Eaton Tb09500001e PDF

Cat Generator Paralleling Switchgear
September 2011
Sheet 40 001
40.0-1
Cat Generator Paralleling Switchgear
Contents
Cat Generator Paralleling Switchgear Introduction General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Denitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cat Switchgear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard and Custom Congurable Products . . . . . . . . . . . . . . . . . . . Cat Switchgear Control Technology Features. . . . . . . . . . . . . . . . . . . . XLM Switchgear General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical DataXLM One-Line Diagrams . . . . . . . . . . . . . . . . . . . . . . Functional Sequences of Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . EGP Switchgear General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical DataEGP One-Line Diagrams . . . . . . . . . . . . . . . . . . . . . . . Functional Sequences of Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . Medium Voltage Systems General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XLM Medium Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EGP Medium Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Custom Systems General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical DataOne-Line Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . Specications See Eatons Product Specication Guide, available on CD or on the Web. CSI Format: . . . . . . . . . . . . . . . . . . . . . . . . . 1995 Low Voltage XLM UL 1558 Switchgear . . . . . . . . . . . . . . . . Low Voltage XLM UL 891 Switchboard . . . . . . . . . . . . . . . . Medium Voltage XLM Metal-Clad Switchgear . . . . . . . . . . . . . . Low Voltage EGP UL 1558 Switchgear . . . . . . . . . . . . . . . . Low Voltage EGP UL 891 Switchboard . . . . . . . . . . . . . . . . Medium Voltage EGP Metal-Clad Switchgear . . . . . . . . . . . . . . Section 16426E Section 16429E Section 16346E Section 16426G Section 16429G Section 16346G 2010
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40.0-2 40.0-4 40.1-1 40.1-2 40.1-3 40.2-1 40.2-2 40.2-3 40.2-4 40.2-10 40.3-1 40.3-2 40.3-3 40.3-4 40.3-12 40.4-1 40.4-4 40.4-8 40.5-1 40.5-2
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Section 26 23 13.11 Section 26 24 13.31 Section 26 13 26.13 Section 26 23 13.13 Section 26 24 13.33 Section 26 13 26.16
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For more information, visit: www.eaton.com/consultants
40.0-2 Cat Generator Paralleling Switchgear Introduction

General Description
September 2011
Sheet 40 002
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Introduction
General Description
Cat Generator Paralleling Switchgear is a product developed through a joint venture between Caterpillar and Eaton Corporation. Caterpillar, an industry leader in electric generator sets, and Eaton, an industry leader in Low and Medium Voltage Switchgear have combined forces to create Cat Generator Paralleling Switchgear... the most reliable and feature rich product available in the market today! Cat Switchgear has been designed to integrate hand-in-glove with Caterpillars on-package, microprocessor-based engine control. Exclusively from your Caterpillar dealer, you can now get the markets best efciency, reliability and dependability all in one package.
Cat Switchgear combines the proven low voltage Magnum DS power circuit breaker and Magnum Switchgear with Cat Switchgear control technology. Cat controls technology is for optimal power generation and electrical distribution system performance. It provides advanced, industryleading, microprocessor-based engine generator set control provided exclusively in Cat Switchgear. Medium voltage systems combine VCP-W breakers and VacClad Metal-Clad switchgear with the same proven generator control technology.
Reliable, exible and powerful. Cat Switchgear is designed with the most critical power needs in mind:

Data center/data processing Healthcare Critical industrial/chemical processes Distributed generation/cogeneration Water/wastewater treatment Government/military Banking/credit card processing Landll gas power
Applications

Cat Switchgear Features

Emergency/legally required standby systems Optional standby backup systems Distributed generation Peak shaving Prime power
Built-in redundancy Reliability Touchscreen interface Simple, intuitive operation Advanced communications capabilities Integrated digital technology Advanced generator control and protection Detailed engine and electrical reports Best-in-class footprint
XLM
Medium Voltage
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September 2011
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Cat Generator Paralleling Switchgear Introduction

General Description
40.0-3
Standards
Low Voltage Cat Switchgear conforms to the following applicable standards:

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Overview
NEMA Standard SG-5 CSA ANSI C37.20.1 ANSI C37.51 UL Standard 1558 NFPA 110, NFPA 99 and NFPA 70
The switchgear uses Magnum DS Breakers that are designed to NEMA Standard SG-3; ANSI Standards C37.13, C37.16, C37.17 and UL 1066. Optional switchboard construction is available that is built to UL Standard 891. These switchboards use Magnum SB Breakers for generator mains, utility mains and electrically operated feeders, and molded-case breakers for non-switched feeders. Medium Voltage Cat Switchgear conforms to the following applicable standards: NEMA SG-5 ANSI/IEEE C37.20.2 CSA-C22.2 No. 31-M89 EEMAC G8-3.2. NFPA 70, 99, 110

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The switchgear uses VCP-W vacuum circuit breakers that are designed to meet or exceed all applicable IEEE/ANSI standards including C37.06.
Common Components Throughout the Entire Facility

Cat Generator Paralleling Switchgear is built with Eatons industry-leading Magnum DS low voltage drawout switchgear with Magnum DS breakers and VacClad medium voltage switchgear with VCPW vacuum breakers. This allows the use of common components on both the normal power systems and the generator power systems. Common and interchangeable breakers, relays, switchgear assembly parts, breaker maintenance procedures, and so on can be used to help reduce the overall operating cost and increase the maintainability of the entire facility.
Detailed Engine Data
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Generator Set Control Screen
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Denitions
September 2011
Sheet 40 004
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Denitions
The terms and acronyms below are referenced throughout this section on Generator Paralleling Switchgear. These denitions can help the reader fully understand the topics discussed. Alternator: A device for converting mechanical energy into alternating current electrical energy. It may also be called an AC or synchronous generator. ATS: Automatic Transfer Switch. Automatic Transfer Switch: A switch designed to sense the loss of one power source and automatically transfer the load to another source of power. Closed-Transition Transfer: A transfer between sources that provides a momentary paralleling of both power sources during a transfer in either direction. This results in no interruption of power to the loads during the transfer. The closed transition transfer is only possible when the sources are properly synchronized and interfaced. DGPS Distributed Generation Power System: Typically a local engine genset and automation connected to the utility system to peak shave or export power. EGP Switchgear (Engine Generator Paralleling Switchgear): Parallels multiple engine/gensets to serve loads transferred via downstream ATS units. EGPT Switchgear: Same as EGP except with a controlled emergency generator bus tie breaker between sets of generators to segregate loads or areas of the bus. EMCP 3.S: A Caterpillar microprocessor module for switchgear control, rugged, industrially hardened, microprocessor-based synchronizer and load controller designed to work exclusively with Cat enginegenerator sets.
EMCP Electronic Modular Control Panel: A Caterpillar microprocessor module for engine/genset control. Emergency Generator Bus Tie: A bus tie breaker used in EGP type systems to segregate groups of generators and/ or loads. Emergency Generator Bus Tie breakers are used where critical loads, required to be powered in 10 seconds, exceed the capacity of a single genset. EPS Emergency Power System : The emergency power sources and emergency distribution to downstream loads. EPSS Emergency Power System Supplier: Supplier of all the components of the EPS, such as the Caterpillar dealer. Emergency Standby Power Application: Typical usage of 50 hours per year with a maximum of 200 hours per year. Generators can be applied at their Standby rating with a typical variable load factor of 70%. Emergency Tie Breaker: A feeder breaker that is used to connect an EGP type system to a separate piece of Normal (utility) switchgear. Feeder Breaker Controls: Automation controls to allow control of the distribution feeder devices for load shed/load add control and monitoring. Generator: A machine for converting mechanical energy into electrical energy. The electrical energy may be direct current (DC) or alternating current (AC). Generator Bus Tie: A bus tie used in XLM type systems for separating the generator bus and/or loads from the normal utility fed bus and/or loads. Generator Demand Priority: Controls that automatically match the online engine generator capacity to the load to avoid unnecessary engine genset operation when loads are low. (Alternatively called Load Sense Load Demand.)
Generator Tie Breaker: A feeder breaker that is used to connect an XLM type system to a separate piece of Normal (utility) switchgear. Governor: A device that regulates prime mover speed by adjusting the fuel input to maintain constant speed. HMI Human Machine Interface: Typically a touchscreen used by the operator for interfacing with the paralleling generator system. LM Switchgear (Load Management Switchgear): A single generator used in distributed generation power systems. Includes automation controls that allow for the load to be served simultaneously by both utility and generator power sources while managing how much each source contributes. Load Shed/Load Add: Automation controls to control distribution devices (turn OFF and restore ON) when only partial emergency engine gensets are available for duty. Typically accomplished by assigning Priority levels to each controlled distribution device. Master Controls: All processors, HMI and programming to implement the desired modes of operation of engine gensets in a paralleling switchgear system. NFPA 110Standard for Emergency and Standby Power Systems: Standard for the assembly, installation and performance of electrical power systems to supply critical and essential needs during outages of the primary power source. NPS Normal Power System: The utility service entrance equipment and distribution circuits to downstream loads. NPSS Normal Power System Supplier : Supplier of all the components of the NPS, such as the distribution equipment vendors authorized distributor.
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Sheet 40 005

Denitions
40.0-5
Paralleling: The procedure of connecting two or more generators, or other power sources, of the same phase, voltage and frequency characteristics supplying the same load. Peak Shaving: Process by which utility customers minimize peak demand utility charges or exports power to the utility grid. Prime Power Application: Prime Power is when the genset is the only power source. Processor: A specially congured logic controller with appropriate inputoutput capability and programming. SAW (Surface Acoustic Wave): A premium touchscreen sensing technology that offers maximum protection from wear or contaminants.
Station Battery: A power supply used for control of switchgear. Synchronizer: A device that will synchronize an on-coming electric generator set with the bus or another electric generator set, and allows multiple power sources to be connected in parallel. Synchroscope: An instrument that provides a visual indication of proper time for closing of the breaker when synchronizing generators to connect them in parallel with another source. TFT (Thin Film Transistor): A type of touchscreen display technology used in HMI devices that offers high levels of brightness and clarity.
Utility Protection: A collection of protective relays or a multifunction relay required by the utility to detect abnormal conditions and open the utility breaker. XLM Switchgear (Emergency Transfer [Xfer] and Load Management Switchgear): Parallels multiple engine/gensets and the utility to serve downstream loads. Typically does not include downstream ATS units. XLMT Switchgear: Same as XLM except with a controlled generator bus tie breaker between the utility bus and the engine genset bus.
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40.0-6 Cat Generator Paralleling Switchgear

September 2011
Sheet 40 006
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Sheet 40 007

Switchgear Selection
40.1-1
Cat Switchgear Selector

Table 40.1-1. Cat Switchgear Selector
Soft Load (Closed Transition) Tab Section Voltage Range Available Switchgear Listings Modes of Operation Parallel Multiple Gensets Application Considerations
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Export
Peak Shaving
Parallel With Utility
Load Shed/ Load Add
Standby Application
Emergency (Standby)
Transfer Switches
25
XLM product is used when generators will be paralleled with a utility (even if utility breaker is not located in the same line-up as generator breakers). Allows closed transition transfer to/from utility, continuous paralleling with utility for peak shaving or exporting.
Transfer and Load Management Paralleling Switchgear (XLM)

40.2 G 208600V UL 1558 UL 891
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XLM
Emergency Generator Paralleling Switchgear (EGP)

40.3 G G 208600V UL 1558 UL 891 EGP product is used to parallel multiple gensets to a common bus where interconnect with the utility is not necessary. EGP systems are typically used where there are downstream Transfer Switches.
EGP
Medium Voltage Paralleling Switchgear

40.4 52 2.427 kV ANSI C37.20.2 ANSI C37.20.3 Medium Voltage product is for applications in excess of 600 Vac. Systems are available in any of the congurations above (XLM or EGP). Medium Voltage systems use vacuum circuit breakers for generator and distribution switching.
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MV
Custom Paralleling Switchgear Products

40.5 20827 kV UL 1558 UL 891 ANSI C37.20.2 ANSI C37.20.3 Custom Products are available to meet the most demanding or unique system requirements. (Ex., multiple utilities, multiple ties, special load control, custom sequence of operations, and so on)
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Standard and Custom Congurable Products
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Standard Congurable Products

Cat Switchgear is available in two standard product congurations: XLM (Emergency Transfer (Xfer) and Load Management) EGP (Emergency Generator Paralleling)
EGP
EGP (Emergency Generator Paralleling) switchgear is used for paralleling multiple generators that are not directly connected to a utility source. EGP switchgear is primarily used in applications where downstream automatic transfer switches provide the switching between normal and emergency sources. This is what is typically required in medical facilities, hospitals, and water/wastewater treatment facilities when multiple generator sets are paralleled. For detailed EGP product description, specications, layouts, and so on, refer to Section 40.3.
Custom Products
Custom switchgear is available to meet the needs of the most demanding, unique or complicated system congurations. Custom engineered systems are available for special system requirements such as: custom sequences of operation, special load control requirements, multiple utility and tie combinations, unique switchgear locations or layouts, and so on. No matter how complicated or unique the system, Cat Switchgear has the power and exibility to handle it. For detailed custom product description, specications, layouts, and so on, refer to Section 40.5.
These congurations are available for both low voltage and medium voltage applications and represent the most typical paralleling switchgear congurations seen in the industry. Additionally, custom congurations are available to meet the demands of even the most unique and complicated systems.
Medium Voltage Switchgear

Medium voltage switchgear is available in custom congurations, as well as standard congurations listed in this section. Medium voltage Cat Switchgear uses the same control technology and operator interface, and has all of the same features and functions as the low voltage systems. At the heart of all medium voltage Cat Switchgear systems is Eatons Vac-Clad metal-clad switchgear with type VCP-W vacuum circuit breakers. For detailed medium voltage (5 and 15 kV class) product descriptions, specications, layouts, and so on, refer to Section 40.4.
XLM
XLM (Emergency Transfer (Xfer) and Load Management) switchgear is used when the Generators are paralleled with a normal utility (or multiple utility) power source(s). XLM switchgear allows closed transition, soft-loading and unloading from utility, and peak shaving capability where generators operate continuously in parallel with the utility. Typically, XLM switchgear eliminates the need for automatic transfer switches. Data centers, industrial process, and other critical process loads are prime candidates for XLM switchgear. For detailed XLM product description, specications, layouts, and so on, refer to Section 40.2.
Cat C175 Genset
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Sheet 40 009

Cat Switchgear
40.1-3
Cat Switchgear Control Technology Features

Remote Operator Station
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Ethernet
ATS Cat ATS
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Cat Switchgear For systems with utility interconnect (XLM Type)
Modbus
ATS
ATS to SCADA or BMS

Data Table Interface
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Redundant Ethernet I/O
Ethernet Switch A Ethernet Switch B
Redundant 100 MHz Ethernet
Touchscreen Processor
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EMCP 3.S (Master) Touchscreen Generator 1
EMCP 3.S (Redundant Master) Generator 2
EMCP 3.S (Redundant Master) Generator X
EMCP 3.S
EMCP 3.S
Redundant Utility/ Tie Controllers Utility Protective Relay
Redundant Hardwired Signals Emergency Start - ATS Run Request - Utility Fail "First Up Dead Bus" Logic
Figure 40.1-1. Cat Switchgear Automation ArchitectureHigh Redundancy Package Features are common to all Low and Medium Voltage congurations. Cat Switchgear uses the EMCP 3.S, an advanced, industry-leading, multifaceted, microprocessor-based generator set control designed to work exclusively with Cat enginegenerator sets. 2. Moving Master Technology. Master control functions, such as modes of operation, load shed controls, generator demand priority controls, and dead bus logic, and so on, reside in the Generator #1 EMCP 3.S. If Generator #1 controller fails for any reason, the next generator controller will assume master control functions without interruption. Each generator controller is redundant to the rst and contains all the settings necessary to assume master control functions. This technology ensures that if a generator set is available, Cat Switchgear will automatically bring it to the bus. 3. Seamless and Bumpless Transfer. With Moving Master Technology, each EMCP 3.S controller monitors system status and data for each generator. Should the EMCP 3.S functioning as the Master controller fail, the new Master already has all the pertinent status and data to seamlessly assume the master controller functions.
4. Distributed Manual Control. In the highly unlikely case of a complete loss of system automation, distributed manual control is available. 5. Redundant Communication Processing. Two independent communication processors are built into the EMCP 3.S to control the Ethernet Channels A and B. 6. Redundant Ethernet Supervisory Networks. Each EMCP 3.S controller contains dual Ethernet ports and is connected to dual, independent Ethernet networks. 7. Instant Auto Switch. If the touchscreen fails, an Instant Auto switch is provided to place all digital controls in the Auto position, protecting your facility from power outages. A functional touchscreen is not required for complete automatic operation of Cat Switchgear.
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Redundancy and Fault Tolerance

Cat Switchgear Control Technology provides maximum efciency and reliability. With Cat Switchgear, single points of failure are eliminated because of the multiple levels of redundancy and fault tolerance that are built into the system: 1. True Distributed Processing. A separate automation controller for each power source ensures the system continues to operate even if a single controller fails. This architecture allows the use of redundant Moving Master Technology.
CA08104001E

Cat Switchgear
8. Remote Operator Stations. The remote operator station functions completely independent of the local operator interface touchscreen. If the local operator interface touchscreen fails, it will not affect the operation of the remote station connected to the system. 9. Hardwired Emergency Start Backup. Each system is designed with a hardwired emergency start backup system installed in the event of a catastrophic network communications failure, utility EMPC 3.S controller failure, or master I/O failures. The hardwired emergency start backup system will initiate a generator start signal to ALL of the generator EMCP 3.S controllers based on any ATS start signal or a Utility Failure signal. This ensures that the system is always alerted of a utility outage or ATS Run Request so generators can be started and power can be restored. 10. Hardwired First Up Dead Bus Backup. Each system is designed with a hardwired hot bus backup system installed in the event of a catastrophic network communications failure. This feature prevents multiple units from closing to a Dead Bus at the same time. Once the rst generator breaker closes to the bus, a hardwired Hot Bus signal is passed to all EMCP 3.S controllers and Ethernet I/O. 11. Best Source DC System. Control power is protected against single point of failure by the use of a 24 Vdc Best Source DC system. Each engine battery and a station battery are connected to a common DC bus. Each engine battery and the station battery are furnished with their own battery charger. The entire system is protected so that no individual battery/charger fault will affect the rest of the system. 12. Redundant Utility Fail Indication. For systems with utility interconnections (XLM type systems), two independent utility failure signals are present in each processor. This ensures that the system is always alerted of a utility outage so generators can be started and power can be restored.
Generator Metering
September 2011
Sheet 40 010
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Touchscreen Interface
Cat Switchgear technology uses a touchscreen for operator interface, monitoring and control of the paralleling switchgear. The screens give the operator an instantaneous, easily understandable view of the entire system status. This feature is standard in all Cat Switchgear. To access system controls, all you have to do is touch the corresponding portion of the screen. The entire engine generator set can be controlled from one touchscreen. The easyto-use touchscreen interface makes it possible to view, monitor and perform multiple functions including:

Engine Data
Metering Engine data Protective relay settings Annunciators Adjust load shed controls and generator demand priority Synchronize and parallel Set modes of operation Voltage and frequency adjustments
Generator Control
With Cat Switchgear, its simple. All the critical information you need is displayed in a manner that is easy to understand. Graphics look exactly like the meters and gauges on conventional switchgear. At a glance, users can easily see how the system is performing and, based on real-time information can quickly do whats necessary to correct or optimize system performance.
Generator Annunciator
Automated Joint Commission Report
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Cat Switchgear
40.1-5
Table 40.1-2. PowerLynx Control Conguration Comparison

Features High Redundancy Standard Standard Standard Standard Standard Standard 19-inch color Standard Standard Optional Standard Optional Optional Standard Standard Unlimited Standard Optional Standard Optional Optional Optional Optional Optional Optional Optional Optional Standard Standard Standard Optional Optional Optional Optional 15-inch color Standard Standard Optional Standard Optional Optional Not available Not available 100 events Not available Optional Standard Not available Optional Optional Not available Optional Optional Not available Not available
Standard Package

Redundancy and Fault Tolerance Features

True distributed processing Best source 24 Vdc system Moving master redundancy Redundant control network Redundant utility/tie automation processors Redundant Ethernet I/O
15-inch color TFT touchscreen High reliability resistive LCD touchscreen technology Limited alarm and event logging Available moving master Available redundant network
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High-Speed Integrated Control System

Cat Switchgear uses a high-speed industrially hardened network for system control. The high redundancy package includes a redundant supervisory communication network. This ensures that the loss of one or more processors or a supervisory communication network will not affect the integrity of the switchgear automation. This feature ensures proper system performance under any condition.
Display Features and Options

Local touchscreen display 3-D generator view for engine data Dynamic system overview one-line Full redundant touchscreen System tuning capabilities via touchscreen Balance of plant monitoring or control Individual genset unit display
Logging and Reporting Features

Historic trending Real-time trend Alarm and event logging Save/export alarm logs Full feature remote monitoring/control Automated reporting Custom automated reporting (ex., Joint Commission Test Report, etc.) Connectivity to BMS or SCADA systems
Best-in-Class Footprint
Cat Switchgear technology uses less than one-third of the components of conventional generator paralleling switchgear. This translates into less wiring, a smaller footprint, higher mean time between failures, and lower mean time to repair.
ATS Monitoring and Control

Cat ATS monitoring and control Cat ATS remote settings capability via touchscreen Cat UPS monitoring only Non-Cat ATS monitoring only Non-Cat ATS monitoring and control Non-Cat UPS monitoring only
Integrated Digital Technology

Integrated with Cat on-package genset controls, Cat controls have built-in synchronizer, power factor controller and load sharing functions. Cat Switchgear products do not require additional discrete components, such as synchronizers, cross-current compensation devices, speed/voltage drop controllers, load sharing modules, and so on.
Cat Switchgear Control Technology

Cat Switchgear offers two different levels of touchscreen operator interface. Each level gives different options for trending, reporting, and logging capabilities.
High Redundancy Package

19-inch color LCD TFT touchscreen SAW (surface acoustic wave) LCD touchscreen technology for unsurpassed reliability Historical trending of engine generator and electrical parameters Unlimited alarm and event logging Ability to save and archive trend and logging data Automated reporting capability Alarm reports Log reports Generator system reports Joint commission compliant reports Optional automatic transfer switch control Moving master Redundant control network
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Cat Switchgear
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Cat Switchgear System Advantages

Cat Switchgear performs generator protective functions internal to the EMCP 3.S controller. With Cat technology, you can monitor, process, compare, display and transmit data with a high degree of precision and controland that control translates into high reliability and functionality. EMCP 3.S technology provides Cat Switchgear with enhanced features that set the standards for the industry. Unequaled fault tolerance World-leading operator interface Sophisticated communications abilities Superior connectivity

Low cost redundancy Enhanced performance UL, NFPA, CSA and IEEE compliant Higher mean time between failure Lower mean time to repair

Advanced Communications Capabilities

Cat Switchgear technology is equipped with exceptional remote communications technologies, enabling you to control and monitor your engine generator sets from anywhere at anytime. Whether at home, in the ofce, or on the road, you can access controls and information on a real-time basis and respond immediately...even control multiple facilities from a single centralized site. Whether on-site or off-site, the available remote communications package gives you the identical interface and same capabilities as standing in front of the generator or Cat Switchgear. Although identical,
the remote communications run completely independent of the paralleling switchgear automation. This ensures remote communication devices or systems will not affect the reliability of your Cat Switchgear. Figures 40.1-2 and 40.1-3 show examples of remote communication connections to the Cat Switchgear.
Communications with Building Management or SCADA Systems

Cat Switchgear can also easily communicate data to third party Building Management, SCADA or other monitoring systems. For these applications, a Data Table Interface acts as a rewall between your Cat Switchgear system and the Building Management or SCADA System. The Data Table Interface serves up the requested data to the third-party monitoring system, but stays completely independent of all critical generator control automation. This ensures remote communication devices or systems will not affect the reliability of your Cat Switchgear.
Additional Cat Switchgear advantages include: Less installation wiring Smaller footprint provides better utilization of available space Detailed engine and electrical reports
End User PC - Full Control or View Only (depending on password) - Dedicated Static I.P. Address
Cat Switchgear HUB or Switch
End User PC - Full Control or View Only (depending on password) - Dedicated Static I.P. Address
Cat. 5 cable (up to approx. 300)
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Switchgear PC - Dedicated Static I.P. Address - Ethernet Port
Ethernet Port End User PC - Full Control or View Only (depending on password) - Dedicated Static I.P. Address
Key Points: 1. Dedicated Ethernet LAN or 2. Utilize customers' LANCoordination with network administrators may be necessary for connection and security issues. 3. Supports multiple clients.
Figure 40.1-2. On-Site RemoteEthernet Network with Multiple Users
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Cat Switchgear
40.1-7
On-Site Provided with Cat Switchgear Your Company Network

VPN Device
Off-Site
Remote Client - Web Browser
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View Only
View Only
Cat Switchgear
VPN TUNNEL
Firewall Device - VPN Access
VP N
Ethernet Port
26
EL
N TU N
Switchgear PC
- 1 Web Server - Ethernet Port
Cat. 5 cable (up to approx. 300')
27 28 29
Firewall Device - VPN Access
Figure 40.1-3. Off-Site Remote(TCP-IP) Web-Based Connection with Multiple Users (View Only)
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CA08104001E
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Sheet 40 015
Cat Generator Paralleling Switchgear XLM Switchgear

General Description
40.2-1
XLM
General Description
Cat XLM SwitchgearGenerator Paralleling Switchgear for Emergency Transfer (Xfer) and Load Management control of multiple engine generator sets with one utility source. For systems with multiple utility and/or tie breakers, please refer to the Custom Congurable Switchgear Section 40.5. For medium voltage application, refer to Section 40.4. Automatic transfer to emergency upon utility failure Automatic start, synchronize, parallel, and load share on a common bus for emergency operation Closed transition transfer back to utility upon stable return of power, with soft generator unloading Closed transition Load Management Mode with soft loading and unloading of generator system
Closed transition transfer to Emergency Mode to facilitate maintenance, or for storm threat avoidance with soft loading and unloading of generator system Load shed/load add Generator demand priority Cost-effective, technically superior alternative to conventional ATS arrangement
22 23 24 25 26 27 28 29 30
Cat Switchgear brings the power and reliability of microprocessor technology to your generator switchgear application. Through the use of the operator interface touchscreen display with easy-to-follow graphical representations, the Cat Switchgear merges the features of: Power monitoring Switchgear automation Generator set control Optional remote communications
XLM2 Switchgear
31 32 33 34
35 36 37 38 39 40 41 42
Figure 40.2-1. XLM2 Low Voltage Switchgear
PR = Protective Relay.
43
CA08104001E
40.2-2 Cat Generator Paralleling Switchgear XLM Switchgear

Standard and Optional Equipment
September 2011
Sheet 40 016
22 23 24 25 26 27
Equipment
Standard EquipmentXLM
28
29 30 31

32 33 34 35

36 37 38 39 40 41

42 43
Low voltage XLM systems use Magnum DS power circuit breaker switchgear and Magnum power circuit breakers. For complete technical details on Magnum DS switchgear, see Tab 20 Operator Interface Touchscreen (Choose one of the following): 19.00-inch surface acoustic wave LCD TFT color touchscreen with key switch 15.00-inch resistive LCD TFT color touchscreen Direct data communication to Cat microprocessor-based engine generator set control network Full function 0.5% accuracy analog and digital AC metering for utility: voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR Full function 0.5% accuracy analog and digital AC metering for generators: voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR Full function engine gauges; RPM, DC battery voltage, oil pressure, engine coolant temperature, engine hours, number of starts Full function synchronizing and paralleling controls with selection for automatic or manual synchronizing NFPA 110 engine/generator status, pre-alarm, lamp test button, shutdown fault annunciation and 85 dBA alarm horn with silence button Full function 0.5% accuracy analog and digital AC metering for system: voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR System control functions for auto (standby for emergency), closed transition to emergency and load management Automatic load shed control with on-screen operator adjustments for essential, critical, and non-essential loads. Manual load shed/load add control Automatic generator demand priority with on-screen operator adjustments for automatic addition and removal of generator to the load bus System status and alarm annuciation with color display and 85 dbA alarm horn with silence button
Password secured settings and adjustments for generator and system setups and protective relaying Alarm summary reports Settings reports Engine and generator load charts 3-D engine data (available with ADEM 3 or ADEM 4 Governor) UL 891, UL 1558 or CSA listed and labeled NEMA 1 or NEMA 3R, deadfront freestanding construction Copper bus, braced for 100 kA Three-phase, four-wire, 100% neutral,1/4-inch x 2.00-inch copper ground bus Available in 600V, 480/277V or 208/120V, 60 Hz UL 1066 listed power circuit breakers, 42200 kAIC, two-step stored energy drawout mounted electrically operated with long time and instantaneous trip, and circuit breaker control switch with lights Continuous cross bus ratings up to 10,000A at 600 Vac Mechanical lugs for incoming and outgoing conductors Top or bottom conduit entry Plug together control connections across shipping split Distribution sections with electrically operated drawout UL 1066 circuit breakers Circuit breaker trip functionsshort time and/or ground fault (in addition to long time and instantaneous) Steel barriers between switchboard or switchgear sections for compartmentalization Bus/cable barriers Distribution sections with group mounted UL 489 molded case circuit breakers. (UL 891 construction only) Also available in 150 kA (UL 891) or 200 kA (UL 1558) bus bracing congurations Also available in 8000 and 10,000A continuous cross bus ratings at 600 Vac Also available with 4000, 5000 and 6000A UL1066 breakers Trip unit metering and communications (Digitrip 520M, 520MC and 1150) Also available in 5 kV, 15 kV and 27 kV class congurations (see Section 40.4)
Remote monitoring and control Building Automation System or SCADA communications Modbus or Ethernet Remote notication Historical data trending

Tie Breaker Application

Many systems require the use of tie breakers to meet Code or system performance requirements. Tie breakers can be used anywhere throughout the line-up to segment or isolate desired sources, loads or sections of bus.
Generator Bus Tie

Generator Bus Ties can be used to separate the normal electric service sources from the generator sources. This can also allow separation of load breakers to either side of the generator bus tie breaker in order to allow isolation of load banks, or dedicated emergency loads. This separation also may be required by NFPA or local codes. Generator bus tie breakers can be applied to serve several purposes. 1. Starting of large loadsthe generator bus tie can be opened to allow multiple generators to be paralleled before being connected to large load(s). Once multiple generators are paralleled, the generator bus tie can be closed to power the large loads. 2. Load banksthe generator bus tie can allow the generators to be isolated from the normal utility fed bus. Having a distribution breaker or set of load take-off lugs on the generator side of the bus allows the generators to be load bank tested without affecting any normal utility fed loads. 3. Emergency standby systems with automatic transfer switches the generator bus tie provides isolation between the normal and emergency buses. During a loss of utility power, the generator bus tie can be opened to isolate all normal loads and allow restoration of power to emergency loads. Once emergency loads are restored, the emergency bus tie can be reclosed to restore power to normal loads.
Note: See Page 40.2-8 for an example of an XLM system with generator bus tie breaker.
Optional EquipmentXLM
CA08104001E
September 2011
Sheet 40 017

Features
40.2-3
Cat XLM Switchgear

Utility Metering
0.5% accuracy Voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR; synchroscope
Engine/Generator Control

Circuit Breakers
100% rated UL 1066 power circuit breakers available 8006000A with two-step stored energy mechanism 42 kAIC standard (50200 kA optional) Some ratings are only available under certain UL ratings (UL 1558200 kA)

Utility Protective Relaying

15automatic synchronizer 27/59under/overvoltage relay 81 O/Uunder/overfrequency relay Multi-function utility grade, drawout with: 47phase sequence/phase failure relay 32reverse direction relay, utility grade, drawout 32/51reverse direction overcurrent relay, utility grade, drawout 32/62reverse direction timing relay, utility grade, drawout 86reverse power lockout relay, manual reset 25sync check relay
Automatic engine start Adjustable engine cool-down timer 15automatic synchronizer 65microprocessor engine governor load sharing and soft loading control 90VAR/PF and cross current compensation controller 0.5% accuracy Voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
System Metering

System Protective Relaying

27/59bus under/overvoltage relay 81 O/Ubus under/overfrequency relay
System Control

Drawout mounted (xed optional) some ratings are only available under certain UL ratings. (UL 1558200 kA) 5 cycle closing Electrically operated Auxiliary and bell alarm contacts Electronic trip unit with long time and instantaneous trip functions (short time and ground fault optional) Available as UL 1558, UL 891 or CSA listed and labeled Optionally service entrance rated NEMA 1 or NEMA 3R, deadfront freestanding construction Copper bus 100 kA bus bracing (150200 kA optional) Three-phase, four-wire, 100% neutral bus, 1/4-inch x 2.00-inch ground bus Also available in UL listed and labeled medium voltage 0C to 50C 0 to 95% humidity, noncondensing
Generator Metering
Generator Protective Relaying

27/59under/overvoltage relay 81 O/Uunder/overfrequency relay 32reverse power relay 40loss of excitation (reverse VAR) relay 25sync check relay
Automatic standby mode Emergency mode with closed transition to normal Closed transition to emergency mode Load management mode Automatic load shed control with bus underfrequency protection and one four-pole,10A,120 Vac, Form C, dry contact output for each load shed level (1 level for each generator in the system) Automatic generator demand priority control Master shutdown button
Enclosure and Bussing

Power Supply
Automatic best DC source selector 24 Vdc station battery, sealed jar, 4-hour, external 120 Vac emergency power required for charger Power from 24 Vdc engine cranking batteries Processor power supplies24 Vdc

Environment

Seismic Qualication
Engine Gauges
RPM meter Engine battery volt meter Oil pressure gauge Engine coolant temperature gauge

Technology Communications
Automation networkhigh speed, high reliability, industrially hardened Optional remote communications networkEthernet, modem Optional communication to building automation or SCADA systems for general monitoring Modbus RTU or Ethernet
Engine Monitoring and Alarms

Refer to Tab 1 for information on seismic qualication for this and other Eaton products.
38 39 40 41 42 43
Low coolant temperature pre-alarm High coolant temperature pre-alarm and shutdown Low oil pressure pre-alarm and shutdown Low fuel alarm (diesel only) Low engine battery alarm Overcrank shutdown Overspeed shutdown
CA08104001E

Technical Data
September 2011
Sheet 40 018
22 23 24 25 26 27 28 29 30 31 32 33 34
XLM SwitchgearOne-Line Diagrams
Figure 40.2-2. Typical Electrical System with XLM1 Switchgear (One Generator Source, One Utility Source) (For Multiple Utility Sources, see Custom Congurable Switchgear Section 40.5)
Generator Breaker Size
Max. Feeder Breaker Size
Max. Utility Bkr. Size
SECT 1
SECT 2
SECT 3
Main Bus Rating
Generator kW (480V) Min. Max.
Dimensions Height Width Depth Weight Lbs (kg) 3400 (1544) 3600 (1634) 78.00 3700 (1981.2) (1680)
35
CELL A
36 37 38 39 40 41 42 43
CELL D
MDS-CXX
52N1 CONTROLS
MDS-CXX
52G1
DIST CONTROLS
800 1600
532
800 1600 1600 99.00 44.00 72.00 3300 (2514.6) (1117.6) (1828.8) (1498) 1600 1600 1600 2000 2000 2000 3000 3200 3200
533 1064
CELL B 96.06 (2440.0)
HMI 19 TOUCHSCREEN
MDS-CXX
2000 1065 1330

52D1
TOUCHSCREEN DISABLE ENABLE
HORN SILENCE
HORN
SYSTEM SR750 CONTROLS

OPEN CLOSED
3000 1331 2000

G R
CELL C
52G1 CONTROLS UCLOS 86
4000A, 5000A and 6000A breakers available in 44.00-inch wide structure. Contact your local Caterpillar Electric Power dealer for more details. Low voltage switchgear for up to 3500 kW generator set ratings at 480V is also available. Contact local Caterpillar Electric Power dealer for more details. 66.00 (1676.4) with D1 (optional as shown).
52N1
Conduit Space for 22.00-Inch (558.8 mm) Wide Structures Top or Bottom Entry
22.00 (558.8) 66.00 (1676.4) FRONT ELEVATION 22.00 (558.8)
22.00 (558.8)
Structure Depth 66.00 (1676.4) 72.00 (1828.8) 78.00 (1981.2) 84.00 (2133.6)
Rear Conduit Opening Width 16.00 (406.4) 16.00 (406.4) 16.00 (406.4) 16.00 (406.4) Depth 19.30 (490.2) 25.30 (642.6) 31.30 (795.0) 37.30 (947.4)
Recommended Number of 3.50 or 4.00-Inch Conduits 9 12 15 18
Figure 40.2-3. XLM1 Low Voltage Switchgear Layout
CA08104001E
September 2011
Sheet 40 019

Technical Data
40.2-5
22 23 24 25 26 27 28 29 30 31
Figure 40.2-4. Typical Electrical System with XLM2 Switchgear (Two Generator Sources, One Utility Source) (For Multiple Utility Sources, see Custom Congurable Switchgear Section 40.5)
32 33
SECT 1
R
SECT 2
SECT 3
Main Bus Rating
Dimensions Height Width Depth Weight Lbs (kg)
34 35 36 37 38 39 40 41 42 43
CELL A
52N1 CONTROLS
MDS-CXX
DIST CONTROLS 52G1
800 1600
532
800 1600 1600 99.00 66.00 72.00 5000 (2514.6) (1676.4) (1828.8) (2270) 1600 1600 1600 2000 2000 2000 3000 3200 3200 5200 (2361) 5600 (2542) 84.00 5800 (2133.6) (2633)
533 1064
OPEN
CLOSED
CELL B 96.06 (2440.0)
HMI 19 TOUCHSCREEN
52G1 CONTROLS
2000 1065 1330

MDS-CXX
HORN SILENCE
HORN
52D1

OPEN CLOSED
3000 1331 2000

G R
CELL C
52G2 CONTROLS UCLOS 86
MDS-CXX
52D2
4000A, 5000A and 6000A breakers available in 44.00-inch wide structure. Contact your local Caterpillar Electric Power dealer for more details. Low voltage switchgear for up to 3500 kW generator set ratings at 480V is also available. Contact local Caterpillar Electric Power dealer for more details.
CELL D
MDS-CXX MDS-CXX
52G2
52N1
Structure Depth
22.00 (558.8) 22.00 (558.8) 66.00 (1676.4) FRONT ELEVATION 22.00 (558.8)
66.00 (1676.4) 72.00 (1828.8) 78.00 (1981.2) 84.00 (2133.6)
CA08104001E

Technical Data
September 2011
Sheet 40 020
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
UCLOS 86
Figure 40.2-6. Typical Electrical System with XLM3 Switchgear (Three Generator Sources,One Utility Source) (For Multiple Utility Sources, see Custom Congurable Switchgear Section 40.5)
SECT 1
SECT 2
SECT 3
SECT 4
Main Bus Rating
Dimensions Height Width Depth

Weight Lbs (kg)
CELL A
52N1 CONTROLS
MDS-CXX MDS-CXX
DIST CONTROLS 52G3
52G1
800 1600
532
800 1600 1600 99.00 88.00 72.00 7100 (2514.6) (2235.2) (1828.8) (3223) 1600 1600 1600 2000 2000 2000 3000 3200 3200 7300 (3314) 7700 (3496) 84.00 7800 (2133.6) (3541)
OPEN
CLOSED
OPEN
CLOSED
CELL B 96.06 (2440.0) CELL C
HMI 19 TOUCHSCREEN
TOUCHSCREEN DISABLE ENABLE HORN SILENCE HORN
533 1064
52G1 CONTROLS
52G3 CONTROLS
MDS-CXX
52D1
2000 1065 1330 3000 1331 2000
SYSTEM
SR750 CONTROLS
OPEN CLOSED
52G2 CONTROLS
MDS-CXX
52D2
39 40 41 42 43
CELL D
MDS-CXX MDS-CXX MDS-CXX
52N1
52G2
52D3
22.00 (558.8)
22.00 (558.8)
88.00 (2235.2)
22.00 (558.8)
22.00 (558.8)
Structure Depth 66.00 (1676.4) 72.00 (1828.8) 78.00 (1981.2) 84.00 (2133.6) Rear Conduit Opening Width 16.00 (406.4) 16.00 (406.4) 16.00 (406.4) 16.00 (406.4) Depth 19.30 (490.2) 25.30 (642.6) 31.30 (795.0) 37.30 (947.4) Recommended Number of 3.50 or 4.00-Inch Conduits 9 12 15 18
FRONT ELEVATION
CA08104001E
September 2011
Sheet 40 021

Technical Data
40.2-7
22 23 24 25 26 27 28 29 30 31
Figure 40.2-8. Typical Electrical System with XLM4 Switchgear (Four Generator Sources, One Utility Source) (For Multiple Utility Sources, see Custom Congurable Switchgear Section 40.5)
32 33
SECT 1
SECT 2
SECT 3
SECT 4
SECT 5
Main Bus Rating

Weight Lbs (kg)
34 35 36 37 38 39 40 41 42 43
CELL A
52N1 CONTROLS
MDS-CXX
MDS-CXX
DIST CONTROLS
52G1
52G3
OPEN
CLOSED
OPEN
CLOSED
CELL B
96.06 (2440.0)
HMI 19 TOUCHSCREEN
HORN SILE NCE
HORN
800
MDS-CXX
MDS-CXX
532
110.00 72.00 9100 800 1600 1600 99.00 (2514.6) (2794.0) (1828.8) (4131) 1600 1600 1600 2000 2000 2000 3000 3200 3200 9300 (4222) 9500 (4313) 84.00 9800 (2133.6) (4449)
52G1 CONTROLS
52G3 CONTROLS
52D1
52D3
1600
533 1064
SR750
SYSTEM CONTROLS
OPEN CLOSED
OPEN CLOSED
CELL C
52G2 CONTROLS
UCLOS 86
2000 1065 1330

52G4 CONTROLS
MDS-CXX
MDS-CXX
52D2
52D4
3000 1331 2000

CELL D
MDS-CXX
MDS-CXX
MDS-CXX
52G4
52N1
52G2
22.00 (558.8)
22.00 (558.8)
22.00 (558.8) 88.00 (2235.2)

FRONT ELEVATION
22.00 (558.8)
22.00 (558.8)
CA08104001E

Technical Data
September 2011
Sheet 40 022
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
Figure 40.2-11. XLMT4 Low Voltage Switchgear Layout
For more information, visit: www.eaton.com/consultants CA08104001E
CELL A
52N1 CONTROLS
DIST CONTROLS
MDS-CXX
MDS-CXX
Figure 40.2-10. Typical Electrical System with XLMT4 Switchgear (Four Generator Sources, One Utility Source, One Generator Bus Tie Breaker) (For Multiple Utility Sources, see Custom Congurable Switchgear Section 40.5)
SECT 3
SECT 1
SECT 2
SECT 4
SECT 5
SECT 6
Main Bus Rating

Weight Lbs (kg)
DIST CONTROLS
MDS-CXX
52D4
52G1
52G3
OPEN
CLOSED
OPEN
CLOSED
OPEN
CLOSED
CELL B
96.06 (2440.0)
HMI 19 TOUCHSCREEN
MDS-CXX
HORN SILE NCE
800
52T1 CONTROLS
532 1064 1330 2000
800 1600
52G1 CONTROLS
MDS-CXX
52G3 CONTROLS
800 99.00 132.00 72.00 9100 (2514.6) (3352.8) (1828.8) (4131) 78.00 9300 (1981.2) (4222) 84.00 9500 (2133.6) (4313) 9800 (4449)
HORN
52D1
52D5

OPEN CLOSED
OPEN CLOSED
1600
G
R
G
R
MDS-CXX
1600 1600 1600 2000 2000 2000 3000 3200 3200
CELL C
MDS-CXX
52G2 CONTROLS
52T1
MDS-CXX
52G4 CONTROLS
UCLOS
86
52D2
52D6
2000 3000
CELL D
MDS-CXX
MDS-CXX
MDS-CXX
MDS-CXX
MDS-CXX
52N1
52D3
52G2
52D7
52G4
22.00 (558.8)
22.00 (558.8)
22.00 22.00 (558.8) (558.8) 110.00 (2794.0)
22.00 (558.8)
22.00 (558.8)
FRONT ELEVATION
4000A, 5000A, and 6000A breakers available in 44.00-inch wide structure. Contact your local Caterpillar Electric Power dealer for more details. Low voltage switchgear for up to 3500 kW generator set ratings at 480V is also available. Contact local Caterpillar Electric Power dealer for more details.
September 2011
Sheet 40 023

Technical Data
40.2-9
Table 40.2-1. Typical Control Circuit WiringLow Voltage Systems

Function (Quantity)/Size/ Type of Cable Diesel(1) x #16 AWG shielded twisted pair (Belden 8719) Gas(1) x #16 AWG shielded twisted quad Control panel discrete control interface Best source 24 Vdc Voltage regulation (VR) control (16) x 1/c #14 AWG (includes spares) (4) x 1/c #10 AWG (2 x + 24 Vdc and 2 x24 Vdc) (1) x #16 AWG twisted pair (Belden 8719) (3) x 1/c #14 AWG (additional for CDVR only) Speed control (governor) Type 2301A speed controller (2) x #16 AWG shielded twisted pair (2301A) ADEMIII speed controller (1) x #16 AWG shielded twisted triplet (Belden 8618) (Additional for pro act gov. only) (3) x #14 AWG XHHW Cu Air fuel ratio (AFR) controller Gas only(1) x #16 AWG shielded twisted pair (3) x 1/c #12 AWG (in master section) (4) x 1/c #10 AWG (2 x + 24 Vdc and 2 x24 Vdc) (next to switchgear) (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (each) (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (each) (2) x 1/c #14 AWG (6) x 1/c #10 AWG (at gen.) (1) x #14 AWG shielded twisted quad per reading (at generator) (2) x 1/c #14 AWG thermo-couple wire per reading (at generator) (1) x #16 AWG shielded twisted pair (Belden 8471) (2) x 1/c #14 AWG (4) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG per required alarm (2) x 1/c #14 AWG per required alarm (3) x 1/c #10 AWG per 10 structures (1) x 4 Pair #24 AWG UTP Cat. 5 (Ethernet) or(1) 4 conductor ber optic cable (Belden I100466varies based on Installation requirements) (1) x #18 AWG shielded twisted pair (Belden 3073) Signal Type Signal level Signal level DC control 30 Vdc DC control 30 Vdc Signal level DC control 0 Vdc DC control 30 Vdc Bipolar DC bias signal for speed control Discrete control (start/stop, emergency stop and crank terminate, includes spares, etc.) 24 Vdc from generator battery system to supplement switchgear 24 Vdc control voltage Bipolar DC bias signal for voltage control Description
22 23 24 25 26 27 28 29
Generator Control
Cat engine generator set communications Network communications for monitoring and display of engine data to switchgear
Signal level
DC control 30 Vdc Signal level For gas engines equipped with AFR controller only 120 Vac/20A emergency circuit for 24 Vdc battery charger power
Battery Systems
Power for 24 Vdc station battery charger 24 Vdc station batteries 24 Vdc station battery charger malfunction Generator battery charger malfunction AC control
30 31 32 33 34 35 36 37 38
DC control 30 Vdc 24 Vdc supply to switchgear controls from 24 Vdc battery system DC control 30 Vdc Alarms DC control 30 Vdc Alarms DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc AC control DC control 30 Vdc DC control 30 Vdc Alarms Alarms Alarms Alarms Alarms Alarms Alarms Alarms Alarms 87G relay alarm/shutdown Indication/alarms/shutdown Indication/alarms/shutdown
Fuel Systems
Low fuel tank level (master fuel tank) Fuel tank rupture basin (master fuel tank) High fuel tank level (master fuel tank) Other fuel tank alarms (master fuel tank) Low fuel tank level (day tank) Fuel tank rupture basin (day tank) High fuel tank level (day tank) Other fuel tank alarms (day tank)
Generator Protection Systems

Genset mounted CB status Generator differential CTs Generator RTD leads Engine thermo-couples
Automatic Transfer Switch Interface (Per ATS)

Cat ATS monitoring and control Engine start Discrete ATS position ATS load shed Signal Level DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc AC control Signal level Monitoring and control of ATS functions Engine start request Normal and emergency ATS status load shed / load add Alarms/shutdown Alarms/shutdowns 120 Vac for space heaters (single-phase/30A) Communication signal to remote monitoring/control PC workstation or LAN
39 40 41 42
Miscellaneous (Optional)
Miscellaneous enclosure alarms Miscellaneous aux. equipment alarms Switchgear 120 Vac space heaters Remote monitoring/control PC
Building management/SCADA interface

Signal level
Communication signal to building management or SCADA system
All control wiring to be stranded copper unless specied otherwise. Conductor size may have to be increased for voltage drop over long distances. Recommend 20% spares of each size single conductor and one of each multi-conductor cable. Separate metallic conduits should be used for each Signal Type. Signal Level and DC Control Signal 30 Vdc wires may be combined in the same conduit.
43
Note: Specic project and equipment requirements will determine exact number and type of control wiring required.
CA08104001E

Functional Sequence of Operations
September 2011
Sheet 40 024
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
XLM Functional Sequence of Operations

A. The EPS Automation shall be provided with the following Modes of Operation: 1. Automatic/Standby Mode a. The utility main breaker is closed serving utility power to the generator/load bus. b. The generator main breakers are open. c. The automation is standing by to act in response to a utility failure. 2. Emergency Mode (Standby) a. Utility Failure 1. Utility protective relaying senses utility voltage or frequency out of tolerance. 2. The utility main breaker is opened. 3. A run request is sent to the generator plant. 4. The rst generator up to voltage and frequency is closed to the bus. 5. [With Generator Bus Tie Breaker] The generator bus tie breaker is closed. 6. The remaining generators are synchronized and paralleled to the bus as they come up to voltage and frequency. 7. The system is now in Emergency Mode. b. Utility Restoration and Exit from Emergency Mode 1. Utility protective relaying senses utility voltage and frequency within tolerance. 2. Following an adjustable time delay (which can be abbreviated by the operator) to ensure that the utility power source is stable, the generator plant is passively synchronized and paralleled to the utility source by closing the utility main breaker. 3. The generator plant is soft ramp unloaded until the utility source is nominally serving the entire system load. 4. The generator breakers are opened. 5. The generators are allowed to run for their programmed cool-down period. 6. The system is now back in Automatic/Standby Mode. 3. Transfer to Emergency Mode a. Entry 1. The operator places the System Mode Selector Switch into the Closed Transfer to Emergency position. 2. A run request is sent to the generator plant. 3. The rst generator up to voltage and frequency is closed to the bus at no load. 4. The remaining generators are synchronized and paralleled to the bus at no load as they come up to voltage and frequency. 5. When all generators are on the bus they are soft ramp loaded until the generator plant is nominally serving the entire load on the bus and the utility main breaker is opened. OR 5. [With Generator Bus Tie Breaker] When all generators are on the bus, they are paralleled across the generator bus tie breaker. They are then soft ramp loaded until the generator plant is nominally serving all of the load on the bus and the utility main is opened.
6. The system is now running in Emergency Mode. b. Exit from Emergency Mode 1. The operator removes the System Mode Selector Switch from Transfer to Emergency position and returns it to the Auto position. 2. Following an adjustable time delay (which can be abbreviated by the operator), the generator plant is passively synchronized and paralleled to the utility source by closing the utility main breaker. 3. The generator plant is soft ramp unloaded until the utility source is nominally serving the entire system load. 4. The generator breakers are opened OR
4. [With Generator Bus Tie Breaker] The generator bus tie breaker is opened and then all of generator breakers are opened. 5. The generators are allowed to run for their programmed cool-down period. 6. The system is now back in Automatic/Standby Mode. 4. Load Management Mode a. Entry 1. Select one of the modes of operation: i. Import LimitThe user places the Import/ Export toggle switch in the Import position and places the Base Load/Utility Tracking toggle switch in the Utility Tracking position. The user sets the Utility Import set point to the desired amount of kW that they want to import through the Utility Circuit Breaker during Load Management Mode. ii. Export LimitThe user places the Import/Export toggle switch in the Export position and places the Base Load/Utility Tracking toggle switch in the Utility Tracking position. The user sets the Utility Export Set point to the desired amount of kW that they want to export through the Utility Circuit Breaker during Load Management Mode. iii. Base Load ImportThe user places the Import/Export toggle switch in the Import position and places the Base Load/Utility Tracking toggle switch in the Base Load position. The user sets the Base Load set point to the desired amount of kW that they want the generator plant to assume during Load Management Mode. The controls shall not allow the generator plant to export kW through the Utility Circuit Breaker and shall always maintain a nominal amount of Utility kW imported through the Utility Circuit Breaker. iv. Base Load ExportThe user places the Import/Export toggle switch in the Export position and places the Base Load/Utility Tracking toggle switch in the Base Load position. The user sets the Base Load set point to the desired amount of kW that they want the generator plant to assume during Load Management Mode. The controls shall allow the generator plant to export kW through the Utility Circuit Breaker.
CA08104001E
September 2011
Sheet 40 025

40.2-11
2. The user places the System Mode Selector Switch in the Load Management position. 3. A run request is sent to the generator plant. 4. The generators are allowed to run for a veminute warm-up time (which can be abbreviated by the operator). 5. The generators are synchronized and paralleled to the bus at no load after completion of the warm-up time. 6. When all generators are on the bus they are soft ramp loaded until the generator plant is nominally serving the required amount of the load on the bus to meet the mode of operation selected. 7. The generator output is dynamically adjusted to maintain the set point to meet the mode of operation selected. If at any time the system is unable to maintain the set point then a Set point Exceeded alarm shall be sounded. 8. Should the utility fail at any time during Load Management operation, the utility protective relays shall cause the utility main to open and be locked out, thus placing the system in Emergency Mode until the Utility is restored (as described in Emergency Mode exit). b. Exit 1. The operator removes the System Mode Selector Switch from Load Management position and returns it to the Auto position. 2. The generator plant is soft ramp unloaded until the utility source is nominally serving the entire system load and the generator main breakers are opened. 3. The generators are allowed to run for their programmed cool-down period.
6. Utility Fail Test Mode a. Entrance into Utility Fail Test Mode 1. The Utility Fail Test Switch is placed in the ON position. 2. Voltage sensing at the utility protective relay is opened, which simulates a loss of utility. 3. The system enters into Emergency Mode as described in the Emergency Mode sequence above. b. Exit from Utility Fail Test Mode 1. The Utility Fail Test Switch is placed in the OFF position. 2. Voltage sensing at the utility protective relay is restored, which simulates the return of utility power. 3. The system exits from Emergency Mode as described in the Emergency Mode sequence above. B. When the Generator Sets are carrying the facility load, the EPS Automation shall support two (2) sub-modes: Load Shed/Load Add, and Generator Demand Priority. 1. Load Shed Control a. The System Controls shall include a Load Shed Control function to control the loads served by the generator plant. b. The Load Shed Control shall have one Essential Load Shed Priority Level for each generator in the system plus one Non-Essential Load Shed Priority Level (which is always shed in the Emergency Mode of operation). c. The Load Shed Control shall control each of the distribution circuit breakers that are shown on the drawings. Distribution circuit breakers to be controlled shall be electrically operated. Each electrically operated distribution circuit breaker shall be eld selectable to be assigned to any of the available Load Shed Priority Levels. 1. Provide the following controls for each Essential Load Shed Priority Level i. Shed Delay Timer, adjustable from 0 to 1024 seconds ii. Add Delay Timer, adjustable from 0 to 1024 seconds iii. Load Shed Override Selector (shed/auto/add) iv. Status indicators to show whether the Priority Level is Added or Shed 2. Provide the following controls for each Non-Essential Load Shed Priority i. Load Shed Override Selector (shed/auto/add) ii. Status indicators to show whether the Priority Level is Added or Shed
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
4. The system is now back in Automatic/Standby Mode.

5. No Load Test Mode a. Entrance into No Load Test Mode 1. The No Load Test Switch is placed in the ON position. 2. All available generators are started. 3. All generators come up to voltage and frequency and remain running disconnected from the bus. 4. The system is now in No Load Test Mode. b. Exit from No Load Test Mode 1. The No Load Test Switch is placed in the OFF position. 2. The generators are allowed to run for their programmed cool-down period.
CA08104001E

3. Additionally, the Load Shed Controls shall have: i. Load Shed Control Switch (On/Off) ii. User-settable Load Shed % (as a function of on-line generator capacity) iii. User-settable Load Shed Time Delay iv. User-settable Load Add % (as a function of on-line generator capacity) v. User-settable Load Add Time Delay vi. User-settable Bus Underfrequency set point vii. User-settable Bus Underfrequency time delay viii. Bus Underfrequency Reset Pushbutton ix. Bus Underfrequency indicator 4. Conditional Load ShedUpon entrance into Emergency Mode of operation, the Load Shed Control shall shed all Essential and Non-Essential loads. As generators come to the bus, Essential Priority Level loads shall be added conditionally based on the number of generators on line. When the rst generator comes to the bus, Priority Level 1 loads shall be added; Second generator, priority 2, and so forth. After a time delay that allows all operational generators to come to the bus, Load Shed Mode shall shift to Load Sensitive Mode. 5. Load Sensitive Load ShedAfter all generators have been given sufcient time to come to the bus, load shed shall shift to Load Sensitive mode. The system shall compare current generator online capacity (in kW) to current load requirements. If surplus capacity is greater than the calculated Load Add set point, after the Load Add Time Delay the next Load Shed Priority shall be added. This calculation shall continue until all Sheddable Loads are added, or until surplus capacity is less than the calculated Load Add set point. If surplus capacity is less than the calculated Load Shed set point, after the Load Shed Time Delay the next Load Shed Priority shall be shed. This calculation shall continue until all Sheddable Loads are shed, or until surplus capacity is greater than the calculated Load Shed set point. The Load Shed Control, in its automatic shedding and adding of loads, shall not override any manual load shed/add operation. 6. Should the load bus frequency fall below the user selected bus underfrequency set point for a period longer than the bus underfrequency time delay, then all Priority Level loads shall be shed and load addition shall not resume until the operator has depressed the Bus Underfrequency Reset button. The bus underfrequency protection shall override any manual load add operation.
September 2011
Sheet 40 026
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
NOTE: The following applies to systems with two or more generators.

2. Generator Demand Priority Control a. The System Controls shall include a Generator Demand Priority Control function to automatically match the on-line generator capacity to the loads to avoid unnecessary operation of all the generators when the loads are low. b. The following controls shall be provided for each generator: 1. User-settable Generator Priority Selector 2. Status indicator for the Generator Priority Selected 3. Status indicator for generator On-line or Off-line c. The Generator Demand Priority Control shall have the following controls: 1. Generator Demand Priority Control Switch (On/Off) 2. User-settable Generator Remove % (as a function of a single generator capacity) 3. User-settable Generator Remove Delay 4. User-settable Generator Add % (as a function of a single generator capacity) 5. User-settable Generator Add Delay d. Upon entrance into Emergency or Load Management modes, all generators shall be started and paralleled to the bus. After the Remove Time Delay, generators shall be removed from the bus as a function of the generator percentage loading by the user selected Generator Remove time delay. Generators shall be removed from the bus in descending priority. Should the generator percentage loading increase to the user selected Generator Add limits for the user selected Add Delay, the next generator shall be started, synchronized and paralleled to the bus. Generators shall be added to the bus in ascending priority order. Should the generator plant ever reach 95% loading, the next priority generator shall be started and added to the bus with no time delay.
CA08104001E
September 2011
Sheet 40 027
Cat Generator Paralleling Switchgear EGP Switchgear

General Description
40.3-1
EGP
General Description
Cat Emergency Generator Paralleling (EGP) Switchgear for multiple engine generator sets.
EGP Switchgear
Automatic start, synchronize, parallel and load/VAR share on a common bus Main lugs output to feed downstream emergency distribution Optional emergency distribution circuit breakers Load shed/load add Generator demand priority For use with multiple downstream Automatic Transfer Switches Cat Switchgear is designed to integrate hand-in-glove with Cat Automatic Transfer Switches. EGP Switchgear is optionally available with direct communication to Cat ATSs to provide ngertip control and monitoring of all your facility ATSs from one convenient central location
Cat Switchgear brings the power and reliability of microprocessor technology to your generator switchgear application. Through the use of the operator interface touchscreen display with easy-to-follow graphical representation, Cat Switchgear merges the features of: Power monitoring Switchgear automation Generator set control Optional remote communications

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Figure 40.3-1. EGP3 Low Voltage Switchgear (Three Generator Sources)
43
CA08104001E
40.3-2 Cat Generator Paralleling Switchgear EGP Switchgear

Standard and Optional Equipment
September 2011
Sheet 40 028
22 23 24 25 26 27 28 29
Equipment
Standard EquipmentEGP
Low voltage EGP systems use Magnum DS power circuit breaker switchgear and Magnum power circuit breakers. For complete technical details on Magnum DS switchgear, see Tab 20 Operator interface touchscreen (Choose one of the following): High Redundancy Product, 19.00-inch surface acoustic wave LCD TFT color touchscreen with key switch Standard product, 15-inch resistive LCD TFT color touchscreen

30 31 32

33 34 35

36 37 38 39 40 41 42 43
Direct data communication to Cat microprocessor-based engine generator set control network (EMCP) System overview screen with one line mimic diagram that depicts real-time metering, status and control Full function 0.5% accuracy analog and digital AC metering for generators: voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR Full function engine gauges: RPM, DC battery voltage, oil pressure, engine coolant temperature, engine hours, number of starts 3-D engine data Full function synchronizing and paralleling controls with selection for automatic or manual synchronizing NFPA 110 engine/generator status, pre-alarm, lamp test button, shutdown fault annunciation and 85 dBA alarm horn with silence button Full function 0.5% accuracy analog and digital AC metering for system: voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR System control functions for auto (standby for emergency), test without load and test with load
Automatic load shed control with on-screen operator adjustments for essential (Life/Safety), critical and non-essential loads. Manual load shed/load add control Automatic generator demand priority with on-screen operator adjustments for automatic addition and removal of generator to the load bus System status and alarm annunciation with color display and 85 dbA alarm horn with silence button Password secured settings and adjustments for generator and system setups and protective relaying Alarm summary reports Settings reports Engine and generator load charts Engine trend data UL 891, UL 1558 or CSA listed and labeled NEMA 1 or NEMA 3R, deadfront freestanding construction Copper bus, braced for 100 kA Three-phase, four-wire, 100% neutral, 0.25-inch x 2.00-inch copper ground bus Available in 600V, 480/277V or 208/120V, 60 Hz UL 1066 listed power circuit breakers, 42200 kAIC, two-step stored energy drawout mounted electrically operated with long time and instantaneous trip, and circuit breaker control switch with lights Continuous cross bus ratings up to 10,000A at 600 Vac Mechanical lugs for incoming and outgoing conductors Top or bottom conduit entry Plug together control connections across shipping splits
Distribution sections with group mounted UL 489 molded case circuit breakers (UL 891 construction only.) Also available in 150 kA or 200 kA bus bracing congurations Also available in 8000 and 10,000A continuous cross bus ratings at 600 Vac Also available with 4000, 5000 and 6000A UL 1066 breakers Trip unit metering and communications (Digitrip 520M, 520MC and 1150) Also available in 5 kV, 15 kV and 27 kV class congurations (See Section 40.4) Remote monitoring and control Building Automation System or SCADA communications Modbus or Ethernet Remote notication Historical data trending Communication to Cat ATS units Automated Joint Commission report

Many systems require the use of tie breakers to meet Code or system performance requirements. Tie breakers can be used anywhere throughout the line-up to segment or isolate desired sources, loads or sections of bus.
Emergency Generator Bus Tie

Certain NFPA Codes require all life safety and critical loads (Priority 1 loads) to be restored in a maximum of 10 seconds. If the total Priority 1 load that must be restored in ten seconds exceeds the capacity of a single generator, an emergency generator bus tie breaker should be used. This allows one generator on each side of the tie to restore power to Priority 1 loads in under 10 seconds. The system can then parallel all generators across the emergency generator bus tie breaker so the full generator plant capacity is available.
Note: Priority 1 loads must be split to either side of the generator tie breaker. See Page 40.3-9 for an example of a system with an emergency generator bus tie breaker.
Optional EquipmentEGP
Distribution sections with electrically operated drawout UL 1066 circuit breakers Circuit breaker trip functionsshort time and/or ground fault (in addition to long time and instantaneous) Steel barriers between switchboard or switchgear sections for compartmentalization Bus/cable barriers
CA08104001E
September 2011
Sheet 40 029

Features
40.3-3
Cat EGP Switchgear

Generator Metering

System Metering
0.5% accuracy Analog and digital voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR
Circuit Breakers
0.5% accuracy Analog and digital voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR; synchroscope
System Protective Relaying

27/59bus under/overvoltage relay 81 O/Ubus under/overfrequency relay

27/59under/overvoltage relay 81 O/Uunder/overfrequency relay 32reverse power relay 40loss of excitation (reverse VAR) relay 25synch check relay

System Control

Engine Gauges
RPM meter Engine battery volt meter Oil pressure gauge Engine coolant temperature gauge 3-D engine data screens


Low coolant temperature pre-alarm High coolant temperature pre-alarm and shutdown Low oil pressure pre-alarm and shutdown Low fuel alarm (diesel only) Low and high engine battery alarm Battery charger alarm Overcrank shutdown Overspeed shutdown
Automatic standby mode Emergency mode Test without load Test with load Automatic load shed control with bus underfrequency protection and one four-pole,10A, 120 Vac, Form C, dry contact output for each load shed level (1 level for each generator in the system) Automatic generator demand priority control UL 1558, UL 891 or CSA listed and labeled Master shutdown
100% rated UL 1066 power circuit breakers available 8006000A with two-step stored energy mechanism 42 kAIC standard (50200 kAIC optional) Drawout mounted (xed optional) 5 cycle closing Electrically operated Auxiliary and bell alarm contacts Electronic trip unit with long time and instantaneous trip functions (short time and ground fault optional) Available as UL 1558, UL 891 or CSA listed and labeled Optionally service entrance rated NEMA 1 or NEMA 3R, deadfront freestanding construction Copper bus 100 kA bus bracing (150 or 200 kA optional) Three-phase, four-wire, 100% neutral bus 0.25-inch x 2.00-inch ground bus Also available in UL listed and labeled medium voltage 0 to 50C 0 to 95% humidity, noncondensing
22 23 24 25 26 27 28 29 30 31 32 33 34 35
Enclosure and Bussing

Power Supply
Best DC source selector Power from 24 Vdc engine cranking batteries 24 Vdc station battery, sealed jar, 4-hour, external 120 Vac emergency power required for charger Processor power supplies24 Vdc
Environment

Seismic Qualication
Automatic engine start Adjustable engine cool-down timer 15automatic synchronizer 65microprocessor engine governor load sharing and soft loading control 90VAR/PF and cross current compensation controller

Communications
Automation networkhigh speed, high reliability, industrially hardened Optional remote communications networkEthernet, Modem Optional communication to building automation or SCADA systems or general monitoring Modbus RTU or Ethernet
Refer to Tab 1 for information on seismic qualication for this and other Eaton products.
36 37 38 39 40 41 42 43
CA08104001E

Technical Data
September 2011
Sheet 40 030
22 23 24 25 26 27 28 29 30 31 32 33 34
EGP2 SwitchgearOne-Line Diagrams
Figure 40.3-2. Typical Electrical System with EGP2 Assembly and ATS Units (Two Generator Sources)
SECT 1
R
SECT 2
SECT 3
35 36 37 38
CELL A
52G1 CONTROLS
MDS-CXX
DIST CONTROLS
52G2
0 533
532 1064 1330 2000
800 1600 2000 3000
1600 3200 4000 6000
1600 3200 3200 3200
99.00 (2514.6)
66.00 (1676.4)
72.00 (1828.8)
CELL B
HMI 19 TOUCHSCREEN
MDS-CXX
96.06 (2440.0)
52D1
1065 1331
HORN SILE NCE
HORN
OPEN
CLOSED
OPEN
CLOSED
CELL C
84.00 (2133.6)
39 40 41
CELL D
MDS-CXX
SYSTEM CONTROLS
52G2 CONTROLS
MDS-CXX
52D2
52G1
22.00 (558.8) 66.00 (1676.4) 22.00 (558.8)
22.00 (558.8)
Structure Depth 66.00 (1676.4) 72.00 (1828.8) 78.00 (1981.2) 84.00 (2133.6)
42 43
FRONT ELEVATION
Figure 40.3-3. EGP2 Low Voltage Switchgear Layout
CA08104001E
Weight Lbs (kg)

5000 (2270) 5100 (2315) 5300 (2406) 5500 (2497)
Min.
Max.
Main Bus Rating
Generator kW (480V)
September 2011
Sheet 40 031

Technical Data
40.3-5
22 23 24 25 26 27 28 29 30 31 32 33
Figure 40.3-4. Typical Electrical System with EGP3 Assembly and ATS Units (Three Generator Sources)
34 35 36 37 38 39 40
ATS Overview Screen
ATS Control Screen
41 42 43
CA08104001E

Technical Data
September 2011
Sheet 40 032
23 24
CELL A
52G1 CONTROLS
MDS-CXX
DIST CONTROLS
52G2
OPEN
CLOSED
0
MDS-CXX
532
CELL B
25 26 27 28 29 30
96.06 (2440.0)
HMI 19 TOUCHSCREEN
800 3200 1600 99.00 66.00 84.00 7000 1 (2514.6) (1676.4) (2133.6) (3178) 1600 5000 2000 1600 4000 3200 2000 6000 2000 2000 4000 3200 3000 6000 2000 3000 6000 3200 88.00 (2235.2) 66.00 (1676.4) 88.00 (2235.2) 66.00 (1676.4) 88.00 (2235.2) 7050 1 (3201) 7500 2 (3405) 7100 1 (3223) 7600 2 (3450) 7200 1 (3269) 7800 2 (3541)
52G2 CONTROLS
52D1
HO RN SILENCE
533 1064 533 1064
HO RN
OPEN
CLOSED
OPEN
CLOSED
CELL C
SYSTEM CONTROLS
52G3 CONTROLS
MDS-CXX
52D2
1065 1330 1065 1330
CELL D
MDS-CXX
MDS-CXX
MDS-CXX
52G1
52G3
52D3
1331 2000 1331 2000

22.00 (558.8)
22.00 (558.8) 66.00 (1676.4)
22.00 (558.8)
FRONT ELEVATION CONFIGURATION 1

SECT 1
R
SECT 2
SECT 3
SECT 4
31 32 33 34 35 36 37 38 39 40 41 42 43
CELL A
52G1 CONTROLS
DIST CONTROLS
MDS-CXX
52G2
Structure Depth 66.00 (1676.4) 72.00 (1828.8) 78.00 (1981.2) 84.00 (2133.6)
OPEN
CLOSED
CELL B
96.06 (2440.0)
HMI 19 TOUCHSCREEN
MDS-CXX
52G2 CONTROLS
52D1
MDS-CXX
52D3
HO RN SILENCE
HO RN
OPEN
CLOSED
OPEN
CLOSED
CELL C
SYSTEM CONTROLS
52G3 CONTROLS
CELL D
MDS-CXX
MDS-CXX
MDS-CXX
MDS-CXX
52G1
52D2
52G3
52D4
22.00 (558.8)
22.00 (558.8)
22.00 (558.8) 88.00 (2235.2)
22.00 (558.8)
Weight Lbs (kg)
Min. Max.
Main Bus Rating
Generator Bkr. Size
Generator kW (480V)
CA08104001E
Conguration Number
22
SECT 1
SECT 2
SECT 3
September 2011
Sheet 40 033

Technical Data
40.3-7
22 23
G1
G2
G3
G4
EGP4 Switchgear Distribution

Revenue Metering
24 25
HMI Touchscreen
52G1
Main Service
52G2
52G3
52G4
D1
D2
D3
D4
26 27 28 29
ATS1
To Normal Distribution Circuits
To Emergency Circuits
ATS2 N
ATS3
ATS4
30 31 32
EDP1
EDP2
EDP3
EDP4
LP1
BP1
LP2
BP2
LP3
BP3
LP4
BP4
33 34 35 36 37 38 39
Figure 40.3-7. Automated Joint Commission Report
Figure 40.3-6. Typical Electrical System with EGP4 Assembly and ATS Units (Four Generator Sources)
40 41 42 43
Engine Exercise Control Screen
CA08104001E

Technical Data
September 2011
Sheet 40 034
23 24 25 26
CELL A
52G1 CONTROLS
MDS-CXX
DIST CONTROLS
52G2
OPEN
CLOSED
CELL B
96.06 (2440.0)
HMI 19 TOUCHSCREEN
0
52G2 CONTROLS
MDS-CXX
532
MDS-CXX
800 3200 1600 99.00 88.00 78.00 7800 1 (2514.6) (2235.2) (1981.2) (3541) 1600 5000 2000 1600 4000 3200 2000 6000 2000 2000 4000 3200 3000 6000 2000 3000 6000 3200 110.0 (279.4) 88.00 (2235.2) 110.0 (279.4) 88.00 (2235.2) 110.0 (279.4) 7950 1 (3609) 84.00 9500 2 (2133.6) (4313) 8000 1 (3632) 9600 2 (4358) 8200 1 (3723) 9800 2 (4449)
52D1
52D2
HORN SILENCE
HORN
533 1064
OPEN CLOSED
OPEN CLOSED
OPEN
CLOSED
CELL C
SYSTEM CONTROLS
52G3 CONTROLS
52G4 CONTROLS
MDS-CXX
533 1064
52D3
1065 1330
CELL D
MDS-CXX
MDS-CXX
MDS-CXX
MDS-CXX
27 28 29 30 31 32 33
CELL D CELL A
52G1
52G3
52G4
52D4
1065 1330 1331 2000 1331 2000
22.00 (558.8)
22.00 (558.8)
22.00 (558.8) 88.00 (2235.2) FRONT ELEVATION CONFIGURATION 1
22.00 (558.8)
SECT 1
R
SECT 2
SECT 3
SECT 4
SECT 5
52G1 CONTROLS
MDS-CXX
MDS-CXX
DIST CONTROLS
52G4
52G2
MDS-CXX
OPEN
CLOSED
OPEN
CLOSED
CELL B
96.06 (2440.0)
CELL C
HMI 19 TOUCHSCREEN
52G2 CONTROLS
52G4 CONTROLS
MDS-CXX
Structure Depth
52D3
52D1
HORN SILENCE
HORN
OPEN
CLOSED
OPEN
CLOSED
SYSTEM CONTROLS
52G3 CONTROLS
MDS-CXX
MDS-CXX
52D2
52D4
66.00 (1676.4) 72.00 (1828.8) 78.00 (1981.2) 84.00 (2133.6)
34 35 36 37 38 39 40 41 42 43
MDS-CXX
MDS-CXX
52G1
52G3
22.00 (558.8)
22.00 (558.8)
22.00 (558.8) 110.00 (2794.0)
22.00 (558.8)
22.00 (558.8)
Weight Lbs (kg)
Min. Max.
Main Bus Rating
Generator Bkr. Size
Generator kW (480V)
CA08104001E
Conguration Number
22
SECT 1
SECT 2
SECT 3
SECT 4
September 2011
Sheet 40 035

Technical Data
40.3-9
Utility Source
22
G1 G2 G3 G4
23 24
Revenue Metering
HMI Touchscreen 52G1 52G2 52G3 52G4
25 26
Main Service Emergency Generator Bus Tie D1 D2 Priority 1 Feeder Priority 1 Feeder D3 D4
27 28
To Normal Distribution Circuits
~ ~
To Emergency Circuits ATS1 N E ATS2 N
~ ~
E ATS3 N
~ ~
E ATS4 N E
29 30 31
BP4
EDP1
EDP2
EDP3
EDP4
Optional Remote PC LP1 BP1 LP2 BP2 LP3 BP3 LP4
32 33 34 35 36 37 38 39 40 41 42 43
Figure 40.3-9. Typical Electrical System with EGPT4 Switchgear (Four Generator Sources, One Emergency Generator Bus Tie Breaker)
CA08104001E

Technical Data
September 2011
Sheet 40 036
23 24 25 26 27 28
CELL A
52G1 CONTROLS
DIST CONTROLS
OPEN
CLOSED
CELL B
96.06 (2440.0)
HMI 19 TOUCHSCREEN
MDS-CXX
52T1 CONTROLS
MDS-CXX
MDS-CXX
0
52D3
OPEN CLOSED
532
52D1
HORN S ILENCE
52D2
HORN
800 3200 1600 99.00 110.00 78.00 7800 1 (2514.6) (2794.0) (1981.2) (3541) 1600 5000 2000 1600 4000 3200 2000 6000 2000 2000 4000 3200 3000 6000 2000 3000 6000 3200 110.00 (2794.0) 132.00 (3352.8) 110.00 (2794.0) 132.00 (3352.8) 132.00 (3352.8) 7950 1 (3609) 84.00 9500 2 (2133.6) (4313) 8000 1 (3632) 9600 2 (4358) 8200 1 (3722) 9800 2 (4449)
OPEN
CLOSED
OPEN
CLOSED
OPEN
CLOSED
CELL C
SYSTEM CONTROLS
52G2 CONTROLS
MDS-CXX
533 1064 533 1064
52G3 CONTROLS
52T1
52G4 CONTROLS
CELL D
MDS-CXX
MDS-CXX
MDS-CXX
MDS-CXX
1065 1330
52G4
52G1
52G2
52G3
22.00 (558.8)
22.00 (558.8)
22.00 (558.8) 88.00 (2235.2)

22.00 (558.8)
22.00 (558.8)
1065 1330 1331 2000 1331 2000

SECT 6
SECT 1
R
SECT 2
SECT 3
SECT 4
SECT 5
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
CELL A
52G1 CONTROLS
DIST CONTROLS
OPEN
CLOSED
CELL B
96.06 (2440.0)
HMI 19 TOUCHSCREEN
MDS-CXX
52T1 CONTROLS
MDS-CXX
MDS-CXX
52D1
HORN S ILENCE
52D3
52D4
HORN
OPEN
CLOSED
OPEN
CLOSED
OPEN
CLOSED
OPEN
CLOSED
CELL C
SYSTEM CONTROLS
52G2 CONTROLS
MDS-CXX
52G3 CONTROLS
52T1
52G4 CONTROLS
CELL D
MDS-CXX
MDS-CXX
MDS-CXX
MDS-CXX
MDS-CXX
52G1
52D2
52G2
52G3
52G4
22.00 (558.8)
22.00 (558.8)
22.00 22.00 (558.8) (558.8) 110.00 (2794.0)

22.00 (558.8)
22.00 (558.8)
Figure 40.3-10. EGPT4 Low Voltage Switchgear Layout
Weight Lbs (kg)
Min. Max.
Main Bus Rating
Generator Bkr. Size
Generator kW (480V)
CA08104001E
Conguration Number
22
SECT 1
SECT 2
SECT 3
SECT 4
SECT 5
September 2011
Sheet 40 037

Technical Data
40.3-11
Table 40.3-1. Typical Control Circuit WiringLow Voltage Systems

Function (Quantity)/Size/ Type of Cable Diesel(1) x #16 AWG shielded twisted pair (Belden 8719) Gas(1) x #16 AWG shielded twisted quad Control panel discrete control interface Best source 24 Vdc Voltage regulation (VR) control (16) x 1/c #14 AWG (includes spares) (4) x 1/c #10 AWG (2 x + 24 Vdc and 2 x24 Vdc) (1) x #16 AWG twisted pair (Belden 8719) (3) x 1/c #14 AWG (additional for CDVR only) Speed control (governor) Type 2301A speed controller (2) x #16 AWG shielded twisted pair (2301A) ADEMIII speed controller (1) x #16 AWG shielded twisted triplet (Belden 8618) (Additional for Pro Act gov. only) (3) x #14 AWG XHHW Cu Air fuel ratio (AFR) controller Gas only(1) x #16 AWG shielded twisted pair (3) x 1/c #12 AWG (in master section) (4) x 1/c #10 AWG (2 x + 24 Vdc and 2 x24 Vdc) (next to switchgear) (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (each) (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (each) (2) x 1/c #14 AWG (6) x 1/c #10 AWG (at generator) (3) x #14 AWG shielded twisted quad per reading (at generator) (2) x 1/c #14 AWG thermo-couple wire per reading (at generator) (1) x #16 AWG shielded twisted pair (Belden 8471) (2) x 1/c #14 AWG (4) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG per required alarm (2) x 1/c #14 AWG per required alarm (3) x 1/c #10 AWG per 10 structures (1) x 4 Pair #24 AWG UTP Cat. 5 (Ethernet-or(1) 4 conductor ber optic cable (Belden I100466 varies based on installation requirements) (1) x #18 AWG shielded twisted pair (Belden 3073) Signal Type Signal level Signal level DC control 30 Vdc DC control 30 Vdc Signal level DC control 30 Vdc DC control 30 Vdc Bipolar DC bias signal for speed control Discrete control (start/stop, emergency stop and crank terminate, includes spares, etc.) 24 Vdc from generator battery system to supplement switchgear 24 Vdc control voltage Bipolar DC bias signal for voltage control Description
22 23 24 25 26 27 28 29
Generator Control
Cat engine generator set communications Network communications for monitoring and display of engine data to switchgear
Signal level
DC control 0 Vdc Signal level For gas engines equipped with AFR controller only 120 Vac/20A emergency circuit for 24 Vdc battery charger power 24 Vdc supply to switchgear controls from 24 Vdc battery system Alarms Alarms Alarms Alarms Alarms Alarms Alarms Alarms Alarms Alarms Alarms 87G relay/alarm/shutdown Indication/alarms/shutdown Indication/alarms/shutdown
Battery Systems
Power for 24 Vdc station battery charger 24 Vdc station batteries 24 Vdc station battery charger malfunction Generator battery charger malfunction AC control DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc AC control DC control 30 Vdc DC control 0 Vdc
30 31 32 33 34 35 36 37 38
Fuel Systems

Genset mounted CB status Generator differential CTs Generator RTD leads Engine thermo-couples

Cat ATS monitoring and control Engine start Discrete ATS position ATS load shed Signal level DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 0 Vdc AC control Signal level Monitoring and control of ATS functions Engine start request Normal and emergency ATS status Load shed/load add Alarms/shutdown Alarms/shutdowns 120 Vac for space heaters (single-phase/30A) Communication signal to remote monitoring/control PC workstation or LAN
39 40 41 42

Signal level
Communication signal to building management or SCADA system
43
All control wiring to be stranded copper unless specied otherwise. Conductor size may have to be increased for voltage drop over long distances. Recommend 20% spares of each size single conductor and one of each multi-conductor cable. Separate metallic conduits should be used for each Signal Type. Signal Level and DC Control Signal 30 Vdc wires may be combined in the same conduit.
CA08104001E

September 2011
Sheet 40 038
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
EGP Functional Sequence of Operations

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

3. No Load Test Mode a. Entrance into No Load Test Mode 1. The No Load Test Switch is placed in the ON position. 2. All available generators are started. 3. The rst generator up to voltage and frequency is closed to the bus. 4. The remaining generators are synchronized and paralleled to the bus as they come up to voltage and frequency. 5. The system is now in No Load Test Mode.
CA08104001E
September 2011
Sheet 40 039

40.3-13
2. Provide the following controls for each Non-Essential Load Shed Priority i. Load Shed Override Selector (shed/auto/add) ii. Status indicators to show whether the Priority Level is Added or Shed 3. Additionally, the Load Shed Controls shall have: i. Load Shed Control Switch (On/Off) ii. User-settable Load Shed % (as a function of on-line generator capacity) iii. User-settable Load Shed Time Delay iv. User-settable Load Add % (as a function of on-line generator capacity) v. User-settable Load Add Time Delay vi. User-settable Bus Under frequency Set point vii. User-settable Bus Under frequency time delay viii. Bus Under frequency Reset Pushbutton ix. Bus Under frequency indicator 4. Conditional Load ShedUpon entrance into Emergency Mode of operation, the Load Shed Control shall shed all Essential and Non-Essential loads. As generators come to the bus, Essential Priority Level loads shall be added conditionally based on the number of generators on line. When the rst generator comes to the bus, Priority Level 1 loads shall be added; Second generator, priority 2, etc. After a time delay that allows all operational generators to come to the bus, Load Shed Mode shall shift to Load Sensitive Mode. 5. Load Sensitive Load ShedAfter all generators have been given sufcient time to come to the bus, load shed shall shift to Load Sensitive mode. The system shall compare current generator on-line capacity (in kW) to current load requirements. If surplus capacity is greater than the calculated Load Add set point, after the Load Add Time Delay the next Load Shed Priority shall be added. This calculation will continue until all Sheddable Loads are added, or until surplus capacity is less than the calculated Load Add setpoint. If surplus capacity is less than the calculated Load Shed setpoint, after the Load Shed Time Delay the next Load Shed Priority shall be shed. This calculation shall continue until all Sheddable Loads are shed, or until surplus capacity is greater than the calculated Load Shed setpoint. The Load Shed Control, in its automatic shedding and adding of loads, shall not override any manual load shed/add operation. 6. Should the load bus frequency fall below the user selected bus underfrequency setpoint for a period longer than the bus underfrequency time delay, then all Priority Level loads shall be shed and load addition shall not resume until the operator has depressed the Bus Underfrequency Reset button. The bus underfrequency protection shall override any manual load add operation.
NOTE: The following applies to systems with two or more generators.

2. Generator Demand Priority Control a. The System Controls shall include a Generator Demand Priority Control function to automatically match the on-line generator capacity to the loads to avoid unnecessary operation of all the generators when the loads are low. b. The following controls shall be provided for each generator: 1. User-settable Generator Priority Selector 2. Status indicator for the Generator Priority Selected 3. Status indicator for generator On-line or Off-line c. The Generator Demand Priority Control shall have the following controls: 1. Generator Demand Priority Control Switch (On/Off) 2. User-settable Generator Remove % (as a function of a single generator capacity) 3. User-settable Generator Remove Delay 4. User-settable Generator Add % (as a function of a single generator capacity) 5. User-settable Generator Add Delay d. Upon entrance into Emergency mode, all generators shall be started and paralleled to the bus. After the Remove Time Delay, generators shall be removed from the bus as a function of the generator percentage loading by the user selected Generator Remove time delay. Generators shall be removed from the bus in descending priority. Should the generator percentage loading increase to the user selected Generator Add limits for the user selected Add Delay, the next generator will be started, synchronized and paralleled to the bus. Generators shall be added to the bus in ascending priority order. Should the generator plant ever reach 95% loading, the next priority generator shall be started and added to the bus with no time delay.
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
CA08104001E

September 2011
Sheet 40 040
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
CA08104001E
September 2011
Sheet 40 041
Cat Generator Paralleling Switchgear Medium Voltage Systems

General Description
40.4-1
Medium Voltage Systems
Recommended Protective Relaying

One typical difference in the design of medium voltage versus low voltage generator paralleling systems is the requirement for protective relays for proper system protection and coordination. The following is a listing of recommended protective relay functions for MV generator paralleling systems with and without utility connections.
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Medium Voltage Systems
(50/51) Instantaneous/ Time Overcurrent (51G) Ground Overcurrent Trip Protection (27/59) Under/Overvoltage (81O/U) Over/Underfrequency (32) Reverse Power Relay (40) Loss of Field (Reverse var) (65) Engine Governor Load Sharing and Soft Loading Control (87G) Generator Differential Phase Fault (15/25) Automatic Synchronizer (25) Manual Paralleling Sync Check (90 PF) Var/Power Factor Controller (86) Lock-out Relay (50/51) Instantaneous/Time Overcurrent (27/59) Under/Overvoltage (81 O/U) Over/Underfrequency (47) Phase Sequence/Phase Failure (32) Reverse Power Relay (32/51) Reverse Direction Overcurrent Relay (15/25) Automatic Synchronizer (25) Manual Paralleling Sync Check Relay (86) Lock-out Relay
General Description
The Cat Generator Paralleling Switchgear Systems described in Section 40.2 for XLM (Emergency Transfer (Xfer) and Load Management), and Section 40.3 for EGP (Emergency Generator Paralleling) are also available for medium voltage systems. These systems use the Eaton VacClad switchgear with VCP-W vacuum circuit breakers and the same Cat generator control technology, features and benets described in Section 40.1.
Continuous Current
Circuit Breakers
1200, 2000 and 3000A (5 and 15 kV) 1200 and 2000A (27 kV)
Utility Breaker Protective Relaying

Main Bus
1200, 2000, 3000 and 4000A (5 and 15 kV) 1200 and 2000A (27 kV)
For complete technical ratings, layouts, and features of VacClad Switchgear and VCP-W vacuum circuit breakers, refer to Tab 5. When reduced footprint, front access only switchgear is required, Cat Switchgear can be built using Eaton Type MEF metal-enclosed front accessible switchgear with Type VCP-T breakers. For complete technical details on MEF switchgear, see Tab 6.
Maximum Voltages
Distribution Breaker Relaying

(50/51) Instantaneous/Time Overcurrent (86) Lock-out Relay
4.76 kV, 8.25 kV, 15 kV, 27 kV
Interrupting Ratings
4.76 kV: Up to 63 kA 8.25 kV: Up to 50 kA 15.0 kV: Up to 63 kA 27.0 kV: Up to 40 kA
CA08104001E
40.4-2 Cat Generator Paralleling Switchgear Medium Voltage Systems

General Description
September 2011
Sheet 40 042
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Other Available Protective Functions and Options

A. (87B) Switchgear Bus Differential Bus differential relays are high speed protective devices that are used to limit damage from faults within the switchgear by quickly isolating the faulted zone. Differential relays measure the difference between the current owing into and the current owing out of a given zone. Systems with multiple utilities and/or tie breakers will typically have more than one bus differential zone. In this conguration, during a differential fault, only breakers feeding in and out of the faulted zone are tripped and locked out. The other zone(s) are unaffected and can continue to operate. B. Generator Neutral Grounding Resistorsprovide added protection for generator windings by limiting the fault current during line to ground faults.
Generator bus tie breakers can be applied to serve several purposes: 1. Starting of large loadsthe generator bus tie can be opened to allow multiple generators to be paralleled before being connected to large load(s). Once multiple generators are paralleled, the generator bus tie can be closed to power the large loads. 2. Load banksthe generator bus tie can allow the generators to be isolated from the normal utility fed bus. Having a distribution breaker or set of load take-off lugs on the generator side of the bus allows the generators to be load bank tested without affecting any normal utility fed loads. 3. Emergency Standby systems with Automatic Transfer Switchesthe generator bus tie provides isolation between the normal and emergency buses. During a loss of utility power, the generator bus tie can be opened to isolate all normal loads and allow restoration of power to emergency loads. Once emergency loads are restored, the emergency bus tie can be reclosed to restore power to normal loads.
See Page 40.4-7 for an example of an XLM system with generator bus tie breaker.

Certain NFPA codes require all life safety and critical loads (Priority 1 loads) to be restored in a maximum of 10 seconds. If the total Priority 1 load that must be restored in 10 seconds exceeds the capacity of a single generator, an emergency generator bus tie breaker should be used. This allows one generator on each side of the tie to restore power to Priority 1 loads in under 10 seconds. The system can then parallel all generators across the emergency generator bus tie breaker so the full generator plant capacity is available.
Note: Priority 1 loads must be split to either side of the emergency generator bus tie breaker.
See Page 40.4-12 for an example of an EGP emergency system with generator bus tie breaker.

Many systems require the use of tie breakers to meet code or system performance requirements. Tie breakers can be used anywhere throughout the line-up to segment or isolate desired sources, loads or sections of bus.
Generator Bus Tie

Generator bus ties can be used to separate the normal electric service sources from the generator sources. This can also allow separation of load breakers to either side of the generator bus tie breaker in order to allow isolation of load banks, or dedicated emergency loads. This separation also may be required by NFPA or local Codes.
Air/Cool System Screen
43
CA08104001E
September 2011
Sheet 40 043

General Description
40.4-3
Other Recommended Protective Functions and Options

Generator Neutral Grounding Resistors are recommended to protect generator windings. 1. NGRs provide added protection for generator windings by limiting the fault current during line to ground faults. 2. Cat Switchgear recommends a Low Resistance Grounding system with a Neutral Grounding Resistor tied to the Generator Neutral rated at10 seconds and the Line to Neutral voltage. a. NGRs protect the alternator windings on MV and HV gensets with 87G schemes. b. On 4160V systems, 2400V 10 seconds, 200A NGRs are commonly specied. c. On 13.8 kV systems, 8000V 10 seconds, 100A NGRs are commonly specied. Surge Arresters are recommended to protect Switchgear. 1. A surge arrester is used to prevent large surges from power inconsistencies, lightning, switching, etc., from reaching electronic instruments and ensure the safety of individuals nearby by limiting the crest of impending voltage surges to safe values. 2. Surge arrestors are connected between each electrical conductor in a power system and the ground, which provides a short-circuit to the ground. 3. Surge arrestors are typically installed on utility feeders, and feeders exiting the building to other loads.
4. Extensive information on Surge Protection, Arrestors and Capacitors can be found in Tab 5 Metal-Clad Switchgear VacClad-WMedium Voltage. 5. Recommended minimum protection: surge arrester for protection from high overvoltage peaks, or surge capacitor for protection from fast-rising transient. Please note that the surge arresters or surge capacitor alone may not provide adequate surge protection from escalating voltages caused by circuit resonance. 6. Good protection: Surge arrester in parallel with surge capacitor for protection from high overvoltage peaks and fast rising transient. This option may not provide adequate surge protection from escalating voltages caused by circuit resonance. When applying surge capacitors on both sides of a circuit breaker, a surge capacitor on one side of the breaker must be RC Snubber or ZORC, to mitigate possible virtual current chopping. 7. Better protection: RC snubber in parallel with surge arrester for protection from high frequency transients and voltage peaks. 8. Recommended best protection : ZORC, plus proper surge arrester preceding ZORC where needed for protection against lightning. ZORC provides protection from high frequency voltage transients and limits peak magnitude of the transient to 1 to 2 PU (see ZORC description in Tab 5 on Page 5.4-18 for more detail). Surge arrester provides protection from higher voltage peaks resulting from lightning surges.
Surge capacitors are recommended to protect the alternator on 5 kV or 15 kV Gensets. 1. Surge capacitors should be used to protect AC alternators. 2. Surge capacitors are used to prevent regular electric ow from being grounded. 3. Protective Surge Capacitor systems should be designed to operate in conjunction with lightning arresters to provide surge protection for generator alternators. 4. The capacitor should reduce the steepness of the wave front of the voltage surge, thereby reducing the stress on the turn and line-toground insulation. 5. Surge capacitors function best when located as close as possible to the generator alternator output leads. 6. Surge capacitors should be connected line-to-ground, and be on the load side of the breaker to eliminate the chance of a bus short-circuit in the event of capacitor failure. 7. Maximum effectiveness is achieved in limiting impulse voltages, if a low-resistance and low-inductance ground connection is established. All ground connections need to be tied together with a minimum #6 AWG copper conductor. 8. Although surge capacitors are installed line-ground, they should be rated for line-to-line voltage in the event they are installed on an ungrounded or poorly grounded system. 9. Cat Switchgear recommends the following values based on system voltage: 0.5 f on 5 and 7.5 kV, 0.25 f on 15 kV, and 0.13 f on systems operating at 24 kV and higher. 10. Where applicable, the surge capacitor shall conform to NEMA CP-1 standards.
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
CA08104001E

General Description
September 2011
Sheet 40 044
22 23
XLM Medium Voltage (5 or 15 kV class switchgear)

SECT 1
Equipment
Standard EquipmentXLM
Cat Switchgear Medium Voltage XLM systems use Eaton VacClad-W metalclad switchgear with Type VCP-W vacuum breakers. For complete technical details on VCP-W switchgear, see Tab 5. When reduced footprint, front access only switchgear is required, Cat Switchgear can be built using Eaton Type MEF metal-enclosed front accessible switchgear with Type VCP-T breakers. For complete technical details on MEF switchgear, see Tab 6.
SECT 2
SECT 3
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
CELL B 95.00 (2413.0) CELL A
VTN1
VTG1
Utility Relay
Gen Relay
86
UCLOS
LOCKOUT
HMI 19 TOUCHSCREEN
CLOSE LOCKOUT SWITCH
AUTO
VTB1
52N1
52G1
36.00 (914.4) 36.00 (914.4) 108.00 (2743.2) FRONT ELEVATION 36.00 (914.4)
Figure 40.4-1. XLM1 5/15 kV Switchgear
General Description
Cat XLM Switchgear
Generator Paralleling Switchgear for Emergency Transfer (Xfer) and Load Management control of multiple engine generator sets with one utility source. For systems with multiple utility and/or tie breakers, please refer to the Custom Congurable Switchgear Section 40.5. Automatic transfer to emergency upon utility failure Automatic start, synchronize, parallel, and load share on a common bus for emergency operation Closed transition transfer back to utility upon stable return of power, with soft generator unloading Closed transition Load Management Mode with soft loading and unloading of generator system. Closed transition transfer to Emergency Mode to facilitate maintenance, or for storm threat avoidance with soft loading and unloading of generator system
Load shed/add Generator demand priority Cost-effective, technically superior alternative to conventional ATS arrangement Cat Switchgear is designed to integrate hand-in-glove with Cat automatic transfer switches (ATSs), Generators and Uninterruptible Power Systems (UPSs)

Cat Switchgear brings the power and reliability of microprocessor technology to your generator switchgear application. Through the use of the operator interface (HMI) touchscreen display with easy-tofollow graphical representations, Cat Switchgear merges the features of: Power monitoring Switchgear automation Generator set control Optional remote communications

Operator Interface Touchscreen (Choose one of the following): 19-inch surface acoustic wave LCD TFT color touchscreen with key switch Standard and high redundancy product 15-inch resistive LCD TFT color touchscreen Direct data communication to Cat microprocessor-based engine generator set control network Full function 0.5% accuracy analog and digital AC metering for utility: voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR Full function 0.5% accuracy analog and digital AC metering for generators: voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR Full function engine gauges; RPM, DC battery voltage, oil pressure, engine coolant temperature, engine hours, number of starts Full function synchronizing and paralleling controls with selection for automatic or manual synchronizing NFPA 110 engine/generator status, pre-alarm, lamp test button, shutdown fault annunciation and 85 dBA alarm horn with silence button Full function 0.5% accuracy analog and digital AC metering for system: voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR
CA08104001E
September 2011
Sheet 40 045

General Description
40.4-5
Standard EquipmentXLM (Continued)
Cat XLM Switchgear

Utility Metering
System Control

System control functions for auto (standby for emergency), closed transition to emergency and load management Automatic load shed control with on-screen operator adjustments for essential (1 level of essential for every generator in the system) and 1 level of non-essential automatic or manual load shed/load add control Automatic generator demand priority with on-screen operator adjustments for automatic addition and removal of generator to the load bus System status and alarm annunciation with color display and 85 dBA alarm horn with silence button Password secured settings and adjustments for generator and system setups and protective relaying Alarm summary reports Settings reports Engine and generator load charts 3-D engine data Historical data trending UL MV listed and labeled NEMA 1, metal-clad construction IEEE 1547 compliant, when a compliant utility protective relay is selected UL or CSA listed Top or bottom conduit entry Plug together control connections across shipping split Distribution sections with singlehigh or two-high construction Tie breaker sections Also available in 27 kV class congurations Also available in arc-resistant congurations Remote PC and software for additional on-site monitoring and control work stations Remote PC and software for offsite monitoring and control Building Automation System or SCADA communications Modbus or Ethernet Remote notication
Generator Metering


Engine Gauges
RPM meter Engine battery volt meter Oil pressure gauge Engine coolant temperature gauge

Automatic standby mode Emergency mode with closed transition to normal Closed transition to emergency mode Load management mode Automatic load shed control with bus underfrequency protection and one four-pole, 10A,120 Vac, Form C, dry contact output for each load shed level (1 level of essential for each generator in the system) Automatic generator demand priority control Master shutdown button
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
Power Supply
Automatic best DC source selector 24 Vdc station battery, sealed jar, 4-hour, external 120 Vac emergency power required for charger Power from 24 Vdc engine cranking batteries Processor power supplies24 Vdc

Low coolant temperature pre-alarm High coolant temperature pre-alarm and shutdown Low oil pressure pre-alarm and shutdown Low fuel alarm (diesel only) Low engine battery alarm Overcrank shutdown Overspeed shutdown Automatic engine start Adjustable engine cool-down timer 15automatic synchronizer 65microprocessor engine governor load sharing and soft loading control 90VAR/PF and cross current compensation controller 0.5% accuracy. Voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR
Technology Communications
Automation networkhigh speed, high reliability, industrially hardened Optional remote communications networkEthernet, Modem Optional communication to building automation or SCADA systems for general monitoring Modbus RTU or Ethernet

Optional EquipmentXLM

Environment
0C to 50C 0 to 95% humidity, noncondensing
System Metering

CA08104001E

Technical Data
September 2011
Sheet 40 046
22 23 24 25 26 27 28 29 30 31 32
Cat XLM SwitchgearOne-Line Diagrams
Figure 40.4-2. Medium Voltage XLM1 Switchgear (One Generator Source, One Utility Source) (For Multiple Utility Sources, see Custom Congurable Switchgear Section 40.5)
Note: 87B = Bus Differential Protection (if applicable).
SECT 1
R
SECT 2
SECT 3
33 34 35
86
VTN1 Utility Relay CELL A

HMI 19 TOUCHSCREEN
VTG1 Gen. Relay
UCLOS
LOCKOUT AUTO
86
36 37 38 39 40 41 42
95.00 (2413.0)
VTB1
CELL B
52N1
52G1
36.00 (914.4)
36.00 (914.4) 108.00 (2743.2) FRONT ELEVATIO N
36.00 (914.4)
Figure 40.4-3. 5/15 kV XLM1 Switchgear Layout
43
Note: All structures are 96.25 inches (2444.8 mm) deep. Note: See Figures 40.4-11 and 40.4-12 for typical distribution structure layouts. Note: See Tab 5 Medium Voltage Metal-Clad Switchgear for conduit space, weights, etc.
CA08104001E
September 2011
Sheet 40 047

Technical Data
40.4-7
TO 87B1 TO 87B1
22 23 24 25 26
TO 87B2
TO 87B1
TO 87B1
TO 87B2
TO 87B2
TO 87B2
27 28 29
Figure 40.4-4. Medium Voltage XLMT3 Switchgear (Three Generator Sources, One Utility Source, One Generator Bus Tie Breaker) (For Multiple Utility Sources, see Custom Congurable Switchgear Section 40.5)
Note: 87B = Bus Differential Protection (if applicable); 87B1 = Zone 1; 87B2 = Zone 2.
30 31
SECT 1
R
SECT 2
SECT 3 52D1 Dist. Relay
SECT 4 52ET1 Tie Relay
SECT 5 VTB2
SECT 6 VTG1 Gen. Relay
32 33 34 35
VTN1 Utility Relay CELL A

86
G R
UCLOS
LOCKOUT AUTO
HMI 19 TOUCHSCREEN
86
86
86
86
86
95.00 (2413.0) VTB1 CELL B 52N1
86
Dist. Relay 52D2 52G1 52G2 52G3
36 37 38 39 40 41 42 43
36.00 (914.4)
36.00 (914.4)
36.00 (914.4)
36.00 (914.4) 288.00 (7315.2)
36.00 (914.4)
36.00 (914.4)
36.00 (914.4)
36.00 (914.4)
FRONT ELEVATION
Figure 40.4-5. 5/15 kV XLMT3 Switchgear Layout

CA08104001E

General Description
September 2011
Sheet 40 048
22 23
EGP Medium Voltage (5 or 15 kV Class Switchgear)

SECT 1
SECT 2
SECT 3
SECT 4
24 25 26 27 28 29 30 31 32 33
Figure 40.4-6. EGP3 5/15 kV Switchgear
36.00 (914.0) CELL B 95.00 (2413.0) CELL A
HMI 19 TOUCHSCREEN
VTG1 Gen. Relay
VTG2 Gen. Relay
VTG2 Gen. Relay
86
86
86
VTB1
52G1
52G2
52G3
36.00 (914.0)
144.00 (3658.0)
36.00 (914.0)
36.00 (914.0)
FRONT ELEVATION
34 35 36 37 38 39 40 41 42 43
General Description
Cat Emergency Generator Paralleling (EGP) Switchgear for multiple engine generator sets.
Automatic start, synchronize, parallel and load share on a common bus Main lugs output to feed downstream emergency distribution Optional emergency distribution circuit breakers Load shed/load add Generator demand priority
For use with multiple downstream Automatic Transfer Switches Cat switchgear is designed to integrate hand-in-glove with Cat Automatic Transfer Switches (ATS), Generators, and Uninterruptible Power Systems (UPS). EGP Switchgear is optionally available with direct communication to Cat ATSs to provide ngertip control and monitoring of all your facility ATSs from one convenient central location
Cat Switchgear brings the power and reliability of microprocessor technology to your generator switchgear application. Through the use of the operator interface (HMI) touchscreen display with easy-to-follow graphical representations, Cat Switchgear merges the features of: Power monitoring Switchgear automation Generator set control Optional remote communications

CA08104001E
September 2011
Sheet 40 049

General Description
40.4-9
Equipment
Standard EquipmentEGP
Cat Switchgear Medium Voltage EGP systems use Eaton VacClad-W metalclad switchgear with Type VCP-W vacuum breakers. For complete technical details on VCP-W switchgear, see Tab 5. When reduced footprint, front access only switchgear is required, Cat Switchgear can be built using Eaton Type MEF metal-enclosed front accessible switchgear with Type VCP-T breakers. For complete technical details on MEF switchgear, see Tab 6.
Operator interface touchscreen (Choose one of the following): 19-inch surface acoustic wave LCD TFT color touchscreen with key switch 15-inch resistive LCD TFT color touchscreen Direct data communication to Cat microprocessor-based engine generator set control network (EMCP) System overview screen with oneline mimic diagram that depicts realtime metering, status and control Full function 0.5% accuracy analog and digital AC metering for generators: voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR Full function engine gauges: RPM, DC battery voltage, oil pressure, engine coolant temperature, engine hours, number of starts 3-D engine data Historical data trending Full function synchronizing and paralleling controls with selection for automatic or manual synchronizing NFPA 110 engine/generator status, pre-alarm, lamp test button, shutdown fault annunciation and 85 dBA alarm horn with silence button Full function 0.5% accuracy analog and digital AC metering for system: voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR
System control functions for auto (standby for emergency), test without load and test with load Automatic load shed control with on-screen operator adjustments for essential (one level of essential for each generator in the system) and one level of non-essential automatic or manual load shed/ load add control Automatic generator demand priority with on-screen operator adjustments for automatic addition and removal of generator to the load bus System status and alarm annunciation with color display and 85 dBA alarm horn with silence button Password secured settings and adjustments for generator and system setups and protective relaying Alarm summary reports Settings reports Engine and generator load charts Engine trend data UL MV listed and labeled NEMA 1, metal-clad construction Top or bottom conduit entry Plug together control connections across shipping split Distribution sections with singlehigh or two-high construction Tie breaker sections. Also available in 27 kV class congurations Also available in arc-resistant congurations Remote monitoring and control Building Automation System or SCADA communications Modbus or Ethernet Remote notication Automated Joint Commission reporting Communication to Cat ATS units
Cat EGP Switchgear

Generator Metering

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
0.5% accuracy Analog and digital voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR; synchroscope
Engine Gauges
RPM meter Engine battery volt meter Oil pressure gauge Engine coolant temperature gauge 3-D engine data screens


Low coolant temperature pre-alarm High coolant temperature pre-alarm and shutdown Low oil pressure pre-alarm and shutdown Low fuel alarm (diesel only) Low and high engine battery alarm Battery charger alarm Overcrank shutdown Overspeed shutdown
Automatic engine start Adjustable engine cool-down timer 15automatic synchronizer 65microprocessor engine governor load sharing and soft loading control 90VAR/PF and cross current compensation controller

Optional EquipmentEGP

System Metering

0.5% accuracy Analog and digital voltage 1-2, 2-3, 3-1; current 1, 2, 3; frequency; power factor; kW; kVAR Automatic standby mode Emergency mode Test without load Test with load Automatic load shed control with bus underfrequency protection and one four-pole, 10A, 120 Vac, Form C, dry contact output for each load shed level (one level of essential for each generator in the system) Automatic generator demand priority control Master shutdown
System Control

CA08104001E

General Description Power Supply
Best DC source selector Power from 24 Vdc engine cranking batteries 24 Vdc station battery, sealed jar, 4-hour, external 120 Vac emergency power required for charger Processor power supplies24 Vdc
September 2011
Sheet 40 050
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Many systems require the use of tie breakers to meet code or system performance requirements. Tie breakers can be used anywhere throughout the line-up to segment or isolate desired sources, loads or sections of bus.

Certain NFPA codes require all life safety and critical loads (Priority 1 loads) to be restored in a maximum of 10 seconds. If the total Priority 1 load that must be restored in 10 seconds exceeds the capacity of a single generator, an emergency generator bus Tie breaker should be used. This allows one generator on each side of the tie to restore power to Priority 1 loads in under 10 seconds. The system can then parallel all generators across the emergency generator bus tie breaker so the full generator plant capacity is available.
Note: Priority 1 loads must be split to either side of the generator tie breaker. See Page 40.4-12 for an example of a system with an emergency generator bus tie breaker.
Communications
Automation networkhigh speed, high reliability, industrially hardened Optional remote communications networkEthernet, Modem Optional communication to building automation or SCADA systems or general monitoringModbus RTU or Ethernet
Environment

0C to 50C 0 to 95% humidity, noncondensing
CA08104001E
September 2011
Sheet 40 051

Technical Data
40.4-11
22 23 24 25 26 27 28 29 30
Figure 40.4-7. Medium Voltage EGP3 Switchgear (Three Generator Sources)
31 32
SECT 1
R
SECT 2
SECT 3
SECT 4
33
VTG1 Gen. Relay VTG2 Gen. Relay VTG3
34
Gen. Relay CELL A
HMI 19 TOUCHSCREEN
35
86
G R
86
86
36 37 38
95.00 (2413.0)
CELL B
39
VTB1 52G1 52G2 52G3
40
36.00 (914.4) 36.00 (914.4) 36.00 (914.4) 36.00 (914.4)
41 42 43
144.00 (3657.6)
FRONT ELEVATION
Figure 40.4-8. 5/15 kV EGP3 Switchgear Layout

CA08104001E

Technical Data
September 2011
Sheet 40 052
22 23 24 25 26 27
TO 87B1 TO 87B1
TO 87B1 TO 87B1
TO 87B2
TO 87B2
TO 87B1
TO 87B2
TO 87B2
TO 87B2
TO 87B2
28 29 30 31 32
R
Figure 40.4-9. Medium Voltage EGPT4 Switchgear (Three Generator Sources, One Emergency Generator Bus Tie)
Note: 87B = Bus Differential Protection (if applicable); 87B1 = Zone 1; 87B2 = Zone 2.
SECT 1
SECT 2 VTG1
SECT 5 52T1
SECT 6 VTB2 Dist. Relay
33 34
Gen. Relay CELL A

HMI 19 TOUCHSCREEN
86
86
86
86
86
86
86
95.00 (2413.0)
86
86
86
35
CELL B
36 37 38 39 40 41 42 43
Dist. Relay VTB1 52G1 52G2 52D2
Tie Relay 52D3 52G3 52G4
Dist. Relay 52D5
36.00 (914.4)
36.00 (914.4)
36.00 (914.4)
36.00 (914.4)
36.00 (914.4) 324.00 (8229.6) FRONT ELEVATIO N
36.00 (914.4)
36.00 (914.4)
36.00 (914.4)
36.00 (914.4)
Figure 40.4-10. 5/15 kV EGPT4 Switchgear Layout

See Section 40.2 for additional information on EGP systems. See the Product Specication Guide (PSG) Section 16346G for Metal-Clad Emergency Generator Paralleling SwitchgearMedium Voltage specications.
CA08104001E
September 2011
Sheet 40 053

Technical Data
40.4-13
Typical Medium Voltage Distribution Section

Note: Single or double (as shown) distribution breaker sections can be added to XLM and EGP layouts as needed.
22 23 24 25 26 27 28 29 30 31
Figure 40.4-11. Typical Medium Voltage Distribution Section

SECT 1
R
32 33 34 35 36 37
86
G R
52D1
CELL A
Dist. Relay
86
95.00 (2413.0)
38
CELL B Dist. Relay
39 40 41
52D2
36.00 (914.4) FRONT ELEVATION
42 43
Figure 40.4-12. 5/15 kV Distribution Section Layout

Note: All structures are 96.25 inches (2444.8 mm) deep. Note: See Tab 5 Medium Voltage Metal-Clad Switchgear for conduit space, weights, etc.
CA08104001E

Technical Data
Table 40.4-1. Typical Control Circuit WiringMedium Voltage Systems
Function (Quantity)/Size/ Type of Cable Diesel(1) x #16 AWG shielded twisted pair (Belden 8719) Gas(1) x #16 AWG shielded twisted quad Control panel discrete control interface (16) x 1/c #14 AWG (includes spares) (4) x 1/c #10 AWG (2 x + 24 Vdc and 2 x24 Vdc) (1) x #16 AWG twisted pair (Belden 8719) (3) x 1/c #14 AWG (additional for CDVR only) Speed control (governor) Type 2301A speed controller (2) x #16 AWG shielded twisted pair (2301A) ADEMIII speed controller (1) x #16 AWG shielded twisted triplet (Belden 8618) (Additional for Pro Act gov. only) (3) x #14 AWG XHHW Cu Air fuel ratio (AFR) controller Gas only(1) x #16 AWG shielded twisted pair (3) x 1/c #12 AWG (in master section) (4) x 1/c #10 AWG (2 x + 24 Vdc and 2 x24 Vdc) (next to switchgear) (2) x 1/c #14 AWG (3) x 1/c #10 AWG Signal Type Signal level Signal level DC control 30 Vdc DC control 30 Vdc Signal level DC control 30 Vdc DC control 30 Vdc Description
September 2011
Sheet 40 054
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
Generator Control
Cat engine generator set communications Network communications for monitoring and display of engine data from EMCP to switchgear Discrete control (start/stop, emergency stop and crank terminate, includes spares, etc.) 24 Vdc from generator battery system to supplement switchgear 24 Vdc control voltage Bipolar DC bias signal for voltage control
Best source 24 Vdc Voltage regulation (VR) control
Bipolar DC bias signal for speed control
Signal level
DC control 0 Vdc Signal level For gas engines equipped with AFR controller only 120 Vac/20A emergency circuit for 24 Vdc battery charger power 24 Vdc supply to switchgear controls from 24 Vdc battery system Alarms 120 Vac/40A emergency circuit for 125 Vdc battery charger power (circuit size varies with charger ampacity requirements). 125 Vdc supply to from 125 Vdc batteries to MV breaker controls (5 kV and 15 kV only) Alarms Alarms Alarms Alarms Alarms Alarms Alarms Alarms Alarms Alarms Alarms 87G relay alarm/shutdown Indication/alarms/shutdown Indication/alarms/shutdown Metering input 51G relay alarm/shutdown
Battery Systems
Power for 24 Vdc station battery charger 24 Vdc station batteries 24 Vdc station battery charger malfunction Power for 125 Vdc battery charger (breaker/relay control power) 125 Vdc batteries (breaker/relay control power) 125 Vdc battery charger malfunction Generator(s) battery charger malfunction AC control DC control 30 Vdc DC control 30 Vdc AC control
(4) x 1/c #10 AWG (2 x + 24 Vdc and 2 x24 Vdc) (next to switchgear) (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (each) (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG (each) (2) x 1/c #14 AWG (6) x 1/c #10 AWG (at generator) (1) x #14 AWG shielded twisted quad per reading (at generator) (2) x 1/c #14 AWG thermo-couple wire per reading (at generator) (4) x 1/c #10 AWG per AWG and (6) x 1/c #10 AWG (at generator panel) (2) x 1/c #10 AWG per NGR (at neutral resistors)
DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc AC control DC control 30 Vdc DC control 30 Vdc AC control AC control
Fuel Systems

Genset mounted CB status Generator differential CTs Generator RTD leads Engine thermo-couples VT and CT wires Neutral grounding resister (NGR) CT

All control wiring to be stranded copper unless specied otherwise. Conductor size may have to be increased for Voltage Drop over long distances. Recommend 20% spares of each size single conductor and one of each multi-conductor cable. Separate metallic conduits should be used for each Signal Type. Signal Level and DC Control Signal 30 Vdc wires may be combined in the same conduit.
CA08104001E
September 2011
Sheet 40 055

Technical Data
40.4-15
Table 40.4-1. Typical Control Circuit WiringMedium Voltage Systems (Continued)

Function (Quantity)/Size/ Type of Cable (1) x #16 AWG shielded twisted pair (Belden 8471) (2) x 1/c #14 AWG (4) x 1/c #14 AWG (2) x 1/c #14 AWG (2) x 1/c #14 AWG per required alarm (2) x 1/c #14 AWG per required alarm (3) x 1/c #10 AWG per 10 structures (1) x 4 pair #24 AWG UTP CAT 5 (Ethernet) or(1) 4 conductor ber optic cable (Belden I100466 varies based on installation requirements) (1) x #18 AWG shielded twisted pair (Belden 3073) Signal Type Signal level DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc DC control 30 Vdc AC control Signal level Description
22 23 24 25 26 27

Cat ATS monitoring and control Engine start discrete ATS position ATS load shed Monitoring and control of ATS functions Engine start request Normal and emergency ATS status Load shed/load add Alarms/shutdown Alarms/shutdowns 120 Vac for space heaters (single-phase/30A) Communication signal to remote Monitoring/control PC workstation or LAN

Signal level
Communication signal to building Management or SCADA system
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
All control wiring to be stranded copper unless specied otherwise. Conductor size may have to be increased for Voltage Drop over long distances. Recommend 20% spares of each size single conductor and one of each multi-conductor cable. Separate metallic conduits should be used for each Signal Type. Signal Level and DC Control Signal 30 Vdc wires may be combined in the same conduit.
CA08104001E

September 2011
Sheet 40 056
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
CA08104001E
September 2011
Sheet 40 057
Cat Generator Paralleling Switchgear Custom Systems

General Description
40.5-1
Custom Systems
General Description
Cat Generator Paralleling Switchgear has the power and exibility to handle even the most unique or demanding congurations and project requirements. If the standard XLM (Emergency Transfer (Xfer) and Load Management), and EGP (Emergency Generator) congurations do not t the needs of your specic project, Cat Switchgear offers fully customized solutions. In many cases, custom congurable systems are based on standard XLM or EGP congurations with additional requirements such as: Multiple utility connections Multiple tie breakers Unique sequence of operations Special switchgear layout requirements, and so forth

22 23 24 25 26 27
Example Custom Overview Screen
28 29 30 31 32 33 34 35
Regardless of what the project requires, Cat Switchgear can meet your needs. Some examples of Custom System one-line diagrams and layouts are on the following pages.
Example Custom Oil/Fuel System Screen
36
Example Custom Overview Screen
37 38 39 40 41 42 43
CA08104001E
40.5-2 Cat Generator Paralleling Switchgear Custom Systems

Technical Data
September 2011
Sheet 40 058
22 23 24 25 26 27
Examples of Custom One-Line Diagrams
52N2
Bus #1
Bus #2
28 29 30 31 32 33 34 35
R
Figure 40.5-1. Low Voltage Main-Generator-Tie-Generator-Main Switchgear (Two Utility Sources, Four Generator Sources, Two Generator Bus Tie Breakers)
SECT 2
SECT 3
SECT 4
SECT 5
SECT 6
SECT 7
36 37 38 39
CELL A
52N1 CONTROLS
DIST CONTROLS
MDS-CXX
MDS-CXX
MDS-CXX
52N2 CONTROLS
52G3
52G1
52D4
OPEN
CLOSED
OPEN
CLOSED
OPEN
CLOSED
CELL B
95.00 (2413.0)
HMI 19 TOUCHSCREEN
MDS-CXX
52G1 CONTROLS
52BT1 CONTROLS
MDS-CXX
52G3 CONTROLS
HMI 19 TOUCHSCREEN
HORN SILE NCE
HORN SILE NCE
HORN
52D1
52D5
HORN
SYSTEM CONTROLS
OPEN CLOSED
OPEN CLOSED
SYSTEM CONTROLS
G
R
G
R
CELL C
40 41 42
22.00 (558.8)
MDS-CXX
52G2 CONTROLS
52D2
MDS-CXX
MDS-CXX
52G4 CONTROLS
52BT1
52D6
CELL D
MDS-CXX
MDS-CXX
MDS-CXX
MDS-CXX
MDS-CXX
MDS-CXX
52N1
52D3
52G2
52D7
52G4
52N2
22.00 (558.8)
22.00 (558.8)
43
22.00 (558.8) 154.00 (3911.6)
22.00 (558.8)
22.00 (558.8)
22.00 (558.8)
FRONT ELEVATION
Figure 40.5-2. Low Voltage Main-Generator-Tie-Generator-Main Switchgear Layout

September 2011
Sheet 40 059

Technical Data
40.5-3
22 23 24 25 26 27 28
Figure 40.5-3. Medium Voltage Main-Tie-Generator-Tie-Main Switchgear (Two Utility Sources, Two Generator Sources, Two Generator Bus Tie Breakers)
29 30 31 32 33
SECT 1
R
SECT 2
SECT 3 52D1
Dist. Relay
SECT 4 52T1
Tie Relay
SECT 5 VTB2
SECT 6 VTG1
Gen. Relay
SECT 7 VTG2
Gen. Relay
SECT 8 52T2
Tie Relay
SECT 9 VTB3
SECT 10 52D3
Dist. Relay
SECT 11 VTN2
Utility Relay
VTN1
CELL A 95.00 (2413.0) CELL B
Utility Relay
HMI 19 TOUCHSCREEN
86
UCLOS
CLOSE L OCKOUT S WITCH
L OC KOUT A UTO
86
86
86
86
86
86
86
UCLOS
CLOSE L OCKOUT S WITCH
L OC KOUT A UTO
86
86
Dist. Relay
Dist. Relay
52N1 36.00 (914.4)
VTB1 36.00 (914.4)
52D2 36.00 (914.4) 36.00 (914.4) 36.00 (914.4)
52G1 36.00 (914.4) 396.00 (10,058.4)
52G2 36.00 (914.4) 36.00 (914.4) 36.00 (914.4)
52D4 36.00 (914.4)
52N2 36.00 (914.4)
34 35 36 37 38 39 40 41 42 43
FRONT ELEVATIO N
Figure 40.5-4. 5/15 kV Main-Tie-Generator-Tie-Main Switchgear Layout

Note: All structures are 96.25 inches (2444.8 mm) deep.
CA08104001E
40.5-4 Cat Generator Paralleling Switchgear Custom Systems

Technical Data
September 2011
Sheet 40 060
22
G1 G2 G3 G4
23 24 25 26 27 28 29 30
Utility TX
Utility TX
Utility TX Bus Duct
Gen Synch & Parallel Gen Synch & Parallel
Utility Metering
Utility Metering
Utility Metering
UF1
Utility Tie Prot.
Gen Synch & Parallel Tie Tie EF6
UF6
Tie EF1
Tie
To Other SWGR Assemblies #2 Thru #6 Closed Transition of Paralleling and Utility, Plus Soft Loading/ Unloading
N1
E1
SWGR#1
31 32 33 34 35
Load Shed/Load Add E.O. Stored Energy Type
Figure 40.5-5. Large Critical Power SystemMultiple Generators Closed Transition and Load Shed/Add LV Complex Utility and Generator Paralleling System
MV Generators X = Number of Units G1 Utility Utility Tie Protection Closed Transition Paralleling and Soft Load/Unload G2 Gx Utility Typical Generator Breaker MV Generator Bus Load Shed/Load Add MV Main Gen Main MV Bus A Typical MV Vacuum Breaker Typical Secondary Substations MV Bus B Synch & Paralleling Closed Transition Soft Loading/Unloading Load Shed/Load Add Gen Main MV Main Gen Synch Utility Tie Protection Closed Transition Paralleling and Soft Load/Unload
36 37 38 39 40 41 42 43
Secondary Main
LV Bus A Typical LV Breaker
No Load Shed/Load Add Open Transition Main-Tie-Main Transfer or Closed Transition Momentary Overlap for Main-Tie-Main Tie
LV Bus B
Figure 40.5-6. Large Critical Power SystemMultiple Generators Closed Transition (Active Sync) and Load Shed/Add MV Complex Utility and Generator Paralleling System
September 2011
Sheet 40 061

Technical Data
40.5-5
22
MV Generators X = Number of Units G1 Utility Utility Tie Protection Closed Transition Paralleling and Soft Load/Unload G2 Gx Utility Typical Generator Breaker MV Generator Bus Load Shed/Load Add MV Main Gen Main MV Bus A Gen Main MV Bus B MV Main Gen Synch Utility Tie Protection Closed Transition Paralleling and Soft Load/Unload
23 24 25 26 27 28 29
Tie Synch & Paralleling Closed Transition Soft Loading/Unloading Load Shed/Load Add
Typical MV Vacuum Breaker Typical Secondary Substations
Secondary Main
Closed Transition Soft Load/Unloading Transfer LV Bus A Typical LV Breaker Tie Load Shed/Load Add LV Bus B
30 31 32
Figure 40.5-7. Large Critical Power SystemMultiple Generators MV/LV Closed Transition and MV/LV Load Shed/Add MV Complex Utility and Generator Paralleling System
33 34
MV Generators X = Number of Units G1 Utility Utility Tie Protection Closed Transition Paralleling and Soft Load/Unload G2 Gx Utility Typical Generator Breaker MV Generator Bus Load Shed/Load Add Field Installed Cable by Contractor Synch & Paralleling Closed Transition Soft Loading/Unloading Load Shed/Load Add Closed Transition Soft Load/Unload MV ATS Load Shed/ Load Add Secondary Main LV Bus Typical LV Breaker Typical Secondary Substations Closed Transition Soft Load/Unload MV ATS Load Shed/ Load Add Gen Main MV Bus B MV Main Gen Synch Utility Tie Protection Closed Transition Paralleling and Soft Load/Unload
35 36 37 38 39 40 41 42 43
MV Main
Gen Main MV Bus A
Typical MV Vacuum Breaker
Figure 40.5-8. Large Critical Power SystemMultiple Generators MV Only Closed Transition and MV/LV Load Shed/Add MV Complex Utility and Generator Paralleling System
CA08104001E For more information, visit: www.eaton.com/consultants

September 2011
Sheet 40 062
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
CA08104001E

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Cat Generator Paralleling Switchgear

Cat Generator Paralleling Switchgear

For more information, visit: www.eaton.com/consultants

40.0-2 Cat Generator Paralleling Switchgear Introduction

Cat Switchgear Features

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Cat Generator Paralleling Switchgear Introduction

Common Components Throughout the Entire Facility

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40.0-4 Cat Generator Paralleling Switchgear Introduction

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Cat Generator Paralleling Switchgear Introduction

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40.0-6 Cat Generator Paralleling Switchgear

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Cat Generator Paralleling Switchgear Introduction

Cat Switchgear Selector

Parallel With Utility

Load Shed/ Load Add

Transfer and Load Management Paralleling Switchgear (XLM)

Emergency Generator Paralleling Switchgear (EGP)

Medium Voltage Paralleling Switchgear

Custom Paralleling Switchgear Products

For more information, visit: www.eaton.com/consultants

40.1-2 Cat Generator Paralleling Switchgear Introduction

Standard Congurable Products

Medium Voltage Switchgear

Cat C175 Genset

For more information, visit: www.eaton.com/consultants

Cat Generator Paralleling Switchgear Introduction

Cat Switchgear Control Technology Features

ATS Cat ATS

ATS to SCADA or BMS

Ethernet Switch A Ethernet Switch B

Redundant 100 MHz Ethernet

EMCP 3.S (Master) Touchscreen Generator 1

EMCP 3.S (Redundant Master) Generator 2

EMCP 3.S (Redundant Master) Generator X

Redundant Utility/ Tie Controllers Utility Protective Relay

Redundancy and Fault Tolerance

40.1-4 Cat Generator Paralleling Switchgear Introduction

Automated Joint Commission Report

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Cat Generator Paralleling Switchgear Introduction

Table 40.1-2. PowerLynx Control Conguration Comparison

Redundancy and Fault Tolerance Features

High-Speed Integrated Control System

Display Features and Options

Logging and Reporting Features

ATS Monitoring and Control

Integrated Digital Technology

Cat Switchgear Control Technology

High Redundancy Package

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40.1-6 Cat Generator Paralleling Switchgear Introduction

Cat Switchgear System Advantages

Advanced Communications Capabilities

Communications with Building Management or SCADA Systems

Cat Switchgear HUB or Switch

Cat. 5 cable (up to approx. 300)

Figure 40.1-2. On-Site RemoteEthernet Network with Multiple Users

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