it may be necessary to start the keyswitch in the RUN position until the warning engine from an external electrical source. light for the glow plugs is extinguished. For information on troubleshooting the charging 3. When the warning light for the glow plugs is system, refer to Special Instruction, REHS0354, extinguished turn the keyswitch to the START "Charging System Troubleshooting". position in order to engage the electric starting motor and crank the engine. Many batteries which are considered unusable are still rechargeable. After jump starting, the alternator Note: The operating period of the warning light for may not be able to fully recharge batteries that • the glow plugs will change due to the temperature are severely discharged. The batteries must be of the engine. charged to the proper voltage with a battery charger. For information on testing and charging, refer to NOTICE the Special Instruction, SEHS7633, "Battery Test Do not engage the starting motor when flywheel is Procedure". turning. Do not start the engine under load. NOTICE If the engine fails to start within 30 seconds, release Using a battery source with the same voltage as the the starter switch or button and wait two minutes to electric starting motor. Use ONLY equal voltage for allow the starting motor to cool before attempting to jump starting. The use of higher voltage will damage start the engine again. the electrical system. Do not reverse the battery cables. The alternator can 4. Allow the to return to the RUN position be damaged. Attach ground cable last and remove after the ennginegine starts, first. 5. Repeat step 2 through step 4 if the engine fails When using an external electrical source to start the to start. engine, turn the generator set control switch to the "OFF"position. Turn all electrical accessories OFF be- fore attaching the jump start cables. Ensure that the main power switch is in the OFF posi- tion before attaching the jump start cables to the en- gine being started. 1. Turn the start switch on the stalled engine to the OFF position. Turn off all the engine's accessories. • SEBU8139-01 59 Operation Section Engine Starting • 2. Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery. Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source. 3. Connect one negative end of the jump start cable to the negative cable terminal of the electrical source. Connect the other negative end of the jump start cable to the engine block or to the chassis ground. This procedure helps to prevent potential sparks from igniting the combustible gases that are produced by some batteries. 4. Start the engine. 5. Immediately after the engine is started, disconnect the jump start cables in reverse order. After jump starting, the alternator may not be able to fully recharge batteries that are severely discharged. The batteries must be replaced or charged to the proper voltage with a battery charger after the engine is stopped. Many batteries which are considered unusable are still rechargeable. Refer to Operation and Maintenance Manual, "Battery - Replace" and Testing and Adjusting Manual, "Battery -Test'. • Refer to the Electrical Schematic for your engine. Consult your Caterpillar dealer for more information. • 60 SEBU8139-01 Operation Section Engine Operation Engine Operation 01457002 Fuel Conservation Practices Engine Operation i01646252 SMCS Code: 1000; 1250 The efficiency of the engine can affect the fuel SMCS Code: 1000 economy. Caterpillar's design and technology in manufacturing provides maximum fuel efficiency in Proper operation and maintenance are key factors all applications. Follow the recommended procedures in obtaining the maximum life and economy of in order to attain optimum performance for the life the engine. If the directions in the Operation and of the engine. Maintenance Manual are followed, costs can be minimized and engine service life can be maximized. Avoid spilling fuel. The time that is needed for the engine to reach Fuel expands when the fuel is warmed up. The fuel normal operating temperature can be less than the may overflow from the fuel tank. Inspect fuel lines for time taken for a walk-around inspection of the engine. leaks. Repair the fuel lines, as needed. The engine can be operated at the rated rpm after Be aware of the properties of the different fuels. the engine is started and after the engine reaches Use only the recommended fuels. Refer to the operating temperature. The engine will reach normal Operations and Maintenance Manual, "Fuel operating temperature sooner during a low engine Recommendations"for further information. speed (rpm) and during a low power demand. This procedure is more effective than idling the engine Avoid unnecessary idling. at no load. The engine should reach operating temperature in a few minutes. Shut off the engine rather than idle for long periods of time. • Gauge readings should be observed and the data should be recorded frequently while the engine • Observe the service indicator frequently. Keep the is operating. Comparing the data over time will air cleaner elements clean. help to determine normal readings for each gauge. Comparing data over time will also help detect • Ensure that the turbocharger is operating correctly abnormal operating developments. Significant so that the proper air/fuel ratio is maintained. Clean changes in the readings should be investigated. exhaust indicates proper functioning. • Maintain a good electrical system. One faulty battery cell will overwork the alternator. This will consume excess power and excess fuel. • Ensure that the belts are properly adjusted. The belts should be in good condition. Refer to the Specifications manual for further information. • Ensure that all of the connections of the hoses are tight. The connections should not leak. • Ensure that the driven equipment is in good working order. • Cold engines consume excess fuel. Utilize heat from the jacket water system and the exhaust system, when possible. Keep cooling system components clean and keep cooling system components in good repair. Never operate the • engine without water temperature regulators. All of these items will help maintain operating temperatures. SEBU8139-01 61 Operation Section Engine Stopping Engine Stopping i02334873 Stopping the Engine SMCS Code: 1000; 7000 NOTICE Stopping the engine immediately after it has been working under load, can result in overheating and ac- celerated wear of the engine components. Avoid accelerating the engine prior to shutting it down. Avoiding hot engine shutdowns will maximize tur- bocharger shaft and bearing life. Note: Individual applications will have different control systems. Ensure that the shutoff procedures are understood. Use the following general guidelines in order to stop the engine. 1. Remove the load from the engine. Reduce the engine speed (rpm) to low idle. Allow the engine to idle for five minutes in order to cool the engine. • 2. Stop the engine after the cool down period according to the shutoff system on the engine and turn the ignition key switch to the OFF position. If necessary, refer to the instructions that are provided by the OEM. • 62 SEBU8139-01 Operation Section Cold Weather Operation Cold Weather Operation The cooling system and the lubrication system • for the engine do not lose heat immediately upon shutdown. This means that an engine can be shut i02525190 down for a period of time and the engine can still Cold Weather Operation have the ability to start readily. • Install the correct specification of engine lubricant SMCS Code: 1000; 1250 before the beginning of cold weather. Caterpillar Diesel Engines can operate effectively in • Check all rubber parts (hoses, fan drive belts, etc) cold weather. During cold weather, the starting and weekly. the operation of the diesel engine is dependent on the following items: • Check all electrical wiring and connections for any • The type of fuel that is used fraying or damaged insulation. • The viscosity of the engine oil • Keep all batteries fully charged and warm. • The operation of the glow plugs • Fill the fuel tank at the end of each shift. • Check the air cleaners and the air intake daily. • Optional Cold starting aid Check the air intake more often when you operate in snow. • Battery condition • Ensure that the glow plugs are in working order. Refer to Special Publication, SEBU5898, "Cold Refer to Testing and Adjusting Manual, "Glow Plug Weather Recommendations for Caterpillar - Test". Machines". This section will cover the following information: T ' • • Potential problems that are caused by cold weather Personal injury or property damage can result operation from alcohol or starting fluids. • Suggest steps which can be taken in order to Alcohol orstarting fluids are highly flammable and minimize starting problems and operating problems toxic and if improperly stored could result in injury when the ambient air temperature is between or property damage. 00 to -40 °C (320 to 40 °F). The operation and maintenance of an engine in ' • freezing temperatures is complex . This is because Do not use aerosol types of starting aids such as of the following conditions: ether. Such use could result in an explosion and • Weather conditions personal injury. • Engine applications For jump starting with cables in cold weather, refer to the Operation and Maintenance Manual, Recommendations from your Carerpillar dealer are "Starting with Jump Start Cables." for instructions. based on past proven practices. The information that is contained in this section provides guidelines for Viscosity of the Engine Lubrication cold weather operation. Oil Hints for Cold Weather Operation Correct engine oil viscosity is essential. Oil viscosity • If the engine will start, operate the engine until a affects the amount of torque that is needed to minimum operating temperature of 81 °C(177.8 °F) crank the engine. Refer to this Operation and is achieved. Achieving operating temperature will Maintenance Manual, "Fluid Recommendations" for • help prevent the intake valves and exhaust valves the recommended viscosity of oil. from sticking. SEBU8139-01 63 Operation Section Cold Weather Operation • Recommendations for the Coolant When the engine is operated below normal operating temperatures, fuel and oil are not completely burned Provide cooling system protection for the lowest in the combustion chamber. This fuel and oil causes expected outside temperature. Refer to this Operation soft carbon deposits to form on the valve stems. and Maintenance Manual, "Fluid Recommendations" Generally, the deposits do not cause problems and for the recommended coolant mixture. the deposits are burned off during operation at normal engine operating temperatures. In cold weather, check the coolant often for the correct glycol concentration in order to ensure When the engine is started and the engine is stopped adequate freeze protection. many times without being operated in order to warm up completely, the carbon deposits become thicker. Engine Block Heaters This will cause the following problems: Engine block heaters (if equipped) heat the • Free operation of the valves is prevented. engine jacket water that surrounds the combustion chambers. This provides the following functions: • Valves become stuck. • Startability is improved. • Pushrods are bent. • Warm up time is reduced. • Other damage to valve train components can result. An electric block heater can be activated once the engine is stopped. An effective block heater is For this reason, when the engine is started, typically a 1250/1500 W unit. Consult your Caterpillar the engine must be operated until the coolant dealer for more information. temperature is 71 °C (160 °F) minimum. Carbon deposits on the valve stems will be kept at a minimum Idling the En and the free operation of the valves and the valve g Engine components will be maintained. When idling after the engine is started in cold In addition, the engine must be thoroughly warmed in weather, increase the engine rpm from 1000 to 1200 order to keep other engine parts in better condition rpm. This will warm up the engine more quickly. and the service life of the engine will be generally Maintaining an elevated low idle speed for extended extended. Lubrication will be improved. There will be periods will be easier with the installation of a hand less acid and less sludge in the oil. This will provide throttle. The engine should not be "raced" in order to longer service life for the engine bearings, the piston speed up the warm up process. rings, and other parts. However, limit unnecessary idle time to ten minutes in order to reduce wear and While the engine is idling, the application of a light unnecessary fuel consumption. load (parasitic load) will assist in achieving the minimum operating temperature. The minimum The Water Temperature Regulator and operating temperature is 82 °C (179.6 F). Insulated Heater Lines Recommendations for Coolant The engine is equipped with a water temperature Warm Up regulator. When the engine coolant is below the correct operating temperature jacket water circulates Warm up an engine that has cooled below normal through the engine cylinder block and into the operating temperatures due to inactivity. This should engine cylinder head. The coolant then returns to the be performed before the engine is returned to full cylinder block via an internal passage that bypasses operation. During operation in very cold temperature the valve of the coolant temperature regulator. This conditions, damage to engine valve mechanisms can ensures that coolant flows around the engine under result from engine operation for short intervals. This cold operating conditions. The water temperature can happen if the engine is started and the engine is regulator begins to open when the engine jacket stopped many times without being operated in order water has reached the correct minimum operating to warm up completely. temperature. As the jacket water coolant temperature rises above the minimum operating temperature the • water temperature regulator opens further allowing more coolant through the radiator to dissipate excess heat. 64 SEBU8139-01 Operation Section Cold Weather Operation The progressive opening of the water temperature There are three major differences between No. 1 and • regulator operates the progressive closing of the No. 2 diesel fuel. No. 1 diesel fuel has the following bypass passage between the cylinder block and properties: head. This ensures maximum coolant flow to the radiator in order to achieve maximum heat • Lower cloud point dissipation. • Lower pour point Note: Caterpillar discourages the use of all air flow restriction devices such as radiator shutters. • Lower rating of kJ (BTU) per unit volume of fuel Restriction of the air flow can result in the following: high exhaust temperatures, power loss, excessive When No. 1 diesel fuel is used, a decrease in power fan usage, and reduction in fuel economy. and in fuel efficiency may be noticed. Other operating effects should not be experienced. A cab heater is beneficial in very cold weather. The feed from the engine and the return lines from the The cloud point is the temperature when a cloud of cab should be insulated in order to reduce heat loss wax crystals begins to form in the fuel. These crystals to the outside air. can cause the fuel filters to plug. The pour point is the temperature when diesel fuel will thicken. The Insulating the Air Inlet and Engine diesel fuel becomes more resistant to flow through Compartment fuel pumps and through fuel lines. When temperatures below -18 °C (-0 °F) will be Be aware of these values when diesel fuel is frequently encountered, an air cleaner inlet that purchased. Anticipate the average ambient is located in the engine compartment may be temperature of the area. Engines that are fueled in specified. An air cleaner that is located in the engine one climate may not operate well if the engines are moved to another climate. Problems can result due compartment may also minimize the entry of snow into the air cleaner. Also, heat that is rejected by the to changes in temperature. engine helps to warm the intake air. Before troubleshooting for low power or for poor • Additional heat can be retained around the engine by performance in the winter, check the type of fuel that insulating the engine compartment. is being used. When No. 2 diesel fuel is used the following 102237624 components provide a means of minimizing problems Fuel and the Effect from Cold in cold weather: Weather • Starting aids SMCS Code: 1000: 1250 • Engine oil pan heaters The following fuels are the grades that are available • Engine coolant heaters for Caterpillar engines: • Fuel heaters • No. 1 • Fuel line insulation • No. 2 For more information on cold weather operation, • Blend of No. 1 and No. 2 see Special Publication, SEBU5898, "Cold Weather Recommendations". No. 2 diesel fuel is the most commonly used fuel. Either No. 1 diesel fuel or a blend of No. 1 and No. 2 is best suited for cold weather operation. Quantities of No. 1 diesel fuel are limited. No. 1 diesel fuels are usually available during the months of the • winter in the colder climates. During cold weather operation, if No. 1 diesel fuel is not available, use No. 2 diesel fuel, if necessary. SEBU8139-01 65 ■ Maintenance Section Refill Capacities Maintenance Section Cat DEO Multigrade can be used in other diesel engines and in gasoline engines. See the engine manufacturer's guide for the recommended specifications. Compare the specifications to the Refill Capacities specifications of Cat DEO Multigrade. The current industry standards for Cat DEO are listed on the product label and on the data sheets for the product. 102540208 Refill ac Ca ities and Consult your Caterpillar dealer for part numbers and p for available sizes of containers. Recommendations Note: Cat DEO in SAE 15W-40 exceeds the SMCS Code: 1348, 1395; 7560 performance requirements for the following API categories: CI-4, CH-4, CG-4, CF-4, and CF. Cat Engine Oil DEO Multigrade exceeds the requirements of the g Caterpillar Engine Crankcase Fluid-1 (ECF-1) specification. Cat DEO in SAE 15W-40 passes the NOTICE following proprietary tests: sticking of the piston ring. These recommendations are subject to change with- oil control tests, wear tests, and soot tests. Proprietary out notice. Contact your local Caterpillar dealer for the tests help ensure that Caterpillar multigrade oil most up to date fluids recommendations. provides superior performance in Caterpillar Diesel Engines. In addition, Cat DEO Multigrade exceeds many of the performance requirements of other Cat DEO (Diesel Engine Oil) manufacturers of diesel engines. Therefore, this oil is an excellent choice for many mixed fleets. True high Caterpillar oils have been developed and tested in performance oil is produced with a combination order to provide the full performance and service of the following factors: industry standard tests, • life that has been designed and built into Caterpillar proprietary tests, field tests, and prior experience Engines. Caterpillar oils are currently used to fill with similar formulations. The design and the diesel engines at the factory. These oils are offered development of Caterpillar lubricants that are by Caterpillar dealers for continued use when the both high performance and high quality are engine oil is changed. Consult your Caterpillar dealer based on these factors. for more information on these oils. Note: Non-Caterpillar commercial oils are second Due to significant variations in the quality and in choice oils. the performance of commercially available oils, Caterpillar makes the following recommendations: Commercial Oils • Cat DEO (Diesel Engine Oil) (SAE 10W-30) Engine Crankcase Fluid Recommendations for all Caterpillar 3500 Series and smaller direct • Cat DEO (Diesel Engine Oil) (SAE 15W-40) injection (DI) diesel engines Cat DEO Multigrade is formulated with the correct Note: If Cat DEO Multigrade is not used, use only amounts of detergents, dispersants, and alkalinity in commercial oils that meet the following categories. order to provide superior performance in Caterpillar Diesel Engines. API CH-4 multigrade oils and API CI-4 multigrade oils are acceptable if the requirements of Cat DEO Multigrade is available in various viscosity Caterpillar's ECF-1 specification are met. CH-4 oils grades that include SAE 1 OW-30 and SAE 15W-40. and CI-4 oils that have not met the requirements To choose the correct viscosity grade for the ambient of Caterpillar's ECF-1 specification may cause temperature, see Table 11. Multigrade oils provide reduced engine life. the correct viscosity for a broad range of operating temperatures. Multigrade oils are also effective in API CG-4 multigrade oils are acceptable for all maintaining low oil consumption and low levels of Caterpillar diesel engines. When the API CG-4 oils piston deposits. are used, the oil drain interval should not exceed • the standard oil drain interval for your engine. Note: When oil meets more than one API category, the applicable footnote is determined by the highest API category that is met. 66 SEBU8139-01 Maintenance Section Refill Capacities Example -An oil meets both the API CH-4 and the Note: Generally, use the highest oil viscosity that is • API CIF oil categories. In this case, the API CH-4 available to meet the requirement for the temperature applies. at start-up. NOTICE If ambient temperature conditions at engine start-up In selecting oil for any engine application, both the require the use of multigrade SAE OW oil, SAE oil viscosity and oil performance category/specifica- OW-40 viscosity grade is preferred over SAE OW-20 tion as specified by the engine manufacturer must be or SAE OW-30. defined and satisfied. Using only one of these param- Table 11 eters will not sufficiently define oil for an engine appli- cation. Engine Oil Viscosities for Ambient Temperatures Ambient Temperature In order to make the proper choice of a commercial Viscosity Grade Minimum Maximum oil, refer to the following explanations: SAE OW-20 -40°C (-40°F) 10 °C (50 °F) API CI4 -API CI-4 oils were developed in order SAE OW-30 -40°C (-40 °F) 30 °C (86 °F) to meet the requirements of high performance diesel engines that use cooled Exhaust Gas SAE OW-40 -40°C (-40°F) 40°C (104 °F) Recirculation (EGR). API CI-4 oils are acceptable if SAE 5W-30 -30°C (-22 °F) 30 °C (86 °F) the requirements of Caterpillar's ECF-1 specification are met. SAE 5W-40 -30°C (-22 °F) 50 °C (122 °F) API CH-4 -API CH-4 oils were developed in order SAE 1OW-30 -18 °C (0 °F) 40°C (104 °F) to protect low emissions diesel engines that use a SAE 1OW-40 -18 °C (0 °F) 50°C (122 °F) 0.05 percent level of fuel sulfur. However, API CH-4 SAE 15W-40 -9.5 °C (15 °F) 50°C (122 °F) oils may be used with higher sulfur fuels. API CH-4 oils are acceptable if the requirements of Caterpillar's • ECF-1 specification are met. Note: Supplemental heat is recommended below the minimum recommended ambient temperature. Note: CH-4 oils and CI4 oils that have not met the requirements of Caterpillar's ECF-1 specification S-O-S Oil Analysis may cause reduced engine life. Caterpillar has developed a tool for maintenance NOTICE management that evaluates oil degradation and the Failure to follow these oil recommendations can cause tool also detects the early signs of wear on internal shortened engine service life due to deposits and/or components. The Caterpillar tool for oil analysis is excessive wear. called S-O-S Oil Analysis and the tool is part of the S-O-S Services program. S-O-S Oil Analysis divides Note: Refer to Special Publication, SEBU6251, oil analysis into three categories: "Caterpillar Commercial Diesel Engine Fluids . Wear Analysis Recommendations" for additional information that relates to lubrication for your engine. . Oil condition Lubricant Viscosity Recommendations . Additional tests The proper SAE viscosity grade of oil is determined The wear analysis monitors metal particles, some oil by the minimum ambient temperature during additives, and some contaminants. cold engine start-up, and the maximum ambient temperature during engine operation. Oil condition uses infrared (IR) analysis to evaluate the chemistry of the oil. Infrared analysis is also used Refer to Table 11 (minimum temperature) in order to detect certain types of contamination. to determine the required oil viscosity for starting a cold engine. Additional tests are used to measure contamination levels from water, fuel, or coolant. Oil viscosity and • Refer to Table 11 (maximum temperature) in order corrosion protection can be evaluated, as needed. to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated. SEBU8139-01 67 Maintenance Section Refill Capacities • Refer to Special Publication, SEBU6251, "Caterpillar If it is necessary to choose a single grease for use Commercial Diesel Engine Fluids Recommendations" on all of the equipment at one site, always choose or contact your local Caterpillar dealer for additional a grease that meets the requirements of the most information concerning the S-O•S Oil Analysis demanding application. A product that barely meets program. the minimum performance requirements will shorten the life of the part. Use the grease that yields the least Lubrication System total operating cost. Base this cost on an analysis that includes the costs of the parts, the labor, the The refill capacities for the engine crankcase reflect downtime, and the cost of the grease that is used. the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will Some greases are not chemically compatible. require additional oil. Refer to the OEM specifications Consult your supplier in order to determine if two or in order to find the capacity of the auxiliary oil filter. more greases are compatible. Table 12 Purge the grease from a joint at the following times: Engine • Switching from one grease to another grease Refill Capacities Compartment or System Minimum Maximum • Switching from one supplier to another supplier 13.5 L 16.5 L If in doubt, Purge! Crankcase Oil Sump(') (14.2653 (17.4354 qQ qt) Note: All Caterpillar brand name greases are (1) These values are the approximate capacities for the crankcase compatible with each other. oil sump(aluminum)which includes the standard factory installed oil filters. Engines with auxiliary oil filters will require additional oil.Refer to the OEM specifications for the capacity Note: Refer to Special Publication, SEBU6251, of the auxiliary oil filter. `Caterpillar Commercial Diesel Engine Fluids • Recommendations" for additional information that Lubricating Grease relates to lubrication for your engine. Caterpillar provides a range of moderate greases Fuel to extremely high performance greases in order to service the entire line of Caterpillar products that Diesel fuels that meet the Caterpillar Specification operate throughout the wide variety of climates. You for Distillate Diesel Fuel are recommended. These will always be able to find a grease that will meet your fuels will help to provide maximum engine service life machine's requirements for a certain application. and performance. In North America, diesel fuel that Caterpillar grease products often exceed Caterpillar is identified as No. 1-D or No. 2-D in "ASTM D975" specifications. generally meet the specifications. Diesel fuels from other sources could exhibit detrimental properties Before selecting a grease product for any application, that are not defined or controlled by this specification. the performance requirements must be determined. Consult the grease recommendations that are made NOTICE by the OEM for the equipment when the equipment is Operating with fuels that do not meet Caterpillar's rec- operated in the expected conditions. Then, consult ommendations can cause the following effects: start- with your Caterpillar dealer for a list of greases and ing difficulty, poor combustion, deposits in the fuel in- the following related characteristics. jectors, reduced service life of the fuel system, de- • Performance specifications posits in the combustion chamber, and reduced ser- vice life of the engine. • Available sizes of containers Note: Refer to Special Publication, SEBU6251, • Part numbers "Caterpillar Commercial Diesel Engine Fluids Recommendations" for the Caterpillar Specification Always choose a grease that meets the for distillate fuel and for additional information that recommendations that are specified by the relates to fuel for your engine. • equipment manufacturer for the application, or choose a grease that exceeds the recommendations Refill Capacities (Fuel System) that are specified by the equipment manufacturer for the application. Refer to the Operation and Maintenance Manual that is provided by the OEM for capacities of the fuel system. 68 SEBU8139-01 Maintenance Section Refill Capacities Coolant Table 13 • The following two coolants are used in Caterpillar Coolant Service Life diesel engines: Coolant Type Service Life Preferred — Cat ELC (Extended Life Coolant) or Cat ELC 6000 Service Hours or a commercial extended life coolant that meets the Six Years Caterpillar EC-1 specification Cat DEAC 3000 Service Hours or Three Years Acceptable — A Cat DEAC (Diesel Engine Commercial Heavy-Duty Antifreeze/Coolant) or a commercial heavy-duty Antifreeze that meets 3000 Service Hours or antifreeze that meets "ASTM D4985" or "ASTM "ASTM D5345" Two Years D5345" specifications Commercial Heavy-Duty 3000 Service Hours or Antifreeze that meets One Year NOTICE "ASTM D4985" Do not use a commercial cool ant/antifreeze that only meets the ASTM "D3306" specification. This type of Caterpillar SCA and 3000 Service Hours or coolant/antifreeze is made for light duty automotive Water Two Years applications. Commercial SCA and 3000 Service Hours or Water One Year Use only the coolant/antifreeze that is recommended. - L Note: Refer to Special Publication, SEBU6251, Caterpillar recommends a 1:1 mixture of water and "Caterpillar Commercial Diesel Engine Fluids glycol. This mixture of water and glycol will provide Recommendations" for additional information that optimum heavy-duty performance as a antifreeze. relates to coolant for your engine. Note: Cat DEAC does not require a treatment with S•0•S Coolant Analysis • an SCA at the initial fill. Commercial heavy-duty antifreeze that meets "ASTM D4985" or "ASTM Table 14 D5345" specifications MAY require a treatment Recommended Interval with an SCA at the initial fill. Read the label or the instructions that are provided by the OEM of the Type of Coolant Level 1 Level 2 product. DEAC Every 250 Hours Yearly0> In stationary engine applications that do not ELC Not Required Yearly require anti-boil protection or freeze protection, a (1) The Level 2 Coolant Analysis should be performed sooner if a mixture of SCA and water is acceptable. Caterpillar problem is identified by a Level 1 Coolant Analysis, recommends a six percent to eight percent concentration of SCA in those cooling systems. S•O•S Coolant Analysis (Level 1) Distilled water or deionized water is preferred. Water which has the recommended properties may be used. A coolant analysis (Level 1) is a test of the properties of the coolant. NOTICE All Caterpillar diesel engines equipped with air-to-air The following properties of the coolant are tested: aftercooling (ATAAC)require a minimum of 30 percent glycol to prevent water pump cavitation. • Glycol concentration for freeze protection and boil protection • Ability to protect from erosion and corrosion • pH • Conductivity • Visual analysis • • Odor analysis The results are reported, and appropriate recommendations are made. SEBU8139-01 69 Maintenance Section Refill Capacities • Refer to the Maintenance Interval Schedule in this Refill Capacity Operation and Maintenance Manual in order to find the maintenance interval for collecting the coolant Table 15 samples. Engine Refill Capacities S•O•S Coolant Analysis (Level 2) Compartment or System Liters A coolant analysis (Level 2) is a comprehensive Engine Only 9 L(9.5102 qt) chemical evaluation of the coolant. This analysis is also a check of the overall condition of the inside of External System Per OEMM the cooling system. (1) The External System includes a radiator or an expansion tank with the following components: heat exchanger and The SOS Coolant Analysis has the following piping. Refer to the OEM specifications. Enter the value for the features: capacity of the External System in this row. • Full coolant analysis (Level 1) • Identification of the source of metal corrosion and of contaminants • Water hardness • Identification of buildup of the impurities that cause corrosion • Identification of buildup of the impurities that cause scaling • The results are reported, and appropriate recommendations are made. Refer to the Maintenance Interval Schedule in this Operation and Maintenance Manual, "Cooling System Coolant Sample (Level 2) - Obtain" for the maintenance interval for collecting the coolant samples. Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and from corrosion. The analysis also tests the ability of the coolant to protect the engine from boiling and from freezing. The S &S Coolant Analysis can be done at your Caterpillar dealer. Caterpillar S O S Coolant Analysis is the best way to monitor the condition of your coolant and your cooling system. S O-S Coolant Analysis is a program that is based on periodic samples. Refer to Special Publication, SEBU6251, "Caterpillar Commercial Diesel Engine Fluids Recommendations" for additional information. • 70 SEBU8139-01 Maintenance Section Maintenance Interval Schedule 102549017 Every 250 Service Hours • Maintenance Interval Schedule Cooling System Coolant Sample (Level 1) - (Prime Power Generator Sets) Obtain ................................................................. 77 Engine Oil Sample - Obtain .................................. 82 SMCS Code: 1000; 7500 Initial 500 Service Hours Ensure that all safety information, warnings, and Engine Valve Lash - Inspect/Adjust ...................... 86 instructions are read and understood before any operation or any maintenance procedures are Initial 500 Hours (for New Systems, Refilled performed. Systems, and Converted Systems) The user is responsible for the performance of Cooling System Coolant Sample (Level 2) - maintenance, including all adjustments, the use of Obtain ................................................................. 78 proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure Every 500 Service Hours to adhere to proper maintenance intervals and procedures may result in diminished performance of Alternator and Fan Belts - Inspect ........................ 73 the product and/or accelerated wear of components. Every 500 Service Hours or 1 Year Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, Battery Electrolyte Level - Check.......................... 74 in order to determine the maintenance intervals. Engine Air Cleaner Element (Single Element) - Products that operate in severe operating conditions Replace ...................... .................................. ..... 79 may require more frequent maintenance. Engine Crankcase Breather Element- Replace ... 81 Engine Oil and Filter- Change ........ . .... ............ 83 Note: Before each consecutive interval is performed, Fuel System Primary Filter (Water Separator) all maintenance from the previous interval must be Element- Replace .......... ................................... 88 • performed. Fuel System Secondary Filter- Replace .............. 90 Hoses and Clamps - Inspect/Replace .................. 94 When Required Every 1000 Service Hours Battery - Replace .................................................. 73 Battery or Battery Cable - Disconnect .................. 74 Engine Valve Lash - Inspect/Adjust ...................... 86 Engine - Clean ...................................................... 79 Fuel System - Prime ............................................. 86 Every 1000 Service Hours or 1 Year Generator- Dry ..................................................... 91 Generator Set-Test ............................................. 94 Rotating Rectifier- Check ..................................... 99 Rotating Rectifier-Test ...................................... 100 Every 2000 Service Hours Daily Engine Mounts - Inspect ....................................... 82 Cooling System Coolant Level - Check ................ 77 Starting Motor- Inspect ...................................... 100 Electrical Connections - Check ............................. 79 Turbocharger- Inspect........................................ 100 Engine Air Cleaner Service Indicator- Inspect ..... 80 Engine Oil Level - Check ...................................... 82 Every 2000 Service Hours or 1 Year Fuel System Primary Filter/Water Separator - Alternator- Inspect ............................................... 73 Drain ................................................................... 89 Engine Mounts - Inspect ....................................... 82 Generator Load -Check ....................................... 93 Walk-Around Inspection ...................................... 101 Every Year Every Week Cooling System Coolant Sample (Level 2) - Generator- Inspect ............................................... 92 Obtain ................................................................. 78 Every 50 Service Hours or Weekly Every 3000 Service Hours or 2 Years •Fuel Tank Water and Sediment - Drain ................. 90 Cooling System Water Temperature Regulator -Replace ............................................................... 78 Every 100 Service Hours or 3 Months Water Pump - Inspect ......................................... 102 Insulation -Test......................................... ........... 95 SEBU8139-01 71 Maintenance Section Maintenance Interval Schedule • Every 6000 Service Hours or 3 Years Cooling System Coolant Extender(ELC) -Add .... 76 Every 12 000 Service Hours or 6 Years Cooling System Coolant(ELC) - Change ............. 75 Overhaul Overhaul Considerations ...................................... 97 • • 72 SEBU8139-01 Maintenance Section Maintenance Interval Schedule 102549570 Engine Air Cleaner Element (Single Element) - • Maintenance Interval ScheduleReplace pect ....................................... 79 Engine Mounts - Ins Inspect ....................................... 82 (Standby Generator Sets) Engine Oil Sample - Obtain .................................. 82 Engine Oil and Filter- Change ............................. 83 SMCS Code: 1000; 7500 Fuel System Primary Filter (Water Separator) Element- Replace .............................................. 88 Ensure that all safety information, warnings, and Fuel System Secondary Filter- Replace .............. 90 instructions are read and understood before any Hoses and Clamps - Inspect/Replace .................. 94 operation or any maintenance procedures are Insulation -Test..................................................... 95 performed. Rotating Rectifier- Check ..................................... 99 Starting Motor- Inspect ...................................... 100 The user is responsible for the performance of Water Pump - Inspect ......................................... 102 maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement Every 3 Years of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and Battery - Replace .................................................. 73 procedures may result in diminished performance of Cooling System Coolant Extender(ELC) -Add .... 76 the product and/or accelerated wear of components. Cooling System Water Temperature Regulator - Use mileage, fuel consumption, service hours, or Ever 6 Years calendar time, WHICH EVER OCCURS FIRST, y in order to determine the maintenance intervals. Cooling System Coolant (ELC) - Change ............. 75 Products that operate in severe operating conditions may require more frequent maintenance. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be • performed. When Required Battery or Battery Cable - Disconnect .................. 74 Fuel System - Prime ............................................. 86 Generator- Dry ..................................................... 91 Generator Load - Check ....................................... 93 Generator Set-Test ............................................. 94 Rotating Rectifier-Test ...................................... 100 Every Week Battery Electrolyte Level - Check .......................... 74 Cooling System Coolant Level - Check ................ 77 Electrical Connections - Check ............................. 79 Engine Air Cleaner Service Indicator- Inspect ..... 80 Engine Oil Level - Check ...................................... 82 Fuel System Primary Filter/Water Separator - Drain ................................................................... 89 Fuel Tank Water and Sediment - Drain ................. 90 Generator- Inspect ............................................... 92 Every 500 Service Hours Engine Crankcase Breather Element - Replace ... 81 Every Year • Alternator- Inspect ............................................... 73 Alternator and Fan Belts - Inspect ........................ 73 Cooling System Coolant Sample (Level 2) - Obtain ................................................................. 78 Engine - Clean ...................................................... 79 SEBU8139-01 73 Maintenance Section Alternator - Inspect • too072207 Alternator - Inspect SMCS Code: 1405-040 0 0 o 0 o 0 Ooo Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose 1 connections and proper battery charging. Inspect the Qo 0 ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or rJ proper performance of the electrical system. Make a I° repairs, as required. Refer to the Service Manual. Check the alternator and the battery charger for proper operation. If the batteries are properly o® o°o charged, the ammeter reading should be very near m ®o® • zero. All batteries should be kept charged. The 0O Q0 batteries should be kept warm because temperature m U affects the cranking power. If the battery is too cold, _ the battery will not crank the engine. The battery will not crank the engine, even if the engine is warm. 901155963 When the engine is not run for long periods of time Illustration 73 or if the engine is run for short periods, the batteries Typical example may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge. i02322315 i02320202 Battery - Replace • Alternator and Fan Belts - SMCS Code: 1401-510 Inspect SMCS Code: 1357-040 Batteries give off combustible gases which can NOTICE explode. A spark can cause the combustible gas- es to ignite. This can result in severe personal in- Ensure that the engine is stopped before any servicing jury or death. or repair is performed. Ensure proper ventilation for batteries that are in To maximize the engine performance, inspect the belt an enclosure. Follow the proper procedures in or- (1) for wear and for cracking. Replace the belt if the der to help prevent electrical arcs and/or sparks belt is worn or damaged. near batteries. Do not smoke when batteries are serviced. • If the belt (1) has more than four cracks per 25.4000 mm (1 inch) the belt must be replaced. • Check the belt of cracks, splits, glazing, grease. / • and splitting. The battery cables or the batteries should not be removed with the battery cover in place. The bat- tery cover should be removed before any servic- ing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury. • 1. Switch the engine to the OFF position. Remove all electrical loads. 2. Turn off any battery chargers. Disconnect any battery chargers. 74 SEBU8139-01 Maintenance Section Battery Electrolyte Level - Check 3. The NEGATIVE "-" cable connects the NEGATIVE 3. Keep the batteries clean. • '-" battery terminal to the NEGATIVE '-" terminal on the starting motor. Disconnect the cable from Clean the battery case with one of the following the NEGATIVE "-" battery terminal. cleaning solutions: 4. The POSITIVE "+" cable connects the POSITIVE • A mixture of 0.1 kg (0.2 lb) of baking soda and "+" battery terminal to the POSITIVE '+" terminal 1 L (1 qt) of clean water on the starting motor. Disconnect the cable from the POSITIVE "+" battery terminal. • A mixture of 0.1 L (0.11 qt) of ammonia and 1 L (1 qt) of clean water Note: Always recycle a battery. Never discard a battery. Dispose of used batteries to an appropriate Thoroughly rinse the battery case with clean water. recycling facility. Use a fine grade of sandpaper to clean the 5. Remove the used battery. terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT 6. Install the new battery. remove material excessively. Excessive removal of material can cause the clamps to not fit properly. Note: Before the cables are connected, ensure that Coat the clamps and the terminals with 5N-5561 the engine start switch is OFF. Silicone Lubricant, petroleum jelly or MPGM. 7. Connect the cable from the starting motor to the POSITIVE "+" battery terminal. i02323088 8. Connect the NEGATIVE "-" cable to the Battery or Battery Cable - NEGATIVE "-" battery terminal. Disconnect SMCS Code: 1402-029 • i02345713 Battery Electrolyte Level - 1%yommi Ilk, Check The battery cables or the batteries should not be SMCS Code: 1401-535 removed with the battery cover in place. The bat- tery cover should be removed before any servic- When the engine is not run for long periods of time or ing is attempted. when the engine is run for short periods, the batteries Removing the battery cables or the batteries with may not fully recharge. Ensure a full charge in order the cover in place may cause a battery explosion to help prevent the battery from freezing. If batteries resulting in personal injury. are properly charged, ammeter reading should be very near zero,when the engine is in operation. 1. Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF position m and remove the key and all electrical loads. ili 1� All lead-acid batteries contain sulfuric acid which 2. Disconnect the negative battery terminal. Ensure can burn the skin and clothing.Always wear a face that the cable cannot contact the terminal. When shield and protective clothing when working on or four 12 volt batteries are involved, two negative near batteries. connection must be disconnected. 1. Remove the filler caps. Maintain the electrolyte 3. Remove the positive connection. level to the "FULL" mark on the battery. 4. Clean all disconnected connection and battery If the addition of water is necessary, use distilled terminals. water. If distilled water is not available use clean water that is low in minerals. Do not use artificially 5. Use a fine grade of sandpaper to clean the • softened water. terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT 2. Check the condition of the electrolyte with the remove material excessively. Excessive removal 245-5829 Coolant Battery Tester Refractometer. of material can cause the clamps to not fit correctly. Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly. SEBU8139-01 75 Maintenance Section Cooling System Coolant (ELC) - Change • 6. Tape the cable connections in order to help Allow the coolant to drain. prevent accidental starting. NOTICE 7. Proceed with necessary system repairs. Dispose of used engine coolant properly or recycle. Various methods have been proposed to reclaim used 8. In order to connect the battery, connect the coolant for reuse in engine cooling systems. The full positive connection before the negative connector. distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant. i02242512 Cooling System Coolant (ELC) For information regarding the disposal and the recycling of used coolant, consult your Caterpillar - Change dealer or consult Dealer Service Tools: SMCS Code: 1350-070; 1395-044 Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Clean the cooling system and flush the cooling Canada: 1-800-523-TOOL system before the recommended maintenance interval if the following conditions exist: Flush • The engine overheats frequently. 1. Flush the cooling system with clean water in order • Foaming is observed. to remove any debris. 2. Close the drain valve (if equipped). Clean the • The oil has entered the cooling system and the drain plugs. Install the drain plugs. Refer to Torque coolant is contaminated. Specifications, SENR3130 for more information • The fuel has entered the cooling system and the on the correct torques. • coolant is contaminated. NOTICE Note: When the cooling system is cleaned, only Do not fill the cooling system faster than 5 L clean water is needed when the ELC is drained and (1.3 US gal) per minute to avoid air locks. replaced. Cooling system air locks may result in engine damage. Note: Inspect the water pump and the water temperature regulator after the cooling system has 3. Fill the cooling system with clean water. Install the been drained. This is a good opportunity to replace cooling system filler cap. the water pump, the water temperature regulator and the hoses, if necessary. 4. Start and run the engine at low idle until the temperature reaches 49 to 66 °C (120 to 150 °F). Drain 5. Stop the engine and allow the engine to cool. i Loosen the cooling system filler cap slowly • in order to relieve any pressure. Remove the Pressurized System: Hot coolant can cause seri- cooling system filler cap. Open the drain valve (if ous burns. To open the cooling system filler cap, equipped) or remove the cooling system drain stop the engine and wait until the cooling system plugs. Allow the water to drain. Flush the cooling components are cool. Loosen the cooling system system with clean water. Close the drain valve (if pressure cap slowly in order to relieve the pres- equipped). Clean the drain plugs. Install the drain sure. plugs. Refer to Torque Specifications, SENR3130 for more information on the correct torques. 1. Stop the engine and allow the engine to cool. Fill Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling NOTICE • system filler cap. Do not fill the cooling system faster than 5 L 2. Open the cooling system drain valve(if equipped). (1.3 US gal) per minute to avoid air locks. If the cooling system is not equipped with a drain valve, remove the cooling system drain plugs. Cooling system air locks may result in engine damage. 76 SEBU8139-01 Maintenance Section Cooling System Coolant Extender(ELC) -Add 1. Fill the cooling system with Extended Life Coolant • (ELC). Refer to this Operation and Maintenance Manual, "Refill Capacities and Recommendations" personal injury can result from hot coolant,steam topic(Maintenance Section) for more information and alkali. on cooling system specifications. Do not install the cooling system filler cap. At operating temperature, engine coolant is hot 2. Start and run the engine at low idle. Increase the and under pressure. The radiator and all lines engine rpm to high idle. Run the engine at high to heaters or the engine contain hot coolant or idle for one minute in order to purge the air from steam. Any contact can cause severe burns. the cavities of the engine block. Stop the engine. Remove cooling system pressure cap slowly to 3. Check the coolant level. Maintain the coolant level relieve pressure only when engine is stopped and within 13 mm (0.5 inch) below the bottom of the cooling system pressure cap is cool enough to pipe for filling. Maintain the coolant level within touch with your bare hand. 13 mm (0.5 inch) to the proper level on the sight Do not attempt to tighten hose connections when glass (if equipped). the coolant is hot,the hose can come off causing 4. Clean the cooling system filler cap. Inspect the burns. gasket that is on the cooling system filler cap. If Cooling System Coolant Additive contains alkali. the gasket that is on the cooling system filler cap Avoid contact with skin and eyes. is damaged, discard the old cooling system filler cap and install a new cooling system filler cap. If the gasket that is on the cooling system filler cap is NOTICE not damaged, use a 9S-8140 Pressurizing Pump Care must be taken to ensure that fluids are contained in order to pressure test the cooling system filler during performance of inspection, maintenance, test- cap. The correct pressure for the cooling system ing,adjusting and repair ofthe product. Be prepared to filler cap is stamped on the face of the cooling collect the fluid with suitable containers before open- • system filler cap. If the cooling system filler cap ing any compartment or disassembling any compo- does not retain the correct pressure, install a new nent containing fluids. cooling system filler cap. Refer to Special Publication, NENG2500, "Caterpillar 5. Start the engine. Inspect the cooling system for Dealer Service Tool Catalog" for tools and supplies leaks and for proper operating temperature. suitable to collect and contain fluids on Caterpillar products. i02482066 Dispose of all fluids according to local regulations and Cooling System Coolant mandates. Extender (ELC) - Add 1. Loosen the cooling system filler cap slowly in SMCS Code: 1352-045; 1395-081 order to relieve pressure. Remove the cooling system filler cap. Cat ELC (Extended Life Coolant) does not require the frequent additions of any supplemental cooling 2. It may be necessary to drain enough coolant from additives which are associated with the present the cooling system in order to add the Cat ELC conventional coolants. The Cat ELC Extender only Extender. needs to be added once. 3. Add Cat ELC Extender according to the NOTICE requirements for your engine's cooling system Use only Cat Extended Life Coolant (ELC) Extender capacity. Refer to the Operation and Maintenance with Cat ELC. Manual, "Refill Capacities and Recommendations" article for more information. Do NOT use conventional supplemental coolant addi- 4. Clean the cooling system filler cap. Inspect the tive(SCA)with Cat ELC. Mixing Cat ELC with conven- gaskets on the cooling system filler cap. Replace tional coolants and/or conventional SCA reduces the the cooling system filler cap if the gaskets are • Cat ELC service life. damaged. Install the cooling system filler cap. Check the cooling system only when the engine is stopped and cool. SEBU8139-01 77 Maintenance Section Cooling System Coolant Level - Check • i01197583 3. Clean the cooling system filler cap and check the COOIIn System Coolant Level condition of the filler cap gaskets. Replace the g y cooling system filler cap if the filler cap gaskets are - Check damaged. Reinstall the cooling system filler cap. SMCS Code: 1395-082 4. Inspect the cooling system for leaks. Check the coolant level when the engine is stopped o232ssas and cool. Cooling System Coolant Ae Sample (Level 1 ) - Obtain SMCS Code: 1350-008; 1395-008; 1395-554; 7542 Note: Obtaining a Coolant Sample (Level 1) is optional if the cooling system is filled with Cat ELC (Extended Life Coolant). Cooling systems that are filled with Cat ELC should have a Coolant Sample (Level 2)that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule. Note: Obtain a Coolant Sample (Level 1) if the cooling system is filled with any other coolant Illustration 74 g00285520 instead of Cat ELC. This includes the following Cooling system filler cap types of coolants. • Table 16 Recommended Interval Pressurized System: Hot coolant can cause seri- Type of Coolant Level 1 Level 2 ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system Cat DEAC EHours very 50 Yearly(1)(2) components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pres- Cat ELC Optionalm Yearly(z) sure. (1) This is the recommended interval for coolant samples for all conventional heavy-duty coolant/antifreeze. This is also the recommended interval for coolant samples of commercial 1. Remove the cooling system filler cap slowly in coolants that meet the Cat EC-1 specification for engine order to relieve pressure. coolant. (2) The Level 2 Coolant Analysis should be performed sooner if a 2. Maintain the coolant level within 13 mm (0.5 inch) problem is suspected or identified. of the bottom of the filler pipe. If the engine is equipped with a sight glass, maintain the coolant • Commercial long life coolants that meet the level to the proper level in the sight glass. Caterpillar Engine Coolant Specification -1 (Caterpillar EC-1) • Cat DEAC (Diesel Engine Antifreeze/Coolant) • Commercial heavy-duty coolant/antifreeze NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may 1 contaminate the samples that are being drawn. This • ` 1 ` contaminate may cause a false analysis and an incor- rect interpretation that could lead to concerns by both dealers and customers. Illustration 75 900103639 Note: Level 1 results may indicate a need for Typical filler cap gaskets Level 2 Analysis. 78 SEBU8139-01 Maintenance Section Cooling System Coolant Sample (Level 2) - Obtain Obtain the sample of the coolant as close as possible Submit the sample for Level 2 analysis. to the recommended sampling interval. In order to receive the full effect of SOS analysis, you For additional information about coolant must establish a consistent trend of data. In order analysis, see Special Publication, SEBU6251, to establish a pertinent history of data, perform "Caterpillar Commercial Diesel Engines Fluids consistent samplings that are evenly spaced. Recommendations" or consult your Caterpillar dealer. Supplies for collecting samples can be obtained from your Caterpillar dealer. 100912898 Use the following guidelines for proper sampling of Cooling System Water the coolant: Temperature Regulator - • Complete the information on the label for the Replace sampling bottle before you begin to take the samples. SMCS Code: 1355-510 • Keep the unused sampling bottles stored in plastic Replace the water temperature regulator before bags. the water temperature regulator fails. This is a • Obtain coolant samples directly from the coolant recommended preventive maintenance practice. sample port. You should not obtain the samples Replacing the water temperature regulator reduces from any other location, the chances for unscheduled downtime. • Keep the lids on empty sampling bottles until you A water temperature regulator that fails in a are ready to collect the sample. partially opened position can cause overheating or overcooling of the engine. • Place the sample in the mailing tube immediately A water temperature regulator that fails in the closed after obtaining the sample in order to avoid position can cause excessive overheating. Excessive O contamination. overheating could result in cracking of the cylinder • Never collect samples from expansion bottles. head or piston seizure problems. • Never collect samples from the drain for a system. A water temperature regulator that fails in the open position will cause the engine operating temperature Submit the sample for Level 1 analysis. to be too low during partial load operation. Low engine operating temperatures during partial loads For additional information about coolant analysis, could cause an excessive carbon buildup inside the see Special Publication, SEBU6251, "Caterpillar cylinders. This excessive carbon buildup could result Commercial Diesel Engine Fluids Recommendations" in an accelerated wear of the piston rings and wear or consult your Caterpillar dealer. of the cylinder liner. NOTICE 01987714 Failure to replace your water temperature regulator Cooling System Coolant on a regularly scheduled basis could cause severe Sample (Level 2) - Obtain engine damage. Caterpillar engines incorporate a shunt design cooling SMCS Code: 1350-008; 1395-008, 1395-554; 7542 system and require operating the engine with a water temperature regulator installed. NOTICE If the water temperature regulator is installed incor- Always use a designated pump for oil sampling, and rectly,the engine may overheat, causing cylinder head use a separate designated pump for coolant sampling. Using the same pump for both types of samples may damage. Ensure that the new water temperature reg- contaminate the samples that are being drawn. This ulator is installed in the original position. Ensure that contaminate may cause a false analysis and an incor- the water temperature regulator vent hole is open. rect interpretation that could lead to concerns by both • dealers and customers. Do not use liquid gasket material on the gasket or cylinder head surface. Refer to Operation and Maintenance Manual, "Cooling System Coolant Sample (Level 1) - Obtain" for the guidelines for proper sampling of the coolant. SEBU8139-01 79 Maintenance Section Electrical Connections - Check • Refer to the Service Manual for the replacement i02345750 procedure of the water temperature regulator, or Engine - Clean consult your Caterpillar dealer. Note: If only the water temperature regulators are SMCS Code: 1000-070 replaced, drain the coolant from the cooling system to a level that is below the water temperature regulator housing. Personal injury or death can result from high volt- i02398768 age. Electrical Connections - Check Moisture can create paths of electrical conductiv- ity. SMCS Code: 4459-535 Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls"DO 1 NOT OPERATE". DANGER: Shock/Electrocution Hazard-Do not op- erate this equipment or work on this equipment NOTICE unless you have read and understand the instruc- Accumulated grease and oil on an engine is a fire haz- tions and warnings in the Operation and Mainte- ard. Keep the engine clean. Remove debris and fluid nance Manual.Failure to follow the instructions or spills whenever a significant quantity accumulates on heed the warnings will result in serious injury or the engine. death. Checking the electrical connections is an important Periodic cleaning of the engine is recommended. • Steam cleaning the engine will remove accumulated part of the maintenance for the generator set. oil and grease. A clean engine provides the following Improper connections may cause the generator set benefits: to malfunction. Check all exposed electrical connections for • Easy detection of fluid leaks tightness. . Maximum heat transfer characteristics Check the following devices for loose mounting or • Ease of maintenance for physical damage: • Transformers Note: Caution must be used in order to prevent electrical components from being damaged by excessive water when the engine is cleaned. • Fuses Pressure washers and steam cleaners should not be directed at any electrical connectors or the junction of • Capacitors cables into the rear of the connectors. Avoid electrical components such as the alternator, the starter, and • Lightning arresters the ECM. Protect the fuel injection pump from fluids Check the connections for the following components: in order to wash the engine. • Load cables i02242500 • Cables for the generator Engine Air Cleaner Element • Potential transformers (Single Element) - Replace • Current transformers SMCS Code: 1051; 1054-510 • Check all lead wires and electrical connections for NOTICE proper clearance. Inspect all cables for chafing, Never service the air cleaner element with the engine abrasion and corrosion. running since this will allow dirt to enter the engine. 80 SEBU8139-01 Maintenance Section Engine Air Cleaner Service Indicator- Inspect • 1 2 ono 0 0 0 0 0 0 O O O O O O O O 25 O O O O 20 a 000 O O 15 00o i 0000 Illustration 76 g00109823 Illustration 77 g00103777 (1)Air cleaner element. (2)Clamp. Typical service indicator 1. Loosen clamp (2) which fastens air cleaner Observe the service indicator. The air cleaner element (1) to the air inlet. Remove the dirty air element should be cleaned or the air cleaner element cleaner element and clamp. should be replaced when one of the following conditions occur: 2. Install clamp (2) on new air cleaner element (1). • The yellow diaphragm enters the red zone. 3. Install new air cleaner element (1) to the air inlet and tighten clamp (2). Refer to Torque • The red piston locks in the visible position. Specifications, SENR3130 for the correct torque. Test the Service Indicator • i02335405 Service indicators are important instruments. Engine Air Cleaner Service Indicator - Inspect • Check for ease of resetting. The service indicator should reset in less than three pushes. SMCS Code: 7452-040 . Check the movement of the yellow core when Some engines may be equipped with a different the engine is accelerated to the engine rated service indicator. speed. The yellow core should latch at the greatest vacuum that is attained. Some engines are equipped with a differential gauge If the service indicator does not reset easily, or if the for inlet air pressure. The differential gauge for inlet yellow core does not latch at the greatest vacuum, air pressure displays the difference in the pressure the service indicator should be replaced. If the new that is measured before the air cleaner element and service indicator will not reset, the hole for the service the pressure that is measured after the air cleaner indicator may be restricted. element. As the air cleaner element becomes dirty, the pressure differential rises. If your engine is The service indicator may need to be replaced equipped with a different type of service indicator, frequently in environments that are severely dusty. follow the OEM recommendations in order to service the air cleaner service indicator. The service indicator may be mounted on the air cleaner element or in a remote location. is SEBU8139-01 81 Maintenance Section Engine Crankcase Breather Element - Replace • i02326553 Engine Crankcase Breather Element - Replace SMCS Code: 1317-510-FQ 3 I m 0 � IL 0 — —� L _ o Illustration 78 g01156334 The breather assembly (1)The 0-ring for the top cover (3)The 0-ring for the filter element (5)The breather body (2)The top cover (4)The filter element (6)The side cover 1. Remove all dirt and oil from the outside of the NOTICE breather assembly. Remove the top cover(2) by Ensure that the components of the breather assembly turning the top cover counterclockwise until the are installed in the correct position. If installed incor- lugs disengage. The breather element includes rectly, engine damage can result. an O ring (3). Remove the breather element (4) by turning and lifting the element. Discard the element. Clean the inner surfaces of the breather Note: There are several vent holes under the top body (5). Clean the top cover and inspect the O cover(2) and under the side cover(6). Keep the area ring (1) in the top cover. If the O ring in the top • around the vent holes clean. Do not restrict the vent cover is worn or damaged, replace the O ring. holes. 82 SEBU8139-01 Maintenance Section Engine Mounts - Inspect 2. Lubricate the O ring (3) in the new filter element Note: Ensure that the engine is either level or that • (4) with clean engine lubricating oil. Carefully the engine is in the normal operating position in order insert the element into the breather body (5). to obtain a true level indication. Lubricate the O ring (1) in the top cover with clean engine lubricating oil. Carefully insert the top cover Note: After the engine has been switched OFF, wait (2) into the breather body (5). Rotate the top cover for ten minutes in order to allow the engine oil to drain clockwise until the lugs are fully engaged. to the oil pan before checking the oil level. 1. Maintain the oil level between the "ADD" mark (Y) 02456872 and the"FULL" mark(X) on the engine oil dipstick. Engine Mounts - Inspect Do not fill the crankcase above the "FULL" mark (X). SMCS Code: 1152-040 NOTICE Inspect the engine mounts for deterioration and for Operating your engine when the oil level is above the proper bolt torque. Engine vibration can be caused "FULL" mark could cause your crankshaft to dip into by the following conditions: the oil. The air bubbles created from the crankshaft dipping into the oil reduces the oil's lubricating char- • Improper mounting of the engine acteristics and could result in the loss of power. • Deterioration of the engine mounts 2. Remove the oil filler cap and add oil, if necessary. Any engine mount that shows deterioration should be Clean the oil filler cap. Install the oil filler cap. replaced. Refer to Special Publication, SENR3130, "Torque Specifications" for the recommended 101935337 torques. Refer to the OEM recommendations for more information. Engine Oil Sample - Obtain SMCS Code: 1000-008, 1348-554-SM, • 02335785 7542-554-OC, SM Engine Oil Level - Check In addition to a good preventive maintenance SMCS Code: 1348-535-FLV program, Caterpillar recommends using SOS oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine. S O S oil analysis provides infrared analysis, which is required Hot oil and hot components can cause personal for determining nitration and oxidation levels. injury. Do not allow hot oil or hot components to contact the skin. Obtain the Sample and the Analysis Hot oil and hot components can cause personal Y X injury. Do not allow hot oil or hot components to contact the skin. r Before you take the oil sample, complete the Label, PEEP5031 for identification of the sample. In order to help obtain the most accurate analysis, provide the following information: • Engine model Illustration 79 g01165836 • • Service hours on the engine (Y) "Min"mark. (X)"Max"mark. • The number of hours that have accumulated since NOTICE the last oil change Perform this maintenance with the engine stopped. SEBU8139-01 83 Maintenance Section Engine Oil and Filter - Change • The amount of oil that has been added since the last oil change NOTICE Care must be taken to ensure that fluids are contained To ensure that the sample is representative of the during performance of inspection, maintenance, test- oil in the crankcase, obtain a warm, well mixed oil ing,adjusting and repair of the product. Be prepared to sample. collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- To avoid contamination of the oil samples, the tools nent containing fluids. and the supplies that are used for obtaining oil samples must be clean. Dispose of all fluids according to local regulations and mandates. Caterpillar recommends using the sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when the NOTICE sampling valve is used. The location of the sampling Keep all parts clean from contaminants. valve allows oil that is flowing under pressure to be obtained during normal engine operation. Contaminants may cause rapid wear and shortened component life. The 169-8373 Fluid Sampling Bottle is recommended for use with the sampling valve. The Do not drain the engine lubricating oil when the fluid sampling bottle includes the parts that are engine is cold. As the engine lubricating oil cools, needed for obtaining oil samples. Instructions are suspended waste particles settle on the bottom of also provided. the oil pan. The waste particles are not removed with draining cold oil. Drain the oil pan with the engine NOTICE stopped. Drain the oil pan with the oil warm. This Always use a designated pump for oil sampling, and draining method allows the waste particles that are use a separate designated pump for coolant sampling. suspended in the oil to be drained properly. • Using the same pump for both types of samples may contaminate the samples that are being drawn. This Failure to follow this recommended procedure will contaminate may cause a false analysis and an incor- cause the waste particles to be recirculated through rect interpretation that could lead to concerns by both the engine lubrication system with the new oil. dealers and customers. Drain the Engine Lubricating Oil If the engine is not equipped with a sampling valve, use the 1 U-5718 Vacuum Pump. The pump is Note: Ensure that the vessel that will be used is large designed to accept sampling bottles. Disposable enough to collect the waste oil. tubing must be attached to the pump for insertion into the sump. After the engine has been run at the normal operating temperature, stop the engine. Use one of the For instructions, see Special Publication, PEHP6001, following methods to drain the engine oil pan: "How To Take A Good Oil Sample". Consult your Caterpillar dealer for complete information and assistance in establishing an S•O-S program for your engine. i02325836 Engine Oil and Filter - Change SMCS Code: 1318-510; 1348-044 • Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. 84 SEBU8139-01 Maintenance Section Engine Oil and Filter- Change • o \ t ° 0 0 ° 00®11 0 �`1 Y v Illustration 81 g00588944 Element with debris 1 2. Cut the oil filter open with a 175-7546 Oil Filter Cutter . Break apart the pleats and inspect the oil filter for metal debris. An excessive amount Illustration 80 g01157128 of metal debris in the oil filter may indicate early Typical example wear or a pending failure. • If the engine is equipped with a drain valve, turn the Use a magnet to differentiate between the ferrous drain valve knob counterclockwise in order to drain metals and the nonferrous metals that are found in the oil. After the oil has drained, turn the drain valve the oil filter element. Ferrous metals may indicate knob clockwise in order to close the drain valve. wear on the steel and cast iron parts of the engine. • If the engine is not equipped with a drain valve, Nonferrous metals may indicate wear on the remove the oil drain plug (1) in order to allow the oil aluminum parts, brass parts or bronze parts of to drain. If the engine is equipped with a shallow oil the engine. Parts that may be affected include pan, remove the bottom oil drain plugs from both the following items: main bearings, rod bearings, ends of the oil pan. turbocharger bearings, and cylinder heads. After the oil has drained, the oil drain plugs should be Due to normal wear and friction, it is not cleaned and installed. If necessary, replace the O uncommon to find small amounts of debris in the ring seal. Tighten the drain plug to 34 N-m (25 lb ft). oil filter. Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter. Replace the Oil Filter NOTICE Caterpillar oil filters are manufactured to Caterpillar specifications. Use of an oil filter that is not recom- mended by Caterpillar could result in severe damage to the engine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubricating system. Only use oil filters rec- ommended by Caterpillar. 1. Remove the oil filter with a 1 U-8760 Chain Wrench. Note: Some oil filters may be installed horizontally. • This type of oil filter can be drained before the filter is removed. The torque for this drain plug is 12 N-m (8 lb ft). Note: The following actions can be carried out as part of the preventive maintenance program. SEBU8139-01 85 Maintenance Section Engine Oil and Filter - Change • NOTICE 2 Do not fill the oil filters with oil before installing them. This oil would not be filtered and could be contaminat- ed. Contaminated oil can cause accelerated wear to O J engine components. 3 5. Install the oil filter. Tighten the oil filter to 12 N-m (8.8 lb ft). Do not overtighten the oil filter. O o Note: Some oil filters may be installed horizontally. Refer to illustration 83. This type of oil filter assembly can be drained before the oil is removed. The torque for the drain plug (4) is 12 N-m (8 lb ft). If necessary, o ( install a new O ring seal (5). Start at 1 in order to remove the oil filter and install the oil filter. Fill the Oil Pan 1. Remove the oil filler cap. Refer to this Illustration 82 g01157129 Operation and Maintenance Manual, "Fluid Typical example Recommendations" for more information on suitable oils. Fill the oil pan with the correct 3. Clean the sealing surface of the oil filter head (2). amount of new engine lubricating oil. Refer Ensure that the union is secure in the filter head. to this Operation and Maintenance Manual, "Refill Capacities" for more information on refill • 4. Apply clean engine oil to the O ring seal (3) for capacities. the new oil filter. NOTICE Note: Some oil filters may be installed horizontally. If equipped with an auxilliary oil filter system or a re- Refer to the illustration . This type of oil filter assembly mote filter system, follow the OEM or the filter manu- can be drained before the filter is removed. The facture's remonmendations. Under filling or overfilling torque for this drain plug (4) is 12 N-m (8 lb ft). If the crankcase with oil can cause engine damage. necessary, install a new O ring seal(5). Start at step 1 in order to remove the oil filter and install the oil filter. 2. Start the engine and run the engine at "LOW IDLE" for two minutes. Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled. Inspect the oil filter for oil leaks. 3. Stop the engine and allow the oil to drain back to the oil pan for a minimum of ten minutes. Y X 5 0 4 Illustration 83 g01169166 Typical example Illustration 84 g01165836 Typical example 86 SEBU8139-01 Maintenance Section Engine Valve Lash - Inspect/Adjust 4. Remove the engine oil level gauge in order to 102326068 • check the oil level. Maintain the oil level between Fuel System - Prime the "MIN" and "MAX" marks on the engine oil level y gauge. SMCS Code: 1258-548 02519453 WARNING Engine Valve Lash - Contact with high pressure fuel may cause fluid Inspect/Adjust penetration and burn hazards. High pressure fu- el spray may cause a fire hazard. Failure to fol- SMCS Code: 1102-025 low these inspection, maintenance and service in- This maintenance is recommended by Caterpillar tructions may cause personal injury or death. as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine Refer to the Operation and Maintenance Manual life. "General Hazard Information and High Pressure Fuel Lines" before adjustments and repairs are performed. NOTICE Note: Refer to Testing and Adjusting Manual Only qualified service personnel should perform this "Cleanliness of Fuel System Components" maintenance. Refer to the Service Manual or your for detailed information on the standards of Caterpillar dealer for the complete valve lash adjust- cleanliness that must be observed during ALL ment procedure. work on the fuel system. Operation of Caterpillar engines with improper valve Ensure that all adjustments and repairs are performed adjustments can reduce engine efficiency. This re- by authorized personnel that have had the correct duced efficiency could result in excessive fuel usage training. and/or shortened engine component life. • NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two Ensure that the engine can not be started while minutes before cranking the engine again. this maintenance is being performed. To help pre- vent possible injury, do not use the starting motor If air enters the fuel system, the air must be purged to turn the flywheel. from the fuel system before the engine can be Hot engine components can cause burns. Allow started. Air can enter the fuel system when the additional time for the engine to cool before mea- following events occur: suring/adjusting valve lash clearance. • The fuel tank is empty or the fuel tank has been partially drained. Ensure that the engine is stopped before measuring the valve lash. To obtain an accurate measurement, • The low pressure fuel lines are disconnected. allow the valves to cool before this maintenance is performed. • A leak exists in the low pressure fuel system. Refer to the Service Manual for more information. • The fuel filter has been replaced. Hand Fuel Priming Pump Use the following procedures in order to remove air from the fuel system: 1. Ensure that the fuel system is in working order. Check that the fuel supply valve (if equipped) is in • the "ON" position. SEBU8139-01 87 Maintenance Section Fuel System - Prime 1, Electric Fuel Priming Pump 1. Ensure that the fuel system is in working order. Check that the fuel supply valve (if equipped) is in the "ON" position. 1 NOTICE The electric fuel priming pump will operate for 90 sec- onds. If necessary the electric fuel priming pump can be stopped during the 90 seconds of operation, by op- eration of the switch. 2. Turn the keyswitch to the"RUN" position. Operate the switch for the electric priming pump. After 90 seconds of the electric fuel priming pump operation the fuel system will be primed and the electric fuel priming pump will turn off. 3. The engine should now be able to start. Illustration 85 so,154164 4. Operate the engine starter and crank the engine. After the engine has started, operate the engine at typical example low idle for a minimum of five minutes, immediately 2. Operate the fuel priming pump (1). Count the after air has been removed from the fuel system. number of operations of the fuel priming pump. Note: Operating the engine for this period of time will After 100 depressions of the fuel priming pump help ensure that the fuel system is free of air. • stop. 3. The engine fuel system should now be primed and Note: Do not loosen the high pressure fuel line the engine should now be able to start. in order to purge air from the fuel system. This procedure is not required. 4. Operate the engine starter and crank the engine. After the engine has stopped, you must wait for After the engine has started, operate the engine at 60 seconds in order to allow the fuel pressure to low idle for a minimum of five minutes, immediately be purged from the high pressure fuel lines before after air has been removed from the fuel system. any service or repair is performed on the engine Note: Operating the engine for this period of time will fuel lines. If necessary, perform minor adjustments. help ensure that the fuel system is free of air. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Note: Do not loosen the high pressure fuel line Replace any high pressure fuel line that has leaked. in order to purge air from the fuel system. This Refer to Disassembly and assembly Manual, "Fuel procedure is not required. Injection Lines - Install'. After the engine has stopped, you must wait for If you inspect the engine in operation, always use 60 seconds in order to allow the fuel pressure to the proper inspection procedure in order to avoid be purged from the high pressure fuel lines before a fluid penetration hazard. Refer to Operation and any service or repair is performed on the engine Maintenance Manual, "General hazard Information". fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, "Fuel Injection Lines - Install'. • If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, "General hazard Information". 88 SEBU8139-01 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace ro2s27046 • Fuel System Primary Filter (Water Separator) Element - Replace SMCS Code: 1260-510-FQ; 1263-510-FQ Fuel leaked or spilled onto hot surfaces or elec- 4 trical components can cause a fire. To help pre- vent possible injury,turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. Note: Refer to Testing and Adjusting Manual , "Cleanliness of Fuel System Components" 3 2 1 for detailed information on the standards of cleanliness that must be observed during ALL Illustration 86 g01153445 work on the fuel system. Typical example NOTICE 3. Install a suitable tube onto the drain (1). Open the Ensure that the engine is stopped before any servicing drain (1). Allow the fluid to drain into the container. or repair is performed. Remove the tube. 4. Tighten the drain (1) by hand pressure only. • After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to 5. If equipped, remove the wiring harness from the be purged from the high pressure fuel lines before sensor on the bottom of the glass bowl. any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. 6. Hold the glass bowl (3) and remove the screw (2). Repair any leaks from the low pressure fuel system Remove the glass bowl (3) from the canister (4). and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. 7. Use a 1 U-8760 Chain Wrench in order to remove Refer to Disassembly and assembly Manual, "Fuel the canister (4). Discard the old seals (5 and 6) Injection Lines - Install". and the canister in a safe place. 1. Turn the fuel supply valve (if equipped) to the OFF 8. Clean the glass bowl (3). position before performing this maintenance. 2. Place a suitable container under the water separator in order to catch any fuel that might spill. Clean up any spilled fuel. Clean the outside of the water separator. • SEBU8139-01 89 Maintenance Section Fuel System Primary Filter/Water Separator- Drain eY• i02334301 Fuel System Primary O Filter/Water Separator - Drain SMCS Code: 1260-543; 1263-543 G Fuel leaked or spilled onto hot surfaces or elec- trical components can cause a fire. To help pre- vent possible injury,turn the start switch off when changing fuel filters or water separator elements. 6 Clean up fuel spills immediately. 4 NOTICE Ensure that the engine is stopped before any servicing 5 2 or repair is performed. Illustration 87 g01153488 NOTICE Typical example The water separator can be under suction during nor- mal engine operation. Ensure that the drain valve is 9. Do not lubricate the O ring seal on the new tightened securely to help prevent air from entering canister. Install the new canister. Do not use a tool the fuel system. in order to install the canister. Tighten the canister • by hand. 1. Place a suitable container under the water 10.Install the new O ring seal (5) onto the setscrew separator in order to catch any fuel that might (2). Install the new O ring seal (6) into the glass spill. Clean up any spilled fuel. bowl. u 11.Align the glass bowl to the canister. Ensure that the sensor(if equipped) is in the correct position. Install the setscrew(2). Tighten the setscrew to a torque of 5 N-m (44 lb in). 12.If equipped, install the wiring harness to the sensor. 13.Remove the container and dispose of the fuel in a safe place. 1 14.The secondary filter must be replaced at the same �\ time as the primary filter. Refer to the Operation and Maintenance Manual , "Fuel System Filter- Replace". 8 Q O Illustration 88 g01153817 Typical example • 2. Install a suitable tube onto the drain (1). Open the drain (1). Allow the fluid to drain into the container. 3. Tighten the drain (1) by hand pressure only. Remove the tube and dispose of the drained fluid in a safe place. 90 SEBU8139-01 Maintenance Section Fuel System Secondary Filter- Replace i02527047 • Fuel System Secondary Filter - - Replace SMCS Code: 1261-510-SEqllfl� o 0 00 (D mmli � i Fuel leaked or spilled onto hot surfaces or elec- trical components can cause a fire. To help pre- vent possible injury,turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. e Note: Refer to Testing and Adjusting Manual ° , "Cleanliness of Fuel System Components" 1 for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. Illustration 89 g01153855 NOTICE Typical example Ensure that the engine is stopped before any servicing or repair is performed. 2. Clean the outside of the fuel filter. Use 1 U-8760 Chain Wrench in order to remove the canister(1) from the engine and dispose of the canister in a After the engine has stopped, you must wait for safe place. • 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before 3. Do not lubricate the O ring seal. Do not fill the new any service or repair is performed on the engine canister with fuel before the canister is installed. fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system 4. Install the new canister. Do not use a tool in order and from the cooling, lubrication or air systems. to install the canister. Tighten the canister by hand. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, "Fuel 5. Remove the container and dispose of the fluid in a Injection Lines - Install'. safe place. If equipped, open the fuel supply valve. NOTICE 6. Prime the fuel system. Refer to the Operation and Do not allow dirt to enter the fuel system. Thoroughly Maintenance Manual, "Fuel System - Prime" for clean the area around a fuel system component that more information. will be disconnected. Fit a suitable cover over discon- nected fuel system component. i02348492 1. Ensure that the fuel supply valve(if equipped) is in Fuel Tank Water and Sediment the OFF position. Place a suitable container under - Drain the fuel filter in order to catch any fuel that might spill. Clean up any spilled fuel. SMCS Code: 1273-543-M&S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before • opening any compartment or disassembling any com- ponent containing fluids. Dispose of all fluids according to local regulations and mandates. SEBU8139-01 91 Maintenance Section Generator - Dry • Fuel Tank If a bulk storage tank has been refilled or moved recently, allow adequate time for the sediment to Fuel quality is critical to the performance and to the settle before filling the engine fuel tank. Internal service life of the engine. Water in the fuel can cause baffles in the bulk storage tank will also help trap excessive wear to the fuel system. sediment. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel. Water can be introduced into the fuel tank when the When possible, water separators should be used. fuel tank is being filled. Condensation occurs during the heating and cooling i02290310 of fuel. The condensation occurs as the fuel passes Generator - Dry through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel SMCS Code: 4450-569 tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water NOTICE in the fuel. Do not operate the generator if the windings are wet. If the generator is operated when the windings are wet, Drain the Water and the Sediment damage can occur due to insulation breakdown. Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the When moisture is present or when moisture is fuel tanks. suspected in a generator, the generator must be dried before being energized. Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close If the drying procedure does not restore the insulation the drain valve. resistance to an acceptable value. the winding should be reconditioned. • Check the fuel daily. Allow five minutes after the fuel tank has been filled before draining water and Note: For additional information, refer to Special sediment from the fuel tank. Instruction, SEHS9124 . Fill the fuel tank after operating the engine in Drying Methods order to drive out moist air. This will help prevent condensation. Do not fill the tank to the top. The The following methods can be used for drying a fuel expands as the fuel gets warm. The tank may generator. overflow. • Self-circulating air method Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel • Oven method supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If NOTICE the engine is equipped with this system, regular Do not allow the winding temperature to exceed 85 C maintenance of the fuel system filter is important. (185.0 °F). Temperatures that are greater than 85 °C (185.0 °F) will damage the winding insulation. Fuel Storage Tanks Drain the water and the sediment from the fuel Self-Circulating Air Method storage tank at the following intervals: Run the engine and disconnect the generator load. • Weekly This will help circulate air. Operate the generator space heaters. • Service intervals Oven Method • Refill of the tank • Place the entire generator inside a forced air drying This will help prevent water or sediment from being oven for four hours at 65 C (149 °F). pumped from the storage tank into the engine fuel tank. 92 SEBU8139-01 Maintenance Section Generator - Inspect • Dirt that is saturated with moisture • NOTICE Use a forced air type oven rather than a radiant type These contaminants will develop a conductive path oven. which may produce shorts. Cleaning is advisable if heavy accumulations of dirt can be seen or if heavy Radiant type ovens can cause localized overheating. accumulations of dust can be seen. If excess dirt is the cause of a restriction in the ventilation, cleaning is also advisable. Restricted ventilation will cause i02283395 excessive heating. Generator - Inspect NOTICE To avoid the possibility of deterioration to the genera- SMCS Code: 4450-040 for windings, do not clean the generator unless there M ��=1111 1� !11111� is visual, electrical, or thermal evidence that dirt is present. Personal injury or death can result from improper If harmful dirt accumulations are present, a variety troubleshooting and repair procedures. of cleaning techniques are available. The cleaning The following troubleshooting and repair proce- procedure that is used may be determined by one of dures should only be performed by qualified per- the items on the following list: sonnel familiar with this equipment. • The extent of the cleaning procedure that is being attempted • The type of enclosure of the generator C, il� The high voltage that is produced by an operating generator set can cause severe injury or death. • The voltage rating of the generator Before performing any maintenance or repairs, . The type of dirt that is being removed ensure that the generator will not start. Place the engine control switch in the "OFF" posi- Cleaning (Assembled Generators) tion. Attach "DO NOT OPERATE" tags to all start- ing controls. Disconnect the batteries or disable NOTICE the starting system. Lock out all switchgear and Do not use water to clean the generator. automatic transfer switches that are associated with the generator. NOTICE Refer to Safety Section, "Generator Isolating for Do not use trichloroethane, perchlorethylene, Maintenance"for information regarding the procedure trichloroethane or any alkaline products to clean to safely isolate the generator. the generator. Proper maintenance of electrical equipment requires Cleaning may be required at the point of installation. periodic visual examination of the generator and At this point, complete disassembly of the generator periodic visual examination of the windings. Proper may not be necessary or feasible. In this case, maintenance of electrical equipment also requires a vacuum cleaner should be used to pick up the appropriate electrical checks and appropriate thermal following items: dry dirt, dust, and carbon. This will checks. Insulation material should be examined for prevent the spreading of these contaminants. cracks. The insulation material should be examined for accumulations of dirt and dust. If there is an A small nonconductive tube may need to be insulation resistance value that is below normal, a connected to the vacuum cleaner. This will allow the conductive path may be present. This conductive vacuum cleaner to clean the surfaces that are not path may be made of one of the following materials: exposed. After most of the dust has been removed, • Carbon a small brush may be attached to the vacuum hose • in order to loosen dirt that is more firmly attached to • Salt the surface. • Metal dust SEBU8139-01 93 Maintenance Section Generator Load - Check • After the initial cleaning with a vacuum, compressed 01e7e834 air may be used to remove the remaining dust and Generator Load - Check dirt. Compressed air that is used for cleaning should be free of moisture and free of oil. Air pressure should be a maximum of 210 kPa (30 psi) in order to SMCS Code: 4450-535-LA prevent mechanical damage to the insulation. If the above cleaning procedures are not effective, consult iWARNING a Caterpillar dealer. Personal injury or death can result from high volt- Cleaning (Disassembled age. Generators) When power generation equipment must be in op- eration to make tests and/or adjustments, high NOTICE voltage and current are present. Do not use water to clean the generator. Improper test equipment can fail and present a high voltage shock hazard to its user. NOTICE Do not use trichloroethane, perch lorethylene, Make sure the testing equipment is designed for trichloroethane or any alkaline products to clean and correctly operated for high voltage and cur- the generator. rent tests being made. An initial insulation resistance check should be During normal operation, monitor the power factor made on the generator in order to confirm electrical and monitor generator loading. integrity. A minimum reading of one megohm would be expected with severely contaminated generators. When a three-phase generator is installed or when A zero megohm reading may indicate an insulation a three-phase generator is reconnected, ensure that • breakdown. An insulation breakdown requires more the total current in any one phase does not exceed than cleaning. An insulation breakdown requires the nameplate rating. Each phase should carry the repair. same load. This allows the three-phase generator to work at the rated capacity. If one phase current Use the following for cleaning the stator, the rotor, the exceeds the nameplate amperage, an electrical exciter and the diode bridge: imbalance will occur. An electrical imbalance can result in an electrical overload and an electrical • Unleaded Gasoline imbalance can result in overheating on three-phase generators. This is not applicable to single-phase • Toluene generators. • Benzene The power factor can be referred to as the efficiency of the load. This can be expressed as the ratio of kVA • Ciclohexare to actual kW. The power factor can be calculated by dividing kW by kVA. Power factor is expressed as a Avoid permitting the solvent to run into the slots. decimal. Power factor is used to mean the portion Apply the solvent with a brush. Use a sponge on the of current that is supplied to a system that is doing windings frequently in order to remove the debris. useful work. The portion of the current that is not Dry the winding with a dry cloth. Allow the solvent to doing useful work is absorbed in maintaining the evaporate before reassembling the generator. magnetic field in motors. This current (reactive load) can be maintained without engine power. Allow the generator to dry at room temperature. Check the insulation resistance. The insulation resistance should now be normal. If the insulation resistance is not normal, repeat the procedure. Note: For more information on drying methods, refer • to Special Instructions, SEHS9124, "Cleaning and Drying of Electric Set Generators". 94 SEBU8139-01 Maintenance Section Generator Set - Test i01593517 • The phase voltages change relative to engine • Generator Set - Test speed. The generator set functional test consists of the SMCS Code: 4450-081 following steps: 1. Stop the generator. Connect the potential transformer's high voltage winding to the Personal injury or death can result from high volt- generator terminals (T1) and (T2). Connect age. the voltmeter to the low voltage winding. If two transformers are available, connect the high When power generation equipment must be in op- voltage winding of the second transformer to the eration to make tests and/or adjustments, high generator terminals (T1) and (T3). Connect the voltage and current are present. secondary terminals that correspond to generator terminal (T2) of both transformers together. Improper test equipment can fail and present a high voltage shock hazard to its user. 2. Disconnect wires °E+" and "E-" from the voltage regulator. Disconnect the generator from the load. Make sure the testing equipment is designed for and correctly operated for high voltage and cur- 3. Connect a 12 VDC automotive battery to wires rent tests being made. "E+" and °E2. When servicing or repairing electric power gener- 4. Measure the AC voltage across the low voltage ation equipment: terminals of the transformer that correspond to the following generator terminals. "71" and "72", "72" • Make sure the unit is off-line (disconnected and 73", and "73" and "71". Record the voltages. from utility and/or other generators power service), and either locked out or tagged DO 02349879 NOT OPERATE. Hoses and Clamps • Make sure the generator engine is stopped. - Inspect/Replace • Make sure all batteries are disconnected. SMCS Code: 7554-040, 7554-510 • Make sure all capacitors are discharged. Table 17 Tools Needed Contact with high pressure fuel may cause fluid -- penetration and burn hazards. High pressure fu- Part Number Part Quantity el spray may cause a fire hazard. Failure to fol- Digital low these inspection, maintenance and service in- 6V-7070 Multimeter 1 structions may cause personal injury or death. 12 VDC battery 1 If you inspect the engine in operation, always use Potential 1 the proper inspection procedure in order to avoid Transformer a fluid penetration hazard. Refer to Operation and Maintenance Manual. "General hazard Information". The generator set functional test is a simplified test that can be performed in order to determine if the Inspect all hoses for leaks that are caused by the generator is functional. The generator set functional following conditions: test should be performed on a generator set that is under load. • Cracking The generator set functional test determines if the • Softness following statements happen: • • Loose clamps • A phase voltage is being generated. Replace hoses that are cracked or soft. Tighten any • The phase voltages are balanced. loose clamps. SEBU8139-01 95 Maintenance Section Insulation - Test • Check for the following conditions: 2. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling • End fittings that are damaged or leaking system filler cap. • Outer covering that is chafed or cut Note: Drain the coolant into a suitable, clean container. The coolant can be reused. • Exposed wire that is used for reinforcement 3. Drain the coolant from the cooling system to a • Outer covering that is ballooning locally level that is below the hose that is being replaced. • Flexible part of the hose that is kinked or crushed 4. Remove the hose clamps. • Armoring that is embedded in the outer covering 5. Disconnect the old hose. A constant torque hose clamp can be used in place 6. Replace the old hose with a new hose. of any standard hose clamp. Ensure that the constant torque hose clamp is the same size as the standard 7. Install the hose clamps with a torque wrench. clamp. Note: For the correct coolant, see this Operation and Due to extreme temperature changes, the hose will Maintenance Manual, "Fluid Recommendations". harden. Hardening of the hoses will cause hose clamps to loosen. This can result in leaks. A constant 8. Refill the cooling system. Refer to the OEM torque hose clamp will help to prevent loose hose information for further information on refilling the clamps. cooling system. Each installation application can be different. The 9. Clean the cooling system filler cap. Inspect the differences depend on the following factors: cooling system filler cap's seals. Replace the cooling system filler cap if the seals are damaged. • Type of hose Install the cooling system filler cap. • Type of fitting material 10.Start the engine. Inspect the cooling system for leaks. • Anticipated expansion and contraction of the hose • Anticipated expansion and contraction of the 102290325 fittings Insulation - Test Replace the Hoses and the Clamps SMCS Code: 4453-081; 4454-081" 4457-081; 4470-081 Refer to the OEM information for further information on removing and replacing fuel hoses (if equipped). WARNING The coolant system and the hoses for the coolant The high voltage that is produced by an operating system are not usually supplied by Perkins. The generator set can cause severe injury or death. following text describes a typical method of replacing Before performing any maintenance or repairs, coolant hoses. Refer to the OEM information for ensure that the generator will not start. further information on the coolant system and the hoses for the coolant system. Place the engine control switch in the "OFF" posi- tion. Attach "DO NOT OPERATE" tags to all start- WARNING ing controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and Pressurized System: Hot coolant can cause seri- automatic transfer switches that are associated ous burns. To open the cooling system filler cap, with the generator. stop the engine and wait until the cooling system • components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pres- sure. 1. Stop the engine. Allow the engine to cool. 96 SEBU8139-01 Maintenance Section Insulation - Test Table 18 • The measured insulation resistance falls below the • TOOLS NEEDED specified amount. The cleanup procedure does not correct the discrepancy. Part Number Tool Quantity 142-5055 Insulation Tester 1 • The measured insulation resistance falls below the Megohmmeter specified amount. The drying procedure does not correct the discrepancy. i The specified insulation resistance is an approximate value. It can be possible to operate the generator with Personal injury or death can result from electro- less than the specified value. However, a generator cution. that has a low winding insulation resistance will be more likely to have a failure. The megohmmeter is applying a high voltage to the circuit. To avoid electrocution, do not touch the instru- Personal injury or death can result from improper ment leads without first discharging them. When troubleshooting and repair procedures. finished testing also discharge the generator windings. The following troubleshooting and repair proce- dures should only be performed by qualified per- The following materials will cause the winding sonnel familiar with this equipment. insulation to deteriorate: The insulation test gives accurate results only when • moisture (water) the generator windings are free of moisture and the • dust generator windings are at room temperature. • grease Each winding must have a minimum insulation resistance of one megohm. • other foreign matter within the generator Main Armature (Stator L4) This deterioration reduces the resistance of the insulation. This test will measure the resistance of 1. Remove the load from the generator by either of the winding insulation. the following: The insulation tester (megohmmeter) produces a • Open the line circuit breaker. high potential voltage between the test leads. During the test, a small current flows. The tester converts • Open the following load connections: T1, T2, this current to a resistance reading. T3, and TO. The insulation test is performed as part of periodic Prevent these wires from coming into contact maintenance in order to detect the deterioration of the with each other and prevent these wires from winding insulation. When there is a rapid decrease contacting ground. in the insulation resistance in a short amount of time, the generator needs to be cleaned. 2. Isolate the main armature (L4) from the voltage regulator by disconnecting the wires for voltage Note: For information on generator cleaning, refer to sensing. If generator lead (TO) is connected to the Special Instruction, SEHS9124. generator frame or ground, open the connection. When generators have not been used for a period 3. Connect one test lead of the insulation tester of time, moisture can accumulate. Therefore, the (megohmmeter) to the generator enclosure insulation test should be performed on generators (ground). that have been idle. If moisture is known to exist, the windings must be dried prior to testing. Refer to 4. Connect the other test lead of the insulation tester • Testing And Adjusting, "Generator- Dry". (megohmmeter) to generator lead (TO). The winding needs to be reconditioned or the winding 5. The insulation resistance must be one megohm needs to be replaced in the following cases: or more. SEBU8139-01 97 Maintenance Section Overhaul Considerations • Exciter Field (Stator 1-1) Oil Consumption as an Overhaul 1. Isolate exciter field (1-1) from the voltage regulator Indicator by disconnecting wires 5+ and 6-. Prevent these Oil consumption, fuel consumption, and maintenance wires from coming into contact with each other information can be used to estimate the total and prevent these wires from contacting ground. operating cost for your Caterpillar engine. Oil 2. Connect one test lead of the insulation tester consumption can also be used to estimate the (megohmmeter) to the generator enclosure required capacity of a makeup oil tank that is suitable (ground). for the maintenance intervals. 3. Connect one test lead of the insulation tester Oil consumption is in proportion to the percentage (megohmmeter) to exciter field lead (5+ or 6-). of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is 4. Measure the resistance of the exciter field winding consumed per hour also increases. insulation to ground. The insulation resistance The oil consumption rate (brake specific oil must be a minimum of 0.25 megohm (250000 consumption) is measured in grams per kW/h (lb per ohms). bhp). The brake specific oil consumption (BSOC) depends on the engine load. Consult your Caterpillar Exciter Armature (Rotor 1-2) dealer for assistance in determining the typical oil consumption rate for your engine. 1. Isolate exciter armature (1-2) from the rectifier circuit. Disconnect the three wires of the exciter When an engine's oil consumption has risen to three armature from the rectifier blocks. times the original oil consumption rate due to normal wear, an engine overhaul should be scheduled. 2. Connect one test lead of the insulation tester There may be a corresponding increase in blowby (megohmmeter) to the rotor shaft. and a slight increase in fuel consumption. • 3. Connect one test lead of the insulation tester Overhaul Options (megohmmeter) to any one exciter field lead. Before Failure Overhaul 4. The insulation resistance must be a minimum of 0.25 megohm (250000 ohms). A planned overhaul before failure may be the best value for the following reasons: Overhaul Considerations 102299454 • Costly unplanned downtime can be avoided. • Many original parts can be reused according to the SMCS Code: 7595-043 standards for reusable parts. Reduced hours of operation at full load will result in a • The engine's service life can be extended without lower average power demand. A decreased average the risk of a major catastrophe due to engine power demand should increase both the engine failure. service life and the overhaul interval. • The best cost/value relationship per hour of The need for an overhaul is generally indicated by extended life can be attained. increased fuel consumption and by reduced power. After Failure Overhaul The following factors are important when a decision is being made on the proper time for an engine Many options are available if a major engine failure overhaul: occurs. An overhaul should be performed if the engine block or the crankshaft can be repaired. • The need for preventive maintenance If the engine block is repairable and/or the crankshaft • The quality of the fuel that is being used is repairable, the overhaul cost should be less than the cost of a new engine with a similar exchange • The operating conditions core. • The results of the S O S analysis This lower cost can be attributed to these aspects: • Caterpillar dealer exchange components 98 SEBU8139-01 Maintenance Section Overhaul Considerations • Caterpillar Inc. remanufactured exchange Inspection and/or Replacement • components The following components may not last until the Overhaul Recommendation second overhaul. To minimize downtime, Caterpillar Inc. recommends • Piston rings a scheduled engine overhaul by your Caterpillar . Thrust bearings dealer before the engine fails. This will provide you with the best cost/value relationship. • Main bearings Note: Overhaul programs vary according to the . Connecting rod bearings engine application and according to the dealer that performs the overhaul. Consult your Caterpillar . Crankshaft seals dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life. • Engine mounts If an overhaul is performed without overhaul service • Hoses from your Caterpillar dealer, be aware of the following Caterpillar Inc. recommends the installation of new maintenance recommendations. parts at each overhaul period. Rebuild or Exchange Inspect these parts while the engine is disassembled for an overhaul. These components should be inspected according to the instructions that are found in various Caterpillar Inspect the crankshaft for any of the following reusability publications. The Special Publication, conditions: SEBF8029 lists the reusability publications that are needed for inspecting the engine parts. • Deflection If the parts comply with the established inspection • Damage to the journals specifications that are expressed in the reusable parts guideline, the parts should be reused. • Bearing material that has seized to the journals Parts that are not within the established inspection Check the journal taper and the profile of the specifications should be dealt with in one of the crankshaft journals. Check these components by following manners: interpreting the wear patterns on the following • Salvaging components: • Repairing • Rod bearing • Replacing • Main bearings Note: If the crankshaft is removed for any reason, Using out-of-spec parts can result in the following use the magnetic particle inspection process to check problems: for cracks in the crankshaft. • Unscheduled downtime Inspect the camshaft for damage to the journals and • Costly repairs to the lobes. Note: If the camshaft is removed for any reason, use • Damage to other engine parts the magnetic particle inspection process to check for cracks in the camshaft. • Reduced engine efficiency Inspect the following components for signs of wear or • Increased fuel consumption for signs of scuffing: • Reduced engine efficiency and increased fuel • Camshaft bearings consumption translates into higher operating costs. Therefore, Caterpillar Inc. recommends repairing . Valve lifters out-of-spec parts or replacing out-of-spec parts. SEBU8139-01 99 Maintenance Section Rotating Rectifier - Check • Testing A coolant analysis can be conducted in order to verify the condition of the water that is being used in the Test the following components during the overhaul. cooling system. A full water analysis can be obtained by consulting your local water utility company or • Fuel injection nozzles an agricultural agent. Private laboratories are also available for water analysis. • Fuel injection pump Caterpillar Inc. recommends an S-O•S Coolant Testing the fuel system during the overhaul will Analysis (Level 11). ensure that your engine operates at peak efficiency. Your Caterpillar dealer can provide these services S•O•S Coolant Analysis (Level II) and components in order to ensure that your fuel system is operating within the appropriate An S-O-S Coolant Analysis (Level 11) is a specifications. comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling Cleaning system.An S.O-S Coolant Analysis(Level 11)provides the following information: Caterpillar Inc. recommends the use of Hydrosolv Liquid Cleaners. Table 19 lists the Hydrosoly Liquid • Complete S-O-S Coolant Analysis (Level 1) Cleaners that are available from your Caterpillar dealer. • Visual inspection of properties Table 19 • Identification of metal corrosion HydrosolvLiquid Cleaners • Identification of contaminants Part Description Size Number • Identification of built up impurities (corrosion and • scale) 1U-8812 4 L (1 US gallon) S-O-S Coolant Analysis (Level 11) provides a report of the results of both the analysis and the maintenance Hydrosolv4165 recommendations. 11J-5490 19 L(5 US gallon) For more information about coolant analysis, see 8T-7570 208 L(55 US gallon) your Caterpillar dealer. 11J-8804 4 L (1 US gallon) i01880286 1U-5492 Hydrosolv100 19 L(5 US gallon) RotatingRectifier - Check 8T-5571 208 L(55 US gallon) SMCS Code: 4465-535 Obtain Coolant Analysis I WARNING The concentration of supplemental coolant additive The high voltage that is produced by an operating (SCA) should be checked regularly with test kits generator set can cause severe injury or death. or with S•O-S Coolant Analysis (Level 1). Further Before performing any maintenance or repairs, coolant analysis is recommended when the engine ensure that the generator will not start. is overhauled. Place the engine control switch in the"OFF" posi- For example, considerable deposits are found in the tion. Attach "DO NOT OPERATE" tags to all start- water jacket areas on the external cooling system, but ing controls. Disconnect the batteries or disable the concentrations of coolant additives were carefully the starting system. Lock out all switchgear and maintained. The coolant water probably contained automatic transfer switches that are associated • minerals that were deposited on the engine over time. with the generator. Check the exciter armature. Ensure that the rotating rectifier is tight. If a failure of a rectifier is suspected, refer to Maintenance Procedure, "Rotating Rectifier- Test". 100 SEBU8139-01 Maintenance Section Rotating Rectifier - Test i02290281 b. Place the black test lead on the negative "=' • Rotatin Rectifier - Test terminal (1). Place the red test lead on the g following rectifier terminals:AC terminal (2),AC terminal (3), and AC terminal (4). In all cases, SMCS Code: 4465-081 the meter should read "OU (overload). 3. To test the positive rectifier block, follow these steps: The high voltage that is produced by an operating generator set can cause severe injury or death. a. Place the red test lead on the positive Before performing any maintenance or repairs, rectifier terminal (1). Place the black test lead ensure that the generator will not start. on the following rectifier terminals: AC terminal (2), AC terminal (3), and AC terminal (4). In all Place the engine control switch in the"OFF" posi- cases, the meter should read "OL" (overload). tion. Attach "DO NOT OPERATE"tags to all start- ing controls. Disconnect the batteries or disable b. Place the black test lead on the positive the starting system. Lock out all switchgear and rectifier terminal (1). Place the red test lead on automatic transfer switches that are associated the following rectifier terminals: AC terminal with the generator. (2), AC terminal (3), and AC terminal (4). All readings on the meter should be between 0.4 and 1.0. t 2 3 Note: A shorted diode can cause damage to the exciter rotor. If a diode is shorted, check the exciter rotor. Refer to the Testing and Adjusting, "Winding - 4 Test" and Testing and Adjusting, "Insulation -Test". Perform these tests. i02348493 • Starting Motor - Inspect SMCS Code: 1451-040; 1453-040 Illustration 90 g00992269 Caterpillar recommends a scheduled inspection of (1)Positive DC terminal or Negative DC terminal the starting motor. If the starting motor fails, the (2)AC terminal engine may not start in an emergency situation. (3)AC terminal (4)AC terminal Check the starting motor for correct operation. Check the electrical connections and clean the electrical The following procedure tests all three diodes within connections. Refer to the Systems Operation, Testing a block. Check the positive rectifier block and the and Adjusting Manual, "Electric Starting System - negative rectifier block. If any meter reading does not Test" for more information on the checking procedure fall within the given ranges, replace the rectifier block. and for specifications or consult your Caterpillar 1. Set the digital multimeter on the diode range. dealer for assistance. Remove all leads from the rectifier block. i02326109 2. To test the negative rectifier block, follow these steps: Turbocharger - Inspect a. Place the red test lead on the negative "-" SMCS Code: 1052-040; 1052 terminal (1). Place the black test lead on the following rectifier terminals: AC terminal(2), AC A regular visual inspection of the turbocharger is terminal (3), and AC terminal (4). All readings recommended. Any fumes from the crankcase are on the meter should be between 0.4 and 1.0. filtered through the air inlet system. Therefore, • by-products from oil and from combustion can collect in the turbocharger compressor housing. Over time, this buildup can contribute to loss of engine power, increased black smoke and overall loss of engine efficiency. SEBU8139-01 101 Maintenance Section Walk-Around Inspection • If the turbocharger fails during engine operation, 2. Check for the presence of oil. If oil is leaking from damage to the turbocharger compressor wheel the back side of the compressor wheel, there is a and/or to the engine may occur. Damage to the possibility of a failed turbocharger oil seal. turbocharger compressor wheel can cause additional damage to the pistons, the valves, and the cylinder The presence of oil may be the result of extended head. engine operation at low idle. The presence of oil may also be the result of a restriction of the line NOTICE for the intake air(clogged air filters), which causes Turbocharger bearing failures can cause large quanti- the turbocharger to slobber. ties of oil to enter the air intake and exhaust systems. Loss of engine lubricant can result in serious engine 3. Inspect the bore of the housing of the turbine damage. outlet for corrosion. Minor leakage of oil into a turbocharger under extend- 4. Fasten the air intake pipe and the exhaust outlet ed low idle operation should not cause problems as pipe to the turbocharger housing. long as a turbocharger bearing failure has not oc- cured. 102323090 When a turbocharger bearing failure is accompanied Walk-Around Inspection by a significant engine performance loss (exhaust smoke or engine rpm up at no load), do not continue SMCS Code: 1000-040 engine operation until the turbocharger is renewed. Inspect the Engine for Leaks and A visual inspection of the turbocharger can minimize for Loose Connections unscheduled downtime. A visual inspection of the turbocharger can also reduce the chance for potential A walk-around inspection should only take a few • damage to other engine parts. minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided. Removal and Installation For maximum engine service life, make a thorough Note: The turbochargers that are supplied are inspection of the engine compartment before starting nonserviceable. the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections and For options regarding the removal, installation, and trash buildup. Make repairs, as needed: replacement, consult your Carerpillar dealer or your Carerpillar distributor. Refer to the Disassembly and • The guards must be in the correct place. Repair Assembly Manual, "Turbocharger- Remove and damaged guards or replace missing guards. Turbocharger- Install"for further information. • Wipe all caps and plugs before the engine is Inspecting serviced in order to reduce the chance of system contamination. NOTICE NOTICE The compressor housing for the turbocharger must For any type of leak(coolant, lube,or fuel)clean up the not be removed from the turbocharger for cleaning. fluid. If leaking is observed,find the source and correct the leak. If leaking is suspected, check the fluid levels The actuator linkage is connected to the compressor more often than recommended until the leak is found housing. If the actuator linkage is moved or disturbed or fixed, or until the suspicion of a leak is proved to be the engine may not comply with emmissions legisla- unwarranted. tion. 1. Remove the pipe from the turbocharger exhaust NOTICE outlet and remove the air intake pipe to the Accumulated grease and/or oil on an engine is a fire turbocharger. Visually inspect the piping for the hazard. Remove the accumulated grease and oil. Re- presence of oil. Clean the interior of the pipes fer to this Operation and Maintenance Manual, "En- in order to prevent dirt from entering during gine - Clean" for more information. reassembly. 102 SEBU8139-01 Maintenance Section Water Pump - Inspect • Ensure that the cooling system hoses are correctly After the engine has stopped, you must wait for • clamped and that the cooling system hoses are 60 seconds in order to allow the fuel pressure to tight. Check for leaks. Check the condition of all be purged from the high pressure fuel lines before pipes. any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. • Inspect the water pump for coolant leaks. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Note: The water pump seal is lubricated by the Replace any high pressure fuel line that has leaked. coolant in the cooling system. It is normal for a small Refer to Disassembly and assembly Manual, "Fuel amount of leakage to occur as the engine cools down Injection Lines - Install". and the parts contract. If you inspect the engine in operation, always use Excessive coolant leakage may indicate the need to the proper inspection procedure in order to avoid replace the water pump. Remove the water pump. a fluid penetration hazard. Refer to Operation and Refer to Disassembly and Assembly , "Water Pump - Maintenance Manual, "General hazard Information". Remove and Install'. For more information, consult your Perkins dealer or your Perkins distributor. Visually inspect the high pressure fuel lines for damage or signs of fuel leakage. Replace any • Inspect the lubrication system for leaks at the front damaged high pressure fuel lines or high pressure crankshaft seal, the rear crankshaft seal, the oil fuel lines that have leaked. pan, the oil filters and the rocker cover. Ensure that all clips on the high pressure fuel lines • Inspect the piping for the air intake system and the are in place and that the clips are not loose. elbows for cracks and for loose clamps. Ensure that hoses and tubes are not contacting other • Inspect the rest of the fuel system for leaks. Look hoses, tubes, wiring harnesses, etc. for loose fuel line clamps. • Ensure that the areas around the rotating parts are • Drain the water and the sediment from the fuel clear. tank on a daily basis in order to ensure that only • clean fuel enters the fuel system. • Inspect the alternator belts and any accessory drive belts for cracks, breaks or other damage. • Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed • Inspect the wiring harness for damage. wires. Check for any loose tie-wraps or missing tie-wraps. Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will • Inspect the ground strap for a good connection and carry more load than the belts that are not replaced. for good condition. The older belts are stretched. The additional load on the new belt could cause the belt to break. • Disconnect any battery chargers that are not protected against the current drain of the starting High Pressure Fuel Lines motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintenance free battery. Check the condition of the gauges. Replace any Contact with high pressure fuel may cause fluid gauges that are cracked. Replace any gauge that penetration and burn hazards. High pressure fu- can not be calibrated. el spray may cause a fire hazard. Failure to fol- low these inspection,maintenance and service in- structions may cause personal injury or death. �ozszsssz Water Pump - Inspect SMCS Code: 1361-040; 1361 A failed water pump might cause severe engine • overheating problems that could result in the following conditions: • Cracks in the cylinder head SEBU8139-01 103 Maintenance Section Water Pump - Inspect • A piston seizure • Other potential damage to the engine Visually inspect the water pump for leaks. If any leaking is observed, replace the water pump assembly. Refer to the Service Manual for the disassembly and assembly procedure. Note: Refer to the Service Manual or consult your Caterpillar dealer if any repair is needed or any replacement is needed. • • ■ 104 SEBU8139-01 Reference Information Section Engine Ratings Reference Information i00819749 • Section Engine Rating Definitions SMCS Code: 1000 Engine Ratings It is important to know the use of the engine so that the rating will match the operating profile. The proper rating selection is also important so that the i00727327 customer's perception of price and value is realized. Engine Rating Conditions In selecting a rating for a specific application, the most important consideration is the time that is spent SMCS Code: 1000 at full throttle. These rating definitions identify the percent of time at full throttle. The definitions also All engine ratings are in compliance with the following identify the corresponding times below rated rpm. standard ambient air conditions of"SAE J1349": Note: The examples of the applications are only • 99 kPa (29.3 inches of Hg) for reference. For an exact determination of the appropriate rating, follow the OEM specifications or • 30 percent relative humidity consult your Caterpillar dealer. • A temperature of 25 °C (77 OF) A Rating — This rating is used for heavy-duty applications that are operated at rated load and at Ratings relate to the standard conditions of rated rpm up to 100 percent. This rating is used for "ISO8665", of"ISO3046/1", of"DIN6271", and of engines that operate without interruption of load "BS5514". cycling. Typical applications include the following • The engine ratings are based on the following fuel examples: pipeline pumping and ventilation. specifications: B Rating —This rating is used when power and/or rpm are cyclic. The engine should be run at full load. • Low heat value (LHV) of the fuel of 42 780 kJ/kg The engine should not exceed 80 percent of the (18,390 Btu/Ib) at 29 °C (84 OF) duty cycle. Typical applications include the following examples: irrigation, operation where normal pump • Gravity (API) of 35 degrees at 15 °C (60 OF) demand is 85 percent of the engine rating, oil pumping/drilling, field mechanical pumping/drilling, • Specific gravity of.849 at 15 °C (60 OF) and stationary/plant air compressors. • Density of 850 kg/m' (7.085 Ib/US gal) C Rating —This rating is used when power and/or rpm are cyclic. The horsepower and the rpm of the The engine ratings are gross output ratings. engine can be utilized continuously for one hour. This is followed by one hour of operation at the A rating Gross Output Ratings —The total output capability or below the A rating. The engine should be run at of the engine that is equipped with standard full load. The engine should not exceed 50 percent accessories. of the duty cycle. Typical applications include the following examples: agricultural tractors, harvesters Standard accessories include the following and combines, off-highway trucks, fire pumps, blast components: hole drills, rock curshers, wood chippers with high • Oil pumps torque rise, and oil field hoisting. D Rating —This rating is used when rated power • Fuel pumps is required for periodic overloads. The maximum horsepower and the rpm of the engine can be utilized • Water pumps continuously for a maximum of 30 minutes. This is followed by one hour of operation at the C rating. The Subtract the power that is required to drive auxiliary engine should be run at full load. The engine should • components from the gross output. This will produce not exceed 10 percent of the duty cycle. Typical the net power that is available for the external load applications include the following examples: offshore (flywheel). cranes, runway snow blowers, water well drills, portable air compressors, and fire pump certification power. SEBU8139-01 105 Reference Information Section Engine Ratings • E Rating — This rating is used when rated power is required for a short time for initial starting or for sudden overload. The rating is also used for emergency service when standard power is not available. The horsepower and the rpm of the engine can be utilized continuously for a maximum of 15 minutes. This is followed by one hour of operation at the C rating or by the duration of the emergency. The engine should be run at full load. The engine should not exceed 5 percent of the duty cycle. Typical applications include the following examples: standby centrifugal water pumps, oil field well servicing, crash trucks, portable air compressors, and gas turbine starting motors. NOTICE Operating engines above the rating definitions can re- sult in shorter service life before overhaul. • • 106 SEBU8139-01 Reference Information Section Customer Service Customer Service Latin America, Mexico, Carribean • Caterpillar Americas Co. 701 Waterford Way, Suite 200 i02O97871 Miami, FL 33126-4670 Customer Assistance USA Phone: 305-476-6800 SMCS Code: 1000 Fax: 305-476-6801 Europe, Africa, and Middle East USA and Canada Caterpillar Overseas S.A. 76 Route de Frontenex When a problem arises concerning the operation of P.O. Box 6000 an engine or concerning the service of an engine, CH-1211 Geneva 6 the problem will normally be managed by the dealer Switzerland in your area. Phone: 22-849-4444 Fax: 22-849-4544 Your satisfaction is a primary concern to Caterpillar and to Caterpillar dealers. If you have a problem that Far East has not been handled to your complete satisfaction, Caterpillar Asia Pte. Ltd. follow these steps: 7 Tractor Road Jurong, Singapore 627968 1. Discuss your problem with a manager from the Republic of Singapore dealership. Phone: 65-662-8333 Fax: 65-662-8302 2. If your problem cannot be resolved at the dealer level without additional assistance, use the phone China number that is listed below to talk with a Field Caterpillar China Ltd. Service Coordinator: 37/F., The Lee Gardens • 33 Hysan Avenue 1-800-447-4986 Causeway Bay G.P.O. Box 3069 The normal hours are from 8:00 to 4:30 Monday Hong Kong through Friday Central Standard Time. Phone: 852-2848-0333 Fax: 852-2848-0440 3. If your needs have not been met still, submit the matter in writing to the following address: Japan Shin Caterpillar Mitsubishi Ltd. Caterpillar Inc. SBS Tower Manager, Customer Service, Engine Division 10-1, Yoga 4-Chome Mossville Bldg AC Setagaya-Ku, Tokyo 158-8530 P.O. Box 610 Japan Mossville, Illinois 61552-0610 Phone: 81-3-5717-1150 Fax: 81-3-5717-1177 Please keep in mind: probably, your problem will ultimately be solved at the dealership, using the Japan dealership's facilities, equipment, and personnel. Caterpillar Power Systems, Inc. Therefore, follow the steps in sequence when a SBS Tower(14th floor) problem is experienced. 4-10-1, Yoga Setagaya-Ku, Tokyo 158-0097 Outside of the USA and of Canada Phone: 81-3-5797-4300 Fax: 81-3-5797-4359 If a problem arises outside the USA and outside Australia and New Zealand Canada, and if the problem cannot be resolved at the Caterpillar of Australia Ltd. dealer level, consult the appropriate Caterpillar office. 1 Caterpillar Drive Private Mail Bag 4 • Tullamarine, Victoria 3043 Australia Phone: 03-9953-9333 Fax: 03-9335-3366 SEBU8139-01 107 Reference Information Section Customer Service • i01028392 Ordering Replacement Parts SMCS Code: 7567 WARNING When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent spec- ifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death. Quality Caterpillar replacement parts are available from Caterpillar dealers throughout the world. Caterpillar dealers' parts inventories are up-to-date. The parts stocks include all of the parts that are normally needed to protect your Caterpillar engine investment. When you order parts, please specify the following • information: • Part number • Part name • Quantity If there is a question concerning the part number, please provide your dealer with a complete description of the needed item. When a Caterpillar engine requires maintenance and/or repair, provide the dealer with all the information that is stamped on the Information Plate. This information is described in this Operation and Maintenance Manual (Product Information Section). Discuss the problem with the dealer. Inform the dealer about the conditions of the problem and the nature of the problem. Inform the dealer about when the problem occurs. This will help the dealer in troubleshooting the problem and solving the problem faster. • 108 SEBU8139-01 Reference Information Section Reference Materials Reference Materials • Special Publication, SEBD0518, "Know Your • Cooling System" i02454636 • Special Publication, SEBD0970, "Coolant and Your Reference Material Engine" SMCS Code: 1000 • Label, PEEP5027, "Extended Life Coolant/Antifreeze" The following literature can be obtained through any . Special Publication, SEBU6251, "Caterpillar Caterpillar dealer. Commercial Diesel Engine Fluids Recomendations" Lubricants Miscellaneous • Special Publication, PEHP8038, "Data Sheet - • Service Manual, KENR6207, "C6.6 Generator Set" Caterpillar Diesel Engine Oils (DEO) (CH-4) (North America)" • Special Publication, PECP6026, "One Safe • Special Publication, PEHP9536, "Data Sheet Source" English language for use in NACD - Caterpillar Diesel Engine Oil (DEO) (CF-4) • Special Publication, PECP6027, "One Safe (International only)" Source" English language for use in COSA • Special Publication, NEDG6022, "Cat Lubricating . Special Publication, PECP6028, "One Safe Grease" Source" English language for use in non NACD • Special Publication, PEHP0002, "Data Sheet - and non COSA Molybdenum (MPGM) Grease" • Special Publication, LEDM5615, "Caterpillar • • Special Publication, NEHP6015, "Data Sheet - Marine Parts and Service Locations Directory" Caterpillar Special Purpose Grease (SPG)" • Special Publication, SEBF8029, "Index to • Special Publication, SEB Guidelines for Reusable Parts and SalvageD0640, "Oil and Your Operations" Engine" • Operation and Maintenance Manual, SEBU5898, • Special Publication, SEBF8062, "Procedure to "Cold Weather Recommendations" Inspect and Clean Air Filters" • Special Publication, SEBU6251, "Caterpillar • Special Instruction, SEHS9031, "Storage Commercial Diesel Engine Fluids Recomendations" Procedure for Caterpillar Products • Special Publication, PEHP6001, "How To Take A • Special Publication, NEHS0526, "Service Good Oil Sample" Technician Application Guide" • Special Publication, SEBU6251, "Caterpillar Fuels Commercial Diesel Engine Fluids Recomendations" • Special Publication, SEBD0717, "Diesel Fuels and • Special Instruction, SEHS7633, "Battery Test Your Engine" Procedure" • Special Publication, SEBU6251, "Caterpillar • Label, SEHS7332, "Danger Do Not Operate" Commercial Diesel Engine Fluids Recomendations" Coolants Emissions Warranty This engine may be Certified and this engine • Special Publication, PEHP4036, "Data Sheet - may be covered by an Emissions Warranty. A Extended Life Coolant" detailed explanation of the Emissions Warranty • that is applicable to Certified engines is found • Special Publication, PEHP7057, "Data Sheet- in Supplement, SEBU6981, "Emissions Control S-O-S Coolant Analysis" Warranty Information". The engine is Certified if the engine has a special label that verifies the certification. A Caterpillar dealer can also inform you if the engine is certified. SEBU8139-01 109 Reference Information Section Reference Materials • 100912149 Maintenance Records SMCS Code: 1000 Caterpillar Inc. recommends the retention of accurate maintenance records. Accurate maintenance records can be used for the following purposes: • Determine operating costs. • Establish maintenance schedules for other engines that are operated in the same environment. • Show compliance with the required maintenance practices and maintenance intervals. Maintenance records can be used for a variety of other business decisions that are related to engine maintenance. Maintenance records are a key element of a maintenance program that is well managed Accurate maintenance records can help your Caterpillar dealer to fine tune the recommended maintenance intervals in order to meet the specific operating situation. This • should result in a lower engine operating cost. Records should be kept for the following items: Fuel Consumption —A record of fuel consumption is essential in order to determine when the load sensitive components should be inspected or repaired. Fuel consumption also determines overhaul intervals. Service Hours — A record of service hours is essential to determine when the speed sensitive components should be inspected or repaired. Documents — These items should be easy to obtain, and these items should be kept in the engine history file. All of the documents should show this information: date, service hours, fuel consumption, unit number, and engine serial number. The following types of documents should be kept as proof of maintenance or repair for warranty: Keep the following types of documents as proof of maintenance for warranty. Also, keep these types of documents as proof of repair for warranty: • Dealer work orders and itemized bills • Owner's repair costs • Owner's receipts • Maintenance log 110 SEBU8139-01 Reference Information Section Reference Materials 01176304 • Maintenance Log SMCS Code: 1000 Table 20 Engine Model Customer Identifier Serial Number Arrangement Number Service Quantity Service Item Date Authorization Hours Of Fuel • • SEBU8139-01 111 ■ Index Section Index A Engine Air Cleaner Element (Single Element) - Replace................................................................ 79 Additional Messages............................................. 18 Engine Air Cleaner Service Indicator- Inspect...... 80 Alternator- Inspect................................................ 73 Test the Service Indicator................................... 80 Alternator and Fan Belts- Inspect......................... 73 Engine Crankcase Breather Element- Replace.... 81 Engine Identification.............................................. 36 Engine Mounts- Inspect........................................ 82 B Engine Oil and Filter-Change.............................. 83 Drain the Engine Lubricating Oil........................ 83 Battery -Replace................................................... 73 Fill the Oil Pan.................................................... 85 Battery Electrolyte Level -Check.......................... 74 Replace the Oil Filter......................................... 84 Battery or Battery Cable - Disconnect................... 74 Engine Oil Level -Check....................................... 82 Before Starting Engine .......................................... 31 Engine Oil Sample-Obtain................................... 82 Burn Prevention..................................................... 28 Obtain the Sample and the Analysis.................. 82 Batteries............................................................. 28 Engine Operation................................................... 60 Coolant............................................................... 28 Engine Rating Conditions.................................... 104 Oils..................................................................... 28 Engine Rating Definitions.................................... 104 Engine Ratings.................................................... 104 Engine Starting................................................ 31, 58 C Engine Stopping.............................................. 32, 61 Engine Valve Lash - Inspect/Adjust....................... 86 Cold Weather Operation........................................ 62 Hints for Cold Weather Operation...................... 62 Idling the Engine................................................ 63 F • Recommendations for Coolant Warm Up.......... 63 Recommendations for the Coolant.................... 63 Features and Controls........................................... 48 Viscosity of the Engine Lubrication Oil............... 62 Fire Prevention and Explosion Prevention ............ 28 ControlPanel......................................................... 48 Ether.................................................................. 30 Alarm Indicators................................................. 49 Fire Extinguisher................................................ 30 Basic Operation ................................................. 49 Lines, Tubes and Hoses.................................... 30 Navigation Keys................................................. 48 Foreword ................................................................. 5 Resetting Events................................................ 50 California Proposition 65 Warning ....................... 5 Viewing Events.................................................. 50 Literature Information........................................... 4 Cooling System Coolant(ELC) -Change.............. 75 Maintenance ........................................................ 4 Drain .................................................................. 75 Maintenance Intervals.......................................... 4 Fill...................................................................... 75 Operation............................................................. 4 Flush.................................................................. 75 Overhaul.............................................................. 4 Cooling System Coolant Extender(ELC) -Add..... 76 Safety................................................................... 4 Cooling System Coolant Level-Check................. 77 Fuel and the Effect from Cold Weather................. 64 Cooling System Coolant Sample (Level 1) - Fuel Conservation Practices.................................. 60 Obtain.................................................................. 77 Fuel System - Prime.............................................. 86 Cooling System Coolant Sample (Level 2) - Electric Fuel Priming Pump................................ 87 Obtain.................................................................. 78 Hand Fuel Priming Pump................................... 86 Cooling System Water Temperature Regulator - Fuel System Primary Filter (Water Separator) Replace................................................................ 78 Element- Replace............................................... 88 Crushing Prevention and Cutting Prevention ........ 31 Fuel System Primary Filter/Water Separator - CustomerAssistance........................................... 106 Drain.................................................................... 89 Outside of the USA and of Canada.................. 106 Fuel System Secondary Filter- Replace............... 90 USA and Canada............................................. 106 Fuel Tank Water and Sediment- Drain ................. 90 Customer Service................................................ 106 Drain the Water and the Sediment..................... 91 Fuel Storage Tanks............................................ 91 FuelTank........................................................... 91 • E Electrical Connections-Check.............................. 79 Electrical System................................................... 32 Grounding Practices.......................................... 32 Engine -Clean....................................................... 79 112 SEBU8139-01 Index Section GModel Views.......................................................... 35 • General Hazard Information.................................. 25 Asbestos Information......................................... 27 O Containing Fluid Spillage................................... 27 Dispose of Waste Properly ................................ 28 Operation Section.................................................. 45 Fluid Penetration................................................ 26 Ordering Replacement Parts............................... 107 Pressurized Air and Water................................. 26 Overhaul Considerations....................................... 97 General Information............................................... 34 Oil Consumption as an Overhaul Indicator........ 97 Generator- Dry...................................................... 91 Overhaul Recommendation............................... 98 Drying Methods.................................................. 91 Generator- Inspect................................................ 92 Cleaning (Assembled Generators)..................... 92 P Cleaning (Disassembled Generators)................ 93 Generator Isolating for Maintenance..................... 33 Plate Locations and Film Locations....................... 36 Generator Lead Connections................................ 38 Emissions Certification Film............................... 36 Connection Diagrams........................................ 39 Serial Number Plate (1) ..................................... 36 Grounding the Frame......................................... 39 Product Identification Information.......................... 36 Neutral Connections.......................................... 39 Product Information Section.................................. 34 Single Units........................................................ 39 Product Lifting........................................................ 45 Generator Load -Check........................................ 93 Engine Lifting with a Fuel Tank.......................... 45 Generator Set-Test.............................................. 94 Lifting of Generator Sets.................................... 45 Generator Set Installation...................................... 47 Product Storage..................................................... 46 Electrical Measurements.................................... 47 Generator Storage............................................. 46 Location ............................................................. 47 Receiving Inspection.......................................... 47 Remote Fuel Tanks and Auxiliary Fuel Tanks ... 47 R Unpacking.......................................................... 47 • Reference Information Section............................ 104 Reference Material.............................................. 108 HCoolants........................................................... 108 Emissions Warranty......................................... 108 Hoses and Clamps- Inspect/Replace................... 94 Fuels................................................................ 108 Replace the Hoses and the Clamps.................. 95 Lubricants........................................................ 108 Miscellaneous.................................................. 108 Reference Materials............................................ 108 1 Refill Capacities..................................................... 65 Refill Capacities and Recommendations............... 65 Important Safety Information................................... 2 Coolant............................................................... 68 Installation ............................................................. 47 Engine Oil .......................................................... 65 Insulation -Test..................................................... 95 Fuel.................................................................... 67 Exciter Armature (Rotor L2)............................... 97 Lubricating Grease............................................. 67 Exciter Field (Stator 1-1)..................................... 97 S-O-S Coolant Analysis...................................... 68 Main Armature (Stator 1-4)................................. 96 Rotating Rectifier-Check...................................... 99 Rotating Rectifier-Test....................................... 100 L S Lifting and Storage................................................ 45 Safety Messages..................................................... 6 SafetySection ......................................................... 6 M Starting Motor- Inspect....................................... 100 Starting the Engine................................................ 58 Maintenance Interval Schedule (Prime Power Starting the Engine............................................ 58 Generator Sets)................................................... 70 Starting with Jump Start Cables............................ 58 Maintenance Interval Schedule (Standby Generator Stopping the Engine.............................................. 61 • Sets).................................................................... 72 Maintenance Log.................................................. 110 Maintenance Records.......................................... 109 T Maintenance Section............................................. 65 Model View Illustrations......................................... 35 Table of Contents..................................................... 3 SEBU8139-01 113 Index Section Turbocharger- Inspect........................................ 100 Inspecting......................................................... 101 Removal and Installation.................................. 101 V Voltage Regulators................................................ 51 R230 Adjustments.............................................. 52 R438 and R448 Adjustment for Maximum Excitation.......................................................... 56 R438 and R448 Adjustments............................. 54 SpecialUse........................................................ 57 W Walk-Around Inspection ...................................... 101 High Pressure Fuel Lines................................. 102 Inspect the Engine for Leaks and for Loose Connections................................................... 101 Water Pump - Inspect.......................................... 102 Welding on Engines with Electronic Controls........ 34 00 • SEBU8139-01 114 Index Section Od • Product and Dealer Information Note: For product identification plate locations, see the section "Product Identification Information" in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: • Customer Equipment Number. Dealer Equipment Number: Dealer Information Name: Branch: Address: Dealer Contact Phone Number Hours Sales: Parts: Service: • • • • ©2006 Caterpillar All Rights Reserved Printed in U.S.A. CATERPILLAR Jannuary 009u SE ry 2009 • Caterpillar Commercial Diesel Engine r Fluids Recommendations For All 3500 Series, C175 Series and Smaller Commercial Diesel Engines i01658146 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous • situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING" or"CAUTION". The Safety Alert "WARNING" label is shown below. i The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. iWARNING _7 " When replacement parts are required for this product Caterpillar recommends using Caterpil- lar replacement parts or parts with equivalent specifications including, but not limited to, phys- ical dimensions, type, strength and material. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death. • SEBU6251-12 3 ■ Table of Contents 10 Table of Contents Foreword ............................................................... 4 Maintenance Section Lubricant Specifications ........................................ 6 Fuel Specifications ................................................ 32 Cooling System Specifications ............................. 60 Reference Information Section Reference Materials .............................................. 82 Index Section Index ..................................................................... 87 • • 4 SEBU6251-12 Foreword Foreword Refer to the applicable Operation and Maintenance • Manual for standard oil drain periods and to the Literature Information Maintenance Section, "Lubricant Specifications" of this publication for engine oil type and viscosity grade This manual should be stored in the literature storage recommendations. area. To reduce the potential risk of failures associated The information contained in this document is the with extended oil drain periods; it is recommended most current information available for coolants, that oil drain intervals only be extended based on oil fuels, and lubricants. Refer to the Operation and analysis, and subsequent engine inspections. Oil Maintenance Manual for any special lubrication analysis alone does not provide an indication of the rate of formation of lacquer, varnish and/or carbon on requirements for your engine. pistons and other engine surfaces. The only accurate Whenever a question arises regarding the engine, way to evaluate specific oil performance in a specific this publication, or the Operation and Maintenance engine and application that utilizes extended oil Manual, please consult any Caterpillar dealer for the drain periods is to observe the effects on the engine latest available information. components. This involves tear-down inspections of engines that have run to their normal overhaul period with extended oil drain intervals. Following Safety this recommendation will help ensure that excessive component wear does not take place in a given Refer to the Operation and Maintenance Manual application. for your engine for all safety information. Read and understand the basic safety precautions listed in the NOTICE Safety Section. In addition to safety precautions, Light loads, low hour accumulation, and excessive this section identifies the text and locations of safety idling time can contribute to excessive water in the signs used on the engine. crankcase oil. Corrosive damage, piston deposits and Read and understand the basic precautions listed in increased oil consumption can also result. If oil analy- • the Safety Section before operating or performing sis is not done or the results are ignored, the potential for corrosive damage and piston deposits increases. lubrication, maintenance and repair on this engine. Refer to the appropriate Operation and Maintenance Manual for guidance. Maintenance Refer to the Operation and Maintenance Manual Note: Failures that result from extended oil drain for your engine to determine all maintenance periods are not warrantable failures, regardless of requirements. use of this recommended procedure. Failures that result from extended engine oil drain periods are Maintenance Intervals considered improper use under the warranty. Use the Maintenance Interval Schedule in the Operation and Maintenance Manual for your engine to determine servicing intervals. The actual operating environment of the engine also governs the maintenance interval schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary. Extended Engine Oil Drains and Warranty Failures that result from extended oil drain periods are not Caterpillar factory defects and therefore are not covered by Caterpillar's warranty. In addition, • failures that result from not using the recommended oil type are not Caterpillar factory defects and therefore are not covered by Caterpillar's warranty. SEBU6251-12 5 Foreword • Aftermarket Products and Warranty NOTICE When auxiliary devices, accessories or consumables (filters, oil, additives, catalysts, fuel, etc.) made by other manufacturers are used on Caterpillar prod- ucts, the Caterpillar warranty is not affected simply because of such use. Failures that result from the installation or usage of other manufacturers auxiliary devices, accessories or consumables, however, are not Caterpillar factory defects and therefore are NOT covered by Caterpillar's warranty. Caterpillar is not in a position to evaluate the many auxiliary devices, accessories or consumables pro- moted by other manufacturers and their effect on Caterpillar products. Installation or use of such items is at the discretion of the customer who assumes ALL risks for the effects that result from this usage. Furthermore, Caterpillar does not authorize the use of its trade name, trademark, or logo in a manner which implies our endorsement of these aftermarket prod- ucts. • • 6 SEBU6251-12 Maintenance Section Lubricant Specifications Maintenance Section NOTICE To avoid potential damage to your Cat machine and/or Cat engine, only purchase Cat fluids and Cat filters Lubricant Specifications through your Caterpillar dealer or Caterpillar autho- rized outlets. For a list of authorized Caterpillar parts outlets in your area, consult your Caterpillar dealer. 103416060 General Lubricant Information If you purchase what appear to be Cat fluids and/ or Cat filters through other outlets/sources, you SMCS Code: 0645; 1000; 1300; 1348; 7581 are at a very high risk of purchasing counterfeit ("look-alike") products. NOTICE Counterfeit or "look-alike" products may visually ap- Every attempt is made to provide accurate, up to date pear the same as the original Cat product, but the information. By use of this document you agree that product performance and internal quality will typical- Caterpillar Inc. is not responsible for errors or omis- ly be very low. sions. Counterfeit or "look-alike" products have a very high The information that is provided is the latest likelihood of causing and/or allowing engine and/or recommendations for Caterpillar diesel engines machine compartment damage. that are covered by this Special Publication. This information supersedes all previous NOTICE recommendations which have been published for Caterpillar diesel engines that are covered by this Many of the guidelines, recommendations, and re- Special Publication. Special fluids are required for quirements that are provided in this Special Publica- some engines and it will be necessary to continue to tion are interrelated. Before using the provided infor- use these special products. Refer to the applicable mation, it is the responsibility of the user of this Spe- Operation and Maintenance Manual. cial Publication to read and understand the informa- • tion provided in its entirety. This publication is a supplement to the Operation and Maintenance Manual. This publication does For questions concerning the information provided in not replace the engine specific Operation and this Special Publication, consult with your Caterpillar Maintenance Manuals. dealer. NOTICE For additional guidelines, recommendations, and requirements (including maintenance interval rec- These recommendations are subject to change with- ommendations/requirements) refer to your product out notice. Consult your local Caterpillar dealer for the most up to date recommendations. specific Operation and Maintenance Manual. NOTICE Commercial products that make generic claims of meeting "Cat' and/or "Caterpillar" requirements with- out listing the specific Cat recommendations and/or requirements that are met may not provide accept- able performance and may cause reduced engine and/or machine fluid compartment life. Refer to this Special Publication and refer to product specific Op- eration and Maintenance Manual for Caterpillar fluids recommendations and/or requirements. • SEBU6251-12 7 Maintenance Section Lubricant Specifications • NOTICE NOTICE It is the responsibility of the user of this Special Publi- Use of fluids that do not meet at least the minimum cation to read, understand, and follow all safety guide- performance recommendations and/or requirements lines found in this Special Publication and in engine may lead to lower compartment performance and/or and/or machine specific Operation and Maintenance compartment failure. Manual when performing all recommended and/or re- quired engine, engine systems, and/or machine main- Problems/failures that are caused by using fluids that tenance. do not meet the minimum recommended and/or re- quired performance level for the compartment are not For questions concerning the information provided in warrantable by Caterpillar Inc., and are the fluid man- this Special Publication and/or in your product Op- ufacturer and customer responsibility. eration and Maintenance Manual, consult with your Caterpillar dealer. In order to help ensure the maximum expected com- partment performance and life, severe duty applica- Note: Instructions for the installation of the filter are tions require the use of higher performing fluids as de- printed on the side of each Caterpillar spin-on filter. scribed in this Special Publication, versus using fluids For non-Caterpillar filters, refer to the installation that meet the minimum performance levels that may instructions that are provided by the supplier of the be allowed for typical applications. filter. When fluids made by other manufacturers are used on Caterpillar products, the Caterpillar warranty is not af- NOTICE fected simply because of such use. Failures that result In order to meet expected fuel system component life, from the installation or usage of other manufacturer 4 micron(c) absolute or less secondary fuel filtration fluids, however, are not Caterpillar factory defects and is required for all Caterpillar diesel engines that are therefore are NOT covered by the Caterpillar warran- equipped with common-rail fuel systems, and for all ty. Caterpillar is not in a position to evaluate the many • Caterpillar diesel engines that are equipped with unit fluids promoted by other manufacturers and their ef- injected fuel systems. For all other Caterpillar diesel fect on Caterpillar products. Installation or use of such engines (mostly older engines with pump, line and items is at the discretion of the customerwho assumes nozzle type fuel systems), the use of 4 micron(c) ab- ALL risks for the effects that result from this usage. solute or less secondary fuel filtration is strongly rec- ommended. Note that all current Caterpillar diesel en- gines are factory equipped with Caterpillar Advanced Note: In order to help ensure the maximum expected Efficiency 4 micron(c) absolute fuel filters. compartment performance and life, it is required to use a fluid that meets Caterpillar highest level of fluid In order to obtain additional information on Caterpillar performance as described in this Special Publication designed and produced filtration products, refer to the for the compartment, rather than using a fluid that "Reference Material" article, "Filters" and "Miscella- is considered an acceptable, but lower performing neous" topics in this Special Publication, and then option for typical applications. (ex: Where fluids consult your Caterpillar dealer for assistance with fil- meeting either Cat ECF-1-a, Cat ECF-2 or Cat ECF-3 tration recommendations for your Caterpillar machine. are offered as an option in typical applications, in order to help ensure the maximum expected engine compartment performance and life, oil meeting the NOTICE Cat ECF-3 specification must be used.) Faulty engine coolant temperature regulators, or op- erating with light loads, short operation cycles, exces- NOTICE sive idling, or operating in applications where normal Not following the recommendations found in this Spe- operating temperature is seldom reached can con- cial Publication can lead to reduced performance and tribute to excessive water in the crankcase oil. Cor- compartment failure. rosive damage, piston deposits and increased oil con- sumption can result. If a complete oil analysis program is not followed or if the results are ignored, the poten- tial for corrosive damage and piston deposits increas- es. • 8 SEBU6251-12 Maintenance Section Lubricant Specifications Caterpillar Fluids This information is for Caterpillar commercial diesel • engines. For more lubricant recommendations, Caterpillar fluids have been approved by Caterpillar see Special Publication, SEBU6250, "Caterpillar in order to increase the performance of Caterpillar Machine Fluids Recommendations", Special components and the life of Caterpillar components. Publication, SEBU6400, "Caterpillar Gas Engine Caterpillar fluids that are currently used for engines Fluids Recommendations", Special Publication, and for machines are offered by Caterpillar dealers. SEBU6385, "Caterpillar On-Highway Diesel Engine Caterpillar fluids are also offered for service refills. Fluids Recommendations", and Special Publication, Consult your Caterpillar dealer for more information SEBU7003, "Caterpillar 3600 Series and C280 on these Caterpillar fluids. Series Diesel Engine Fluids Recommendations". Always check with your Caterpillar dealer in order Caterpillar recommends the use of the following to ensure that you have the current revision level of Caterpillar fluids: the publication. • Cat DEO (Multigrade Diesel Engine Oil) i03465122 • Cat DEO-ULS (Multigrade Diesel Engine Oil - Ultra Engine Oil Low Sulfur) (Engine Crankcase Fluid • Cat DEO SYN (Synthetic Diesel Engine Oil SAE Recommendations for all 5W-40) Caterpillar 3500 Series, C175 • Cat Arctic DEO SYN (Synthetic Diesel Engine Oil Series, and Smaller Direct SAE OW-30) Injection (DI) Engines) • Cat Multipurpose Grease SMCS Code: 1348, 7581 • Cat Advanced 3Moly Grease • Exceptions to these recommendations are 3116 • Cat Ultra 5Moly Grease and 3126 Marine Engines with Mechanical Unit Injection (MUI). • Cat Desert Gold Grease • Cat Arctic Platinum Grease Cat DEO (Diesel Engine Oil) • Cat High Speed Ball Bearing Grease Cat oils have been developed and tested in order to provide the full performance and service life that has • Cat White Assembly Grease been designed and built into Cat engines. Cat oils are currently used to fill diesel engines at the factory. • Cat ELC (Extended Life Coolant) These oils are offered by Cat dealers for continued use when the engine oil is changed. Consult your Cat • Cat DEAC (Diesel Engine Antifreeze/Coolant) dealer for more information on these oils. Note: Caterpillar fluids availability will vary by Due to the additional full-scale proprietary engine region. testing required of Cat DEO and Cat DEO-ULS, and due to significant variations in the quality and Note: Additional Caterpillar fluids are available for in the performance of commercially available oils, Cat machine applications. Caterpillar makes the following recommendations: • Cat DEO (Diesel Engine Oil) (10W-30) • Cat DEO (Diesel Engine Oil) (15W-40) • Cat DEO-ULS (Diesel Engine Oil - Ultra Low Sulfur) (10W-30) • Cat DEO-ULS (Diesel Engine Oil - Ultra Low • Sulfur) (15W-40) SEBU6251-12 9 Maintenance Section Lubricant Specifications • Note: Cat DEO-ULS and Cat DEO multigrade oils Note: Cat DEO multigrade exceeds the requirements are the preferred oils for use in ALL Cat diesel of the following Cat Engine Crankcase Fluid (ECF) engines that are covered by this Special Publication. specifications: Cat ECF-1-a and Cat ECF-2. Cat DEO Commercial alternative diesel engine oils are, as a multigrade exceeds the performance requirements group, second choice oils. for the following American Petroleum Institute (API) oil categories: API CI-4, API CI-4 PLUS, API CH-4, Cat DEO multigrade and Cat DEO-ULS multigrade API CG-4, and API CF. The availability of Cat DEO oils are formulated with the correct amounts of multigrade exceeding the noted requirements will detergents, dispersants, and alkalinity in order to vary by region. Cat DEO SAE 15W-40 also passes provide superior performance in Cat diesel engines additional proprietary tests that include the following where recommended for use. tests: sticking of the piston ring, oil control tests, wear tests, and soot tests. Proprietary tests help ensure Cat DEO-ULS and Cat DEO multigrade oils are that Cat multigrade oil provides superior performance available in various viscosity grades that include SAE in Cat diesel engines. In addition, Cat multigrade oil 1 OW-30 and SAE 15W-40. Multigrade oils provide exceeds many of the performance requirements of the correct viscosity for a broad range of operating other manufacturers of diesel engines. Therefore, temperatures. this oil is an excellent choice for many mixed fleets. True high performance oil is produced by using Multigrade oils are effective in maintaining low oil a combination of the following factors: industry consumption and low levels of piston deposits. standard tests, proprietary tests, field tests, and prior experience with similar formulations. Note: Do not use single grade oils in Caterpillar 3500 The design and the development of Caterpillar Series, C175 Series, and smaller Direct Injection (DI) lubricants that are both high performance and diesel engines. high quality are based on these factors. NOTICE Note: Cat DEO-ULS multigrade exceeds the Oils that have more than 1%total sulfated ash should requirements of the Cat ECF-1-a, Cat ECF-2, and not be used in aftertreatment device equipped en- Cat ECF-3 specifications. Cat DEO-ULS multigrade • gines. exceeds the performance requirements for the following API oil categories: API CJ-4, API CI-4, In order to achieve expected ash service intervals, API CI-4 PLUS, API CH4, API CG-4, and API CF. performance, and life, aftertreatment device equipped Cat DEO-ULS multigrade also passes additional diesel engines require the use of Cat DEO-ULS or oils proprietary tests that include the following tests: meeting the Cat ECF-3 specification and the API CJ-4 sticking of the piston ring, oil control tests, wear tests, oil category. Oils that meet the Cat ECF-2 specifica- and soot tests. Proprietary tests help ensure that tion and that have a maximum sulfated ash level of Cat multigrade oil provides superior performance in 1%are also acceptable for use in most aftertreatment Cat diesel engines. In addition, Cat multigrade oil equipped engines. Use of oils with more than 1% to- exceeds many of the performance requirements of tal sulfated ash in aftertreatment device equipped en- other manufacturers of diesel engines. Therefore gines will cause the need for more frequent ash ser- this oil is an excellent choice for many mixed fleets. vice intervals, and/or cause loss of performance. Re- True high performance oil is produced by using fer to your engine specific Operation and Maintenance a combination of the following factors: industry Manual, and refer to your aftertreatment device docu- standard tests, proprietary tests, field tests, mentation for additional guidance. and prior experience with similar formulations. The design and the development of Caterpillar lubricants that are both high performance and Cat DEO multigrade and Cat DEO-ULS multigrade high quality are based on these factors. oils can be used in other manufacturer's diesel engines and in gasoline engines. See Commercial Oils the engine manufacturer's literature for the recommended categories/specifications. Compare Engine Crankcase Fluid Recommendations for the categories/specifications to the specifications of all Current and Noncurrent Caterpillar Diesel Cat DEO multigrade and Cat DEO-ULS multigrade Engines that are Covered by this Special oils. The current industry standards for Cat DEO Publication multigrade and Cat DEO-ULS multigrade oils are • listed on the product labels and on the datasheets Note: Non-Caterpillar commercial oils are, as a for the product. group, second choice oils. Within this grouping Consult your Cat dealer for part numbers and for of second choice oils there are tiered levels of available sizes of containers. performance. 10 SEBU6251-12 Maintenance Section Lubricant Specifications • When the recommended and preferred Cat diesel • NOTICE engine oils are not used, commercial oils that meet Caterpillar does not warrant the quality or perfor- the requirements of the Cat ECF-3 specification mance of non-Caterpillar fluids. are acceptable for use in Cat diesel engines that are covered by this Special Publication. After Cat DEO-ULS and Cat DEO, commercial oils that meet Caterpillar developed the Engine Crankcase Fluid the Cat ECF-3 specification are preferred oils, (ECF) specifications to ensure the availability of high when compared to commercial diesel engine oils performance commercial diesel engine oils in order that do not meet the Cat ECF-3 specification for to provide satisfactory life and performance in Cat use in Cat diesel engines that are covered by this diesel engines where recommended for use. Special Publication. Note that in order to achieve the maximum expected engine performance and There are three current Cat ECF specifications: life, some engines/engine applications will require Cat ECF-1-a, Cat ECF-2, and Cat ECF-3. Each the use of higher performance oils such as those higher Cat ECF specification provides increased meeting Cat ECF-3 versus meeting Cat ECF-2 or performance over lower Cat ECF specifications. For Cat ECF-1-a. example, Cat ECF-3 provides higher performance than Cat ECF-2 and Cat ECF-3 provides much higher Oils that meet the API CJ4 oil category requirements performance than Cat ECF-1-a. are Cat ECF-3 specification compliant. Note:The Cat ECF-1-a and Cat ECF-2 specifications NOTICE replaced the Cat ECF-1 specification as of 1 March 2007. Oils that have more than 1%total sulfated ash should not be used in aftertreatment device equipped en- Note: Cat DEO and DEO-ULS are required to pass gines. additional proprietary full-scale diesel engine testing that is above and beyond the testing required by the In order to achieve expected ash service intervals, various Cat ECF specifications and by the various performance, and life, aftertreatment device equipped API oil categories that they also meet. This additional diesel engines require the use of Cat DEO-ULS or oils proprietary testing helps ensure that Cat multigrade meeting the Cat ECF-3 specification and the API CJ-4 • diesel engine oils, when used as recommended, oil category. Oils that meet the Cat ECF-2 specifica- provide superior performance in Cat diesel engines. If tion and that have a maximum sulfated ash level of Cat DEO multigrade or DEO-ULS multigrade oils are 1%are also acceptable for use in most aftertreatment not used, as a second choice, use only commercial equipped engines. Use of oils with more than 1% to- oils that meet the following specifications: tal sulfated ash in aftertreatment device equipped en- gines will cause the need for more frequent ash ser- • When the recommended and preferred Cat diesel vice intervals, and/or cause loss of performance. Re- engine oils are not used, commercial oils that meet fer to your engine specific Operation and Maintenance the requirements of the Cat ECF-1-a, Cat ECF-2, Manual, and refer to your aftertreatment device docu- and/or the Cat ECF-3 specification are acceptable mentation for additional guidance. for use in Cat diesel engines that are covered by this Special Publication. API category oils that Severe Applications Require the Use of have not met the requirements of at least one Cat ECF specification may cause reduced engine Higher Performing Diesel Engine Oils life. Note that in order to achieve the maximum expected engine performance and life, some In order to help ensure the maximum expected engines/engine applications will require the use of compartment performance and life, severe duty higher performance oils such as those meeting Cat applications such as those operating at greater than ECF-3 versus meeting Cat ECF-2 or Cat ECF-1-a. 75% load factor, operating in high humidity, operating with fuel sulfur levels that are above 0.1% (1000 ppm), etc., require the use of higher performing fluids as described in this Special Publication, versus using fluids that meet the minimum performance levels that may be allowed for typical applications. (ex: Where fluids meeting either Cat ECF-1-a, Cat ECF-2 or Cat ECF-3 are offered as an option in typical applications, in order to help ensure the maximum expected engine • compartment performance and life, oil meeting the Cat ECF-3 specification must be used.) SEBU6251-12 11 Maintenance Section Lubricant Specifications • Note: There are additional oil considerations that are Note: The minimum TBN of the new oil is 7 related to fuel sulfur levels. Refer to the various "Total regardless of the fuel sulfur level. Reaching one half Base Number(TBN) and Fuel Sulfur Levels..." topics of new oil TBN is one of the condemning factors for in this Special Publication. Also refer to the "Diesel diesel engine oil, but, in order to help provide the Fuel Sulfur" topic in this Special Publication. best protection for your engine, Cat S-O-S Services oil analysis is the preferred method of determining oil NOTICE life. For best results when determining oil life using In selecting oil for any engine application, both the the one half new oil TBN method, determine the new oil viscosity and oil performance category/specifica- and used oil TBN using both the "ASTM D2896" and tion as specified by the engine manufacturer must be the "ASTM D4739" test methods. Change the oil defined and satisfied. Using only one of these param- when reaching one half of new oil TBN with either eters will not sufficiently define oil for an engine appli- respective TBN test method using the results from cation. which ever respective test method shows reaching one half of new oil TBN first. In order to make the proper diesel engine oil viscosity For example, new oil with a TBN of 10 by "ASTM grade choice, refer to the "Lubricant Viscosities for D2896" should be changed when, during use, the Ambient Temperatures for DI Diesel Engines" table in TBN deteriorates to 5 as determined by the "ASTM this Special Publication. D2896" test method, and new oil with a TBN of 10 by "ASTM D4739" should be changed when, during NOTICE use, the TBN deteriorates to 5 as determined by the Oils that have not met the requirements of at least one "ASTM D4739" test method. Use the results from Cat ECF specification may cause reduced engine life. which ever respective test method reaches one half of new oil TBN first. NOTICE Excessive piston deposits can be produced by oil Failure to follow these oil recommendations can cause with a high TBN and/or high ash. These deposits can shortened engine service life due to deposits and/or lead to a loss of control of the oil consumption and to • excessive wear. the polishing of the cylinder bore. There are many factors that contribute to rapid TBN Total Base Number (TBN) and Fuel depletion, a not all inclusive list follows: Sulfur Levels for Direct Injection • High sulfur fuel (The more fuel sulfur, the more (DI) Diesel Engines rapid the TBN depletion.) The use of Cat S-O-S Services oil analysis is strongly • Faulty engine coolant regulators recommended for determining oil life. • Light loads Note: The following information concerning oil life relative to used oil TBN level is provided for general • Short operation cycles information only, and is not the recommended method for determining oil life. If the one half of new • Excessive idling oil TBN guideline that is stated below is used for determining oil life it must only be used in . Operating in applications were normal operating conjunction with a complete S-O-S Services oil temperature is seldom reached analysis program. • High humidity (allowing excessive condensation) Note: TBN is also commonly referred to as Base Number (BN). Note that bullets 2 through 7 directly above all can contribute to excessive water in the crankcase oil. The minimum required Total Base Number (TBN) The water combines with available sulfur to form for oil depends on the fuel sulfur level. For direct sulfuric acid, neutralizing this and other acids that are injection engines that use distillate fuel, the minimum formed contribute to rapid TBN depletion. new oil TBN must be 10 times the fuel sulfur level. • The TBN for new oil is typically determined by the "ASTM D2896"procedure. 12 SEBU6251-12 Maintenance Section Lubricant Specifications • Following maintenance intervals as published • NOTICE in engine specific Operation and Maintenance Depending on application severity and localized envi- Manuals ronmental conditions, and also depending on mainte- nance practices, operating Direct Injection (DI) diesel More severe applications may require shortened oil engines and operating PC (Precombustion Chamber) drain intervals, while less severe applications may diesel engines on fuel with sulfur levels over 0.1 per- allow for longer than standard oil drain intervals. High cent (1000 ppm) may require significantly shortened load factors (above 75%), particularly in conjunction oil change intervals in order to help maintain adequate with high sulfur fuels, can contribute significantly to wear protection. Refer to this Special Publication, "Fu- reducing oil drain intervals below standard oil drain el Specifications"section, "Diesel Fuel Sulfur"topic for intervals. additional information. Consult with your Caterpillar dealer regarding the Note: For PC (Precombustion Chamber) diesel testing that is required in establishing oil drain engines, which are mainly 1990 and older engines, intervals that are optimized for your application. the minimum new oil TBN must be 20 times the fuel In order to help protect your engine, and in order sulfur level. The diesel engine oil types, specifications, to help optimize oil drain intervals for engine and viscosity grades recommendations provided for specific applications and duty cycles, Cat S•O•S DI diesel engines in this Special Publication are also Services oil analysis is: applicable to PC diesel engines. For additional fluids information related to PC diesel engines, refer to this . Recommended as a matter of course Special Publication, "Engine Oil for Precombustion Chamber (PC) Diesel Engines (Engine Crankcase • Very strongly recommended in order to determine Fluid Recommendations for All Series 3500 Series oil drain intervals when operating on fuel with sulfur and Smaller PC Diesel Engines)" article. levels between 0.05% (500 ppm) and 0.5% (5000 Note: DO NOT USE ONLY THIS SPECIAL ppm) PUBLICATION AS A BASIS FOR DETERMINING • Required in order to determine oil drain intervals • OIL DRAIN INTERVALS. when operating on fuel with sulfur levels that are This Special Publication does not address above 0.5% (5000 ppm) recommended oil drain intervals, but rather provides Note: Engine operating conditions play a key role guidance that should be used in conjunction in determining the effect that fuel sulfur will have on with your specific engine/machine Operation and engine deposits and on engine wear. Consult your Maintenance Manuals in determining acceptable Caterpillar dealer for guidance when fuel sulfur levels oil drain intervals. Consult your engine/machine are above 0.1% (1000 ppm). Operation and Maintenance Manuals, and consult Caterpillar dealers for additional guidance, including but not limited to guidance on establishing optimized Lubricant Viscosity and/or acceptable oil drain intervals. Recommendations for Direct Note: The use of Cat SOS Services oil analysis Injection (DI) Diesel Engines helps environmental sustainability as it is the best way to optimize oil life, and will help engines reach The proper SAE viscosity grade of oil is determined their expected life. Consult with your Caterpillar by the minimum ambient temperature during dealer regarding the testing required to establish a cold engine start-up, and the maximum ambient safe, optimized oil drain interval. temperature during engine operation. Standard oil drain intervals as published in engine Refer to Table 1 (minimum temperature) in order to specific Operation and Maintenance Manuals are for determine the required oil viscosity for starting a cold typical applications: engine. • Using recommended oils Refer to Table 1 (maximum temperature) in order to select the oil viscosity for engine operation at the • Using good fuel highest ambient temperature that is anticipated. • Using industry standard good maintenance Note: Generally, use the highest oil viscosity that is • practices available to meet the requirement for the temperature at start-up. SEBU6251-12 13 Maintenance Section Lubricant Specifications • If ambient temperature conditions at engine start-up Table 1 require the use of multigrade SAE OW oil, SAE Lubricant Viscosities for Ambient Temperatures OW-40 viscosity grade is generally preferred over for DI Diesel Engines(l)(2)(3)(4) SAE OW-30. Ambient Temperature Note: SAE 1 OW-30 is the preferred viscosity grade Viscosity Grade Minimum Maximum for the following diesel engines when the ambient temperature is above -18 °C (0 T), and below 40 °C SAE OW-30 -40 °C (-40°F) 30 °C (86 °F) (104 °F). SAE OW-40 -40 °C (-40 °F) 40 °C (104 °F) C7 SAE 5W-30 -30 °C (-22 °F) 30 °C (86 °F) • C-9 SAE 5W-40 -30 °C (-22 °F) 50°C (122 °F) SAE 1OW-30 -18 °C (0 °F) 40°C (104 °F) • C9 SAE 1OW-40 -18 °C (0 °F) 50 °C (122 °F) • 3116 SAE 15W-40 -9.5 °C (15 °F) 50 °C (122 °F) (1) Refer to this Special Publication,"Engine Oil'article in this • 3126 section for recommendations of diesel engine oil type. (2) Supplemental heat is recommended for cold-soaked starts Refer to table 1 and associated footnotes for below the minimum ambient temperature. Supplemental guidance on selecting the proper oil viscosity grade heat may be required for cold-soaked starts that are above the minimum temperature that is stated,depending on the for various ambient temperatures. parasitic load and other factors. Cold-soaked starts occur when the engine has not been operated for a period of time, Note: C175 Series diesel engines require the use allowing the oil to become more viscous due to cooler ambient of multigrade SAE 40 oil. IE: SAE OW-40, SAE temperatures. (3) SAE10W-30 is the preferred viscosity grade for the 3116, 5W-40, SAE 10W-40, or SAE 15W-40. In ambient 3126, CT C-9 and C9 diesel engines when the ambient temperatures of -9.5° C (150 F) or above, SAE temperature is between-18°C(0°F)and 40°C(104°F). • 15W-40 is the preferred oil viscosity grade. Refer to (4) C175 Series diesel engines require the use of multigrade SAE table 1 and associated footnotes for guidance on 40 oil. IE: SAE OW-40, SAE 5W-40, SAE 10W-40,or SAE selecting the proper oil viscosity grade for various 15W-40. In ambient temperatures of-9.5°C(15°F)or above, ambient temperatures. SAE 15W-40 is the preferred oil viscosity grade. Note: Supplemental heat is recommended for cold-soaked starts below the minimum ambient temperature. Supplemental heat may be required for cold-soaked starts that are above the minimum temperature that is stated, depending on the parasitic load and other factors. Cold-soaked starts occur when the engine has not been operated for a period of time, allowing the oil to become more viscous due to cooler ambient temperatures. Refer to this Special Publication, "Lubricant Viscosities" and "Cold Weather Lubricants" articles for additional information. • 14 SEBU6251-12 Maintenance Section Lubricant Specifications i02754267 • Lubricant Viscosities NOTICE Proper oil viscosity AND oil type (category/specifica- SMCS Code: 1000; 7000; 7581 tion) are required to maximize engine performance and life. Do NOT use only oil viscosity, or only oil type to determine the engine oil selection. Using only the oil Selecting the Viscosity viscosity or only the oil type to determine the engine oil selection can lead to reduced performance and en- Ambient temperature is the temperature of the air gine failure. Refer to the"Lubricant Viscosities for Am- in the immediate vicinity of the engine. This may bient Temperatures" tables and to ALL of the associ- differ due to the engine application from the generic ated footnotes, and to the"Lubricant Specifications"in ambient temperature for a geographic region. When this publication. selecting the proper oil viscosity for use, review both the regional ambient temperature and the potential ambient temperature for a given engine application. NOTICE Generally, use the higher temperature as the criterion The footnotes are an integral part of the "Lubricant for the selection of the oil viscosity. Generally, use the Viscosities for Ambient Temperatures" tables - read highest oil viscosity that is allowed for the ambient ALL footnotes! temperature when you start the engine. Refer to the "Lubricant Viscosities for Ambient Temperatures" NOTICE tables and the associated footnotes for guidance. In In colder ambient conditions an engine warm-up pro- arctic applications, the preferred methods are to use cedure and/or supplemental engine fluid compartment a heated enclosure, or properly sized engine heaters heat may be required. Engine specific warm-up pro- and a higher viscosity grade oil. Thermostatically cedures can typically be found in the Operation and controlled heaters that circulate the oil are preferred. Maintenance Manual for the engine. The "Lubricant The proper oil viscosity grade is determined by Viscosities for Ambient Temperatures" tables in this the minimum ambient air temperature (the air in publication include footnotes that address compart- the immediate vicinity of the engine). This is the ment warm-up. • temperature when the engine is started and while the engine is operated. In order to determine the proper NOTICE oil viscosity grade, refer to the "Min" column in the Not following the recommendations found in the "Lu- table. This information reflects the coldest ambient bricant Viscosities for Ambient Temperatures" Tables temperature condition for starting a cold engine and and associated footnotes can lead to reduced perfor- for operating a cold engine. Refer to the"Max"column mance and engine failure. in the table in order to select the oil viscosity grade for operating the engine at the highest temperature that is anticipated. Unless specified otherwise in the NOTICE "Lubricant Viscosities for Ambient Temperatures" Do NOT use only the oil viscosities when determining Table, use the highest oil viscosity that is allowed for the recommended oil for an engine compartment. The the ambient temperature when you start the engine. oil type (category/specification) MUST also be used. Engines that are operated continuously and/or are heavily loaded should use oils that have the higher oil Note: Different brand oils may use different additive viscosity. The oils that have the higher oil viscosity will packages to meet the various engine performance maintain the highest possible oil film thickness. Refer category/specification requirements. For the best to this Special Publication, "Lubricant Viscosities results, do not mix oil brands. for Ambient Temperatures" Tables and associated footnotes for any exceptions. Consult your dealer if Note: The availability of the various Caterpillar oils additional information is needed. will vary by region. Note: SAE OW and SAE 5W oils are generally not recommended for use in engines that are operated continuously and/or are heavily loaded. Refer to the "Lubricant Viscosities for Ambient Temperatures" tables and the associated footnotes for guidance. • The oils that have the higher oil viscosity will maintain the highest possible oil film thickness. Consult your Caterpillar dealer if additional information is needed. SEBU6251-12 15 Maintenance Section Lubricant Specifications • i03420881 For additional information concerning cold weather Cold Weather Lubricants operation, refer to this Special Publication, "Fuel Specifications" section. Also refer to this Special SMCS Code: 1300; 1348; 7581 Publication, "Cooling System Specifications" section. Before attempting to start the engine, make sure that NOTICE the oil in the engine is fluid enough to flow. Check the Recommended engine warm-up procedure must be oil by removing the dipstick. If the oil will drip from followed. Refer to the engine Operation and Mainte- the dipstick, then the oil should be fluid enough to nance Manual. Also refer to the relevant "Lubricant allow the engine to start. Do not use oil that has been Viscosities for Ambient Temperatures" table footnote diluted with kerosene. Kerosene will evaporate in the in this Special Publication. engine. This will cause the oil to thicken. Kerosene will cause swelling and softening of the silicone seals. Kerosene will dilute the oil's additives. Dilution of NOTICE the oil's additives will reduce the oil's performance, Excessive engine idling time can contribute to exces- and reduce the engine protection that the additives sive water in the crankcase oil, causing corrosion, provide. sludge, and other problems. Excessive engine idling time can also lead to injector fouling, piston and com- If the viscosity of the oil is changed for colder bustion chamber deposits, corrosive damage, and in- weather, also change the filter element. If the filter is creased oil consumption. not changed, the filter element and the filter housing can become a solid mass. After you change the oil, For proper selection of oil type, refer to the applicable operate the engine in order to circulate the thinner oil. "Engine Oil" article in this Special Publication. When you start a cold-soaked engine or when you For the proper selection of oil viscosity grade, refer to operate an engine in ambient temperatures that the "Lubricant Viscosities for Ambient Temperatures" are below-18 C (0 F) use base oils that can flow tables in this Special Publication. Also, refer to this in low temperatures. These multigrade oils have • Special Publication, "Lubricant Viscosities" article. lubricant viscosity grade of SAE OW or of SAE 5W. An example of viscosity grade is SAE 5W-40. NOTICE When you start a cold-soaked engine or when you Not following the recommendations found in the "Lu- operate an engine in ambient temperatures that bricant Viscosities for Ambient Temperatures" table are below -30°C (-220F), use a synthetic base and associated footnotes can lead to reduced perfor- stock multigrade oil. The oil should have a lubricant mance and engine failure. viscosity grade of SAE OW or SAE 5W. Use an oil with a pour point that is lower than -40°C (-40oF). NOTICE Note: Use the highest oil viscosity grade that is Do NOT use only the oil viscosities when determining allowed for the ambient temperature when you the recommended oil for an engine compartment. The start the engine. If a different oil viscosity grade is oil type (specification) MUST also be used. specified in the table for"Lubricant Viscosities for Ambient Temperatures", use the viscosity grade that For easier cold weather starting, make sure that all is specified in the table. In arctic applications, of the components of the engine electrical system the preferred method of lubrication is to use an are properly maintained. All electrical wiring and engine compartment heater that is properly sized connections should be free of the following: fraying, and to use oil that is a higher viscosity grade. damaged insulation, and corrosion. Batteries should Refer to the "Lubricant Viscosities" article in this be kept fully charged and warm. The batteries and Special Publication for further details. the battery cables should be properly sized for the application. Note: Cold-soaked starts occur when the engine has not been operated for a period of time, allowing the A variety of starting aids are available in order to oil to become more viscous due to cooler ambient assist with cold engine starts in low temperature temperatures. Supplemental heat is recommended conditions. Follow the recommendations that are for cold-soaked starts that are below the minimum • provided by the manufacturer of the starting aid. ambient temperatures listed in the "Lubricant Refer to the foreword of this Special Publication, Viscosities for Ambient Temperatures" tables. "Aftermarket Products and Warranty". Supplemental heat may be required for cold-soaked starts that are above the minimum temperature that is stated, depending on the parasitic load and other factors. 16 SEBU6251-12 Maintenance Section Lubricant Specifications When the crankcase blowby flows through the • NOTICE turbocharger and the aftercooler, the viscosity Engines that use fluid or pan heaters, or heated index improvers in the oil vapor can adhere to the enclosures, or are kept running under load, etc. turbocharger compressor and aftercooler core. can, and generally should use higher viscosity oil. The "Lubricant Viscosities for Ambient Tempera- The fouling of the turbocharger and aftercooler can tures" tables (Maintenance Section) "Minimum" vis- cause reduced air flow, loss of power, and increased cosity for ambient temperature recommendations are black smoke. The emission of black smoke results in for cold-soaked conditions. Use the highest viscosity buildup of soot on the transom of the boat. oil that is allowed for the ambient temperature when you start the engine - BUT, under Continuous Us- Note: Caterpillar recommends the use of single grade age (Multiple Shifts/Day), and/or when using fluid oils that pass all API CF-4 category requirements or pan heaters, etc., use a higher viscosity oil, NOT for all 3116 and 3126 MUI Marine Engines unless the oil with the minimum recommended viscosity for crankcase blowby has been routed completely away cold-soaked starting conditions. The higher viscosity from the air cleaner inlet. oil will maintain the highest possible oil film thickness. Refer to the "Lubricant Viscosities for Ambient Tem- Cat SAEO (Special Application Engine peratures" tables and the table footnotes for excep- Oil) tions. Example: The oil viscosity recommended for use Note: Cat SAEO is for use in Caterpillar 3116 and in Caterpillar diesel engines for cold-soaked starts 3126 Marine Diesel Engines with mechanical unit at -40 °C (-40 OF) is multigrade oil of the SAE OW injection. This includes all 3116 and 3126 Marine viscosity grade(SAE OW-30, etc.). If the diesel engine Diesel Engines that begin with the following serialnumber prefixes: (S/N: 6SR), (S/N: 8NM), (S/N:4KG), is run continuously, SAE 15W-40 viscosity grade diesel engine oil can be used - and is generally the (S/N: 1SK), (S/N: 1ZJ), (S/N: 6MK), and (S/N: 4EZ). preferred oil viscosity in this situation. The factory fill in 3116 and 3126 Marine Engines is Cat SAEO. The oil that is used for the factory fill has • NOTICE the following properties: If ambient conditions warrant, a higher viscosity oil of . API CF-4 category the recommended specification/category for a given compartment may need to be installed in order to pro- . Viscosity grade of SAE 30 vide adequate film thickness. For maximum performance in 3116 and 3126 Marine NOTICE Diesel Engines with mechanical unit injection, Recommended engine warm-up procedure must be Caterpillar recommends the following engine oil: followed. Refer to the Operation and Maintenance Manual. • Cat SAEO (SAE 30) • Cat SAEO (SAE 40) i03420180 Engine Oil (3116 and 3126 Commercial Oils (3116 and 3126 Marine Engines) Marine Engines) SMCS Code: 1348; 7581 NOTICE Caterpillar does not warrant the quality or perfor- Recommendations mance of non-Caterpillar fluids. Caterpillar does not recommend the use of multigrade When Cat SAEO is not used, use the following oils in the 3116 and 3126 Marine Diesel Engines that commercial oils: use mechanical unit injection (MUI). • Single grade oil with a viscosity of SAE 30 or SAE • Multigrade oils use high molecular weight polymers 40 that pass all API CF-4 category requirements as viscosity index improvers. is preferred. SEBU6251-12 17 Maintenance Section Lubricant Specifications • Single grade oil with a viscosity of SAE 30 or SAE The minimum required Total Base Number (TBN) 40 with an API CF-4 or API CG-4 additive package for oil depends on the fuel sulfur level. For direct that does NOT contain viscosity improvers is injection engines that use distillate fuel, the minimum acceptable oil. new oil TBN must be 10 times the fuel sulfur level. The TBN for new oil is typically determined by the For an acceptable commercial single grade oil, "ASTM D2896" procedure. contact your oil supplier or Caterpillar Customer Service: Note: The minimum TBN of the new oil is 6.5 regardless of the fuel sulfur level. Reaching one half 1-800-447-4986 of new oil TBN is one of the condemning factors for diesel engine oil but, in order to help provide the best The following explanation of the API CF-4 category protection for your engine, Cat S-O-S Services oil can be used to make the proper choice when analysis is the preferred method of determining oil commercial single grade oil with API CF-4 category life. For best results when determining oil life using is chosen. the one half new oil TBN method, determine the new and used oil TBN using both the "ASTM D2896" and API CF-4 — API CF-4 oils provide more stable oil the "ASTM D4739" test methods. Change the oil control and reduced piston deposits in comparison to when reaching one half of new oil TBN with either API CIF and the obsolete CE and CD categories of oil. respective TBN test method using the results from API CF-4 oils provide improved soot dispersancy in which ever respective test method shows reaching comparison to API CIF and obsolete CD oils. The API one half of new oil TBN first. CF-4 category was developed with a 0.40 percent sulfur diesel fuel. For example, new oil with a TBN of 10 by "ASTM D2896" should be changed when, during use, the Some commercial oils that meet the API CF-4 TBN deteriorates to 5 as determined by the "ASTM categories may require reduced oil change intervals. D2896" test method, and new oil with a TBN of 10 To determine the oil change interval, closely monitor by "ASTM D4739" should be changed when, during • the condition of the oil and perform a wear metal use, the TBN deteriorates to 5 as determined by the analysis. Caterpillar's S.O.S Services oil analysis "ASTM D4739" test method. Use the results from program is the preferred method. which ever respective test method reaches one half of new oil TBN first. NOTICE Excessive piston deposits can be produced by oil Failure to follow these oil recommendations can cause with a high TBN and/or high ash. These deposits can shortened engine service life due to deposits and/or lead to a loss of control of the oil consumption and to excessive wear. the polishing of the cylinder bore. Total Base Number (TBN) and Fuel NOTICE Sulfur Levels for Direct Injection Depending on application severity and localized envi- ronmental conditions, and also depending on mainte- nance practices, operating Direct Injection (DI) diesel Marine Engines) engines and operating PC (Precombustion Chamber) diesel engines on fuel with sulfur levels over 0.1 per- The use of Cat S.O-S Services oil analysis is strongly cent (1000 ppm) may require significantly shortened recommended for determining oil life. oil change intervals in order to help maintain adequate wear protection. Refer to this Special Publication, "Fu- Note: The following information concerning oil life el Specifications"section, "Diesel Fuel Sulfur"topic for relative to used oil TBN level is provided for general additional information. information only, and is not the recommended method for determining oil life. If the one half of new Consult with your Caterpillar dealer regarding the oil TBN guideline that is stated below is used testing that is required in establishing oil drain for determining oil life it must only be used in intervals that are optimized for your application. conjunction with a complete S•O•S Services oil analysis program. In order to help protect your engine, and in order • to help optimize oil drain intervals for engine Note: TBN is also commonly referred to as Base specific applications and duty cycles, Cat S•O•S Number (BN). Services oil analysis is: • Recommended as a matter of course 18 SEBU6251-12 Maintenance Section Lubricant Specifications • Very strongly recommended in order to determine i03467326 • oil drain intervals when operating on fuel with sulfur Engine Oil for Precombustion levels between 0.05% (500 ppm) and 0.5% (5000 g ppm) Chamber (PC) Diesel Engines • Required in order to determine oil drain intervals (Engine Crankcase Fluid when operating on fuel with sulfur levels that are Recommendations for All 3500 above 0.5% (5000 ppm) Series and Smaller PC Diesel Note: Engine operating conditions play a key role Engines) in determining the effect that fuel sulfur will have on engine deposits and on engine wear. Consult your SMCS Code: 1348; 7581 Caterpillar dealer for guidance when fuel sulfur levels are above 0.1% (1000 ppm). Most Caterpillar medium and heavy-duty PC diesel Lubricant Viscosity engines were produced before 1991. Recommendations (3116 and Cat DEO (Diesel Engine Oil) 3126 Marine Engines) Cat oils have been developed and tested in order to The proper SAE viscosity grade of oil is determined provide the full performance and service life that has by the minimum ambient temperature during been designed and built into Cat engines. Cat oils cold engine start-up, and the maximum ambient are currently used to fill diesel engines at the factory. temperature during engine operation. These oils are offered by Cat dealers for continued use when the engine oil is changed. Consult your Cat Refer to Table 2 (minimum temperature) in order to dealer for more information on these oils. determine the required oil viscosity for starting a cold Due to the additional full-scale proprietary engine engine. testing required of Cat DEO and Cat DEO-ULS, • Refer to Table 2 (maximum temperature) in order to and due to significant variations in the quality and select the oil viscosity for engine operation at the in the performance of commercially available oils, highest ambient temperature that is anticipated. Caterpillar makes the following recommendations: Generally, use the highest oil viscosity that is allowed • Cat DEO (Diesel Engine Oil) (10W-30) for the ambient temperature at start-up. • Cat DEO (Diesel Engine Oil) (15W-40) Table 2 Lubricant Viscosities for Ambient Temperatures(') • Cat DEO-ULS (Diesel Engine Oil - Ultra Low Sulfur) (10W-30) Cat SAEO Ambient Temperature Viscosity Grade • Cat DEO-ULS (Diesel Engine Oil - Ultra Low Minimum Maximum Sulfur) (15W-40) SAE 30 0 °C (32 °F) 40°C (104 °F) SAE 40 5 °C (41 °F) 50 °C (122 °F) NOTICE (1) Supplemental heat is recommended for cold-soaked starts Do not use single grade API CF oils or multigrade API CF oils in Caterpillar 3500 Series, C175 Series and below the minimum ambient temperature. Supplemental heat may be required for cold-soaked starts that are above smaller Direct Injection (DI) diesel engines. the minimum temperature that is stated, depending on the parasitic load and other factors. Cold-soaked starts occur API CF oils are only recommended for Caterpillar when the engine has not been operated for a period of time, 3600 Series and C280 Series diesel engines, and allowing the oil to become more viscous due to cooler ambient Caterpillar engines that have precombustion chamber temperatures. (PC) fuel systems. Oils that are used in Caterpillar 3600 Series and C280 Series diesel engines must also pass a 7000 hour field performance evaluation. Contact your Caterpillar dealer for details. Note: Cat DEO-ULS and Cat DEO multigrade oils • are the preferred oils for use in ALL Cat diesel engines that are covered by this Special Publication. Commercial alternative diesel engine oils are, as a group, second choice oils. SEBU6251-12 19 Maintenance Section Lubricant Specifications • Note: Do not use single grade oils in Caterpillar Note: Cat DEO multigrade exceeds the requirements Series 3500 series, Series C175 series, and smaller of the following Cat Engine Crankcase Fluid (ECF) Direct Injection (DI) diesel engines. specifications: Cat ECF-1-a and Cat ECF-2. Cat DEO multigrade exceeds the performance requirements Cat DEO multigrade and Cat DEO-ULS multigrade for the following American Petroleum Institute (API) oils are formulated with the correct amounts of oil categories: API CI-4, API CI-4 PLUS, API CH-4, detergents, dispersants, and alkalinity in order to API CG-4, and API CF. The availability of Cat DEO provide superior performance in Cat diesel engines multigrade exceeding the noted requirements will where recommended for use. vary by region. Cat DEO SAE 15W-40 also passes additional proprietary tests that include the following Cat DEO-ULS and Cat DEO multigrade oils are tests: sticking of the piston ring, oil control tests, wear available in various viscosity grades that include SAE tests, and soot tests. Proprietary tests help ensure 1 OW-30 and SAE 15W-40. Multigrade oils provide that Cat multigrade oil provides superior performance the correct viscosity for a broad range of operating in Cat diesel engines. In addition, Cat multigrade oil temperatures. exceeds many of the performance requirements of other manufacturers of diesel engines. Therefore, Multigrade oils are effective in maintaining low oil this oil is an excellent choice for many mixed fleets. consumption and low levels of piston deposits. True high performance oil is produced by using a combination of the following factors: industry NOTICE standard tests, proprietary tests, field tests, Oils that have more than 1% total sulfated ash should and prior experience with similar formulations. not be used in aftertreatment device equipped en- The design and the development of Caterpillar gines. lubricants that are both high performance and high quality are based on these factors. In order to achieve expected ash service intervals, Note: Cat DEO-ULS multigrade exceeds the performance, and life, aftertreatment device equipped requirements of the Cat ECF-1-a, Cat ECF-2, and diesel engines require the use of Cat DEO-ULS or oils Cat ECF-3 specifications. Cat DEO-ULS multigrade • meeting the Cat ECF-3 specification and the API CJ-4 exceeds the performance requirements for the oil category. Oils that meet the Cat ECF-2 specifica- following API oil categories: API CJ-4, API CI-4, tion and that have a maximum sulfated ash level of 1%are also acceptable for use in most aftertreatment API CI-4 PLUS, API CH-4, API CG-4, and API CF. equipped engines. Use of oils with more than 1% to- Cat DEO-ULS multigrade also passes additional tal sulfated ash in aftertreatment device equipped en- proprietary tests that include the following tests: gines will cause the need for more frequent ash ser- sticking of the piston ring, oil control tests, wear tests, vice intervals, and/or cause loss of performance. Re- and soot tests. Proprietary tests help ensure that fer to your engine specific Operation and Maintenance Cat multigrade oil provides superior performance in Manual, and refer to your aftertreatment device docu- Cat diesel engines. In addition, Cat multigrade oil mentation for additional guidance. exceeds many of the performance requirements of other manufacturers of diesel engines. Therefore this oil is an excellent choice for many mixed fleets. Cat DEO multigrade and Cat DEO-ULS True high performance oil is produced by using multigrade oils can be used in other manufacturer a combination of the following factors: industry diesel engines and in gasoline engines. See standard tests, proprietary tests, field tests, the engine manufacturer literature for the and prior experience with similar formulations. recommended categories/specifications. Compare The design and the development of Caterpillar the categories/specifications to the specifications of lubricants that are both high performance and Cat DEO multigrade and Cat DEO-ULS multigrade high quality are based on these factors. oils. The current industry standards for Cat DEO multigrade and Cat DEO-ULS multigrade oils are Commercial Oils listed on the product labels and on the datasheets for the product. Engine Crankcase Fluid Recommendations for Consult your Cat dealer for part numbers and for all Current and Noncurrent Caterpillar Diesel available sizes of containers. Engines that are Covered by this Special Publication isNote: Non-Caterpillar commercial oils are, as a group, second choice oils. Within this grouping of second choice oils there are tiered levels of performance. 20 SEBU6251-12 Maintenance Section Lubricant Specifications • When the recommended and preferred Cat diesel • NOTICE engine oils are not used, commercial oils that meet Caterpillar does not warrant the quality or perfor- the requirements of the Cat ECF-3 specification mance of non-Caterpillar fluids. are acceptable for use in Cat diesel engines that are covered by this Special Publication. After Cat DEO-ULS and Cat DEO, commercial oils that Caterpillar developed the Engine Crankcase Fluid meet the Cat ECF-3 specification are preferred oils (ECF) specifications to ensure the availability of high when compared to commercial diesel engine oils performance commercial diesel engine oils in order that do not meet the Cat ECF-3 specification for to provide satisfactory life and performance in Cat use in Cat diesel engines that are covered by this diesel engines where recommended for use. Special Publication. Note that in order to achieve the maximum expected engine performance and There are three current Cat ECF specifications: life, some engines/engine applications will require Cat ECF-1-a, Cat ECF-2, and Cat ECF-3. Each the use of higher performance oils such as those higher Cat ECF specification provides increased meeting Cat ECF-3 versus meeting Cat ECF-2 or performance over lower Cat ECF specifications. For Cat ECF-1-a. example, Cat ECF-3 provides higher performance than Cat ECF-2 and Cat ECF-3 provides much higher Oils that meet the API CJ-4 oil category requirements performance than Cat ECF-1-a. are Cat ECF-3 specification compliant. Note:The Cat ECF-1-a and Cat ECF-2 specifications NOTICE replaced the Cat ECF-1 specification as of 1 March 2007. Oils that have more than 1% total sulfated ash should not be used in aftertreatment device equipped en- Note: Cat DEO and DEO-ULS are required to pass gines. additional proprietary full-scale diesel engine testing that is above and beyond the testing required by the In order to achieve expected ash service intervals, various Cat ECF specifications and by the various performance, and life, aftertreatment device equipped API oil categories that they also meet. This additional diesel engines require the use of Cat DEO-ULS or oils • proprietary testing helps ensure that Cat multigrade meeting the Cat ECF-3 specification and the API CJ-4 diesel engine oils, when used as recommended, oil category. Oils that meet the Cat ECF-2 specifica- provide superior performance in Cat diesel engines. If tion and that have a maximum sulfated ash level of Cat DEO multigrade or DEO-ULS multigrade oils are 1%are also acceptable for use in most aftertreatment not used, as a second choice, use only commercial equipped engines. Use of oils with more than 1% to- oils that meet the following specifications: tal sulfated ash in aftertreatment device equipped en- gines will cause the need for more frequent ash ser- • When the recommended and preferred Cat diesel vice intervals, and/or cause loss of performance. Re- engine oils are not used, commercial oils that meet fer to your engine specific Operation and Maintenance the requirements of the Cat ECF-1-a, Cat ECF-2, Manual, and refer to your aftertreatment device docu- and/or the Cat ECF-3 specification are acceptable mentation for additional guidance. for use in Cat diesel engines that are covered by this Special Publication. API category oils that Severe Applications Require the Use of have not met the requirements of at least one Cat ECF specification may cause reduced engine Higher Performing Diesel Engine Oils life. Note that in order to achieve the maximum expected engine performance and life, some In order to help ensure the maximum expected engines/engine applications will require the use of compartment performance and life, severe duty higher performance oils such as those meeting Cat applications such as those operating at greater than ECF-3 versus meeting Cat ECF-2 or Cat ECF-1-a. 75% load factor, operating in high humidity, operating with fuel sulfur levels that are above 0.1% (1000 ppm), etc., require the use of higher performing fluids as described in this Special Publication, versus using fluids that meet the minimum performance levels that may be allowed for typical applications. (ex: Where fluids meeting either Cat ECF-1-a, Cat ECF-2 or Cat ECF-3 are offered as an option in typical applications, in order to help ensure the maximum expected engine • compartment performance and life, oil meeting the Cat ECF-3 specification must be used.) SEBU6251-12 21 Maintenance Section Lubricant Specifications • Note: There are additional oil considerations that are Note: While API CIF category single grade and related to fuel sulfur levels. Refer to the various"Total multigrade oils may be acceptable for use in PC Base Number(TBN) and Fuel Sulfur Levels..." topics diesel engines, API CIF oils and single grade oils in this Special Publication. Also refer to the "Diesel are not acceptable for use in Caterpillar DI engines. Fuel Sulfur" topic in this Special Publication. Excessive piston deposits will occur when oils that meet only the API CIF oil category are used in NOTICE Caterpillar 3500 Series, C175 Series and smaller DI In selecting oil for any engine application, both the diesel engines. oil viscosity and oil performance category/specifica- tion as specified by the engine manufacturer must be The minimum required Total Base Number (TBN) defined and satisfied. Using only one of these param- for oil depends on the fuel sulfur level. For direct eters will not sufficiently define oil for an engine appli- injection engines that use distillate fuel, the minimum cation. new oil TBN must be 20 times the fuel sulfur level. The TBN for new oil is typically determined by the "ASTM D2896" procedure. In order to make the proper diesel engine oil viscosity grade choice, refer to the "Lubricant Viscosities for Note: The minimum TBN of the new oil is 7 Ambient Temperatures for DI Diesel Engines" table in regardless of the fuel sulfur level. Reaching one half this Special Publication. of new oil TBN is one of the condemning factors for diesel engine oil but, in order to help provide the best NOTICE protection for your engine, Cat S.O-S Services oil Oils that have not met the requirements of at least one analysis is the preferred method of determining oil Cat ECF specification may cause reduced engine life. life. For best results when determining oil life using the one half new oil TBN method, determine the new and used oil TBN using both the"ASTM D2896" and NOTICE the "ASTM D4739" test methods. Change the oil Failure to follow these oil recommendations can cause when reaching one half of new oil TBN with either shortened engine service life due to deposits and/or respective TBN test method using the results from • excessive wear. which ever respective test method shows reaching one half of new oil TBN first. Total Base Number (TBN) and Fuel For example, new oil with a TBN of 10 by "ASTM Sulfur Levels for Precombustion D2896" should be changed when, during use, the TBN deteriorates to 5 as determined by the "ASTM Chamber (PC) Diesel Engines D2896" test method, and new oil with a TBN of 10 by "ASTM D4739" should be changed when, during The use of Cat S.O-S Services oil analysis is strongly use, the TBN deteriorates to 5 as determined by the recommended for determining oil life. "ASTM D4739" test method. Use the results from which ever respective test method reaches one half Note: The following information concerning oil life of new oil TBN first. relative to used oil TBN level is provided for general information only, and is not the recommended Excessive piston deposits can be produced by oil method for determining oil life. If the one half of new with a high TBN and/or high ash. These deposits can oil TBN guideline that is stated below is used lead to a loss of control of the oil consumption and to for determining oil life it must only be used in the polishing of the cylinder bore. conjunction with a complete S•O•S Services oil analysis program. NOTICE Note: TBN is also commonly referred to as Base Depending on application severity and localized envi- Number (BN). ronmental conditions, and also depending on mainte- nance practices, operating Direct Injection (DI) diesel Note: Oils that have not met the requirements of at engines and operating PC (Precombustion Chamber) least one Cat ECF specification may cause reduced diesel engines on fuel with sulfur levels over 0.1 per- engine life. cent (1000 ppm) may require significantly shortened oil change intervals in order to help maintain adequate wear protection. Refer to this Special Publication, "Fu- el Specifications"section, "Diesel Fuel Sulfur'topic for additional information. 22 SEBU6251-12 Maintenance Section Lubricant Specifications Note: For PC (Precombustion Chamber) diesel Table 3 • engines, which are mainly 1990 and older engines, Lubricant Viscosities for Ambient Temperatures the minimum new oil TBN must be 20 times the fuel for PC Diesel Engines(l)(2> sulfur level.The diesel engine oil types,specifications, and viscosity grades recommendations provided for Ambient Temperature DI diesel engines in this Special Publication are also Viscosity Grade Minimum Maximum applicable to PC diesel engines. SAE OW-30 -40 °C (-40°F) 30 °C (86 °F) Consult with your Caterpillar dealer regarding the SAE OW-40 -40 °C (-40°F) 40 °C (104 °F) testing that is required in establishing oil drain intervals that are optimized for your application. SAE 5W-30 -30 °C (-22 °F) 30 °C (86 °F) In order to help protect your engine, and in order SAE 5W-40 -30 °C (-22 °F) 50 °C (122 °F) to help optimize oil drain intervals for engine SAE 10W-30 -18 °C (0 °F) 40 °C (104 °F) specific applications and duty cycles, Cat S•O•S SAE 1OW-40 -18 °C (0 °F) 50 °C (122 °F) Services oil analysis is: SAE 15W-40 -9.5°C (15°F) 50°C (122 °F) • Recommended as a matter of course SAE 30A 0 °C (32 °F) 40°C (104 °F) • Very strongly recommended in order to determine SAE 40A 5 °C (41 °F) 50°C (122 °F) oil drain intervals when operating on fuel with sulfur Refer to this publication, "Engine Oil for Precombustion levels between 0.05% (500 ppm) and 0.5% (5000 Chamber(PC)Diesel Engines"article for recommendations of ppm) diesel engine oil type. (2) Supplemental heat is recommended for cold-soaked starts • Required in order to determine oil drain intervals below the minimum ambient temperature. Supplemental heat may be required for cold-soaked starts that are above when operating on fuel with sulfur levels that are the minimum temperature that is stated,depending on the above 0.5% (5000 ppm) parasitic load and other factors. Cold-soaked starts occur when the engine has not been operated for a period of time, • Note: Engine operating conditions play a key role allowing the oil to become more viscous due to cooler ambient in determining the effect that fuel sulfur will have on temperatures. engine deposits and on engine wear. Consult your (4) PC engines only Caterpillar dealer for guidance when fuel sulfur levels Note: Supplemental heat is recommended for are above 0.1 /o (1000 ppm). cold-soaked starts below the minimum ambient temperature. Supplemental heat may be required Lubricant Viscosity Recommendations for cold-soaked starts that are above the minimum for Precombustion Chamber (PC) Diesel temperature that is stated, depending on the parasitic Engines load and other factors. Cold-soaked starts occur when the engine has not been operated for a period The proper SAE viscosity grade of oil is determined of time, allowing the oil to become more viscous due by the minimum ambient temperature during to cooler ambient temperatures. cold engine start-up, and the maximum ambient Refer to this Special Publication, "Lubricant temperature during engine operation. Viscosities" and "Cold Weather Lubricants" articles Refer to Table 3 (minimum temperature) in order to for additional information. determine the required oil viscosity for starting a cold engine. i02434366 Refer to Table 3 (maximum temperature) in order to Marine Transmission Oil select the oil viscosity for engine operation at the highest ambient temperature that is anticipated. SMCS Code: 3080; 3300; 7581 Generally, use the highest oil viscosity that is Cat TDTO (Transmission/Drive Train Oil) is balanced available to meet the requirement for the temperature in order to give maximum frictional material service at start-up. life and performance in Caterpillar transmissions. Cat TDTO exceeds the requirements for the Caterpillar Note: Table 3 is only for PC diesel engines. TO-4 oil specification which includes the frictional requirements and gear wear requirements. Cat TDTO is offered in different lubricant viscosity grades for maximum service life of components at high ambient temperatures and heavy duty cycles. SEBU6251-12 23 Maintenance Section Lubricant Specifications • For maximum transmission service life and performance, Caterpillar recommends Cat TDTO. Table 4 Cat TDTO Lubricant Viscosities For Operating Temperatures Cooling of Oil Viscosities Minimum Maximum Transmission Temperature Temperature SAE 30 -15 °C (5 °F) 80 °C (176 °F) Raw/Sea water SAE 50 -5 °C (23 °F) 95 °C (203 °F) Jacket Water SAE 50 -5 °C (23 °F) 95 °C (203 °F) Contact your Caterpillar dealer for part numbers and - Synthetic base oils have improved flow at low for sizes of available containers. temperatures, especially in arctic conditions. NOTICE - Synthetic base oils have improved oxidation This oil is formulated for transmissions and drive trains stability, especially at high operating temperatures. only, and should not be used in engines. Shortened engine life will result. Some synthetic base oils have performance characteristics that enhance the service life of the oil. However, Caterpillar does not recommend the NOTICE automatic extension of oil drain intervals for any type Cat GO (Gear Oil) is not the same as Cat TDTO, and of oil, whether synthetic or non-synthetic. does not meet Caterpillar's specifications for TO-4 oil. Cat GO or commercial gear oils should not be used in Oil drain intervals for Caterpillar engines can only be • compartments which specify TO-4 oil. adjusted higher(longer interval) after an oil analysis program that contains the following data: Caterpillar Transmission/Drive - Oil condition, oil contamination, and wear metal Train Oils analysis (Caterpillar S-O-S Services oil analysis) If Cat TDTO (Transmission/Drive Train Oil) is not - Trend analysis used, commercial oils meeting the Caterpillar TO-4 - Fuel consumption specification must be used in Caterpillar marine transmissions. Use TO-4 specification oils that are - Oil consumption single grade only. Refer to the "Extended Engine Oil Drains and Commercial Marine Transmissions Warranty" article in the Foreword of this Special Publication. For marine transmissions which are not manufactured by Caterpillar, refer to the lubrication recommendation of the Original Equipment Manufacturer (OEM) for i03304768 the marine transmission or the vessel. Re-refined Basestock Oils 103002053 SMCS Code: 1300; 1348; 7581 Synthetic Base Stock Oils Re-refined basestock oils are acceptable for use in Caterpillar engines IF these oils meet the SMCS Code: 1300; 1348; 7581 performance requirements that are specified by Caterpillar. Synthetic base oils are acceptable for use in • Caterpillar engines if these oils meet the Re-refined basestock oils can be used exclusively performance requirements that are specified by in finished oil or in a combination with new Caterpillar for the engine compartment. basestock oils. The US military specifications and the specifications of other heavy equipment Synthetic base oils generally perform better than manufacturers also allow the use of re-refined conventional oils in the following two areas: basestock oils that meet the same criteria. 24 SEBU6251-12 Maintenance Section Lubricant Specifications The process that is used to make re-refined i03002O59 • basestock oil should adequately remove all wear Lubricating Grease metals that are in the used oil and all additives that are in the used oil. Vacuum distillation and the hydrotreating of the used oil are acceptable SMCS Code: 0645, 1000; 7000; 7581 processes that are used for producing re-refined base oil. NOTICE These recommendations are subject to change with- Note: Filtering is inadequate for the production of out notice. Consult your local Caterpillar dealer for the high quality re-refined basestock oils from used oil. most up to date recommendations. 103451083 Caterpillar provides various greases that vary in Aftermarket Oil Additives performance from a moderate performance to an extremely high performance. These greases service the entire line of Caterpillar products in the wide SMCS Code: 1300; 1348; 7581 variety of climates throughout the world. From this variety of Caterpillar grease products, you can Caterpillar does not recommend the use of find Caterpillar grease that will meet or exceed aftermarket additives in oil. It is not necessary to the performance requirements for almost every use aftermarket additives in order to achieve the machine that is produced by any Original Equipment engine's maximum service life or rated performance. Manufacturer (OEM), and for almost every machine Fully formulated, finished oils consist of base oils application or equipment application. and of commercial additive packages. These additive packages are blended into the base oils at precise Before selecting a grease product, the performance percentages in order to help provide finished oils requirements must be determined. Consult the with performance characteristics that meet industry grease recommendations that are made by the OEM standards. for the equipment. Then, consult with your Caterpillar dealer for a list of greases that have the performance • There are no industry standard tests that evaluate specifications and the available container sizes. the performance or the compatibility of aftermarket additives in finished oil. Aftermarket additives may Note: Always choose grease that meets or exceeds not be compatible with the finished oil's additive the recommendations that are specified by the package, which could lower the performance of the equipment manufacturer for the application, finished oil. The aftermarket additive could fail to mix with the finished oil. This could produce sludge If it is necessary to choose a single grease to use in the crankcase. Caterpillar discourages the use of for all of the equipment at one site, always choose aftermarket additives in finished oils. grease that meets or exceeds the requirements of the most demanding application. Remember To achieve the best performance from a Caterpillar that the products which barely meet the minimum engine, conform to the following guidelines: performance requirements can be expected to barely produce the minimum parts life. False economy is • Select the proper Caterpillar oil or commercial oil. being used if grease is purchased with the lowest Refer to the "Selecting a Commercial Oil" article cost as the only consideration. Instead, use the in the "Lubricant Specifications" section of this grease that yields the lowest total operating cost. This Special Publication. cost should be based on an analysis that includes the costs of parts, labor, downtime, and the cost of the • Refer to the appropriate "Lubricant Viscosities amount of grease that is required. for Ambient Temperatures" table in this Special Publication in order to find the correct oil viscosity grade for your engine. NOTICE Do NOT mix brands and/or types of grease. • At the specified interval, service the engine compartment. Use appropriate new oil and install Different brands and/or types of grease may not be an appropriate new oil filter. chemically compatible. • Perform maintenance at the intervals that are When switching grease brands and/or grease types, specified in the Operation and Maintenance it is strongly recommended that the old grease be Manual, "Maintenance Interval Schedule". purged. If in doubt, Purge! SEBU6251-12 25 Maintenance Section Lubricant Specifications • Even when grease brands and/or types are Cat Advanced 3Moly Grease chemically compatible, mixing greases can affect characteristics such as penetration, water washout Cat Advanced 3Moly Grease is NLGI grade 2 grease. resistance, etc., with a potential negative affect on This grease is made with petroleum base oil and grease performance. a lithium complex thickener. This grease also has three percent Molybdenum disulfide (MoSz or"Moly"). To help ensure expected grease performance, it is Cat Advanced 3Moly Grease is formulated for use strongly recommended that grease brands and/or in applications with low severity to high severity at types NOT be mixed. moderate temperatures. In addition, the molybdenum in Cat Advanced 3Moly Grease is a special grade When switching brands and/or types of grease, it is that has a median particle size of 3 microns in order strongly recommended to purge as much of the old to meet the special requirements of some rolling grease as possible from the compartment or system, element bearings. and to reduce the greasing interval for a short period thereafter. Cat Advanced 3Moly Grease meets the NLGI certification of"GC-LB". Note: While all Cat brand greases (except Cat "High Speed Ball Bearing Grease") are chemically Note: If the application calls for a multipurpose compatible, they are formulated with different levels grease with molybdenum and Cat Advanced 3Moly of performance and mixing them can affect the Grease is not available, consult the data sheets for expected grease performance. the greases. Use a substitute that meets or exceeds the performance characteristics of Cat Advanced Cat Multipurpose Grease 3Moly Grease. Cat Multipurpose Grease is National Lubricating Severe Applications Grease Institute (NLGI) grade 2 grease. This grease is made with petroleum base oil and a lithium complex Caterpillar has greases which are made with a • thickener. Cat Multipurpose Grease is formulated Calcium Sulfonate Complex thickener. This type of for use in applications that have a low severity to a grease is necessary for more severe applications. medium severity and moderate temperatures. These greases provide more load carrying (galling resistance), lower wear, longer working life, Cat Multipurpose Grease meets the NLGI certification exceptional water washout, and resistance to of"GC-LB". corrosion. Note: If the application calls for a multipurpose Cat Ultra 5Moly Grease grease and Cat Multipurpose Grease is not available, consult the grease data sheets. Use a substitute that Cat Ultra 5Moly Greases are available in NLGI meets or exceeds the performance characteristics of grades 1 and 2. Cat Ultra 5Moly Greases are made Cat Multipurpose Grease. with special blends of petroleum base oils and a Calcium Sulfonate Complex thickener. These Cat White Assembly Grease greases also have five percent Molybdenum disulfide (MoSz or"Moly") and an added tackifier. Cat Ultra Cat Multipurpose Grease is also available in an 5Moly Greases are specially formulated in order extra tacky version, known as Cat White Assembly to protect all of the most heavily loaded points in Grease. Cat White Assembly Grease has the same any Caterpillar application where grease is required formula and the same performance as regular Cat against galling, wear, and corrosion. This protection Multipurpose Grease. One difference between Cat is sustained while work is being done in moderate Multipurpose Grease and Cat White Assembly temperatures and with wet working conditions or dry Grease is the white color. In addition, this grease working conditions. has been made extra tacky in order to hold gaskets, O-rings, and needle bearings better in the assembly Cat Ultra 5Moly Greases are formulated with special of engines and other components. blends of naphthenic petroleum base oils that have low pour points. This allows the Cat Ultra 5Moly Greases to pump at lower temperatures. The ability to • pump Cat Ultra 5Moly Greases at lower temperatures means added insurance that all of the grease joints will be adequately lubricated even if the ambient temperature drops unexpectedly. 26 SEBU6251-12 Maintenance Section Lubricant Specifications A significant challenge exists in order to get grease Cat Desert Gold Grease is NLGI grade 2 grease. • to pump into the joints at low temperatures. Once This grease is made with synthetic base oil that the grease gets to the joint, the grease must have has a very high viscosity and a Calcium Sulfonate extremely high resistance to galling, wear, fretting, Complex thickener. This grease also has five percent water washout, and corrosion in order to adequately Molybdenum disulfide (MoS, or "Moly") and a protect highly loaded joints. tackifier. Even under severely loaded conditions, the grease As the temperature changes, Cat Desert Gold should preferably have a very long working life. Grease will experience a minimal change in viscosity In order to make greases that meet these greater because the base is synthetic oil. Because Cat demands, a Calcium Sulfonate Complex thickener Desert Gold Grease has a synthetic base oil with a with properly blended naphthenic oil and/or synthetic high viscosity, Cat Desert Gold Grease maintains a base oil is required. This is the reason that Caterpillar thick lubricant film even at very hot temperatures. uses these ingredients in Cat Ultra 5Moly Greases. Cat Desert Gold Grease is made with a Calcium Cat Ultra 5Moly Greases also have five percent Sulfonate Complex thickener. This provides the Moly, instead of the zero to three percent that is necessary protection against galling, wear, fretting, found in most other greases. This additional Moly water washout, and corrosion. Cat Desert Gold greatly improves the ability of the grease to protect Grease also has a very long life. This grease will parts from damage in applications with severe resist breakdown even when the application is under impact (slamming). In addition, the Moly in Cat Ultra extremely heavy loads. This protection is sustained 5Moly Grease is a special grade that has a median while work is being done at moderate temperatures particle size of 3 microns in order to meet the special to very hot temperatures with wet conditions or dry requirements of some rolling element bearings. conditions. Cat Ultra 5Moly Greases are also made to be extra Cat Desert Gold Grease has five percent tacky. In some applications, the film of grease must molybdenum instead of the zero to three percent adhere to the vertical surfaces. Many conventional that is found in most other greases. This additional • types of grease do not have enough of the tacky molybdenum greatly improves the ability of the characteristic in order to allow the grease to stay grease to protect parts from damage in applications in place. In addition, many of these greases do not with severe impact (slamming). In addition, the have the performance in order to adequately protect molybdenum in Cat Desert Gold Grease is a special the gear teeth in these applications. grade. This grade has a median particle size of 3 microns in order to meet the special requirements of Cat Ultra 5Moly Grease exceeds the NLGI some rolling element bearings. certification of"GC-LB". Cat Desert Gold Grease is made in order to Note: If the application calls for Cat Ultra 5Moly be extra tacky. In some applications, the film of Grease and Cat Ultra 5Moly Grease is not available, grease must adhere to the vertical surfaces. Many consult the datasheets for the grease. From conventional type of grease do not have enough of these datasheets, use a substitute that meets the the tackifier in order to allow the grease to stay in performance characteristics of Cat Ultra 5Moly place. In addition, many of these greases do not Grease. have the performance, particularly at high ambient temperatures, to adequately protect the gear teeth in Cat Ultra 5Moly Grease is formulated not to contain these applications. lead, antimony, barium, zinc, phosphorous, or chlorine additives. Thus, when Cat Ultra 5Moly Cat Desert Gold Grease has the ability to prevent Greases are compared to many other types of galling and wear at very hot temperatures under grease, the Cat Ultra 5Moly Greases are more extremely severe loads and conditions. In moderate environmentally friendly. temperatures, Cat Desert Gold Grease can be used in those extremely severe applications if an Cat Desert Gold Grease improvement over Cat Ultra 5Moly Grease is desired. Cat Desert Gold Grease is formulated in order to Cat Desert Gold Grease can be used in applications protect the most severely loaded joints in Caterpillar that require the lubricant to last for very long periods machines against galling, wear, and corrosion. This of time because this grease has an extremely high • protection is sustained while work is being done at performance and long life. moderate temperatures to very hot temperatures with Cat Desert Gold Grease exceeds the NLGI wet conditions or dry conditions. certification of"GC-LB". SEBU6251-12 27 Maintenance Section Lubricant Specifications • Note: If the application calls for Cat Desert Gold Cat Arctic Platinum Grease performs well for long Grease and Cat Desert Gold Grease is not available, periods of time. This grease resists breakdown even consult the datasheets for the grease. From with extremely heavy loads. This grease provides these datasheets, use a substitute that meets the protection that will be sustained in conditions that are performance characteristics of Cat Desert Gold wet or dry. Also, this grease will provide protection Grease. With consideration given to the application, in moderate temperatures as well as extremely cold Cat Ultra 5Moly Grease, or Cat Arctic Platinum temperatures. Grease may perform adequately. However, the use of these greases may require a different schedule Cat Arctic Platinum Grease has five percent of for lubrication. molybdenum instead of zero to three percent that is found in most of the other greases. This additional Cat Desert Gold Grease is formulated not to contain molybdenum greatly improves the ability of the lead, antimony, barium, zinc, phosphorous, or grease in order to protect parts from damage in chlorine additives. Thus, when Cat Desert Gold applications with severe impact (slamming). In Grease is compared to many other types of grease, addition, the molybdenum in Cat Arctic Platinum the Cat Desert Gold Grease is more environmentally Grease is a special grade. This molybdenum has a friendly. median particle size of 3 microns in order to meet the special requirements of some rolling element Cat Arctic Platinum Grease bearings. Cat Arctic Platinum Grease is formulated to Cat Arctic Platinum Grease is made in order to protect the most heavily loaded joints in Caterpillar be extra tacky. In some applications, the film of machines against galling, wear, and corrosion. With grease must adhere to the vertical surfaces. Many dependence on the consistency of the grease, this conventional greases do not have enough tackifier protection is sustained, while work is being done in in order to adhere well to the vertical surfaces. This moderate temperatures and in temperatures that may ability is necessary in order to adequately protect the reach a temperature of-50 °C (-58 OF). In addition, gear teeth in these applications. • the conditions may be wet or dry. Cat Arctic Platinum Cat Arctic Platinum Grease has the ability to prevent Grease is available in NLGI grade 0. galling and wear at very cold temperatures under Cat Arctic Platinum Grease is made with synthetic extremely severe loads and conditions. In moderate base oil that has a very low viscosity and a Calcium temperatures, Cat Arctic Platinum Grease can be Sulfonate Complex thickener. The performance is used in the application if the compartment is sealed enhanced with five percent Molybdenum disulfide tightly in order to contain the grease. (MoS, or"Moly") and a tackifier. Cat Arctic Platinum Grease is sometimes used in Because the base oil is synthetic, Cat Arctic applications that require the lubricant to last for very Platinum Grease has a minimal change in viscosity long periods of time. This is due to the fact that this as the temperatures drop. Because the synthetic grease has an extremely high performance and this base oil has a very low viscosity, the Cat Arctic grease also has a long life. Platinum Grease that is made with this base oil Note: If the application calls for Cat Arctic Platinum has a minimal change in viscosity and flows easily Grease and no Cat Arctic Platinum Grease is as the temperature drops. Cat Arctic Platinum available, consult the data sheets for the grease. Use Grease pumps easily at extremely low temperatures. a substitute that most closely meets the performance In fact, Cat Arctic Platinum Grease NLGI grade 0 can be pumped through standard automatic characteristics. lubrication systems that are machine mounted and at Cat Arctic Platinum Grease is formulated not to temperatures down to -50 °C (-58 OF). This means contain lead, antimony, barium, zinc, phosphorous, that the grease can be pumped through those long or chlorine additives. Thus, when Cat Arctic unheated lines and into the required joints. Platinum Grease is compared to many other types Cat Arctic Platinum Grease is made with Calcium of grease, the Cat Arctic Platinum Grease is more Sulfonate Complex thickener in order to provide the environmentally friendly. necessary protection against galling, wear, fretting, water washout, and corrosion. • 28 SEBU6251-12 Maintenance Section Lubricant Specifications Cat High Speed Ball Bearing • Grease Cat High Speed Ball Bearing Grease is NLGI grade 2 grease. This grease is made with petroleum base oil and a polyurea thickener. This grease is recommended for applications that utilize roller bearings and ball bearings at low loads to moderate loads at high speed. Cat High Speed Ball Bearing Grease is formulated not to contain lead, antimony, barium, zinc, phosphorous or chlorine additives. Thus, when Cat High Speed Ball Bearing Grease is compared to many other types of grease, the Cat High Speed Ball Bearing Grease is more environmentally friendly. • • C/) E m m a' C o � N Vt Grease Application Chart N Severe NLGI 'Low Temp. Severe Severe Severe Applications 'Severe Extreme x 5Environnmentally "Corrosion 'Water Washout Caterpillar Grease Name Grade Pum abili Applications Applications Applications with Extremely A lications Pressure Service Life FriendlyProtection Resistance Pump ability PP PP PP Y pP (EP) Heavy Loads [In Centralized Extremely Low Low Moderate Moderate High Recommended Operating to to (Anti-Wear (Shear (Auto-Cube) to to to Conditions Systems] Low Temps Moderate High Temps Vfig hTemps Extremely High Protection) Stability) Temps Temps Optimum Temperature 50'C(-58"F) 231C(-10`F) +181C(+65"F) +18'C(+65"F) +38'C(+100`F) Range to to to to to -18'C 0'F +29"C +85'F +60'C +140`F +411C +105'F +2321C +450"F Desert Gold 2 above +35'F N/R Excellent Excellent Excellent Very Good Excellent Excellent Yes Excellent Excellent Ultra 5Moly 2 above+20'F N/R Excellent Excellent Very Good Good Excellent Excellent Yes Excellent Excellent Ultra 511iloly 1 above 0'F Good Excellent Good Good Fair Excellent Excellent Yes Excellent Excellent Arctic Platinum 0 0 above-45'F Excellent Very Good N/R N/R N/R Excellent Excellent Yes Excellent Excellent Advanced 3Moly 2 above 0'F N/R Fair Good Good N/R Very Good Good No Fair Fair Multipurpose Grease 2 above-10'F N/R N/R N/R N/R N/R Fair Good No Fair Fair High Speed Ball Bearing N/R N/R N/R N/R N/R Very Good No Good Good Grease 2 above 0'F N/R Based on LISS Mobilitv and Lincoln Ventmeter Tests, Performance may vary depending on lubrication ui ment and Ion gth of lines a depending on the application 2 Severe Applications are those with:very heavy loads,frequent oscillations,and heav shock bads. a Extreme pressure E refer to 4-Ball Weld point in technical data sheet ASTM D 25 "Service Life refer to%chInge after 100,000 strokes in technical data sheet ASTM D 21 a Is not formulated to contain.Lead,Antimony,Barium,Zinc,Phosphorous,or Chlorine additives. —_I Resistance to Salt water and Salt S ra ASTM B 11 "Iffla—te-r-119is-Fo—utIlesistance,refer referto Hollwith Water, Change N/R=Not Recommended Note:For additional performance data on these greases refer to this Special Publication,"Reference Material"article. c Note:Cat Ultra 5Moly grease is also available in NLGI grade 0 for use in autolube systems that are used in moderate to cold ambient temperatures. � n) 0 0 _. (D o n Cf) a 0) (D N � n u 7 O N a (n =3 ro 30 SEBU6251-12 Maintenance Section Lubricant Specifications i03421168 These four types of analysis are used to monitor the • S•O•S Services Oil Analysis condition of your equipment, and to help you identify y potential problems. A properly administered S-O-S Services oil analysis program will reduce repair costs SMCS Code: 1000; 1348; 3080; 4070; 4250; 4300; and the program will lessen the impact of downtime. 5095; 7000; 7542; 7581 The S-O-S oil analysis program uses a wide range NOTICE of tests to determine the condition of the oil and the These recommendations are subject to change with- condition of the lubricated compartment. out prior notice. Consult your local Caterpillar dealer for the most up to date recommendations. Guidelines that are based on experience and a correlation to failures have been established for these tests. See the following chart for the guidelines. Caterpillar has developed a maintenance Exceeding one or more of these guidelines could management tool that evaluates oil degradation indicate serious fluid degradation or a pending and detects the early signs of wear on internal component failure. A trained person at your components. The Caterpillar tool for oil analysis is Caterpillar dealership should make the final analysis. called S-O-S oil analysis and the tool is part of the S-O-S Services program. S-O-S oil analysis divides Note: Cooling system problems will also reduce oil analysis into four categories: the life of engines. S-O-S coolant analysis together with S-O-S oil analysis provide a complete and • Component wear rate accurate method for monitoring the health of all engine systems. Refer to the S-O-S Services coolant • Oil condition analysis information in this Special Publication. A properly administered S-O-S Services program • Oil contamination will reduce repair costs and lessen the impact of downtime. • Oil identification •Component Wear Rate analysis evaluates the Table 5 wear that is taking place inside the lubricated S-O-S Oil Analysis Guidelines compartment. The S-O-S Services analyst uses the Test Parameter Guideline results of elemental analysis and particle count tests Oxidation to evaluate the wear. Trend analysis and proprietary wear tables are then used to determine if wear rates Soot (11 are normal or abnormal. Sulfation Oil Condition analysis is used to determine if the oil Wear Metals Trend Analysis and Cat has degraded. Tests are done to look at the oxidation, Wear Table0) norms sulfation, and viscosity of the oil. The S-O.S Services Water 0.5% maximum analyst uses established guidelines or trend analysis to determine if the oil has reached the end of its Glycol 0% useful life. Fuel Dilution based on viscosity0i and performed to determine of o>fuel dilution in excess Oil Contamination tests are p of 4/o if anything harmful has entered the oil. This analysis relies on the results from the following tests: Viscosity "ASTM D445" +/-3 centistoke (cSt) elemental analysis, soot, particle count, fuel dilution, measured at 100' C change from new oil water, and glycol. The S-O-S Services program has (212- F) viscosity. guidelines for the level of contamination that are (1) Acceptable values for these parameters are proprietary to the allowed in Cat engines. S-O-S oil analysis program. (2) Gas Chromatograph Oil Identification is another very important part of the S-O-S oil analysis program. The wrong oil in an Consult your Caterpillar dealer for complete engine can severely damage major components. information and assistance about the S-O-S oil The S-O-S Services analyst uses elemental analysis analysis program. • and viscosity results to identify key characteristics of the oils. Obtaining S-O-S Oil Samples Before you obtain an S-O-S oil sample, operate the engine until the oil is warm and the oil is well circulated. Then obtain the S-O-S oil sample. SEBU6251-12 31 Maintenance Section Lubricant Specifications • In order to obtain a good oil sample, do not take Consult your Caterpillar dealer for complete the oil sample from the drain stream. The drain information and assistance in order to establish an stream method can allow a stream of dirty oil from S-O-S Services program for your engine. the bottom of the compartment to contaminate the sample. Likewise, never dip an oil sample from an oil More Frequent S-O-S Sampling Improves container or pour a sample from a used filter. Life Cycle Management There are two acceptable ways to obtain S-O-S oil Traditionally, the suggested S-O-S sampling samples. The following methods are listed in the intervals for diesel engines have been at 250 hours. order that is preferred: However in severe applications, more frequent • Use an in-line sampling valve on the pressurized oil sampling is recommended. Severe service for oil manifold. lubricated compartments occurs at high loads, in high temperatures, and in dusty conditions. If any of • Use a sampling gun (vacuum pump)that is inserted these conditions or other severe service indicators into the sump. exist, sample the engine oil at 125 hour intervals. These additional samples will increase the chance of Use of the in-line sampling valve is the preferred detecting a potential failure. method. This method provides samples that are less Determining Optimum Oil Change Intervals likely to be contaminated. In order to obtain an oil sample from the engine, it Sampling the engine oil at every 125 hours provides may be necessary to increase the engine's speed. information for oil condition and for oil performance. Normally, the oil sample is taken at low idle. If the This information is used to determine the optimum flow rate is too low, increase engine speed to high usable life of a particular oil. Also, more points of idle in order to obtain the oil sample. data will allow closer monitoring of component wear rates. Close monitoring also allows you to obtain the maximum use of the oil. For detailed information on NOTICE optimizing oil change intervals, please consult your • Always use a separate vacuum pump for oil sampling, Caterpillar dealer. and use a separate pump for coolant sampling. Using the same pump for both types of samples may con- Optimizing the Component Life Cycle taminate the samples that are being drawn. This con- taminate may cause a false analysis and an incorrect An increase in the number of oil samples provides interpretation that could lead to concerns by both deal- a better definition of the trends in data between oil ers and customers. change intervals. More oil samples will allow you to closely monitor wear patterns of components. This Oil Sampling Interval action will ensure that the full life of the components p 9 are achieved. Take the oil samples as close as possible to the standard intervals. In order to receive the full value from S-O.S oil analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent oil samplings that are evenly spaced. Table 6 S-O-S Oil Sampling Interval Compartment Interval(l)a) Engine crankcase Every 250 Service Hours (1) Severe applications may require a more frequent oil sampling interval. (2) Under certain conditions, the Caterpillar dealer or the • Operation and Maintenance Manual may allow a longer interval between oil samplings. Note: Refer to the Operation and Maintenance Manual for your specific engine for recommended oil drain intervals. 32 SEBU6251-12 Maintenance Section Fuel Specifications Fuel Specifications NOTICE Many of the guidelines, recommendations, and re- i03446720 quirements that are provided in this Special Publica- General Fuel Information tion are interrelated. Before using the provided infor- mation, it is the responsibility of the user of this Spe- SMCS Code: 1250; 1280 cial Publication to read and understand the informa- tion provided in its entirety. NOTICE For questions concerning the information provided in Every attempt is made to provide accurate, up to date this Special Publication, consult with your Caterpillar information. By use of this document you agree that dealer. Caterpillar Inc. is not responsible for errors or omis- sions. For additional guidelines, recommendations, and requirements (including maintenance interval rec- The information provided are the latest ommendations/requirements) refer to your product recommendations for the Caterpillar diesel engines specific Operation and Maintenance Manual. that are covered by this Special Publication. This information supersedes all previous NOTICE recommendations which have been published for the It is the responsibility of the user of this Special Caterpillar diesel engines that are covered by this Publication to read, understand, and follow all safety Special Publication. Special fluids are required for guidelines found in this Special Publication and in some engines and it will be necessary to continue to engine and/or machine specific Operation and Main- use these special products. Refer to the applicable tenance Manuals when performing all recommended Operation and Maintenance Manual. and/or required engine, engine systems, and/or ma- This publication is a supplement to the Operation chine maintenance. and Maintenance Manual. This publication does For questions concerning the information provided in • not replace the engine specific Operation and this Special Publication and/or in your product Op- Maintenance Manuals. eration and Maintenance Manual, consult with your NOTICE Caterpillar dealer. These recommendations are subject to change with- Follow all industry standard safety practices when op- out notice. Consult your local Caterpillar dealer for the erating engines and/or machines and when perform- most up to date recommendations. ing all recommended and/or required maintenance. NOTICE NOTICE To avoid potential damage to your Cat machine and/or Commercial products that make generic claims of Cat engine, only purchase Cat fluids and Cat filters meeting Cat and/or Caterpillar requirements without through your Caterpillar dealer or Caterpillar autho- listing the specific Cat recommendations and/or re- rized outlets. For a list of authorized Caterpillar parts quirements that are met may not provide acceptable outlets in your area, consult your Caterpillar dealer. performance and may cause reduced engine and/or machine fluid compartment life. Refer to this Special If you purchase what appear to be Cat fluids and/ Publication and refer to product specific Operation or Cat filters through other outlets/sources, you and Maintenance Manuals for Caterpillar fluids rec- are at a very high risk of purchasing counterfeit ommendations and/or requirements. ("look-alike") products. Counterfeit or "look-alike" products may visually ap- Note: Instructions for the installation of the filter are pear the same as the original Cat product, but the printed on the side of each Caterpillar spin-on filter. product performance and internal quality will typical- For non Caterpillar filters, refer to the installation ly be very low. instructions that are provided by the supplier of the filter. Counterfeit or "look-alike" products have a very high • likelihood of causing and/or allowing engine and/or machine compartment damage. SEBU6251-12 33 Maintenance Section Fuel Specifications • Use fuel that meets or exceeds Caterpillar NOTICE requirements for distillate diesel fuel. Refer to In order to meet expected fuel system component life, the "Caterpillar Specification for Distillate Diesel 4 micron(c) absolute or less secondary fuel filtration Fuel for Off-Highway Diesel Engines" table in this is required for all Caterpillar diesel engines that are Special Publication, "Distillate Diesel Fuel" article. equipped with common-rail fuel systems, and for all Caterpillar diesel engines that are equipped with unit • Use a properly designed and maintained bulk injected fuel systems. For all other Caterpillar diesel storage fuel tank. engines (mostly older engines with pump, line and nozzle type fuel systems), the use of 4 micron(c) ab- • Confirm with the filter manufacturer that the fuel solute or less secondary fuel filtration is strongly rec- filter/filters to be used are compatible with the fuel ommended. Note that all current Caterpillar diesel en- type that will be filtered. gines are factory equipped with Caterpillar Advanced Efficiency 4 micron(c) absolute fuel filters. • Filter the fuel coming into the bulk storage fuel tank to 20 microns(c) absolute or less. In order to obtain additional information on Caterpillar designed and produced filtration products, refer to the • Follow all industry standard grounding and other "Reference Material" article, "Filters" and "Miscella- safety practices. neous" topics in this Special Publication, and then consult your Caterpillar dealer for assistance with fil- • Test for microbial contamination on a regular basis tration recommendations for your Caterpillar diesel and take proper corrective action if contamination engine. is present. Properly dispose of cleanup waste according to all applicable regulations and mandates. NOTICE Caterpillar does not warrant the quality or perfor- Install and properly maintain a properly designed mance of non-Caterpillar fluids and filters. and grounded filtration system on bulk storage • fuel tanks for continuous filtration of stored fuel. The filter element/elements should be rated at a General Recommendations and maximum of 5 microns(c) absolute. Change fuel Guidelines filters based on manufacturers recommendations. Follow all applicable industry standards and all Every 3 months, or sooner if problems are applicable governmental, environmental, and safety suspected, have a complete analysis of the bulk guidelines, practices, regulations, and mandates. storage fuel per the "Caterpillar Specification for Distillate Diesel Fuel for Off-Highway Diesel Note: These general recommendations and Engines" table in this Special Publication, "Distillate guidelines concerning maintenance and care of Diesel Fuel" article. Take corrective action if fuel and fuel storage systems are not intended to necessary. Corrective actions may include, but are be all inclusive. Discuss proper fuel safety and not limited to, treating the fuel, cleaning of the fuel health, handling, and maintenance practices storage tank/system, and replacing the problematic with your fuel supplier. Use of these general fuel with fresh fuel. recommendations and guidelines does not lessen the Keep the fuel storage tank clean of water, debris engine owners and/or fuel supplier's responsibility to and sediment. follow all industry standard practices for fuel storage and for fuel handling. Drain water and sediment from the fuel storage Note: Where recommendations for draining water tank weekly. Drain water and sediment before the and/or sediment and/or debris are stated, dispose tank is refilled. of this waste according to all applicable regulations . Keep the area around the fuel tank filler neck clean and mandates. of debris in order to prevent contamination of the • Discuss application specific fuel concerns, needs, fuel tank. and requirements with a reputable fuel supplier. • As required, clean the inside of the engine fuel • Purchase fuel from a reputable supplier. tank and the inside of the bulk storage fuel tank. 34 SEBU6251-12 Maintenance Section Fuel Specifications • Drain water and sediment from the engine fuel Note: Fuel storage tanks should be thoroughly • tank daily. Drain water and sediment from the tank cleaned before converting to Ultra Low Sulfur at the start of each shift. After the fuel tank has Diesel (ULSD) (15 ppm or less sulfur) and/or been filled, allow the fuel to settle for ten minutes. biodiesel/biodiesel blends. Conversion to ULSD This will allow the water and sediment to separate and/or biodiesel/biodiesel blends can loosen fuel from the fuel. Then, drain the water and sediment system and fuel storage tank deposits. Bulk tank from the tank. continuous filtration unit and dispensing point filters, and onboard engine filters change intervals may • Install fuel/water separators at the bulk storage need to be shortened for an extended period of time fuel tank dispensing point and install fuel/water in order to allow for this cleaning effect. separators on the engine. Wire mesh media is NOT recommended. Note: Caterpillar strongly recommends the filtration of distillate diesel fuel and/or biodiesel/biodiesel • Drain the water from the fuel/water separators blends through a filter with a rating of four microns(c) daily. absolute or less. This filtration should be located on the device that dispenses the fuel to the fuel tank for • Caterpillar Advanced Efficiency fuel filters are the engine, and also on the device that dispenses required for distillate fueled diesel engines in order fuel from the bulk storage tank. Series filtration is to provide maximum life to the fuel system. recommended. • Change fuel filters at the scheduled interval. Never Note: Even when all fuel storage maintenance fill the new secondary fuel filter with fuel before practices that are relevant to your application are installation. Use the fuel priming pump to remove followed, Caterpillar recommends a maximum of air from the system. one year from production for distillate fuel storage, and a maximum of six months from production for • Install and properly maintain four micron(c) biodiesel and blended biodiesel storage. Storage life absolute breather filters on the engine fuel tank for biodiesel and biodiesel blends that are greater vent, and install and properly maintain four than B20 may be much shorter than six months. micron(c) absolute breather filters on the bulk storage fuel tank vent. Desiccant type breather vent filters are also recommended in order to 103422996 remove moisture from air entering the fuel tank. Fuel Information for Diesel Breather filters are typically changed every six months, and desiccant type breather filters are Engines typically changed on saturation. Refer to the literature that was included with the filter. Discuss SMCS Code: 1250; 1280 the availability of desiccant breather vent filters for your application with your filter supplier. NOTICE For on-highway diesel engine fluids requirements, • Top off fixed roof fuel tanks as often as practical refer to specific engine Operation and Maintenance in order to reduce tank breathing and in order to Manuals, and also refer to the most current revision reduce the amount of condensation generated level of Special Publication, SEBU6385, "Caterpillar water. On-Highway Diesel Engine Fluids Recommenda- • Protect fuel tanks from dirt and water entry. tions". Also consult with your Caterpillar dealer. Note: Caterpillar has four different size coalescer type fuel filters available for bulk storage fuel tank applications that filter both dirt and water. The filter elements are rated at four microns(c) absolute. Consult your Caterpillar dealer for information on the coalescer filters available through Cat. • SEBU6251-12 35 Maintenance Section Fuel Specifications • The two basic types of distillate diesel fuel are No. With either type of heater, starting aids and/or fuels 2 diesel fuel and No. 1 diesel fuel. No. 2 diesel with higher cetane numbers are less important fuel is the most commonly available summer grade because the engine is warm. Problems with fuel diesel fuel. No. 1 diesel fuel is a winter grade diesel cloud point can cause the plugging of fuel filters. fuel. During the winter months fuel suppliers will Problems with fuel cloud point cannot be corrected typically blend No. 1 and No. 2 diesel fuel in various by engine coolant heaters. This is especially true for percentages in order to meet the historical low fuel filters that are cooled by air flow during operation. ambient temperature cold-flow needs for a given area or region. No. 2 diesel fuel is a heavier diesel fuel than Fuel Heaters No. 1 diesel fuel. In cold weather, heavier fuels can cause problems with fuel filters, fuel lines, fuel tanks, The fuel cloud point is related to problems with fuel and fuel storage. Heavier diesel fuels such as No. 2 filters. The fuel heater heats the fuel above the diesel fuel can be used in diesel engines that operate cloud point before the fuel enters the fuel filter. This in cold temperatures with an appropriate amount of a prevents wax from blocking the filter. Fuel can flow well proven pour point depressant additive. For more through pumps and lines at temperatures below the information on fuels which include blends of No. 1 cloud point. The cloud point is often above the pour and No. 2 diesel fuel, consult your fuel supplier. point of a fuel. While the fuel can flow through these When you use No. 2 diesel fuel or other heavier lines, the wax in the fuel can still plug the fuel filter. fuels, some of the fuel characteristics may interfere In some engine installations, small modifications with successful cold weather operation. Additional can prevent problems that are caused by the cloud information about the characteristics of diesel fuel is point. One of the following changes can prevent available. This information contains a discussion on problems in many conditions: a change in the location the modification to the characteristics of diesel fuel. of fuel filters and/or supply lines and the addition There are several possible methods that can be used of insulation. In extreme temperatures, heating of to compensate for the fuel qualities that may interfere the fuel may be required to prevent the filters from with cold weather operation. These methods include plugging. There are several types of fuel heaters that • the use of starting aids, engine coolant heaters, fuel are available. The heaters typically use either engine heaters, and de-icers. In addition, the manufacturer coolant or exhaust gas as a heat source. These of the fuel can add cold flow improvers and/or blend systems may prevent filter waxing problems without No. 1 and No. 2 diesel in various percentages. the use of de-icers or cold flow improvers. These systems may be ineffective when the fuel contains a Not all areas of the world classify diesel fuel using large amount of dirt or of water. Use of a fuel heater the No. 1 and No. 2 nomenclature described above. can help eliminate some cold weather problems. But, the basic principles of using additives and/or A fuel heater should be installed so that the fuel is blending fuels of different densities in order to help heated before flowing into the fuel filter. compensate for the fuel qualities that may interfere with cold weather operation are the same. Note: A fuel heater is not effective for cold-soaked starts unless the fuel heater can be powered from Starting Aids an external power source. External fuel lines may require the use of heaters that circulate the fuel. The use of a starting aid is a conventional method of assistance for cold starts in low temperature Note: Only use properly sized fuel heaters that are conditions. A variety of starting aids are available for controlled by thermostats or use fuel heaters that Caterpillar engines. Follow the recommendations are self-regulated. Thermostatically controlled fuel that are provided by the manufacturer of the starting heaters generally heat fuel to 15.50 C (600 F). Do not aid. Refer to the foreword section in this Special use fuel heaters in warm temperatures. Publication, "Aftermarket Products and Warranty" article. For distillate fuel configured engines, Caterpillar recommends a fuel viscosity as delivered to rotary Engine Coolant Heaters fuel injection pumps of between 1.4 cSt and 4.5 cSt, and between 1.4 cSt and 20 cSt for all other fuel These heaters heat the engine coolant. The heated injection pumps. coolant flows through the cylinder block. The flow Note: If a fuel with a low viscosity is used, cooling • of heated coolant keeps the engine warm. A warm of the fuel may be required in order to maintain 1.4 engine is easier to start in cold weather. Most coolant cSt or greater viscosity at the fuel injection pump. heaters use electrical power. A source of electricity Fuels with a high viscosity might require fuel heaters is necessary for this type of heater. Other heaters in order to lower the viscosity to either 4.5 cSt or less that burn fuel are available as a source of heat. for rotary fuel injection pumps or 20 cSt viscosity or These heaters may be used in place of the electrical less for all other fuel injection pumps. heaters. 36 SEBU6251-12 Maintenance Section Fuel Specifications Lubricity and Low Sulfur Diesel • NOTICE (LSD) and Ultra Low Sulfur Diesel Do not allow the fuel to get too warm, because fu- el above 52°C (125°F) will affect the power output of (ULSD) Fuel the engine. Never exceed 750C (165°F) with straight distillate fuel. The high fuel temperatures also affect In the United States (U.S.), LSD will have 0.05 the fuel viscosity. When the fuel viscosity falls below percent (500 ppm) maximum sulfur. ULSD will have 1.4 cSt at the fuel injection pump, pump damage may 0.0015 percent (15 ppm) maximum sulfur. Refer occur. to this Special Publication, "Distillate Diesel Fuel' article, and also refer to the"Characteristics of Diesel Fuel' article, "Diesel Fuel Sulfur" and other related i topics for additional information. Also, refer to the most current revision level of"ASTM D975 (Standard Overheating the fuel or the fuel filter can result in Specification for Diesel Fuel Oils)" for additional personal injury and/or damage to the engine. Use information. extreme care and caution for heating of the fuel and/or the fuel filter. Note: "ASTM D975" currently allows up to 5 percent biodiesel blends. Refer to the "Fuel Specifications" Select a fuel heater that is mechanically simple, yet section and the "Biodiesel" topic in this Special adequate for the application. The fuel heater should Publication for guidance when biodiesel will be used. also prevent overheating of the fuel. Disconnect the In Europe, the commonly available diesel fuel will fuel heater or deactivate the fuel heater in warm have 0.005 percent (50 ppm) maximum sulfur. In weather. An unacceptable loss of fuel viscosity and Europe, ULSD fuel will have 0.0010 percent (10 engine power will occur if the fuel supply temperature ppm) maximum sulfur, and is typically referred to is allowed to become too hot. as "sulfur-free". Refer to the most current revision For additional information on fuel heaters, consult level of"European Standard EN 590 (Automotive your Caterpillar dealer. Fuels - Diesel - Requirements and Test Methods)" • for additional information. De-Icers Note: "EN 590" currently allows up to 5 percent biodiesel blends. Refer to the "Fuel Specifications" De-icers lower the freezing point of the moisture in section and the "Biodiesel' topic in this Special the fuel. De-icers are not generally needed when Publication for guidance when biodiesel will be used. fuel heaters are used. If you experience trouble, consult your fuel supplier for recommendations of a The lubricity of a fuel is a concern with low sulfur compatible commercial de-icer. and ultra low sulfur fuel. To determine the lubricity of the fuel, use the "ASTM D6079 High Frequency Reciprocating Rig (HFRR)" test. The maximum 03423334 allowable wear scar is 0.52 mm (0.0205 inch) at Characteristics of Diesel Fuel 60° C (140° F). If the lubricity of a fuel does not meet the minimum requirements, consult your fuel supplier. SMCS Code: 1250; 1280 Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These NOTICE additives can cause problems in the fuel system. For on-highway diesel engine fluids requirements, The fuel lubricity is important. You should consider refer to specific engine Operation and Maintenance the fuel lubricity whenever you operate the equipment Manuals, and also refer to the most current revision in temperature extremes, whether extremely hot or level of Special Publication, SEBU6385, "Caterpillar extremely cold. Also, you should consider the fuel On-Highway Diesel Engine Fluids Recommenda- lubricity whenever you use fuels that are lower in tions". Also consult with your Caterpillar dealer. viscosity or that have been hydro-treated. Consult with your fuel supplier to make sure that the supplied fuel meets Caterpillar minimum requirements. There are many aftermarket additives that are • available to treat fuel. If the fuel lubricity is an issue, consult your fuel supplier for proper recommendations regarding fuel additives. Also, refer to this Special Publication, "Distillate Diesel Fuel' article, "Aftermarket Fuel Additives" and "Cat Diesel Fuel Conditioner" topics. SEBU6251-12 37 Maintenance Section Fuel Specifications • Fluid lubricity describes the ability of the fluid Note: Lighter fuels are frequently used in arctic to reduce the friction between surfaces that are temperatures. Lighter fuels may include the following under load. This ability reduces the damage that is fuels: Jet A-1, JP-8, JP-5, and kerosene. The caused by friction. Fuel injection systems rely on specifications that apply to these fuels do not include the lubricating properties of the fuel. Until fuel sulfur a minimum lubricity requirement. Do not assume that limits were mandated, the fuel lubricity was generally a fuel meets the minimum Caterpillar specification. believed to be a function of fuel viscosity. Consult the fuel supplier for proper recommendations on fuel lubricity additives. The process that is most commonly used to remove sulfur from fuel is called hydro-treatment. This Note: The sulfur levels for Jet A, Jet A-1, JP-8, process is also the most economical process. Each JP-5, and kerosene fuels typically exceed 15 ppm source of crude oil contains different amounts of and the fuel sulfur levels for these fuels typically far sulfur. Crude oils typically require hydro-treatment exceed 50 ppm. Refer to this Special Publication, to obtain the 0.0015 percent maximum sulfur limit. "Distillate Diesel Fuel" article, "Alternative Fuels - Crude oils with high sulfur require a more severe Arctic Applications" topic for additional information treatment. on these fuels. The hydro-treatment removes the sulfur as well as Note: For best results, your fuel supplier should treat other components. The treatment removes nitrogen the fuel when additives are required. Refer to this compounds, polar materials, bicyclic aromatics, Special Publication, "Distillate Diesel Fuel" article, polycyclic aromatics, and oxygen compounds. While "Aftermarket Fuel Additives" and "Cat Diesel Fuel the removal of sulfur has shown no detrimental Conditioner" topics for guidance. effects to the engine, the removal of other compounds have lowered the lubricity of the fuel. As a result Viscosity of the lowered lubricity, the fuel is less tolerant of contamination by water and dirt. The lower fuel The viscosity of the fuel is significant because the fuel lubricity can be seen as abrasive wear of fuel system serves as a lubricant for fuel system components. • comdto ponents. Fuels that have a low lubricity may not Fuels need to have sufficient viscosity. The fuel must ovide adequate lubrication to plungers, to barrels, lubricate the fuel system in both extremely cold and in injectors. This problem may be compounded extremely hot temperatures. If the kinematic viscosity in areas that require winter blends of fuel. The lighter of the fuel is lower than 1.4 cSt as supplied to the winter fuel blend has the following characteristics: fuel injection pump or to the unit injectors, excessive lower viscosity, lower cloud point, and lower pour scuffing and seizure can occur. point. When required, the fuel lubricity may be enhanced For distillate fuel configured engines, Caterpillar with additives. Many fuel suppliers treat the fuel recommends a fuel viscosity as delivered to rotary with these additives. Do not use a fuel lubricity fuel injection pumps of between 1.4 cSt and 4.5 cSt, additive before you consult the fuel supplier. Some and between 1.4 cSt and 20 cSt for all other fuel aftermarket additives may not be compatible with the injection pumps. additives that are already in the fuel, and some may Note: If a fuel with a low viscosity is used, cooling damage emission control systems. Some additive of the fuel may be required in order to maintain 1.4 packages that are supplied by the aftermarket cSt or greater viscosity at the fuel injection pump. manufacturer may not be compatible with the Fuels with a high viscosity might require heaters in seals that are used in fuel systems of some diesel order to lower the viscosity to either 4.5 cSt or less engines. Other additive packages that are supplied for rotary fuel injection pumps or 20 cSt or less for all by aftermarket manufacturers cannot provide proper other fuel injection pumps. performance in high temperature conditions. These additives may leave deposits because of the high temperatures that exist in the fuel systems of diesel Cetane Number engines. The cetane number of the fuel has an effect on the Maximum life of the fuel system can be achieved ability of the engine to start. Also, the cetane number by performing the following tasks: using a reliable has an effect on the interval of time before the engine fuel supplier and performing proper maintenance runs smoothly. Generally, an increase of ten in the • of the fuel system. Caterpillar Advanced Efficiency cetane number will allow the engine to be started at fuel filters are required for diesel engines that run on a lower temperature. The starting temperature can diesel fuel in order to provide maximum life to the be improved approximately 7 to 80C (12 to 15°F) for fuel system. every increase of ten in the cetane number. After the engine reaches the normal operating temperature, a change in the cetane from 40 to 50 will have a minimal effect on engine performance. 38 SEBU6251-12 Maintenance Section Fuel Specifications Most fuels that have a cetane number above 40 will The cloud point of the fuel is important because the • permit acceptable engine starts in warmer outside cloud point can limit the performance of the fuel temperatures. The engine will start satisfactorily with filter. The wax can alter the fuel characteristics in this fuel when the engine is kept warm. The engine cold weather. Solid wax can fill the fuel filters. The can be kept warm by using either a heated room or a solidified wax will stop the flow of fuel. Fuel filters are properly sized coolant heater. necessary in order to remove dirt from the fuel. The filters block foreign material, and the filters protect During average starting conditions, direct injection the parts for the fuel injection system. Since fuel must diesel engines require a minimum cetane number flow through the filters, installing a fuel heater is the of 40. A higher cetane value may be required most practical way to prevent the problem. A fuel for operation in high altitudes or for cold weather heater will keep the fuel above the cloud point as the operation. The minimum fuel cetane number that is fuel flows through the fuel system. The fuel heater will required for the precombustion chamber (PC) diesel permit the wax to flow through the filters with the fuel. engine is 35. Modifying the Cetane Number Modifying the Cloud Point You can lower the cloud point of a diesel fuel by The cetane number of a fuel can be changed if the mixing the diesel fuel with a different fuel that has a fuel is mixed with a fuel that has a different cetane lower cloud point. No. 1 diesel fuel or kerosene may number. Generally, the cetane number of the mixture be used to lower the cloud point of a diesel fuel. The will be in direct relation to the ratio of the fuels that efficiency of this method is not good, because the were mixed. Your fuel supplier can provide the ratio of the mixture does not have a direct relation information about the cetane number of a particular to the improvement in cloud point. The amount of fuel. fuel with low cloud point that is required makes the process less preferable to use. Additives can also be used to improve the cetane number of a fuel. Additives are evaluated through The following illustration contains a table that can be testing in special engines. However, the fuel used to find the necessary mixture for two fuels with • characteristics of additives are not identical to a different cloud points. In order to use the table, you natural product. While both fuels may be rated as must know the exact fuel cloud point of each fuel. having the same cetane number, starting may be This specification can change from one purchase of different. fuel to the next purchase of fuel. This specification is normally available from personnel at the source of Cloud Point the fuel supply. When fuels that have a lower cloud point are not available, this method cannot be used. It is important to understand that the cloud point of The manufacturer of the fuel can add cold flow a fuel is different from the pour point. There is no improvers to the fuel. Cold flow improvers modify the relationship between cloud point and the pour point. wax crystals in the fuels. The cold flow improvers do The cloud point is the temperature that allows some not change the fuel cloud point. However, the cold of the heavier components in the wax to solidify in flow improvers keep the wax crystals small enough the fuel. This wax is not a contaminant in the fuel. to pass through standard fuel filters. For mixing The wax is an important element of No. 2 diesel fuel. precautions, see the section "Pour Point". The wax has a high fuel energy content and the wax has a very high cetane value. Removal of the heavier wax lowers the cloud point of the fuel. Removal of the wax also increases the cost because less fuel can be made from the same amount of crude oil. Basically, a No. 1 diesel fuel is formulated by removing the wax from a No. 2 diesel fuel. • SEBU6251-12 39 Maintenance Section Fuel Specifications • Modifying the Pour Point 2'C(36'F) You can lower the fuel pour point by using additives. You can also lower the pour point of a diesel fuel by mixing the diesel fuel with a different fuel that has a -,c(3oF) lower pour point. No. 1 diesel fuel or kerosene may be used to lower the pour point of a diesel fuel. The W w amount of fuel with low pour point that is required makes the process less preferable to use. Uj W -7•C(20•F) The following illustration contains a table that can Q CD be used to find the necessary mixture for two fuels Li J with different pour points. This is true only if the fuels CD o do not have additives which change the pour point. In order to use the table, you must know the exact 6'C 0'F our point of each fuel. This specification can change o ( ) -18•C( 0•r) o P P P g a from one purchase of fuel to the next purchase of ci) -23'C(-10'F) -23•C(-10-F) o fuel. This specification is normally available from OJ -29'C(-20'F) -29•C(-20'F) personnel at the source of the fuel supply. When CJ -34'C(-301 -34-C(-30'F) fuels that have a lower pour point are not available, -40'C (-40'F) l -40•C(-40•F) this method cannot be used. -46•C(-50'F) l -46-C(-50•F) l -51•C (-60•F) 2'C(36'F)I I 1 1 1 1 1 1 1 1 0 10 20 30 40 50 60 70 80 90 100 PERCENT OF LIGHTER FUEL IN MIXTURE -1'C(30'F) • Illustration 2 g00592741 ui Cloud point of fuel mixtures w Z) 0 u- Generally,the most practical method that is used to prevent -----Q----�� problems that are caused by fuel cloud point at low temperatures w -7 C(20•F) Lu is the use of fuel heaters. In most applications,fuel heaters can j _ be used at a lower cost than fuel mixtures. w Pour Point ° z Z Z -18-C(0'F) -18'C( 0'F) Q The fuel pour point is a temperature below the ° CB) � fuel cloud point. Fuel stops flowing below the pour -23-C(-101 i - 3'C(-10'F) a point. The pour point is the temperature which limits ° -29-C(-20'F) ; -29'C(`20'F) a movement of the fuel with pumps. -34•c(-30•F -34'C(-30'F)\ -40'C (-40•F) ; -40-C(-40•F) To measure the pour point, the fuel temperature is -46'C(-50'F) -46•C(-50'F) lowered below the cloud point in steps of YC (5°F) -51•C (-60•F) at a time. The temperature is lowered until the fuel does not flow. The pour point is the last temperature 0 10 20 30 40 so so 70 80 90 100 that is shown before the flow stops. At the pour point, PERCENT OF LIGHTER FUEL IN MIXTURE the wax has solidified out of the fuel. This makes the fuel more solid than liquid. The pour point of the fuel can be improved. This does not require the removal Illustration 3 go„sosss of important elements. This process is the same Pour point of fuel mixtures process that is used to improve the cloud point of a fuel. In order to calculate the amount of lighter fuel that is required to be blended with the heavier fuel, perform A fuel pour point should be at least 60C (10°F) below the following steps: • the lowest ambient temperature that is required for engine start-up and for engine operation. To operate 1. Obtain the specification for the cloud point or the the engine in extremely cold weather, No. 1 fuel or pour point of both fuels from your fuel supplier. No. 1-D fuel may be necessary because of these lower pour points. 40 SEBU6251-12 Maintenance Section Fuel Specifications 2. Locate the cloud point or the pour point of the Diesel Fuel Sulfur • heavier fuel on the left side of the table. Mark the point on the table. NOTICE Refer to your engine/machine specific Operation and 3. Locate the cloud point or the pour point of the Maintenance Manual, and refer to your aftertreatment lighter fuel on the right side of the table. Mark the device documentation for the recommended and/or point on the table. maximum allowable fuel sulfur levels. 4. Draw a line between the two points that were Use of fuels with higher than recommended and/or established. Label this line "A". maximum allowed fuel sulfur levels can and/or will: 5. Determine the lowest outside temperature for - Increase wear machine operation. Find this point on the left side of the table. Mark this point. Draw a horizontal line - Increase corrosion from this point. Stop the line at the intersection of line "A". Label this new line "C°. - Increase deposits 6. Line "C" and line "A" intersect. Mark this point. -Shorten the time interval between aftertreatment de- Draw a vertical line from this point. Stop the line vice service intervals (cause the need for more fre- at the bottom of the table. Label this line "B". quent service intervals) The point at the bottom of line "B" reveals the percentage of lighter fuel that is required to modify - Lower fuel economy the cloud point or the pour point. - Shorten the time period between oil drain intervals The above example shows that the blending will (cause the need for more frequent oil drain intervals) require a thirty percent mixture of lighter fuel. Additives are a good method to use in order to lower - Increase overall operating costs the pour point of a fuel. These additives are known Depending on operating conditions,and depending on • by the following names: pour point depressants, maintenance practices, the potential issues stated in cold flow improvers, and wax modifiers. When the this NOTICE may and/or will take place with fuel sul- additives are used in a low concentration, the fuel will fur levels that are at or below the recommended fuel flow through pumps, lines, and hoses. sulfur levels, and/or that are at or below the maximum allowable fuel sulfur levels. Note: These additives must be thoroughly mixed into the fuel at temperatures that are above the cloud point. The fuel supplier should be contacted in order Modern Caterpillar diesel engines are designed to to blend the fuel with the additives. The blended fuel meet mandated gaseous emissions requirements. To can be delivered to your fuel tanks. meet these emissions requirements, the engines are tested and developed with specific sulfur levels in the diesel fuel. Ultra-Low Sulfur Diesel (ULSD) The United States (U.S.) Environmental Protection Agency (EPA)defines Ultra-Low Sulfur Diesel (ULSD - S15) as a U.S. diesel fuel with a sulfur content not to exceed 15 parts per million (ppm) or 0.0015% by weight. Low Sulfur Diesel (LSD) Low Sulfur Diesel (LSD-S500) is defined by the U.S. EPA as a U.S. diesel fuel with sulfur content not to exceed 500 ppm or 0.05% by weight. The LSD fuel commonly available in North America normally does • not exceed 350 ppm sulfur. Note: Both ULSD and LSD must meet the fuel requirements outlined in the most current revision level of"ASTM D975". SEBU6251-12 41 Maintenance Section Fuel Specifications • Sulfur-free Diesel Fuel More severe applications may require shortened oil drain intervals, while less severe applications may In Europe, ultra low sulfur diesel fuel will have a allow for longer than standard oil drain intervals. High maximum of 0.0010 percent (10 ppm) sulfur and is load factors (above 75%), particularly in conjunction typically referred to as "sulfur-free". This sulfur level with high sulfur fuels, can contribute significantly to is defined in European Standard "EN 590:2004". reducing oil drain intervals below standard oil drain intervals. Note: The most commonly available diesel fuel in Europe has a maximum sulfur content of 0.005 Consult with your Caterpillar dealer regarding the percent (50 ppm). This sulfur level is defined in testing that is required in establishing oil drain European Standard "EN 590:2004". intervals that are optimized for your application. Note: DO NOT USE ONLY THIS SPECIAL In order to help protect your engine, and in order PUBLICATION AS A BASIS FOR DETERMINING to help optimize oil drain intervals for engine OIL DRAIN INTERVALS. specific applications and duty cycles, Cat S-O-S Services oil analysis is: This Special Publication does not address recommended oil drain intervals, but rather • Recommended as a matter of course provides guidance that should be used in conjunction with your specific engine/machine • Very strongly recommended in order to determine Operation and Maintenance Manuals in oil drain intervals when operating on fuel with sulfur determining acceptable oil drain intervals. Consult levels between 0.05% (500 ppm) and 0.5% (5000 your engine/machine Operation and Maintenance ppm) Manuals, and consult Caterpillar dealers for additional guidance, including but not limited to guidance on Required in order to determine oil drain intervals establishing optimized and/or acceptable oil drain when operating on fuel with sulfur levels that are intervals. above 0.5% (5000 ppm) • Note: The use of Cat S-O-S Services oil analysis Note: Engine operating conditions play a key role helps environmental sustainability as it is the best in determining the effect that fuel sulfur will have on way to optimize oil life, and will help engines reach engine deposits and on engine wear. Consult your their expected life. Consult with your Caterpillar Caterpillar dealer for guidance when fuel sulfur levels dealer regarding the testing required to establish a are above 0.1% (1000 ppm). safe, optimized oil drain interval. Fuel sulfur levels may affect the oil life in a diesel Fuel sulfur levels affect exhaust emissions. High engine. Diesel fuels with higher levels of sulfur may sulfur fuels also increase the potential for corrosion of shorten oil life, and may shorten engine life. The oil internal components. Fuel sulfur levels above 0.5% drain recommendations in the Caterpillar Operation (5000 ppm) may significantly shorten the oil change and Maintenance Manuals are partially dependent on interval. the level of sulfur in diesel fuel. Note: Oil drain intervals are affected by many factors There are many factors that affect maximum allowed that are in addition to fuel sulfur levels, so that even and/or acceptable fuel sulfur levels, including but not when using fuel with lower sulfur levels, significantly limited to: shortened oil change intervals may be required. • Engine model/design Standard oil drain intervals as published in engine specific Operation and Maintenance • Engine application Manuals are for typical applications: • Overall fuel quality • Using recommended oils • Using recommended fluids • Using good fuel • Oil TBN (Total Base Number) • Using industry standard good maintenance • practices • Environmental factors and other site specific operating conditions • Following maintenance intervals as published in engine specific Operation and Maintenance • Fuel costs versus risk of shortened engine/engine Manuals component life 42 SEBU6251-12 Maintenance Section Fuel Specifications • Fuel costs versus shortened oil drain intervals For commercial and machine diesel engines that • are equipped with an aftertreatment device that is • Exhaust aftertreatment device type not listed in this section, refer to the engine/machine specific Operation and Maintenance Manual • Maintenance intervals and other maintenance and refer to the aftertreatment device specific practices documentation for guidance. • Engine Certification For commercial and machine diesel engines that are retrofitted with an aftertreatment device, refer to • Laws, regulations, and other legal mandates the aftertreatment device specific documentation. Note: Consult federal, state, local, and other The preferred fuel sulfur level for non aftertreatment governing authorities for guidance concerning fuel device equipped commercial and machine diesel requirements for your area. engines is 0.05% (500 ppm) or less. Note: Consult specific engine Operation and Note: "non DOC and non DPF equipped" refers to Maintenance Manuals for additional guidance, engines that were not originally designed to require including but not limited to guidance on acceptable oil DOC and/or DPF aftertreatment, and did not come drain intervals and guidance on maximum acceptable from the factory with a DOC and/or a DPF installed fuel sulfur level. and/or required. The list below provides a quick reference for When other factors do not preclude, and acceptable sulfur levels for diesel fuel that will be understanding that there may be trade-offs such as used in Cat commercial and machine diesel engines shortened oil drain intervals, certain commercial but the controlling documents are the specific and machine diesel engines that are covered by engine Operation and Maintenance Manuals, the this Special Publication MAY be able to operate specific Aftertreatment device documentation, and satisfactorily on fuels with up to 1% (10, 000 ppm) the applicable emissions laws, regulations and sulfur if the following conditions are met: • mandates. • All emissions laws, regulations and mandates are • The maximum allowable fuel sulfur level is also followed controlled by various emissions laws, regulations and mandates. Consult federal, state, and local • The engine/engines are not equipped with authorities for guidance on fuel requirements for aftertreatment device/devices your area. • All appropriate guidelines and maintenance • The maximum fuel sulfur level allowed for a DPF practices as stated in engine specific Operation (Diesel Particulate Filter) equipped commercial and Maintenance Manuals are followed and machine diesel engines is 0.0015% (15 ppm). • All appropriate guidelines and maintenance • The preferred maximum fuel sulfur level for DOC practices as stated in this Special Publication are (Diesel Oxidation Catalyst) equipped commercial followed and machine diesel engines is 0.005% (50 ppm). Some DOC equipped engines REQUIRE the • Operating in otherwise low to moderate severity use of fuel with a maximum of 0.005% (50 ppm) applications fuel sulfur. Refer to the engine/machine specific Operation and Maintenance Manual and refer to • Your Cat dealer is consulted and approves the aftertreatment device specific documentation for guidance. • You refer to this Special Publication, and you refer to your specific Cat commercial engine and/or • The maximum fuel sulfur level allowed for most refer to your specific Cat machine Operation and DOC (Diesel Oxidation Catalyst) equipped Maintenance Manual for additional guidance and commercial and machine diesel engines is exceptions 0.05% (500 ppm). Some DOC equipped engines REQUIRE the use of fuel with a In order to help protect your engine: maximum of 0.005% (50 ppm) fuel sulfur. Refer • to the engine/machine specific Operation and Cat S-O-S Services oil analysis is recommended Maintenance Manual and refer to the aftertreatment as a matter of course. device specific documentation for guidance. SEBU6251-12 43 Maintenance Section Fuel Specifications • Cat S-O-S Services oil analysis is very strongly The particles of ice are lighter than the fuel, and the recommended in order to determine oil drain particles of ice will not settle to the bottom of the intervals when operating on fuel with sulfur levels tank. When this type of moisture is mixed in the fuel, between 0.05% (500 ppm) and 0.5% (5000 ppm). this moisture will fill the fuel filters. The ice crystals will plug the fuel filters in the same way as wax plugs • Cat S-O-S Services oil analysis is required in order the fuel filters. to determine oil drain intervals when operating on fuel with sulfur levels that are above 0.5% (5000 If a filter is plugged and fuel flow is stopped, perform ppm). the following procedure to determine the cause: • Consult your Caterpillar dealer for guidance when 1. Remove the fuel filters. fuel sulfur levels are above 0.1% (1000 ppm). 2. Cut the fuel filters open. Note: For guidance related to on-highway diesel engines refer to specific engine Operation and 3. Inspect the fuel filter before the filter warms. This Maintenance Manuals, and to the most current inspection will show that the filter is filled with revision level of Caterpillar On-Highway Diesel particles of either ice or wax. Engine Fluids Recommendations, SEBU6385. The moisture which is free and settled at the bottom Moisture Content of the tank can become mixed with the fuel. The force of any pumping action will mix the moisture with the Problems with fuel filters can occur at any time. The fuel whenever fuel is transferred. This moisture then cause of the problem can be water in the fuel or becomes free and dispersed water. This moisture can moisture in the fuel. At low temperatures, moisture cause ice in the filters. This moisture can cause other causes special problems. There are three types of problems with filters at any temperature. Generally, moisture in fuel: dissolved moisture (moisture in the same force that mixes the water into the fuel will solution), free and dispersed moisture in the fuel, and also mix dirt and rust from the bottom of the tank with free and settled at the bottom of the tank. the water. The result is a dirty mixture of fuel and • water which can also fill the filters and stop fuel flow. Most diesel fuels have some dissolved moisture. Note: Among other potential problems, such as Just as the moisture in air, the fuel can only contain breaking down of the fuel protective film strength, a specific maximum amount of moisture at any one excessive water in the fuel can lead to sulfuric acid temperature. The amount of moisture decreases as creation from the sulfur present in the diesel fuel, the temperature is lowered. For example, a fuel could increasing the potential for corrosion of internal contain 100 ppm (0.010 percent) of water in solution at 18°C (65°F). This same fuel can possibly hold only components. Refer to this Special Publication, 30 ppm (0.003 percent) at 4°C (400F). the "Characteristics of Diesel Fuel" article, "Diesel Fuel Sulfur" and other related topics for additional After the fuel has absorbed the maximum possible information. Also, refer to the most current revision amount of water, the additional water will be free level of"ASTM D975 (Standard Specification for and dispersed. Free and dispersed moisture is fine Diesel Fuel Oils)" for additional information. droplets of water that is suspended in the fuel. Since the water is heavier than the fuel, the water will slowly Specific Gravity / API Gravity become free and settled at the bottom of the tank. In the above example, when the fuel temperature was The specific gravity of diesel fuel is the weight of a lowered from 18°C (65°F) to 4°C (40°F), 70 ppm of fixed volume of fuel in comparison to the weight of water became free and dispersed in the fuel. the same volume of water at the same temperature. A higher specific gravity correlates into a heavier The small drops of water cause a cloudy appearance fuel. Heavier fuels have more energy or power per in the fuel. If the change in temperature is slow, the volume for the engine to use. small drops of water can settle to the bottom of the tank. When the fuel temperature is lowered rapidly Note: The settings for the fuel mixture should not be to freezing temperature, the moisture that comes adjusted in order to compensate for a loss of power out-of-solution changes to very fine particles of ice with fuels that are lighter. The life of fuel system instead of small drops of water. components can be decreased with fuels that are • very light because lubrication will be less effective as a result of the lower viscosity. This is compounded if the fuel does not have sufficient lubricity. Refer to the "Lubricity and Low Sulfur Diesel (LSD) and Ultra Low Sulfur Diesel (ULSD) Fuel" topic in this Special Publication, "Characteristics of Diesel Fuel" article. 44 SEBU6251-12 Maintenance Section Fuel Specifications The API gravity of a fuel is also a measure of the Note: Even when all fuel storage maintenance • density of the fuel or the relationship of the weight to practices that are relevant for your application are the volume. The scale for API gravity is inverse to the followed, Caterpillar recommends a maximum of one scale for specific gravity. The API gravity will become year from production for distillate diesel fuel storage, higher as the fuel becomes lighter. and a maximum of six months from production for biodiesel and blended biodiesel storage. Storage life Lighter fuels will not produce the rated power. Lighter for biodiesel and for biodiesel blends that are greater fuels may also be a blend of ethanol or methanol with than B20 may be much shorter than six months. diesel fuel. Blending alcohol or gasoline with diesel fuel will create an explosive atmosphere in the fuel The Thermal Stability and Oxidation tank. In addition, water condensation in the tank can cause the alcohol to separate in the tank. Stability of Fuel Diesel fuels can deteriorate rapidly for a variety of reasons. When the fuel is stressed and stored Mixing alcohol or gasoline with diesel fuel can pro- for long intervals, degradation and oxidation canoccur. Degradation and oxidation are complex duce explosive mixture in the engine crankcase chemical changes. These changes lead to deposits or fuell tank. or sediment from certain hydrocarbons and traces of naturally occurring nitrogen and sulfur containing Personal injury and damage to the engine may compounds in the fuel. Fuel composition and result. Caterpillar recommends against this prac- environmental factors influence the process. tice. Diesel fuel is being used as a coolant for high NOTICE pressure fuel injection systems with high temperature Mixing alcohol or gasoline with diesel fuel may cause fuel wetted walls. This can stress the fuel in the damage to the engine. Caterpillar recommends fuel system. The thermal stress and an increase in against this practice. Water condensation in the fuel recirculation fuel temperature is often responsible for tank can cause the alcohol to separate which could fuel degradation and the formation of gums, resins • cause damage to the engine. and sediment, which can cause fuel flow restriction through fuel filters and fuel injection systems. Heavier fuels tend to create more deposits from Certain products are often left with the fuel in the fuel combustion. Deposits from combustion can cause system for long periods. This exposes the fuel to abnormal cylinder liner and ring wear. This is most oxygen. Complex reactions between the oxygen and noticeable in smaller diesel engines that operate at the fuel components can generate fuel particulates. higher speeds. The particulates in the fuel system can turn into the sludge that is found in fuel tanks, fuel lines and the Gums and Resins fuel filters. This will deteriorate the performance of the fuel system. Degradation also leads to a plugged The gums and resins that occur in diesel fuel are fuel filter, a restriction to the fuel line and deposit the result of dissolved oxidation products in the formation in the fuel injection nozzle. fuel that do not evaporate easily. The products that Biodiesel and blends of biodiesel have poor thermal are dissolved in the fuel also do not burn cleanly. stability and oxidation stability compared to petroleum Excessive gum in the fuel will coat the inside of fuel distillate diesel fuels. The use of these biodiesels lines, pumps, and injectors. Excessive gum will also and blends of biodiesel can accelerate the problems interfere with the close tolerances of the moving parts that are addressed in this Special Publication. Using of the fuel systems. Gum and resin in the fuel will biodiesel blends above the maximum level approved also cause the filter to plug rapidly. Oxidation of the for the engine is not recommended. fuel will occur and the formation of additional gums and resins will occur during fuel storage. The storage Thermal and oxidative degradation of diesel fuel can time for fuel needs to be minimized in order to help result in a darkening of fuel color. Fuel color is not reduce the formation of gums and resins. necessarily an indication of excessive degradation that will lead to the problems outlined in this Special Publication. But darkened fuel color can be an • indicator of degradation leading to concerns about the stability of darkened fuel. Thermal oxidation and oxidative stability tests should be run to confirm actual fuel degradation. SEBU6251-12 45 Maintenance Section Fuel Specifications • Thermal Oxidation Stability A test that can be used to help determine the degradation of biodiesel and biodiesel blends is Caterpillar recommends the use of the "Accelerated the measurement of the Total Acid Number (TAN). Fuel Oil Stability Test (ASTM D6468)". This is a This number represents the amount of acid present test method that determines the instability of a fuel in the biodiesel or biodiesel blend as a result of subjected to a thermal degradation process. This degradation. The following test methods may be test exposes the fuel to actual operating conditions used: "EN 14104 Fat and oil derivatives - Fatty Acid when the fuel cools the injectors during the engine Methyl Esters (FAME) - Determination of Acid Value" operation. or "ASTM D664 Standard Test Method for Acid Number of Petroleum Products by Potentiometric The test is performed by using a spectrophotometer. Titration". For neat(6100) biodiesel, this value should The percentage reflectance of fuel should not be less not exceed 0.5 mg KOH/g. For biodiesel blends such than eighty percent after aging for three hours at a as 20% biodiesel and 80% diesel (620), this value temperature of 150' C (302' F). should not exceed 0.3 mg KOH/g. Biodiesel and biodiesel blends that exceed these values should Oxidative Stability Test be considered degraded beyond acceptable limits and further testing would not be required. Biodiesel Caterpillar recommends the use of the "Oxidative and biodiesel blends that exceed 0.16 mg KOH/g Stability Test". This is a test method that determines may result in the formation of undesired degradation long term storage of distillate fuels such as home by-products that can cause the problems discussed heating oils, kerosene and diesel oils. The test in this document. Samples that exceed 0.16 mg method is not suitable for highly volatile fuels with KOH/g but do not exceed 0.3 mg KOH/g should be flash points under 38' C (100' F). This test method is tested with the other methods in order to determine used for storage stability, with the use of stabilizing the thermal and oxidative stability of the fuel. additives and without the use of stabilizing additives. i03424066 As per the specification "EN590:2004 Automotive • Fuels - Diesel", a test for a direct measurement of Fuel Recommendations oxidation stability is the test method "ISO 12205 Petroleum products - Determination of the oxidation SMCS Code. 1250; 1280 stability of middle distillate diesel fuels". The fuel sample is heated at 95' C (203' F) for 16 hours while NOTICE bubbles of oxygen travel through the sample. The These recommendations are subject to change with- resulting amount of solid oxidation by products are out prior notice. Contact your local Caterpillar dealer then measured. The process of cavitating oxygen for the most up to date recommendations. into the fuel can simulate an impact over a long term of contact with fuel with oxygen that results in degradation. With diesel fuel the maximum amount Diesel engines have the ability to burn a wide variety of soluble that are formed should not exceed 25 g of fuels. These fuels are divided into two general per cubic meter. groups. The two groups are called the preferred fuels and the permissible fuels. Caterpillar recommends that for diesel, biodiesel, or biodiesel blends that are going to be used several The preferred fuels provide maximum engine months after purchase, artificially aging the fuel to service life and performance. The preferred fuels predict the storage stability, followed by an analysis are distillate fuels. These fuels are commonly called of the fuel. For most distillate fuels that age the diesel fuel, furnace oil, gas oil, or kerosene. These fuel for 7 days at 80' C (176' F) is equivalent to fuels must meet the "Caterpillar Specification for storage for 4 to 8 months at typical ambient storage Distillate Diesel Fuel for Off-Highway Diesel Engines" temperatures. Analysis of this matured fuel per the found in this Special Publication, "Distillate Diesel methods discussed in this document can then be Fuel" article. used to aid in predicting the stability of the fuel after numerous months of storage. Note: The permissible fuels are some crude oils, some blends of crude oil with distillate fuel, some biodiesel, and some marine diesel fuel. These fuels are not suitable for use in all engine applications. • The acceptability of these fuels for use is determined on a case by case basis. A complete fuel analysis is required. Consult your Caterpillar dealer for further information. For information concerning biodiesel/biodiesel blends, refer to this Special Publication, "Biodiesel" article. 46 SEBU6251-12 Maintenance Section Fuel Specifications Note: With the exception of some biodiesel, • Some fuel parameters that are outside of the • permissible fuels are not acceptable for use in specification limits can be compensated for (e.g. on-highway applications. fuel can be cooled to address low viscosity, etc.). NOTICE • Some fuel parameters that are outside of Use of permissible fuels can result in higher mainte- specification limits may be able to be improved nance costs and reduced engine service life. with the use of appropriate amounts of well proven fuel additives. Refer to this Special Publication, "Distillate Diesel Fuel" article, "Aftermarket Fuel Additives" and "Cat Diesel Fuel Conditioner" topics i03424203 for guidance. Distillate Diesel Fuel To help ensure optimum engine performance, a SMCS Code: 1280 complete fuel analysis should be obtained before engine operation. The fuel analysis should include NOTICE all of the properties that are listed in the "Caterpillar For on-highway diesel engine fluids requirements, Specification for Distillate Fuel for Off-Highway Diesel Engines", Table 7. refer to specific engine Operation and Maintenance Manuals, and also refer to the most current revision Note: The diesel fuel cannot have any visually level of Special Publication, SEBU6385, "Caterpillar apparent sediment, suspended matter, or undissolved On-Highway Diesel Engine Fluids Recommenda- water. tions". Also consult with your Caterpillar dealer. Diesel Fuels that meet the specifications in table 7 Caterpillar is not in the position to continuously will help provide maximum engine service life and evaluate and monitor all of the many worldwide performance. distillate diesel fuel specifications and their on-going revisions that are published by governments and In North America, diesel fuels that are identified technological societies. as "ASTM D975-08a" Grades No. 1-D or No. 2-D (all listed sulfur levels) generally meet the table 7 The "Caterpillar Specification for Distillate Fuel for requirements. Off-Highway Diesel Engines" provides a known, reliable baseline to judge the expected performance In Europe, diesel fuels that are identified as meeting of distillate diesel fuels that are derived from "European Standard EN590:2004" generally meet conventional sources (crude oil, shale oil, oil sands, the table 7 requirements. etc.) when used in Caterpillar diesel engines. Table 7 is for diesel fuels that are distilled from Using the Caterpillar distillate diesel fuel specification conventional sources (crude oil, shale oil, oil sands, as the baseline, it is much easier to determine any etc.). Diesel fuels from other sources could exhibit potential economic and/or performance trade-offs, detrimental properties that are not defined or and overall acceptability when using fuels of varying controlled by this specification. characteristics and quality levels. NOTICE • When required, have the diesel fuel that either is Ultra Low Sulfur Diesel (ULSD)fuel will have_<15 ppm being used or is planned to be used, tested per the (0.0015%) sulfur using the "ASTM D5453", "ASTM Caterpillar distillate diesel fuel specification. D2622", "ISO 20846", or "ISO 20884" test methods. Certain applications and/or governments/localities • Use the Caterpillar distillate diesel fuel specification MAY require the use of ULSD fuel. Emission con- as a fuel quality baseline for comparison of trolled diesel engines and/or diesel engines equipped distillate diesel fuel analysis results, and/or a with exhaust aftertreatment devices MAY require baseline for comparison of other distillate diesel the use of ULSD fuel. Diesel engines equipped with fuel specifications. a Diesel Particulate Filter (DPF) require the use of ULSD. Consult federal, state, and local authorities • Typical fuel characteristics can be obtained from for guidance on fuel requirements for your area. AI- the fuel supplier. so, refer to this Special Publication, "Characteristics of Diesel Fuel", article, refer to the specific engine Fuel parameters outside of the Cat fuel specification Operation and Maintenance Manual, and refer to the limits have explainable consequences. aftertreatment device documentation for guidance. SEBU6251-12 47 Maintenance Section Fuel Specifications • When ULSD is used, there are concerns with Engines that are manufactured by Caterpillar are fuel viscosity, lubricity, and thermal stability. The certified by use of the prescribed U.S. Environmental fuel lubricity and thermal stability limits stated in Protection Agency (EPA) and European Certifications the "Caterpillar Specification for Distillate Fuel fuels. Caterpillar does not certify diesel engines on for Off-Highway Diesel Engines" address these any other fuel. concerns. In North America, diesel fuels that are identified as meeting "ASTM D975 Grade No. Note: The owner and the operator of the engine 1-D S15" or "ASTM D975 Grade No. 2-D S15" has the responsibility of using the correct fuel that is and meet the "ASTM D975-08a Thermal Stability recommended by the manufacturer and allowed by Guideline X3.10.2.2", generally meet the Caterpillar the U.S. EPA and, as appropriate, other regulatory requirements for ULSD fuel. agencies. In Europe, diesel fuels that are identified as meeting NOTICE "European Standard EN590:2004" requirements Operating with fuels that do not meet Caterpillar rec- for <_ 10 ppm sulfur fuel (typically referred to as ommendations can cause the following effects: start- "sulfur-free") generally meet Caterpillar requirements ing difficulty, reduced fuel filter service life, poor com- for ULSD fuel. bustion, deposits in the fuel injectors, reduced ser- Using fuels with higher than recommended fuel vice life of the fuel system, deposits in the combustion sulfur levels can or will: chamber, and reduced service life of the engine. • Reduce engine efficiency and durability NOTICE The footnotes are a key part of the"Caterpillar Specifi- • Cause more frequent aftertreatment ash cleaning cation for Distillate Diesel Fuel for Off-Highway Diesel intervals Engines" Table. Read ALL of the footnotes. • Damage emission control systems Table 7 • Cause the need for more frequent oil drain intervals Caterpillar Specification for Distillate Fuel for Off-Highway Diesel Engines(') • Reduce fuel economy Specifications ' Requirements ASTM ISO Test Refer to this Special Publication, "Characteristics of Test Diesel Fuel"article for additional pertinent information Aromatics 35%maximum "D1319" "ISO concerning fuel lubricity, fuel oxidative stability, fuel 3837" sulfur, and aftertreatment devices. Also refer to 0.01% "ASTM D975-08a", to the specific engine Operation Ash maximum "D482" "ISO and Maintenance Manual, and to aftertreatment (weight) 6245" device documentation for guidance. Carbon 0.35% "ISO Residue on maximum "D524" 4262" NOTICE 10% Bottoms (weight) For on-highway diesel engine fluids requirements, refer to specific engine Operation and Maintenance 40 minimum "D613" Manuals, and also refer to the most current revision Cetane (DI engines) "ISO level of Special Publication, SEBU6385, "Caterpillar Number m 35 minimum "D6890" 5165" On-Highway Diesel Engine Fluids Recommenda- (PC engines) tions". Also consult with your Caterpillar dealer. The cloud point must Note: Caterpillar strongly recommends the filtration not exceed "ISO of distillate fuel and/or biodiesel/biodiesel blends Cloud Point the lowest "D2500" 3015" through a fuel filter with a rating of four microns c expected 9 g ( ) ambient absolute or less. This filtration should be located on temperature. the device that dispenses the fuel to the fuel tank for the engine, and also on the device that dispenses Copper Strip No. 3 "D130" "ISO • fuel from the bulk storage tank. Series filtration is Corrosion maximum 2160" recommended. (continued) 48 SEBU6251-12 Maintenance Section Fuel Specifications (Table 7,contd) (Table 7,contd) • Caterpillar Specification for Distillate Fuel for Caterpillar Specification for Distillate Fuel for Off-Highway Diesel Engines() Off-Highway Diesel Engines() Specifications Requirements ASTM ISO Test Specifications Requirements ASTM ISO Test Test Test 10% at 282 °C Gums and 10 mg per 100 "ISO (540 °F) Resins(6) mL maximum "D381" 6246" Distillation maximum "D86" "ISO 0.52 mm 90% at 360°C 3405" (0.0205 inch) No (680 °F) Lubricity M maximum at "D6079" equivalent maximum 60°C (140°F) test "ISO (1) For additional guidance related to many of the fuel Flash Point legal limit "D93" 2719" characteristics that are listed in this table, refer to this Special Publication, "Characteristics of Diesel Fuel", Minimum article.This specification includes the requirements for Ultra of 80% Low Sulfur Diesel (ULSD). ULSD fuel will have<_ 15 ppm reflectance No (0.0015%)sulfur using the"ASTM D5453","ASTM D2622", Thermal after aging for "D6468" equivalent or"ISO 20846","ISO 20884"test methods.This specification Stability 180 minutes test includes the requirements for Low Sulfur Diesel(LSD). LSD at 150 °C fuel will have<_500 ppm (0.05%)sulfur using the"ASTM D5453","ASTM D2622"or the"ISO 20846","ISO 20884"test (302 °F) methods.Aftertreatment devices can be permanently damaged 30 minimum No by the use of high sulfur fuels. Refer to this Special Publication, API Gravit > "D287" equivalent "Characteristics of Diesel Fuel"article,refer to the specific Y q engine Operation and Maintenance Manual,and refer to the 45 maximum test aftertreatment device documentation for guidance. 6 °C (10 °F) (2) Alternatively,to ensure a minimum cetane number of 35(PC engines), and 40(DI engines),distillate diesel fuel should have Pour Point minimum „D97„ "ISO a minimum cetane index of 37.5(PC engines), and 44.2(DI below ambient 3016" engines)when the"ASTM D4737-96a"test method is used.A • temperature fuel with a higher cetane number may be required for operation ISO at a higher altitude or in cold weather. (3) Via standards tables,the equivalent kg/m'(kilograms per cubic "D5453" 20846 meter)using the"ASTM D287"test method temperature of Sulfur (1)(4) or or 15.56'C(60°F)for the minimum API gravity of 30 is 875.7 "D2622" ISO kg/m',and for the maximum API gravity of 45 is 801.3 kg/m'. 20884 (4) Engine operating conditions play a key role in determining the effect that fuel sulfur will have on engine deposits 1.4 cSt and on engine wear.Consult your Caterpillar dealer for minimum guidance when fuel sulfur levels are above 0.1%(1000 and 20.0 cSt ppm).There are many factors that affect maximum allowed maximum and/or acceptable fuel sulfur levels. Fuel sulfur levels affect as delivered exhaust emissions. High sulfur fuels increase the potential for to the fuel corrosion of internal components,and can shorten expected injection oil life,and can shorten expected aftertreatment device life. Aftertreatment devices can be permanently damaged by the Kinematic pumps use of high sulfur fuels. For additional information related to Viscosity(5) 1.4 cSt fuel sulfur, including fuel sulfur limits, refer to this Special Publication,"Characteristics of Diesel Fuel"article,refer to this minimum Special Publication,"Engine Oil"article,refer to the specific and 4.5 cSt engine Operation and Maintenance Manual,and refer to the maximum as aftertreatment device documentation. delivered to (5) The values of the fuel viscosity are the values as the fuel is the rotary delivered to the fuel injection pumps.For ease of comparison, fuel injection fuels should also meet the minimum and maximum viscosity pumps requirements at 40°C(104°F)that are stated by the use of either the"ASTM D445"test method or the"ISO 3104"test Water and 0.05% "ISO method. If a fuel with a low viscosity is used,cooling of the fuel Sediment maximum "D1796" 3734" may be required to maintain 1.4 cSt or greater viscosity at the fuel injection pump. Fuels with a high viscosity might require 0.05% No fuel heaters in order to lower the viscosity to either 4.5 cSt or Water maximum "D1744" equivalent less for rotary fuel injection pumps or 20 cSt viscosity or less test for all other fuel injection pumps. • (6) Follow the test conditions and procedures for gasoline(motor). 0.05% „ISO (7) The lubricity of a fuel is a concern with low sulfur and ultra Sediment maximum "D473" 3735" low sulfur fuel. To determine the lubricity of the fuel, use the (weight) "ASTM D6079 High Frequency Reciprocating Rig (HFRR)" (continued) test.There are many aftermarket additives that are available to treat fuel. If the lubricity of a fuel does not meet the (continued) SEBU6251-12 49 Maintenance Section Fuel Specifications • (Table 7, contd) minimum requirements,consult your fuel supplier for proper NOTICE recommendations regarding fuel additives.Also, refer to this Ultra Low Sulfur Diesel (ULSD)fuel will have s15 ppm Special Publication,"Characteristics of Diesel Fuel"article, (0.0015%) sulfur using the "ASTM D5453", "ASTM "Aftermarket Fuel Additives"and"Cat Diesel Fuel Conditioner" D2622 or "ISO 20846", "ISO 20884" test methods. topics. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible.These additives can cause Certain applications and/or governments/localities problems in the fuel system. MAY require the use of ULSD fuel. Emission con- trolled diesel engines and/or diesel engines equipped There are many other diesel fuel specifications that with exhaust aftertreatment devices MAY require are published by governments and by technological the use of ULSD fuel. Diesel engines equipped with societies. Usually, those specifications do not a Diesel Particulate Filter (DPF) require the use of review all the requirements that are addressed ULSD. Consult federal, state, and local authorities for in the "Caterpillar Specification for Distillate Fuel guidance on fuel requirements for your area. Also, for Off-Highway Diesel Engines", Table 7. To help refer to this Special Publication, "Characteristics of ensure optimum engine performance, a complete fuel Diesel Fuel" article, refer to the specific engine Op- analysis should be obtained before engine operation. eration and Maintenance Manual, and refer to the The fuel analysis should include all of the properties aftertreatment device documentation for guidance. that are listed in the "Caterpillar Specification for Distillate Fuel for Off-Highway Diesel Engines", Table When ULSD is used, there are concerns with fuel vis- 7. cosity, lubricity, and thermal stability. The fuel lubrici- ty and thermal stability limits stated in the "Caterpillar Ultra Low Sulfur Diesel (ULSD) Specification for Distillate Fuel for Off-Highway Diesel Engines" address these concerns. In North America, Caterpillar recommends that all distillate diesel fuel, diesel fuels that are identified as meeting"ASTM D975 including ULSD fuel (fuel <_ 15 ppm sulfur using Grade No. 1-D S15" or "ASTM D975 Grade No. 2-D "ASTM D5453", "ASTM D2622", or"ISO 20846", "ISO S15" and meet the"ASTM D975-08a Thermal Stabili- 20884") meet the requirements of the "Caterpillar ty Guideline X3.10.2.2", generally meet the Caterpillar • Specification for Distillate Fuel for Off-Highway Diesel requirements for ULSD fuel. Engines", that are specified in Table 7. In Europe, diesel fuels that are identified as meeting Note: ULSD has less electrical conductivity than "European Standard EN590:2004" requirements LSD. Follow all industry standard grounding and for <_ 10 ppm sulfur fuel (typically referred to as safety practices. "sulfur-free") generally meet Caterpillar requirements for ULSD fuel. Using fuels with higher than recommended fuel sulfur levels can or will: • Reduce engine efficiency and durability • Cause more frequent aftertreatment ash cleaning intervals • Damage emission control systems • Cause the need for more frequent oil drain intervals • Reduce fuel economy Refer to this Special Publication, "Characteristics of Diesel Fuel"article for additional pertinent information concerning fuel lubricity, fuel oxidative stability, fuel sulfur, and aftertreatment devices. Also refer to "ASTM D975-08a", to the specific engine Operation • and Maintenance Manual, and to aftertreatment device documentation for guidance. 50 SEBU6251-12 Maintenance Section Fuel Specifications NOTICE i • For on-highway diesel engine fluids requirements, Mixing alcohol or gasoline with diesel fuel can pro- refer to specific engine Operation and Maintenance duce an explosive mixture in the engine crankcase Manuals, and also refer to the most current revision or fuel tank. level of Special Publication, SEBU6385, "Caterpillar On-Highway Diesel Engine Fluids Recommenda- Personal injury and damage to the engine may tions". Also consult with your Caterpillar dealer. result. Caterpillar recommends against this prac- tice. Engines that are manufactured by Caterpillar are certified by use of the prescribed U.S. Environmental Protection Agency (EPA)and European Certifications Heavy Fuel Oil, Residual Fuel, fuels. Caterpillar does not certify diesel engines on Blended Fuel any other fuel. Note: The owner and the operator of the engine NOTICE has the responsibility of using the correct fuel that is Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel recommended by the manufacturer and allowed by must NOT be used in Caterpillar diesel engines (ex- the U.S. EPA and, as appropriate, other regulatory cept in 3600 Series HFO engines). Blended fuel is residual fuel that has been diluted with a lighter fuel agencies. (cutter stock) so that they will flow. Blended fuels are also referred to as heavy fuel oils. Severe component NOTICE wear and component failures will result if HFO type Operating with fuels that do not meet Caterpillar rec- fuels are used in engines that are configured to use ommendations can cause the following effects: start- distillate fuel. ing difficulty, reduced fuel filter service life, poor com- bustion, deposits in the fuel injectors, reduced ser- vice life of the fuel system, deposits in the combustion Alternative Fuels - Arctic chamber, and reduced service life of the engine. Applications • NOTICE In extreme cold ambient conditions, you may choose In order to meet expected fuel system component life, to use the distillate fuels that are specified in table 4 micron(c) absolute or less secondary fuel filtration 8. However, the fuel that is selected must meet the is required for all Caterpillar diesel engines that are requirements that are specified in the "Caterpillar equipped with common-rail fuel systems, and for all Specification for Distillate Diesel Fuel for Off-Highway Caterpillar diesel engines that are equipped with unit Diesel Engines", Table 7. These fuels are intended injected fuel systems. For all other Caterpillar diesel to be used in operating temperatures that are down engines (mostly older engines with pump, line and to -54 °C (-65 OF). nozzle type fuel systems), the use of 4 micron(c) ab- Note: The fuels that are listed in table 8 typically have solute or less secondary fuel filtration is strongly rec- much higher sulfur levels than the 15 ppm maximum ommended. Note that all current Caterpillar diesel en- sulfur allowed for ULSD. The sulfur levels for these gines are factory equipped with Caterpillar Advanced Efficiency 4 micron(c) absolute fuel filters. fuels typically far exceed 15 ppm. These fuels typically will not be acceptable for use in areas that restrict maximum fuel sulfur levels to 15 ppm of less. Note: Caterpillar strongly recommends the filtration of distillate fuel and/or biodiesel/biodiesel blends Note: The fuels that are listed in table 8 typically through a fuel filter with a rating of four microns(c) have much higher sulfur levels than the 50 ppm absolute or less. This filtration should be located on maximum sulfur allowed in the European Standard the device that dispenses the fuel to the fuel tank for "EN 590:2004". The sulfur content of these fuels the engine, and also on the device that dispenses typically far exceeds 50 ppm. These fuels typically fuel from the bulk storage tank. Series filtration is will not be acceptable for use in areas that restrict recommended. maximum fuel sulfur levels to 50 ppm or less. In order to obtain additional information on Caterpillar • designed and produced filtration products, refer to this Special Publication, "Reference Material' article, "Filters" and "Miscellaneous" topics, and then contact your Caterpillar dealer for assistance with filtration recommendations for your Caterpillar machine. SEBU6251-12 51 Maintenance Section Fuel Specifications • Table 8 In special circumstances, Caterpillar recognizes the Alternative Distillate Fuels -Arctic Applications(1)(2) need for fuel additives. Fuel additives need to be used with caution. The additive may not be compatible with Specification Grade the fuel. Some additives may precipitate. This action "MIL-DTL-5624U" JP-5 causes deposits in the fuel system. The deposits may cause seizure. Some additives may plug fuel "MIL-DTL-83133F" JP-8 filters. Some additives may be corrosive, and some "ASTM D1655-08a" Jet AP), Jet A-1(3) additives may be harmful to the elastomers in the fuel system. Some additives may damage emission (1) The fuel that is selected must meet the requirements that are control systems. Some additives may raise fuel sulfur specified in the"Caterpillar Specification for Distillate Diesel levels above the maximum allowed by the United Fuel for Off-Highway Diesel Engines"table,table 7.Cooling of the fuel may be required to maintain 1.4 cSt or greater States (U.S.) Environmental Protection Agency (EPA) viscosity at the fuel injection pump. Consult the supplier for and/or, as appropriate, other regulatory agencies. the recommended additives in order to maintain the proper Consult your fuel supplier for those circumstances fuel lubricity. when fuel additives are required. Your fuel supplier (2) The fuel specifications listed in this table allow and/or can make recommendations for additives to use and recommend the use of fuel additives that have not been tested by Caterpillar for use in Caterpillar fuel systems. The for the proper level of treatment. use of these specifications allowed and/or recommended fuel additives are at the risk of the user. Note: Metallic fuel additives can cause fuel (3) Jet A is the standard fuel used by U.S.commercial airlines system/injector fouling and after treatment device when operating within the U.S.Jet A-1 is the standard fuel used fouling. Caterpillar discourages the use of metallic by commercial airlines worldwide. Per"ASTM D1655-08a, Table 1 (Detailed Requirements of Aviation Turbine Fuels)",Jet fuel additives in most applications. Metallic fuel A and Jet A-1 have identical requirements except for freezing additives should only be used in applications where point.Jet A has a freeze point requirement of-40°C(-40°F) their use is specifically recommended by Caterpillar. versus the Jet A-1 has a freeze point requirement of-47°C (-52.6°F), but other freezing points may be agreed on by the Note: The U.S. EPA bans the use of metallic fuel fuel purchaser and the fuel supplier. additives in on-highway applications. . These fuels are lighter than the No. 2 grades of fuel. The cetane number of the fuels in table 8 must be Note: Diesel fuel additives/conditioners may not at least 40. If the viscosity is below 1.4 cSt at 40 °C improve markedly poor diesel fuel properties enough (104 °F), use the fuel only in temperatures below to make them acceptable for use. 0 °C (32 °F). Do not use any fuels with a viscosity of less than 1.2 cSt at 40 °C (104 °F). Note: For best results, your fuel supplier should treat the fuel when additives are needed. Note: Fuel cooling may be required in order to maintain the minimum viscosity of 1.4 cSt at the fuel Cat Diesel Fuel Conditioner injection pump. Note: Cat Diesel Fuel Conditioner, part number Note: These fuels may not prove acceptable for all 256-4968, is the only fuel conditioner/additive applications. available to the end user that is tested and approved by Caterpillar for use in Caterpillar diesel engines. Aftermarket Fuel Additives Cat Diesel Fuel Conditioner is a proprietary metal and There are many different types of fuel additives that ash free formulation that has been extensively tested are available to use. Caterpillar does not generally for use with distillate diesel fuels for use in Caterpillar recommend the use of fuel additives. diesel engines. Cat Diesel Fuel Conditioner helps address many of the challenges that various fuels worldwide present in regards to fuel life/stability, engine startability, injector deposits, fuel system life, and long term engine performance. Note: Diesel fuel additives/conditioners may not improve markedly poor diesel fuel properties enough to make them acceptable for use. • 52 SEBU6251-12 Maintenance Section Fuel Specifications Note: For maximum overall benefits, ask your fuel Caterpillar strongly recommends that Cat Diesel Fuel • supplier to add Cat Diesel Fuel Conditioner at the Conditioner be used with biodiesel and biodiesel recommended treat rate before fuel delivery, or blends. Cat Diesel Fuel Conditioner is suitable for use you may add Cat Diesel Fuel Conditioner at the with biodiesel/biodiesel blends that meet Caterpillar recommended treat rate during the early weeks of biodiesel recommendations and requirements. Note fuel storage. Follow all applicable national, regional, that not all fuel additives are suitable for use and local laws, mandates, and regulations concerning with biodiesel/biodiesel blends. Read and follow the use of diesel fuel conditioners/additives. all applicable label usage instructions. Also, refer to this Special Publication, "Distillate Diesel Fuel" Cat Diesel Fuel Conditioner is a proven high article and also refer to the "Biodiesel" article, which performance, multipurpose diesel fuel conditioner includes Caterpillar biodiesel recommendations and that is designed to improve: requirements. • Fuel economy (through fuel system cleanup) When used as directed, Cat Diesel Fuel Conditioner has proven to be compatible with existing and • Lubricity U.S. EPA 2007 on-highway certified diesel engine emission control catalysts and particulate filters. • Oxidative stability Note: When used as directed, Cat Diesel Fuel • Detergency/dispersancy Conditioner will not raise fuel sulfur levels measurably in the final fuel/additive blend. In the U.S. the current • Moisture dispersancy formulation of Cat Diesel Fuel Conditioner must be blended in at the recommended treat-rate at the • Corrosion protection fuel supplier/distributor level for use in on-highway or other applications where use of ULSD fuel is • Cetane (typically 2-3 cetane numbers) mandated (15 ppm or less fuel sulfur). Follow all applicable national, regional, and local laws, Cat Diesel Fuel Conditioner has been validated mandates, and regulations concerning the use of • through lab and field tests to improve/reduce diesel diesel fuel conditioners/additives. fuel consumption and emissions for typical fleets through fuel system/injector cleanup, and to help NOTICE maintain new engine performance by keeping fuel When used as directed Cat Diesel Fuel Conditioner systems clean. Note that while fuel system/injector will not raise fuel sulfur levels measurably in the final cleanup takes place over time, maintaining fuel fuel/additive blend. But, in the U.S., aftermarket fuel system/injector cleanliness is an ongoing process. additives (retail consumer level versus bulk fuel ad- ditives used at the fuel supplier/distributor level) with Data indicates that average fuel economy more than 15 ppm sulfur are NOT allowed to be used improvements across typical fleets may be in the in applications where ULSD usage is mandated (15 2-3+ percentage range. Note that improvements may ppm or less fuel sulfur). The current formulation of Cat vary based on factors such as engine model, age Diesel Fuel Conditioner has more than 15 ppm sul- and condition of the engine, and application. fur. Follow all applicable national, regional, and local laws, mandates and regulations concerning the use of Cat Diesel Fuel Conditioner also reduces the diesel fuel conditioners/additives. formation of gums, resins, and sludge, and disperses insoluble gums. This can dramatically improve fuel storage life, reduce fuel related engine deposits and i03432160 corrosion, and extend fuel filter life. Biodiesel NOTICE Use of Cat Diesel Fuel Conditioner does not lessen SMCS Code: 1280 the engine owner and/or responsibility of the fuel sup- plier to follow all industry standard maintenance prac- NOTICE tices for fuel storage and for fuel handling. Refer to These recommendations are subject to change with- the "General Fuel Information" article in this Special out notice. Consult your Caterpillar dealer for the most Publication for additional information. Additionally, use up to date recommendations. of Cat Diesel Fuel Conditioner does NOT lessen the • engine responsibility of the owner to use appropriate diesel fuel. Refer to the "Fuel Specifications" section in this Special Publication (Maintenance Section) for guidance. SEBU6251-12 53 Maintenance Section Fuel Specifications • Note: For guidance related to on-highway diesel This Special Publication does not address engines refer to specific engine Operation and recommended oil drain intervals, but rather provides Maintenance Manuals and to the most current guidance that should be used in conjunction revision level of Special Publication, SEBU6385, with your specific engine/machine Operation and "Caterpillar On-Highway Diesel Engine Fluids Maintenance Manuals in determining acceptable Recommendations". oil drain intervals. Consult your engine/machine Operation and Maintenance Manuals, and consult Referenced Documents: Caterpillar dealers for additional guidance, including but not limited to guidance on establishing optimized • "ASTM D6751 Standard Specification for Biodiesel and/or acceptable oil drain intervals. Fuel Blend Stock(B100)for Middle Distillate Fuels" Note: The use of a Caterpillar S O-S Services oil • "EN 14214 Automotive fuels - Fatty acid methyl analysis program helps environmental sustainability esters (FAME) for diesel engines - Requirements as it is the best way to optimize oil life, and will help and test methods" engines reach their expected life. Consult with your Caterpillar dealer regarding the testing required to • "ASTM D7467 Standard Specification for Diesel establish a safe, optimized oil drain interval. Fuel Oil, Biodiesel Blend (B6 to B20)" Biodiesel is a fuel that can be made from a variety • "ASTM D975-08a Standard Specification for Diesel of feedstocks. Soybean oil and rapeseed oil are the Fuel Oils" (includes requirements for B5 and lower primary feedstocks. Without esterification, these oils biodiesel blends) gel in the crankcase and the fuel tank. These fuels may not be compatible with many of the elastomers • "EN 590 Automotive fuels - Diesel - Requirements that are used in engines. In original forms, these oils and test methods" (includes requirements for B5 are not suitable for use as a fuel in compression and lower biodiesel blends) ignition engines. Alternate base stocks for biodiesel may include animal tallow, waste cooking oils, or a • "EN 14078 Liquid petroleum products - variety of other feedstocks. To use any of the oils • Determination of fatty acid methyl esters (FAME) in listed above as fuel, the oil must be esterified. middle distillates - Infrared spectroscopy method" Biodiesel and biodiesel blends are known to cause • "EN 14104 Fat and oil derivatives - Fatty Acid an increase in fuel system deposits, most significant Methyl Esters (FAME) - Determination of Acid of which is deposits within the fuel injector. These Value" deposits can cause a loss in power due to restricted or modified fuel injection or cause other functional • "ASTM D664 Standard Test Method for Acid issues associated with these deposits. Caterpillar Number of Petroleum Products by Potentiometric Diesel Fuel Conditioner helps to limit these issues Titration" by improving the stability of biodiesel and biodiesel blends while also cleaning formed deposits and • "ASTM D6469 Standard Guide for Microbial hindering the production of new deposits. Therefore, Contamination in Fuels and Fuel Systems" the use of Caterpillar Diesel Fuel Conditioner is strongly recommended when running biodiesel Note: For the purpose of these recommendations, and biodiesel blends, especially when using B20 or the cautions, guidelines and recommendations higher blend levels. Refer to this Special Publication, applicable to biodiesel (B100) are also applicable to "Distillate Diesel Fuel" article, "Caterpillar Diesel Fuel biodiesel blends (62, B5, B20, etc.). Conditioner" topic for additional information. Note: A complete Caterpillar S-O.S Services oil Note: Engines that are manufactured by Caterpillar analysis program is strongly recommended when are certified by use of the prescribed U.S. EPA and using biodiesel blends B1 (1 percent) through B19 European Certification fuels. Caterpillar does not (19 percent), and a complete Caterpillar S.O-S certify engines on any other fuel. Services oil analysis program is required when using biodiesel/biodiesel blends that are B20 or above Note: The user of the engine has the responsibility (when requesting oil analysis, be sure to note the of using the correct fuel that is recommended by the level of biodiesel being used (B5, B20, etc.)). manufacturer and allowed by the U.S. EPA and other • appropriate regulatory agencies. Note: DO NOT USE ONLY THIS SPECIAL PUBLICATION AS A BASIS FOR DETERMINING Caterpillar is not in a position to evaluate the many OIL DRAIN INTERVALS. variations of biodiesel and the long-term effects on performance, durability, or compliance to emissions standards for Caterpillar products. 54 SEBU6251-12 Maintenance Section Fuel Specifications Note: Visually apparent phase separation, sediment, • C4.4 (Mechanical) Tier 3/Stage IIIA, at model • suspended matter, or undissolved water should not introduction, starting Nov 2007 be present in biodiesel and biodiesel blends. • C4.4 ACERT Technology Tier 3/Stage IIIA Biodiesel and biodiesel blends should not contain electronic diesel engines manufactured after 1 July any constituent, additive or other substance that 2008, Serial numbers: makes them unacceptable for use in diesel engines. - Cat Machine Group - C4E05524-UP "EN 14078" is the recommended test method for determining the volume percent biodiesel in a - Cat Industrial - 44404304-UP biodiesel blend. • C6.6 ACERT Technology electronic diesel engines NOTICE built after 1 July 2008, Serial numbers: Failures that result from the use of any fuel are not Caterpillar factory defects. Therefore, the cost of re- - Cat Machine Group - CE614624-UP pair would NOT be covered by the Caterpillar warran- ty for materials and/or the warranty for workmanship. - Cat Industrial - 66609016-UP Note: Diesel fuels that meet the requirements of the Recommendation for the Use of most current versions of the "Caterpillar Specification for Distillate Diesel Fuel for Off-Highway Diesel Biodiesel in Caterpillar Commercial Engines", the "Caterpillar Specification for Distillate and Machine Diesel Engines Diesel Fuel for On-Highway Diesel Engines", the National Conference on Weights and Measures For Caterpillar Series C175 Series diesel engines, (NCWM) Premium Diesel definition, "EN 590" and/or consult the Caterpillar Application & Installation "ASTM 975 (No.1-D, No.2-D)", are examples of fuels Group or consult your Caterpillar dealer before using that are acceptable for creating biodiesel blends. biodiesel or biodiesel blends. These biodiesel blends must meet the Caterpillar • recommendations and requirements for biodiesel For Caterpillar off-highway ACERT Technology blends. diesel engine model numbers CT C9, C11, C13, C15, C18, C27, and C32 and also for Caterpillar Note: Crankcase oil fuel dilution may be much 3114, 3116, 3126, 3176, 3196, 3208, 3306, C-9, higher when biodiesel and/or biodiesel blends C-10, C-12, 3406, C-15, C-16, C-18, 3456, 3408, are used. This increased level of fuel dilution when 3412, Series 3500 Series, Series 3600 Series, using biodiesel and/or biodiesel blends is related to Series C280 Series, CM20, CM25, and CM32 the typically lower volatility of biodiesel. In-cylinder engines, biodiesel that meets the requirements that emissions control strategies utilized in many of the are listed in the"Caterpillar Specification for Biodiesel industries latest engine designs may lead to a higher Fuel", "ASTM D6751", or"EN 14214" are acceptable level of biodiesel concentration in the sump. blendstock. Biodiesel may be blended in amounts up to a maximum of 20 percent(B20)with an acceptable The long-term effect of biodiesel concentration diesel fuel. This blend is acceptable provided that in crankcase oil is currently unknown, but some the biodiesel constituent meets the requirements that potential issues are: are outlined in Table 9 prior to blending. In addition, the final blend must meet the requirements for • A higher risk of corrosion distillate diesel fuel that are listed in the "Caterpillar Specification for Distillate Diesel Fuel for Off-Highway • A higher risk of wear Diesel Engines", Table in this Special Publication, "Distillate Diesel Fuel" article. Biodiesel that meets • A higher risk of piston deposits "ASTM D7467° (136 to B20), or biodiesel that meets "ASTM D975-08a" or"EN 590" requirements for B5 • Either increased or deceased oil viscosity and lower biodiesel blends are also acceptable for use in the listed engines. • Shortened aftertreatment device ash service intervals (more frequent) and/or shortened C0.5-C2.2, C4.4, and C4.4 ACERT Technology diesel aftertreatment device life engines and C6.6 ACERT Technology diesel engines • compatible with up to B20 biodiesel as described • Shortened oil life (more frequent oil drain intervals) above have been released as follows: • C0.5-C2.2 Tier 4 Interim/Stage IIIB, at model introduction, starting April 2007 SEBU6251-12 55 Maintenance Section Fuel Specifications • The use of a complete Caterpillar S•O•S Services Note: When biodiesel, or any blend of biodiesel is oil analysis program is strongly recommended used, the user has the responsibility for obtaining when B19 and lower biodiesel blends are used, the proper local exemptions, regional exemptions, and the use of a complete Caterpillar S•O•S and/or national exemptions, if required, for the use of Services oil analysis program is required when biodiesel in any Caterpillar engine that is regulated using biodiesel/biodiesel blends that are B20 or by emissions standards. Biodiesel that meets the above (when requesting oil analysis, be sure to note requirements that are listed in the "Caterpillar the level of biodiesel being used (65, B20, etc.)). Specification for Biodiesel Fuel", "ASTM D6751", or "EN 14214" is not expected to pose major problems For blends of biodiesel B20 or above, consult your when blended with an acceptable distillate diesel fuel Caterpillar dealer for guidance.A complete Caterpillar and when used as recommended at the maximum S-O-S Services oil analysis program is required when stated percentages. In addition, biodiesel that meets biodiesel or blends of biodiesel that are B20 or above "ASTM D7467" (B6 to B20), or biodiesel that meets are used. Biodiesel or blends of biodiesel as used "ASTM D975-08a" or"EN 590" requirements for 65 in the engine must meet the requirements that are and lower biodiesel blends are not expected to pose stated in the "Caterpillar Specification for Distillate major problems and when used as recommended. Diesel Fuel for Off-Highway Diesel Engines" Table However, the following additional recommendations in this Special Publication, "Distillate Diesel Fuel' must be followed. article. For Caterpillar C0.5 through C2.2 and for C4.4 Recommendations mechanical engines that meet Tier2/Stage2 or earlier For the purpose of these recommendations, emissions regulations, for C4.4 (machine engine the cautions, guidelines and recommendations serial numbers C4E05523 and lower, and industrial applicable to biodiesel (B100) are also applicable to engine serial numbers 44404303 and lower) and biodiesel blends (B2, B5, B20, etc.). C6.6 (machine engine serial numbers CE614623 and lower, and industrial engine serial numbers 66609015 Note: Fuel storage tanks should be thoroughly • and lower) ACERT Technology diesel engines, and cleaned before converting to biodiesel/biodiesel for C3.4, 3003 through 3034, 3044, 3046, 3054, blends. Conversion to biodiesel/biodiesel blends can 3056, 3064, and 3066 engines, biodiesel that meets loosen fuel system and fuel storage tank deposits. the requirements that are listed in the "Caterpillar Bulk tank continuous filtration unit and dispensing Specification for Biodiesel Fuel", "ASTM D6751", point filters, and onboard engine filters change or"EN 14214" may be blended with an acceptable intervals may need to be shortened for an extended diesel fuel. This blend should be a maximum ratio period of time in order to allow for this cleaning effect. of 5% biodiesel to 95/o of an acceptable diesel fuel. The biodiesel must meet the requirements that are In North America, the use of biodiesel from listed in Table 9 prior to blending. Biodiesel that "BQ-9000" accredited producers and "BQ-9000" meets "ASTM D975-08a" or"EN 590" requirements certified marketers is required. Look for the"BQ-9000" for B5 and lower biodiesel blends are also acceptable biodiesel quality accreditation program certification for use in the listed engines. Use of more than a 5/o logo that is available to distributors that meet the biodiesel can cause premature failures. The repair requirements of"BQ-9000". For more information on for these failures would not be covered under the the "BO-9000" program, go to "www.BQ-9000.org". Caterpillar warranty. In other areas of the world, the use of biodiesel that is "BQ-9000" accredited and certified, or that is accredited and certified by a comparable biodiesel quality body to meet similar biodiesel quality control standards, is required. • 56 SEBU6251-12 Maintenance Section Fuel Specifications • The oil change interval can be negatively affected Biodiesel has poor oxidation stability, which can • by the use of biodiesel. Use Caterpillar S-O-S result in long term storage problems. Biodiesel Services oil analysis in order to monitor the should be used within six months of production. condition of the engine oil. Use Caterpillar S-O-S Storage life for biodiesel and biodiesel blends Services oil analysis also in order to determine the that are greater than B20 may be much shorter oil change interval that is optimum. A complete than six months. The poor oxidation stability may Caterpillar S-O-S Services oil analysis program accelerate fuel oxidation in the fuel system. This is strongly recommended when using biodiesel is especially true in engines with electronic fuel blends B1 through B19, and a complete Caterpillar systems because these engines operate at higher S-O-S Services oil analysis program is required temperatures. In addition to this"Biodiesel" article, when using biodiesel/biodiesel blends that are B20 also refer to this Special Publication, "Distillate or above (when requesting oil analysis, be sure to Diesel Fuel' article, "Aftermarket Fuel Additives" note the level of biodiesel being used (B5, B20, and "Cat Diesel Fuel Conditioner" topics for etc.)). information concerning oxidation stability and fuel additives. • Confirm with the filter manufacturer that the fuel filter/filters to be used are compatible with Biodiesel can be produced using various biodiesel. Caterpillar fuel filters are compatible with feedstocks. The feedstock used can affect product biodiesel that meets the quality requirements given performance. Two of the fuel characteristics in this Special Publication. affected are cold flow and oxidation stability. Consult your fuel supplier for guidance. • Conversion to biodiesel can loosen fuel system deposits. Fuel filter change intervals may need Due to poor oxidation stability and other potential to be shortened for an extended period of time issues, it is strongly recommended that engines in order to allow for this cleaning effect when with limited operational time either not use converting used engines and/or used fuel tanks biodiesel/biodiesel blends or,while accepting some to biodiesel. risk, limit biodiesel to a maximum of B5. Examples of applications that should limit the use of biodiesel • • Filter biodiesel and biodiesel blends through a are the following: Standby Generator sets and fuel filter with a rating of four microns(c) absolute certain emergency vehicles. or less. This filtration should be located on the device that dispenses the fuel to the fuel tank for Biodiesel is an excellent medium for microbial the engine, and also on the device that dispenses contamination and growth. Microbial contamination fuel from the bulk storage tank. Series filtration is and growth can cause corrosion in the fuel system recommended. and premature plugging of the fuel filter. Refer to "ASTM D6469", and consult your supplier of • In a comparison of distillate fuels to biodiesel, fuel and fuel additive for assistance in selecting biodiesel typically provides less energy per gallon appropriate anti-microbial additives. by 5% to 8%. Do NOT change the engine rating in order to compensate for the power loss. This Care must be taken in order to remove water will help avoid engine problems when the engine is from fuel tanks. Water accelerates microbial converted back to 100 percent distillate diesel fuel. contamination and growth. When biodiesel is compared to distillate fuels, water is naturally more • Compatibility of the elastomers with biodiesel is likely to exist in the biodiesel. currently being monitored. The condition of seals and hoses should be monitored regularly by the • Refer to this Special Publication, "General Fuel end user. Information"article for additional recommendations. • Biodiesel may pose low ambient temperature Seasonal Operation problems for both storage and operation. At low ambient temperatures, fuel may need to be stored It is strongly recommended that seasonally operated in a heated building or a heated storage tank. The engines have the fuel systems, including fuel tanks, fuel system may require heated fuel lines, filters, flushed with conventional diesel fuel before prolonged and tanks. Filters may plug and fuel in the tank may shutdown periods. An example of an application that solidify at low ambient temperatures if precautions should seasonally flush the fuel system is school are not taken. Consult your biodiesel supplier for buses (U.S.). • assistance in the blending and attaining of the proper cloud point for the fuel. Perform the following items in the listed order before shutting down the engine for prolonged periods: SEBU6251-12 57 Maintenance Section Fuel Specifications • 1. Operate the engine until the fuel level in the tank Refer to this Special Publication, and refer to your is very low. specific Cat commercial engine Operation and Maintenance Manual and/or refer to your specific 2. Refill the fuel tank with high quality conventional Cat machine Operation and Maintenance Manual for distillate diesel fuel. additional guidance. 3. Repeat the previous steps a minimum of two times NOTICE before the engine is shut down for prolonged In order to meet expected fuel system component life, periods. 4 micron(c) absolute or less secondary fuel filtration is required for all Caterpillar diesel engines that are Biodiesel Degradation equipped with common-rail fuel systems, and for all Caterpillar diesel engines that are equipped with unit Biodiesel and blends of biodiesel have poor thermal injected fuel systems. For all other Caterpillar diesel stability and oxidation stability compared to petroleum engines (mostly older engines with pump, line and distillate diesel fuels. The use of these biodiesels nozzle type fuel systems), the use of 4 micron(c) ab- and blends of biodiesel can accelerate the problems solute or less secondary fuel filtration is strongly rec- that are addressed in this Special Publication. Using ommended. Note that all current Caterpillar diesel en- biodiesel blends above the maximum level approved gines are factory equipped with Caterpillar Advanced for the engine is not recommended. Efficiency 4 micron(c) absolute fuel filters. A test that can be used to help determine the In order to obtain additional information on Caterpillar degradation of biodiesel and biodiesel blends is designed and produced filtration products, refer to the measurement of the Total Acid Number(TAN). this Special Publication, "Reference Material" article, This number represents the amount of acid present "Filters" and "Miscellaneous" topics, and then contact in the biodiesel or biodiesel blend as a result of your Caterpillar dealer for assistance with filtration degradation. The following test methods may be used: "EN 14104" or"ASTM D664". For neat (13100) recommendations for your Caterpillar machine. • biodiesel, this value should not exceed 0.5 mg KOH/g. For biodiesel blends such as 20% biodiesel Fuel System Deposits and 80% diesel (1320), this value should not exceed 0.3 mg KOH/g. Biodiesel and biodiesel blends Biodiesel and biodiesel blends are known to cause that exceed these values should be considered an increase in fuel system deposits, most significant degraded beyond acceptable limits and further of which is deposits within the fuel injector. These testing would not be required. Biodiesel and deposits can cause a loss in power due to restricted biodiesel blends that exceed 0.16 mg KOH/g may or modified fuel injection or cause other functional result in the formation of undesired degradation issues associated with these deposits. Caterpillar by-products that can cause the problems discussed Diesel Fuel Conditioner helps to limit these issues in this document. Samples that exceed 0.16 mg by improving the stability of biodiesel and biodiesel KOH/g but do not exceed 0.3 mg KOH/g should be blends while also cleaning formed deposits and tested with the other methods in order to determine hindering the production of new deposits. Therefore, the thermal and oxidative stability of the fuel. the use of Caterpillar Diesel Fuel Conditioner is strongly recommended when running biodiesel With the following considerations, commercial and biodiesel blends, especially when using B20 or and machine diesel engines that are covered by higher blend levels. Refer to this Special Publication, this Special Publication should be able to operate "Distillate Diesel Fuel" article, "Caterpillar Diesel Fuel satisfactorily on fuels with the stated maximum Conditioner" topic for additional information. biodiesel levels: • The biodiesel/biodiesel blends meet all of the Biodiesel Specification requirements that are stated in this Special The final blend of biodiesel as used in the engine Publication. must meet the requirements that are stated in the • All appropriate guidelines and maintenance "Caterpillar Specification for Distillate Diesel Fuel for practices as stated in engine specific Operation Off-Highway Diesel Engines" Table in this Special and Maintenance Manuals and in this Special Publication, "Distillate Diesel Fuel" article. • Publication are followed. NOTICE • The engines are operating in applications with low The footnotes are a key part of the"Caterpillar Specifi- to moderate severity. cation for Biodiesel Fuel'Table 9. Read ALL footnotes. • When other factors do not preclude. 58 SEBU6251-12 Maintenance Section Fuel Specifications Table 9 • Caterpillar Specification for Biodiesel Fuel0) Property Test Method Test Method Units Limits Specific Properties United States International of Fuel Density at 15°C "ASTM D1298" "ISO 3675" g/cm3 0.86-0.90 Viscosity at 40°C "ASTM D445" "ISO 3104" mm2/s (cSt) 1.9-6.0 Flash Point "ASTM D93" "ISO 3679" °C 93 minimum Pour Point 6 °C (10 °F) - Summer "ASTM D97" "ISO 3016" °C minimum -Winter below ambient temperature Cloud Point "ASTM D2500" °C Report Sulfur Content "ASTM D5453" "ISO 20846" % weight 0.0015 "ISO 20884" maximum Distillation To Be - 10% Evaporation "ASTM D1160" °C Determined -90% Evaporation 360 Carbon Residue, "ASTM D4530" "ISO 10370" % weight 0.05 maximum Conradson (CCR) Cetane Number "ASTM D613" "ISO 5165" 45 minimum Sulfated Ash "ASTM D874" "ISO 3987" % weight 0.02 maximum Water/Sediment Content "ASTM D2709" "ISO 12937" % volume 0.05 maximum • Copper Corrosion "ASTM D130" "ISO 2160" No. 1 Oxidation Stability "EN 14112" "EN 14112" hours 3 minimum Esterification "EN 14103" "EN 14103" % volume 97.5 minimum Acid Value "ASTM D664" "EN 14104" mg NaOH/g 0.5 maximum Methanol Content "EN 14110" "EN 14110" % weight 0.2 maximum Monoglycerides "ASTM D6584" "EN 14105" % weight 0.8 maximum Diglycerides "ASTM D6584" "EN 14105" % weight 0.2 maximum Triglycerides "ASTM D6584" "EN 14105" % weight 0.2 maximum Free Glycerin "ASTM D6584" "EN 14105" % weight 0.02 maximum Total Glycerin "ASTM D6584" "EN 14105" % weight 0.240 maximum Phosphorus Content "ASTM D4951 "EN 14107" % weight 0,001 Calcium and Magnesium "EN 14538" "EN 14538" ppm 5 maximum combined Sodium and Potassium "EN 14538" "EN 14538" ppm 5 maximum combined Cold Soak Filterability Annex Al in"ASTM D6751" seconds 360 maximumR) (1) The final blend of biodiesel as used in the engine must meet the requirements that are stated in the"Caterpillar Specification for Distillate Diesel Fuel for Off-Highway Diesel Engines"Table in this Special Publication,"Distillate Diesel Fuel"article. • (2) B100 intended for blending into diesel fuel that is expected to give satisfactory vehicle performance at fuel temperatures at or below -12°C(10.4°F)shall comply with a cold soak filterability limit of 200 seconds maximum. Passing this"ASTM D6751"200 seconds Cold Soak Filterability test limit does not guarantee cold performance for all biodiesel blends at all possible fuel temperatures, but biodiesel that fails this Cold Soak Filterability test requirement will produce biodiesel blends that will likely plug fuel filters when fuel temperatures are below-12°C (10.4° F). SEBU6251-12 59 Maintenance Section Fuel Specifications • Note: Fuels that meet the most current revision level of"ASTM D6751" or"EN 14214" may be used for blending with an acceptable distillate fuel. The conditions, recommendations, and limits that are noted in this biodiesel article apply. • • 60 SEBU6251-12 Maintenance Section Cooling System Specifications Cooling System NOTICE Specifications Many of the guidelines, recommendations, and re- quirements that are provided in this Special Publica- tion are interrelated. Before using the provided infor- i03467365 mation, it is the responsibility of the user of this Spe- General Coolant Information cial Publication to read and understand the informa- tion provided in its entirety. SMCS Code: 1350; 1395 For questions concerning the information provided in this Special Publication, consult with your Caterpillar NOTICE dealer. Every attempt is made to provide accurate, up to date information. By use of this document you agree that For additional guidelines, recommendations, and Caterpillar Inc. is not responsible for errors or omis- requirements (including maintenance interval rec- sions. ommendations/requirements) refer to your product specific Operation and Maintenance Manual. The information that is provided is the latest recommendations for the Caterpillar diesel engines NOTICE that are covered by this Special Publication. This information supersedes all previous Commercial products that make generic claims of recommendations which have been published for the meeting Cat and/or Caterpillar requirements without Caterpillar diesel engines that are covered by this listing the specific Cat recommendations and/or re- Special Publication. Special fluids may be required re- quirements that are met may not provide acceptable for some engines and it will be necessary to continue performance and may cause reduced engine and/or to use these special products. Refer to the applicable machine fluid compartment life. Refer to this Special Operation and Maintenance Manual. Publication and refer to product specific Operation and Maintenance Manuals for Caterpillar fluids rec- • This publication is a supplement to the Operation ommendations and/or requirements. and Maintenance Manual. This publication does not replace the engine specific Operation and NOTICE Maintenance Manual. It is the responsibility of the user of this Special Publication to read, understand, and follow all safety NOTICE guidelines found in this Special Publication and in These recommendations are subject to change with- engine and/or machine specific Operation and Main- out notice. Consult your local Caterpillar dealer for the tenance Manuals when performing all recommended most up to date recommendations. and/or required engine, engine systems, and/or ma- chine maintenance. NOTICE For questions concerning the information provided in To avoid potential damage to your Cat machine and/or this Special Publication and/or in your product Op- Cat engine, only purchase Cat fluids and Cat filters eration and Maintenance Manual, consult with your through your Caterpillar dealer or Caterpillar autho- Caterpillar dealer. rized outlets. For a list of authorized Caterpillar parts outlets in your area, consult your Caterpillar dealer. Follow all industry standard safety practices when op- If you purchase what appear to be Cat fluids and/ erating engines and/or machines and when perform- or Cat filters through other outlets/sources, you ing all recommended and/or required maintenance. are at a very high risk of purchasing counterfeit ("look-alike") products. Note: For the purpose of this Special Publication, the term "coolant' is interchangeable with the Counterfeit or "look-alike" products may visually ap- terms "antifreeze", "coo la nt/a ntifreeze", and/or pear the same as the original Cat product, but the "antifreeze/coolant". product performance and internal quality will typical- ly be very low. NOTICE Never add coolant to an overheated engine. Engine • Counterfeit or "look-alike" products have a very high damage could result. Allow the engine to cool first. likelihood of causing and/or allowing engine and/or machine compartment damage. SEBU6251-12 61 Maintenance Section Cooling System Specifications • Many engine failures are related to the cooling NOTICE system. The following problems are related to cooling If the engine is to be stored in, or shipped to an area system failures: overheating, leakage of the water with below freezing temperatures, the cooling system pump, plugged radiators or heat exchangers, and must be either protected to the lowest outside tem- pitting of the cylinder liners. perature or drained completely to prevent damage caused by freezing coolant. These failures can be avoided with proper cooling system maintenance. Cooling system maintenance is as important as maintenance of the fuel system and NOTICE the lubrication system. Quality of the coolant is as Frequently check the specific gravity of the coolant for important as the quality of the fuel and the lubricating proper freeze protection or for anti-boil protection. oil. Clean the cooling system for the following reasons: Coolant is normally composed of three elements: water, additives, and glycol. • Contamination of the cooling system Water • Overheating of the engine NOTICE • Foaming of the coolant Never use water alone without Supplemental Coolant Additives (SCA) or without inhibited coolant. Water • Changing from conventional heavy-duty alone is corrosive at engine operating temperatures. coolant/antifreeze to Cat ELC or ELC-1 coolant In addition, water alone does not provide adequate protection against boiling or freezing. Note: Air pockets can form in the cooling system if the cooling system is filled at a rate that is greater than 20 L (5 US gal) per minute. The maximum Note: Caterpillar strongly recommends a minimum of • recommended cooling system fill rate for some 30 percent glycol in diesel engine cooling systems, smaller engine models will be less. Refer to the with a minimum of 50 percent glycol very strongly engine's Operation and Maintenance Manual for recommended. Use only glycol based coolants exceptions. that meet one or more of the coolant specifications that are defined as preferred or acceptable in this After you drain the cooling system and after you refill Special Publication and that also comply with any the cooling system, operate the engine. Operate the additional requirements that are stated in this Special engine without the filler cap until the coolant level Publication (i.e. chemical composition, the use stabilizes. Ensure that the coolant is maintained to of SCA, the use of Extender, etc.). Refer to the the proper level. Operation and Maintenance Manual for your engine for any exceptions. NOTICE Never operate an engine without water temperature NOTICE regulators in the cooling system. Water temperature Water alone and/or water mixed with SCA are not ap- regulators help to maintain the engine coolant at the proved coolants for use with C7-C32 Heat Exchanger proper operating temperature. Cooling system prob- cooled marine engines. C7-C32 heat exchanger lems can develop without water temperature regula- cooled marine engines require a minimum of 30 tors. Removing the regulators allows some coolant to percent glycol to prevent cavitation of cooling system bypass the radiator, potentially causing overheating. components, with a minimum of 50 percent glycol very strongly recommended. Use only glycol based coolants that meet one or more of the coolant speci- Note: Refer to the specific engine Operation fications that are defined as preferred or acceptable and Maintenance Manual, "Maintenance Interval in this Special Publication and that also comply with Schedule" for the correct interval for the replacement any additional requirements that are stated in this of the cooling system water temperature regulator. Special Publication (i.e. chemical composition, the use of SCA, the use of Extender, etc.). Refer to Special Instruction, SEBD0518, "Know • Your Cooling System" and Special Instruction, SEBD0970, "Coolant and Your Engine" for more detailed information. 62 SEBU6251-12 Maintenance Section Cooling System Specifications • Local water utility company • NOTICE All Caterpillar diesel engines equipped with air-to-air • Agricultural agent aftercooling (ATAAC) require a minimum of 30 per- cent glycol to prevent water pump cavitation, with a • Independent laboratory minimum of 50 percent glycol very strongly recom- mended. Use only glycol based coolants that meet Note: Periodic analysis of water used in the one or more of the coolant specifications that are de- cooling system is recommended. Water quality fined as preferred or acceptable in this Special Pub- can be affected by a variety of factors including lication and that also comply with any additional re- malfunctioning purification equipment, earthquakes, quirements that are stated in this Special Publication and droughts. (i.e. chemical composition, the use of SCA, the use of Extender, etc.). Additives Water is used in the cooling system in order to Additives help to protect the metal surfaces of transfer heat. the cooling system. A lack of coolant additives or insufficient amounts of additives enable the following Note: Caterpillar recommends a minimum of 30 conditions to occur: percent glycol in diesel engine cooling systems. Refer to the Operation and Maintenance Manual for • Corrosion your engine for exceptions. • Formation of mineral deposits Distilled water or deionized water is recommended for use in engine cooling systems. • Rust DO NOT use the following types of water in cooling • Scale systems: hard water, softened water that has been conditioned with salt, and sea water. • Pitting and erosion from cavitation of the cylinder • liner If distilled water or deionized water is not available, use water that meets or exceeds the minimum Foaming of the coolant acceptable water requirements that are listed in Table 10. Many additives are depleted during engine operation. These additives must be replaced periodically. This Table 10 can be done by adding Cat SCA (Supplemental Caterpillar Minimum Acceptable Water Requirements Coolant Additive) to Cat DEAC (Diesel Engine Antifreeze/Coolant) or by adding ELC Extender to Property Maximum Limit ASTM Test Cat ELC (Extended Life Coolant). Chloride (CI) 40 mg/L "D512", Additives must be added at the proper concentration. (2.4 grains/US gal) "D4327" Overconcentration of additives can cause the Sulfate (SO,) 100 mg/L "D516" inhibitors to drop out-of-solution. The deposits can (5.9 grains/US gal) "D4327" enable the following problems to occur: Total Hardness 170 mg/L °D1126" (10 grains/US gal) Formation of gel compounds "D1888" • Reduction of heat transfer Total Solids 340 mg/L "Federal (20 grains/US gal) Method • Leakage of the water pump seal 2504B"(1) Acidity pH of 5.5 to 9.0 "D1293" • Plugging of radiators, coolers, and small passages (1) Total dissolved solids dried at 103' C (217' F)- 105' C (221° F), "Standard Method for the Examination of Water Glycol and Wastewater", "American Public Health Association", "www.apha.org","www.aphabookstore.org", (888)320-APHA. Glycol in the coolant helps to provide protection For a water analysis, consult one of the following against the following conditions: • sources: • Boiling • Caterpillar dealer • Freezing SEBU6251-12 63 Maintenance Section Cooling System Specifications • Water pump cavitation (ATAAC equipped engines) Testing the Concentration of Glycol For optimum performance, Caterpillar recommends a To check the concentration of glycol, use the 1:1 mixture of properly inhibited distilled or deionized 245-5829 Coolant/Battery Tester/Refractometer. water and glycol. The tester gives readings that are immediate and accurate in both degrees Celsius and degrees Note: Use a mixture that will provide protection Fahrenheit. The tester can be used with ethylene or against the lowest ambient temperature. propylene glycol. Note: 100 percent pure ethylene glycol will freeze at a temperature of-23 °C (-9 °F). Most conventional heavy-duty coo la nt/a nti freezes use ethylene glycol. Propylene glycol may also be 10 used. In a 1:1 mixture with water, ethylene and 40 propylene glycol provide similar protection against 0 freezing and boiling. See Tables 11 and 12. 20 -10 Table 11 0 0 Ethylene Glycol Concentration -20 Concentration Freeze Boil a 20 -30 a Protection Protection(') m �' 50 Percent -37°C(-34°F) 106°C(223°F) � 40 40 P U_ u- 60 Percent -52°C(-62°F) 111 T (232°F) -60 -50 (1) Boiling protection is increased with the use of a pressurized -60 • radiator. -80 NOTICE -100 70 Do not use propylene glycol in concentrations that ex- 0 20 40 60 80 100 ceed 50 percent glycol because of propylene glycol's reduced heat transfer capability. Use ethylene glycol Ethylene Glycol Antifreeze in conditions that require additional protection against Percent by Volume boiling or freezing. Do not use ethylene glycol in con- centrations that exceed 60 percent glycol. Illustration 4 g01189253 Table 12 Approximate curve of the freezing point for a typical ethylene glycol solution. Propylene Glycol Concentration Freeze Boil Table 13 Concentration Protection Protection(') Freeze Protection for Antifreeze Concentrations() 50 Percent —32 °C (-26 °F) 106°C(223°F) Protection to: Concentration (1) Boiling protection is increased with the use of a pressurized —15 °C (5 -F) 30% glycol radiator. 70% water Note: Propylene glycol coolant that is used in -24 `C (-12 -F) 40% glycol the cooling systems for Caterpillar diesel engines 60% water must meet ASTM D6210-06, "Fully-Formulated -37 °C (-34 °F) 50% glycol Glycol-Based Engine Coolant for Heavy-Duty 50% water Engines". When propylene glycol coolant is used 60% glycol in heavy-duty diesel engines, a regular addition of -52 °C (-62 °F) 40% water SCA is required for protection against liner cavitation. Consult your Caterpillar dealer for additional (1) Ethylene glycol based antifreeze. • information. Note: Ethylene or propylene glycols used in cooling systems for Caterpillar diesel engines must meet ASTM E1177-06, "Standard Specification for Engine Coolant Grade Glycol". 64 SEBU6251-12 Maintenance Section Cooling System Specifications Note: Alternative products that are used to protect Supplemental Coolant Additive (SCA) — SCA • from boiling or freezing of the engine coolant include is a general term for an inhibitor package that is 1,3 propandiol° (PDO), glycerin, and mixtures of added to a cooling system. SCA is added for one these alternative products with glycol. At the time of of three reasons: to pre-charge a new coolant publication of this document, there currently exists that is not fully formulated, to provide corrosion no ASTM, "specifications" for coolants using these protection in water/SCA cooling systems, or to chemicals. Until specifications are published recharge an in-service conventional coolant on a and then evaluated by Caterpillar, use of PDO maintenance basis to maintain proper inhibitor levels. and glycerin or glycerin/glycol coolants are not Conventional coolants typically require SCA additions recommended in Caterpillar cooling systems. at approximately 250-300 service hours. Coolant, SCA, and Extender Extender —An inhibitor package that is added to a coolant, typically an OAT or HOAT coolant, to Terminology re-charge an in-service coolant. Extenders, such as Cat Extender being added to Cat ELC, typically only Conventional coolant — A coolant (often also need to be added at one half the service life of the referred to as a heavy-duty coolant, heavy-duty fully coolant. formulated coolant, or traditional coolant) that relies largely on inhibitors for corrosion and cavitation protection that are inorganic in nature, such as 103467500 silicate and nitrite. To be used in most Caterpillar Coolant Recommendations cooling systems, conventional coolants must meet "ASTM D4985-05" or "ASTM D6210-06". Cat DEAC SMCS Code: 1350, 1352, 1395 is a conventional coolant. Organic Additive Technology (OAT) coolant — NOTICE A coolant that includes carboxylate inhibitors that Do Not Mix Brands and/or Types of Products provide corrosion and cavitation protection. Cat ELC is an OAT-type coolant that also includes nitrites and Mixing other products with Cat ELC reduces the effec- molybdates for increased cavitation protection. tiveness of the Cat ELC and shortens the Cat ELC ser- vice life. Use only Caterpillar products or commercial • Do not use OAT-type coolants with more than 125 products that have passed the Cat EC-1 specification ppm silicon (present in the coolant in the form of for premixed or concentrate coolants, and that have silicate) also passed the additional requirements for EC-1 as found in the coolant section of this Special Publication. • OAT-Type coolants containing silicate do not meet Use only Cat ELC Extender with Cat ELC. Do NOT the additional requirements set in this Special mix brands or types of coolants. Do NOT mix brands Publication for coolants claiming to meet EC-1 or types of SCA. Do NOT mix brands or types of ex- tenders. Do NOT mix SCAs and extenders. Hybrid Organic Additive Technology coolant (HOAT) — Similar to an OAT coolant, but also Failure to follow these recommendations can result in includes additional inhibitors, such as silicate, that are shortened cooling system component life. typically found in conventional heavy-duty coolants but are not present in non-hybrid OAT coolants. • HOAT-type coolants containing silicate do not meet the additional requirements set in this Special Publication for coolants claiming to meet EC-1. • Do not use HOAT-type coolants with more than 125 ppm silicon (present in the coolant in the form of silicate) • HOAT-type coolants that meet "ASTM D4985-05° or "ASTM D6210-06° may be used at the recommended maximum coolant service life • intervals stated in this Special Publication for coolants that meet these "ASTM" specifications SEBU6251-12 65 Maintenance Section Cooling System Specifications • • Coolants that are prediluted at the coolant NOTICE manufacturer must be diluted with water that meets Use Only Approved SCAs and Extenders Reagent 4 ("ASTM D1193") requirements Conventional coolants require the maintenance ad- Acceptable Coolants — Cat DEAC, "ASTM dition of SCA throughout their expected life. Do D6210-06", or"ASTM D4985-05" (after the addition NOT use an SCA with a coolant unless specifically of the specification required SCA precharge) approved by the coolant supplier for use with their coolant. It is the responsibility of the coolant man- • A minimum concentration of nitrite (as NO,) of ufacturer to ensure compatibility and acceptable 1200 ppm performance. • A minimum silicon concentration of 100 ppm To help ensure expected performance, EC-1 coolants require the one time maintenance addition of an ex- • A maximum silicon concentration of 275 ppm tender at coolant service mid-life. Do NOT use an ex- tender with a coolant unless the extender has been • Coolants that are prediluted at the coolant specifically approved for use by the coolant manufac- manufacturer must be diluted with water that meets turer for use with their coolant. It is the responsibility of Reagent 4 ("ASTM D1193") requirements the coolant manufacturer to ensure compatibility and acceptable performance. Note: "ASTM D4985" and "ASTM D6210" require coolants that are properly dosed with SCA and that Failure to follow these recommendations can result in are in a properly maintained cooling system in normal shortened cooling system component life. service to be suitable for use for a minimum of one year ("ASTM D4985") and 2 years ("ASTM D6210"). The suitability for use requirement is the direct The following two types of coolants may be used in responsibility of the coolant manufacturer and Caterpillar diesel engines: SCA manufacturer. Consult with the coolant and/or SCA manufacturer concerning the suitability of their • Preferred — Cat ELC (Extended Life Coolant) or products for use in a given application. a commercial extended life coolant that meets the Caterpillar EC-1 (Engine Coolant -1) specification. NOTICE In order to be used in Caterpillar diesel engines in accordance with the service interval for EC-1 Do not use a commercial coolant/antifreeze that only coolants that is listed in this Special Publication, meets the ASTM "D3306" specification. This type of commercial EC-1 coolants must also pass/conform applications. tifreeze is made for light duty automotive to the additional requirements for EC-1 specification applications. coolants as stated in the coolant section of this Special Publication. Use only the coolant/antifreeze that is recommended. Acceptable — Cat DEAC (Diesel Engine Caterpillar recommends a 1:1 mixture of properly Antifreeze/Coolant) or a commercial heavy-duty inhibited distilled or deionized water and glycol. This antifreeze/coolant that meets "ASTM D4985-05" or mixture will provide optimum heavy-duty performance "ASTM D6210-06" specifications as a coolant/antifreeze. Chemical Requirements for New Note: Cat DEAC does not require a treatment with Coolant 50 volume % diluted an SCA at the initial fill. However, a commercial heavy-duty coolant/antifreeze that only meets "ASTM D4985", by specification, WILL require a Preferred Coolants — Cat ELC or EC-1 treatment with an SCA at the initial fill. A commercial heavy-duty coolant/antifreeze that meets the "ASTM • Organic Additive Technology (OAT) based on D6210" specification WILL NOT require a treatment a combination of a monocarboxylic acid and a with an SCA at the initial fill. Read the label or the dicarboxylic acid instructions that are provided by the manufacturer of • Phosphate, borate, and silicate free the commercial heavy-duty coolant/antifreeze. • Minimum typical tolyltriazole level of 900 ppm • Minimum typical nitrite level of 500 ppm 66 SEBU6251-12 Maintenance Section Cooling System Specifications Note: When adding SCA at initial fill to a Note: Caterpillar strongly recommends a minimum of • coolant/antifreeze that only meets the "ASTM 30 percent glycol in diesel engine cooling systems, D4985", ensure the SCA is compatible with the with a minimum of 50 percent glycol very strongly antifreeze/coolant. For example, a HOAT coolant recommended. Use only glycol based coolants that meets the "ASTM D4985" specification may that meet one or more of the coolant specifications not be compatible with an SCA designed for use that are defined as preferred or acceptable in this with conventional coolants. It is the responsibility Special Publication and that also comply with any of the coolant manufacturer to provide sources of additional requirements that are stated in this Special compatible SCAs. It is the responsibility of the coolant Publication (i.e. chemical composition, the use manufacturer and SCA manufacturer to demonstrate of SCA, the use of Extender, etc.). Refer to the a positive influence on reducing cavitation corrosion Operation and Maintenance Manual for your engine in an operating diesel engine. for any exceptions. Note: These coolants WILL require a treatment with NOTICE a supplemental coolant additive on a maintenance Water alone and/or water mixed with SCA are not ap- basis. proved coolants for use with C7-C32 Heat Exchanger Note: When adding SCA at initial fill to a cooled marine engines. C7-C32 heat exchanger coolant/antifreeze that only meets the "ASTM cooled marine engines require a minimum of 30 D4985", it is a collective responsibility of the user, percent glycol to prevent cavitation of cooling system and the coolant manufacturer to ensure the SCA components, with a minimum of 50 percent glycol is compatible with the antifreeze/coolant based very strongly recommended. Use only glycol based on the recommendations provided by the coolant coolants that meet one or more of the coolant speci- manufacturer and SCA manufacturer. One of the test fications that are defined as preferred or acceptable methods required to be used to help ensure SCA in this Special Publication and that also comply with compatibility with the antifreeze/coolant concentrate any additional requirements that are stated in this is "ASTM D5828-97". 6% SCA in the solution that Special Publication (i.e. chemical composition, the is 60 parts antifreeze/coolant of interest, 34 parts use of SCA, the use of Extender, etc.). water, and 6 parts SCA must have no more than 0.1 • mL of formed insolubles. 12% SCA in a solution that NOTICE is 60 parts antifreeze/coolant of interest, 28 parts All Caterpillar diesel engines equipped with air-to-air water, and 12 parts SCA must have no more than 2 aftercooling (ATAAC) require a minimum of 30 per- mL of formed insolubles. The SCA manufacturer is cent glycol to prevent water pump cavitation, with a responsible for ensuring their SCA is compatible with minimum of 50 percent glycol very strongly recom- water meeting the "Caterpillar Minimum Acceptable mended. Use only glycol based coolants that meet Water Quality Requirements"as found in this"Special one or more of the coolant specifications that are de- Publication, and as found in "ASTM D6210-06", Table fined as preferred or acceptable in this Special Pub- X1.1. lication and that also comply with any additional re- quirements that are stated in this Special Publication In stationary engine applications and marine engine (i.e. chemical composition, the use of SCA, the use of applications that do not require protection from Extender, etc.). boiling or freezing, a mixture of SCA and water is acceptable. Caterpillar recommends a minimum of six percent to a maximum of eight percent concentration of Cat SCA in those cooling systems. Distilled water or deionized water is preferred. If distilled or deionized water is not available, use water that meets or exceeds the minimum acceptable water requirements that are listed in this Special Publication, "General Coolant Information" article (Maintenance Section). • SEBU6251-12 67 Maintenance Section Cooling System Specifications • Table 14 Table 15 Coolant Service Life Part Numbers of Coolant Coolant Type Service Life M0 Description Size Part Numl Cat ELC 12000 Service Hours or 2P-9868 Six Years(3) Bulk or 156-2649 Commercial coolant that 6000 Service Hours or Cat DEAC meets the Caterpillar Six Years(4)(5) (Concentrate) 208.2 L 8C-3686 EC-1 Specification (55 US gal) 238-8653(2) Cat DEAC 3000 Service Hours or 3.8 L(1 US gal) 8C-3684 Three Years 238-8651(2) Commercial Heavy-Duty 3000 Service Hours or Bulk 156-2653 Coolant/Antifreeze that Two Years 208.2 L 101-2845 meets"ASTM D6210" (55 US gal) 238-86500 Commercial Heavy-Duty 3000 Service Hours or Cat ELC 129-2151 Coolant/Antifreeze that (50/50 Premix) 18.9 L(5 US gal) meets "ASTM D4985" One Year 238-8649 Cat SCA(6) and water) 3000 Service Hours or 3.8 L (1 US gal) 101-2844 Two Years 238-86480 Commercial Cat ELC 3.8 L (1 US gal) 119-5150 supplemental coolant 3000 Service Hours or (Concentrate) 238-8647(2) additive(8)and water(6)m(8) One Year Cat ELC 0.946 L (1 qt) 119-5152 (1) Use the interval that occurs first. Extender 3.8 L(1 US gal) 210-0786 (2) Refer to the engine's Operation and Maintenance Manuals, (1) The availability of part numbers will vary by the region.Consult "Maintenance Interval Schedule"for the correct interval for your Caterpillar dealer. • replacement of the cooling system water temperature regulator. (2) With embitterment. Embitterment makes the coolant taste (3) Cat ELC Extender must be added at 6000 service hours or bad.This is done in order to deter accidental human or animal one half of the service life of the Cat ELC. ingestion of the coolant/antifreeze. (4) An extender must be added at 3000 service hours or one half of the service life of the coolant. (5) In order to be used in Caterpillar diesel engines in accordance i03435641 with the service interval for EC-1 coolants that is listed in this Special Publication, commercial EC-1 coolants must Extended Life Coolant also pass/conform to the additional requirements for EC-1 specification coolants as stated in the coolant section of this Special Publication. SMCS Code: 1350; 1352; 1395 (6) The concentration of Cat SCA in a cooling system that uses Cat SCA and water should be from 6 to 8 percent by volume. Cat ELC (7) Refer to this Special Publication,"General Coolant Information" under the section that discusses the requirements for water. (8) Consult the supplier for the commercial SCA for Caterpillar provides Cat ELC (Extended Life Coolant) instructions on usage.Also, refer to this Special Publication, for use in the following applications: "Water/Supplemental Coolant Additive"topic for additional information. • Heavy-duty diesel engines Note: These coolant change intervals are only . Automotive applications achievable with annual S-O-S Services Level 2 coolant sampling and analysis. When Cat ELC is compared to conventional coolants Cat ELC can be recycled into conventional coolants. the Cat ELC anti-corrosion package is based on a totally different additive system. Cat ELC has been Cat ELC, Cat DEAC, Cat Extender, and Cat SCA are formulated with the correct amounts of additives in available in several container sizes. order to provide superior corrosion protection for all metals that are in engine cooling systems. Cat ELC extends the service life of the coolant to • 12000 service hours or six years. Cat ELC does not require the frequent addition of a SCA(Supplemental Coolant Additive). An Extender is the only additional maintenance that is needed at 6000 service hours or one half of the Cat ELC service life. 68 SEBU6251-12 Maintenance Section Cooling System Specifications Cat ELC is available in a 1:1 premixed cooling 103435762 • solution with distilled water. The premixed Cat ELC Extended Life Coolant Conlin provides freeze protection to -37 °C (-34 °F). The g premixed Cat ELC is recommended for the initial fill System Maintenance of the cooling system. The premixed Cat ELC is also recommended for topping off the cooling system. SMCS Code: 1350; 1352; 1395 Cat ELC Concentrate is also available. Cat ELC Proper Additions to the Cat ELC Concentrate can be used to lower the freezing point p to -52 °C (-62 °F) for arctic conditions. Extended Life Coolant) Containers of several sizes are available. Refer to this Special Publication, "Coolant Recommendations" NOTICE article for available quantities and part numbers. Use only Caterpillar products or commercial products that have passed Caterpillar's EC-1 specification for Note: Cat ELC can be used in most OEM engines pre-mixed or concentrated coolants. In order to be of the following types: diesel and gasoline. Cat ELC used in Caterpillar diesel engines in accordance with meets the performance requirements of "ASTM the service interval for EC-1 coolants that is listed in D4985" and "ASTM D6210" for heavy-duty low this Special Publication, commercial EC-1 coolants silicate antifreeze/coolants. Cat ELC does not require must also pass/conform to the additional require- treatment with a conventional SCA. Cat ELC also ments for EC-1 specification coolants as stated in the meets the performance requirements of "ASTM coolant section of this Special Publication. D3306" for automotive applications. Use only Cat ELC Extender with Cat ELC. Do NOT use conventional SCA with Cat ELC. Mixing Cat ELC with conventional coolants and/or conven- tional SCA reduces the Cat ELC service life. Do NOT mix brands or types of coolant. Do NOT mix • brands or types of SCA and/or brands or types of ex- tenders. Different brands or types may use different additive packages to meet the cooling system require- ments. Different brands or types may not be compati- ble. Do not mix brands or types of coolants with different brands or types of SCA or extender. Cat Extender is compatible with Cat ELC. If using non Cat branded EC-1 coolant, refer to the coolant manufacturer for information on a compatible extender. Failure to follow the recommendations can reduce cooling system component life unless appropriate corrective action is performed. In order to maintain the correct balance between the antifreeze and the additives, you must maintain the recommended concentration of ELC. Lowering the proportion of antifreeze lowers the proportion of additive. This will lower the ability of the coolant to protect the system from pitting, from cavitation, from erosion, and from deposits. • SEBU6251-12 69 Maintenance Section Cooling System Specifications • During daily maintenance, use the premixed Cat Table 17 ELC as a cooling system top-off. This will bring the Example Of The Equation For Adding Cat coolant up to the proper level. Check the specific ELC Extender To Cat ELC gravity of the coolant system with the 245-5829 Coolant/Battery Tester/Refractometer. This tester Total Volume Multiplication Amount of Cat gives readings that are immediate and accurate in of the Cooling Factor ELC Extender both degrees Celsius and degrees Fahrenheit. Use System (V) that is Required Cat ELC Concentrate to restore the proper glycol (X) concentration in the coolant system. This should 946 L X 0.02 19 L(5 US gal) be done before the engine is exposed to freezing (250 US gal) temperatures. NOTICE NOTICE When using Cat ELC, do not use conventional SCAs, Do not use a conventional coolant to top-off a cooling or, if equipped, SCA maintenance elements. To avoid system that is filled with Cat ELC. SCA contamination of an ELC system, remove the SCA element base and plug off or bypass the coolant Do not use conventional SCA. Only use Cat ELC Ex- lines. tender in cooling systems that are filled with Cat ELC. Do not top-off the cooling system with water unless Cat ELC Cooling System Cleaning there is a specific need to adjust the water/glycol Note: If the cooling system is already using Cat ratio. Compatible 50/50 (water/glycol) coolant is ELC, cleaning agents are not required to be used typically used and recommended when cooling at the specified coolant change interval. Cleaning system top-off is required. agents are only required if the system has been contaminated by the addition of some other type of Cat ELC Extender coolant or by cooling system damage. • Cat ELC Extender is added to the cooling system Clean water is the only cleaning agent that is required halfway through the Cat ELC service life. Treat the when Cat ELC is drained from a properly maintained cooling system with Cat ELC Extender at 6000 cooling system. hours or one half of the coolant service life. Refer to the "Part Number of Coolant' table in this Special After the cooling system is drained and after the Publication, "Coolant Recommendations" article for cooling system is refilled, operate the engine while available quantities and part numbers. the cooling system filler cap is removed. Operate the engine until the coolant level reaches the normal Use the formula in Table 16 to determine the proper operating temperature and until the coolant level amount of Cat ELC Extender for your cooling system. stabilizes. As needed, add the coolant mixture in Refer to Operation and Maintenance Manual, "Refill order to fill the system to the proper level. Capacities and Recommendations" in order to determine the capacity of the cooling system. A Level II coolant analysis by S.O-S Services is recommended after cooling system cleaning and refill Table 16 in order to ensure proper additive levels are present Formula For Adding Cat ELC Extender To Cat ELC and in order to ensure there are no excessive levels of physical contaminants and chemical contaminants. VX0.02 = X V is the total capacity of the cooling system. Recycling Cat ELC X is the amount of Cat ELC Extender that is required. Cat ELC can be recycled into conventional coolants. The drained coolant mixture can be distilled in order Table 17 is an example for using the formula that is to remove the ethylene glycol and the water. The in Table 16. ethylene glycol and the water can be reused. The distilled material does not contain the additives that are required to be classified as either Cat ELC or • Cat DEAC. Consult your Caterpillar dealer for more information. Recycled coolants should meet"ASTM D6210-06". 70 SEBU6251-12 Maintenance Section Cooling System Specifications Changing to Cat ELC 7. In systems with heavy deposits, it may be • necessary to disconnect the hoses. Clean the To change from heavy-duty coolant/antifreeze to the deposits and debris from the hoses and the Cat ELC, perform the following steps: fittings. Install the hoses and tighten the hose fittings. Refer to Specifications, SENR3130, NOTICE "Torque Specifications" for the proper torques. Care must be taken to ensure that fluids are contained Pipe threads may also need to be cleaned and during performance of inspection, maintenance, test- sealed. Seal the threads with 5P-3413 Pipe ing,adjusting and repair of the product. Be prepared to Sealant. collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- $• Fill the cooling system with clean water and Went containing fluids. operate the engine until the engine is warmed to 49 °C to 66 °C (120 OF to 151 OF). Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" and to Special Publica- NOTICE tion, PECJ0003, "Cat Shop Supplies and Tools" for Improper or incomplete rinsing of the cooling system tools and supplies suitable to collect and contain fluids can result in damage to copper and other metal com- on Caterpillar products. ponents. Dispose of all fluids according to applicable regula- To avoid damage to the cooling system, make sure tions and mandates. to completely flush the cooling system with clear wa- ter. Continue to flush the system until all signs of the 1. Drain the coolant into a suitable container cleaning agent are gone. 2. Dispose of the coolant according to local 9. Drain the cooling system into a suitable container regulations. and flush the cooling system with clean water. 3. If equipped, remove the empty SCA maintenance NOTICE element and remove the element base. Plug the The cooling system cleaner must be thoroughly coolant lines or bypass the coolant lines. flushed from the cooling system. Cooling system cleaner that is left in the system will contaminate the NOTICE coolant. The cleaner may also corrode the cooling Do not leave an empty SCA maintenance element on system. a system that is filled with Cat ELC. The element housing may corrode and leak causing 10.Repeat Steps 8 and 9 until the system is an engine failure. completely clean. Remove the SCA element base and plug off or 11.Fill the cooling system with the Cat ELC. by-pass the coolant lines. 12.Operate the engine until the engine is warmed. 4. Flush the system with clean water in order to While the engine is running, inspect the engine for Y leaks. Tighten hose clamps and connections in remove any debris. order to stop any leaks. 5. Use Caterpillar cleaner for cooling systems in 13.Attach the Special Publication, PMEP5027, order to clean the system. Follow the instructions "Label' to the cooling system filler for the engine on the label. Consult your Caterpillar dealer in in order to indicate the use of Cat ELC. order to determine the appropriate cleaner type and in order to obtain the corresponding part Note: Clean water is the only flushing agent that is number. required when Cat ELC is drained from a properly 6. Drain the cleaner into a suitable container. Flush maintained cooling system. the cooling system with clean water. 14.A Level II coolant analysis by S-O-S Services is recommended after changing over to Cat ELC in • Note: Deposits that remain in the system may be order to ensure proper additive levels are present loosened and removed by the Cat ELC. and in order to ensure there are no excessive levels of physical and chemical contaminants SEBU6251-12 71 Maintenance Section Cooling System Specifications • Cat ELC Cooling System Contamination NOTICE Do Not Mix Brands and/or Types of Products NOTICE Mixing other products with Cat ELC reduces the effec- Mixing other products with Cat ELC reduces the ef- tiveness of the Cat ELC and shortens the Cat ELC ser- fectiveness of the Cat ELC and shortens the Cat ELC vice life. Use only Caterpillar products or commercial service life. Use only Cat ELC Extender with Cat ELC. products that have passed the Cat EC-1 specification Failure to follow these recommendations can result in for premixed or concentrate coolants, and that have shortened cooling system component life. also passed the additional requirements for EC-1 as found in the coolant section of this Special Publication. Cat ELC cooling systems can withstand Use only Cat ELC Extender with Cat ELC. Do NOT contamination to a maximum of ten percent of mix brands or types of coolants. Do NOT mix brands conventional heavy-duty coolant/antifreeze and/or or types of SCA. Do NOT mix brands or types of ex- SCA before the advantages of Cat ELC are reduced. tenders. Do NOT mix SCAs and extenders. If the contamination exceeds ten percent of the total system capacity, perform ONE of the following Failure to follow these recommendations can result in procedures: shortened cooling system component life. • If the cooling system contamination is caused by cooling system damage, follow the procedures NOTICE under the "Changing to Cat ELC" heading. Also Use Only Approved SCAs and Extenders follow the procedures under the "Changing to Cat ELC" heading if the engine has been operated Conventional coolants require the maintenance ad- since being contaminated with more than ten dition of SCA throughout their expected life. Do percent conventional heavy-duty coolant/antifreeze NOT use an SCA with a coolant unless specifically and/or SCA. Certain types of cooling system approved by the coolant supplier for use with their • coolant. It is the responsibility of the coolant man- contamination may require disassembly of the p ty cooling system and manual cleaning of system ufacturer to ensure compatibility and acceptable components. performance. • If the cooling system is contaminated with To help ensure expected performance, EC-1 coolants more than ten percent conventional heavy-duty require the one time maintenance addition of an ex- coolant/antifreeze and/or SCA, but the engine tender at coolant service mid-life. Do NOT use an ex- has not been operated, drain the cooling system tender with a coolant unless the extender has been into a suitable container. Dispose of the coolant specifically approved for use by the coolant manufac- according to local regulations. Thoroughly flush turer for use with their coolant. It is the responsibility of the system with clean water. Fill the system with the coolant manufacturer to ensure compatibility and the Cat ELC. acceptable performance. • Maintain the system as a conventional DEAC Failure to follow these recommendations can result in (Diesel Engine Antifreeze/Coolant) or other shortened cooling system component life. conventional coolant. If the SCA concentration is less than three percent, treat the system with an SCA. Maintain a three to six percent SCA Commercial Extended Life Coolant concentration in the coolant. Change the coolant at the interval that is recommended for Cat DEAC NOTICE or at the interval that is recommended for the Caterpillar does not warrant the quality or perfor- conventional commercial coolants. mance of non-Caterpillar fluids. In order to be used in most Cat diesel engines cooling systems according to the service interval listed in this Special Publication for Commercial coolant that meets the Cat EC-1 specification, the • commercial extended life coolants must meet the following requirements: • Cat EC-1 specification • The minimum performance requirements of the "ASTM D6210" specification 72 SEBU6251-12 Maintenance Section Cooling System Specifications • The additional requirements that are stated in this • Special Publication for EC-1 coolants NOTICE In order to be marketed as a product that meets Cat In Cat diesel engines, extended life coolant that EC-1,all Cat EC-1 specification requirements must be does not meet both the Cat EC-1 specification and met, including, but not limited to the following: the additional requirements that are stated in this Special Publication for EC-1 coolants cannot be used - Physical and Chemical Properties according to the service interval listed in this Special Publication for commercial coolant that meets the - Compatibility Characteristics Cat EC-1 specification. Follow the maintenance guide for the coolant from the supplier of the - Bench Testing commercial extended life coolant. Use an extender that is recommended by the EC-1 coolant supplier - Field Testing (Including using the required radiator at coolant in-service mid-life. Follow the Caterpillar types, using the required minimum field test duration, guidelines for the quality of water and the specified using the required minimum number of diesel engines, coolant change interval. and using the required Caterpillar diesel engine mod- Coolants that pass all of the Cat EC-1 specification els of the required minimum power rating.) requirements, and that complete the additional requirements stated in this Special Publication, have a recommended service life of 482,803 kilometers 03260542 (300,000 miles), 6000 hours, or years, which ever Diesel Engine Antifreeze/ comes first. Coolant Note: Coolants that meet the Cat EC-1 specification requirements only meet the minimum Caterpillar SMCS Code: 1350; 1352; 1395 requirements for extended life coolants. Caterpillar recommends using Cat DEAC (Diesel Note: As they have not been tested against the Cat Engine Antifreeze/Coolant) for cooling systems that • EC-1 specification requirements, coolants that only require a high performance conventional heavy-duty claim to meet the performance requirements of the coolant/antifreeze. Cat DEAC is alkaline single-phase Cat EC-1 specification may not meet all the minimum ethylene glycol type antifreeze that contains corrosion EC-1 specification requirements. inhibitors and antifoam agents. Note: The Cat EC-1 specification describes the Cat DEAC is formulated with the correct amount of minimum requirements for extended life coolants. Cat SCA (Supplemental Coolant Additive) . Do not use Cat SCA at the initial fill when Cat DEAC is used at the recommended 1:1 or higher concentration with NOTICE recommended water. Because of the ongoing commitment to improve engine performance and life, Caterpillar places Containers of several sizes are available. Refer to the following additional requirements on ECA this Special Publication, "Coolant Recommendations" coolants that will be used in most Caterpillar for available container sizes and part numbers, or diesel engine cooling systems in order to help consult your Caterpillar dealer for the part numbers. ensure optimal protection: If concentrated Cat DEAC is used, Caterpillar -Organic Additive Technology(OAT) based on a com- recommends mixing the concentrate with distilled bination of a monocarboxylic acid and a dicarboxylic water or with deionized water. If distilled water or acid deionized water is not available, use water which has the required properties. For the water properties, see - Phosphate, borate and silicate free this publication, "General Coolant Information". -Minimum typical tolyltriazole level of 900 ppm for new Note: The concentrated Cat DEAC and the coolants recommended water must be thoroughly mixed prior - Minimum typical nitrite level of 500 ppm in new to filling the cooling system. coolants • - The one time addition of an extender at in-service coolant mid-life in order to maintain the coolant nitrite level between 300 — 600 ppm SEBU6251-12 73 Maintenance Section Cooling System Specifications • i03260560 Containers of Cat SCA are available in several sizes. Supplemental Coolant Additive Refer to this Special Publication, "Conventional pp Coolant/Antifreeze Cooling System Maintenance" article for available quantities and part numbers. SMCS Code: 1350, 1352; 1395 Note: Do not exceed a six percent maximum NOTICE concentration of SCA. Maintain a three to six percent Do NOT mix brands or types of SCA. Do NOT mix SCA concentration in the coolant. SCAs and extenders. Failure to follow these recommendations can result in i03437200 shortened cooling system component life. Conventional Coolant/ Antifreeze Cooling System NOTICE Maintenance Use Only Approved SCAs. Conventional coolants require the maintenance ad- SMCS Code: 1350; 1352; 1395 dition of SCA throughout their expected life. Do NOT use an SCA with a coolant unless specifically NOTICE approved by the coolant supplier for use with their Caterpillar does not warrant the quality or perfor- coolant. It is the responsibility of the coolant man- mance of non-Caterpillar fluids. ufacturer to ensure compatibility and acceptable performance. NOTICE Failure to follow these recommendations can result in Do NOT mix brands or types of SCA. Do NOT mix shortened cooling system component life. SCAs and extenders. • Failure to follow the recommendations can result in Supplemental Coolant Additive (SCA) — SCA shortened cooling system component life. is a general term for an inhibitor package that is added to a cooling system. SCA is added for one of three reasons: to precharge a new coolant NOTICE that is not fully formulated, to provide corrosion Use Only Approved SCAs. Conventional coolants protection in water/SCA cooling systems, or to require the maintenance addition of SCA throughout recharge an in service conventional coolant on a their expected life. Do NOT use an SCA with a coolant maintenance basis to maintain proper inhibitor levels. unless specifically approved by the coolant supplier Conventional coolants typically require SCA additions for use with their coolant. It is the responsibility of the at approximately 250-300 service hours. coolant manufacturer to ensure compatibility and ac- ceptable performance. The use of SCA(supplemental coolant additive) helps to prevent the following conditions from occurring: Failure to follow the recommendations can result in shortened cooling system component life. • Corrosion • Formation of mineral deposits Note: Cat SCA is compatible with Cat DEAC. If you use non Cat-brand conventional coolants, consult • Cavitation erosion of the cylinder liners with the coolant manufacturer for information on a compatible SCA. • Foaming of the coolant Note: Do not top-off the cooling system with Cat DEAC (Diesel Engine Antifreeze/Coolant) is water unless there is a specific need to adjust the formulated with the correct level of Cat SCA. When water/glycol ratio. Compatible 50/50 (water/glycol) the cooling system is initially filled with Cat DEAC, coolant is typically used and recommended when adding more Cat SCA is not necessary until the cooling system top-off is required. concentration of Cat SCA has been reduced to an unacceptable level. To ensure that the correct amount of Cat SCA is in the cooling system, the concentration of Cat SCA must be tested on a scheduled basis. Refer to the Operation and Maintenance Manual, "Maintenance Interval Schedule" (Maintenance Section) of the specific engine. 74 SEBU6251-12 Maintenance Section Cooling System Specifications Refer to Table 18 and refer to table 19 for part • NOTICE numbers and for the quantities of SCA maintenance Never operate an engine without water temperature elements and/or liquid SCA. regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the Table is proper operating temperature. Cooling system prob- Caterpillar Liquid SCAM lems can develop without water temperature regula- tors. Part Number Size of Container 6V-3542 0.24 L (8 oz) Note: Refer to the specific engine Operation 8T-1589 0.47 L (16 cz) and Maintenance Manual, "Maintenance Interval Schedule" for the service interval for the cooling 3P-2044 0.94 L (32 oz) system water temperature regulator. 217-0616 1 L (34 oz) NOTICE 237-7673 5 L (1.3 US gal) Do NOT mix brands or types of coolant. Do NOT mix 8C-3680 19 L (5.0 US gal) brands or types of SCA and/or brands or types of ex- 217-0617 20 L (5.3 US gal) tenders. Different brands or types may use different additive packages to meet the cooling system require- 5P-2907 208 L (55 US gal) ments. Different brands or types may not be compati- 217-0618 208 L (55 US gal) ble. The availability of part numbers will vary from one region to Failure to follow the recommendations can reduce another region. cooling system component life unless appropriate corrective action is performed. Check the coolant/antifreeze (glycol concentration) • in order to ensure adequate protection against boiling or freezing. Caterpillar recommends the use of a refractometer for checking the glycol concentration. Use the 245-5829 Coolant/Battery Tester/Refractometer. The tester gives readings in both degrees Celsius and degrees Fahrenheit that are immediate and accurate. The tester can be used with ethylene or with propylene glycol. Caterpillar engine cooling systems should be tested at 250 hour intervals or at the PM Level 1 intervals for the concentration of SCA (Supplemental Coolant Additive). SCA test kits are available from your Caterpillar dealer. Test the concentration of SCA or submit a coolant sample to your Caterpillar dealer at 250 hour intervals or at the intervals for PM Level 1. Refer to this Special Publication, "SOS Services Coolant Analysis" for more information on this topic. Additions of SCA are based on the results of the test or based on the results of the coolant analysis. An SCA may be needed at 250 hour intervals or at the intervals for PM Level 1. Note: Acceptable conventional heavy-duty coolant/antifreeze of all types REQUIRE periodic additions of SCA. • Note: Specific engine applications may require maintenance practices to be periodically evaluated in order to properly maintain the engine's cooling system. SEBU6251-12 75 Maintenance Section Cooling System Specifications • Table 19 Caterpillar SCA Requirements for Heavy-Duty Coolant/Antifreeze Spin-on Cooling 250 hours or Element at Quantity System Initial Fill() Intervals for 250 hours or of Capacity PM Level 1 m(3) at Intervals Elements for PM Level 1(2)(3)(4) 22 to 30 L 0.95 L 0.24 L (8 fl oz) 111 -2370 1 (6 to 8 US gal) (32 fl oz) 31 to 38 L 1.18 L 0.36 L ) 12 fl oz 11 1 -2369 1 (9 to 10 US gal) (40 fl oz) ( 39 to 49 L (11 1.42 L 0.36 L(12 fl oz) 11 1 -2369 1 to 13 US gal) (48 fl oz) 50 to 64 L (14 1.90 L 0.47 L(16 fl oz) 9N-3368 1 to 17 US gal) (64 fl oz) 65 to 83 L (18 2.37 L 0.60 L(20 fl oz) 111 -2371 1 to 22 US gal) (80 fl oz) 84 to 114 L (23 3.32 L 0.95 L(32 fl oz) 9N-3718 1 to 30 US gal) (112 fl oz) 115 to 163 L(31 4.75 L 1.18 L(40 fl oz) 11 1 -2371 2 to 43 US gal) (160 fl oz) 164 to 242 L(44 7.60 L 1.90 L(64 fl oz) 9N-3718 2 to 64 US gal) (256 fl oz) • (1) When the coolant system is first filled,the SCA is not required to be used with Cat DEAC or with fully formulated coolants that meet the"ASTM D6210"specification. (z) Do not exceed the six percent maximum concentration.Check the concentration of SCA with a SCA test kit,or check the concentration of SCA with Cat S•O•S coolant analysis. (3) Do not use the maintenance element for the SCA and the liquid for the SCA at the same time. (4) Spin-on elements may not be available for all applications. Cooling Systems with Larger By specification, commercial heavy-duty Capacities coolant/antifreeze that meets only the"ASTM D4985" specification WILL require adding supplemental coolant additive at the initial fill. Read the label or the Adding the SCA to Conventional instructions that are provided by the manufacturer of Coolant/Antifreeze at the Initial Fill the commercial heavy-duty coolant/antifreeze. Note: When non-Cat conventional coolants that Use the equation that is in Table 20 as a guideline in meet Cat minimum published requirements are used, order to aid in determining the amount of Cat SCA confirm with the coolant manufacturer before using that is required when the cooling system is initially Cat SCA that Cat SCA is acceptable for use with filled with fluids that only meet the "ASTM D4985" their coolant. specification. Note: When the coolant system is first filled, the SCA Note: When adding SCA at initial fill to a is not required to be used with Cat DEAC or with fully cool ant/antifreeze that only meets the "ASTM formulated coolants that meet the "ASTM D6210" D4985", ensure the SCA is compatible with the specification when used at the recommended 1:1 or antifreeze/coolant. For example, a HOAT coolant higher concentration with a recommended water. that meets the"ASTM D4985" specification may not be compatible with an SCA designed for use with • Note: Do not exceed the six percent maximum conventional coolants. It is the responsibility of concentration. Check the concentration of SCA with the coolant manufacturer to provide sources of a SCA test kit, or check the concentration of SCA compatible SCAB. It is the responsibility of the with Cat S-O-S coolant analysis. coolant manufacturer and SCA manufacturer to demonstrate a positive influence on reducing cavitation corrosion in an operating diesel engine. 76 SEBU6251-12 Maintenance Section Cooling System Specifications Note: When adding SCA at initial fill to a Test the coolant/antifreeze periodically for the • coolant/antifreeze that only meets the "ASTM concentration of SCA. For the interval, see the D4985", it is a collective responsibility of the user, Operation and Maintenance Manual, "Maintenance and the coolant manufacturer to ensure the SCA Interval Schedule" for your engine. SCA test kits is compatible with the antifreeze/coolant based are available from your Caterpillar dealer. Test the on the recommendations provided by the coolant concentration of SCA or submit a coolant sample manufacturer and SCA manufacturer. One of the test to your Caterpillar dealer. Refer to this Special methods required to be used to help ensure SCA Publication, "S.O.S Services Coolant Analysis" compatibility with the antifreeze/coolant concentrate article. is "ASTM D5828-97". 6% SCA in the solution that is 60 parts antifreeze/coolant of interest, 34 parts Additions of SCA are based on the results of the test water, and 6 parts SCA must have no more than 0.1 or based on the results of the coolant analysis. The mL of formed insolubles. 12% SCA in a solution that size of the cooling system determines the amount of is 60 parts antifreeze/coolant of interest, 28 parts SCA that is needed. water, and 12 parts SCA must have no more than 2 mL of formed insolubles. The SCA manufacturer is Use the equation that is in Table 22 to determine the responsible for ensuring their SCA is compatible with amount of Cat SCA that is required, if necessary. water meeting the "Caterpillar Minimum Acceptable Water Quality Requirements"as found in this"Special Table 22 Publication, and as found in"ASTM D6210-06", Table Equation For Adding The Cat SCA To Conventional X1.1. Coolant/Antifreeze For Maintenance It is also the responsibility of the coolant manufacturer V x 0.014 = X and the SCA manufacturer to ensure that when V is the total volume of the cooling system. used according to their recommendations that their products will not cause cooling system harm. X is the amount of Cat SCA that is required. Table 20 Table 23 is an example for using the equation that • Equation For Adding The Cat SCA To Conventional is in Table 22. Coolant/Antifreeze At The Initial Fill V x 0.045 = X Note: Specific engine applications may require maintenance practices to be periodically evaluated V is the total volume of the cooling system. in order to properly maintain the engine's cooling X is the amount of Cat SCA that is required. system. Table 23 Table 21 is an example for using the equation that Example Of The Equation For Adding The Cat SCA is in Table 20. To Conventional Coolant/Antifreeze For Maintenance Table 21 Total Volume Multiplication Amount of Cat of the Cooling Factor SCA that is Example Of The Equation For Adding The Cat SCA System (V) Required (X) To Conventional Coolant/Antifreeze At The Initial Fill 946L x0.014 9L Total Volume Multiplication Amount of Cat (250 US gal) (4 US gal) of the Cooling Factor SCA that is System (V) Required (X) Table 19 lists part numbers and the sizes of 946 L x 0.045 43 L containers for Cat SCA that is available from your (250 US gal) (11 US gal) Caterpillar dealer. Adding the SCA to Conventional Cleaning the System of Heavy-Duty Coolant/Antifreeze For Maintenance Coolant/Antifreeze Conventional heavy-duty coolant/antifreeze of all Before Caterpillar's SCA can be effective, the cooling types REQUIRE periodic additions of a supplemental system must be free from rust, scale, and other coolant additive. deposits. Preventive cleaning helps avoid downtime caused by expensive out-of-service cleaning required • for extremely dirty and neglected cooling systems. Caterpillar Cooling System Cleaner: SEBU6251-12 77 Maintenance Section Cooling System Specifications • • Dissolves or depresses mineral scale, corrosion i03260567 products, light oil contamination, and sludge. Commercial Heavy-Duty • Cleans the cooling system after used coolant is Coolant/Antifreeze and drained or before the cooling system is filled with new coolant. SCA (Supplemental Coolant • Cleans the cooling system whenever the coolant is Additive) contaminated or whenever the coolant is foaming. SMCS Code: 1350; 1352; 1395 • The "Standard" version of the Caterpillar Cooling System Cleaner cleans the cooling system while NOTICE still in service. Caterpillar does not warrant the quality or perfor- mance of non-Caterpillar fluids. • Reduces downtime and cleaning costs. • Helps avoid costly repairs from pitting and other NOTICE internal problems caused by improper cooling Do NOT mix brands or types of SCA. Do NOT mix system maintenance. SCAs and extenders. • Can be used with glycol-based antifreeze. Failure to follow the recommendations can result in shortened cooling system component life. • For the recommended service interval, refer to the Operation and Maintenance Manual, "Maintenance NOTICE Interval Schedule" for your engine. Use Only Approved SCAs. Conventional coolants require the maintenance addition of SCA throughout Caterpillar Standard Cooling System Cleaner is their expected life. Do NOT use an SCA with a coolant c scale and corrosion without removing the engine • designed t clean the cooling system of harmful unless specifically approved by the coolant supplier for use with their coolant. It is the responsibility of the from service. The cleaners, both "Standard" and coolant manufacturer to ensure compatibility and ac- "Quick Flush" can be used in all Caterpillar engine ceptable performance. cooling systems. Contact your Caterpillar dealer for part numbers. Failure to follow the recommendations can result in Note: These cleaners must not be used in systems shortened cooling system component life. that have been neglected or that have heavy scale buildup. These systems require a stronger If Cat DEAC (Diesel Engine Antifreeze/Coolant) is commercial solvent that is available from local not used, select a coolant/antifreeze with low silicate distributors. content for heavy-duty applications that meets"ASTM D6210-06" or"ASTM D4985-05" specifications. Follow label directions for proper usage. Note: When NOT using Cat DEAC (or coolant that Recycling Cat DEAC does not meet the Cat EC-1 specification) the cooling system must be drained one time every year. The Cat DEAC can be recycled. The drained coolant cooling system must be flushed out at this time as mixture can be distilled in order to remove the well. ethylene glycol and water. The ethylene glycol and the water can be reused. The distilled material does not contain the additives that are required to be classified as either Cat ELC or Cat DEAC. Consult your Caterpillar dealer for more information. When recycled coolants are used, use only coolants that have been recycled from extended life, heavy-duty or automotive coolants that were • originally manufactured from virgin ethylene or propylene glycol. Recycled coolants should meet"ASTM D6210-06". 78 SEBU6251-12 Maintenance Section Cooling System Specifications Note: When adding SCA at initial fill to a Coolant/antifreezes for heavy-duty applications that • coolant/antifreeze that only meets the "ASTM meet the "ASTM D6210" specification do not require D4985", it is a collective responsibility of the user, treatment with SCA at the initial fill when used at and the coolant manufacturer to ensure the SCA the recommended 1:1 or higher concentration with is compatible with the antifreeze/coolant based recommended water. Treatment with SCA is required on the recommendations provided by the coolant on a maintenance basis. manufacturer and SCA manufacturer. One of the test methods required to be used to help ensure SCA When concentrated coolant/antifreeze is mixed, compatibility with the antifreezelcoolant concentrate Caterpillar recommends mixing the concentrate with is "ASTM D5828-97". 6% SCA in the solution that distilled water or with deionized water. If distilled is 60 parts antifreeze/coolant of interest, 34 parts water or deionized water is not available, water water, and 6 parts SCA must have no more than 0.1 which has the required properties may be used. For mL of formed insolubles. 12% SCA in a solution that the water properties, see this Special Publication, is 60 parts antifreeze/coolant of interest, 28 parts "General Coolant Information" article. water, and 12 parts SCA must have no more than 2 mL of formed insolubles. The SCA manufacturer is responsible for ensuring their SCA is compatible with i03465003 water meeting the "Caterpillar Minimum Acceptable Water/SCA (Supplemental Water Quality Requirements"as found in this"Special Publication, and as found in"ASTM D6210-06", Table Coolant Additive) X1.1. SMCS Code: 1350; 1352; 1395 It is also the responsibility of the coolant manufacturer and the SCA manufacturer to ensure that when Note: Caterpillar strongly recommends a minimum of used according to their recommendations that their 30 percent glycol in diesel engine cooling systems, products will not cause cooling system harm. with a minimum of 50 percent glycol very strongly recommended. Use only glycol based coolants Note: Do not mix brands or types of coolants that meet one or more of the coolant specifications with different brands or types of SCA or extender. that are defined as preferred or acceptable in this • Cat SCA is compatible with Cat DEAC. If using Special Publication and that also comply with any non Cat-branded coolants, refer to the coolant additional requirements that are stated in this Special manufacturer for information on a compatible SCA Publication (i.e. chemical composition, the use of SCA, the use of Extender, etc.). Refer to the When a heavy-duty coolant/antifreeze is used Operation and Maintenance Manual for your engine and compatibility with Cat SCA is confirmed as for any exceptions. previously described, treat the cooling system with three to six percent Cat SCA by volume. Maintain NOTICE a concentration level of SCA in the cooling system Water alone and/or water mixed with SCA are not ap- that is between three percent and six percent. For proved coolants for use with C7-C32 Heat Exchanger more information, see this Special Publication, cooled marine engines. C7-C32 heat exchanger "Conventional Coolant/Antifreeze Cooling System cooled marine engines require a minimum of 30 Maintenance" article. percent glycol to prevent cavitation of cooling system If Cat SCA is not used, select a commercial SCA. components, with a minimum of 50 percent glycol very strongly recommended. Use only glycol based The commercial SCA must provide a minimum of coolants that meet one or more of the coolant speci- in the mnal o 1ant ppm (82 grains/US gal) of nitrites fications that are defined as preferred or acceptable in the final coolant mixture. in this Special Publication and that also comply with Maintain a concentration level of nitrites in the cooling any additional requirements that are stated in this Special Publication (i.e. chemical composition, the system that is between 1200 ppm (70grains/US gal)and 2400 ppm (140 grains/US gal). use of SCA, the use of Extender, etc.). By specification, coolant/antifreeze for heavy-duty applications that only meets the "ASTM D4985" specification WILL require treatment with SCA at the initial fill. These coolants WILL require treatment with • SCA on a maintenance basis. SEBU6251-12 79 Maintenance Section Cooling System Specifications • Note: Do not exceed the eight percent maximum NOTICE concentration. Check the concentration of Cat SCA All Caterpillar diesel engines equipped with air-to-air with a 298-5311 Coolant Nitrite Test Kit for SCA aftercooling (ATAAC) require a minimum of 30 per- or perform an S-O-S coolant analysis. The test cent glycol to prevent water pump cavitation, with a kit includes: testing tool, 30 nitrite test ampoules, minimum of 50 percent glycol very strongly recom- instruction, and hardcase. 294-7420 contains refill mended. Use only glycol based coolants that meet ampoules for the 298-5311 Coolant Nitrite Test Kit. one or more of the coolant specifications that are de- fined as preferred or acceptable in this Special Pub- Note: The 298-5311 Coolant Nitrite Test Kit is NOT lication and that also comply with any additional re- calibrated to test the nitrite levels of conventional quirements that are stated in this Special Publication coolants or extended life coolants. (i.e. chemical composition, the use of SCA, the use of Extender, etc.). Refer to Table 24 for part numbers and for the sizes of containers of SCA. NOTICE Table 24 Never use water alone without SCA (Supplemental Caterpillar Liquid SCAM Coolant Additives). Water alone is corrosive at en- gine operating temperatures. In addition, water alone Part Number Size of Container does not provide adequate protection against boiling 6V-3542 0.24 L (8 oz) or freezing. 8T-1589 0.47 L (16 oz) In engine cooling systems that use water alone, 3P-2044 0.94 L (32 oz) Caterpillar recommends the use of Cat SCA. Cat 217-0616 1 L (34 oz) SCA helps to prevent the following conditions from 237-7673 5 L (1.3 US gal) occurring: 8C-3680 19 L (5.0 US gal) • Corrosion 217-0617 20 L (5.3 US gal) • Formation of mineral deposits 5P-2907 208 L (55 US gal) • Cavitation erosion of the cylinder liner 217-0618 208 L (55 US gal) (1) The availability of part numbers will vary from one region to • Foaming of the coolant another region. If Cat SCA is not used, select a commercial SCA. The Maintain the Cat SCA in the same way as you would commercial SCA must provide a minimum of 2400 maintain a cooling system that uses heavy-duty mg/L or 2400 ppm (140 grains/US gal) of nitrites in cool ant/antifreeze. Adjust the maintenance for the the final coolant mixture. amount of Cat SCA additions. The quality of the water is a very important factor Adding the Cat SCA to Water at the in this type of cooling system. Distilled water or deionized water is recommended for use in cooling Initial Fill systems. If distilled water or deionized water is not available, use water that meets or exceeds the Use the equation that is in Table 25 to determine minimum requirements that are listed in the table the amount of Cat SCA that is required at the initial for recommended water properties in this Special fill. This equation is for a mixture of only Cat SCA Publication, "General Coolant Information" topic. and water. A cooling system that uses a mixture of SCA and Table 25 water only needs more SCA than a cooling system Equation For Adding The Cat SCA To Water that uses a mixture of glycol and water. The SCA At The Initial Fill concentration in a cooling system that uses SCA and V x 0.07 = X water should be six to eight percent by volume. V is the total volume of the cooling system. isX is the amount of Cat SCA that is required. Table 26 is an example for using the equation that is in Table 25. 80 SEBU6251-12 Maintenance Section Cooling System Specifications Table 26 i03447588 • Example Of The Equation For Adding The Cat S•0•S Services Coolant SCA To Water At The Initial Fill Total Volume Multiplication Amount of Cat Analysis of the Cooling Factor SCA that is SMCS Code: 1350; 1395; 7542 System (V) Required (X) 946 L x 0.07 66 L Testing the engine coolant is important to ensure (250 US gal) (18 US gal) that the engine is protected from internal cavitation and corrosion. The analysis also tests the ability of Addingthe Cat SCA to Water for the coolant to protect the engine from boiling and freezing. S-O-S coolant analysis can be done at Maintenance your Caterpillar dealer. Caterpillar S-O-S coolant analysis is the best way to monitor the condition of For the recommended service interval, refer to the your coolant and your cooling system. S-O-S coolant Operation and Maintenance Manual, "Maintenance analysis is a program that is based on periodic Interval Schedule" for your engine. samples. Submit a coolant sample to your Caterpillar dealer. NOTICE See this Special Publication, "S-O-S Services Coolant Do not use the same vacuum sampling pump for ex- Analysis" topic. tracting oil samples that is used for extracting coolant Additions of Cat SCA are based on the results of samples. the coolant analysis. The size of the cooling system A small residue of either type sample may remain in determines the amount of Cat SCA that is required. the pump and may cause a false positive analysis for Use the equation that is in Table 25 to determine the the sample being taken. amount of Cat SCA that is required for maintenance, Always use a separate pump for oil sampling and a • if necessary: separate pump for coolant sampling. Table 27 Failure to do so may cause a false analysis which Equation for the Addition of Cat SCA To could lead to customer and dealer concerns. Water For Maintenance V x 0.023 = x New Systems, Refilled Systems, V is the total volume of the cooling system. and Converted Systems X is the amount of Cat SCA that is required. Perform an S-O-S coolant analysis (Level 2) at the Table 28 is an example for using the equation that following maintenance intervals. is in Table 25. • Every Year Table 28 • Initial 500 service hours Example of the Equation for the Addition of Cat SCA To Water For Maintenance Perform this analysis at the interval that occurs first Total Volume Multiplication Amount of Cat for new systems, for refilled systems, or for converted of the Cooling Factor SCA that is systems that use Cat ELC (Extended Life Coolant) or System (V) Required (X) use Cat DEAC (Diesel Engine Antifreeze/Coolant). 946 L x 0.023 22 L This 500 hour check will also check for any residual (250 US gal) (6 US gal) cleaner that may have contaminated the system. Note: Specific engine applications may require maintenance practices to be periodically evaluated in order to properly maintain the engine's cooling • system. Table 24 lists part numbers and the sizes of containers for Cat SCA that are available from your Caterpillar dealer. SEBU6251-12 81 Maintenance Section Cooling System Specifications • Recommended Interval for S-O-S • Identification of metal corrosion and of Services Coolant Sample contaminants Table 29 • Identification of buildup of the impurities that cause corrosion Recommended Interval Type of Coolant Level 1 Level 2 • Identification of buildup of the impurities that cause scaling Cat DEAC Every 250 Yearly(l)(2)(3) hours(l)(2) • Determination of the possibility of electrolysis Cat ELC Optional(3) Yearly(3) within the cooling system of the engine (1) This is also the recommended sampling interval for all commercial coolants that meet Cat EC-1 (Engine Coolant The results are reported, and appropriate specification- 1) recommendations are made. (2) This is also the recommended sampling interval for all conventional heavy-duty coolant/antifreeze. For more Information on S-O-S coolant analysis, (3) The Level 2 Coolant Analysis should be performed sooner if a consult your Caterpillar dealer. problem is suspected or identified. Note: Check the SCA (Supplemental Coolant Additive) of the conventional coolant at every oil change or at every 250 hours. Perform this check at the interval that occurs first. S-O-S Services Coolant Analysis (Level 1) • A coolant analysis (Level 1) is a test of the properties of the coolant. The following properties of the coolant are tested: • Glycol concentration for freeze protection and boil protection • Ability to protect from erosion and corrosion • pH • Conductivity • Visual analysis • Odor analysis The results are reported, and appropriate recommendations are made. S-O-S Services Coolant Analysis (Level 2) A coolant analysis (Level 2) is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the cooling • system. The S-O-S coolant analysis (Level 2) has the following features: • Full coolant analysis (Level 1) ® 82 SEBU6251-12 Reference Information Section Reference Materials Reference Information ULSD is required by U.S. EPA regulations for • highway vehicles to ensure that these vehicles will Section meet emissions standards to improve air quality. In California, other properties of vehicular diesel fuel are also controlled to help reduce smog. Reference Materials For additional on-highway diesel engine fluids requirements, refer to the most current revision level of Special Publication, SEBU6385, 03437680 "Caterpillar On-Highway Diesel Engine Fluids Frequently Asked Questions Recommendations". (Ultra Low Sulfur Diesel (ULSD) 3. Can I use ULSD in the non-highway engines? Fuel) Yes. Refer to these"Frequently Asked Questions" SMCS Code: 1000; 7000 and to the "Fuel Specifications" section in this Special Publication for guidance when ULSD will be used. NOTICE Every attempt is made to provide accurate, up do date 4. Should I be concerned with the lubricity of ULSD? information. By use of this document, you agree that Caterpillar is not responsible for errors or omissions. Diesel fuel lubricity is necessary to minimize wear on fuel pumps and injectors. ULSD fuel requires NOTICE good lubricity and corrosion inhibitors in order to For on-highway diesel engine fluids requirements, prevent unacceptable engine wear. In the U.S., as refer to specific engine Operation and Maintenance necessary, additives to increase lubricity and to Manuals, and also refer to the most current revision inhibit corrosion will be added to ULSD fuel prior level of Special Publication, SEBU6385, "Caterpillar to its retail sale. With these additives, ULSD fuel On-Highway Diesel Engine Fluids Recommenda- is expected to perform as well as LSD fuel. All tions". Also consult with your Caterpillar dealer. Caterpillar electronic engines produced since model year(MY) 2000 are qualified to run on ULSD fuel. Note: For additional information on ULSD, refer to this Special Publication, "Fuel Specifications"section. Note: Have the fuel supplier confirm that the ULSD fuel available meets the most current revision level of 1. What is ULSD and how is it different from Low "ASTM D975" and/or"EN 590" lubricity requirements. Sulfur Diesel (LSD)? In North America, diesel fuel that is identified The United States(U.S.) Environmental Protection as "ASTM D975' Grade No. 2-D S15 or"ASTM Agency (EPA) defines Ultra-Low Sulfur Diesel D975'Grade No. 1-D S15 and meeting the"ASTM (ULSD - S15) as a U.S. diesel fuel with a sulfur D975-08a" Thermal Stability Guideline X3.10.2.2 content not to exceed 15 parts per million (ppm) generally meet the "Caterpillar Specification for or 0.0015% by weight. Low Sulfur Diesel (LSD Distillate Diesel Fuel for Off-Highway Diesel - S500) is defined as a U.S. diesel fuel with a Engines" requirements for ULSD fuel. sulfur content not to exceed 500 ppm or 0.05% by weight. The LSD fuel commonly available in Diesel fuels that are identified as meeting "EN North America normally does not exceed 350 ppm 590:2004" 10 ppm or less sulfur requirements sulfur. Both ULSD and LSD should meet the fuel ("sulfur-free"), and diesel fuels that are identified requirements outlined in the most current revision as meeting "ASTM D975-08a" 15 ppm or less level of"ASTM D975". sulfur requirements ("S15"), generally meet the Caterpillar requirements for ULSD fuel. Note: In Europe, ultra low sulfur diesel fuel will have a maximum of 0.0010 percent(10 ppm) sulfur and is Note: The current revision level of both "EN 590" and typically referred to as "sulfur-free". Also, the most of"ASTM D975'allows up to 5 percent(135)biodiesel. commonly available diesel fuel in Europe has a Refer to the "Fuel Specifications" section and to maximum sulfur content of 0.005 percent (50 ppm). the "Biodiesel" article in this Special Publication for • These sulfur levels are defined in European Standard guidance when biodiesel will be used. "EN 590:2004". 5. Will a special color or dye identify the ULSD fuel? 2. Why is the sulfur content of diesel fuel in the U.S. reduced to 15 ppm? SEBU6251-12 83 Reference Information Section Reference Materials • Due to the processing required to produce ULSD Yes, ULSD fuel is fully compatible with current fuel, ULSD fuel color can vary widely from the fuel filter technology. ULSD fuel has a tendency traditional colorless to amber, to anything from a to clean fuel tanks and other fuel system parts light toned green, yellow, orange, or pink. Under efficiently, which may cause fuel filter plugging certain light conditions, the color may appear to during the initial transition period. More frequent be slightly fluorescent. fuel filter changes may be required during the transition period from LSD to ULSD fuel. In the U.S., diesel fuel destined for off-highway use is required by law to be dyed red. Use of this ULSD fuel typically has a slightly higher wax red dyed fuel in on-highway applications is illegal. content than LSD fuel. Have your fuel supplier There are currently no regulations that require confirm that the fuel is blended to flow at the diesel fuel destined for on-highway use to be dyed. ambient temperatures being experienced in your region. In the U.S., diesel fuels are typically There is no relationship between the natural diesel blended to provide cold performance per the fuel color and such desirable diesel fuel qualities guidelines that are provided in the most current as heat content, viscosity, cloud point, cetane revision level of"ASTM D975". number or distillation range. Diesel fuel color varies with the crude source, refinery methods 8. Are aftermarket fuel additives recommended with and the use of dyes. However, if the fuel color ULSD? darkens appreciably during storage, this could indicate oxidation and/or contamination from dirt, There are many different types of fuel additives. water, algae, bacteria, or other sources that can Caterpillar does not generally recommend the use cause operational problems. of fuel additives. 6. Does ULSD affect the fuel system seals? In special circumstances, Caterpillar recognizes the need for fuel additives. Fuel additives need Caterpillar has completed the review of the to be used with caution. The additive may not engine fuel system technology and the system be compatible with the fuel. Some additives may • compatibility with ULSD fuel for on and off-highway precipitate and cause deposits in the fuel system. products. Electronically controlled (ECM) engines, The deposits may cause seizure. Some additives manufactured after 2000 and that have been may plug fuel filters. Some additives may be properly maintained, are compatible with fuel corrosive, and some additives may be harmful to with less than 50 ppm sulfur content and comply the elastomers in the fuel system. Some additives with "ASTM D975" Grade No. 2-D S15 or"ASTM may damage emission control systems. Some D975" Grade No. 1-D S15 or"EN 590""sulfur-free" additives may raise fuel sulfur levels above the (10 ppm or less sulfur). Refer to this Special maximum allowed by the U.S. EPA and/or, as Publication, "Fuel Specifications" section for more appropriate, other regulatory agencies. Consult information. your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier Earlier engines including those with mechanical can make recommendations for additives to use fuel systems should be watched for external and for the proper level of treatment. For best leaks. The belief is that only a small number of results, your fuel supplier should treat the fuel fuel system seals may be affected. Leaks that do when additives are needed. Refer to the answer to develop are expected to typically be experienced question 4 for more information. Also, refer to this as minor seepage, slobber, or drips. If a leak Special Publication "Fuel Specifications" section, should develop, a possible correction is to tighten "Aftermarket Fuel Additives", and "Cat Diesel Fuel the joint and/or connection to the proper torque. If Conditioner" topics. a leak is detected, please contact your Caterpillar dealer or authorized service center as soon 9. Can biodiesel fuel be blended as ULSD? as possible and schedule a repair. Whenever possible, use Viton seal material and hoses that Biodiesel can be blended as either LSD or as are compatible with diesel fuel as your best ULSD. protection against fuel system leaks. For additional information, refer to the "Fuel Note: Fuel additives will not stop or will not prevent Specifications" section, and to the "Biodiesel" • seal leaks, seepage, slobber, or drips that may result article in this Special Publication. from transitioning to ULSD fuel. The engine user has the responsibility of using 7. Can I use the current Caterpillar fuel filters? the correct fuel that is recommended by the manufacturer and is allowed by the U.S. EPA and other appropriate regulatory agencies. 84 SEBU6251-12 Reference Information Section Reference Materials 10.What effect does blending used lubricating oil into Diesel fuel suppliers advise that the new ULSD • diesel fuel have on engine performance and fuel fuel contains more wax, but will deliver 0% to 2% quality? lower fuel economy (approximately 1% lower on average). How can this be? In general, this practice is not recommended. It may adversely affect fuel quality features and Diesel engine operators often consider the waxes could lead to fuel system and piston deposits, found in diesel fuel as delivering most of the fuel's increased exhaust emissions and fuel filter energy. This is assumed because lighter fuels plugging. This practice may also result in the such as No. 1 D and kerosene do not typically diesel fuel being out of compliance with U.S. EPA, have winter wax problems and because No. 1 D state, and other appropriate regulatory agencies and kerosene give lower fuel economy. requirements. During desulfurization, a percentage of the Note: Blending lubricating oil with ULSD fuel may fuels aromatic and naphthenic components are raise the sulfur level above 15 ppm. converted to less dense paraffinic waxes. There is now more wax, but the density of the fuel is Do not use diesel fuel that has been blended with lower. The lower fuel density of ULSD results in lubricating oil in the following applications. less energy per gallon. • MY2007 and newer on-highway diesel engines. 13.What specification requirements of diesel fuel Use of oil/fuel blends in MY2007 and newer should concern me? (U.S. EPA 2007 certified) on-highway diesel engines and/or EURO IV certified on-highway Cetane number (ignition quality), cleanliness, diesel engines may cause engine damage. low-temperature operability, stability, and lubricity are the diesel fuel requirements of principal • Engines that are equipped with an aftertreatment concern to the end user. device. Use of oil/fuel blends in aftertreatment device equipped diesel engines may cause Refer to this Special Publication, "Fuel . the need for more frequent cleaning cycles, Specifications" section for more information. contribute to aftertreatment device plugging and may cause aftertreatment device damage. Note: For applications where ULSD is required, have the fuel supplier confirm that the ULSD fuel available The user of the engine has the responsibility of meets all Caterpillar requirements for distillate using the correct fuel that is recommended by the diesel fuel and/or the most current revision level of manufacturer and allowed by the U.S. EPA and "ASTM D975 S15" and/or the "EN 590" ("sulfur-free") other appropriate regulatory agencies. The user requirements. also has the responsibility of obtaining the proper local exemptions, regional exemptions, and/or Note: "ASTM D975-08a" and "EN 590" currently national exemptions that are required for the use allow up to 5 percent (135) biodiesel. Refer to the of crankcase oil/fuel blends in any Caterpillar "Fuel Specifications" section, and to the "Biodiesel" engine that is regulated by emissions standards. article in this Special Publication for guidance when biodiesel will be used. 11.What about special fuels (JP-5, JP-8, Kerosene, Jet A, Jet A-1)? Note: ULSD has less electrical conductivity than LSD. Follow all industry standard grounding and These fuels typically have a much higher safety practices. sulfur content than is allowed by the U.S. EPA regulations for maximum sulfur content of ULSD. 14. Does ULSD fuel require a different storage The sulfur content for these fuels typically far procedure? exceeds 15 ppm. No. When properly treated by the fuel supplier These fuels typically have a much higher sulfur with a fuel stability additive, both LSD and ULSD content than the maximum fuel sulfur content fuel can typically be stored for up to one year. The allowed by the European Standard "590:2004". same commonly used and approved storage tank The sulfur content of these fuels typically far maintenance practices used for LSD fuel should exceeds 50 ppm. also be used with ULSD fuel. The storage tanks • and containers commonly used with LSD fuel are 12. Does ULSD affect engine performance and fuel typically suitable for ULSD fuel. economy? SEBU6251-12 85 Reference Information Section Reference Materials • i03437681 • Datasheet, PEHJ0021, "Cat DEO (SAE 1OW-30 Reference Material and SAE 15W-40)" (Worldwide - except North America, Egypt, Saudi Arabia, and Brazil) SMCS Code: 1000; 7000 • Datasheet, PEHJ0072, "Cat DEO (SAE 1OW-30 The following literature can be obtained through any and SAE 15W-40)" (Brazil) Caterpillar dealer. • Datasheet, PEHJ0091, "Cat DEO (SAE 1OW-30 Note: The information that is contained in the listed and SAE 15W-40)" (Egypt and Saudi Arabia) publications is subject to changes without notice. • Datasheet, PEHP7062, "Cat DEO SYN (SAE Note: Refer to this Special Publication, the respective 5W-40)" product datasheet and other special publications, and • Datasheet, PEHJ0093, "Cat DEO (SAE 30 the appropriate Operation and Maintenance Manual and SAE 40)" (For use in 3600 Series diesel for product application recommendations. engines, C280 Series diesel engines and in older precombustion chamber diesel engines. Do NOT NOTICE use in 3500 Series, C175 Series and smaller direct To avoid potential damage to your Cat machine and/or injected diesel engines.) Cat engine, only purchase Cat fluids and Cat filters through your Caterpillar dealer or Caterpillar autho- Datasheet, PEHP9516, "Cat SAEO (SAE30 and rized outlets. For a list of authorized Caterpillar parts SAE40)" (For use in certain Cat 3116 and 3126 outlets in your area, consult your Caterpillar dealer. Marine Diesel Engines with mechanical fuel injection. Refer to this Special Publication, "Engine If you purchase what appear to be Cat fluids and/ Oil (3116 and 3126 Marine Engines)" article. Do or Cat filters through other outlets/sources, you NOT use in other engine applications.) are at a very high risk of purchasing counterfeit ("look-alike") products. Datasheet, PEHJ0008, "Cat Arctic DEO (SAE OW-30)" (Canada and United States) Counterfeit or "look-alike" products may visually ap- pear the same as the original Cat product, but the Grease product performance and internal quality will typical- ly be very low. • Special Publication, PEGJ0035, "Grease Selection Guide" Counterfeit or "look-alike" products have a very high likelihood of causing and/or allowing engine and/or • Datasheet, PEHP0002, "Cat Advanced 3Moly machine compartment damage. Grease" (NLGI grade 2) Coolants • Datasheet, NEHP6010, "Cat Ultra 5Moly Grease" (NLGI grades 1 and 2) • Special Publication, PMEP5027, "Label - Cat ELC • Datasheet, NEHP6011, "Cat Arctic Platinum Radiator Label" Grease" (NLGI grade 0) • Datasheet, PEHJ0067, "Cat ELC (Extended Life • Datasheet, NEHP6012, "Cat Desert Gold Grease" Coolant)" (Worldwide) (NLGI grade 2) • Datasheet, PEHP9554, "Cat DEAC (Diesel Engine . Datasheet, NEHP6015, "Cat High Speed Ball Antifreeze/Coolant) (Concentrate)" Bearing Grease" (NLGI grade 2) Diesel Engine Oil • Datasheet, PEHJ0088, "Cat Multipurpose Grease" (NLGI grade 2) • Datasheet, PEHJ0159, "Cat DEO-ULS (SAE 15W-40)" (North America - Canada, Mexico, and S•O•S Services • United States) • Special Publication, PEHJ0191, "S.O.S Coolant • Datasheet, PEHJ0059, "Cat DEO (SAE 1OW-30 Analysis" and SAE 15W-40)" (North America - Canada, Mexico, and United States) . Special Publication, PEGJ0047, "How To Take A Good Oil Sample" 1 86 SEBU6251-12 Reference Information Section Reference Materials • Special Publications, PEDP7036, "S.O S Fluids • Special Publication, SENR3130, "Torque • Analysis Cornerstone" Specifications" • Special Publications, PEHP7076, "Understanding • Special Publication, SENR9620, "Improving Fuel S O S Services Tests" System Durability" (Package of 10) • Special Publication, PEHP7052, "Making the Most • Special Publication, SEBF1018, "Improving of S O S Services" Component Durability - Engines" (Package of 10) • Special Publication, PEGJ0045, "Reporting Particle • Special Publication, SEBF1020, "Improving Count by ISO Code" Component Durability - Managing Fluid Cleanliness" (Package of 10) • Special Publication, PEGJ0046, "Understanding Your SOS Services Results" • Special Publication, SEBD0349, "Caterpillar Performance Handbook" (Edition 39) Filters "ASTM D6469 Standard Guide for Microbial • Datasheet, PEHP6028, "Cat Ultra High Efficiency Contamination in Fuels and Fuel Systems" Air Filters" • Datasheet, PEHP7032, "Radial Seal Air Filters" • Datasheet, PEHP7077, "Cat Turbine Pre-Cleaners" • Datasheet, PEHP9013, "Air Filter Service Indicator" • Datasheet, PEHJ0082, "Cat Fuel Water Separators and Prime Time Priming Pumps" • • Datasheet, PEHP7046, "Fuel Contamination Control" • Datasheet, PEHJ0068, "Cat Advanced Efficiency Engine Oil Filter" • Datasheet, PEHJ0165, "Open Crankcase Ventilation Filter" Miscellaneous • Special Publication, PECP9067, "One Safe Source" • Special Publication, AECQ1042, "Caterpillar Product Line Brochure" • Special Publication, PEWJ0074, "Cat Filter and Fluid Application Guide" • Datasheet, PEHJ0030, "Cat Synthetic GO (SAE 75W-140)" • Datasheet, PEHP7058, "Cat GO (SAE 80W-90 and SAE 85W-140)" • Special Publication, NENG2500, "Caterpillar • Dealer Service Tool Catalog" • Special Publication, GECJ0003, "Cat Shop Supplies and Tools" catalog SEBU6251-12 87 ■ Index Section r• Index A E Aftermarket Oil Additives....................................... 24 Engine Oil (3116 and 3126 Marine Engines)......... 16 Commercial Oils (3116 and 3126 Marine Engines)........................................................... 16 B Lubricant Viscosity Recommendations (3116 and 3126 Marine Engines)...................................... 18 Biodiesel................................................................ 52 Recommendations............................................. 16 Biodiesel Degradation........................................ 57 Total Base Number(TBN) and Fuel Sulfur Levels Biodiesel Specification....................................... 57 for Direct Injection (DI) Diesel Engines (3116 and Fuel System Deposits........................................ 57 3126 Marine Engines)...................................... 17 Recommendation for the Use of Biodiesel in Engine Oil (Engine Crankcase Fluid Caterpillar Commercial and Machine Diesel Recommendations for all Caterpillar 3500 Engines............................................................ 54 Series, C175 Series, and Smaller Direct Injection Recommendations............................................. 55 (DI) Engines)........................................................ 8 Seasonal Operation........................................... 56 Cat DEO (Diesel Engine Oil).............................. 8 Commercial Oils................................................. 9 Lubricant Viscosity Recommendations for Direct C Injection (DI) Diesel Engines............................ 12 Total Base Number (TBN) and Fuel Sulfur Levels Characteristics of Diesel Fuel................................ 36 for Direct Injection (DI) Diesel Engines............ 11 Cetane Number.................................................. 37 Engine Oil for Precombustion Chamber (PC) Cloud Point........................................................ 38 Diesel Engines (Engine Crankcase Fluid Gums and Resins.............................................. 44 Recommendations for All 3500 Series and Smaller Lubricity and Low Sulfur Diesel (LSD) and Ultra PC Diesel Engines).............................................. 18 Low Sulfur Diesel (ULSD) Fuel ........................ 36 Cat DEO (Diesel Engine Oil).............................. 18 Moisture Content................................................ 43 Commercial Oils................................................. 19 Oxidative Stability Test....................................... 45 Total Base Number (TBN) and Fuel Sulfur Pour Point.......................................................... 39 Levels for Precombustion Chamber (PC) Diesel Specific Gravity /API Gravity............................. 43 Engines............................................................ 21 The Thermal Stability and Oxidation Stability of Extended Life Coolant........................................... 67 Fuel.................................................................. 44 Cat ELC ............................................................. 67 Thermal Oxidation Stability................................ 45 Extended Life Coolant Cooling System Viscosity............................................................. 37 Maintenance........................................................ 68 Cold Weather Lubricants....................................... 15 Cat ELC Cooling System Cleaning.................... 69 Commercial Heavy-Duty Coolant/Antifreeze and SCA Cat ELC Cooling System Contamination........... 71 (Supplemental Coolant Additive)......................... 77 Cat ELC Extender.............................................. 69 Conventional Coolant/Antifreeze Cooling System Changing to Cat ELC......................................... 70 Maintenance........................................................ 73 Commercial Extended Life Coolant................... 71 Cleaning the System of Heavy-Duty Proper Additions to the Cat ELC (Extended Life Coolant/Antifreeze............................................ 76 Coolant)............................................................ 68 Cooling Systems with Larger Capacities ........... 75 Recycling Cat ELC............................................. 69 Recycling Cat DEAC.......................................... 77 Coolant Recommendations................................... 64 Chemical Requirements for New Coolant (50 F volume % diluted)............................................. 65 Cooling System Specifications.............................. 60 Foreword ............................................................... 5 Literature Information......................................... 4 Maintenance ...................................................... 4 DSafety................................................................. 4 Frequently Asked Questions (Ultra Low Sulfur Diesel Diesel Engine Antifreeze/Coolant.......................... 72 (ULSD) Fuel)........................................................ 82 • Distillate Diesel Fuel.............................................. 46 Fuel Information for Diesel Engines...................... 34 Aftermarket Fuel Additives................................. 51 Starting Aids...... ................................................ 35 Alternative Fuels-Arctic Applications................ 50 Fuel Recommendations......................................... 45 Cat Diesel Fuel Conditioner............................... 51 Fuel Specifications ................................................ 32 Heavy Fuel Oil, Residual Fuel, Blended Fuel.... 50 Ultra Low Sulfur Diesel (ULSD) ......................... 49 88 SEBU6251-12 Index Section G S General Coolant Information ................................. 60 S-O-S Services Coolant Analysis.......................... 80 Additives............................................................ 62 New Systems, Refilled Systems, and Converted Coolant, SCA, and Extender Terminology ......... 64 Systems........................................................... 80 Glycol................................................................. 62 Recommended Interval for S•O•S Services Coolant Water................................................................. 61 Sample............................................................. 81 General Fuel Information....................................... 32 S-O-S Services Coolant Analysis (Level 1)........ 81 General Recommendations and Guidelines...... 33 S-O-S Services Coolant Analysis (Level 2)........ 81 General Lubricant Information............................... 6 S-O-S Services Oil Analysis.................................. 30 Caterpillar Fluids................................................ 8 Obtaining S-O-S Oil Samples............................. 30 Oil Sampling Interval.......................................... 31 Supplemental Coolant Additive............................. 73 Synthetic Base Stock Oils..................................... 23 Important Safety Information................................. 2 T L Table of Contents................................................... 3 Lubricant Specifications......................................... 6 Lubricant Viscosities.............................................. 14 W Selecting the Viscosity....................................... 14 Lubricating Grease................................................ 24 Water/SCA (Supplemental Coolant Additive)........ 78 Cat Advanced 3Moly Grease............................. 25 Adding the Cat SCA to Water at the Initial Fill ... 79 Cat Arctic Platinum Grease................................ 27 Adding the Cat SCA to Water for Maintenance.. 80 Cat Desert Gold Grease .................................... 26 Cat High Speed Ball Bearing Grease................ 28 Cat Multipurpose Grease................................... 25 Cat Ultra 5Moly Grease..................................... 25 Cat White Assembly Grease.............................. 25 M Maintenance Section............................................. 6 Marine Transmission Oil........................................ 22 Caterpillar Transmission/Drive Train Oils........... 23 Commercial Marine Transmissions.................... 23 R Re-refined Basestock Oils..................................... 23 Reference Information Section.............................. 82 Reference Material................................................ 85 Coolants............................................................. 85 Diesel Engine Oil ............................................... 85 Filters................................................................. 86 Grease............................................................... 85 Miscellaneous.................................................... 86 S-O.S Services................................................... 85 Reference Materials.............................................. 82 • Product and Dealer Information Note: For product identification plate locations, see the section Product Identification Information" in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: I Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number: Dealer Information Name: Branch: Address: Dealer Contact Phone Number Hours Sales: Parts: Service: 0 i I I i I I • 02009 Caterpillar Cat, Caterpillar, their respective logos, "Caterpillar Yellow" and the Power edge Printed in U.S.A. All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. L (� L_ L AVTRON LOADBANK POWER TEST SOLUTIONS Q 0 Instruction K675AD46622 l�J A VT RON MODEL K675A OUTDOOR RESISTIVE LOAD BANK . Part Number K675AD46622 175 kW @ 480V, 3-Phase, 60 Hz ■ 25 kW Resolution ■ © 2009 Avtron Loadbank, Inc. September 11, 2009 Cleveland, Ohio Rev. October 6, 2009 ■ ■ ■ PROPRIETARYNOTE ■ ■ This document contains information PROPRIETARY TO ■ Avtron Loadbank, Inc. It is furnished solely to provide ■ information sufficient for instruction, operation, ■ p ■ maintenance, evaluation, and testing of the equipment herein disclosed; is not to be used for manufacturing or procurement; and is not to be disclosed to anyone other than ■ persons in the Division, or the Company, or the Government, ■ as the case may be, responsible for action relating to this ocument without the express written permission of Avtron o adb ank, Inc. ■ ■ WARRANTY ■ ■ ■The last page of this document contains an express limited ■warranty. The provisions of this warranty cover any and all ■rights extended to holders of Avtron Loadbank, Inc. ■equipment. ■ 7-1 ■ orm 831E-LB Rev 02-12 ((PAv-rRC>N LOAOBANK ■ 2545 <.?I. Grave i Cleveland. OH 34125- 615 : 216.573.7600 f: 216,573,5953 •rJw--nr.avtronloadbank.cr3r3i AVTRON LOADBANK, INC. Cleveland, Ohio . AVTRON MODEL K675A RESISTIVE LOAD BANK Part Number K675AD46622 TABLE OF CONTENTS Paize Section I SAFETY CONSIDERATIONS............................................................... 1-1 SectionII DESCRIPTION........................................................................................ �-1 Section III INSTALLATION..................................................................................... 3-1 SectionIV OPERATION...........................................................................................4-1 Section V MAINTENANCE.................................................................................... 5-1 SectionVI OPTIONS................................................................................................. 6-1 Section VII REPLACEMENT PARTS LIST.............................................................. 7-1 APPENDIX - Avtron Load Bank Troubleshooting Guide ■ DRAWINGS ■ SB3808 Outline Drawing, Control Panel SB3823 Outline Drawing, Load Bank * SB1635 Outline Drawing, Control Unit C22339-3 Option Drawing, Transformer **D41094 Digital Power Metering Option ■ D46623 Schematic K675AD46622 Load.Bank, Assembly * Provided only when Option 3 is included. " Provided Provided only when Option 39 is included. ■ i ■ ■ AVTRON MODEL K675A RESISTIVE LOAD BANK Part Number K675AD46622 ■ ■ ■ ■ SECTION I ■ SAFETY CONSIDERATIONS ■ ■ ■ Throughout this manual,you will find WARNING and CAUTION statements. Personal injury or death may occur to an operator using or repairing the equipment if a WARNING statement is ■ ignored. Damage to the equipment and potentially hazardous conditions for personnel may occur if a CAUTION statement is ignored. ■ Each Avtron unit is safety checked for opens and shorts,and the insulation is high potential tested to ensure safe operation. All fuses,safety interlocks, and related safety equipment have been tested as part of the testing procedure of each unit. ■ As part of your safety program, an initial inspection after receiving the unit(s) and periodic ■ preventive maintenance and safety inspections should be conducted to ensure the reliability and safety built into your Avtron equipment. ■ The Model K675A Load Bank is an industrial test unit designed to be used outdoors safely. ■ However,because the function of the Load Bank is to dissipate electrical energy,there are inherent ■ dangers to operators and equipment. These dangers are outlined in this section. ■ Electrical energy is transformed into heat by the resistors. This heat must be removed from the Load Bank by the cooling blower. If there is any restriction or stoppage of airflow, the Load Bank may ■ overheat and may even start a fire. It is recommended that: ■ l. The operator should read the manual before using the Load Bank. ■ 2. Run an approved ground wire from the Load Bank ground lug to the generator frame. Run ■ an approved ground wire from the generator frame to a good earth ground. ■ 3. Do not bypass the airflow safety switch to prevent nuisance tripping. The switch drops out if insufficient air is reaching the load elements. ■ ■ 1-1 ■ Safety Considerations Avtron Resistive Load Bank • Part Number K675AD46622 ■ 4. Replace any burned out bulbs on the Control Panel. Each lamp is an indication that a system is active or has failed and is important to the operation of the Load Bank and safety of the operator. ■ 5. Maintenance personnel must always exercise caution when the access panels are removed. ■ Personal injury from electrical shock or from the moving blower blade may result if all sources of power are not disconnected before servicing. Maintenance work must be done only by qualified personnel. 6. The Load Bank must be used in a cool, well ventilated area as described in the ■ INSTALLATION section of this manual. Do not allow exhaust air to recirculate through the Load Bank. 7. Venting the heated air from the exhaust toward overhead cables, sprinkler systems,or into a room with insufficient volume or "Make-Up" air is a potential hazard. The Load Banks ■ should be used in a cool, well ventilated area. 8. Allow cool room air to pass into the unit to cool the elements. Do not allow the unit to be placed where hot exhaust air can recirculate back through the unit causing a constant rise in cooling air temperature. ■ 9. After running a load test,residual heat may be removed from the Load Bank by allowing the blower to operate for a few minutes after load is removed. This procedure is not required for maintaining Load Bank integrity,but it may guard operating personnel from possible burn injuries. ■ 10. The operator should avoid coming in contact with the resistor elements or surrounding covers . during and for some time after operation. These portions of the Load Bank become quite hot and may result in a serious burn should contact be made with them. 11. Do not allow objects to enter or block the air intake or exhaust of the Load Bank. A blockage would cause Load Bank overheating. If an object enters the screens, it will cause . damage to the resistor elements, possibly shorting them and causing shock and/or fire hazards. ■ 12. Operators must not operate the Load Bank with the access panels or screens removed and doors open. To do so would expose the operator and other persons to possible personal . injury from electrical shock or from the moving fan blade. 13. Emergency shutdown procedure: ■ A. In an emergency, shut down the MASTER LOAD switch, then the generator. The ■ MASTER LOAD switch will allow disconnection of all load steps and still allow for the motor to run, cooling any heated elements. 1-2 ■ Safety Considerations Avtron Resistive Load Bank • Part Number K675AD46622 B. The CONTROL POWER ON/OFF switch will disconnect both load steps and the fan motor. The Generator Emergency OFF switch should be located near the load ■ system. ■ 14. An approved electrical fire extinguisher should be on hand at all times. . 15. It is the responsibility of the customer to take diligent care in installing the Load Bank. The National Electrical Code (NEC), sound local electrical and safety codes, and the Occupational Safety and Health Act (OSHA) should be followed when installing the ■ equipment to reduce hazards to persons and property. ■ 16. Read and heed all WARNING and CAUTION statements in the manual. 1-3 ■ . Description Avtron Resistive Load Bank - Part Number K675AD46622 ■ SECTION II ■ DESCRIPTION ■ ■ ■ The Avtron Model K675A Load Bank is an outdoor unit designed to absorb a balanced resistive load of unity power factor, at 480V, 3-phase voltage. The total load capability is 175 kW @ 480 VAC, ■ 3-phase,60 Hz. Load steps are 25,50,and 100 kW. Using the toggle switches on the control panel, ■ any combination of the available load steps may be selected to achieve a desired load. ■ ■ CAUTION Only 60 Hz, 3-phase, 480V power should be connected to the load bus terminals. Other frequencies or voltages may cause severe damage to the Load Bank. ■ ■ The K675AD46622 Load Bank contains a 2 hp fan/blower motor that operates from a 480 volt, 3-phase, 60 Hz power source, and provides the necessary cooling air for the load elements. The ■ fan/blower motor is controlled by a motor starter contactor. Overcurrent protection is provided by ■ fuses and overload relays. The faniblower air delivery is 8,500 cfrn at 3/ inch of static pressure. ■ CAUTION ■ This Load Bank should never be used without the Fan Blower Motor operating. Inadequate cooling airflow will result in resistor elements ■ overheating and a definite fire hazard. ■ 2-1 ■ Description Avtron Resistive Load Bank • Part Number K675AD46622 ■ An AIRFLOW switch is provided to monitor the flow of cooling air. This differential pressure switch is electrically interlocked with the load application controls to prevent load application if the faniblower is not working properly(AIR FAILURE light comes on). ■ An overtemperature switch is provided to monitor the exhaust cooling air. The switch is electrically ■ interlocked with the load application controls to prevent load application in the event of an overtemperature condition. The control panel contains a control POWER ON/OFF switch, a CONTROL POWER light, a BLOWER POWER light, an AIR FAILURE light, a MASTER LOAD ON-OFF switch, blower ■ START and STOP pushbutton switches, and individual KW load step switches. All load step switches are the toggle type with metal levers. The control panel also contains a fuse for the control circuit. Sized for mounting into a 19-inch rack enclosure, the control panel has a vertical height of ■ 8.75 inches and requires a minimum of 3 inches of clearance behind the panel. The K675A Load Bank is fabricated using heavy-gauge aluminized sheet steel, making a rigid structure. Mounted within the structure are the load element resistor assemblies and the cooling blower. The resistive elements are porcupine type, fully supported along their length. Mounted ■ within the enclosure are the necessary load step contactors, motor starter, motor overload relay, fuses, and customer connection terminals. The cooling air is drawn in from one end, forced across the resistor elements, and exhausted out the opposite end. The control section has a temperature controlled heater that is used to prevent condensation and increase enclosure temperature for cold weather operation of the Load Bank. ■ The unit is equipped with an intake screen mounted on the inlet and a louver mounted at the exhaust. ■ These provide protection for the motor and resistor assembly from the weather. The Load Bank utilizes a formed sheet metal base to facilitate handling by a forklift truck. Bolt holes are also supplied in the base to permit permanent mounting. CAUTION Never exceed the rated voltage as this will cause the Load Bank to . overheat. Do not apply DC voltages as the contactors do not have arc blowout magnets. r 2.2 • ■ ■ Description Avtron Resistive Load Bank • Part Number K675AD46622 Lower voltages and different frequencies may be applied to the load circuit of the Load Bank. Frequency change causes no derating of the load; however, the applied kW with a lower voltage is computed with the following formula: ■ ■ kW kW X (Voltage Applied)' Applied — Rated (Voltage Rated)' ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ y ■ ■ 2-3 ■ ■ Installation Avtron Resistive Load Bank • Part Number K675AD46622 ■ SECTION III ■ INSTALLATION ■ ■ ■ . BEFORE INSTALLATION ■ Inspect the Load Bank for obvious damage such as broken wires,broken or dented panels, cracked ■ ceramic insulators, or any other component breakage that may have occurred in shipment. ■ . WARNING It is vitally important to install the Load Bank properly. Installation errors may result in a catastrophic failure. The AIRFLOW switch, a protective device in the Load Bank,will guard against some of these problems. If protective circuitry prevents application of the load, determine the source of the problem. DO NOT DISABLE the ■ AIRFLOW SWITCH. This will cause a safety hazard and will void our warranty. The following installation instructions are critical to . the safe operation of the Load Bank. Refer to the SAFETY CONSIDERATIONS section of this manual. ■ ■ ■ LOCATION ■ The Load Bank must be used in a cool, well-ventilated area. It must be installed where cool air is ■ continually available and where hot exhaust air will not be recirculated through the Load Bank. If the Load Bank is operated in a closed space, ventilation of 10,000 cfm or greater is required. ■ Exhaust temperature can exceed 250°F in approximately 3 minutes without the proper ventilation. The exhaust air maybe in excess of 250°F under full load conditions. The unit must not be installed near any equipment,wiring,or plumbing which may be damaged by high air temperatures or which may constitute a fire hazard. Care should also be taken so as not to set off a sprinkler system by ■ exposing it to hot exhaust air. ■ 3-1 Installation Avtron Resistive Load Bank • Part Number K675AD46622 . Do not install the Load Bank in any area where standing water can pool or accumulate.Do not install near: a drainage basin, surface/ground or roof runoff, sewer collection,or any location where water . can back up or collect. If flooding can occur,we recommend a different location or a raised platform sufficiently above high water level. Do not operate if any portion of the Load Bank is submerged. ■ Always install above grade. The Load Bank should be mounted outdoors in a free field. A prerequisite to approval of site ■ location is to read the next section titled AIRFLOW CONSIDERATIONS. If the installation dictates mounting in close proximity to any external or adjacent device,transformer,generator set,building, ■ structure or protuberance, follow these guidelines: 1. Position the Load Bank with a minimum of 36 inches of clearance on both sides. This is in line with the airflow to allow access for service(Figure 3-1). 2. The inlet requires a free unobstructed hemispherical zone. The radius of this sphere must be at least 6 feet. Refer to Figure 3-1. If a unit is backed into a corner, the 6 feet is no longer ■ sufficient. Consult Avtron Engineering to review prior to installation. The intake must not ingest heated air from another source. The maximum ambient intake air temperature is 120°F. 3. Provide a minimum of 8 feet from any obstruction for exhaust clearance to prevent air restrictions and to limit air recirculation. For thermal considerations, provide a minimum clearance of 30 feet from any temperature sensitive object. The heated exhaust air stream will damage temperature sensitive items if they are positioned within the 30 foot clearance area. Refer to Figure 3-1. 4. Load Banks mounted into a channel,trough,hollow,well,pit,or exhausting into a full wall • or corner require special considerations even if the above conditions are met. In these cases, provide detailed site layout drawings to Avtron for inspection and comments. ■ 5. Locations which have full or partial perimeter fence necessitate a review. The fencing ■ material should have at least 75% open area. The 36" minimum side clearances shown in Figure 3A still apply. Clearance on intake and exhaust can be adjusted only after approval by an authorized Avtron representative. Painted or plated metal chain link fence is the preferred material. All nonmetallic fencing materials are not recommended. r 3-2 . Installation Avtron Resistive Load Bank Part Number K675AD46622 LOAD BANK ■ 36" MIN. FOR SERVICE ■ J AIR FLOW Q ■ z /►_ x w ■ 6 FT 36 SERNIC OR MIN. 3m FT MIN. HATCHED SECTION IS REQUIRED FREE FIELD D65m5C1LAN Figure 3-1. Load Bank Installation Airflow Clearance Requirements ADDITIONAL LOCATION NOTES 1. Do not stack, tier, or layer Load Banks without Avtron approval, as air recirculation will occur. 2. Indoor installations will always require review. Make up air must be by a supplemental air . moving device. The Load Bank cooling system cannot be used for any purpose other than cooling the Load Bank. ■ 3. In northern climates with snow depths exceeding 6 inches,a physical inspection of the Load Bank intake and exhaust is required prior to operation. Any significant snow drifts or snow ■ depths must be cleared prior to operation. 4. Standard Load Banks are designed for operation between sea level and 2,000 feet maximum ■ altitudes. Operation at altitudes over 2,000 feet above sea level requires special consideration. Contact Avtron for assistance. K675AD46622 is designed for operation up to . 6,500 feet elevation at a 95°F maximum temperature. ■ 5. In general, these guidelines also apply to portable or trailer mounted Load Banks. FAILURE TO FOLLOW THESE GUIDELINES WILL VOID THE WARRANTY. 3-3 Installation Avtron Resistive Load Bank • Part Number K675AD46622 . AIRFLOW CONSIDERATIONS Even with an ample supply of cooling air,the Load Bank may overheat if it is not properly installed. There are two types of airflow problems that should be avoided: 1. Recirculating airflow- If the hot, exhausted air is permitted to recirculate through the Load ■ Bank, it will reach such a high temperature and low density that it will no longer cool the elements. A Load Bank should not be installed so close to any surface as to reflect the ■ exhausted air back to the air intake. When two or more Load Banks are being used, care must be taken in positioning the Load Banks so that the exhausted air of one unit does not ■ feed the air intake of another. If a Load Bank is to be mounted on a raised structure,a shield must be incorporated in the structure to prevent exhaust air from being drawn back under the ■ unit. 2. Restriction of Cooling Air-Any obstruction located within the outlined parameters listed in ■ the previous LOCATION section of the manual will restrict the Load Bank's airflow. Do not modify louvers or screens on intake and exhaust. Ducting or diverting of airflow will ■ increase system airflow resistance and will void the warranty. If ducting is mandatory,obtain written approval from Avtron prior to installation. Airflow is also restricted when two or more Load Banks have air inlets positioned close to each other. This competition for cooling ■ air causes a low pressure area, restricting adequate airflow. When operating a Load Bank outdoors, the wind can work for or against the Load Bank cooling system. If the Load Bank is positioned with the prevailing wind opposing the airflow from the blower, inadequate cooling may result and damage to the Load Bank can occur. Improper positioning may also result in the air switch being deactivated, thus dropping the load. CONTROL PANEL The Control Panel is made to be mounted in a 19-inch rack-type enclosure. A NEMA 4 enclosure, . option#3,A20712,can be used to house the control panel. Connect terminals of the Control Panel to terminals of the Load Bank as shown on the Schematic/Interconnection Diagram. ■ For remote load dump capability, connect normally closed contacts between Control Panel TB 1(8) and Load Bank TB11(8)terminals. ■ Connect terminals TB 11 (1 and 2) on the Load Bank to a 120V, 60 Hz single-phase power source. ■ Connect terminals of the Control Panel to terminals of the Load Bank as shown on the Schematic/ Interconnection Diagram. r 3-4 ■ Installation Avtron Resistive Load Bank - Part Number K675AD46622 ENCLOSURE HEATERS ■ The Load Bank contains a 100 watt strip heater and a temperature switch. The heater is to be used to prevent problems of condensation and icing. It is recommended to maintain heater function during storage and prior to operation to assure Load ■ Bank operation and prevent icing. BLOWER MOTOR CONNECTIONS ■ The blower circuit consists of fuses, an overload relay,blower motor, and motor starter contactor. Required power for the blower motor is 480V f10%, 3-phase, 60 Hz. If the blower motor is to be connected to the source under test,make sure that the voltage source is . within f 10%of motor rating. When operating the blower from the generator, an additional load is created. With any connection, make sure that the correct phase rotation is wired to the blower motor. Improper phase rotation will cause the blower to run in the reverse direction. The cooling air must be pushed from the blower, across the resistor elements, and out the exhaust screen. This phase rotation check is mandatory every time the source or blower connections are changed. If airflow direction is incorrect,shut down the Load Bank and disconnect all power from it. Switch any two of the three blower input connections at terminals TB 11 (38-40). Reconnect power and verify that the blower rotates in the correct direction. Safe practice dictates that the blower power should be wired through a safety disconnect switch that can be locked out. LOAD CONNECTIONS ■ The Load Bank has three connections marked A, B, and C, which are located in the relay compartment. The connections are made to the bus bars using the .562 diameter holes and appropriate hardware. Cables to the Load Bank should be of adequate size to handle maximum rated load according to the National Electric Code and any local codes. ■ GROUNDING A ground conductor must be connected to the Load Bank enclosure to prevent a potential above WO ground on the enclosure. There is a ground stud in the Load Bank for this connection. This ground ■ conductor should be run with the load power conductors to provide the lowest impedance fault path. 3-5 Installation Avtron Resistive Load Bank • Part Number K675AD46622 ■ The ground stud must be connected to both the power source frame and to a good earth ground. The ground conductor should be sized per the National Electric Code Table 250.122,if not superseded by local codes. INSTALLATION CHECKOUT PROCEDURE-- TO BE DONE PRIOR TO OPERATION ■ This Installation Checkout Procedure is intended to be used upon initial receipt of equipment and following any relocation of a permanent mounted Load Bank. These procedures apply to Load ■ Banks in general and may include steps not relevant to the specific unit being installed. Disregard those procedures which do not apply. ■ WARNING ■ THE FOLLOWING TESTS ARE TO BE ACCOMPLISHED BY A QUALIFIED ELECTRICIAN OR TECHNICIAN USING EXTREME CAUTION AS POTENTIALLY LETHAL VOLTAGES AND DANGEROUS ROTATING COMPONENTS ARE PRESENT. IF ASSISTANCE IS REQUIRED, AVTRON CAN PROVIDE START UP SERVICE AT A NOMINAL CHARGE. AVTRON Ic ALSO WILL PROVIDE TELEPHONE ASSISTANCE IF REQUIRED BY CALLING (216) 573-7600. I. Verify the Load Bank placement meets the installation requirements found in the INSTALLATION section of the instruction manual: ■ A. Check the clearance from both intake and exhaust to any obstruction. . B. If the location has a prevailing wind,make the wind aid in the cooling of the resistor elements. ■ C. If the Load Bank is elevated,a plate under the Load Bank will be needed to block hot exhaust from returning to the intake. . 2. Check the mechanical integrity of all customer-supplied interconnection wiring: A. Check lugs that they are properly crimped. B. Check terminations that they are properly torqued. 3-6 ■ Installation Avtron Resistive Load Bank • Part Number K675AD46622 3. Utilize system schematics to ohm out customer-supplied interconnection control wiring and safety circuits: A. If control wiring is all the same color, ohm out each individual wire to confirm ■ proper labeling and placement. CAUTION Control wiring must be a minimum of 14 AWG for wire runs ■ under 50 feet. Consult Avtron Loadbank, Inc., for wire sizing when wire run exceeds 50 feet. B. Confirm the correct wire gauge has been used for interconnection wiring. Control ■ wiring should be a minimum of 14 AWG for control panel to Load Bank lengths of 50 feet or less. For lengths greater than 50 feet, consult Avtron Loadbank, Inc. ■ C. If a Control Transformer is the source of control power, disconnect the control transformer before proceeding. ■ CAUTION ■ When control power is supplied by a transformer within the Load Bank, it must be disconnected before running this ■ installation checkout procedure. Failure to disconnect the control transformer may damage the Load Bank. 3-7 Installation Avtron Resistive Load Bank • Part Number K675AD46622 ■ 4. Energize the source of control power only: A. Check the control voltage and confirm it is within 10% of the required voltage. ■ WARNING Control power is present on terminal block in steps 4 through 6. . B. Operate the safety circuitry with a jumper across the air switch contact at its ■ termination at the terminal block. 5. Turn on the POWER switch and verify the proper relays energize with each individual load • switch as follows: A. Turn on the MASTER LOAD switch. Turn on each load step individually and observe that each relay(or relays) pulls in without chatter or hesitation. B. Turn off the MASTER LOAD switch. Turn on all the load steps. Turn on the MASTER LOAD switch and observe the pull in of all the contactors. If chatter or ■ hesitation is observed, locate the cause of the voltage drop causing the problem. 6. While the load relays are energized, remove the jumper across the air switch. All the load contactors should drop out as soon as the jumper is removed. Leave the jumper off the air ■ switch. 7. Open intake and exhaust covers. Exhaust cover hinges down. Intake cover must be . removed. 8. Apply the rated fan voltage. Start blower and verify that air is exiting the resistor assembly ■ end. This checkout procedure is intended to be a guide to Load Bank installations in general. Special ■ installation considerations not addressed herein may be necessary due to installation site or environment. Any questions or concerns regarding Load Bank installation should be directed to Avtron Field Service at (216) 573-7600. ■ r 3-8 ■ ■ Operation Avtron Resistive Load Bank • Part Number K675AD46622 ■ SECTION IV ■ OPERATION ■ ■ ■ ■ WARNING DO NOT touch the exhaust screen during operation. The screen will ■ become hot from the exhausted heat and may cause a serious burn. Refer to the SAFETY CONSIDERATIONS section of this manual. ■ ■ DO NOT allow objects to enter or block screens. ************************************************************* NOTE ■ Lower voltages and different frequencies may be applied to the load ■ circuit of the Load Bank. Frequency change causes no derating of the load;however,the applied kW with a lower voltage is computed with ■ the following formula: ■ (Voltage Applied)' ■ kW Applied — kW RatedX (Voltage Rated)' ■ ■ CAUTION ■ Never exceed the rated voltage as this will cause the Load Bank to ■ overheat. ■ Do not apply DC voltages as the contactors do not have arc blowout magnets. ■ ■ 4-1 ■ Operation Avtron Resistive Load Bank • Part Number K675AD46622 ■ PROCEDURE 1. Place all switches on the control panel to the OFF position. ■ 2. Connect the power source to be tested to the Load Bank as described in the INSTALLATION . section. 3. Start the generator under test. Verify correct voltage and frequency. 4. Place the POWER ON/OFF switch to the ON position. The CONTROL POWER light ■ (DS20) will be energized, indicating control power is present. CAUTION ■ DO NOT operate the Load Bank over the rated voltage as this will ■ cause catastrophic failure in the Load Bank. 5. Push the blower START pushbutton. Note that the(fan)BLOWER POWER light turns on and the AIR FAILURE indicator flashes ON momentarily. When the blower motor has reached proper speed,the AIR FAILURE lamp will be de-energized. Load voltage will not be connected to Load Bank resistance elements unless the AIRFLOW switch has closed. ■ Also note airflow direction. If airflow is not "OUT" the exhaust end, shut off the blower, . disconnect power, and reverse any two phase connections to the blower input terminals. CAUTION ■ The operation of the fan/blower is vital to the safe operation of this ■ Load Bank. When the blower START switch is depressed, the AIR FAILURE light will come on momentarily until the fan/blower accelerates up to its operating speed, at which time the light will go ■ off. If the load elements are energized when this fan/blower is not operating, the Load Bank will burn up. If the AIR FAILURE ■ indicator light stays on for more than a few seconds, shut down the Load Bank, and do not operate the unit until the problem is corrected. Refer to the SAFETY CONSIDERATIONS section of this manual. 4-2 . Operation Avtron Resistive Load Bank • Part Number K675AD46622 6. The resistive loading is selected by toggle switches, using any one or combination of the toggle switches to make up a given load. 7. By placing the MASTER LOAD ON/OFF switch to the ON position, the preselected load ■ will be applied to the power source. . 8. Any load switch can be added or removed as required with the MASTER LOAD ON/OFF switch closed (ON). . 9. To remove the load, open the MASTER LOAD ON/OFF switch by placing it in the OFF position. ■ SHUTDOWN ■ 1. Place the MASTER LOAD switch to the OFF position. ■ NOTE After running a load test, residual heat may be removed from the Load Bank by allowing the fan/blower to operate for a few minutes after load is removed. This procedure is not required for maintaining Load Bank integrity, but it may guard operating personnel from possible burn injuries. ■ The fan/blower motor will operate until the STOP pushbutton is depressed. 2. Place the POWER switch to the OFF position. Other switches on the control panel should be ■ turned OFF. ■ 3. Shut down the power source(s). 4. Disconnect the Load Bank from the power source(s). 4-3 ■ ■ ESD PRECAUTIONARY GUIDELINES ■ ■ C A U T I O N ■ Certain circuit card assemblies and their components, typically integrated circuits, may ■ be damaged by seemingly undetectable ■ electrostatic discharge (ESD) . Care must be exercised during handling/repair of these ■ items . Use electrostatic discharge precautionary procedures . ■ ■ The following guidelines are not necessarily all inclusive but rather serve as reminders for good shop practices for the handling/ ■ repair of ESD sensitive circuit card assemblies and devices . ■ Store ESD sensitive items in their original containers . These items are often marked with the symbol shown at the top of this page. Put on a grounded wrist strap before handling any ESD sensitive item. ■ Clear work area of Styrofoam®* , plastic, and vinyl items ■ such as coffee cups . ■ Handle ESD items by the body, never the open edge connectors . • Never slide ESD sensitive items over any surface. ■ Transport ESD sensitive items in a static shielding ■ container to a static-free work station. ■ If a static-free work station is no-t available, ground the transport container before removing or inserting an ■ ESD item. ■ Electric tools used during repair should be grounded. For example, use only anti-static type solder suckers and ■ grounded tip soldering irons . Discharge non-electric tools before use . ■ Pack ESD items in static shielding containers before shipping them to Avtron for repair . ■ * Styrofoam® is a registered trademark of Dow Chemical . ■ ■ ■ ■ Maintenance Avtron Resistive Load Bank • Part Number K675AD46622 ■ SECTION V ■ MAINTENANCE ■ ■ ■ ■ To provide long equipment life and to reduce the chance of electric shock,fires,and personal injury, good maintenance procedures must be used. Before servicing, review the SAFETY ■ CONSIDERATIONS section of this manual. ■ The following are examples of scheduled maintenance procedures. These examples are not intended ■ to be all-inclusive but must be accomplished to maintain the equipment in a good, safe condition. All maintenance work must be done by qualified personnel only. ■ WARNING ■ Personal injury from electrical shock or from the moving-fan blade may result if ALL sources of power are not disconnected. Refer to ■ the SAFETY CONSIDERATIONS section of this manual. ■ Eye protection should be worn when cleaning the unit with ■ compressed air. ■ ■ DAILY ■ 1. Remove any restrictions to the airflow through the Load Bank. ■ 2. Check the screens to make sure that no objects have blocked or entered the openings. ■ ■ 3. Verify that the airflow is in the proper direction. 4. Assure that there is no recirculation of the exhaust air through the Load Bank. ■ 5. Verify all heaters and temperature switches are functional. ■ 5-1 ■ Maintenance Avtron Resistive Load Bank • Part Number K675AD46622 THREE MONTHS 1. Remove the access panels and screens, and inspect the load resistors for mechanical . breakdown which is demonstrated by excessive sagging of the elements. Replace worn resistor elements with new resistor elements as required. . 2. Inspect for broken ceramic insulators. Replace any broken or cracked insulator with a new ceramic insulator. ■ 3. Inspect for loose hardware or loose connections. Tighten where required. . 4. Inspect all connections for oxidation or corrosion. Clean the connection or replace the ■ hardware where required. 5. Verify that the AIRFLOW switch works properly. ■ 6. Inspect all magnetic contactors to make sure that the contacts are not severely pitted or ■ corroded. The contacts must move freely and be properly seated. 7. Clean all dirt and debris out of the Load Bank. This can be accomplished by blowing the ■ inside of the units with clean, dry compressed air (not to exceed 40 PSI). Eye protection should be worn when cleaning the Load Bank with compressed air. 8. Inspect all the wiring for any sign of insulation failure. 9. Replace all access panels and screens. Tighten all the fastening hardware securely. 10. Check the indicator lamps on the control panel. ■ ANNUALLY ■ The fan/blower motor should be lubricated per the motor manufacturer's requirements and ■ specifications on the motor nameplate if applicable. 5-2 ■ Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) ■ SECTION VI ■ ■ OPTIONS ■ The following options are available for Avtron Model K675A Load Banks. Not all options can be ■ installed in the same unit. ■ ■ Part No. Option Description ■ C22398 1 Lifting eyes D25111-1 Thru 2 Fused load steps (Refer to drawing D25111-1 thru D25111-47 ■ D25111-47 for parts breakdown.) ■ A20712 3 NEMA 12 control panel enclosure C22339-1 4 Control Transformer 208/120V C22339-2 5 Control Transformer 240/120V C22339-3 6 Control Transformer 480/120V ■ C22339-4 7 Control Transformer 600/120V ■ ■ D25060-1 8 1 KW Resolution 480V ■ D25060-2 9 1 KW Resolution 240/480V ■ D25060-3 10 1 KW Resolution 300/600V ■ D25060-4 11 1 KW Resolution 380V ■ D25060-5 12 1 KW Resolution 208V ■ ■ C22339-5 13 Control Transformer 380/120V ■ C22339-6 14 Control Transformer 488/240V C22482 15 5 HP Dual Voltage Blower ■ ■ ■ 6-1 Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) Part No. Option Description C22491 16 0-5 KW Resolution D26697-1 Thru 18 Load Bank Option Installation D26697-15 Load Shedder(for Load Banks K675AD24617 thru ■ K675AD24628; K675AD25086-1, K675AD25086-2, K675AD25086-7; and K675AD25087-1 thru K675AD25087-3 . A22386 19 Installation of Control Panel to top of Load Bank ■ D26079 20 Addition of Load Shedder to 208 Volt units. Relay version. * A23468 21 Installation of 230 Volt, 2HP Blower operation, Option 21 A25142 22 Installation of Option 22 into K675A Load Bank 230 Volt Blower (5 HP) operation . * A25151 23 Control Transformer and a 208-230 Volt Single Phase Blower * A25152 24 Addition of CAM-LOKS, 400 Amp Max. * A25258 25 Addition of CAM-LOKS, 1200 Amp Max. A25270 26 Travel Cover ■ * A25799 27 Remote, Full Load Application S A26015 28 480V Blower in a 575V Load Bank (2 hp) A26468 30 Internal Blower Power Connections * A26469 31 Remote Signaling Contacts C25002 32 2 HP Dual Voltage Blower A27143 33 Installation of Option 33, 575V Blower in a 480V Unit ■ D25060-6 34 Load Bank Installation Option, 600V ■ Fine Step Kit (1, 2, 2, kW) ■ * Include this drawing if option is provided. 6-2 ■ Avtron Model K675A Outdoor Resistive Load Bank Options (Load Banks S/Ns 1710 and Above) Part No. Option Description A28777 35 Installation of Option 35, 480V Blower . (5 HP), in a 575V Unit ■ *A33454 36 Reverse Power Relay(480V) *A33455 37 Reverse Power Relay(208V) D41094 39 Digital Metering (SHARK style) *Include this drawing if option is provided. ■ 6-3 Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) ■ K675A OPTIONS REPLACEMENT PARTS LIST SCHEMATIC AVTRON QTY/ REFERENCE DESCRIPTION P/N UNIT ■ OPTION 4 - Installation of C22339-1 ■ 208 Volt Control Transformer T1 Transformer, 1000 VA 371072 1 ■ F6, 7 Fuse, 8A, 500V 324159 2 XF5-7 Fuseblock 324615 1 ■ F5 Fuse, 12 Amp, 600V 324500 1 OPTION 5 - Installation of C22339-2 ■ 240 Volt Control Transformer T1 Transformer, 1000 VA 371077 1 . F6, 7 Fuse, 10A, 600V 324709 2 XF5-7 Fuseblock 324615 1 ■ F5 Fuse, 12A, 600V 324500 1 OPTION 6 - Installation of C22339-3 480 Volt Control Transformer T1 Transformer, 1000 VA 371077 1 F6, 7 Fuse, 5A, 500V 324475 2 XF5-7 Fuseblock 324615 1 ■ F5 Fuse, 12A, 600V 324500 1 ■ OPTION 7 - Installation of C22339-4 600 Volt Control Transformer T1 Transformer, 1000 VA 371071 1 ■ F6, 7 Fuse, 3A, 500V 324453 2 XF5-7 Fuseblock 324615 1 F5 Fuse, 12A, 600V 324500 1 ■ OPTION 8 - 1, 2, 2 KW Fine Step Kit, 480V D25060-1 ■ F71-73 Fuse, 2A, 600V 325048 3 F74-79 Fuse, 3A, 600V 324478 6 ■ XF71-79 Fuseholder 324977 3 K73-75 Relay B14795 3 S26-28 Switch Toggle 360589 3 R12-26 Resistor A16450 15 ■ OPTION 9 - 1, 2, 2 KW Fine Step Kit, 240/480V D25060-2 ■ F71-73 Fuse 324478 3 F74-79 Fuse, 3A, 600V 324479 6 XF71-79 Fuseholder 324977 3 K70-75 Relay B14795 6 . S26-28 Switch, Toggle 360589 3 R12-26 Resistor A16450 15 ■ Form No.755 6-4 ■ ■ Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) ■ SCHEMATIC AVTRON QTY/ REFERENCE DESCRIPTION P/N UNIT ■ OPTION 10 - 1, 2, 2 KW Fine Step Kit, 300/600 Volt D25060-3 F71-73 Fuse, 3A, 600V 324478 3 ■ F74-79 Fuse, 3A, 600V 324479 6 XF71-79 Fuseholder 324977 3 K70-75 Relay B14795 6 . S26-28 Switch, Toggle 360589 3 R12-26 Resistor A22096 15 ■ ■ OPTION 11 - 1, 2, 2 KW Fine Step Kit, 380 Volt D25060-4 ■ F71-73 Fuse, 2A, 600V 325048 3 F74-79 Fuse, 6A, 600V 324479 6 XF71-79 Fuseholder 324977 3 ■ K73-75 Relay 314795 3 S26-28 Switch, Toggle 360589 3 ■ R12-26 Resistor A22097 15 ■ ■ OPTION 12 - 1, 2, 2, KW Fine Step Kit, 208V D25060-5 F71-73 Fuse, 6A, 600V 324479 F74-79 Fuse, 10A, 600V 324480 ■ XF71-79 Fuseholder 324977 K73-75 Relay B14795 = S26-28 Switch, Toggle 360589 R12-26 Resistor A22098 -_ ■ OPTION 13 - Control Transformer 380/120 Volt C22339-5 T1 Transformer, 1000 VA 371075 - ■ F6, 7 Fuse, 4A, 500V 324454 = XF5-7 Fuseblock 324615 _ ■ F5 Fuse, 12A, 600V 324500 ■ OPTION 14 - Installation of C22339-6 ■ Control Transformer, 480/240V T1 Transformer, 500 VA 371077 1 ■ K101 Relay 350740 1 T40 Transformer, 50 VA 370528 1 ■ F440 Fuse, 0.5A, 250V 324005 1 XF440 Fuseholder 324964 1 . XK101 Socket 358215 1 S100 Switch, PB Black 360309 1 S101 Switch, PB Red 360308 1 ■ K100, 240 Relay B14795 2 K480 Relay B16148 1 . CB1 Circuit Breaker 310336 1 S102 Switch 360785 1 ■ TB3, 13, 20 Terminal Block 364289 18 XTB3, 13, 20 Marker Strip 364295 6 .Fuse 324500 1 Fuseholder 324618 1 ■ ■ Form No.755A 6-5 Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) ■ SCHEMATIC AVTRON QTY/ ■ REFERENCE DESCRIPTION P/N UNIT OPTION #15 - 5 HP Dual Voltage Blower C22482 ■ S13 Switch, Toggle 360747 1 S14 Switch, Rotary 620288 1 ■ .Knob 453602 1 TB4, 14 Terminal Block 364289 12 .Marker Strip 364295 4 ■ K22, 23 Relay B17839 2 K24-26, 50, 51 Relay B14795 5 ■ K30 Relay* 350980* 1 .Bracket, Relay Mounting* 408304* 1 ■ F2-4, 8-10 Fuse, 20A, 600V 324283 6 XF8-10 Fuseblock 324997 1 ■ OPTION #16 - 0-5 KW Resolution C22491 ■ .Control Unit C14677 1 ■ .Resistance Element 606351 6 .Bus Link A17912 5 . TB101 Terminal Board 364103 1 .Insulator 450028 1 . OPTION #18 - Installation of Load Shedder D26697-1 • K50, 51 Relay 351060 2 XK50, 5l Relay Socket 358280 2 .Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 ■ A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 ■ .Retainer, Relay 467550 2 ■ OPTION #18 - Installation of Load Shedder D26697-2 ■ K50, 51 Relay 351060 2 XK50, 51 Relay Socket 358280 2 ■ .Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 ■ XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 ■ A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 ■ .Retainer, Relay 467550 2 ■ ■ *If relay fails, replace relay and relay mounting bracket. Forth No.755A . 6-6 ■ Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) ■ SCHEMATIC AVTRON QTY/ REFERENCE DESCRIPTION P/N UNIT ■ OPTION #18 - Installation of Load Shedder D26697-3 K50, 51 Relay 351060 2 ■ XK50, 51 Relay Socket 358280 2 Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 ■ XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 ■ A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 ■ Retainer, Relay 467550 2 ■ OPTION #18 - Installation of Load Shedder D26697-4 . K50, 51 Relay 351060 2 XK50, 51 Relay Socket 358280 2 ■ .Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 . XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 ■ A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 2 ■ OPTION #18 - Installation of Load Shedder D26697-5 K50, 51 Relay 351060 2 XK50, 51 Relay Socket 358280 2 .Modification, Control Panel D33621 1 ■ DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 ■ S30 . .Switch, Toggle 360747 1 A101 PC Board, Load Shed A22829 1 ■ XK22 Auxiliary Contact 312401 1 Retainer, Relay 467550 2 ■ OPTION #18 - Installation of Load Shedder D26697-6 K50, 51 Relay 351060 2 . XK50, 51 Relay Socket 358280 2 .Modification, Control Panel D33621 1 ■ DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 ■ S30 . .Switch, Toggle 360747 1 A101, 102 PC Board, Load Shed A22829 2 XK22 Auxiliary Contact 312401 1 ■ Retainer, Relay 467550 2 ■ ■ ■ Form No.755A 6-7 Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) ■ SCHEMATIC AVTRON QTY/ ■ REFERENCE DESCRIPTION P/N UNIT AIM OPTION #18 - Installation of Load Shedder D26697-7 ■ K50, 51 Relay 351060 2 XK50, 51 Relay Socket 358280 2 ■ .Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 ■ S30 . .Switch, Toggle 360747 1 A101, 102 PC Board, Load Shed A22829 2 ■ XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 2 ■ OPTION #18 - Installation of Load Shedder D26697-8 K50, 51 Relay 351060 2 ■ XK50, 51 Relay Socket 358280 2 .Modification, Control Panel D33621 1 ■ DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 . S30 . .Switch, Toggle 360747 1 A101, 102 PC Board, Load Shed A22829 2 . XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 2 OPTION #18 - Installation of Load Shedder D26697-9 K50, 51 Relay 351060 2 XK50, 51 Relay Socket 358280 2 .Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 . XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 ■ A101, 102 PC Board, Load Shed A22829 2 XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 2 OPTION #18 - Installation of Load Shedder D26697-10 ■ K50, 51 Relay 351060 2 XK50, 51 Relay Socket 358280 2 . .Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 ■ XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 ■ A101, 102 PC Board, Load Shed A22829 2 XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 2 ■ ■ Form No.755A 6-8 Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) ■ SCHEMATIC AVTRON QTY/ REFERENCE DESCRIPTION P/N UNIT ■ OPTION #18 - Installation of Load Shedder D26697-11 K50, 51 Relay 351060 2 ■ XK50, 51 Relay Socket 358280 2 Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 ■ XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 ■ A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 ■ Retainer, Relay 467550 2 OPTION #18 - Installation of Load Shedder D26697-12 ■ K50, 51 Relay 351060 2 XK50, 51 Relay Socket 358280 2 ■ .Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 ■ A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 2 OPTION #18 - Installation of Load Shedder D26697-13 K50, 51 Relay 351060 2 XK50, 51 Relay Socket 358280 2 .Modification, Control Panel D33621 1 . DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 Retainer, Relay 467550 2 ■ OPTION #18 - Installation of Load Shedder D26697-14 K50, 51 Relay 351060 2 ■ XK50, 51 Relay Socket 358280 2 .Modification, Control Panel D33621 1 ■ DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 ■ S30 . .Switch, Toggle 360747 1 A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 ■ Retainer, Relay 467550 2 ■ Form No.755A 6-9 Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) . SCHEMATIC AVTRON QTY/ ■ REFERENCE DESCRIPTION P/N UNIT OPTION #18 - Installation of Load Shedder D26697-15 ■ K50,51 .Relay 351060 2 XK50, 51 Relay Socket 358280 2 ■ .Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 ■ S30 . .Switch, Toggle 360747 1 A101 PC Board, Load Shed A22829 1 ■ XK22 .Auxiliary Contact 312401 1 .Retainer, Relay 467550 2 ■ OPTION #18 - Installation of Load Shedder 26697-16 K50, 51 Relay 351060 2 . XK50, 51 Relay Socket 358280 2 .Modification, Control Panel D33621 1 ■ DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 . S30 . .Switch, Toggle 360747 1 A101 PC Board, Load Shed A22829 1 ■ XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 2 OPTION #18 - Installation of Load Shedder 26697-17 K50-52 Relay 351060 3 XK50-52 .Relay Socket 358280 3 .Modification, Control Panel D33621 1 ■ DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 S A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 3 ■ OPTION #18 - Installation of Load Shedder 26697-18 ■ K50-53 Relay 351060 4 XK50-53 Relay Socket 358280 4 . .Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 ■ XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 ■ A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 4 ■ ■ low ■ Form No.755A . 6-10 ■ Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) ■ SCHEMATIC AVTRON QTY/ REFERENCE DESCRIPTION P/N UNIT ■ OPTION #18 - Installation of Load Shedder D26697-19 K50-52 Relay 351060 3 ■ XK50-52 Relay Socket 358280 3 Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 ■ XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 ■ A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 ■ Retainer, Relay 467550 3 ■ OPTION #18 - Installation of Load Shedder 26697-20 ■ K50-53 Relay 351060 4 XK50-53 Relay Socket 358280 4 ■ .Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 ■ A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 4 ■ OPTION #18 - Installation of Load Shedder 26697-21 K50-52 Relay 351060 3 XK50-52 Relay Socket 358280 3 .Modification, Control Panel D33621 1 ■ DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 ■ S30 . .Switch, Toggle 360747 1 A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 Retainer, Relay 467550 3 ■ ■ OPTION #18 - Installation of Load Shedder 26697-22 K50-52 Relay 351060 3 . XK50-52 Relay Socket 358280 3 .Modification, Control Panel D33621 1 ■ DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 ■ S30 . .Switch, Toggle 360747 1 A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 ■ Retainer, Relay 467550 3 ■ ■ y ■ ■ Fonn No.755A ■ 6-11 Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) ■ SCHEMATIC AVTRON QTY/ ■ REFERENCE DESCRIPTION P/N UNIT OPTION #18 - Installation of Load Shedder D26697-23 ■ K50-52 Relay 351060 3 XK50-52 Relay Socket 358280 3 ■ .Modification, Control Panel D33621 1 DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 ■ S30 . .Switch, Toggle 360747 1 A101 PC Board, Load Shed A22829 1 . XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 3 ■ ■ OPTION #18 - Installation of Load Shedder D26697-24 K50-53 Relay 351060 4 ■ XK50-53 Relay Socket 358280 4 .Modification, Control Panel D33621 1 ■ DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 A101 PC Board, Load Shed A22829 1 ■ XK22 Auxiliary Contact 312401 1 .Retainer, Relay 467550 4 ■ OPTION #18 - Installation of Load Shedder D26697-25 K50-52 Relay 351060 3 XK50-52 Relay Socket 358280 3 .Modification, Control Panel D33621 1 ■ DS30 . .Indicator (Amber) 329138 1 XDS30 . .Lamp 333011 1 S30 . .Switch, Toggle 360747 1 . A101 PC Board, Load Shed A22829 1 XK22 Auxiliary Contact 312401 1 . .Retainer, Relay 467550 3 ■ OPTION #21- Installation of 230 Volt, A23468 ■ 2HP Blower Operation, Option 21 .Relay, Overload* 350980* - ■ F2-4 Fuse, 10 Amp, 600V 324282 OPTION #22- Installation of Option 22 into A25142 . K675A Load Bank 230 Volt Blower (5 HP) Operation F2-4 Fuse, 20 Amp, 600V 324283 3 . K22 Relay 351611 1 ■ Forth No.755A . 6-12 Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) . SCHEMATIC AVTRON QTY/ REFERENCE DESCRIPTION P/N UNIT ■ PTION #23- Control Transformer A25151 and a 208-230 Volt 1 Phase Blower ■ T1 Transformer, 1000 VA 371077 1 T2 Transformer, 3000 VA 371184 1 XF5 Fuseblock 324618 1 ■ F5 Fuse, 12 Amp, 600V 324500 1 K101 Relay, Volt Sense 350740 1 ■ T40 Transformer, Control, 50 VA 370528 1 F440 Fuse, 0.5 Amp, 250V 324005 1 . XF440 Fuseblock 324964 1 S100 Switch, Pushbutton, Black 360017 1 ■ S101 Switch, Pushbutton, Red 360019 1 K100, K240 Relay B14795 2 K480 Relay B16148 1 ■ CB1 Circuit Breaker, 16 Amp 310336 1 S102 Switch 360785 1 ■ TB3, TB13 Terminal Board 364054 2 K22, 23 Relay 351925 2 ■ B1 Blower Motor 208-230V (2 HP) 341460 1 K21 Relay, Overload* 350980* 1 F2, 3 Fuse, 20 Amp, 600V 324283 2 ■ • PTION #27 - Remote, Full Load Application A25799 K90 Relay 350676 PTION #28 - 480V Blower Installation in a 575V Unit A26015 ■ B2 . .Motor B16220 1 F2-4 . .Fuse, 6 Amp, 600V 324290 3 ■ PTION #30 - Installation of Current Transformers A26446-2 ■ CT1,2 Current Transformer, 600:5 370932 2 ■ PTION #31 - Remote Signaling Contacts A26469 ■ K101-103 Relay, 2 PDT 350539 3 ■ ■ PTION #32 - 2 HP Dual Voltage Blower C25002 S13 .Switch, Toggle 360747 1 S14 Switch, Rotary 620288 1 ■ Knob 453602 1 K22, 23 Relay B17839 2 ■ K24-26, 50, 51 Relay B14795 5 K30 Relay* 350991* 1 ■ F2-4, 8-10 Fuse, 10A, 600V 324282 6 XF8-10 Fuseblock 324997 1 Bracket, Relay Mounting* 408369* 1 ■ *If relay fails, replace relay and relay mounting bracket. ■ Form No.755A 6-13 Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) ■ SCHEMATIC AVTRON I QTY/ ■ REFERENCE DESCRIPTION P/N UNIT OPTION #33 - Installation of 575V A27143-1 ■ Blower in a 480V Unit B2 Motor, AC (2 HP) 341280 1 ■ F2-4 Fuse, 3 Amp, 600V 324733 3 ■ OPTION #33 - Installation of 575V A27143-2 ■ Blower in a 480V Unit B3 Motor (5 HP) 341093 1 ■ ■ OPTION 34 - 1, 2, 2 kW Fine Step Kit, 600V D25060-6 F71-73 Fuse, 2A, 600V 325048 3 . F74-79 Fuse, 3A, 600V 324478 6 XF71-79 Fuseholder 324977 3 ■ K73-75 Relay B14795 3 S26-28 Switch Toggle 360589 3 ■ R12-26 Resistor A22096 15 ■ OPTION 35 - Installation of 480V A28777 ■ Blower 75 HP) in a 575V Unit B3 Motor, AC (5 HP) 341064 1 K21 Relay, Overload 350980 1 OPTION 36 - Installation of Reverse Power Relay (480V) A33454 . K100 Relay, Reverse Power 350680 1 K101, 102 Relay, 3PDT 351060 2 ■ XK101, 102 Socket, Relay 358280 2 XK101, 102 Hold Down Spring 467550 2 . F103-105 Fuse, 1 Amp, 600V 324815 3 XF103-105 Fuseholder 324998 1 . OPTION 37 - Installation of Reverse Power Relay (208V) A33455 ■ K100 Relay, Reverse Power 350177 1 ■ 101, 102 Relay, 3PDT 351060 2 XK101, 102 Socket, Relay 358280 2 ■ XK101, 102 Hold Down Spring 467550 2 F103-105 Fuse, 1 Amp, 600V 324815 3 XF103-105 Fuseholder 324998 1 . OPTION 39 - Digital Metering D41094-1 . F100-F102 FUSE, 1 AMP 324449 3 XF100-XF102 FUSEHOLDER 324998 1 ■ CT1,CT2 TRANSFORMER, CURRENT 370932 2 Form No.755A ■ 6-14 ■ Avtron Model K675A Outdoor Resistive Load Bank ■ Options (Load Banks S/Ns 1710 and Above) ■ SCHEMATIC AVTRON QTY/ REFERENCE DESCRIPTION P/N UNIT OPTION 39 - Digital Metering D41094-2 ■ F100-F102 FUSE, 1 AMP 324449 3 XF100-XF102 FUSEHOLDER 324998 1 CT1,CT2 TRANSFORMER, CURRENT 370937 2 ■ OPTION 39 - Digital Metering D41094-3 ■ F100-F102 FUSE, 1 AMP 324449 3 XF100-XF102 FUSEHOLDER 324998 1 ■ CT1,CT2 TRANSFORMER, CURRENT 371334 2 ■ OPTION 39 - Digital Metering D41094-4 . F100-F102 FUSE, 1 AMP 324449 3 XF100-XF102 FUSEHOLDER 324998 1 ■ CT1,CT2 TRANSFORMER, CURRENT 370908 2 ■ OPTION 39 - Digital Metering D41094-5 . F100-F102 FUSE, 1 AMP 324449 3 XF100-XF102 FUSEHOLDER 324998 1 CT1,CT2 TRANSFORMER, CURRENT 371188 2 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Fonn No.755A ■ 6-15 ■ ■ Replacement Parts List Avtron Resistive Load Bank • Part Number K675AD46622 ■ ■ SECTION VII ■ REPLACEMENT PARTS LIST ■ ■ ■ ■ INTRODUCTION ■ The parts list in this section contains the description,quantity required,and Avtron part numbers for . each listed part. The list also includes schematic reference designators to aid in schematic location. ■ NOTE ■ ■ Every effort has been made to ensure the accuracy of this information. However,changes are sometimes necessary and revisions to the parts list may be made at any time without notice. ■ REFERENCE DESIGNATORS ■ Service personnel may use this parts list along with the Avtron system schematics to identify and order replaceable parts. The reference designators were carefully selected and matched to those on ■ the schematic diagrams and equipment to simplify the troubleshooting and repair process. ■ NOTE ■ When ordering replacement parts, be certain to state the part's ■ description, Avtron = number, and the schematic reference ■ designator number if one is available. Also include the model and serial number of the equipment. ■ ■ ■ y ■ ■ 7_1 ■ Replacement Parts List Avtron Resistive Load Bank Part Number K675AD46622 ■ REPLACEMENT PARTS LIST SCHEMATIC AVTRON TQTY/ ■ REFERENCE DESCRIPTION P/N UNIT ■ AVTRON MODEL K675A OUTDOOR LOAD BANK K675A- ■ D46622 ■ .SCHEMATIC/INTERCONNECTION DIAG D46623 REF .CONTROL PANEL D46624 1 ■ . .SCHEMATIC D46623 REF F1 . .FUSE, 5 A, 600 V 324475 1 XF1 . .FUSEHOLDER 324985 1 ■ DS20 . .LIGHT, INDICATOR (GREEN) 329049 1 DS21 . .LIGHT, INDICATOR (RED) 329048 1 ■ K99 . .RELAY 350539 1 S4,S6,S8,S20, . .SWITCH, TOGGLE 360589 5 ■ S21 DS22 . .LIGHT, INDICATOR (AMBER) 329065 1 ■ S23 . .SWITCH, PUSHBUTTON (RED) 361873 1 S22 . .SWITCH, PUSHBUTTON (BLACK) 361874 1 K8 RELAY, 120 AMP 351885 1 ■ K6 RELAY, 62 AMP B14796 1 K4 RELAY, 35 AMP B14795 1 . K22 RELAY (STARTER) 351687 1 A RESISTANCE ELEMENT 606508 6 B RESISTANCE ELEMENT 606319 18 .TUBE, INSULATOR 411182 96 .TUBE, INSULATOR 411181 48 .TUBE, INSULATOR 411141 360 .TUBE, INSULATOR 411145 24 . S60 SWITCH, TEMP 360379 1 S62 TEMPERATURE, SWITCH 363099 1 ■ HR1 RESISTOR, 10OW , 15M 352026 1 K21 RELAY, OVERLOAD 350991 1 . B2 MOTOR, AC B16220 1 S61 SWITCH, SENSING 360772 1 .IMPELLER, FAN 406023 1 ■ F2-4 FUSE, 6 AMP 324290 3 XF2-4 FUSEHOLDER 324997 1 ■ F20-22 ..FUSE, 40 AMP 324419 3 F23-25 FUSE, 80 AMP 324420 3 F26-28 FUSE, 150 AMP 324463 3 ■ XF20-22 FUSEBLOCK (31-60 AMP) 324660 1 ■ Form No.755 ■ 7-2 ■ ■ APPENDIX ■ LOAD BANK TROUBLESHOOTING GUIDE ■ ■ NOTE Servicing should always be done only by ■ trained, qualified service technicians. ■ WARNING ■ Be sure that all sources of power to the Load ■ Bank are disconnected before servicing. **ie�c�F�ck�Y�E4e�EE�tF�E4cdc*�Fk�Y�k*�* Y** F�FF�F�k�F�k* t�t�E�E�E�c4e�e*�F�tk�ct�;*�:�e9ck ■ ■ ■ PROBLEM POSSIBLE CAUSES/REMEDIES ■ 1. Load Bank main a. Main switch or circuit breaker is not closed. power fails to come on. b. Unit is not connected according to the Schematic/Interconnection Diagram. C. Terminals were damaged during shipment. ■ d. Fuses are blown. (Check and replace as required. )* ■ e. Fuse is blown in Load Bank control. circuit. . (Check and replace as required. )* f. Dirty or loose connection at Main Power ■ Switch. ■ 2. Blower motor does a. Main switch or circuit breaker is not closed. not operate. . b. Power is not connected to Load Bank blower circuit. ■ C. External power source is inadequate. ■ d. Motor fuses are blown. (Check and replace as required. )* ■ ■ * When checking fuses for continuity, be sure to remove all fuses from clips (in fuseblock or Disconnect Switch) . Test each fuse ■ individually, out of circuit. (If tested in circuit, there is the possibility of feedback which causes false readings. A blown fuse may still check out OK. ) y ■ ■ 1T/kv 4/12/88,Rev.3/7/00 A-1 ■ Load Bank APPENDIX Troubleshooting Guide ■ ■ PROBLEM POSSIBLE CAUSES/REMEDIES 2. Blower motor does e. Motor overload is tripped. ■ not operate. ■ (Cont. ) f. Motor start is malfunctioning. g. Main Power Switch is inoperative. ■ h. Connections are broken or loose. ■ i. Motor shaft does not turn due to improper ■ lubrication. (Replace or repair as necessary. ) 3. BLOWER FAILURE a. Airflow restrictions present at Load Bank ■ indicator lights, intake or exhaust. yet blower is operating. b. Improper fan blade rotation or phase ■ reversal. (Check fan motor power connections for proper phase sequence. ) ■ C. Air Differential Pressure Switch is ■ malfunctioning. d. Blower Fail Relay is malfunctioning. ■ 4. Fan blade is broken a. Fan blade motion is obstructed. or not turning. b. Fan blade is loose at hub or is not keyed properly. 5. Load step(s) cannot a. A blower failure exists. (See problem 2. ) ■ be energized. . b. MASTER LOAD Switch is inoperative. C. Control power is inadequate. d. Fuse is blown in Load Bank control circuit or . individual branch circuit load fuse (if so equipped) is blown. (Check and replace as ■ required. )* e. Blower Fail Relay is malfunctioning. ■ f. Load step switch is inoperative. ■ g. Load step contactor is inoperative. ■ h. Magnetic contactor has an open coil. ■ i. Load step resistor is open. * When checking fuses for continuity, be sure to remove all fuses from ■ clips (in fuseblock or Disconnect Switch) . Test each fuse individually, out of circuit. (If tested in circuit, there is the possibility of feedback which causes false readings. A blown fuse may still check out OK. ) MP/kV 4/12/88,Rev.3/7/00 A—Z ■ Load Bank ■ APPENDIX Troubleshooting Guide ■ PROBLEM POSSIBLE CAUSES/REMEDIES ■ 6. Contactor a. Contacts and/or core are dirty or corroded. ■ "chattering" exists. b. Connections to contactor coil are loose. C. Control circuit line voltage is too low. ■ 7. Load Bank or load a. Applied load voltage is either derated or ■ step does not give inadequate. rated load. ■ b. Contactor does not close properly. C. Load step resistor element is open. ■ d. One of the individual load branch circuit ■ fuses is blown (if so equipped) . ■ 8. Disconnect Switch a. Fuses are undersized.* fuses are blown. ■ b. A short circuit exists in the blower or control circuit.* ■ * When checking fuses for continuity, be sure to remove all fuses from clips (in fuseblock or Disconnect Switch) . Test each fuse individually, out of circuit. (If tested in circuit, there is the possibility of feedback which causes false readings. A blown fuse may still check out OK. ) ■ ■ ■ ■ ■ ■ ■ ■ MP/kv 4/12/88,Rev.3/7/00 A-3 ■ ■ ■ ■ ■ ' DRAWINGS ■ ■ ■ ■ PROPRIETARYNOTE ■ ■ ■ ■ ■ This document contains information PROPRIETARY TO vtron Loadbank, Inc. It is furnished solely to provide information sufficient for instruction, operation, maintenance, evaluation, and testing of the equipment herein ' disclosed; is not to be used for manufacturing or ' procurement; and is not to be disclosed to anyone other than ' persons in the Division, or the Company, or the Government, ' as the case may be, responsible for action relatin ■ p g to this ■ document without the express written permission of Avtron ■ Loadbank, Inc. ■ ■ Form 831A-LB Rev.02-12 Lr Av-rRON ■ 6255 Haile Drive : Cleveland, OH 44125-4615 2163 573.7660 �a f. 216,573.5953 vvww,evtronioadbaok,com ■ ■ ■41 mom NON NON ■ ■ IV NON NON NON ■ ■ ■ ■ CUSTOMER CONNECTION TERMINAL B S 4.25[108] MAX OPTIONAL DIGITAL METERING .125 [3] R TYP SEE NOTE 3 4 PLACES -11 PQ O—O --------Z-1 8.75 [222] —_------- -S 5.75 ® o [146] CF 0— ———_ O U O (E) a 1.50[38] ® TYP 0.38[9.5] TYP 18.25[464] 19.00[483] —I FOR APPLICATION ENGINEERING USAGE ONLY 3.FRONT PANEL COMPONENT LAYOUT WILL THIS DOCUMENT CONTAINS DRAWN Fuckelmonn 12 15 O6 * DRAWING NUMBER PROPRIETARY INFORMATION OF �V T R O N ."FAC➢RI WG VARY DEPENDING UPON OPTIONS. AVTRON MI INC.AND MAY CHECKED J.FLAUTO 12 16 O6 — rom000la oN S63808 2.WEIGHT: DIMENSIONS ARE APPROX. IN INCHES & [MM] NOT BE DISCLOSED TO OTHERS 0096 B A9QIF-SAA/R01 RAYNERI2 02 09J.HUOSON xxE 1.I IGHT: OR USED FOR MANUFACTURING E799 A 4.2 106 WAS 5.2 133 RAYNER 4 16 07 J.HUDSON APPROVED J.HUDSON 3 8 PURPOSES WITHOUT THE WRITTEN ECN REv CONTROL PANEL NOTES. CONSENT OF AVTRON MFG. NO. LET. CHANGE CHO CHK'D MODEL K675A OEJTLJNE DRAWING ■ ■ ■ ■ ■ ■ MEN ■ ■ NON IV NON NON NON ■ ■ IV ■ ■ LOUVERED PANEL REMOVABLE ACCESS PANEL 58.00 [1473] 46.50 [1181]- THIS END r--1 I I I I 36.00 [914] ' ' MIN AIR OUT 42.00 SCREENED ° i i AIR IN I I ' [1066] i i ° SCREENED I I 51.00 �_� (1320] L-� ° ALLOW 36 IN MIN CLEARANCE INPUT BUS FOR MAINTENANCE I � ° Li CONNECTIONS FAN POWER CONNECTIONS 36.00 [914] 64.00[1625] CONTROL POWER CONNECTIONS } INTAKE END VIEW EXHAUST END VIEW 13.00 22.00 GROUND STUD CONDUIT J ENTRY SIDE 9 DIA - 4 HOLES [330] 7.00 [558] 2.25 (SEE BOTTOM VIEW) 7501 [ ] [177] [57] i-2.00[50] 6.00 [152] CONDUIT ENTRY AREA 42.00 PRIMARY CONDUIT ENTRY AREA [1066] FOR STRAIGHT THROUGH LOAD WIRING CONDUIT ENTRY AREA OPTIONAL CONDUIT ENTRY AREA CONSULT AVTRON TO REVIEW INSTALLATION 3.AS A GENERAL GUIDE, THE MINIMUM CLEARANCE 2.253-REQUIRED FROM ANY OBSTRUCTION IS: [57] [3$ 27.00 [685] 3 FEET �,9813METERS)]ONNSIDESINLET BOTTOM VIEW F 0 R APPLICATION ENGINEERING USAGE ONLY 8 FEET [2.44 METERS] ON EXHAUST REVIEW MANUAL FOR DETAILED INSTALLATION AND THIS DOCUMENT CONTAINS DRAMI Fackelmpnn 1 25 07 * DRAWING NUMBER 1E SITE CONDITIONS. °R0PTARY INFORMATION OF V T R O N a MAIA►AcmK AIC S B 3 8 2 3 :D AVIRON MFa,INC.AND MAY cHEa O J.FLAUTO 1 30 07 NDEREEU1FNfLF, 2. ALL DIMENSIONS ARE APPROX. STANDARD & [METRIC] NOT BE DISCU -Onaxs MAU OR USED FOR MANUFACTURING 1. WEIGHT: 1100 LBS, [499 KG] APPROX PURPOSES WATIOUT THE MRITTEN ECN APPROVED J.HUDSON 1 16 A N SHEET 1 OF 1 m NOTES: CONSENT OF AvoN MFa NO LET CHANGE �'n Cw'D MODEL K675A OUTDOOR WTUNE DRAW NC ME oil NONE ME M M NON IV 0 MEN NON NOE 0 IV 0 0 0 0 O 12.00 14.50 13.250 [305] [369] [337] L-i Li 18.000 [457.2] L24.00 [610] 7.34 [187] 6.00 REF [1521 FOR APPLICATION ENGINEERING USAGE ONLY THIS DOCUMENT CONTAINS JIM A JADD METRIC DIMENSIONS RRAYV D.KOZAR DRAm BW 2 4 86 * DRAWING NUMBER PROPRIETARY INFORMATION OF CDNVERTED CAD FILE �V T R O N NNEIACIMNf NC AMON MFG..INC.AND MAY -- 2. ALL DIMENSIONS ARE APPROX. IN INCHES [mm]. NOT BE DISCL TO OTHERS &STANDARDIZED °1E� �oEPvuoNCE ON SB1635 1. WEIGHT: OR USED FOR TO WITHOUT CHANGE MARTIN PAlW ��S 2/4/ B6 961L 1 4 ENCLOSURE, PURPOSES WITHOUT THE WRITTEN NOTES: CONSENT OF AM+pN MFG. NO E. � CHANGE DCD CHIN WALL MOUNT OUTIJNE DRAWING ■ . . . . . . . . VON ME No ■ ■ ■ ■ . REVISIONS REVISIONS REVISIONS CN NO REV DESCRIPTION DATE APPROVED ECN N0. REV DESCRIPTION DATE APPROVED ECN NO. REV DESCRIPTION DATE APPROVED Cf873 AA SEE SHEET 2 REVISE-6,NOTE i R.RAYNER 10 28 09 J.HUDSON AF993 K ITEM 5 ON OPTION4 WAS 517543 CORBETT 3 11 99 PALINKAS Z9970 A IADDED C22339-5 TURNMIRE 8 18 94 D.SOHRER 1A0315 AB REV SHT 2 PER ECN fACKELMANN 1 6 30 12 1 J.HUDSON AG548 L REVISED SHEET 2 CORBETT 11 12 99 PA INKA AA175 8 REVISED PER ECN J CORBETT 10 13 94 D.BOHRER 1A0543 AC REV SHT 2 PER ECN R.RAYNER 1 31 11 D.KOZAR CC165 M REVISED PER ECN ZMECEK 5 17 00 EMERY AA3 8 C REVISEDSHEET 1&2 PER ECN J CORBETT 11 30 94 D.BOHRER CC17O N ITEM 2 OF C22339-1 WAS 324744 DZHULAY 5 19 00 HUDSON AA623 D REVISED PER ENC CILLISSIE 3 1 95 D.BOHRER CC388 P REV PER ECN SEE SHT 2 FACKELMANN 12 00 K.KUK A8094 E REVISED SHEET 2,ITEM 7 GOUAS 10/23/95 D.BOHRER CC754 R REV SEE SHT 2 PER ECN FACKELMANN 1 24 O1 MITCHELL AD074 F REVISED SHT 2 DEMIN 7/18/96 D.BOHRER CC758 T ADDEO ITEMS 6&7 TO-1 FACKELMANN 8 20 01 HUDSON CA171 G REVISED PER ECN CILLISSIE 4 28 96 D.BOHRER THRU-5,REVISED PICTORIAL PER ECN, / / SEE SHT 2 CA238 H AT-5 ITEM 2 WAS 324453 FACKELMANN 6 3 97 J.HUDSON CD576 U REVISED PER ECN ZMECEK 12 18 03 KOZAR CA276 J REVISED C22339-6 pLUSSIE 6 27 97 J.HUDSON C0870 V REVISED PICTORIAL OF K101 FACKELMANN 12 6 04 J.HUDSON SEE SHT 2 LINE DRILL WHEN NEEDED AND MOUNT CD926 W ADDED'LINE DRILL WHEN NEEDED AND'TO J.FLAUTO P.PIAllA ITEM 1 BUBBLE.SEE SH 2. 2-1-05 WITH #3/8-16 OR 10-32 OR 1/4-20 5 CE565 Y REV PER ECN FACKELMANN 9 23 O6 J.HUDSGN RIVNUT AND SST HARDWARE 1 7LINE SEE NOTE 2 & 3 26 OR & MOUNT OOOFS AS REQUIRED SEE NOTE 2 & 3 27 OR 7 35-1 I I 4 3 2 0 ZD 19 17 6 e Y pOp Y O Y MOUNT WITH #8 TFS AS SHOWN ON TOP LEVEL ASSEMBLY O C22339-6 ONLYLY (ITEMS 6,17,1 10 9 8 C22339-6 ONLY LINE DRILL AND MOUNT WITH #B TFS OPTION #13 OPTION #7 OPTION #6 OPTION #5 OPTION #4 380 VOLT 600 VOLT 480 VOLT 240 VOLT 208 VOLT 425002 4fl. 425002 4ft. 425002 4ft. 425002 4ft. 425002 4ft. 7 CONDUIT, 0.5 431252 2 431252 2 431252 2 431252 2 431252 2 6 f f ELBOW, CONDUIT, 0.5 517542 4 517543 4 517543 4 517543 4 517535 4 5 RIVNUT F5 324500 1 F5 324500 1 1 F5 324500 1 F5 324500 1 F5 324500 1 1 4 FUSE XF5—XF7 324615 1 XF5—XF7 324615 1 XF5—XF7 324615 1 XF5—XF7 324615 1 XF5—XF7 324615 1 3 FUSEBLOCK F6,F7 324454 2 F6,F7 324453 2 F6,F7 324475 2 F6,1`7 324709 2 F6,F7 324159 2 2 FUSE T1 1 371075 1 T1 371071 1 T1 371077 1 T1 371077 1 T1 371072 1 1 -1�— TRANSFORMER DESIG PART NO. NO' E�;2339-4 RT N0. NO. DESIG PART N0. NO DESIG PART NO N0. DESIG PART NO. NO. ITEM NO. PART NO. DESCRIPTION MATERIAL READ REOD REDD REOD REOD NO. REOO C22339-5 C22339-3 I C22339-2 C22339-1 LIST Of MATERIAL UNLESS OTHERWISE SPECIFIED DRAWN DATE THIS DOCUMENT CONTAINS DIMENSIONS ARE IN INCHES ZMECEK 5 6 94 7M E PEEASMIT VAEEEV ROAD PROPRIETARY INFORMATION TOLERANCES ANGLES}t' CHECKED VTRON uANUTActURIUD INC NDEPENpEKK.F,p1 A1tst-5519 OF AVTRON MFG.,INC. AND DECIMALS.XXi .XXX4 OPTIONS ❑ MAY NOT BE DISCLOSED TO FINISH ENG'D.BOHRER 5 9 94 PAINT PER PS Pff OTHERS OR USED FOR APw PRoo CONTROL TRANSFORMER MANUFACTURING PURPOSES K675A PLATE PER .WE 5 9 94 SZE CAGE N0. OMG.N0. REV SEC SKEET 2 FOR NOTES WITHOUT THE WRITTEN NEXT ASSY USED ON COAT PER PS C 01014 C22339-1 THRU —6 AC CONSENT OF AVTRON MFG. ANODIZED PER WINLESS OTHERWISE SPECIFIED THE ABOVE NOTES APPLY APPLICATION OTHER I-LENONEIMODEL K675A ISHEET. 1 OF 2 ■ ■ ■ ■ ■ ■ MEMO ■ ■ ■ ■ ■ ENO ON ■ ■ ■ ■ ■ ■ ■ ■ REVISIONS REVISIONS ECN NO REV DESCRIPTION I DATE JAPPROVED ECN NO, REV DESCRIPTION DATE APPROVED CF873 I AA ON-6 ITEM 19 WAS 164054,ITEM 260 .450098, AA175 B ADDED SHEET 2 J CORBETT 10 13 94 D BOHRE ITEM 23 WAS 365068,ITEM 24 WAS 364012, AA378 C ADDED ITEM 21 J CORBETT 11 30 94 D BOHRE ITEM 25 WAS 450087,REVISED NOTE 1. R.RAYNER 10 28 D9 J.HUDSON 0 4 I M 7 WA$351906 IA It 4 OHRE AD074 F ITEM 7 WAS 350517 M.DEMIM 7 18 96 D BOHRE CA276 G REVISED PER ECN GILLI$SIE 6 27 97 HUDSON AC548 L ITEMS 19&20 WAS23,REDD CORBETT 11 12 99 ALINKAS CC388 P ADDED ITEM 22 FACKELMANN 12 7 00 K.KUK CC754 R ITEM 12 WAS 360017,ITEM 13 FACKELMANN 7/24/01 MITCHELL WAS 360019 CC758 T IADDED ITEMS 26.27 @ NOTE 2 FACKELMANN 8 20 01 HUDSON CD576 U ADDED NOTE 3 ZMECEK 12 18 03 KOZAR 5870 V ITEM 5 WAS A17451-1,ITEM 6 FACKELMANN 12/6/04 J.HUDSON WAS 364433,ITEM 7 WAS 350740,ITEM 11 WAS 358215,ITEM 16 WAS 467522,ITEM 22 WAS A27158 CD926 W ON C26339-6,ITEM 26 WAS PN 431252, J.FLAUTO P.PIAllA ITEM 27 WAS PN 425002. 2-1-05 OPTION #14 240/480 VOLT 425003 4ft 27 CONDUIT, 0.75 431253 2 26 ELBOW, CONDUIT, 0.75 25 24 23 22 517543 4 21 RIVNUT, 3 8-16 XTB3,XTB13,XT020 364295 6 20 f MARKER-STRIP - TB3,TB13,TB20 364289 18 19 +— + TERMINAL BLOCK SEE NOTE 1 S102 360785 1 18 f SWITCH SEE NOTE 1 C81 310336 1 17 CICUIT BREAKER 16 K480 B16148 1 15 f RELAY CONDUIT ELBOWS ARE SHOWN AS TYPICAL. ACTUAL TRANSFORMER K100,K240 B14795 2 14 f + RELAY MAY HAVE KNOCKOUTS LOCATED ON SAME SIDE OR OPPOSITE S101 360308 1 13 SWITCH, PB RED SEE NOTE 1 SIDES. USE KNOCKOUTS WHEREVER PROVIDED ON TRANSFORMER S100 360309 1 12 SWITCH, PB BLACK SEE NOTE 1 AND USE DRAWINGS AS A REFERENCE. 11 2- INSTALL ITEMS 6 OR 26 ONTO CONTROL TRANSFORMER AS REQUIRED XF440 324964 1 10 — FUSEBLOCK LINE DRILL AS NEEDED. ROUTE CONDUIT FROM MOTOR TO TRANSFORMER, F440 324005 1 9 f FUSE, 5A, 250V THEN FROM TRANSFORMER TO BEHIND RELAY PANEL. WIRE COMPONENTS T40 370528 1 8 — ► TRANSFORMER ACCORDINGLY, PASS THE BLOWER WIRING THROUGH THE CONTROL K101 350583 1 7 RELAY, VOLT SENSE TRANSFORMER. 364291 2 6 END BRACKET 1- TOR OPTION #14, 408189 8in 5 MOUNTING RAIL A) ON CONTROL PANEL, REMOVE THREE HOLE PLUGS TO THE RIGHT OF F5 324500 1 4 FUSE "POWER ON" SWITCH AND INSTALL ITEM 12 IN TOP LEFT , ITEM 13 XF5 324618 1 3 FUSEBLOCI IN BOTTOM LEFT AND ITEM18 IN RIGHT. REMOVE EXISTING "POWER ON" 2 SWITCH AND REPLACE WITH A #16 AWG JUMPER (PN 390008). T1 371077 1 1 1 ITRANSFORMER B) ON CONTROL PANEL INSTALL TERMINAL BLOCKS, QTY 6 OF ITEM 19 DESIG PART NO. REQD INO. REOD PART N0. DESCRIPTION MATERIAL ONTO EXISTING DINRAIL. LABEL AS "T83 (1-6") C22339-6 LIST OF MATERIAL C) ON LOAD BANK, INSTALL TERMINAL BLOCKS, QTY 12 OF ITEM 19 ONTO 7900 E.PLEASANT VALLEY ROAD EXISTING DINRAIL AS SHOWN IN PICTORIAL ON TOP LEVEL ASSEMBLY INDEPENDENCE,OH 44131-5529 OPTIONS D) WIRE COMPONENTS PER LOAD BANK SCHEMATIC. VTRON MANUFACTURING INC CONTROL TRANSFORMER THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF SIZE CAGE NO. DWG.NO. REV AVTRON MFG., INC. AND MAY NOT BE DISCLOSED TO OTHERS C 01014 C22339-1 THRU -6 AA UNLESS OTHERWISE SPECIFIED THE ABOVE NOTES APPLY ORITUTEN coFOR MANUFACTURIN MPURPOSES WITHOUT THE ENONE MODEL K675A SHEET 2 OF 2 ■ REVISIv1J5 . TB 1 1 ly, F2 LGi�D BANK �.b 5 1 B 1 f B f B G46n 17.. ��'F I NO RE CRI D DESPTION- - - DATE APPROVED �, A��B ,T1 Ll Tl CF894 A REVISED SHEET 2. JFLAUTO 9/30/09 C.KULBAGD BLOWER INPUT 38 —� —�" 4AS VAC, F3 L2 e, _ 6A 8 5 3 PHASE, 60 HZ, a9 Ar�T6 s' �� ,T2r1 L2� vT2 IB 2 62 4� ' 6p 1 7 ■ 40 �I A Fv B le' L3L T3�' L3 T3 C' 3 6 9 2HP A" 4 6A 2 80V, 3PH, -""—"� (MS) (OL) 60HZ ■ ; PART OF -- __— IA CONTROL F6`I F7 :1 ; TRANSFORMER 5A t� 5A t� WHT :WHT WHT i:WHT �K4 T WHT WHT ■ I OPTION B --- B I ---- --+-- ' C22339-3 i i I i ' r --'----------�� ( K6 (KS T1 H4¢I H3¢' H2�-"Ht� i I ��T TO SHT 3 A101[P1(11)] B IF 114 480:120V =______________ , , K22 ' PART OF ,K51; A A A I , , , 1 , , ;14 , LOAD SHED 100E V X1¢ X2 , I PART OF I A I OPTION '13 GI LOAD SHED K50 f ; D41055-K223—(AUX) i Gvi , WHT OPTION �13 T 95 54 I ■ 'A i ��_� HR1 I !---PTO SHT 3 A101[P1(12)] I t14 -----i--J ' PART OF ' FS c I I I , O.T. , x x x , GND , , K50 , K2N.O. 1 3 N LOAD SHED ---- 12At, WHT' , _ N.C. I o 0 o OPTION ■ L- 1 _-—-- J 2 I i 4 12 1 13 S60 D41055- - OS62 i S61 (TS) SEE SHEET 3 K50 , L AS) + i T811 `1 2 CND 3 4 6 8 9 0 11 12 7 18 9 ' I I I I I I CONTROL POWER "I ` _ --- SEE NOTE 4- --"""---- I � � I 1 TRANSFER ■ 120 VAC, - T CONTROL 60 HZ. LO ----------------r------------------9 SEE NOTE 5 LOAD DUMP LOAD DUMP I MANUAL _ - - _ AUTO MODE _MODE GND ________________L__________________1__♦ - I I I I , SEE NOTE 4 � ;SEE NOTE 3 1- 1 - TB1 1 2 GND 8 6 7 8 10 1 12 17 18 19 GY J CONTROL I PART OF AUTO ;� BLOWER AIR 1 POWER 'LOAD SHED ON ; POWER FAILURE A DS20 ' OPTION DS30 ' DS22 OS21 K99 F1 WHT I D41055- 0 2 2 2 ■ SA A B A I i B A B A B WHT' WHT WHT WHT S4 S6 SS WHT ■ i , 1 1 1 CONTROL POWER I 1 I BLOWER BLOWER + 1 2 r 2-0�__" """"' STOP STD ■ I ' S30 03----------- - A S23 B C 522 D MASTER 7. 2P DENOTES TWO RESISTANCE ELEMENTS i AUTO/MANUAL_ K99 LOAD ■ IN PARALLEL. 3 4 -_— —� 1 2 6. FUSE REPLACMENT CHART: S20 ,--I --T_-- 2 � 25KW 50KW 100KW CONTROL ; �-PTO SHT 3 M1(L+) PART OF _J F2-4 - 600V, DUAL ELEMENT TIME DELAY, CLASS J, 300 KAIR , __ METER OPTION ; LOAD STEPS F1,5-7,100-102 - 600V, TIME DELAY, CLASS CC, 200 KAIR -------- SHT 3 M1(N-) _D41094_-� LOAD ALL LOAD STEP FUSES ON SHEETS 2 & 4 ARE 600V, FAST ACTING, CLASS T, 200 KAIR. CONTROL PANEL D46624 5. FOR REMOTE LOAD DUMP IN AUTO MODE, ADD N/C CONTACT IN SERIES WITH TRANSFER CONTROL CONTACT. 4. REMOVE JUMPER AT TB1(5-7) AND TB11(8-9) FOR AUTO OPERATION WHEN INSTALLING LOAD SHED OPTION. 3. FOR REMOTE LOAD DUMP INSTALL N/C CONTACT. OTHERWISE INSTALL INTERCONNECTION WIRE. 2. ———DASH LINES REPRESENT CUSTOMER WIRING. SOLID LINES REPRESENT AVTRON WIRING. 1. WIRE CODE: ALL WIRE TO BE BLACK UNLESS OTHERWISE SPECIFIED. ALL UNMARKED WIRE TO BE #16 AWG (PN 390008) UNLESS OTHERWISE SPECIFIED DRAMN DATE DIMENSIONS ARE IN INCHES R.RAYNER 7 30 09 790E ENDE CE, VALLEY ROAD ■ 1 Q 0 3 �3 �6� / / INDEPENDENCE,OH 44 7 31-5529 Q - DENOTES WIRE TO BE #8 AWG (PN 390019) I I I TOLERANCES: ANCLES31' CHECKED v7RON Q - DENOTES WIRE TO BE #6 AWG (PN 390020) DESIGNATION CODE 2 8 all l5 DECIMALS xx: .03 .Xxx±.015 J.FLAUTO 7 30 09 Q # ( ) AS - DENOTES AIRFLOW SWITCH (S61) I I I I THIS DOCUMENT CONTAINS FINISH ENc APw SCHEMATIC/INTCON IMF s - DENOTES WIRE TO BE 2 AWG PN 390022 PROPRIETARY INFORMATION ML - DENOTES MASTER LOAD (S21) 2 U 0 4 1 8 0 4 PAINT PER P$ C.KULBAGO 7 30 09 I I I I OF AVTRON AND PSF 0 - DENOTES WIRE TO BE BLACK #14 AWG (PN 390011) MS - DENOTES MOTOR STARTER (K22) APw PRO) DIAGRAM ❑ SWITCH CONFIGURATION SWITCH CONFIGURATION MAY NOT BE DISCLOSED TO PLATE PER OL - DENOTES OVERLOAD RELAY K21 oTHERs oR useo FOR K675AD46622 K675AD46622 D.JANICKI 7 31 09 G7 - DENOTES WIRE TO BE GREEN YELLOW TWIN COLOR ( ) REAR VIEW OF SWITCH REAR VIEW OF SWITCH MANUFACTURING PURPOSES SIZE CAGE NO. DWG.NO. REV / ( ) TS - DENOTES OVERTEMP SWITCH S60 --—-- --—-- COAT PER PS #14 AWG (PN 390011) ( ) WITHOUT THE WRITTEN NEXT ASSY USED ON ANODIZED PER D m1014 D46623 A SWITCHES 54,6,8,20,21 SWITCH Sib CONSENT OF AVTRON. UNLESS OTHERWISE SPECIFIED THE ABOVE NOTES APPLY APPLICATION OTHER scaE 1 1 MODEL K675A sHeeT 1 OF 3 SIMILAR TO D46440 i c.N llo a[.I _ _-LESCRIPTIDN -- -- LATE APPROVED CF8941 A IPEq PEP ECN JFLAUTG 10/1/09 C.KULBA60 ■ ■ ■ ■ ■ LOAD INPUT I75KW 480 V, 3 PH, r-_----------I 0 H A 21 A0.5 AMP � USE COPPER O 0 CONDUCTORS ONLY SEE SHEET 3 a 3 3 RATED AT 75'C FOR OPTIONAL F20r F22 F23 124 F25 F26 F27 F28 MINIMUM METERING 40A 40A 40A 80A 80A 80A 150A 150A 150A ■ CIRCUITRY , O O O O O 0 s s s -------------� L1 L2 L3 U - L2 L3 L1 L2 L3 K4 '----- ----- K6 K8 ------ ----- ■ O T1 O T2 O T3 O T1 O T2 O T3 Ok2P2P T2 T3 RAIA B4 f4 J4 01 O1 S1 D2 X2RA12P 2P 2P 2P RAIB 25 KW 50 KW 100 KW ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ NOTE: WIRES FROM BUS BARS A,B, & C TO FUSES ARE ALL INDIVIDUAL RUNS BOLD LINES FROM FUSES INDICATE DIRECT CONNECTION TO RESPECTIVE BUS BARS. _�A I,/TRON Yseo L.PIEASANi VALLLY ROID SCHEMATIC/INTCON IMUEND`".E°"'°"-u29 DIAGRAM ■ SEE SHEET 1 FOR NOTES AND WIRE CODE THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION S0. DWG.NO. REY IZE CACE N 3 OF AVTRON AND MAY NOT BE DISCLOSED p 01014 D4662 A UNLESS OTHERWISE SPECIFIED THE ABOVE NOTES APPLY TO OTHERS OR USED FOR MANUFACTURING PURPOSES WITHOUT THE WRITTEN CONSENT OF AVTRON. SCALE 1 1 MODEL K675A SHEET 2 ■ REVISIONS CN NO REV I DESCRIPTION DATE APPROVED ------------ ------------------------- PART OF LOAD SHED OPTION 38 D41055— ■ I A CT10 ----------—B-- GENERATOR ---r --------r-----+------------- MAIN ---- ++-----;------ ------------- LOAD LOAD METER OPTION (D41094-2� i ■ BANK I � SEE NOTE 4 31 32 I A • CT1 400:5 TB11 ■ X1 WNT LOAD INPUT B — TO LOAD STEPS K51 I CT2 400:5 4 12 I C ✓� ------ -- ----- -------- I A X1 WI.iT P1 1 2 4 5 ; I F1GO 1A J1 1 2 4 5 A B F101 ■ � lA B F102A P2 J2 J1 P1i 1A ■ I 1 1 1 Al 01 10 10 i GRN FROM SHT 1 TB11(GND) I I B ■ I 3 3 11 11 �WHT FROM SHT 1 TB11(2) PC BOARD ASSY A22829 I TB11 25 26 27 28 29 30 5 5 LOAD SHED CONTROLLER 12 12 FROM SHT 1 TB11(6) 7 7 I I I I I RED REDS TEMPORARY J.JMPERS, wo -,K CUSTOMER MIST REMOVE g g I WHEN INTERCONNECTING LOAD BANK TO CONTROL PANEL J2 12 1 1416 8 10 I i TB1 25 26 271 128129 30 2 4 6 8 10 P2 ■ I `-------- ---- ----- ..... f-----T TO TO TO TO TO �—SEE CHART BELOW FOR CONNECTION REQUIREMENT --J I I Q 1 a 1 c GND HI , ■ I A101 (P2) I FROM TBt(5) SHT 1 L+ ■ I �'k 2 4 6 B 10 I FROM T81(2) WHT N- P�� WIRE FROM ABOVE POINTS TO LOAD BANK I SHT 1 Vref M� SH ■ I D41055-6 TB11(17)TB11 18) TB11(19) NC NC I Va RS485 B— D41055-11 TB11(18) TB11(19) NC NC NC I Vb A+ ■ I I � Vc Lp ■ ' I la I bl 11c 4. DASHED LINES REPRESENT CUSTOMER WIRING. ■� 3.ADJUST VARIABLE RESISTORS ON PC BOARD A101 (R26,R39,R52,R65 k R78) TO 3 SECONDS, ADJUST (R14) TO 5 SECONDS. 2. ADJUST VARIABLE RESISTORS ON PC BOARD A101 (R21,R34,R47,R60 do R73) PER PROJECT NOTES. 1.ALL WIRING TO BE BLACK #16 AWG (PN 390008) UNLESS OTHERWISE NOTED. �AvTRaN SCHEMATIC/INTCON nm Enr was �° ICL�a"�3c� DIAGRAM . SEE SHEET 1 FOR NOTES AND WIRE CODE THIS DOCUMENT CONT.JNS PROPRIETARY INFORMATION Sa CAG N0 DW6.NO. REV OF AVTRON AND MAY NOT BE DISCLOSED D 01014 D46623 q UNLESS OTHERWISE 'OR THE ABOVE NOTES APPLY TO OTHERS OR USED -OR MANUFACTURING PURPOSES MITHOUT THE WRITTEN CONSENT of AVTRON. SCALE 1 1 1 MODEL K675A s+EET 3 i DESCRIPTION ,7 APPROVED CF894 A ITEM 36 WAS OTY 15.5" ITEM 5 WAS "K4" J.FLAUTG GKUL8AG0 ITEM 7 WAS"K.8" SEE SHEET 3. 9/30/09 ■ ■ ■ 175KW @ 480V 25KW RESOLUTION 50 2 C20562 WARNING SIGN ■ 49 2 C20561 WARNING SIGN 48 47 1 ! 815905 LABEL, INSTRUCTION, WARNING ■ 46 1 815871 LABEL, INSTRUCTION, WARNING 45 1 B15869 LABEL, INSTRUCTION, WARNING ■ 44 2 B15868 LABEL, INSTRUCTION, WARNING 43 1 1 406023 IMPELLER, FAN S61 42 1 360772 SWITCH, SENSING ■ 41 1 A97075 PLATE, IDENT XK21 40 1 408369 BRACKET, PANEL MOUNTING B2 39 1 B16220 MOTOR, AC ■ K21 38 1 350991 RELAY, OVERLOAD 37 2 364291 END BRACKET 36 115in 408189 RAIL, MOUNTING ■ 35 1 D24771 FRAME ASSEMBLY 34 2 C22195 SIDE, COVER 33 ■ 32 1 623495 COVER, ENTRY HR1 31 1 352026 RESISTOR, 100W, 150f1 XTB11 80 2 364298 MARKER STRIP 31-40 S62 30 1 363099 TEMPERATURE, SWITCH XTBIIGND 79 1 450362 MARKER STRIP GND 29 2 D36938 LOUVER ASSEMBLY TBIIGND 78 1 364290 TERMINAL BLOCK (GND) 28 1 D46623 SCHEMATIC INTERCONNECTION DIAG ■ XTB11 77 1 364292 END COVER S60 27 1 360379 SWITCH, TEMP 76 26 96 523205 NUT ASSEMBLED WASHER, 10-32 75 25 24 822519-32 ROD, ELEMENT SUPPORT ■ 74 24 XF20-22 1 73 1 324660 FUSEBLOCK 31-60 AMP 23 1 469004 GROMMET, RUBBER F26-28 72 3 324463 FUSE 150 AMP 22 ■ F23-25 71 3 324420 FUSE 80 AMP 21 1 24 411145 TUBE, INSULATOR F20-22 70 3 324419 FUSE 40 AMP 20 360 411141 TUBE, INSULATOR 69 19 48 411181 TUBE, INSULATOR ■ 68 18 96 411182 TUBE, INSULATOR 67 17 5 602708 BUS, LINK . 66 2 D32574 GUARD WIRE WELDED 16 48 A21179 SUPPORT ROD BUSHING 65 2 431252 ELBOW, CONDUIT, 0.5" 15 6 411508 INSULATOR, STANDOFF 64 4ft 425002 CONDUIT, FLEX, 0.5" 14 4 660205 STUD, CONT THREAD ■ 63 B 13 18 606319 RESISTANCE ELEMENT 62 16 540227 RIVET, DOMEHEAD 12 61 4 440131 HANDLE 11 ■ 60 AR 905403 GASKET, ADHESIVE BACKED A 10 6 606508 RESISTANCE ELEMENT 59 2 823496 PLATE, DESIGNATION 9 10. MOUNT "S60 WITH #8-32 HARDWARE. XF2-4 58 1 324997 FUSEHOLDER K22 8 1 351687 RELAY STARTER 9.MOUNT "S62 WITH #6-32 HARDWARE. F2-4 57 3 324290 FUSE, 6 AMP K4 7 1 B14795 RELAY, 35 AMP ■ 8. APPLY PENEOROX (B ORE A) C EQUIVALENT TO XTB11 56 2 364297 MARKER STRIP 21-30 K6 6 1 814796 RELAY, 62 AMP LUGGED COPPER BEFORE ATTACHING FUSES OR XTB11 55 2 364296 MARKER STRIP 11-20 K8 5 1 351885 RELAY, 120 AMP ■ LUGGED WIRES O BUS. XTB11 54 2 364295 MARKER STRIP 1-10 4 3 C22274 BUS BAR 7. JUMPER WIRE CODE: TB11 53 40 364289 TERMINAL, BLOCK 3 21 A17912 BUS LINK "J Qz " INDICATES #8 AWG WIRE (PN 390019) 52 4ft 902403 TUBING SEE NOTE 4 2 1 D46624 CONTROL PANEL SEE NOTE 4 ■ J 0" INDICATES #6 AWG WIRE (PN 390020) AR 540211 RIVET, BLIND DOMEHEAD 1 1 C22203 PANEL, RELAY MOUNTING 'J s INDICATES 2 AWG WIRE PN 390022 tE:::rN N0. REF ITEM NO. # ( ) REDO PART N0. DESCRIPTION MATERIAL DES NO. REDO PART N0. DESCRIPTION MATERIAL ■ 6 5 FILL UNUSED ELEMENT HOLES WITH SNAP IN PLUGS LIST of MATERIAL LIST OF MATERIAL (PN's 416507 & 416533). UNLESS OTHERWISE SPECIFIED DRAW DATE ■ 4. SUPPLIED SEPARATELY. DIMENSIONS ARE IN INCHES R.RAYNER 7 30 09 INDEPENDENCE. ENDE CE.C VALLEY ROAD 3. LOCATE COMPONENTS USING REFERENCE DESIGNATORS. TOLERANCES: ANGLES31' CHECKED VT R O N INDEPENDENCE,OH 44t3t-5519 2 MARK REFERENCE DESIGNATORS 12 HIGH MINIMUM USING DECIMALS.xx2 xxxt JFLAUTO 7 30 09 IMF THIS DOCUMENT CONTAINS FINISH ENG APVD PRODUCTION DECALS AND OR INK STAMPING. SPRAY OVER PROPRIETARY INFORMATION LOAD BANK, OUTDOOR 0 INK STAMPING WITH CLEAR ACRYLIC LACQUER. REFERENCE OF AVTRON AND PAINT PER PS C KULBAGO 7 30 09 PSF DESIGNATORS SHALL BE LOCATED ADJACENT TO COMPONENTS MAY NOT BE DISCLOSED TO PLATE PER APVD PROD (OUTLINE DRAWING 563823) ■ SO THAT THEY REMAIN VISIBLE AFTER WIRING. OTHERS OR USED FOR MANUFACTURING PURPOSES SIZE CAGE N0. DWG.NO. REV 1 USE 8 TFS TO MOUNT COMPONENTS UNLESS OTHERWISE NOTED. NEXT USED ONp 01014 K675AD46622 A # WITHOUT THE WRITTEN \ ■ UNLESS OTHERWISE SPECIFIED THE ABOVE NOTES APPLY CONSENT OF AVTRON APPLICATIONSCALE 1/1 MODEL K675A SHEET 1 OF 3 SIMILAR TO D46439 ■ ■ FE;ISi3NS ESN IJD REV DESCRIPTION DATE APPROVED LOCATE 114 MT USING 1/4-20 SST HOW (34 06) VISIBLE AREA Lam) ^ 39)MT USING 5/16-18 HOW ON B2 43) "4 SETS OF HOW IN OUTER HOLES OF MOTOR" i D SEE VIEW B-B I I 65/USE REDUCING WASHERS AS REQUIRED LOCATE INSIDE (19 rIII n li N I �' OF ITEM 18 (26 TORQUE INSIDE NUT UP TO 5 IN-LBS ■ TORQUE OUTSIDE NUT TO 30 t5 IN-LBS LOCATE NEXT TO ITEM 29184 I' I °I I' I I v PN 461156 PIN, SPRING CLIP IF REQUIRED 25 "62" 45 3 PN 530075 WASHER, FLAT 5/16 ■ I I I PN 530073 WASHER, FLAT #10 LOCATE AT SPACE ABOVE ITEM 29 47 16 SEE NOTE 10 PN 473042 SPRING, TAPERED, CPRSN �I i ,11 i .I I i 11 i 2.00� ; 64 18 ■ 3.00- LOCATE THIS ITEM ON 21 5,00 THIS END ONLY PN 530073 WASHER, FLAT #10 C■ 20 C i..-.. REF 52 cNu 65 REF I 13 REF 1 32 MT USING 1/4-20 HOW ■ (44 I SECTIONA-A VIEW B-B IDENTIFY GROUND STUD WITH "GND" SCALE: NONE .18 HIGH MIN. USE 1/2-13 SST HOW FOR GROUND STUD. 60 34 MT USING 1/4-20 SST HOW 46 TYP BOTH SIDES AT SAME LOCATION 51 49 APPLY GASKET TO FRAME FLANGES WHERE SIDE . PANELS ARE ATTACHED. 51 41 iFILL UNUSED HOLES WITH I I A A RIVET PN 540211 29 REF 66 29 MT USING 1/4-20 SST HOW ■ BEFORE INSTALLATION, SLIDE ITEM 66 INTO ITEM 29 THEN . SECURE BY BENDING SIX TANGS. ; TYPICAL BOTH ENDS 29 66 REF I i i 50 51 TYP BOTH SIDES AT SAME LOCATION I ; ■ 0 0 0 ■ 59 TYP BOTH SIDE AT SAME LOCATION 3s 1k VTRON i 31559 LOAD BANK OUTDOOR ■ SEE SHEET 1 FOR NOTES THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION SIZE CAGE NO DWG.NO REV -- OF AVTRON AND MAY NOT BE DISCLOSED p 01 014 K 6 7 5 AD 4 6 6 2 2 A UNLESS OTHERWISE SPECIFIED THE ABOVE NOTES APPLY TO OTHERS OR USED FOR MANUFACTURING PURPOSES ■ WITHOUT THE WRITTEN CONSENT OF AVTRON. SCALE 1/1 1 MODEL K675A 15HEET 2 ■ ■ r _ _ DES i - APPROVED LOCATE IN MT USING 1/4-20 SST HDW 34 60) VISIBLE AREA I 4) 39)MT USING 5/16-18 HDW ON 62 "4 SETS OF HDW IN OUTER HOLES OF MOTOR" r D i D SEE VIEW 6-B I 65 USE REDUCING WASHERS AS REQUIRED LOCATE INSIDE 19 ■ III III III n I OF ITEM 18 126 TORQUE INSIDE NUT UP TO 5 IN-LBS TORQUE OUTSIDE NUT TO 30 f5 IN-LBS LOCATE NEXT TO ITEM 29(84 r I"I I°'I I10I i y PN 461156 PIN, SPRING CLIP (25 IF REQUIRED I l j 'Ili •I I j„ j„ j„ .! 45 3 I1 11 11: i "82" PN 530075 WASHER, FLAT 5/16 ■ sce' PN 530073 WASHER, FLAT #10 LOCATE AT SPACE ABOVE ITEM 29 47 j l l j i I i i II I II' II' II' 16 . SEE NOTE 10 i l I l I I III I I I 12 00 64 PN 473042 SPRING, TAPERED, CPRSN 18 3.00- LOCATE THIS ITEM ON 21 5,00 THIS END ONLY PN 530073 WASHER, FLAT10 C C i 20 D!D E------------- REF 52 - :J"""@ REF I I 13 ■ 44 REF 61 32 MT USING 1/4-20 HDW j SECTION A-A i I r - VIEW B-B IDENTIFY GROUND STUD WITH "GND" SCALE: NONE .18 HIGH MIN. USE 1/2-13 SST HDW FOR GROUND STUD. S60 34 MT USING 1/4-20 SST HDW 46 TYP BOTH SIDES AT SAME LOCATION 51 49 APPLY GASKET TO FRAME FLANGES WHERE SIDE PANELS ARE ATTACHED. 51 41 FILL UNUSED HOLES WITH I A A RIVET PN 540211 29 REF r 66 29 I ■ MT USING 1/4-20 SST HDW 61 62 BEFORE INSTALLATION, SLIDE ITEM 66 INTO ITEM 29 THEN ; SECURE BY BENDING SIX TANGS. TYPICAL BOTH ENDS 29 66 REF I 1 ■ 50 51 TYP BOTH SIDES AT SAME LOCATION ■ ■ 1 1 � I • I ■ e e o _ 1 r �59TYP BOTH SIDE AT SAME LOCATION VTRON INDDERDENCEµOH44131--u9 LOAD BANK OUTDOOR r SEE SHEET 1 FOR NOTES THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION SIZE CAGE N0. DWG NO REv OF AVTRON AND MAY NOT BE DISCLOSED p m1 ml 4 K 6 7 5 AD 46 6 2 2 A TO OTHERS OR USED FOR MANUFACTURING PURPOSES . UNLESS OTHERWISE SPECIFIED THE ABOVE NOTES APPLY WITHOUT THE WRITTEN CONSENT OF AVTRON. SCALE I/1 MODEL K675A SHEET 2 ■ ECN N0.1 RE,I DESCRIPTION L'All APPROVED CF8941 1, IREV PER ECN JFLAUTO 1 9/30/09 jC.KULBAGO CHECK SCHEMATIC TO FIND — WHICH ELEMENT LOCATION WILL MOUNT USING 1) BE WIRED TO WHICHRELAY (52) 3/8-16 HDW SEE NOTE 9 ------------------ "S61 SJ- - ----F------ F-1 D- MOUNT USING HI o 0 0 1/2-13 HDW 0 0 0 M1415 K6 0 F F 0 x o o x 0 Lj r-1HI F25 0 01 fn 0 x 0 x 1 0 x x 0 1 F28 W x 0 K8 o x o 0 x 0 LB�—- o x w 0 0 IT :a c [9] V 0 x 0 x x 0 x 0 V F25Q 0 D x x 0 65 INSTALL PRIOR TO C) F27Q REF x 0 o x U U x 0 0 x 0 INSTALLING ITEM 1 T 0 B, 0 x D x x 0 USE REDUCING WASHERS 0 x x C 8 0 T F241 F26 AS REOURIED 0 x 0 x 0 8 S S 0 0 0 x x C x 0 R F23Q x 0 x 0 R 0 K06 0 x D x x 0 "F5"r----i c INK STAMP "A,B,C" 1.00 HIGH 0 x 0 x 0 0 0 11 ..,E--::], 0 0 0 0 0 x 0 x 0 F6 SPRAY OVER WITH CLEAR 0 x x C 05 X 0 iq> 0 x D x x 0 1 L-===-i i u B ACRYLIC LACQUER 0 0 P P HRI" 'F7"' 0 0 0 0 0 x 0 x 0 0 B,0 x 0 x 0 1 0 A 0 x x C x 0 J<�>x 0 N N 0 x 0 x D x x 0 0 0 0 0 REF 0 x 0 x 0 x M M x 0 x 0 0 FF-2 2-1 K52 "F2- I REF 0 x 0 x 0 D xx T-2-1 I F3:: F 0 x C x 0 x 0 L L A,0 F �-----4 U K 0 0 E�:] K50 :F 0 x 0 x 0 x K x x x 0 F—F2 07 —E 0 0 IIE-Y 0 x C x 0 x 0 J x x D x 0 A 0 x 0 0 x I I x 0 x 0 x 0 0 "K22" H 0 x 0io D x � 0 01 0 K21" 0 0 � x G G x 0 K8 x OK4 j 2 40 0 x C 0 x 0 F SECTION F-F F 0 x 0 D x 0 E x 0 0 x 0 A101:.: 0 x 0 lryt 0 x E SCALE: NONE D 0 x on Dx 0 "iiT611" 0 x C 0 x 0 0 0 x 09 0 x C C x o K8 o .1 6 0 x 0 x A�0 A x 0 go x 0 0 x O 0 x AEND 1 4 3 RA18 2 1 E` 1 2 RAl 3 4 0 END 0 0 SEE NOTE 2 REF 3 [— /F SEE NOTE 5 �70 LINE DRILL AS RE 'D 23 & MOUNT WITH #8 TFS 36 37 53 54 55 56 66 77 78 79 SECTION C-C SECTION D-D REF 30 SCALE: 7/32 SCALE: 7/32 ROTATED 180* *DASHED COMPONENTS INDICATE OPTIONAL WIRING* RESISTANCE ELEMENT AND BUS BAR CODE■ SYMBOL ITEM NO.1 DESCRIPTION — SECTION E-E A le RESISTANCE ELEMENT B 13 RESISTANCE ELEMENT SCALE: NONE 3 BUS LINK 17 BUS LINK JO "=JUMPER (SEE NOTE 7) X=NO ELEMENT (SEE NOTE 5) kVT R 0 N INDEPENDERM,W 44131-5529 LOAD BANK, OUTDOOR THIS DOCUMENT MAY NOT BE DISCLOSED ENT CONTAINS PROPRIETARY INFORMATION SIZE lAll'' NO. "V OF AVTRON 0 1014 K675AD46622 A UNLESS OTHERWISE SPECIFIED THE ABOVE NOTES APPLY TO OTHERS OR USED FOR MANUFACTURING PURPOSES WITHOUT THE WRITTEN CONSENT OF AVTRON. SCALE 1/1 MODEL K675A SHEET 3 "to$ Itiff fto * 4 04i f A44 ff f44 ff 101 Of `7 o #M #1411 of 1#16 ef 'Of', 4 Ili If###fit ' ' ...... ff, %;, 400 off 0 f Mll$ tNl" I 7XNl t lff IL=ffi 111114 ,Ill,I l iulv, LL.1111 1 M111111 ii Wknit_ W11A ALLiAl i Warranty Warranty and Duration For a period of one (1) year after installation, or fifteen (15) months from date of shipment from our facility, whichever expires first, Avtron LoadBank, Inc. warrants the equipment, except as hereinafter provided, to be free from harmful defects in material and workmanship. Notwithstanding any other term or provision hereof,warrantee(Buyer)shall notify warrantor(Avtron LoadBank, Inc.), in writing,of a breach within this warranty period.Claims received after this period will not be honored. Use of Equipment The Warranty applies only if the equipment has been utilized,operated,and maintained in a manner consistent with its purpose and to .114 the extent defined in applicable instructions provided by Avtron LoadBank, Inc. Avtron LoadBank, Inc. makes no express or implied warranties or representations, except as herein expressly provided,with respect to the equipment or its use. Unless otherwise agreed in writing by Avtron LoadBank, Inc., use of equipment hereunder in a nuclear facility or application shall render this Warranty null and W.-4 void and any claims for damages resulting from such use will be rejected. Notification of Breach When claiming a breach of this Warranty, Buyer must promptly (within 10 days from the date of the discovery of the defect) notify Avtron LoadBank, Inc.in writing. Equipment Disposition Upon notification of a claimed breach of this Warranty,Avtron LoadBank, Inc.,at its discretion,will either(i)authorize the return of the defective equipment or part thereof for repair(transportation costs to be prepaid by Buyer),(ii)provide a suitable replacement, or(iii) authorize the Buyer in writing to effect repairs at Avtron LoadBank's expense.Avtron LoadBank, Inc.will pay the transportation costs associated with the return of repaired or replacement equipment to Buyer. Any customs fees, tariffs, duties, or taxes incurred in %%,.,oil shipping equipment pursuant to this Warranty shall be the responsibility of the Buyer.This Warranty does not cover transportation of factory service personnel to and from the installation site or expenses incurred while there. The removal of a defective part, the installation of a replacement part and calibration,if any,are the responsibility of the Buyer. Remedial Options Avtron LoadBank's sole obligation under this Warranty shall be,at its option,to either replace or repair any defective equipment or part Ov. thereof or to issue a credit with respect to the defective equipment equal to the purchase price thereof,less depreciation. Excluded Equipment The Warranty specifically excludes equipment and components that Avtron LoadBank, Inc. purchases and resells as part of a system, product, or spare part order- The warranties provided to Avtron LoadBank, Inc. by the manufacturers of the foregoing will be, to the extent possible, passed to the Buyer. Copies of such warranties, if on file at Avtron LoadBank, Inc., will be made available for inspection upon the request of Buyer. Equipment such as, but not limited to, computers, operator interface modules and monitors normally have a short warranty period and should be covered by a continuous service contract generally available to Buyer from the original manufacturer at a reasonable cost. Consumable items including, but not limited to, lamps,filters,fuses,fluids,motor brushes, etc. are excluded from all warranties. Other items or components may be excluded from this Warranty to the extent noted in the governing purchase order or contract. Resale or Lease of Equipment In the event the Buyer resells or leases equipment purchased from Avtron LoadBank, Inc., the Buyer may assign the rights and ,Ni W obligations of this Warranty to said purchaser or lessee. Buyer shall inform Avtron LoadBank, Inc.of such assignment. Unauthorized Repairs/Modifications Unless written authorization is first obtained from Avtron LoadBank, Inc.,any repair or modification of the equipment by the Buyer shall 144 render this Warranty null and void and any claim by Buyer for reimbursement of costs associated with such repair/modification will be rejected. Governing Law[Venue/Saving Clause This Warranty shall be governed by the laws of the State of Ohio and any legal action arising here from shall be adjudicated in the Courts of Cuyahoga County, Ohio, U.S.A.Any provision hereof which is deemed prohibited or unenforceable shall not serve to prohibit or make unenforceable any other provision of this Warranty- Limitation of Liability IN NO EVENT SHALL AVTRON LOADBANK, INC. BE LIABLE IN CONTRACT, IN TORT OR OTHERWISE, FOR SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR PUNITIVE DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF PROFITS OR REVENUES, LOSS OF USE OF THE EQUIPMENT OR ANY DAMAGE TO ASSOCIATED EQUIPMENT, PROPERTY DAMAGE OR PERSONAL INJURY, COST OF CAPITAL, COST OF SUBSTITUTE OR TEMPORARY EQUIPMENT, DOWNTIME OR CLAIMS OF W", X CUSTOMERS, ARISING OUT OF OR AS A RESULT OF BREACH OF WARRANTY, DEFECT IN MATERIAL OR WORKMANSHIP OR ANY OTHER OBLIGATION OF AVTRON LOADBANK,INC. HEREUNDER. Disclaimer of All Other Warranties THIS WARRANTY COMPRISES AVTRON LOADBANK'S SOLE AND ENTIRE WARRANTY OBLIGATION TO BUYER, ITS CUSTOMERS AND ASSIGNS IN CONNECTION WITH EQUIPMENT SOLD,ASSIGNED, LEASED,OR OTHERWISE PROVIDED BY AVTRON LOADBANK, INC. ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, WARRANTIES OF MERCHANTABILITY AND FITNESS,ARE EXPRESSLY EXCLUDED. AVTRON FORM 297 Rev.09-11 LOADBANK IT11111 TITY1171 TIPTY11 1111117 1111TT 11111111 T111111 N-JR1 IFT1111 V!,F!1 I I fit!' 111111 A 111 I V.111M A N►Ilt A I A I V1411.11P VAMP tMAQ11 A 11 A V1111V A 11M Y . to O C + O m 3 3 CD 0 m U ZY Z o LO 0Z UO Q m o ca � v 0 a J W °a o 0 co N > N 2 Ln Ln N CA ® O & M Manual for the ATC-300+ Automatic Transfer Switch Controller Contents Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Status Monitoring and Setpoints . . . . . . . . . . . . . . . . . . 11 Typical Function of the ATC-300+ Controller. . . . . . . . . . 13 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . 23 Appendix A: Display Messages for Status and Timers . . . . 25 Appendix B: Operational Flowcharts . . . . . . . . . . . . . . . . 26 Appendix C: Display Menu Tree . . . . . . . . . . . . . . . . . . . 29 Appendix D: Pickup / Dropout Tables . . . . . . . . . . . . . . . 35 Ung Status I LIM .. i T. 1'�79E1i CI-AEOM-00003-03-E For more information visit: www.cat.com 1B01602035E •P eration and Maintenance Manual CAT' Page 2 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller -0 A CAUTION A CAUTION THE ATC-300+ CONTROLLER IS FACTORY PROGRAMMED FOR A COMPLETELY READ AND UNDERSTAND THE MATERIAL PRESENTED SPECIFIC AUTOMATIC TRANSFER SWITCH. DO NOT ATTEMPT TO IN THIS DOCUMENT BEFORE ATTEMPTING INSTALLATION, OPERA- INTERCHANGE ATC-300+ CONTROL DEVICES WITHOUT CONSULT- TION,OR APPLICATION OF THE EQUIPMENT. IN ADDITION, ONLY ING YOUR CAT DEALER. QUALIFIED PERSONS SHOULD BE PERMITTED TO PERFORM ANY — WORK ASSOCIATED WITH THIS EQUIPMENT. ANY WIRING All possible contingencies that may arise during installation, oper- INSTRUCTIONS PRESENTED IN THIS DOCUMENT MUST BE FOL- ation, or maintenance, and all details and variations of this equip- LOWED PRECISELY. FAILURE TO DO SO COULD CAUSE PERMANENT ment do no purport to be covered by these instructions. If further EQUIPMENT DAMAGE. information is desired by the purchaser regarding a particular 1.2 Background installation, operation, or maintenance of particular equipment, please contact your Cat dealer. Transfer switches are used to protect critical electrical loads against loss of power. The load's Source 1 power source is Section 1 : Introduction backed up by a Source 2 power source. A transfer switch is con- nected to both the Source 1 and Source 2 power sources and supplies the load with power from one of the two sources. In the 1.1 Preliminary Commentsand Safety Precautions event that power is lost from Source 1, the transfer switch trans- This technical document is intended to cover most aspects asso- fers the load to the Source 2 power source. This transfer can be ciated with the installation, application, operation, and mainte- automatic or manual, depending upon the type of transfer switch nance of the Automatic Transfer Controller. It is provided as a equipment being used. Once Source 1 power is restored, the guide for authorized and qualified personnel only in the selection load is automatically or manually transferred back to the Source 1 and application of the ATC-300+ Controller. Please refer to the power source, again depending upon the type of transfer equip- specific WARNING and CAUTION in Section 1.1.2 before pro- ment being used. ceeding. If further information is required by the purchaser In automatic transfer switch (ATS) equipment, the switch's intel- regarding a particular installation, application, or maintenance ligence system initiates the transfer when the Source 1 power activity, please contact your Cat dealer. falls below or rises above a preset voltage or frequency. If the 1.1.1 Warranty and Liability Information Source 2 power source is a standby generator, the ATS initiates No warranties, expressed or implied, including warranties of fit- generator start up then transfers to the Source 2 power source ness for a particular purpose of merchantability, or warranties when sufficient generator voltage is available. When Source 1 arising from course of dealing or usage of trade, are made regard- power is restored, the ATS automatically transfers back to the ing the information, recommendations and descriptions contained Source 1 power source and initiates generator engine shutdown. herein. In no event will Caterpillar be responsible to the pur- An ATS consist of three basic elements: chaser or user in contract, in tort (including negligence), strict lia- bility or otherwise for any special, indirect, incidental or 1. Main contacts to connect and disconnect the load to and consequential damage or loss whatsoever, including but not lim- from the power sources. ited to damage or loss of use of equipment, plant or power sys- 2. A mechanism to transfer the main contacts from source to tem, cost of capital, loss of power, additional expenses in the use source. of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information 3. Intelligence/supervisory circuits to constantly monitor the and descriptions contained herein. condition of the power sources and thus provide the intelli- 1.1.2 Safety Precautions gence necessary for the switch and related circuit operation. All safety codes, safety standards, and/or regulations must be This manual deals with the third basic element of the ATS, the strictly observed in the installation, operation, and maintenance required intelligence/supervisory circuits. Earlier ATSs were con- of this device. trolled by relay logic type or a solid-state,single board controllers. In either case, the control panel consisted of a number of individ- ually mounted and wired devices offering a limited amount of sys- tem flexibility, especially in the case of the relay logic design. WARNING The ATC-300+ Controller advances the application of intelli- gence, supervisory, and programming capabilities for ATS equip- THE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE PRO- ment. CEDURAL STEPS IN THIS DOCUMENT ARE FOR PERSONNEL SAFETY AND PROTECTION OF EQUIPMENT FROM DAMAGE. AN EXAMPLE 1.3 Product Overview OF A TYPICAL WARNING LABEL HEADING IS SHOWN ABOVE TO FAMILIARIZE PERSONNEL WITH THE STYLE OF PRESENTATION. The ATC-300+ Controller is a comprehensive, multi-function, THIS WILL HELP TO INSURE THAT PERSONNEL ARE ALERT TO microprocessor based ATS controller. It is a compact, self-con- WARNINGS,WHICH APPEAR THROUGHOUT THE DOCUMENT. IN tained, panel mounted device designed to replace traditional relay ADDITION,WARNINGS AND CAUTIONS ARE ALL UPPER CASE AND and solid-state logic panels. BOLDFACE. For more information visit: www.cat.com Cl-AEOM-00003-03-E PAT* ATC•300+ Automatic Effective: July 2011 Page 3 Transfer Switch Controller •Designed to meet the needs of markets worldwide, the Re-Transfer ATC-300+ Controller: Re-transfer is defined as a change of the load connection from • Is a UL Recognized Component the Source 2 to the Source 1. • Complies with UL 1008/CSA 22.2-178 Source 1 • Meets the Intent of UL 991 Source 1 is the primary source (normal source, normal power • Meets IEC 1000-4-2, 1000-4-3, 1000-4-4, 1000-4-5, 1000-4- source, or normal). 6, and 1000-4-11 Source 2 • Meets CISPR 11, Class A Source 2 is the secondary source (emergency source, emergency • Complies with FCC Part 15, Class A power source, emergency, standby, or backup source). • Meets European Standards Conformance ICE mark) Source 1: Failed or Fails The ATC-300+ Controller provides an unmatched degree of pro- Source 1 is defined as "failed" when it is outside of its undervolt- grammed flexibility to address the needs of any system. It oper- age/overvoltage/ underfrequency/overfrequency (if applicable) ates from all system voltages between 120 and 600 Vac, single- setpoint ranges for the nominal voltage and frequency setting. phase and 3-phase, at 50 or 60 Hz. In addition, a period of no Source 2: Failed or Fails control power operation is provided. The ATC-300+ Controller Source 2 is defined as "failed" when it is outside of its undervolt- monitors the condition of the 3-phase line-to-line voltage and fre- age/overvoltage/ underfrequency/overfrequency (if applicable) quency of both the Source 1 and Source 2 power sources. It can setpoint ranges for the nominal voltage and frequency setting for also be programmed for single-phase operation. The ATC-300+ a time exceeding 0.5 seconds after the TDEF time delay expires. Controller provides the necessary intelligence to insure that the switch operates properly through a series of programmed sensing Transfer and timing functions. Transfer is defined as a change of the load connection from the A standard ATC-300+ Controller will: Source 1 to the Source 2 power source, except when specifically used as "Transfer to Neutral". • Monitor Source 1 and Source 2 power source voltages and fre- Transfer to Neutral quencies; Transfer to neutral is defined as when the load circuits are dis- • Provide undervoltage monitoring of the Source 1 and Source 2 connect from both the Source 1 and Source 2 power sources. power sources; • Permit customer programming; Unconnected • Display real-time and historical information; Unconnected is defined as when the input is not shorted by an• external contact or connection. • Permit system testing; • Store customer/factory established parameters in nonvolatile VrN,RMS memory; and Refers to the operating input voltage (Vac, RMS). • Provide faceplate source status indications. 1.5 Functions/Features/Options 1.4 Glossary The primary function of ATC-300+ Controller is to accurately monitor power sources and provide the necessary intelligence to With respect to their use within this document and as they relate operate an ATS in an appropriate and timely manner. In addition, to ATS and controller operation, the following terminology is the ATC-300+ Controller provides programming through the defined. device's faceplate or communication option. Available 1.5.1 Operational Simplicity A source is defined as "available" when it is within its undervolt- age/overvoltage/ underfrequency/overfrequency (if applicable) From installation to programming to usage, the ATC-300+ Con- setpoint ranges for the nominal voltage and frequency setting. troller was designed with operational simplicity in mind. Only one style needs to be considered, regardless of input/output require- Connected ments or system voltages and frequencies. The ATC-300+ Con- Connected is defined as when the input is shorted by an external troller provides the functionality of numerous other devices contact or connection. combined in one package that mounts in 6.5 by 8.5 inches of Failed or Fails panel space. A source is defined as "failed"when it is outside of the applicable The user-friendly front panel interface simplifies routine opera- voltage and frequency setpoint ranges for the nominal voltage tion, programming, data presentation, and setting adjustments. and frequency setting for a time exceeding 0.5 seconds after the An LCD-based display provides the flexibility of a back-lit display time delay emergency fail (TDEF) time delays expires. for enhanced visibility. The operation of the front panel mem- Failsafe brane pushbuttons move the ATC-300+ Controller display from Failsafe is a feature that prevents disconnection from the only function to function or step to step within a function. available power source and also forces a transfer or re-transfer operation to the only available power source. a CI-AEOM-00003-03-E For more information visit: www.cat.com CAT' Page 4 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller 1.5.2 Standard and Optional Features 5. Source 2 Monitoring and Protection • A variety of programmable features are available with the ATC- This feature provides monitoring and protection based on the 300+ Controller to meet a wide variety of application require- Source 2 voltage and/or frequency setpoints. All feature 5 ments. Individual features or feature combinations provide the functions are "failsafe" operations. intelligence required to tailor ATSs to individual needs. The features are factory activated, depending upon customer 5H. Phase Reversal requirements. The specific variable setpoints associated with For a 3-phase wye source, this feature monitors the phase standard and factory activated features are stored in nonvolatile sequence of the sources. If a source does not have the same memory. Activated feature setpoints are available for customer ABC or CBA sequence as the setpoint value, that source will adjustment. Any feature not selected and factory activated can- be considered "Unavailable". not be viewed or adjusted. Fora 3-phase delta source, this feature should be turned off 1.5.2.1 Standard Features via the PHASE REV setpoint. The following is a list of the standard features of the ATC-300+ 5J. 3-Phase Undervoltage and Underfrequency Protection Controller. 1. Time Delay Normal to Emergency (TDNE) Adjustable Undervoltage:Dropout (Breaker Style): 50- 97% of nominal This feature provides a time delay when transferring from Dropout (Contactor Style): 78 - 97% of nominal the Source 1 to the Source 2 power source. Timing begins Pickup: (Dropout +2%) - 99% of nominal when Source 2 becomes available. It permits controlled Adjustable Underfrequency: transfer of the load circuit to Source 2. Dropout (Breaker Style): 90- 97% of nominal Adjustable 0 - 1800 Seconds Dropout (Contactor Style): 90- 97% of nominal Pickup: (Dropout +1 Hz) - 99% of nominal 2. Time Delay on Engine Starting (TDES) 5K. 3-Phase Overvoltage/Overfrequency This feature provides a time delay of the signal to initiate the engine/generator start cycle in order to override momentary Adjustable Overvoltage: power outages or voltage fluctuations of Source 1. Dropout (Breaker Style): 105 - 120% of nominal Dropout (Contactor Style): 105 - 110% of nominal Adjustable 0 - 120 Seconds Pickup: 103% - (Dropout —2%) of nominal 3. Time Delay Emergency to Normal (TDEN) Adjustable Overfrequency: • This feature provides a time delay of the re-transfer opera- Dropout (Breaker Style): 103 - 110% of nominal tion to permit stabilization of Source 1. Timing begins when Dropout (Contactor Style): 103 - 105% of nominal Source 1 becomes available. If Source 2 fails during timing, Pickup: 101% - (Dropout -1 Hz) of nominal then re-transfer is immediate, overriding the time delay. 5L. Source 2 3-Phase Source 2 Voltage Unbalance Adjustable 0 - 1800 Seconds 4. Time Delay for Engine Cool-down (TDEC) For a 3-phase wye source, this feature/o)eature monitors phase volt- age ratios. Voltage unbalance ( is calculated as the dif- This feature provides a time delay of the signal to initiate the ference between the maximum and minimum phase engine/generator stop cycle after the re-transfer operation. voltage, divided by the minimum phase voltage. User- This allows the engine/generator to cool-down by running selectable setpoints are available for dropout and pickup unloaded. Timing begins on completion of the re-transfer unbalance settings (minimum 2% differential). Dropout is cycle. adjustable from 5 to 20%. Pickup is adjustable from 3 to (Dropout —2%). A setpoint for user-selectable time delay Adjustable 0 - 1800 Seconds from 10 to 30 seconds is provided. The factory default setpoints are: 5% dropout, 3% pickup, and 30 seconds time delay. A user-selectable setpoint for enable and dis- able is also provided. When an unbalance condition is detected on Source 2, the Unbalance Timer (TO UNBAL) starts timing. After TD UNBAL times out, Source 2 is declared "failed". For a 3-phase delta source, this feature should be turned off via the VOLT UNBAL setpoint. For more information visit: www.cat.com CI-AEOM-00003-03-E CST' ATC-300+ Automatic Effective: July 2011 Page 5 Transfer Switch Controller 06. Test Operators 12D. Source 2 -Source Connected Cat ATSs are provided with a Test Pushbutton that simu- This feature provides an LED that, when lit, indicates the lates a loss of the Source 1 power source as standard (Fea- load is connected to Source 2. ture 6B). All programmed time delays (TDNE, TDEN, etc.) will be performed as part of the Test. Engine run time of Power Source Availability the Test is equal to the Plant Exerciser (Feature 23) pro- Provides LEDs to indicate if a power source is available. grammed setpoint. All Tests are Failsafe protected. LEDs may be integral or separate from the controller. 6B. Test Pushbutton 12G. Source 1 -Available Programmable setpoints include: This feature provides an LED that, when lit, indicates 1. Load, No Load Testing, or Disabled and Source 1 is available. 2. Engine run time is equal to the Plant Exerciser 12H. Source 2-Available Feature 23) setting. This feature provides an LED that, when lit, indicates 7. Time Delay Emergency Fail (TDEF) Source 2 is available. This feature provides a time delay that prevents a con- 23. Plant Exerciser (PE) nected emergency source from being declared "failed" in This feature provides a means for automatic testing of the order to override momentary generator fluctuations. If the engine/generator set or standb y power system. All pro- Source 2 power source remains in the failed state then, 0.5 grammed time delays will be performed during plant exer- seconds after the TDEF timer expires, the transfer switch ciser operations. will proceed with the programmed sequence for re-transfer. This time delay is only implemented when the Source 2 23K. Plant Exerciser Selectable Disabled/1/7/14/28 Day Inter- power source is a generator. val Adjustable 0 - 6 Seconds This feature provides for automatic test operation of the generator. Available test cycles are daily, 7, 14, or 28 8. Time Delay Bypass Pushbutton days with duration equal to the programmed engine test This feature provides a way (by pushing the Help and Step time. pushbutton simultaneously) to bypass the TDNE (Feature Programmable setpoints allow for selection of three test • 1) and/or TDEN (Feature 2) time delays. The Time Delay cycles: Bypass function, when activated by pushing the Help and Step pushbutton simultaneously, will reduce any or all of Engine Start/Run Only (No Load); the programmed time delay to zero. Exercise with Load Transfer; or Disabled 8C. Bypass TDEN This is a "Failsafe" operation. This feature provides a membrane pushbutton to bypass 26. Source 1 - Monitoring and Protection the TDEN time delay. This feature provides Source 1 monitoring and protection 8D. Bypass TDNE functions. If the Source 1 power supply fails, then the ATC-300+ will begin the sequence of operations neces- This feature provides a membrane pushbutton to bypass sary to transfer the load circuit to the Source 2 power the TDNE time delay. source. All Feature 26 monitoring and protection func- 12. Power Source Annunciation tions are "failsafe" operations. This feature provides LEDs to give switch position and 26D. Go to Source 2 power source availability indications. This feature provides the capability for an external contact Switch Position opening to initiate a load power transfer to the Source 2 power source. This includes starting the engine/generator, Provides LEDs to indicate the switch position. performing the programmed time delays, and the transfer operation. Re-transfer will occur when the external con- 12C. Source 1 -Source Connected tact is closed or under a "failsafe"condition. A Connection This feature provides an LED that, when lit, indicates the point on the controller for the connection of an external load is connected to Source 1. contact is included. • CI-AEOM-00003-03-E For more information visit: www.cat.com C - Page 6 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller 26H. Phase Reversal Protection 32. Delayed Transition Transfer Modes for Open Transition • Fora 3-phase wye source, this feature monitors the phase Transfer Switches sequence of the sources. If a source does not have the This feature provides delayed transition transfer modes for same ABC or CBA sequence as the phase reversal setpoint, an open transition transfer switch. Often used in systems the source will be considered "Unavailable". with inductive loads, a delayed transition transfer switch Fora 3-phase delta source, this feature should be turned may prevent or reduce in-rush currents due to out of off via the PHASE REV setpoint. phase switching of inductive loads. 26J. 3-Phase Undervoltage and Underfrequency Protection 32A. Time Delay Neutral Adjustable Undervoltage: This feature provides a time delay in the neutral position Dropout (Breaker Style): 50- 97% of nominal during the transfer and re-transfer operations during which Dropout (Contactor Style): 78 - 97% of nominal both Source 1 and Source 2 are disconnected from the Pickup: (Dropout +2%) - 99% of nominal load circuit. The time delay is programmable and is the same for both transfer and re-transfer operations. Adjustable Underfrequency: Adjustable 0- 120 Seconds Dropout (Breaker Style): 90- 97% of nominal Dropout (Contactor Style): 90- 97% of nominal 35. Pre-Transfer Signal Pickup: (Dropout +1 Hz) - 99% of nominal This feature provides a signal to a remote device prior to a 26K.3-Phase Overvoltage/Overfrequency re-transfer operation. It provides one Form "C"contact Adjustable Overvoltage: (NO/NC) for interface with other equipment (typically ele- Dropout (Breaker Style): 105 - 120% of nominal vator controls). The contacts close/open on a timed basis Dropout (Contactor Style): 105 - 1 10% of nominal prior to transfer in either direction. After TDNE/TDEN Pickup: 103% - (Dropout -2%) of nominal times out, this relay closes and the Pre-transfer Timer (TPRE) starts timing. After the TPRE times out, the trans- Adjustable Overfrequency: fer proceeds by starting the TON timer if enabled. The Dropout (Breaker Style): 103 - 1 10% of nominal pre-transfer relay opens after the transfer is complete. Dropout (Contactor Style): 103 - 105% of nominal Adjustable 0 - 120 Seconds/o Pickup: 101 - (Dropout -1 Hz) of nominal 26L. Source 1 3-Phase Voltage Unbalance 35A. Pre-transfer Signal with 1 N.O. and 1 N.C. Contacts •Fora 3-phase wye source, this feature monitors phase volt- This feature provides pre-transfer signal and includes 1N.O. and 1 N.C. contact. age ratios. Voltage unbalance (%1 is calculated as the dif ference between the maximum and minimum phase 1.5.2.2 Optional Features voltage, divided by the minimum phase voltage. User- The following is a list of the optional features of the ATC-300+ selectable setpoints are available for dropout and pickup Controller. unbalance settings (minimum 2% differential). Dropout is adjustable from 5 to 20%. Pickup is adjustable from 3 to 12. Power Source Annunciation (Dropout -2%). A setpoint for user-selectable time delay This feature provides LEDs to give switch position and from 10 to 30 seconds is provided. The factory default power source availability indications. setpoints are: 5% dropout, 3% pickup, and 30 seconds time delay. A user-selectable setpoint for enable and dis- Overcurrent Trip Indication able is also provided. Available only with integral Overcurrent Protection When an unbalance condition is detected on Source 1, the (Feature 16). (Shown on Automatic Transfer Controller Dis- Unbalance Timer (TD UNBAL) starts timing. After TO play.) UNBAL times out, Source 1 is declared "failed". 12L. Source 1 Tripped (Requires Feature 16) Via ATC-300+ For a 3-phase delta source, this feature should be turned LCD-Based Display off via the VOLT UNBAL setpoint. The Automatic Transfer Controller LCD display will read 29. Alternate Transfer Modes of Operation (new feature) "Lockout" if the Source 1 circuit breaker is in the "tripped" Provides standard or optional transfer modes, mode selec- position. tion devices, and operational methods for ATSs. 12M. Source 2 Tripped (Requires Feature 16)Via ATC-300+ LCD-Based Display The Automatic Transfer Controller LCD display will read "Lockout" if the Source 2 circuit breaker is in the "tripped" position. For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC-300+ Automatic Effective: July 2011 Page 7 Transfer Switch Controller 0�29J. Type of Operation (MANTR) Operation Section 2: Hardware Description This feature provides for a seletion between an automatic transfer and re-transfer mode or a manual pushbutton re- 2.1 General transfer to Normal from the Emergency Source mode. If The purpose of this section is to familiarize the reader with the this option is not selected the factory default selection is ATC-300+ Controller hardware, its nomenclature, and to list the automatic. unit's specifications. The information presented is divided into 32F. In-Phase Transition the following three parts: Provides In-phase transition, which is a feature that will • Operator Panel; permit a transfer or re-transfer between 2 available sources • Rear Access Area; and that have a phase angle difference of 8 degrees or less. • Specification Summary. The In-phase transition feature includes permissible fre- quency difference and synchronization time setpoints. In 2.2 Front (Operator) Panel the event source 1 and source 2 fail to synchronize within The front panel, depending on the installation, is normally acces- a specified amount of time, due to excessive phase angle sible from the outside of a panel or door. The front panel pro- difference or frequency difference, then the transfer will vides a means to: take place under delayed transition. Alarm relay will ener- gize and failure will be logged into the transfer history as • Alert the user to specific conditions; either "Sync Fail - Freq" or "Sync Fail - Phase" depending . Program the controller; and on whether the frequency difference or the phase differ- . Set and monitor the operating parameters. ence was excessive. The adjustable frequency difference is 0.0 to 3.0 Hz. If the synchronization does not occur within The ATC-300+ Controller front panel serves two primary func- a specified amount of time, the alarm relay will energize tions: output and input. The output function consists of: and the failure will be logged into the Transfer History as either "Sync Fail - Freq" or "Sync Fail - Phase" depending A two-line, 16 character LCD display module on whether the frequency difference or the phase differ- Five LED outputs ence was excessive. 1 Unit Status 36. Emergency Inhibit(new feature) 2 Source 1 Available This feature enables the Emergency inhibit control input to • inhibit transfers to the Emergency Source. See Control 3 Source 1 Connected Inputs section for more information. 4 Source 2 Available 48F. RS-485 with Modbus Option 5 Source 2 Connected Provides communications for the ATC-300+ via RS-232 or There are seven input functions accessible through the pushbut- Modbus through an integrated RS-485 port. Registers are tons: available to read back status, voltages, frequencies, and historical data. Registers are also available for transfer 1 Help/Lamp Test switch control. Setpoints may be read back and/or pro- 2 Engine Test grammed via a pass-through command. See the ATC- 300+ Modbus Communication Guide. 3 Step/Enter 4 Increase 5 Decrease 6 Alarm Reset 7 Bypass Time Delay • CI-AEOM-00003-03-E For more information visit: www.cat.com CAT' Page 8 Effective: July 2011 ATC•300+ Automatic Transfer Switch Controller The LEDs • Unit Status s The Unit Status LED blinks at a rate of once per second while in the ATC-300+ Controller is in the "Run" Mode. This indicates that the ATC-300+ has completed a self-diagnostic and system diagnostic cycle. The self-diagnostic cycle checks include the: ..._ • Microprocessor operation and • Memory operation. The system diagnostic cycle checks include the: ® Output relay operation; • Control input operation; and • Transfer switch operation. The Unit Status LED blinks at an increased rate while the ATC- 300+ Controller is in the "Program" Mode. Source 1 Available Or $No , The Source 1 Available LED illuminates if the Source 1 power source meets the criteria to be considered "available". That is, when it is within its undervoltage/overvoltage/underfrequency/ gyp� overfrequency/voltage unbalance/phase reversal (if applicable) tpl$1tAtiE setpoint ranges for the nominal voltage and frequency setting. Source 1 Connected The Source 1 Connected LED illuminates when the Source 1 Figure 1. The ATC-300+ Controller Front Panel. switching device and its associated position indicating auxiliary 2.2.1 The Output Function Components contact are closed. The Display Source 2 Available • A 2-line, 16-character alphanumeric LCD Display module is used The Source 2 Available LED illuminates if the Source 2 power to display all ATC-300+ Controller monitored parameters, set- source meets the criteria to be considered "available". That is, when it is within its undervoltage/overvoltage/underfrequency/ points, and messages in easy read formats The display has a overfrequency/voltage unbalance/phase reversal (if applicable) green high contrast backgroundd that allows clear visibility of any setpoint ranges for the nominal voltage and frequency setting. information displayed. The display is continuously lit for clear vis- ibility under poorly lit or no light conditions. Source 2 Connected Six different displays can be presented via the LCD Display: The Source 2 Connected LED illuminates when the Source 2 • Status Display switching device and its associated position indicating auxiliary Source 1 Display contact are closed. • • Source 2 Display 2.2.2 The Input Function Components • Time/Date Display The Pushbuttons and Combinations • History Display • Setpoints Display Help/Lamp Test Pushbutton The Help/Lamp Test pushbutton serves two functions. If the As a default when there are no active commands or timers being Help/Lamp Test pushbutton is pressed when a message is displayed, the display shows information from the source that is present on the LCD Display, a detailed description of the message connected to the load. This is referred to as the "Home" screen. will appear. The detailed message description will scroll across Line 1: Source 1 or 2 Metered Voltage the bottom of the display. The detailed description can be Line 2: Date Time aborted by pressing Help/Lamp Test key a second time. Example: Source 1 480V 1/20/06 3:35PM See Section 3 for more detailed information. • For more information visit: www.cat.com CI-AEOM-00003-03-E CAT ATC•300+ Automatic Effective: July 2011 Page 9 Transfer Switch Controller Of the LCD Display is displaying the Home screen when the Help/ 2.3 Rear Access Area Lamp Test key is pressed, all of the LED's will momentarily illumi- The rear access area of the ATC-300+ Controller is normally nate, then the following information will scroll across the display: accessible from the rear of an open panel door (Figure 2). • Serial number of the ATC-300+ Controller; • Hardware revision number (= parts list revision number); • Software version and revision number; ., • Feature code - a decodable string listing all optional features programmed in the ATC-300+ Controller; and • Firmware version. + tEltk+>I 1 �« s Engine Test Pushbutton The Engine Test pushbutton allows the user to test the Source 2 x '� (generator) engine. The engine test function can be set with the t ATC-300+ Controller to one of three setpoint modes to allow flexibility in how the test is run: 4 xtddAraRtF 0 No Load Engine Test; '04 rr�uafjrt; atd 1i(i t tFsi��rnatt#tt n t 1 Load Engine Test; or 2 Disabled. s v ft , The factory default is set to 0 - Load Engine Test. �, 4 n For complete information on the Engine Test function, see Sec- tion 5.7. zk � s a Step/Enter Pushbutton b �' The Step/Enter pushbutton allows the user to scroll through the information and setpoint displays. By pressing the Step/Enter pushbutton, the information on the LCD Display will advance through the voltage(s), frequency, and status condition of Source •1, then Source 2, then the time and date information, then the s £ # p7 history information, then the setpoints. The information on the LCD Display advances one step through the displayed information "6n$ cycle with each depression of the Step/Enter pushbutton. fr k 1 1 Increase Pushbutton The Increase pushbutton allows the user to increase the value of ` ° Ow :a the setpoints. When ATC-300+ Controller is in the "Program" "� Mode (to change setpoint values), each time the Increase push- button is pressed, the value of the displayed item will increase by one. Figure 2. ATC-300+ Controller (Rear View). Decrease Pushbutton All wiring connections to the ATC-300+ Controller are made at The Decrease pushbutton allows the user to decrease the value the rear of the chassis. of the setpoints. When ATC-300+ Controller is in the "Program" Note:To allow for uniform identification,the frame of reference when dis- Mode (to change setpoint values), each time the Decrease push- cussing the rear access area is with the panel door open and the User fac- button is pressed, the value of the displayed item will decrease ing the back of the ATC-300+ Controller. by one. Located at the left rear of the chassis are connectors J1, J2, and Alarm Reset Function (Increase + Decrease Pushbuttons) J7. J1 and J2 provide for voltage monitoring of Source 1 and Source 2 respectively. J7 is provided for Sources 1 and Source 2 Pressing the Increase and Decrease pushbuttons simultaneously control power input. Located at the right rear of the chassis is will reset the Alarm function. In addition, if both pushbuttons are the J3 programming port connector. The J4 and J5 connectors pressed simultaneously while viewing any of the historical logged are located at the bottom of the controller. The J4 connector values in the program mode, the value of the current item dis- provides DC wetted connections for various control inputs. The played resets to zero. J5 and J8 connectors provide dry relay contacts for primary con- Bypass Time Delay Function (Step/Enter + Help/Lamp Test) trol outputs. Pressing the Step/Enter and Help/Lamp Test pushbuttons simulta- See Section 5.5.1 for contact ratings. neously will bypass the TDNE or TDEN functions when they actively counting. The "Bypass TDNE/TDEN"function does not have a user accessible, programmable setpoint for enable or dis- able. is CI-AEOM-00003-03-E For more information visit: www.cat.com CAT Page 10 Effective: July 2011 ATC•3OO+ Automatic Transfer Switch Controller 2.4 Specification Summary Table 1. ATC-300+ Controller Specifications Input Control Voltage 65 to 145 Vac 50160 Hz Voltage Measurements of Source 1 VAB Source 2 VAB Source 1 VBC Source 2 VBC Source 1 VCA Source 2 VCA Voltage Measurement Range 0 to 790 Vac RMS(50160 Hz) Voltage Measurement Accuracy . 1%of Full Scale Frequency Measurements of Source 1 and Source 2 Frequency Measurement Range 40 Hz to 70 Hz Frequency Measurement Accuracy t 0.3 Hz Over the Measurement Range Undervoltage Dropout Range: BreakerlSwitch Style ATS 50 to 97%of the Nominal System Voltage Contactor Style ATS 78 to 97%of the Nominal System Voltage Undervoltage Pickup Range: BreakerlSwitch Style ATS (Dropout+2%)to 99%of the Nominal System Voltage Contactor Style ATS (Dropout+2%)to 99%of the Nominal System Voltage Overvoltage Dropout Range: BreakerlSwitch Style ATS 105 to 120%of the Nominal System Voltage Contactor Style ATS 105 to 110%of the Nominal System Voltage Overvoltage Pickup Range: BreakerlSwitch Style ATS 103%to(Dropout-2%)of the Nominal System Voltage Contactor Style ATS 103%to(Dropout-2%)of the Nominal System Voltage Underfrequency Dropout Range: BreakerlSwitch Style ATS 90 to 97%of the Nominal System Frequency Contactor Style ATS 90 to 97%of the Nominal System Frequency Underfrequency Pickup Range: BreakerlSwitch Style ATS (Dropout+1 Hz)to 99%of the Nominal System Frequency Contactor Style ATS (Dropout+1 Hz)to 99%of the Nominal System Frequency _• Overfrequency Dropout Range: BreakerlSwitch Style ATS 103 to 110%of the Nominal System Frequency Contactor Style ATS 103 to 105%of the Nominal System Frequency Overfrequency Pickup Range: BreakerlSwitch Style ATS 101%to(Dropout-1 Hz)of the Nominal System Frequency Contactor Style ATS 101%to(Dropout-1 Hz)of the Nominal System Frequency Operating Temperature Range -20 to+70°C(4 to+158°F) Storage Temperature Range -30 to+85°C(22 to+185°F) Operating Humidity 0 to 95%Relative Humidity(Non-condensing) Operating Environment Resistant to Ammonia,Methane,Nitrogen,Hydrogen,and Hydrocarbons Generator Start Relay 5 A,116 HP @ 250 Vac 5 A @ 30 Vdc with a 150 W Maximum Load K1,K2,Pretransfer,Alarm Relays 10 A,1.3 HP @ 250 Vac K3,K4 10 A @ 30 Vdc Applicable Testing UL Recognized Component Meets UL 1008 Meets Intent of UL 991, Meets IEC 1000 4-2,1000.4-3,1000-4 4,1000.4-5,1000.4.6,1000-4-11 Meets CISPR 11,Class A Complies with FCC Part 15,Class A Enclosure Compatibility NEMA 1,NEMA 3R,and NEMA 12 UV Resistant ATC-300+ Faceplate • For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC-300+ Automatic Effective: July 2011 Page 11 Transfer Switch Controller *Section 3: Status Monitoring and The source voltage has risen above the dropout setting and not Setpoints dropped below the pickup setting. SOURCE 1 U-F SOURCE 2 U-F The source frequency has dropped below the dropout setting and not risen above the pickup setting. SOURCE 1 0-F SOURCE 2 0-F The source frequency has risen above the dropout setting and not ALTHOUGH A WIDE VARIETY OF PARAMETERS AND SETPOINTS dropped below the pickup setting. CAN BE DISPLAYED,THEY ARE NOT DISPLAYED IF THEY WERE NOT SOURCE 1 UNBAL SOURCE 2 UNBAL ORIGINALLY ORDERED AND PROGRAMMED. The voltage unbalance has risen above the dropout setting and not dropped below the pickup setting. S1 PHASE REVERSE S2 PHASE REVERSE The phase sequence does not agree with the setpoint value, indi- WHETHER VIEWING OR PROGRAMMING,THE DISPLAY RETURNS TO cating that the phase sequence is reversed. THE HOME SCREEN IF NO PUSHBUTTON ACTIVITY IS DETECTED 3.1.2 Time/Date Display FOR APPROXIMATELY 2.5 MINUTES. The Time/Date Display indicates real time in terms of hours, min- 3.1 Status Display utes, and seconds; and month, day, and year. It also indicates individual time and date items for programming purposes. The The Status Display provides messages regarding anything that is day of the week can also be set with 1 = Sunday, 2 = Monday, presently changing or happening to the ATS's status, including etc. The time, date, and day of the week can be set in the Pro- source information, timer countdown, and failure reports. Refer gram Mode. to Appendix A for a complete list of Status Display messages. 3.1.3 History Display The History Display indicates historical and cumulative counter values as follows: Engine Run Time • This counter will log the generator run time in hours. Time will start being logged at the time the GEN START contacts are closed, and it will stop as soon as they are opened. This counter will count up to 9999 hours and then turn over to 0000. It can be reset to zero in the Program Mode. Source 1 Connected Time This counter logs the time in hours that Source 1 has been con- nected to the load. Time will be logged while the SOURCE 1 CLOSED control input is in the "connected" state. This counter will count up to 9999 hours and then turn over to 0000. It can be reset to zero in the Program Mode. Source 2 Connected Time 111110 This counter logs the time in hours that Source 2 has been con- r� �;. ' nected to the load. Time will be logged while the SOURCE 2 ` CLOSED control input is in the "connected" state. This counter � will count up to 9999 hours and then turn over to 0000. It can ttoa€ be reset to zero in the Program Mode. Source 1 Available Time When Source 1 meets the voltage and frequency setpoint criteria, Figure 3. The LCD Display. this counter logs the time in hours. This counter will count up to 3.1.1 Source 1 and Source 2 Displays 9999 hours and then turn over to 0000. It can be reset to zero in The Source 1 and Source 2 displays indicate the present status of the Program Mode. the sources in terms of voltage and frequency. If the source is Source 2 Available Time available, the condition display will be "SOURCE 1 GOOD" or "SOURCE 2 GOOD". If it is unavailable, one of the following pos- When Source 2 meets the voltage and frequency setpoint criteria, sible conditions will be shown: this counter logs the time in hours. This counter will count up to 9999 hours and then turn over to 0000. It can be reset to zero in SOURCE 1 U-V SOURCE 2 U-V the Program Mode. • The source voltage has dropped below the dropout setting and not risen above the pickup setting. SOURCE 1 0-V SOURCE 2 0-V CI-AEOM-00003-03-E For more information visit: www.cat.com CAT' Page 12 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller Load Energized Time • When either of the two sources is connected to the load and the connected source is available, this counter will start logging the time in hours. This counter will count up to 9999 hours and then turn over to 0000. It can be reset to zero in the Program Mode. Total Number of Transfers This counter logs the number of transfer cycles that occur. This counter will count up to 9999 cycles and then turn over to 0000. It can be reset to zero in the Program Mode. Reason/Date/Time for the 16 Most Recent Transfers The 16 most recent transfer events are stored in history and may be viewed at the LCD Display as follows: • Use the Step/Enter pushbutton to step to the "TRANSFER HIS- TORY" message. • Press the Increase pushbutton to display the most recent transfer event (T01) along with the type and cause of the event. • Press the Decrease pushbutton to display the date and time of the event. Continually pressing the Decrease pushbutton will cycle the display between the event display and the date/time of event display. • Press the Increase pushbutton to display the next most recent transfer event (T02). • Pressing the Step/Enter pushbutton, while viewing any of the transfer history displays, will exit the Transfer History dis- plays. 3.1.4 Setpoints Display • The Setpoints Display indicates presently programmed setpoints. The setpoints can be altered with valid password entry. Keep in mind; if an optional ATC-300+ Controller feature was not origi- nally ordered and programmed, it will not be displayed. Refer to Section 6 for more details on setpoints. 3.1.5 Help Display This display presents moving language messages, explanations, and prompts to assist the operator. When the Help/Lamp Test Pushbutton is pressed and released a second time during the scrolling of a message, the message is aborted. • For more information visit: www.cat.com CI-AEOM-00003-03-E C ' AU ATC-300+ Automatic Effective: July 2011 Page 13 Transfer Switch Controller •Section 4: Typical Function of the ATC- when S1 returns and becomes available per the programmed set- points, TDEN, if programmed, will time out. The pretransfer relay will energize. TD PRE-TRAN, if programmed, will time out. K1 The ATC-300+ Controller operates as follows. will energize for no longer than 6 seconds or until the S2 con- nected input is removed. If the 6 seconds times out, then an S2 The input connections of the ATC-300+ controller are wetted device Alarm will trigger and K1 will open. Once the input is and work on an opening or closure of an external contact. The removed,then K1 will open if TDN is programmed. TDN will time output connections are dry contacts and function depending on down and K1 and K3 will reclose until the S1 input is satisfied, input connections and /or source availability. but for no longer than 6 seconds. If the 6 seconds is reached, then an S1 device Alarm will be triggered and the K1 and K3 120 Vac, 60 Hz is required to power the ATC-300+ controller. relays will open. If the S1 connected input is satisfied, then K1 Power is supplied to either pins 1 and 2 or 3 and 4 on the J-7 will open, the pretransfer relay will de-enerigize, and TDEC will connector. time down and open the engine start contact. Source 1 (S1) sensing is supplied on the J-1 connector; Source 2 The Go To Source 2 input (normally closed, open to initiate) (S2) sensing is supplied on the J-2 connector. causes the Engine Start contacts to close. Once the S2 sensing K1 and K2 relays, located on pins 1 and 2 (K1) or pins 3 and 4 satisfies the setpoints programmed, then a transfer is initiated. (K2) on the J-5 connector, along with the K3 and K4 relays, The transfer functions as described above. The controller will located on pins 1 and 2 (K3) and pins 3 and 4 (K4) on the J8 con- maintain the Engine Start contacts and the S2 connected as long nector, are use to control device position. S1 and S2 inputs are as the Go To Source 2 input is maintained. Once it is removed, a located on pins 1 and 2 (S1) or pins 3 and 4 (S2) on the J-4 con- retransfer to S1, if S1 is available per the setpoints, will occur nector and are used to sense device position. and functions as described above. "Go To Source 2"is displayed on the controller. K1 and K3 close until the S1 input is satisfied but no longer than The Monitor Mode input (normally open, close to initiate) is uti- 6 seconds before the S1 device Alarm is triggered and the K1 and lized to put the controller in a "Monitor"only state. No other K3 relays are deenergized. The K2 and K4 relays function the inputs will affect the operation of the controller when the Monitor same as the K1 relay in that they close until the S2 input is satis- Mode input is initiated. The controller will ONLY monitor the volt- fied (closed) but no longer than 6 seconds before the S2 device age and frequency of the S1 and S2 inputs. Changing of the set- Alarm is triggered and the K2 and K4 relays are deenergized. points of the controller MAY be accomplished while in Monitor Either input MUST be satisfied prior to resetting the Alarm. The Mode. All setpoints are accessible and all timers can be reset. S1 and S2 connected inputs are wetted inputs that require a con- "ATS Not In Automatic" is displayed on the controller. •tact closure in order to be satisfied. The S1 device Alarm will occur if the switch is commanded to go The Lockout input (normally closed, open to initiate) is utilized to from S1 to S2 and the S1 connected input is NOT removed place the controller in a state where it will NOT supply any out- within 6 seconds after the command to transfer. The S1 device puts regardless the inputs. It is used to monitor the state of any Alarm will also occur if the switch is commanded to go from S2 fault indicating devices. If the fault device trips due to an over to S1 and the S1 connected input is NOT connected within 6 sec- current or over load condition, then a contact opening will place onds after the command to transfer from the neutral position. the controller in the Lockout state. The Alarm contact will That is the K2 relay closes AFTER TDNE or after TD PRE-TRAN change state when the lockout signal is sensed. "Lockout" is dis- times out, if the S1 connected input is NOT opened within 6 sec- played on the controller. The fault indicating device MUST be onds the K2 relay will open and an S1 device error message, reset before the controller can be reset or the Alarm will continue "SOURCE 1 DEVICE", will be displayed. to indicate. A typical transfer request will begin with an S1 outage (S1 becomes unavailable per the programmed setpoints), Engine Test, or Plant Exercise function. After TDES, if programmed, counts down, the Generator Start contact will close. For a Plant Exer- cise or Engine Test,the S2 available light MUST become available within 90 seconds or the generator start contacts will reopen. Once S2 meets the requirements to be considered available, then TDNE, if programmed, will time down. The pretransfer relay will energize if S1 is available. TD PRE-TRAN will time down if pro- grammed and if S1 is available (Engine Test or Plant Exercise). The K2 relay will energize. The S1 connected input MUST open within 6 seconds (see above). K2 will open IF TDN is pro- grammed. TDN will then time down and K2 and K4 will energize until the S2 connected input is closed (this MUST happen within 6 seconds of K2/K4 closure or the S2 device alarm will trigger and the K2 and K4 relays will deenergize). Once the S2 con- nected input is satisfied, K2 and K4 will open and the pretransfer relay will de-energize. • CI-AEOM-00003-03-E For more information visit: www.cat.com CAT' Page 14 Effective: July 2011 ATC•300+ Automatic Transfer Switch Controller O O Rs4a5 ON t Termination a SHD RS-485 S1 -Line Jt� 3 Corn MODBUS Control S1 -Neut 2 A(-)S2-Line Power J7 1 B(+) S2-Neut 7 Tx 6 Rx J3 5 G id Programming Phase C a 5V Port Source Phase A Out PhaseA 2 In 8.0 in. 1 Clk Phase C A 8 Emergency Source 2 Phase B J2 7 Inhibit Control Phase 6 Manual Inputs 5 Re-Transfer 4 K4 No 3 K4 C an}c ose Output 2 K3 NO Relays ti st • K3 Com Close F1O J5 J4 1 1 2 3 4 5 1 6 1 7 1 8 L9 10 11 1 12 13 14 1 2 3 4 1 5UU 6 7 8 9 10 j > j j j o U U v Z - �� U CV O N 7 Q _ C:J Cl)+ J O M S m � ° 0 w � CDR c� �0 u,o CL a o Output Relays Control Inputs 6.5 in. ATC-300+ Controller - Breaker type (TDN) - #EP8160AOOG22 ATC-300+ Controller - 2 Position Contactor type (In-Phase) - #EP8160AOOG27 ATC-300+ Controller - 3 Position Contactor type (TDN) - #EP8160AOOG28 Figure 4. Connectors on the ATC-300+ Controller. • For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC-300+ Automatic Effective: July 2011 Page 15 Transfer Switch Controller OSection 5: Operation Source 2 Closed When this input is in the "Connected" state, it indicates to the 5.1 General ATC-300+ Controller that the Source 2 device is closed. When This section specifically describes the operation and functional this input is in the "Unconnected" state, it indicates to the ATC- use of the ATC-300+ Controller. The practical use of and opera- 300+ that the Source 2 device is open. This input is typically tion within each category will be discussed. In this section, it is wired to the Source 2 device auxiliary contact that is closed assumed that prior sections of this manual were reviewed and when the Source 2 device is closed. The Source 2 input is that the operator has a basic understanding of the hardware. always enabled. 5.2 Automatic Mode Lockout The Automatic Mode of the ATC-300+ Controller provides for When the "Lockout" input is in the "Unconnected" state, the automatic transfer and re-transfer from Source to Source as dic- ATC-300+ Controller will not permit an automatic transfer opera- tated by the features supplied and their programmed setpoint val- tion. When the "Lockout" input is in the "Unconnected" state, ues. It provides a summary of the ATC-300+ Controller the LCD Display will be active continuously. It will read "Lock- intelligence and supervisory circuits that constantly monitor the out" on Line 2 of the LCD Display screen immediately, regardless condition of both the Source 1 and Source 2 power sources,thus of any controller or switching device operation. When the "Lock- providing the required intelligence for transfer operations. These out" input is in the "Connected" state and the Alarm is reset, the circuits, for example, automatically initiate an immediate transfer ATC-300+ will permit automatic transfer operation. This input is of power when the power fails or the voltage level drops below a typically wired to the normally closed Source 1 and Source 2 preset value. Exactly what the ATC-300+ Controller will initiate device alarm contact that opens when one of the devices has in response to a given system condition depends upon the combi- tripped due to a fault current. The "Lockout" input is selectable nation of standard and selected optional features. as enabled or disabled via factory control only. 5.3 Monitor Mode Go To Source 2 Monitor Mode is a special operating mode in which the ATC- When the "Go to Source 2"input is in the"Connected"state,the 300+ Controller does not provide control for transfer operations. ATC-300+ Controller is be in a normal, automatic operation The ATC-300+ will, however, continuously monitor both Source mode. When the "Go To Source 2"input is in the "Unconnected" 1 and Source 2 voltages and frequencies. state, the ATC-300+ controller will initiate a generator start and then transfer to the Source 2 power source. The ATC-300+ will The ATC-300+ will be in Monitor Mode when the "Monitor maintain the connection to Source 2 until the input changes to Mode" control input is in the "Connected" state as described in the "Connected" state, upon which it will initiate a re-transfer to Section 5.4. While in the Monitor Mode of operation, the ATC- the Source 1 power source. When the "Go To Source 2" input is 300+ LCD Display will display "ATS NOT IN AUTOMATIC". in the "Unconnected" state, the LCD Display will be active con- tinuously. Active time delays will be constantly displayed on Line 5.4 Control Inputs 1, with real-time remaining countdown to zero status. It will con- stantly read "Go To Source 2"on Line 2 of the LCD Display. This The ATC-300+ has five individual input control signals. The operation is "failsafe". The "Go To Source 2" input is always inputs are DC wetted with the unregulated DC supply and appro- enabled. The "Go To Source 2" input does not have a user priate current limiting to provide a nominal current of 10 mA per accessible programmable setpoint for enable or disable. channel. 5.4.1 Control Input Descriptions Monitor Mode The Control Input "State" definitions are as follows. When the "Monitor Mode" input is in the "Unconnected" state, operation of the ATC-300+ Controller will not be effected. Connected -When the input is shorted by an external contact or When the "Monitor Mode" input is in the "Connected" state, the connection. ATC-300+ will monitor the Source 1 and Source 2 voltages and Unconnected -When the input is NOT shorted by an external frequencies but will not provide any control capabilities. When contact or connection. the "Monitor Mode" input is in the "Connected" state, the ATC- 300+ LCD Display will be active continuously and will constantly The Control Input operations are defined as follows. read "ATS" on Line 1 and "NOT IN AUTOMATIC" on Line 2 of the LCD Display. The "Monitor Mode" input is selectable as Source 1 Closed enabled or disabled via factory control. The "Monitor Mode" When this input is in the "Connected" state, it indicates to the input does not have a user accessible programmable setpoint for ATC-300+ Controller that the Source 1 device is closed. When enable or disable. This is NOT a "failsafe" operation. this input is in the "Unconnected" state, it indicates to the ATC- Manual Re-Transfer 300+ that the Source 1 device is open. This input is typically With manual operation set, momentary closure on Pins 5 and 6 of wired to the Source 1 device auxiliary contact that is closed Connector J8 allows ATC-300+ to proceed with a re-transfer when the Source 1 device is closed. The "Source 1 Closed" operation at the operators discretion. Should a failure of the input is always enabled. emergency source occur while waiting for the manual return, the re-transfer proceeds automatically. • CI-AEOM-00003-03-E For more information visit: www.cat.com CAT' Page 16 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller Emergency Inhibit 5.5 Output Relay • This input is located on Pins 7 and 8 of Connector J8 and is The primary control outputs of the ATC-300+ Controller are dry enabled when the Emergency Inhibit optional feature (36) is relay contacts. These relays are comprised of one latching "Form enabled. The contact is closed for normal operation. Opening this A" relay to provide the generator start contacts, and six conven- contact will activate the Emergency Inhibit input. tional coil "Form C" relays (four of which implement only the If the Emergency Inhibit contact is opened when the load is con- Form A contact) necessary to complete the electrical control nected to the Normal Source, no action will be taken if the Nor- function. Since the outputs were tested per the UL 1008 Dielec- mal Source is available. If the Normal Source is not available, an tric Test, the dielectric rating for each output is a minimum of immediate transfer to the neutral position will occur. 1500 Vac. The output relays are pulsed to eliminate error caused If the Emergency Inhibit contact is opened when the load is con- by software "races" between Lockout and Source 1 or Source 2 nected to the Emergency Source, the ATC-300+ will transfer the Closed inputs. load to the Normal Source if it is available. If the Normal Source is The latched coil relay is UL/CSA rated at 5 A, 1/6 HP, 250 Vac. not available, an immediate transfer to the neutral position will occur. The DC rating is 5 A, 30 Vdc, with a 150 W maximum load. The remaining conventional relays are UL/CSA rated at 10 A, 1/3 HP, The Emergency Inhibit input is only active when either Source 1 250 Vac. The DC rating is 10 A at 30 Vdc. or Source 2 is preferred. This input is not active when the Pre- ferred Source selection is set to None. Note:The ATC-300+ Controller MUST BE properly grounded at J-5, Pin The Emergency Inhibit input takes priority over the Go To Emer- 12 for proper operation. gency input if both inputs are activated at the same time. In this The Output Relay functions are divided into two categories: case, the generator will start but a transfer to the Emergency Source will be inhibited until the Emergency Inhibit input is de- Customer Connections and activated. Transfer Operation Contacts. A jumper must be included between Pins 7 and 8 of connector J8 5.5.1 Output Relay Descriptions when a two position contactor is being used. The Inhibit function transfers to the open position which is on a three position contac- Specifically the relay functions are as follows. tor. 5.5.1.1 Customer Connections ,& CAUTION THE ATC-300+ CONTROLLER MUST BE PROPERLY GROUNDED AT • J-5,PIN 12 FOR PROPER OPERATION. For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC-300+ Automatic Effective: July 2011 Page 17 Transfer Switch Controller O . 0 1 , ON RS485 t Termination 4 SHD RS-485 S1-Line J10 3 Com MODBUS Control S1-Neut J7 z A(-) Power S2-Line 1 BH S2-Neut 7 Tx 6 Rx J3 5 Gnd Programming Phase C 4 SV Port Source 1 Phase B A 3 Out Phase A 2 In 8.0 in. E1 Clk Phase C A8 Emergency Source 2 Phase B J2 7 Inhibit Control Phase A 6 Manual Inputs 6 Re-Transfer 4 K4 NO J5 CONNECTOR 3 K4Com c2bse Output 2 K3 NO1• ro- Relays ��1 Cbse O J5 J4 1 1 2 3 4 1 S 6 1 718 1 9 10 11 12 13 14 �1y 2 �3y 4 5 6 c7� 6 �9..�10 z z .0z Z z o � S 8 S g > -2 � > o 0 U M U N O N 7 N Y Y Y € € m f2 + + N + J + (n + 8 co b I. a a Uj C 7 pp 0 b d d C N Cn !n 0 N O `n 0 a d a 0 Output Relays Control Inputs 6.5 in. Figure 5. Connector Output Relay Connections. CI-AEOM-00003-03-E For more information visit: www.cat.com CAT' Page 18 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller Generator Start Relay Output Relay K1 This latching relay is the generator start relay for system configu- This Form A relay is used for control of the transfer switch motor rations that employ a generator as the Source 2 power source. to close the Source 1 breaker/switch for breaker/switch style This relay provides a Form A contact of silver alloy with gold transfer switches. The K1 relay momentarily energizes until the flashing for c;osure of the generator start circuit. ATC-300+ senses that the Source 1 breaker/switch is closed, The Form A contact is implemented with the Common Pin (J 5, then K1 de-energizes. For contactor style transfer switches, this relay opens the Source 2 contactor via its trip coil. The Pin 13) and the Normally Open Pin (J-5, Pin 14). The generator (J puts are common pin (J-5, pin 1) and Normally Open pin IJ-5, pin start relay contacts are rated for 5 A, 1/6 HP @ 250 Vac. The 2) DC rating is 5 A @ 30 Vdc with a 150 W maximum load. Alarm Relay Output Relay K2 This Form A relay is used for control of the transfer motor to The alarm relay is de energized to indicate an absence of an alarm state and energized to indicate the presence of an alarm condi close the Source 2 breaker/switch for breaker/switch style trans- fer switches. The K2 relay momentarily energizes until the ATC- tion. Alarm conditions include the following. 300+ senses that the Source 2 breaker/switch is closed,then K2 1. Improper circuit breaker (or contactor) operation (breaker[or de-energizes. For contactor style transfer switches, this relay contactor] fails to open or close within six [61 seconds) opens the Source 1 contactor via its trip coil. The K2 outputs are common pin (J-5, pin 3) and Normally Open pin (J-5, pin 4). 2. Motor operator failure (Breaker Type ATS only) Output Relay K3 3. Lockout This Form A output is used for control of the close coil of the 4. Failsafe condition Source 1 contactor for contactor style switches. The K3 relay 5. Aborted engine test due to Source 2 unavailability momentarily energizes until the ATC-300+ senses that the Source 1 contactor is closed, then K3 de-energizes. The K3 out- 6. Aborted plant exerciser test due to Source 2 puts are common pin (J-8, pin 1) and Normally Open pin (J-8, pin unavailability 2). 7. Unsuccessful in-phase transition Output Relay K4 The alarm relay will remain energized until "Alarm Reset" is This Form A output is used for control of the close coil of the pressed. Source 2 contactor for contactor style switches. The K4 relay • momentarily energizes until the ATC-300+ senses that the The full Form C contact of this relay may be wired to an alarm Source 2 contactor is closed, then K4 de-energizes. The K4 out- annunciator panel to indicate a problem with the ATS. The full puts are common pin (J-8, pin 3) and Normally Open pin (J-8, pin Form C contact of this relay is implemented with the Common Pin 4). (J-5, Pin 8), the Normally Closed Pin (J-5, Pin 10), and Normally Open Pin (J-5, Pin 9). The alarm relay contacts are rated for 10 5.6 Operating Voltage and Measurements A, 1-3 HP @ 250 Vac. The DC rating is 10A @ 30 Vdc. The ATC-300+ Controller operates with control power from Pre-transfer Relay 65 to 145 Vac. The ATC-300+ operates on single and three This Form C relay opens/closes on a timed basis (adjustable from phase systems with selectable frequency settings of 50 or 60 Hz 1 to 120 seconds) prior to the transfer operation between two depending on the system ordered. available sources to allow the load to be de-energized prior to The ATC-300+ can perform the time delay engine start function transfer in either direction. After TDNE/TDEN times out, this without control power. This is accomplished by the use of a relay energizes and the Pre-transfer timer (TD PRE-TRAN) starts supercap and a latching control relay. The supercap stays timing. After TD PRE-TRAN times out, the transfer proceeds. charged for several minutes to power the logic circuitry that pro- The pre-transfer relay de-energizes after the transfer is complete. vides the start pulse to the latching control relay. The latching The full Form C contact of this relay is implemented with the control relay, which controls the generator, only changes state when it receives start or stop pulses. The coil voltage for the Common Pin (J-5, Pin 5), the Normally Closed Pin (J-5, Pin 7), latching relay comes from another capacitor that also stays and the Normally Open Pin (J-5, Pin 6). The pre-transfer relay charged for several minutes. contacts are rated for 10 A, 1-3 HP @ 250 Vac. The DC rating is 10 A @ 30 Vdc. The ATC-300+ Controller operates directly from the line sensing inputs of the Source 1 and Source 2 power sources. The nominal 5.5.1.2 Transfer Operations Connections operating system inputs are from 120 to 600 Vac. The standard K1, K2, K3, and K4 are factory wired to operate the transfer system assumes that neutral is available and that the transfer switch. The relay contacts for each are rated for 10 A, 1/3 HP @ mechanism can therefore be powered from an available 120 Vac 250 Vac. The DC rating is 10 A @ 30 Vdc. K1 - K4 are Form C source. If a neutral conductor is not available, a 120 Vac supply relays but only the Form A contacts are used to operate the trans- is created by an external transformer. fer switch. All voltage monitoring and measurements are true RMS measure- Note:The ATC-300+ Controller MUST BE properly grounded at J-5, Pin ments. 12 for proper operation. • For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC-300+ Automatic Effective: July 2011 Page 19 Transfer Switch Controller 5.7 Engine Test During an engine test, if the Engine Test pushbutton is pressed a The Engine Test is intended to permit the periodic performance of second time before the Engine Test is complete and correct pass- tests of the system. The exact test conditions are determined by word has been entered; the Engine Test will be terminated. An the programmed setpoints. The operator-selected parameters engine test may also be aborted in the following ways: include setting the engine run time and the Test Mode. Refer to 1. If the Emergency Source does not become available within Table 2 for test programming details. 90 seconds of the ATC-300+ providing the engine start There are three test modes: command; 0 No Load Engine Test; 2. If, during the TDNE countdown, the Emergency Source goes unavailable more than three times (Each time, TDNE will 1 Load Engine Test; or restart); 2 Disabled. 3. If the Emergency Source is powering the load and it goes The factory default is set to 0- Load Engine Test unavailable for more than the TDEF setting; and 4. If the Normal source becomes unavailable. Note:If the Source 2 power source is not programmed as a generator,this function will be inactive. When an engine test is aborted due to an unavailable source dur- ing TONE countdown, the Alarm relay will energize, a "TEST ABORTED" message with appear on the display, and the event will be logged into the Transfer History as "Aborted Test". IF THE ATS IS UNABLE TO PROCESS A ENGINE TEST REQUEST DUE 5.8 Plant Exerciser TO THE ATS STATUS,THE REQUEST IS IGNORED. When the Engine Test pushbutton is pressed, the following mes- sage will appear on the LCD Display: Line 1: Password 0 0 0 0 THE PLANT EXERCISER FEATURE ALLOWS FOR AUTOMATIC PRO- Line 2: Use Inc/Dec & Step GRAMMING OF THE DESIRED TEST CYCLE ON A DAILY, 7-DAY, 14-DAY,OR 28-DAY BASIS. IF THE ATS IS UNABLE TO PRO- After entering the 4-digit password and pressing the Step/Enter CESS A PLANT EXERCISER REQUEST DUE TO THE ATS STATUS,THE pushbutton,the ATC-300+ will display the Time Delay on Engine REQUEST IS IGNORED. • Starting (TDES) timer countdown. Once the TDES countdown The plant exerciser is a feature that provides an automatic test of reaches zero, the ATC-300+ Controller will initiate an engine the generator. The test can be run daily, every start. The engine run duration will be per the Engine Run Test 7 days, every 14 days, or every 28 days with durations equal to Time setpoint. the programmed engine test time. Two optional modes of plant If the (0) No Load Engine Test Mode has been selected, the trans- exercising are available: fer from Source 1 to Source 2 will not occur. If the No Load Exercise; and (1) Load Engine Test Mode has been selected, the transfer from Load Exercising with "Failsafe". Source 1 to Source 2 will occur after the generator output has reached the specified setpoints. If the (2) Disabled Mode has The ATC-300+ Controller allows the user to program the exact been selected, or if the "Number of Generators" setpoint is pro- day, hour, and minute that the Plant Exercise will occur. This grammed to zero, the Engine Test will not occur. allows for the Plant Exercise to take place at the most opportune All enabled and programmed time delays will be performed per time for the specific facility. the setpoints during an engine test. The time delays will appear The hour and minute that the Plant Exerciser is performed are on the LCD Display with "countdown to zero" when active. programmed with the "PE HOUR" and "PE MINUTE" setpoints Depending on the setpoints and the optional features selected where "PE HOUR" is in military time (1:00 PM = 13:00) and the with the ATC-300+ Controller, these can include: "PE MINUTE" can be set from 0 to 59. The test day is pro- TDES; grammed with the "PE DAY"setpoint. The ATC-300+ Controller compares the "PE DAY" setpoint with the "WEEKDAY" setting, • Time Delay Normal to Emergency (TDNE); which is set along with the time and date. If a 7-day plant exer- • Time Delay Emergency to Normal (TDEN); cise is programmed, the selections are from • Time Delay for Engine Cool-down (TDEC); "1 SUN" through "7 SAT". • Time Delay Neutral (TDN); and If a 14-day plant exercise is programmed, the "PE DAY" setpoint • Pre-transfer Delay Signal (TD PRE-TRAM. can be set from "1 SUN"to "14 SAT" where "1 SUN" is the first All operations are "Failsafe", that is they prevent disconnection Sunday of the 14-day period and "14 SAT" is the second Satur- from the only available power source and also force a transfer or day of the 14-day period. re-transfer operation to the only available power source. If a 28-day plant exercise is programmed, the "PE DAY" setpoint can be set from "1 SUN"to "28 SAT" where "1 SUN" is the first Sunday of the 28-day period and "28 SAT" is the fourth Saturday of the 28-day period. • If desired, the Plant Exerciser can be disabled by choosing "OFF" for the "Plant Exer-" setpoint. CI-AEOM-00003-03-E For more information visit: www.cat.com CAT' Page 20 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller Plant Exercising in the Load Exercising Mode is "Failsafe". If the Section 6: Programming generator fails during testing for any reason, the ATC-300+ will signal the transfer switch to return to the Source 1 power source. 6.1 Introduction The ATC-300+ will display "FAILSAFE" until a pushbutton is pressed. 5.9 In-phase Transition (Optional Feature 32F) The In-phase transition feature permits a transfer or re-transfer ALTHOUGH ALL ATC-300+ CONTROLLER PROGRAMMABLE FEA- only between 2 available sources that have a phase angle differ- TURES ARE ADDRESSED IN THIS SECTION,ONLY THOSE ORDERED ence of eight (8) degrees or less. The In-phase transition feature BY THE CUSTOMER AND INITIALLY PROGRAMMED AT THE FAC- includes user-adjustable permissible frequency difference setpoint TORY WILL APPEAR IN THE DISPLAY FOR PROGRAMMING CHANGES (0.0- 3.0 Hz) and a programmable Sync timer. The Sync times IN THE FIELD. will count down and be displayed while waiting for the two The ATC-300+ Controller is fully programmable from the sources to synchronize. device's faceplate or remotely through the communications port. In-phase transition is an open transition with both sources in- Users can reprogram setpoints as well as other parameters. The phase. An anticipatory scheme is used for controlling the circuit time, date, and setpoints can only be changed while the device is breakers. The advance angle is calculated based on the fre- in the Program Mode. quency difference between the two sources and also the Program Mode is achieved by entering a valid password when response time of the breaker. This results in the optimum recon- prompted by the Setpoints screens. The Unit Status LED will nect angle of 0 degrees for all of the frequency difference values. blink at a faster rate when viewing the setpoints while in Program Both sources must be available and the frequency difference Mode. must be less than the in-phase transition frequency difference setpoint (0.0 to 3.0 Hz). When these conditions are met, the ATC-300+ Controller will monitor the phase difference between the two sources. The synchronization timer will count down and be displayed as "SYNC TIME" while waiting for synchronization WHILE IN THE PROGRAM MODE,THE ATC-300+ CONTROLLER IS to be detected. When the phase difference is within the advance NEVER OFF-LINE AND CONTINUES TO FUNCTION IN ACCORDANCE angle window, the "transfer" command is given. This is an open WITH PREVIOUSLY PROGRAMMED SETPOINTS. transition but both sources will be in-phase when the transfer occurs. 6.2 Password In the event source 1 and source 2 fail to synchronize within a To enter the Program Mode, the ATC-300+ Controller requires a • specified amount of time,due to excessive phase angle difference password to prevent unauthorized persons from modifying set- or frequency difference,then the transfer will take place under point values. delayed transition. Alarm relay will energize and failure will be logged into the transfer history as either "Sync Fail - Freq" or There are five screens related to the password, which is a four "Sync Fail - Phase" depending on whether the frequency differ- digit number from 0000 to 9999. ence or the phase difference was excessive. 1. VIEW YES SETPOINTS? 5.10 Program Mode Use the Increase or Decrease pushbuttons to select Yes, then use The ATC-300+ Controller is fully programmable from the the Step/Enter pushbutton to enter the selection and move to the device's faceplate once the Password has been correctly entered. next screen Any operator associated with programming the ATC-300+ Con- troller will quickly discover that ATC-300+ programming is just a 2. CHANGE YES matter of simple, repetitive steps. However, because of the SETPOINTS? importance placed on this function and its critical relationship to Use the Increase or Decrease pushbuttons to select Yes or No, the proper functioning of the system, Section 6 of this manual is then use the Step/Enter pushbutton to enter the selection and dedicated to the Program Mode. Refer to that section and Table move to the next screen. If No is selected, the user will be able 2 for details. to review the setpoints but not make any changes. If Yes is selected, the Password screen will appear. 3. PASSWORD 0000 (Use Inc/Dec) Use the Increase or Decrease keys taodId:o the desired value(0-9)for the first digit,then us66 Step/Enter key to entt m value and move to the next digit. Repeat for remaining threjiUdi After all four numerals of the password are entered,press the Stepp pushbutton to enter the pass- word and proceed to the next screen. If an invalid password is entered,the LCD Display shall read"Invalid Passwoidd the user must press the Step/ Enter pushbutton to initiatmother password entry sequence. Note:The factory default password is "0300". If the password is forgot- • ten, contact the factory for the backdoor password. For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC-300+ Automatic Effective: July 2011 Page 21 Transfer Switch Controller 104. CHANGE YES PASSWORD? Use the Increase or Decrease pushbuttons to select Yes or No, then use the Step/Enter pushbutton to enter the selection and move to the next screen. If No is selected, the first Setpoint screen will appear. If Yes is selected, the following screen will appear. 5. NEW PASSWORD 0000 (Use Inc/Dec) Use the Increase or Decrease pushbuttons to scroll to the desired value (0- 9) for the first digit of the new password, then use the Step/Enter pushbutton to enter the value and move to the next digit. Repeat for remaining three digits. The user then steps through the setpoint screens and can change the setpoint values. During this time, the Unit Status LED will blink at a faster rate. At the end of the setpoint screens,the user will be prompted to save the setpoints. 6.3 Display Only Mode In the Display Only Mode, the ATC-300+ Controller allows the user to view all setpoints and their programmed values. Each press of the Step/Enter pushbutton will advance the program to the next setpoint. Setpoint values CANNOT be changed while in the Display Only Mode. 6.4 Change Setpoints Mode In the Change Setpoints Mode, the user can step through the Set- •point screens and change the Setpoint values using the Increase and Decrease pushbuttons. During this time,the Unit Status LED will blink at a faster rate to indicate Program Mode. At the end of the setpoint screens, the LCD Display will read Save Setpoints? Either the Increase or Decrease pushbutton may be used to select either Yes or No". The Step/Enter pushbutton is then pressed to enter the selection. If Yes is selected at the Save Setpoints? Screen, the ATC-300+ shall save the Setpoint settings and the LCD Display shall read Programming Setpoints to confirm entry. If "No" is selected, then all Setpoints will remain unchanged. 6.5 Programmable Features and Setpoints A CAUTION CHANGING THE SYSTEM NOMINAL VOLTAGE OR FREQUENCY SET- POINT WILL AUTOMATICALLY CHANGE ALL THE PICKUP AND DROPOUT SETTINGS TO THE NEW DEFAULT VALUES. All ATC-300+ Controller programmable features and associated setpoint possibilities with any required explanations are presented in Table 2. Remember that only features originally ordered and factory programmed will appear in the display. CI-AEOM-00003-03-E For more information visit: www.cat.com CAT' Page 22 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller The following setpoints are programmable if the corresponding feature is programmed. Table 2. Programmable Features and Setpoints SETPOINT SETPOINT UNITS DESCRIPTION RANGE FACTORY DEFAULT New Password Four Digits Set New Password 0000 to 9999 0300 TOES Minutes:Seconds Time Delay Engine Start 0 to 120 seconds 0:03 TONE Minutes:Seconds Time Delay Normal to Emergency 0 to 1800 seconds 0:00 TDEN Minutes:Seconds Time Delay Emergency to Normal 0 to 1800 seconds 5:00 TDEC Minutes:Seconds Time Delay Engine Cool-off 0 to 1800 seconds 5:00 NOM FRED Hertz Nominal Frequency 50 or 60 Hz As ordered NOM VOLTS Volts Nominal Voltage 120 to 600 volts As ordered Sl UV DROP Volts Source 1 Undervoltage Dropout Range: Breaker/Switch Style ATS 50 to 97%of Nominal System Voltage 80% Contactor Style ATS(2-position/3-position) 78 to 97%of Nominal System Voltage 85% S2 UV DROP Volts Source 2 Undervoltage Dropout Range: Breaker/Switch Style ATS 50 to 97%of Nominal System Voltage 80% Contactor Style ATS(2-position/3-position) 78 to 97%of Nominal System Voltage 85% St UV PICK Volts Source 1 Undervoltage Pickup Range: Breaker/Switch Style ATS (Dropout+2%)to 99%of Nominal System Voltage 90% Contactor Style ATS(2-position/3-position) (Dropout+2%)to 99%of Nominal System Voltage 90% S2 UV PICK Volts Source 2 Undervoltage Pickup Range: Breaker/Switch Style ATS (Dropout+2%)to 99%of Nominal System Voltage 90% Contactor Style ATS(2-position/3-position) (Dropout+2%)to 99%of Nominal System Voltage 90% S1 OV DROP Volts Source 1 Overvoltage Dropout Range: Breaker/Switch Style ATS 105 to 120%of Nominal System Voltage 115% Contactor Style ATS(2-position/3-position) 105 to 110%of Nominal System Voltage 110% S2 OV DROP Volts Source 2 Overvoltage Dropout Range: Breaker/Switch Style ATS 105 to 120%of Nominal System Voltage 115% • Contactor Style ATS(2-position/3-position) 105 to 110%of Nominal System Voltage 110% S1 OV PICK Volts Source 1 Overvoltage Pickup Range: Breaker/Switch Style ATS 103%to(Dropout-2%)of Nominal System Voltage 110% Contactor Style ATS(2-position/3-position) 103%to(Dropout-2%)of Nominal System Voltage 105% S2 OV PICK Volts Source 2 Overvoltage Pickup Range: Breaker/Switch Style ATS 103%to(Dropout-2%)of Nominal System Voltage 110% Contactor Style ATS(2-positionf3-position) 103%to(Dropout-2%)of Nominal System Voltage 105% S1 OF DROP Hertz Source 1 Underfrequency Dropout Range: Breaker/Switch Style ATS 90 to 97%of Nominal System Frequency 94% Contactor Style ATS(2-position/3-position) 90 to 97%of Nominal System Frequency 90% S2 OF DROP Hertz Source 2 Underfrequency Dropout Range: Breaker/Switch Style ATS 90 to 97%of Nominal System Frequency 94% Contactor Style ATS(2-position/3-position) 90 to 97%of Nominal System Frequency 90% St OF PICK Hertz Source 1 Underfrequency Pickup Range: Breaker/Switch Style ATS (Dropout+1 Hz)to 99%of Nominal System Frequency 96% Contactor Style ATS(2-position/3-position) (Dropout+1 Hz)to 99%of Nominal System Frequency 95% S2 OF PICK Hertz Source 2 Underfrequency Pickup Range: Breaker/Switch Style ATS (Dropout+1 Hz)to 99%of Nominal System Frequency 96% Contactor Style ATS(2-position/3-position) (Dropout+1 Hz)to 99%of Nominal System Frequency 95% S1 OF DROP Hertz Source 1 Overfrequency Dropout Range: Breaker/Switch Style ATS 103 to 110%of Nominal System Frequency 106% Contactor Style ATS(2-position/3-position) 103 to 105%of Nominal System Frequency 105% S2 OF DROP Hertz Source 2 Overfrequency Dropout Range: Breaker/Switch Style ATS 103 to 110%of Nominal System Frequency 106% Contactor Style ATS 12-positionl3-position) 103 to 105%of Nominal System Frequency 105% S1 OF PICK Hertz Source 1 Overfrequency Pickup Range: Breaker/Switch Style ATS 101%to(Dropout-1 Hz)of Nominal System Frequency 104% Contactor Style ATS(2-position/3-position) 101%to(Dropout-1 Hz)of Nominal System Frequency 102% S2 OF PICK Hertz Source 2 Overfrequency Pickup Range: Breaker/Switch Style ATS 101%to(Dropout-1 Hz)of Nominal System Frequency 104% Contactor Style ATS(2-position/3-position) 101%to(Dropout-1 Hz)of Nominal System Frequency 102% TON Minutes:Seconds Time Delay Neutral 0 to 120 seconds 0:00 • BAUD RATE Modbus Baud Rate 9600 or 19200 9600 ADDRESS Modbus Address 1 to 247 1 PLANT EXER Days Plant Exerciser Programming OFF,DAILY,TDAY,14-DAY or 28 DAY OFF PE LOAD XFR Plant Exerciser Load Transfer 0 or 1(1 -yes) 0 For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC-300+ Automatic Effective: July 2011 Page 23 Transfer Switch Controller •Table 2 Programmable Features and Setpoints (Cont.) SETPOINT SETPOINT UNITS DESCRIPTION RANGE FACTORY DEFAULT PE DAY [lays Plant Exerciser Day of the Week 1 SUN,2 MON,3 TUE,4 WED,5 THU,6 FRI or 7 SAT PE HOUR Hours Plant Exerciser Hour 0 to 23 0 PE MINUTE Minutes Plant Exerciser Minute 0 to 59 0 TEST MODE Test Mode 0,1 or 2(0-No Load Engine Test,1 -Load Engine Test,2— 0 Disabled) TER Hours:Minutes Engine run test time 0 min to 600 min 5:00 TPRE Minutes:Seconds Pretransfer delay timer 0 sec to 120 sec 0:00 PHASES Three phase or single phase 1 or 3 AS ORDERED VOLT UNBAL Volts Voltage Unbalanced 0 or 1(1 —Enabled) 1 UNBAL DROP% Percent Percent for Unbalanced Voltage Dropout 5 to 20%of Phase to Phase Voltage Unbalance 20% UNBAL PICK% Percent Percent for Unbalanced Voltage Pickup Dropout minus(UNBAL DROP%-2)to 3% 10% UNBAL DELAY Seconds Unbalanced Delay Timer 10 to 30 0:20 TDEF Seconds Time Delay Emergency Fail Timer 0 sec to 6 sec 6 IN-PHASE Hertz In-Phase Transition 0 or 10—Enabled) 1 IP FRED DIFF Hertz In-phase Transition FrequencyDifference 0.0 Hz to 3.0 Hz 1.0 SYNC TIME Minutes In-phase Transition Synchronization Timer 1 min to 60 min 5 PHASE REV Phase Reversal OFF,ABC,or CBA OFF DST ADJUST Day Light Savings 0 or 1(1-Enabled) 1 MAN RETRAN Manual Retransfer 0 or 10-Enabled) 0 LANGUAGE Selected Language English,French,or Spanish English CHANGE TIMEIDATE? Set Time and Date • Hours Set Hour 0 to 23 Eastern Standard Time MINUTES Set Minute 0 to 59 Eastern Standard Time WEEKDAY Set Weekday SUN,MON,TUE,WED,THU,FRI or SAT Eastern Standard Time MONTH Set Month JAN or 01 Eastern Standard Time DAY Set Day 1 to 31 Eastern Standard Time YEAR Set Year Current Year Eastern Standard Time RESET Yes or No No SYSTEM COUNTERS? RESET ALL? Resets all System Counters Yes or No No RESET Hours Resets ENGINE RUN Counter 0 to 9999 XXXX ENGINE RUN? RESET Hours Resets S1 CONN Counter 0 to 9999 XXXX S1 CONN RESET Hours Resets S2 CONN Counter 0 to 9999 XXXX S2 CONN RESET Hours Resets S1 AVAIL Counter 0 to 9999 XXXX S1 AVAIL RESET Hours Resets S2 AVAIL Counter 0 to 9999 XXXX S2 AVAIL RESET Hours Resets LOAD ENERG Counter 0109999 XXXX LOAD ENERG RESET Cycles(Counts) Resets TRANSFERS Counter 0 to 9999 XXXX TRANSFERS qWSAVE Save Changed Setpoints Yes or No Yes SETPOINTS? See tables in the appendix for Voltage and Frequency Pickup and Dropout settings. CI-AEOM-00003-03-E For more information visit: www.cat.com CAT' Page 24 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller Section 7: Troubleshooting and 7.2 ATC-300+ Controller Troubleshooting • Maintenance The Troubleshooting Guide (Table 3) is intended for service per- sonnel to identify whether a problem being observed is external or 7.1 Level of Repair internal to the unit. For assistance with this determination, con- tact your Cat dealer. If a problem is identified to be internal, the This manual is written with the assumption that only ATS trouble- unit should be returned to the factory for replacement. shooting will be performed. If the cause of malfunction is traced to an ATC-300+, the unit should be replaced with a new unit. The malfunctioning unit should then be returned to your Cat dealer. WHILE PERFORMING TESTING, IF AN UNDESIRED OR UNDOCU- MENTED RESULT OCCURS, FIRST CONTACT THE LOCAL GENSET DEALER.IF THE RESULT IS NOT CORRECTED,CONTACT YOUR CAT DEALER Table 3. Troubleshooting Guide SYMPTOM PROBABLE CAUSE POSSIBLE SOLUTIONIS) All front panel indicator LED's are off. Control power is deficient or absent. Verify that control power is connected at J7 and that it is within specifications. ATC-300+is malfunctioning. Replace the unit. 'Unit Status'LED is not blinking. Control power is deficient or absent. Verify that control power is connected at J7 and that it is within specifications. ATC-300+is malfunctioning. Replace the unit. One or more voltage phases read incorrectly. Incorrect wiring. Verify voltage with multimeter. Check wiring. Replace the unit. • ATC-300+is malfunctioning. Verify ground connection at J-5,Pin 12 Front panel pushbuttons do not work. Bad connection inside the ATC-300+. Replace the unit. Unit did not accept new setpoints via front panel. Operator error. Enter the correct Password and change the setpoints. No pushbuttons pressed for 2.5 minutes. Avoid intervals of 2.5 minutes of inactivity with pushbuttons when changing setpoints. Source 1 or Source 2 is not available when it should Voltage andlor frequency are not within setpoint values. Verify voltage and/or frequency with multimeter. Check the pro- be. grammed setpoint values. Unit displays"LOCK-OUT". Circuit breaker tripped. Check for a overloadlshort circuit condition Lockout circuit wiring problem. Check lockout circuit wiring. Unit displays"INHIBIT". No contact closure at Emergency Inhibit Input Check Emergency Inhibit Vining at J6,Pins 7 and 8. Unit displays"SOURCE 1 DEVICE". Source 1 breaker/contactor did not open when it was commanded to open Check the Source 1 circuit breaker shunt trip(ST)wiring. Iwithin 6 seconds). Source 1 breakerlcontactor did not close when it was commanded to close Check the Source 1 circuit breaker spring release(SR)wiring. (within 6 seconds). Source 1 closed contacts did not open when Source 1 breaker opened Check the Source 1 closed control input wiring on J-4,Pins 1 (within 6 seconds). and 2 and J-8,Pins 1 and 2. Source 1 closed contacts did not close when Source 1 breaker closed Check the Source 1 closed control input wiring on J-4,Pins 1 (within 6 seconds). and 2 and J-8,Pins 1 and 2. Unit displays"SOURCE 2 DEVICE". Source 2 breaker/contactor did not open when it was commanded to open Check the Source 2 circuit breaker shunt trip(ST)wiring. (within 6 seconds). Source 2 breakerlcontactor did not close when it was commanded to close Check the Source 2 circuit breaker spring release(SR)wiring. (within 6 seconds). Source 2 closed contacts did not open when Source 2 breaker opened Check the Source 2 closed control input wiring on J-4,Pins 3 (within 6 seconds). and 4 and J-8,Pins 3 and 4. Source 2 closed contacts did not close when Source 2 breaker closed Check the Source 2 closed control input wiring on J-4,Pins 3 (within 6 seconds). and 4 and J-8,Pins 3 and 4. For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC-300+ Automatic Effective: July 2011 Page 25 Transfer Switch Controller •Table 3. Troubleshooting Guide (Cont.) SYMPTOM PROBABLE CAUSE POSSIBLE SOLUTION(S) Unit will not perform an Engine Test. Engine Test pushbutton was not pressed. Press the Engine Test pushbutton to initiate the test. Display is not displaying the Home screen before initiating the test. Use the Step/Enter pushbutton to step to the Home screen. If a timer is timing down,wait until it is done. Engine Test setpoint is set to Disable(Value of"2"). Re-program the Engine Test setpoint. Number of generators setpoint is set to 0. Re-program the number of generators setpoint. Generator became unavailable when connected to the load. Increase the Time Delay Emergency Fail(TDEF)timer setpoint. Generator became unavailable before connecting to the load. Check the generator for proper function. Generator voltage and/or frequency did not become available within 90 sec- Verify the voltage and/or frequency with a multimeter. Check onds of engine starting. the programmed setpoint values. Check the engine mainte- nance. Plant Exerciser failed to exercise. Incorrect date or time setting. Verify real time clock settings for the time and date. Incorrect setpoint programmed for the PE DAY,PE HOUR,and/or PE Re-program the PE DAY,PE HOUR,andlor PE MINUTE setpoint. MINUTE. Generator voltage and/or frequency did not become available within 90 sec- Verify the voltage and/or frequency with a multimeter. Check onds of engine starting. the programmed setpoint values. Check the engine mainte- nance. Generator became unavailable when connected to the load. Increase the TDEF timer setpoint. Generator became unavailable before connecting to the load. Check the generator for proper function. Engine fails to start after the TOES times out. Incorrect wiring. Check the wiring between the Gen Start relay(J-5,Pins 13 and 14►and the engine. • Gen Start relay contacts are not closed. Replace the unit. Engine did not start. Check the generator for proper function. 7.3 ATC-300+ Replacement Follow these procedural steps to replace the ATC-300+. Step 6: Remove the unit from the door or panel. Lay the original Step 1: Turn off the control power at the main disconnect or iso- mounting screws aside for later use. lation switch of the control power supply. If the switch Step 7: Align the unit with the opening in the door or panel. is not located within view from the ATC-300+, lock it out to guard against other personnel accidentally turning Step 8: Using the original mounting hardware, secure the it on. replacement unit to the door or panel. Step 2: Verify that all "foreign"power sources wired to the ATC- Step 9: Using the sketch mentioned in Step 3, replace each wire 300+ are de-energized. These foreign power sources at the correct terminal and make sure each is secure. may also be present on some of the terminal blocks. Make certain that each harness plug is securely seated. Step 3: Before disconnecting any wires from the unit, make sure Step 10: Restore control power to the unit. they are individually identified to assure that reconnec- tion can be correctly performed. Make a sketch to help with the task of terminal and wire identification. The ATC-300+ is designed to be a self-contained and mainte- nance-free unit. The printed circuit boards are calibrated and Step 4: Remove all wires and disconnect plug type connectors. conformally coated at the factory. They are intended for service by factory-trained personnel only. A CAUTION SUPPORT THE ATC-300+ FROM THE REAR WHEN THE SCREWS ARE LOOSENED OR REMOVED IN STEP 5. WITHOUT SUCH SUP- PORT,THE UNIT COULD FALL OR THE PANEL COULD BE DAM- AGED. •Step 5: Remove the four (4) mounting screws, located on the four corners, which hold the unit and trim plate against the door or panel. These are accessed from the front of the unit. Support the unit and remove the two center screws. CI-AEOM-00003-03-E For more information visit: www.cat.com CAT' Page 26 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller Appendix A: Display Message • for Status and Timers Display Message TDEC Countdown cool-off timing before the generator contacts are opened. TDES Countdown timing before the generator contacts are closed. TONE Countdown timing before Source 1 is disconnected before transferring to Source 2. Timing begins when Source 2 is available. TON Countdown timing with both sources disconnected from the load. TDEN Countdown timing before Source 2 is disconnected before transferring to Source 1. Timing begins when Source 1 becomes available. TRANSFER Waiting for the switch to make the transfer from the neutral position to the intended source. ATS NOT IN AUTOMATIC Control input for monitor mode is closed. LOCK-OUT OVERCURRENT TRIP A trip condition has been detected by either breaker,and the system is locked-out from further transfers. MANUAL Waiting for an input signal to complete the manual re-transfer INHIBIT Indicates that a transfer to the Emergency Source is inhibited because the Emergency inhibit input is activated. ENGINE RUN The engine run test timer is counting down before the test is completed. Pressing the Engine Test pushbutton will abort this timer and the test. START TEST? To initiate an engine test sequence,press the Engine Test pushbutton again,or press Increase and Decrease pushbut- tons simultaneously to clear. WAIT FOR S2 Waiting for the Source 2 source voltage and frequency to become available. • TO PRE-TRAN Countdown timer while waiting for a pre-transfer acknowledge input. SYNC TIME Countdown timing in minutes while waiting for sources to synchronize during an in phase transition. SOURCE 1 DEVICE Indicates that the Source 1 device(i.e.circuit breaker,contactor)failed to open or close SOURCE 2 DEVICE Indicates that the Source 2 device(i.e.circuit breaker,contactor)failed to open or close. TDEF Countdown timing before declaring Source 2 unavailable(accounts for momentary generator fluctuations). TO UNBAL Countdown timer before declaring a source unavailable due to a voltage unbalance condition. TEST ABORTED Indicates that an engine test or plant exercise was aborted after three unsuccessful attempts. Source 2 did not remain- available while TONE was timing. GO TO SOURCE 2 Indicates that the load is connected to Source 2 because the Go To Source 2 control input is in the"unconnected" state. FAILSAFE Indicates that the load was connected to Source 2 but Source 2 became unavailable so the load transferred back to Source 1. SETPOINTS ERROR Memory problem with the setpoints. Contact the factory. OPTIONS ERROR Memory problem with the factory options. Contact the factory. PROGRAMMING SETPOINTS Setpoints are being saved in memory. WAITING FOR NEUTRAL Waiting for the neutral position to be reached by the switch. WAITING FOR S1 TO OPEN Waiting for the Source 1 device(i.e.circuit breaker,contactor)to open. WAITING FOR S2 TO OPEN Waiting for the Source 2 device(i.e.circuit breaker,contactor)to open. • For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC-300+ Automatic Effective: July 2011 Page 27 Transfer Switch Controller *Appendix B: Operational Flowcharts • Utility - Generator Transfer Switch • Dual Utility Transfer Switch • In-phase Transition Implementation Utility-Generator Transfer Switch Source 1 is available Close Source 1 (Energize K1) Source 1 is powering the load No Source 1 becomes unavailable (or Engine Test, Plant Exercise,Go To Emergency) Is Source 1 Available? TIDES timer times out Yes MEN timer times out Send"Engine Start"signal (Energize Gen Start relay) Sends pretransfer signal TPRE timer times out No Open Source 2 Is Source 2 F_ (Energize K1) Available? Yes Close Source 1 (Energize K1) TDNE timer times out Source 1 is powering the load Sends pretransfer signal TPRE timer times out (If Source 1 is Available) TDEC timer times out Open Source 1 Remove"Engine Start"signal (Energize K2) (De-energize Gen Start relay) Close Source 2 (Energize K2) Source 2 is powering the load CI-AEOM-00003-03-E For more information visit: www.cat.com c�r� Page 28 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller • Dual Utility Transfer Switch Source 1 is available Close Source 1 (Energize K1) Source 1 is powering the load Source 1 becomes unavailable (or Go To Emergency) No No Is SoFYes Is SoFYes Avail Avail • MEN timer times out TDNE timer times out Sends pretransfer signal Sends pretransfer signal TPRE timer times out TPRE timer times out (if Source 1 is Available) ilr Open Source 2 Open Source 1 (Energize K1) (Energize K2) Close Source 1 Close Source 2 (Energize K3) (Energize K4) Source 1 is powering the load Source 2 is powering the load 0 For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC-300+ Automatic Effective: July 2011 Page 29 Transfer Switch Controller • In-Phase Transition Implementation Source 1 is available Close Source 1 (Energize K1) Source 1 is powering the load Receive request to transfer to Source 2 (or Engine Test, Plant Exercise,Go To Emergency) TIDES timer times out Send'Engine Start'signal (Energize Gen Start relay) No Is Source 2 Available? Yes TDNE timer times out Sends pretransfer signal TPRE timer times out (If Source 1 is available) Sync timer times out Energize Alarm relay Open Source 1 (Energized K2) +Yes No Close Source 2(out of Sync) (Momentarily energize K4) TDN timer times out if not Open Source 1 and close programmed equal to zero Source 2 (For 2-position contactor ATS, (Energize K2) TDN is not applicable&hence (Energize K4) recommended to program TDN=O) Source 2 is powering the load Source 2 is powering the load CI-AEOM-00003-03-E For more information visit: www.cat.com Cf- Page 30 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller Appendix C: Display Menu Tree Note: Only standard and programmed optional Features will appear on the LCD Display. Optional Features that are not programmed will be skipped and will not appear on the LCD display. ATC-300 DISPLAY MENU TREE 2n9ro3 10:01:02 AM DATE 417/04 SOURCE 1 120 VAC 60 Hz STEP VIEW NO STEP(YES) SOURCE 2 SYSTEM COUNTERS? 120 VAC 60 Hz STEP STEP(NO) ENGINE RUN 9999 S1 Vab 120 STEP STEP S1 CONN 9999 S1 Vbc 120 STEP STEP S2 CONN 9999 S1 Vca 120 STEP • STEP S1 AVAIL 9999 S1 FREQ 60.0 STEP STEP S2 AVAIL 9999 SOURCE GOOD STEP LOAD ENERG 9999 STEP S2 Vab 120 STEP TRANSFERS 9999 STEP S2 Vbc 120 STEP STEP TRANSFER HISTORY Decrease(YES) S2 Vca 120 Dec=YES,Step=NO STEP(NO) T01 OPEN S2-+S1 STEP Preferred Source S2 FREQ 60.0 STEP Decrease 1/31102 STEP 11:15:32 PM SOURCE 2 GOOD STEP Decrease T02 OPENSI-S2 STEP Undervoltage • TIME 10:01:02 AM • s A For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC-300+ Automatic Effective: July 201 1 Page 31 Transfer Switch Controller • VIEW r E' STEP r 10} Back to SETPOINTS? beginning menu STEP(YES) CHANGE NO STEP(YES) SET?OINTS? STEP(NO) PASSWORD 0000 Use IncrDec STEP PASSWORD 0000 Use In0Dec STEP PASSWORD 0000 Use IncrDec STEP PASSWORD 0000 Use IncrDec STEP • CH :PASSM;RD NO STEP(YES) STEP(NO) NEW PASSWORD 000n Use Inc Dec STEP NEW PASSWORD 0000 Use Inc/Dec STEP NEW PASSWORD 0000 UseInc/Dec STEP NEW PASSWORD 0000 Use Inc ec STEP TIDES 003 Use IncrDec STEP TDNE 0:00 Use IncA)ec STEP Cl-AEOM-00003-03-E For more information visit: www.cat.com VAT. al Page 32 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller • B TDEN 5:00 j Use Inc Dec STEP S1 OV PICK 228 Use Inc0ec TDEC 5:00 STEP } Use Inc/Dec STEP S2 OV PICK 228 Use IncDec I NOM FREQ 60.0 STEP I i Use IncA)ec STEP S1 OF DROP 57.O Use IncJDec PJOM VOLTAGE 208 STEP Jse Inc Dec STEP 52 OF DROP Use Inc/Dec S1 UV DROP 166 STEP i Jse IncA)ec STEP S1 OF PICK 58 • Use inuDec I I'+/DROP 166 STEP ` !Ise IncA)ec STEP S2 OF PICK 58.2 Use IncMec S1 U%,'PICK 176 STEP Use IncJDeC STEP 11 OF DROP 63.0 Use IncA)ec S2 UV PICK 176 STEP Use Inc/Dec STEP S2 OF DROP 63.0 Use InclDec S1 OV DROP 239 STEP Use InclDec STEP S1 OF PICK 61.2 Use IncA)ec S2 OV DROP 239 STEP Use IncA)ec STEP S2 OF PICK 61.2 Use IncA)ec STEP C For more information visit: www.cat.com CI-AEOM-00003-03-E IMAT Lau- ATC-300+ Automatic Effective: July 2011 Page 33 Transfer Switch Controller C TDN 0:00 VOLT UNBAL 1 Use IncA)ec Use IncA)ec STEP STEP PLANT EXER- OFF rUNBAL DROP% 20 Use Inc/Dec IncrDec STEP STEP PE LOAD XFR 0 UNBAL PICK% 10 Use InciDec Use IncJDec STEP STEP PE DAY 1 SUN rUNIBIAL DELAYUse IncA)ec IncA)ec STEP STEP PE HOUR 0 TDEF 6 UselnGDec UselnGDec STEP STEP PE MINUTE 0 IP FREQ DIFF 1.0 Use IncA)ec Use IncA)ec STEP STEP TEST MODE 0 SYNC TIME 5 Use IncA)ec Use IncA)ec STEP STEP TER 5:00 PHASE REV OFF Use IncA)ec Use IncA)ec STEP STEP IF TPRE 0:00 DST ADJUST 1 Use IncA)ec Use IncA)ec STEP STEP LANGUAGE -ENG PHASES 3 use linco C STEP D ' CI-AEOM-00003-03-E For more information visit: www.cat.com ex, Page 34 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller D CHANGE NO STEP(YES) TIMEIDATE? STEP HOURS 10AM (NO) Use IncOec STEP MINUTES 2 Use kioAec STEP WEEKDAY 4 WED Use Inc.Dec STEP MONTH 4 Use kiaDec STEP DAY 7 Use W-DeC STEP YEAR 2004 Use Inc/Dec STEP RESET STEP(YES) • SYSTEM COUNTERS? STEP(NO) RESET NO STEP(NO) ALL COUNTERS? STEP(YES) ENGINE RUN 9999 PUSH Alarm Reset STEP S1 CONN 9999 PUSH Alarm Reset STEP S2 CONN 9999 PUSH Alarm Reset STEP E P For more information visit: www.cat.com CI-AEOM-00003-03-E C - al ATC-300+ Automatic Effective: July 2011 Page 35 Transfer Switch Controller E F S1 AVAIL 9999 PUSH Alarm Reset STEP S2 AVAIL 9999 PUSH Alarm Reset STEP LOAD ENERG 9999 PUSH Alarm Reset STEP TRANSFERS 9999 P US H Alarm Reset • STEP SAVE YES SETPOINTS? STEP Bark to beginning menu • CI-AEOM-00003-03-E For more information visit: www.cat.com 11M Page 36 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller Appendix D: Pickup / Dropout Tables • UNDERVOLTAGE PICKUP IDROPOUT TABLE PERCENTAGE VOLTAGE 120 208 220 240 380 415 480 600 97 116 202 213 233 369 403 466 582 96 115 200 211 230 365 398 461 576 95 114 198 209 228 361 394 456 570 94 113 196 207 226 357 390 451 564 93 112 193 205 223 353 386 446 558 92 110 191 202 221 350 382 442 552 91 109 189 200 218 346 378 437 546 91I 1E18 187 198 210 342 374 432 540 1'lckug Break,Cantactor12•position(3•pasitiori} 89 107 185 196 214 338 369 427 534 88 106 183 194 211 334 365 422 528 87 104 181 191 209 331 361 418 522 86 103 179 189 206 327 357 413 516 85 102 177 187 204 323 353 408 610 0ropoat•Cantactor{2•positiontlWition} 84 101 175 185 202 319 349 403 504 83 100 173 183 199 315 344 398 498 82 98 171 180 197 312 340 394 492 81 97 168 178 194 308 336 389 486 60 86 16G 176 ! 192 304 232 384 480 Oropart•Breaker 79 95 164 174 190 300 328 379 474 78 94 162 172 187 296 324 374 468 77 92 160 169 185 293 320 370 462 76 91 158 167 182 289 315 365 456 75 90 156 165 180 285 311 360 450 74 89 154 163 178 281 307 355 444 73 88 152 161 175 277 303 350 438 72 86 150 158 173 274 299 346 432 71 85 148 156 170 270 295 341 426 70 84 146 154 168 266 291 336 420 69 83 144 152 166 262 286 331 414 68 82 141 150 163 258 282 326 408 67 80 139 147 161 255 278 322 402 66 79 137 145 158 251 274 317 396 65 78 135 143 156 247 270 312 390 64 77 133 141 154 243 266 307 384 63 76 131 139 151 239 261 302 378 62 74 129 136 149 236 257 298 372 61 73 127 134 146 232 253 293 366 60 72 125 132 144 228 249 288 360 59 71 123 130 142 224 245 283 354 58 70 121 128 139 220 241 278 348 57 68 119 125 137 217 237 274 342 56 67 116 123 134 213 232 269 336 55 66 114 121 132 209 228 264 330 54 65 112 119 130 205 224 259 324 53 64 110 117 127 201 220 254 318 52 62 108 114 125 198 216 250 312 51 61 106 112 122 194 212 245 306 • 50 60 104 110 120 190 208 240 300 For more information visit: www.cat.com CI-AEOM-00003-03-E CAT` ATC-300+ Automatic Effective: July 2011 Page 37 Transfer Switch Controller OVERVOLTAGE PICKUP/DROPOUT TABLE PERCENTAGE VOLTAGE 120 208 220 240 380 415 480 600 120 144 250 264 288 456 498 576 720 119 143 248 262 286 452 494 571 714 118 142 245 260 283 448 490 566 708 117 140 243 257 281 445 486 562 702 116 139 241 255 278 441 481 557 696 t15 138 i 239 253 276 437 477 552 690 Dropout-Breaker 114 137 237 251 274 433 473 547 684 113 136 235 249 271 429 469 542 678 112 134 233 246 269 426 465 538 672 111 133 231 244 266 422 461 533 666 110 132 229 242 264 418 457 528 660 Pickup-Breaker Dropout-Contactor(2-position13 position) 109 131 227 240 262 414 452 523 654 108 130 225 238 259 410 448 518 648 107 128 223 235 257 407 444 514 642 106 127 220 233 254 403 440 509 636 105 126 218 231 252 399 436 504 630 Pickup-Contactor(2-positionl3-position) UNDERFREQUENCY PICKUP I DROPOUT TABLE PERCENTAGE FREQUENCY 50 60 97 49 58 96 48 58 Pickup-Breaker j 95 48 57 Pickup-Contactor(2 positionl3-position) 84 _ 47 56 Dropout-Breaker 93 47 56 92 46 55 91 46 55 90 45 54 Dropout-Contactor(2 positioni3-position) OVERFREQUENCY PICKUP I DROPOUT TABLE PERCENTAGE FREQUENCY 50 60 110 55 66 109 55 65 108 54 65 107 54 64 106 53 64 Dropout-Breaker 105 53 63 Dropout-Contactor(2-positiont1position), 104 52 62 Pickup-Breaker 103 52 62 102 51 61 Pickup-Contactor(2-positiiosil1060lon) CI-AEOM-00003-03-E For more information visit: www.cat.com CAT' Page 38 Effective: July 2011 ATC-300+ Automatic Transfer Switch Controller NOTES: For more information visit: www.cat.com CI-AEOM-00003-03-E CAT' ATC•300+ Automatic Effective: July 2011 Page 39 Transfer Switch Controller NOTES: • • CI-AEOM-00003-03-E For more information visit: www.cat.com Page40 Effective: July 2011 ATC•300+ Automati Transfer Switch Controlled This instruction booklet is published solely for information pur- poses and should not be considered all-inclusive. If further infor- mation is required, you should consult Caterpillar Sale of product shown in this literature is subject to terms and conditions outlined in appropriate Caterpillar selling policies or other contractual agreement between the parties. This literature is not intended to and does not enlarge or add to any such con- tract. The sole source governing the rights and remedies of any purchaser of this equipment is the contract between the pur- chaser and Caterpillar. NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WAR- RANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MER- CHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN. In no event will Caterpillar be responsible to the purchaser or user in contract, in tort(including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not lim- ited to damage or loss of use of equipment, plant or power sys- tem, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and description contained herein. CSA is a registered trademark of the Canadian Standards Associ- ation. National Electrical Code and NEC are registered trademarks of the National Fire Protection Association, Quincy, Mass. NEMA • is the registered trademark and service mark of the National Elec- trical Manufacturers Association. Uniform Building Code (UBC) is a trademark of the International Conference of Building Officials (ICBO). UL is a federally registered trademark of Underwriters Laboratories Inc. CA ® Generator Switchgear Products �T Automatic Transfer Switches 4955 Marconi Drive Alpharetta, GA 30005 • (770) 442-9442 AdhhT • 0 & M Manual for ATC-300+ , 3-Position Contactor Based Transfer Switch 40-400A Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Receiving, Handling and Storage . . . . . . . . . . . . . . . . . . . . 6 Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Testing and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .21 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Renewal Parts Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 ATC-300+ Contactor Based ATS Quick Start Instructions . .25 Appendix A: Pickup/ Dropout Tables . . . . . . . . . . . . . . . . .34 • ye • Cl-AEOM-00074-01-E For more information visit: www.Cat.com IB01602076E PAW VAU Page 2 Effective: July 2011 0&M Manual for the ATC-300+, 3-Postion Contactor Based Transfer Switch 40-400A Section 1 : Introduction AWARNING 1.1 Preliminary Comments and Safety Precautions READ AND UNDERSTAND THE INSTRUCTIONS CONTAINED HEREIN- This technical document is intended to cover most aspects asso- AFTER BEFORE ATTEMPTING TO UNPACK,ASSEMBLE, OPERATE, ciated with the installation, application, operation, and mainte- OR MAINTAIN THIS EQUIPMENT. nance of the Automatic Transfer Controller (ATC-300+) HAZARDOUS VOLTAGES ARE PRESENT INSIDE TRANSFER SWITCH controlled contactor based ATS with ratings from 40 through ENCLOSURES THAT CAN CAUSE DEATH OR SEVERE PERSONAL 400 amperes (A). It is provided as a guide for authorized and INJURY. FOLLOW PROPER INSTALLATION,OPERATION,AND MAIN- qualified personnel only. Please refer to the specific WARNING TENANCE PROCEDURES TO AVOID THESE VOLTAGES. and CAUTION in Section 1.1.2 before proceeding. If further infor- TRANSFER SWITCH EQUIPMENT COVERED BY THIS INSTRUCTION mation is required by the purchaser regarding a particular installa- BOOK IS DESIGNED AND TESTED TO OPERATE WITHIN ITS NAME- tion, application, or maintenance activity, please contact your Cat PLATE RATINGS. OPERATION OUTSIDE OF THESE RATINGS MAY dealer. CAUSE THE EQUIPMENT TO FAIL RESULTING IN DEATH,SERIOUS BODILY INJURY,AND/OR PROPERTY DAMAGE. ALL RESPONSIBLE 1.1.1 Warranty and Liability Information PERSONNEL SHOULD LOCATE THE DOOR MOUNTED EQUIPMENT NAMEPLATE AND BE FAMILIAR WITH THE INFORMATION PROVIDED No warranties, expressed or implied, including warranties of fit- ON THE NAMEPLATE. A TYPICAL EQUIPMENT NAMEPLATE IS ness for a particular purpose of merchantability, or warranties SHOWN IN FIGURE 1. arising from course of dealing or usage of trade, are made regard- ing the information, recommendations and descriptions contained herein. In no event will Caterpillar be responsible to the pur- chaser or user in contract, in tort (including negligence), strict lia- bility or otherwise for any special, indirect, incidental or tt�'�' IrlD[��/�@� consequential damage or loss whatsoever, including but not lim- ill R1�[ f1,l ited to damage or loss of use of equipment, plant or power sys- MODEL MODES na' tem, cost of capital, loss of power, additional expenses in the use Ma°I` mo.ottO of existing power facilities, or claims against the purchaser or MODtL MODELO user by its customers resulting from the use of the information MODELL M$bI tL SEtiENUMMER 5E AL O. and descriptions contained herein. SERIENUMMER N910lt0: '. SARIANUMERO NUMERC�F�EBfRXE 1.1.2 Safety Precautions NUMERO DE SERIE HtlMft�kt � SERIENNUMMERRtEta All safety codes, safety standards, andior regulations must be • eATERPItLARLNE. 1f strictly observed in the installation, operation, and maintenance of this device. Figure 1. Typical Automatic Transfer Switch (ATS) Equipment Nameplate. All possible contingencies that may arise during installation, oper- A WARNING ation, or maintenance, and all details and variations of this equip- ment do no purport to be covered by these instructions. If further THE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE PRO- information is desired by the purchaser regarding a particular CEDURAL STEPS IN THIS DOCUMENT ARE FOR PERSONAL SAFETY installation, operation, or maintenance of particular equipment, AND PROTECTION OF EQUIPMENT FROM DAMAGE. AN EXAMPLE please contact an authorized Cat dealer or the installing contrac OF A TYPICAL WARNING LABEL HEADING IS SHOWN ABOVE TO FAMILIARIZE PERSONNEL WITH THE STYLE OF PRESENTATION. tor. THIS WILL HELP TO INSURE THAT PERSONNEL ARE ALERT TO WARNINGS,WHICH APPEAR THROUGHOUT THE DOCUMENT. IN ADDITION,WARNINGS AND CAUTIONS ARE ALL UPPER CASE AND BOLDFACE. A CAUTION COMPLETELY READ AND UNDERSTAND THE MATERIAL PRESENTED IN THIS DOCUMENT BEFORE ATTEMPTING INSTALLATION,OPERA- TION,OR APPLICATION OF THE EQUIPMENT. IN ADDITION, ONLY QUALIFIED PERSONS SHOULD BE PERMITTED TO PERFORM ANY WORK ASSOCIATED WITH THIS EQUIPMENT. ANY WIRING INSTRUCTIONS PRESENTED IN THIS DOCUMENT MUST BE FOL- LOWED PRECISELY. FAILURE TO DO SO COULD CAUSE PERMANENT EQUIPMENT DAMAGE. • For more information visit: www.cat.com CI-AEOM-00074-01-E CAT' 0&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 3 Contactor Based Transfer Switch 40-400A 1.2 General Information 1.2.1 Design Configuration Transfer switches are used to protect critical electrical loads The Cat contactor based ATS is a compact design that uses a against loss of power. The load's Source 1 power source is power contactor to transfer essential loads from one power backed up by a Source 2 power source. A transfer switch is source to another (Figure 3 [400A]). connected to both the Source 1 and Source 2 power sources and supplies the load with power from one of the two sources. In the event that power is lost from Source 1,the transfer switch trans- VOLTAGE SELECTION AND LOGIC fers the load to the Source 2 power source. This transfer is auto- TRANSFORMER PANEL PANEL matic. Once Source 1 power is restored, the load is a automatically transferred back to the Source 1 power sources (Figure 2). E 7 � E 1 IM, Figure 2.Typical Load Transfer Switch Schematic(Contactor ; Type). In ATS equipment, the switch's intelligence system initiates the transfer when the Source 1 power fails, falls below, or rises FOVIIERV ANEL above a preset voltage. If the Source 2 power source is a standby generator, the ATS initiates generator startup and trans- Figure 3. Typical Power Panel for a 400A Model. fers to the Source 2 power source when sufficient generator voltage is available. When Source 1 power is restored, the ATS The Cat contactor based ATS was designed with easy installa- automatically transfers back and initiates generator shutdown. tion and simplified maintenance in mind. Three main panels com- In the event the Source 1 power source fails and the Source 2 prise the contactor based ATS design: power source does not appear, the ATS remains connected to the Source 1 power source until the Source 2 power source does 1. Power panel; appear. Conversely, if connected to the Source 2 power source 2. Voltage selection and transformer panel (if required); and and the Source 2 power source fails while the Source 1 power source is still unavailable, the ATS remains connected to the 3. Microprocessor-based logic panel. Source 2 power source. ATSs automatically perform the transfer function and include three basic elements: 1. A power contactor to connect and disconnect the load to and from either power source. 2. Solenoids to make the transfer of the main contacts from source to source. •3. Intelligence/supervisory circuits to constantly monitor the condition of the power sources and thus provide the intelli- gence necessary for the switch and related circuit operation. CI-AEOM-00074-01-E For more information visit: www.cat.com CAT' Page 4 Effective: July 2011 0&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A -- -• �— Table 1. Withstand Ratings. UL 1008 WITHSTAND AND CLOSE-ON RATINGS IkAI k Ul 1008 Ampere Rating _ 480 Volts 600 Volts Any Specific Any Specific Breaker Breaker Breaker Breaker 100 30,000 30,000 22,000 35,000 200 30,000 30,000 22,000 35,000 260 30,000 50,000 - - 320 30,000 50,000 - us a 4 400 30,000 50,000 - - -- A $" 1.3 ATS Catalog Number Identification rj Transfer switch equipment catalog numbers provide a significant r. amount of relevant information that pertains to a particular piece ,< sN of equipment. The Catalog Number Identification Table (Table 2) provides the required interpretation information. An example is offered here to initially simplify the process. Example:Catalog Number(circled numbers correspond to position headings in Table 2). Oto(z 03 ® ©to© ® ® Qto� 0 (9 0 AT C 3 C3 X 3 0400 W R U The catalog number ATC3C3X30400WRU describes an ATS with • a 3-pole, 3 position Power Contactor mounted on a baseplate A`I within the enclosure. The intelligence represented by the logic panel is ATC-300+ controller. The continuous current rating of this equipment is 400A and applicable at 240 Vac, 60 Hz. The transfer switch equipment is enclosed in a NEMA 3R enclosure and is listed for UL applications. Figure 4. Contactor Based ATS (400A). Each panel is independently mounted with interconnecting wiring terminated at the connector receptacles on the ATC-300+ Con- troller. Door or individual panel removal is achieved without dis- turbing critical connections by removing the connectors from the receptacles and cutting the wire ties that secure the wires to the door. Mounting the enclosure is simple using top and bottom mounting flanges with elongated (teardrop) mounting holes. These mount- ing holes, along with power panel positioning bolts and pre- tapped inserts, insure proper power panel mounting after the ini- tial enclosure installation. Refer to Section 4 for specific mount- ing and modification details. • For more information visit: www.cat.com CI-AEOM-00074-01-E ca• 0&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 5 Contactor Based Transfer Switch 40-400A • Table 2. Transfer Switch Catalog Number Guide POSITIONS 1 TO 2 POSITION 3 POSITION 4 POSITIONS 5 TO 6 BASIC DEVICE SWITCHING DEVICE CONTROL PANEL SWITCHING DEVICE Automatic Transfer Switch AT Contactor C ATC-300+ Controller 3 3 Position Power Contactor C3 POSITION 7 POSITION 8 POSITIONS 9 TO 12 POSITION 13 POSITION 14 POSITION 15 SWITCHING DEVICE NUMBER AMPERE VOLTAGE/ ARRANGEMENT OF POLES RATING FREQUENCY ENCLOSURE LISTING Fixed Mount X Two(2) 40A-0040 208 Vac160 Hz B Type 1 S ULICSA Listing U Three(3) BOA-0080 220 Vac150 Hz G Type 12 J No Listing X Four(4) 100A-0100 240 Vac/60 Hz W Type 3R R 150A-0150 380 Vac150 Hz H Open N 200A-0200 415 Vac150 Hz 0 '225A-0225 480 Vac/60 Hz X '260A-0260 600 Vac160 Hz E '400A-0400 'For 225A tc 40GA.600 Vac application,please refer to CI-AEOM-00010.02E 1.4 Environmental Conditions Re-Transfer Re-transfer is defined as a change of the load connection from 1.4.1 Operational Conditions the Source 2 to the Source 1. Normally, an ATS is applied indoors in an electrical equipment Source 1 room. In the appropriate enclosure, it can be used for outdoor Source 1 is the primary source (riormal source, normal power ,applications where the equipment is subject to falling rain, freez- source, or normal). ing temperatures, and no greater than 90% humidity (non-con- densing). The ambient temperature range for operation is between -20 and 700C (-4 to 1580F). Source 2 is the secondary source (emergency source, emer- gency power source, emergency, standby, or backup source). 1.5 Glossary Source 1: Failed or Fails Source 1 is defined as "failed" when it is outside of its under- With respect to their use within this document and as they relate voltage/overvoltage/ underfrequency/overfrequency (if applica- to transfer switch and controller operation, the fallowing termi- ble) setpoint ranges for the nominal voltage and frequency nology is defined. setting. Available Source 2: Failed or Fails A source is defined as "available" when it is within its undervolt- Source 2 is defined as "failed" when it is outside of its under- age/overvoltage/underfrequency/overfrequency (if applicable) voltage/overvoltage/ underfrequency/overfrequency (if applica- setpoint ranges for the nominal voltage and frequency setting. ble) setpoint ranges for the nominal voltage and frequency Connected setting for a time exceeding 0.5 seconds after the Time Delay Connected is defined as when the input is shorted by an external Emergency Fail (TDEF) time delay expires. contact or connection. Transfer Failed or Fails Transfer is defined as a change of the load connection from the A source is defined as "failed" when it is outside of the applica- Source 1 to the Source 2 power source. ble voltage and frequency setpoint ranges for the nominal volt- Unconnected age and frequency setting for a time exceeding 0.5 seconds Unconnected is defined as when the input is not shorted by an after the time delay emergency fail (TDEF) time delays expires. external contact or connection. Failsafe Failsafe is a feature that prevents disconnection from the only available power source and also forces a transfer or re-transfer operation to the only available power source. • CI-AEOM-00074-01-E For more information visit: www.cat.com CST' Page 6 Effective: July 2011 O&M Manual for the ATC-300+, 3-Postion Contactor Based Transfer Switch 40-400A Section 2: Receiving, Handling, and 2.3 Storage Storage Although well packaged, this equipment is not suitable for out- door storage. The equipment warranty will not be applicable if 2.1 Receiving there is evidence of outdoor storage. If the equipment is to be stored indoors for any period of time, it should be stored with its Every effort is made to ensure that the ATS equipment arrives at protective packaging material in place. Protect the equipment at its destination undamaged and ready for installation. Packing is all times from excessive moisture, construction dirt, corrosive designed to protect internal components as well as the enclo- conditions, and other contaminants. sure. Care should be exercised, however, to protect the equip- ment from impact at all times. Do not remove the protective It is strongly suggested that the package-protected equipment be packaging until the equipment is ready for installation. stored in a climate-controlled environment with temperatures from-30 to 85°C (-22 to 185°F) and with a relative humidity of When the ATS equipment reaches its destination, the customer 80% or less. DO NOT, under any circumstance, stack other should inspect the shipping container for any obvious signs of equipment on top of a transfer switch equipment enclosure, rough handling and/or external damage that occurred during whether packaged or not. transportation. Record any external and internal damage for reporting to the transportation carrier and Caterpillar, once a thorough inspection is complete. All claims should be as specific as possible and include the catalog and serial numbers. A shipping label affixed to the shipping container includes a vari- ety of equipment and customer information, such as serial num- ber and catalog numbers. Make certain that this information matches other shipping paper information. Each transfer switch is packed securely with appropriate ship- ping materials to prevent damage during shipment. Do not remove or discard the packing material until the equipment is ready for installation. Once the top packaging is removed from the shipment, the enclosure door can be opened. A plastic bag of documents will • be found in the enclosure, usually attached to the inside of the enclosure. Important documents, such as test reports, wiring diagrams, and appropriate instruction leaflets, are enclosed within the bag and should be filed in a safe place. 2.2 Handling As previously mentioned, ATS equipment is packaged for forklift movement. Protect the equipment from impact at all times and DO NOT double stack. Once the equipment is at the installation location and ready to be installed, packaging material can be removed and discarded. Once the enclosure is unbolted from the wooden pallet, it can be hand moved to its installation position. Be careful not to damage the top or bottom enclosure mounting flanges. Refer to Section 4 of this manual for specific installation instructions. For more information visit: www.cat.com CI-AEOM-00074-01-E CAT' O&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 7 Contactor Based Transfer Switch 40-400A • Section 3: Equipment Description 3.1 General i The ATS consists of three basic panels: 1. The power panel; 2. The voltage selection and transformer panel (if required); and n s. 3. The microprocessor-based logic panel. These panels are interconnected via connector plugs and mounted in an enclosure (Figure 5). ca s: VOLTAGE SELECTION $W ESSELECT � AND TRANSFORMER PANEL LOGIC PANEL °L`r r> +x " � * s# 4..,;Ili- 4 ,_ _ � ae•',_: .:.: Figure 6. Typical Power Panel for 40-400A Models. 3.3 Voltage Selection 3.3.1 Voltage Selection (208, 240, 480, 600, 60 Hz and 220, 380, 415, 50 Hz.) 3 The optional voltage selection panel consists of multi-tap trans- formers, contained in a steel case mounted in the enclosure (Fig- ure 7). The voltage is selected by simply removing the wires from the default primary taps of both transformers and installing them ` on the primary taps for the desired voltage. Taps are provided for 208 to 600 Vac to satisfy application voltage. The factory default position is 600 Vac. Figure 5.Three Basic Panels of the ATS (40-400A). A 3.2 Power Panel CAUTION WHEN CHANGING THE SELECTED VOLTAGE,THE POWER MUST The power panel is used for making load, power, and neutral con- BE REMOVED FROM THE ATS AND THE WIRES MUST BE MOVED nections. The power contactor is mounted on a steel baseplate ON THE TAPS OF BOTH TRANSFORMERS. (Figure 6). 3.2.1 Main Contacts This ATS incorporates a power contactor. The main contacts connect and disconnect the load to and from the different power • sources. The power contactor is mechanically and electrically interlocked to prevent the two sets of main contacts from being closed simultaneously. CI-AEOM-00074-01-E For more information visit: www.cat.com CAT' Page 8 Effective: July 2011 O&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A fi ' 3 x2QdtS�i�.11x � ' a v. Figure 8. ATC-300+ Logic Control Panel. r x The ATC-300+ controller has an operating temperature of s ...<a s r:. , -20 to 700C (-4 to 158OF). Figure 7. Voltage Selection Terminals (Shown Connected to the The controller circuit board is protected by an insulating confor-• 480 Vac Taps). mal coating. 3.4 ATC-300+ Logic Panel The specifications, under normal operating conditions, are as fol- lows: The ATC-300+ is a microprocessor-based transfer switch logic control package. The hardware and software of the controller ■ Tolerance for voltage sensing function: ±1% of full scale contain the intelligence/supervisory circuits that constantly moni- ■ Tolerance for frequency sensing function: ±0.3 Hz of setting for the condition of the power sources. It provides the intelli- gence necessary for the operation of the ATS (Figure 8). • For more information visit: www.cat.com CI-AEOM-00074-01-E C . 0&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 9 Contactor Based Transfer Switch 40-400A • 3.5 Features 5J. All Phase Undervoltage and Underfrequency Protection A variety of standard and optional features are available for Cat Adjustable Undervoltage: ATSs. All features or combinations of features may not be avail- Dropout: 78 - 97% of nominal able on specific ATSs. All features and/or accessories are Under- Pickup: (Dropout +2%) to 99% of nominal writers Laboratories (UL) listed unless noted. Adjustable Underfrequency: 3.5.1 Standard Features Dropout: 90 - 97% of nominal Pickup: (Dropout +1 Hz) to 99% of nominal The following is a list of the standard features for the ATC-300+ 5K. All Phase Overvoltage/Overfrequency Controlled ATS. 1. Time Delay Normal to Emergency (TDNE) Adjustable Overvoltage: Dropout: 105 - 110% of nominal This feature provides a time delay when transferring from Pickup: 103% to (Dropout -2%) of nominal the Source 1 to the Source 2 power source. Timing begins Adjustable Overfrequency: when Source 2 becomes available. It permits controlled Dropout: 103 - 105% of nominal transfer of the load circuit to Source 2. Pickup: 101% to (Dropout -1 Hz) of nominal Adjustable 0 - 1800 Seconds 5L. Source 2 3-Phase Voltage Unbalance 2. Time Delay on Engine Starting (TIDES) For a 3-phase wye source, this feature monitors phase volt- This feature provides a time delay of the signal to initiate age ratios. Voltage unbalance (%) is calculated as the dif- the engine/generator start cycle in order to override ference between the maximum and minimum phase momentary power outages or voltage fluctuations of voltage, divided by the minimum phase voltage. User- Source 1. selectable setpoints are available for dropout and pickup unbalance settings (minimum 2% differential). Dropout is Adjustable 0- 120 Seconds adjustable from 5 to 20%. Pickup is adjustable from 3 to 3. Time Delay Emergency to Normal (TDEN) (Dropout -2%). A setpoint for user-selectable time delay from 10 to 30 seconds is provided. The factory default set- This feature provides a time delay of the re-transfer opera- points are: 5% dropout, 3% pickup, and 30 seconds time tion to permit stabilization of Source 1. Timing begins delay. A user-selectable setpoint for enable and disable is • when Source 1 becomes available. If Source 2 fails during also provided. timing, then re-transfer is immediate overriding the time delay. When an unbalance condition is detected on Source 2, the Unbalance Timer (TD UNBAL) starts timing. After TO Adjustable 0- 1800 Seconds UNBAL times out, Source 2 is declared "failed". 4. Time Delay for Engine Cool-down (TDEC) For a 3-phase delta source,this feature should be turned off This feature provides a time delay of the signal to initiate via the VOLT UNBAL setpoint. the engine/generator stop cycle after the re-transfer opera- 6. Test Operators tion. This allows the engine/generator to cool down by run- ning unloaded. Timing begins on completion of the re- Cat ATSs are provided with a Test Pushbutton that simu- transfer cycle. lates a loss of the Source 1 power source as standard (Fea- ture 66). All programmed time delays (TDNE, TDEN, etc.) Adjustable 0- 1800 Seconds will be performed as part of the Test. Engine run time of 5. Source 2 Monitoring and Protection the Test is equal to the Plant Exerciser (Feature 23) pro- grammed setpoint. All Tests are Failsafe protected. This feature provides monitoring and protection based on 6B. Test Pushbutton the Source 2 voltage and/or frequency setpoints. All fea- ture 5 functions are Failsafe operations. Programmable setpoints include: 5H. Phase Reversal 1. Load or No Load Testing, or Disabled For a 3-phase wye source, this feature monitors the phase 2. Engine run time equal to the plant exerciser sequence of the sources. If a source does not have the (Feature 23) setting same ABC or CBA sequence as the setpoint value, that source will be considered "Unavailable. For a 3-phase delta source,this feature should be turned off via the PHASE REV setpoint. i Cl-AEOM-00074-01-E For more information visit: www.cat.com CAT' Page 10 Effective: July 2011 O&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A 7A. Time Delay Emergency Fail (TDEF) 15. Switch Position Indication Contact This feature provides a time delay that prevents a con- This feature provides a contact that indicates if the power nected Source 2 power source from being declared "Failed" switching device is in the "Open" or "Closed" position. in order to override momentary generator fluctuations. If the Source 2 power source remains in the failed state then, 15E. Source 1 Position Indication Contact 0.5 seconds after the TDEF timer expires, the transfer This feature provides 1 dry form "C" contact that indicates switch will proceed with the programmed sequence for the position of the Source 1 power switching device. retransfer. This time delay is only implemented when the Source 2 power source is a generator. 15F. Source 2 Position Indication Contact Adjustable 0- 6 Seconds This feature provides 1 dry form "C"contact that indicates 8. Time Delay Bypass Pushbutton the position of the Source 2 power switching device. This feature provides a way (by pushing the Help and Step 23. Plant Exerciser(PE) pushbutton simultaneously) to bypass the TDNE (Feature 1) This feature provides a means for automatic testing of the and/or TDEN (Feature 2) time delays. The Time Delay engine generator set or standby power system. All pro- Bypass function, when activated by pushing the Help and grammed time delays will be performed during plant exer- Step pushbutton simultaneously, will reduce any or all of ciser operations. the programmed time delay to zero. 23K. Plant Exerciser Selectable Disabled/1/7114/28 Day Inter- 8C. Bypass TDEN val This feature provides one set of pushbuttons to bypass the This feature provides for automatic test operation of the TDEN time delay. generator. Available test cycles are daily, 7, 14, or 28 days with duration equal to the programmed engine test 8D. Bypass TDNE time. This feature provides one set of pushbuttons to bypass the Programmable setpoints allow for selection of three test TDNE time delay. cycles: 12. Power Source Annunciation ■ Engine Start/Run Only (No Load); This feature provides LEDs to give switch position and ■ Exercise with Load Transfer; or . power source availability indications. ■ Disabled Switch Position This is a "Failsafe" operation. Provides LEDs to indicate the switch position 26. Source 1 - Monitoring and Protection 12C. Source 1 -Source Connected This feature provides Source 1 monitoring and protection This feature provides an LED that, when lit, indicates the functions. If the Source 1 power supply fails, then the Automatic Transfer Controller will begin the sequence of load is connected to Source 1. operations necessary to transfer the load circuit to the 12D. Source 2 -Source Connected Source 2 power supply. All Feature 26 monitoring and protection functions are Failsafe operations. This feature provides an LED that, when lit, indicates the load is connected to Source 2. 26D. Go to Source 2 Power Source Availability This feature provides the capability for an external contact opening to initiate a load circuit transfer to the Source 2 Provides LEDs to indicate if a power source is available. power source. This includes starting the engine/generator, LEDs may be integral or separate from the controller. Performing the programmed time delays, and the transfer 12G. Source 1 -Available operation. Re-transfer will occur when the external con- tact is closed or under a Failsafe condition. This feature provides an LED that, when lit, indicates 26H. Phase Reversal Protection Source 1 is available. 12H. Source 2 -Available For a 3-phase wye source, this feature monitors the phase sequence of the sources. If a source does not have the This feature provides an LED that, when lit, indicates same ABC or CBA sequence as the phase reversal set- Source 2 is available. point, the source will be considered "Unavailable". For a 3-phase delta source, this feature should be turned off via the PHASE REV setpoint. i For more information visit: www.cat.com CI-AEOM-00074-01-E UXII O&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 11 Contactor Based Transfer Switch 40-400A 26J. All Phase Undervoltage and Underfrequency Protection 35A. Pre-Transfer Signal with 1 N.O. and 1 N.C. Contacts Adjustable Undervoltage: This feature provides pre-transfer signal and includes 1 Dropout: 78 - 97% of nominal N.O. and 1 N.C. contacts. Pickup: (Dropout +2%) to 99% of nominal 36. Emergency Inhibit (new feature) Adjustable Underfrequency: Dropout: 90- 97% of nominal This feature enables the Emergency inhibit control input to Pickup: (Dropout +1 Hz) to 99% of nominal inhibit transfers to the Emergency Source. See Control Inputs section for more information. 26K.All Phase Overvoltage/Overfrequency This input is located on Pins 7 and 8 of Connector J8 and Adjustable Overvoltage: is enabled when the Emergency Inhibit is enabled. The Dropout: 105 - 1 10% of nominal contact is closed for normal operation. Opening this con- Pickup:103% to (Dropout —2%) of nominal tact will activate the Emergency Inhibit input. Adjustable Overfrequency: If the Emergency Inhibit contact is opened when the load Dropout: 103 - 105% of nominal is connected to the Normal Source, no action will be taken Pickup: 101% to (Dropout-1 Hz) of nominal if the Normal Source is available. If the Normal Source is not available, an immediate transfer to the neutral position 26L. Source 1 3-Phase Voltage Unbalance will occur. .For a 3-phase wye source, this feature monitors phase If the Emergency Inhibit contact is opened when the load voltage ratios. Voltage unbalance (%) is calculated as the is connected to the Emergency Source, the ATC-300+ difference between the maximum and minimum phase will transfer the load to the Normal Source if it is available. voltage, divided by the minimum phase voltage. User- If the Normal Source is not available, an immediate trans- selectable setpoints are available for dropout and pickup fer to the neutral position will occur. unbalance settings (minimum 2% differential). Dropout is adjustable from 5 to 20%. Pickup is adjustable from 3 to The Emergency Inhibit input is only active when either (Dropout—2%)). A setpoint for user-selectable time delay Source 1 or Source 2 is preferred. This input is not active from 10 to 30 seconds is provided. The factory default when the Preferred Source selection is set to None. setpoints are: 5% dropout, 3% pickup, and 30 seconds time delay. A user-selectable setpoint for enable and dis- The Emergency Inhibit input takes priority over the Go To • able is also provided. Emergency input if both inputs are activated at the same time. In this case, the generator will start but a transfer to When an unbalance condition is detected on Source 1,the the Emergency Source will be inhibited until the Emer- Unbalance Timer (TD UNBAL) starts timing. After TD gency Inhibit input is de-activated. UNBAL times out, Source 1 is declared "failed". i 42. Seismic Withstand Capability For a 3-phase delta source, this feature should be turned off via the VOLT UNBAL setpoint. Provides transfer switch with seismic capability exceeding the worst case Zone 4 required per both the Uniform 32. Delayed Transition Transfer Modes for Open Transition Building Code and the California Building Code. Transfer Switches 48F. RS-485 with Modbus Option This feature provides delayed transition transfer modes for an open transition transfer switch. Often used in sys- Provides communications for the ATC-300+ via Modbus tems with inductive loads, a delayed transition transfer through an integrated RS-485 port. Registers are available switch may prevent or reduce in-rush currents due to out to read back status, voltages, frequencies, and historical of phase switching of inductive loads. data. Registers are also available for transfer switch con- trol. Setpoints may be read back and/or programmed via a 32A. Time Delay Neutral pass-through command. See the ATC-300+ Modbus This feature provides a time delay in the neutral position Communication Guide CI-AECG-00079-01-E (66A7787). during the transfer and re-transfer operations during 3.5.2 Optional Features which both Source 1 and Source 2 are disconnected from the load circuit. The time delay is programmable and is The following is a list of the optional features for the ATC-300+ the same for both transfer and re-transfer operations. Controlled ATS. All features or combinations of features may Adjustable 0 - 120 Seconds not be available on specific ATSs 35. Pre-Transfer Signal 9B. Maintenance Selector Switch (MSS) Marked "OFF", "ON". This feature provides selector This feature provides a signal to a remote device prior to a switch disconnection of control to transfer thus allowing re-transfer operation. It provides one Form "C" contact testing of the transfer switch control logic circuitry with- (NO/NC) for interface with other equipment (typically ele- out initiating load transfer. Positioning the MSS in the vator controls). The contacts close/open on a timed basis "OFF" position isolates the control circuit, permitting prior to transfer in either direction. After TDNE/TDEN manual operation of the transfer switch or testing of logic • times out, this relay closes and the Pre-transfer Timer circuitry without load transfer.Indication light is illumi- (TPRE) starts timing. After the TPRE times out, the trans- nated and display on ATC-300+ controller shows "ATS fer proceeds by starting the TDN timer if enabled. The NOT IN AUTOMATIC" when the switch is in maintenance pre-transfer relay opens after the transfer is complete. mode. Adjustable 0- 120 Seconds CI-AEOM-00074-01-E For more information visit: www.cat.com CAT' Page 12 Effective: July 2011 0&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A 14. Relay Auxiliary Contacts: This feature provides form "C" 18V. IQ Analyzer Load relay auxiliary contacts. 18R. IQ DP-4000 Normal (S1) Only 14C. Source 1 Present: Provides four(4) normally open and four 18S. IQ DP-4000 Emergency (52) Only (4) normally closed contacts. The relay is energized when Source 1 is available. 18T. IQ OP-4000 Normal (S1) & Emergency (S2) Switch Select- 14D. Source 2 Present: Provides four(4) normally open and four able (4) normally closed contacts. The relay is energized when 18U. IQ DP-4000 Load Source 2 is available. 18V11.Ammeter 14G. Source 1 Present: Provides two (2) normally open and two (2) normally closed contacts. The relay is energized when A single ammeter is a true RMS sensing device that dis- Source 1 is available. plays single phase current only. 14H. Source 2 Present: Provides two (2) normally open and two The ammeter can be mounted on Source 1. Source 2, or (2) normally closed contacts. The relay is energized when load. The meter can also be configured for 1, 2, or 3-phase Source 2 is available. sensing by supplying one meter per phase for Source 1, Source 2, or load. Ammeters for both Source 1 and Source 15. Switch Position Indication Contact 2 can also be grouped together. This feature provides a contact that indicates if the power 23L. 24 Hour, 7day, 365 Day Programmable Plant Exerciser switching device is in the "Open" or "Closed position. This plant exerciser has two channel electronic time 15G. Source 1 Position Indication Contact switches with 365-day, 7-day, 24-hour programming. Each This feature provides 3 Dry Form "C" contacts that indi- channel can be independently programmed and can provide cate the position of the Source 1 power-switching device. up to 400 events. The plant exerciser offers daily, weekly or annual programming capability with up to 99 separate 15H. Source 2 Position Indication Contact holiday periods of any duration and priority. An LCD display This feature provides 3 Dry Form "C" contacts that indi- indicates load status, time-of-day, weekday and date. cate the position of the Source 2 power-switching device. 29G. Auto/Manual Operation 18. Metering This feature provides 2-position auto/manual selector This feature includes all required external devices (CTs, switch marked "Auto/Manual" which permits the selectior>• of automatic or manual operation. Once the selector switch shorting blocks, fuses, etc.) for a fully functional metering is tranferred to manual mode, manual transfer between system. Normal (S1) Neutral and Emergency (82) can be achieved 18AN.IQ 250/260 Normal (S1) Only by operating 3-position selector switch marked "Normal- OFF-Emergency". Indication light is Illuminated and display 18AE. IQ 250/260 Emergency (S2) Only on ATC-300+ controller shows "ATS NOT IN AUTO- 18AL. IQ 250/260 Load MATIC" when the switch is in manual mode. 18CN.IQ 1 10/1 15 Normal (S1) Only 29• Alternate Transfer Modes of Operation 18CE. IQ 1 10/1 15 Emergency (S2) Only Provides standard or optional transfer modes. mode selec- tion devices, and operational methods for ATSs. 18CL. IQ 110/11 5 Load 29J. Type of Operation (MANTR) Operation (new feature) 18DN.IQ 130/140/150 Normal (S1) Only This feature provides for a seletion between an automatic 18DE. IQ 130/140/150 Emergency (S2) Only transfer and re-transfer mode or a manual pushbutton re- transfer to Normal from the Emergency Source mode. If 18DL. IQ 130/140/150 Load this option is not selected the factory default selection is 18EN. PXM2250/2260/2270 Normal (S1) Only automatic. 18EE. PXM2250/2260/2270 Emergency (S2) Only 38. Stainless Steel Logic Cover 18EL. PXM2250/2260/2270 Load 38A. Stainless Steel Cover for Device Panel 180. IQ Analyzer Normal (S1) Only Provides an added level of security by providing a pad lock- able stainless steel cover for use with standard transfer 18P. IQ Analyzer Emergency (S2) Only switch device panel. The-coverIs designed for NEMA 1, 18Q. IQ Analyzer Normal (S1) & Emergency (S2) Switch Select- 3R, 4X, and 12 applications. � able • For more information visit: www.cat.com CI-AEOM-00074-01-E CAT' O&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 13 . Contactor Based Transfer Switch 40-400A 388. Stainless Steel Cover for Controller 3.6 Enclosure Provides an added level of security by providing a pad lock- The rugged steel ATS enclosure is supplied with three door able stainless steel cover for use with standard transfer hinges, regardless of enclosure size. They ensure proper support switch logic controllers and/or associated device panels. of the door and door mounted devices (Figure 9). The hinges These covers function with Cat s ATC series logic control- have removable hinge pins to facilitate door removal. Certain lers and device panels. The covers are designed for NEMA procedures, such as switch mounting, are simplified with the 1, 3R, 4X, and 12 applications. door removed. The doors are supplied as standard with pad-lock- 41. Space Heater With Thermostat able latches. This feature provides a space heater and non-adjustable thermostat. External control power is not required. 41 A. Space Heater With Thermostat - 100 Watt This feature provides a 100 watt (W) space heater with a non-adjustable thermostat. 48F. RS-485 with Modbus Option Provides communications for the ATC-300+ via Modbus through an integrated RS-485 port. Registers are available to read back status, voltages, frequencies, and historical data. Registers are also available for transfer switch con- trol. Setpoints may be read back and/or programmed via a .. passthrough command. See the ATC-300+ Modbus Communication Guide. 498. Sensing Isolation Transformer (Up to 600 VAC only) This feature provides 3-phase, 4-wire for Source-1 and Source-2 sensing input on ATC controller for a high resis- . tance grounded delta system.51D1. 50kA CVX Surge Device This feature gives protection for surge current capacity rating 50kA, upto 480VAC by providing a low impedance surge path to ground while supporting rated voltage. It provides LED indication. 51F1. 100kA CVX Surge Device Figure 9. Typical Type 1 Enclosure (Door Closed). The door is used to mount a variety of lights, switches, and This feature gives protection for surge current capacity push-buttons, depending upon the options required for a particu- rating 100kA, upto 480VAC by providing a low imped- lar ATS. All lights and switches are mounted in the plastic door- ance surge path to ground while supporting rated volt mounted panel. age. It provides LED indication. The rear of the enclosure is supplied with teardrop shaped holes in the top and bottom mounting flanges to facilitate mounting. It is also supplied with two positioning bolts and various pre-tapped inserts to insure proper positioning of the power panel anytime the power panel must be repositioned to accommodate a differ- ent cable entry position. Cable entry holes are the responsibility of the customer. • CI-AEOM-00074-01-E For more information visit: www.cat.com CAT' Page 14 Effective: July 2011 O&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A ATS enclosures and all internal steel mounting plates, such as the Section 4: Installation and Wiring power panel mounting plate, go through a pretreatment cleaning system prior to painting to ensure a durable finish. 4.1 General The standard ATS enclosure is NEMA 1 Type for general use. However, a variety of enclosures are available to address almost Cat ATSs are factory wired and tested. Installation requires sol- any environmental circumstance (see Table 3). idly mounting the enclosed unit and connecting power cables and auxiliary pilot circuits. Physical mounting procedures and power Table 3. Transfer Switch Equipment Enclosures cable connections are covered in this section. All other required NEMA TYPE DESIGN PROTECTION wiring or electrical connection references are covered in a sepa- Open Indoor rate Customer Wiring Booklet packaged with the ATS. 1 Indoor Enclosed Equipment Locate the wiring schematic, review it, and keep it readily avail- 3R Outdoor Rain,Ice Fortnation able for reference purposes during installation and testing. Once an ATS is properly installed and wired, it should be mechanically 12 Indoor Dust,Dirt,and and electrically checked for proper installation and operation. Non-Corrosive Liquids The procedures for these initial mechanical and electrical checks 3.7 Standards are outlined in Section 6 of this instruction manual. Cat ATS equipment, enclosed in any of the enclosures listed in ® WARNING Table 3, is listed for application by UL and ULC. In addition, Cat ATSs are listed in File E381 16 by Underwriters Laboratories, Inc. BE CERTAIN THAT THE SOLID STEEL DOOR IS PROPERLY under Standard UL 1008. This standard covers requirements for INSTALLED BEFORE THE TRANSFER SWITCH EQUIPMENT IS PUT automatic transfer switches intended for use in ordinary locations INTO SERVICE. THE DOOR PROVIDES PROTECTION FROM DAN- to provide lighting and power as follows: GEROUS VOLTAGES AT THE LINE AND LOAD TERMINALS WHEN THE EQUIPMENT IS IN OPERATION. FAILURE TO DO SO COULD a. In emergency systems, in accordance with articles 517 RESULT IN PERSONAL INJURY OR DEATH. and 700 in the National Electrical Code, ANSI/ NFPA 70, and the National Fire Protection Association No. 76A; 4.2 Mounting Location and/or b. In standby systems, in accordance with article 702 of the Choose a location that offers a flat, rigid mounting surface capa- National Electrical Code; and/or ble of supporting the weight of the enclosed ATS equipment. For• standard ATSs, avoid locations that are moist, hot, or dusty. C. In legally required standby systems in accordance with However, Caterpillar offers optional enclosure designs that can article 701 of the National Electrical Code. be used in special environments. If there are any doubts as to a Cat ATSs are available to meet NFPA 110 for emergency and location s suitability, discuss them with your Cat dealer. standby power systems, and NFPA 99 for health care facilities Check to make certain that there are no pipes, wires, or ether when ordered with the appropriate options. mounting hazards in the immediate mounting area that could cre- Standard UL 1008 for ATSs lists devices under the reexamination ate a problem. program which only require a continual physical reexamination of Carefully remove all packing material from the ATS at the mount- the components used in the product to ensure consistency with ing location. Even though an equipment inspection should have the originally submitted device. Follow-up testing is not required been made when the equipment was received, make another by UL 1008. careful inspection of the enclosure and the enclosed ATS compo- nents as the packing material is removed and the enclosure read- ied for mounting. Be especially alert for distorted metal, loose wires, or damaged components. • For more information visit: www.cat.com CI-AEOM-00074-01-E CAT O&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 15 Contactor Based Transfer Switch 40-400A 4.3 Mounting Procedure With the enclosed ATS equipment unpacked and ready for mounting, proceed with the following steps. ® CAUTION Step 1: The ATS enclosure door is hinge mounted with remov- able hinge pins. To simplify the mounting procedure and SINCE THE ENCLOSED ATS MUST BE LIFTED INTO PLACE FOR avoid damaging the door-mounted logic panel, it is MOUNTING,BE CERTAIN THAT ADEQUATE RESOURCES ARE strongly suggested that the door be carefully removed AVAILABLE FOR LIFTING TO AVOID PERSONNEL INJURIES OR and put it in a safe place until mounting is complete. To EQUIPMENT DAMAGE. remove the door, open the door and disconnect the con- nectors at the back of the ATC-300+ logic panel. All equipment enclosures and power panels are of the same Remove the wire ties securing the harness to the inside design. Only the overall physical dimensions change. Note that of the door. Carefully remove the hinge pins then the the enclosure is provided with four teardrop (elongated) mount- door from the enclosure. ing holes, two in the top mounting flange and two in the bottom. Step 2: Install the required upper and lower mounting bolt Cable entry holes are not part of the enclosure when shipped anchors and the two upper mounting bolts in the mount- from the factory and must be provided in the field, either before ing surface. or after mounting the enclosure. Cable access may be from the top, bottom, and/or side. Step 3: Gently lift the enclosure and guide the teardrop holes in the upper mounting flange over the upper mounting ACAUTION bolts. Do not completely tighten the bolts at this time. Step 4: While still supporting the enclosure, install the two EXTREME CARE SHOULD BE TAKEN TO PROTECT THE TRANSFER lower mounting bolts in the lower mounting flange. SWITCH FROM DRILL CHIPS, FILINGS,AND OTHER CONTAMI- Again, do not completely tighten the bolts at this time. NANTS WHEN MAKING THE CABLE ENTRY HOLES. EXTREME CARE SHOULD ALSO BE TAKEN WHEN MOUNTING THE ENCLO- Use shims, if required, to prevent deformation of the SURE TO PREVENT COMPONENT DAMAGE OR A FUTURE MAL- enclosure if the mounting surface is distorted. FUNCTION. Step 5: Tighten all four mounting bolts after any required shim- ming is completed. E i a p -x gi I Figure 11.Typical Mounting of the ATS to a Mounting Surface. Step 6: Double check to ensure that all packing and shipping materials have been removed. Figure 10.Typical(40A-400A)Contactor Based ATS Equipment (Door Open). CI-AEOM-00074-01-E For more information visit: www.cat.com