CAT 3500B Generator Electrical System

Page 1

FRONT VIEW RIGHT SIDE VIEW

101-MB6

101-MB7

229-MB2

229-MB3

229-MB4

229-MB5

E565-MB1

X711-MB9

X713-MB13

X712-MB10

F407-MB8

TOP VIEW

E488-VF3NOTE B

E487-VF2NOTE B

E486-VF1NOTE B

F409-VF4NOTE B

DETAIL DSCALE 1:1SH 1 D-7

E488-VF3

E487-VF2

E486-VF1

F409-V4

E488-V3

E487-V2

E486-V1

F409-VF4

REAR EXTENSION BOX

CUSTOMER WIRINGBOX

4-PIN PLUG

6-PIN PLUG

LEFT SIDE EXTENSION BOXBOX GP-BASICRIGHT SIDE EXTENSION BOX

BUS ASSYAC/DC BOX

LEFT SIDE VIEW

Y910-AC54

F408-AC62

N718-AC28

N719-AC27

N720-AC26

G488-AC60

G487-AC61

N715-AC30

N713-AC21

N714-AC20

N752-AC22

N717-AC29

Y911-AC65

J904-AC23

J905-AC24

N716-AC25

Y911-JU2

229-JU1

229-SJ7

229-SJ6

229-SJ5

Y903-AC69

229-SJ5

229-SJ6

229-SJ7

A235-AC71

220-AC70

F406-AC63

F405-AC66

101-AC3

101-AC17

229-AC4

229-AC18

838-AC19

200-AC49

Y903-AC68

E565-AC57

229-JU1

101-AC16

N704-GEN9

N703-GEN6

N702-GEN5

N705-GEN7

N706-GEN8

CB1-1-SJ1

CB1-2-SJ2

CR2-12-SJ3

CR2-22-SJ4

CR2-12-SJ3

CR2-22-SJ4

CB1-1-SJ1

CB1-2-SJ2

AC-PMG-C

AC-PMG-B

AC-PMG-A

AC-F1

AC-F2

Y911-JU2

CR2

SM1

A3 - ELECTRONIC GOVERNOR

AI - ANOLOG INPUT

ALT - ALTERNATOR

ASOS - AIR SHUTOFF SYSTEM

AS1 - AIR SHUTOFF SOLENOID (RH)

AS2 - AIR SHUTOFF SOLENOID (LH)

AUX - AUXILLARY CONTACT

BATT+ - BATTERY POWER +24V

BATT- - BATTERY POWER - 24V

BDS - BATTERY DISCONNECT SWITCH

CB - CIRCUIT BREAKER

CDVR - CATERPILLAR DIGITAL VOLTAGE REGULATOR

CONN - CONNECTOR

CR2 - CONTROL RELAY 2 (SHORE POWER)

DIN RTN - DIGITAL INPUT RETURN

DI - DIGITAL INPUT

DI 2 - DISCRETE INPUT#2 (REMOTE INITIATE)

DO 2 - DISCRETE OUTPUT#2

DR SUP - DRIVER SUPPLY

EMCP 3.3 - ELECTRONIC MODULAR CONTROL PANEL 3.3

ENA - ENABLE

ES - ETHER START

ESPB - EMERGENCY STOP PUSH BUTTON

ESV1 - ETHER START VALVE 1

ESV2 - ETHER START VALVE 2

GEN - GENERATOR

KR - KEY REMOVABLE

MES - MANUAL ETHR SWITCH

MPU - MAGNETIC PICKUP

PDB - POWER DISTRIBUTION BOX

PL - PANEL LIGHT

PLS - PANEL LIGHT SWITCH

PMG - PERMENANT MAGNET GENERATOR

PP - PRELUBE PRESSURE

PPM - PRELUBE PUMP MOTOR

PPR - PRELUBE PUMP RELAY

PPS - PRELUBE PRESSURE SWITCH

PS - PINION SOLENOID

GND - GROUND

RO1 (NO) - RELAY OUTPUT #1 NORMALLY OPEN (STARTER MOTOR RELAY)

R08 (NO) - RELAY OUTPUT #8 NORMALLY OPEN (PRELUBE)

RTD/THERMO - RTD/THERMO COUPLE MODULE

SC - SERVICE CONNECTOR

SH - SPACE HEATER

SHDWN - SHUT DOWN

SMMS - STARTING MOTOR MAGNETIC SWITCH

SM - STARTER MOTOR

PF - POWER FACTOR

SMR - STARTER MOTOR RELAY

SP - SPEED POTENTIOMETER

SPA - SPARE

STC - SHUNT TRIP COIL

STR - SHUNT TRIP RELAY

ST+ - SHUNT TRIP+

V- - ADD CONTACT VOLTAGE LOWER

V+ - ADD CONTACT VOLTAGE HIGHER

VAR - VOLTAGE ADJUST REMOTE

V COM - CONTACT SENSE COMMON

- GENERATOR TERMINAL STRIP

- CONTROL PANEL TERMINAL STRIP

- RELAY COIL

- RELAY CONTACT NORMALLY OPEN

- MOTOR

- DIODE

- NORMALLY CLOSED CONTACT

- SWITCH CONTACT

- NORMALLY OPEN CONTACT

- EMERGENCY STOP PUSH BOTTON

- CIRCUIT BREAKER

- RELAY CONTACT NORMALLY CLOSED

- CONTROL PANEL WIRING/ GENERATOR WIRING

- INTERCONNECT WIRING

- OPTIONS WIRING

- NORMALLY CLOSED CONTACT

- CUSTOMER WIRING

RE

NR

9844-0

22

0 P

ag

e

©2012 CaterpillarAll Rights Reserved

Printed in U.S.A.

Volume 1 - EMCP 3.2 and 3.3

RENR9844-02July 2012

3500B GeneratorElectrical SystemZAB1-UPZAF1-UPYAK1-UPYAL1-UPZAL1-UPZBL1-UPYAS1-UPYBS1-UPYAX1-UP1JZ1-UP1LZ1-UP

Page 2

This schematic is for a 3500 MUI Generator with EMCP 3.2/3.3255-8887

RE

NR

9844-0

2 V

OL

12

0 P

ag

e,

Bla

ck

& W

hit

e

GEN

13

77

99

1111

13

3939

5757

4747

EMCP 3.2/3.3

3131

8

9

6

4

5

7

5

9

4

2

1

10

12

11

6

CDVR

1

3

3

2

4

6

5

1

1

1

2

2

2

EMCP 3.2/3.3

(OPTIONAL)LSM

13 11 9 31 47 57

T3

EXCITER

C

B APMG

-

+

T2

N

T1

F-T1

F-T2

F-T3

SP3 2 1

LOADSHARELINES

301 302 303

SENSING VOLTAGE PHASE A

SENSING VOLTAGE PHASE C

SENSING VOLTAGE NEUTRAL

SENSING VOLTAGE PHASE B

I AC COMMON

IC GEN IN

IB GEN IN

IA GEN IN

CONN9 PIN

EXCITATION DISABLE

FAULT RESET

VAR/PF ENABLE

CONTACT SENSE - LOWER

CONTACT SENSE - RAISE

CONTACT SENSE - COMMON

ALARM OUTPUT DRIVER

FAULT SHUTDOWN DRIVER

DRIVER SUPPLY

PHASE B CURRENT SENSING (2)

PHASE B CURRENT SENSING (1)

GEN VOLTAGE SENSING C

GEN VOLTAGE SENSING B

GEN VOLTAGE SENSING A

+/- 10Vdc INPUT (A)

CONN12 PIN

CONN6 PIN

+/- 10Vdc INPUT (B)

PMG PHASE A

PMG PHASE C

PMG PHASE B

CHASSIS GND

EXCITER (+)

EXCITER (-)

J20 P20

J9 P9

J12 P12

J6 P6

GND

E486A

E488A

E487A

F453

F452

F450

F448

N717

N715

N718

N720

N716

N719

F454

N752

F455

J905

J904

N713

E488B

E487B

E486B

N714

N703

N704

N705

N706

N702

200

F453

F453

F450

F453

F452

E488

E487

E486

C

B

BUSBARS

F448

F455

A

B

F2

11

13

12

N704

N703

N705

N702

N706

F1

F454

NT1 T2 T3

H3

H2

H1X1

X2

X3E488

E487

E486

CHASSISGROUND

100 - 240 VAC50 - 400 HzPOTENTIAL

A0

Batt +

1

F448A

F448

2 3

10WB0 C0

4 5

CTA0

F450A

F450

76

CTB0

F452A

F452

8 9

CTC0

Batt -

10W24 Vdc+ -15 16

488C

487C

486C

488A

487A

486A

IC GEN IN

IB GEN IN

IA GEN IN

VC GEN IN

VB GEN IN

VA GEN IN

23 24

RED

BK

WH

22

BK

RD SH

10 11 12

304

305

306

307

308

309

GND

T1

T2

T3

310

311

312

313

314

IA1

IB1

IC1

IN

319

318

317

316

315

321

320

T3

T2

T1

IB

IC

IA

T1

T2

T3

IA IB

IA1 IB1

IC

IC1

J20P20

BATT LOW (-)

MPU

MPU

A B

SENSOROIL TEMP COOLANT

SENSORTEMP

SENSORPRESS OIL

ESV2 ESV1

(189-5746)

LOW COOLANTLEVEL

A B

(189-5746)

CONTROL GP

+-

CONTROL GP

+-

T

(9X3207)

(9X3207)

4P2729

SMMS2SMMS1

ALT

PPRS

EMCP 3.3/3.2

REMO

TE I

NITI

ATE

SPARE

PPM

PPRM

SM1 SM2

PS1 PS2

-

24V

+

ASR

(3E5239)

AS1AST

AS2

SPARE

ASRSTR SPARE SMR

ASRLH RH

(3E5239)

IRSS SPARE

ES

(3E5239)

SPARE

8T-9834

FCR

CONTROL PANEL

GND

CHASSISGROUND

2

GND

GND

1

8T-9834

ENG CONN

ENG CONN

GNDD-8SEE

2 2

101371 1

S1

L1 L2

11

2

9X-1339

(EMCP 3.3 ONLY)

1

CHARGINGALTERNATOR

(OPTIONAL)AIR SHUTOFF

ASR

AND CONTROL (OPTIONAL)PRELUBE PUMP

PPRS

AIR

(OPTIONAL)START

PPRM

PRELUBE

PRESSURE SWITCH

51

6561 70

33

41

(OPTIONAL)ETHER

200

30

87

69

200

304

32

40

35

43 55 45 28

36

#4 #5 #1#3

DI 7

DO 1

DI 1

DI 2

DI 5

DI 8

46

AI 1

(-)

6766

MPU

(-)

MPU

(+)

839

AI 1

(+)

56

PPRMPPRMB

A

NOTE:BREAK CONNECTIONA & B FOR OPTIONALPRELUBE PUMP

AI 2

(-)

37

AI 2

(+)

38

AI 3

(-)

29

AI 3

(+)

30

MOTOR #1

DISCONNECT

REMOVABLEKEY

SWITCH

(IF REQUIRED)STARTER MOTOR #2STARTER

BATTERY

PS1 PS2

SMMS1 SMMS2

(40A)

RD-6

CB1

101

CB3(25A) (30A)

104

CB4

139

(60A)CB2

(+)2

GOV3 5

(-)1

11 12 (+) (-) 8 7

SP

213

EGA

1 14

#8

24

2 25

#7

15

85

86

2301A

109

87ASR

30

CB5(20A)

CB6(20A)

852

852

200

14ES

11

85

86

A2

A1

MANUAL ETHERSWITCH

#6

27

26

52

6 1620101991513341772523 2

#2

48

58

101

54

DI 3

44

DI 6

18 3831

31 12623 14 4 93 25 20 16 13 10 58 15 17 2

839

11

24 27

27 P7A/J7A

P7/J7

>>> > >>> > > > > > >> > > > > > >J20/P20

J20/P20< < < <<< < < < < < < < < <

>

101

101H

Y918

101D

101C

101E

382

382

12 21 14

19 15

20

J7P7

1

1

220

799

A235

709

995

F411

G429

B482

220

799

A235

709

F411

G429

C527

221

708

838

838

838

807

807

807

852

852

R955

>

68

DO 2

26

26

839

839

839

200

F709

G490

G487

F406

7 17

412

5

8

AA

BB

33

44

1

1

Y918

101D

(8C-9812)

101F

Y915

Y910

306

Y911

Y916

Y917

Y909

306

L11

L12

L21

L22

R11

R12

<

F408

>

53

DI 4

31

22

34

27

28

32

25

26

23

24

4 3

2

11

353330 2A

ACT SH

ACT +

ACT -

MPU SH

MPU +

MPU -

29

30

37

382

101E

200

807

807

807

838

838

838

708

200

200

C527

306

221

G429

A235

F411

709

799

220

839

839

839

200

200

E560

F405

Y905

Y903

Y914

Y913LIGHTS

(8D2676)

103

SWITCH

(25A)CB7

36

200 200 200

200

200

2

AUTO

MAN.

(7G-9730)

PANEL

101

38

39

Y919

G489

1817

16

Y912

NOTE: SEE SHEET 6 FOR INTERCONNECTION

NOTE: SEE SHEET 6 FOR INTERCONNECTION

Y796

Y795

Y794

101

200

BATT +

BATT -

NC

CAN2 SH

CAN2 -

CAN2 +

CAN2 SH

CAN2 +

CAN2 -

BATT -

BATT +

CAN2 SH

CAN2 +

BATT -

CAN2 -

BATT +

RTD/THERMOMODULE

34

62

64

63

42

50

3

2

1

7

8

36

34

35

52

65

ANNUNCIATOR#1

OPTIONAL DATA LINK

CONN(155-2273)

(9W-1951)

SERVICECONN

(155-2264)CONN

GENERATOR

22

21

48

49

50

5

3

4

(174-0502)

BA

A B

C

CCONN

TERMINATING

(134-2540)RESISTOR #22

OHMS

120

(174-0502)

C

BA

A B

CCONN

TERMINATING

(134-2540)RESISTOR #21

120

OHMS

TERMINATING

(134-2540)RESISTOR #23

B

A

C

A

B

C

120OHMS

(174-0502)CONN

>

>

>

>

>

P12

P9

64

62

63

4

3

5

42

34

50

52

65

<

<

<

<

<

<

<

<

<

<

<

P20

PRIMARY

J12

J9

J20

J7/P7 J7A/P7A

5

1

4

MODULERTD/THERMO

2

3

TERMINATING

(134-2540)

CONN(169-8670)

C

C

A

A

B

B

120

OHMS

RESISTOR

(155-2264) DICRETEI/O MODULE

CONN

SECONDARYGENERATOR

(9W-1951)

SERVICECONN

37

46B45B

47B

11

37

21

22

18

29

28

12

47

46

45

1

2A

47A

46A

45A

RESISTOR MUST MOVE TOEND OF LINE WHENREMOTE DEVICE IS INSTALLED

REMOTE DEVICE IS INSTALLEDEND OF LINE WHENRESISTOR MUST MOVE TO

SEE SHEET 6FOR INTERCONNECT

SEE SHEET 6 FORINTERCONNECTION

4

5

3

2

1

EMCP3.2/3.3

CONN9-PIN

12-PINDVR II

CONN

ENG CONN

5

2

4

3

1

66

5

4

3

2

1

J

I

H

G

E

F

D

C

B

A

8

7

6

XX

P16

>

>

>

>

>

>

>

>

>

>

J10

J14

J16

8T-9834 9X-1339

Engine

7

8

6

5

2

3

4

1J19

> G

> J

> I

> H

> F

> E

> D

> C

XX

> A

> B

J11

7

8

6

1

5

4

2

3

P14

4

8

7

6

5

3

2

1P19

CAN1 -

CAN2 +

CAN2 SH

CAN2 -

CAN1 SH

CAN1 +

CAN1 SH

CAN1 -

CAN1 +

BATT -

BATT +

BATT +

BATT -

CAN1 +

CAN1 -

BATT -

BATT +

MODBUS +

MODBUS -

MODBUS REF

CAN1 SH

M755

M757

M756

42

41

40

1

2A

101

200

M756

M755

M757

M756

M755

M757

200

101

200

101

M756

M755

M757

R951

R952

R953

Y796

Y795

Y794

101

200

Y796

Y795

Y794

Y796

200

Y795

Y794

101

Y796Y795Y794

CAN1 SH

BATT +

BATT -

101

200

CAN1 -

CAN1 +

M755

M757

M756

200

101

M755

M757

M756

200

101

200

101

Y796

Y794

Y795

200

101

CAN1 +

BATT -

BATT +

CAN1 -

CDL +

CDL -

CAN1 SH

Y794

Y795

Y796

200

101

2A

BATT -

-

H3

H1

H4

H4L2

L1

GND

H2

H3

1 36

2

HEATERWATERJACKET

3

1L2

1

4

1L1

CR1

CR1

CR2

CR2

A

CHARGERBATTERY

B

H2

H4

H1

H3

SPACE HEATER

P

10AMP

CR2

A2A1CR1

T

9KW

240V AC SUPPLY

CUSTOMER

L2

L1

240

N

1211

21 22

3231

L4 T4

T3L3

AMP50

CR1L2 T2

CR1L1 T1

2

3

1L2

1

4

1L1

ALM

166 167

170170169

173173172

176176175

C210C210

802

806806

804 803 803

807

N725

N728

802

801801800

805 806 808806 807

N725

N728

C987

C988

801

CUSTOMER AC CONNECTIONS

167

A1CR2 A2

TO EMCP 3.2/3.3TERM 69

SHEET 3, D-6

F709101TO SHT 3E-6

325

324

323

322

TO DIGITAL INPUTEMCP3

326

323

322

11

12

4

3

15

17

20

9

24

7

18

38

23

13

ENGINE COOLANT LEVEL SENSOR C

ELECTRONIC GOVERNOR ACTUATOR (+)

ENGINE OIL TEMP SENSOR C

ENGINE OIL TEMP SENSOR A

LH MPU (-)

ENGINE COOLANT TEMP SENSOR A

ELECTRONIC GOVERNOR ACTUATOR-SH

ENGINE COOLANT LEVEL SENSOR B

CRANK SIGNAL CONNECTOR

AIR SHUT OFF RELAY

POWER (-)

POWER (+)

708 (16 AWG)

306 (16 AWG)

F411 (16 AWG)

838 (16 AWG)

220 (16 AWG)

709 (16 AWG)

807 (16 AWG)

221 (16 AWG)

C527 (16 AWG)

807 (16 AWG)

G429 (16 AWG)

31

37

ENGINE OIL PRESSRE SENSOR C

POWER (-)/LO200 (16 AWG)

382 (16 AWG)

RH MPU-A 6839 (16 AWG)

10

ENGINE OIL PRESSURE B

ENGINE OIL PRESSURE A799 (16 AWG)

19ENGINE COOLANT TEMP SENSOR BA235 (16 AWG)

LH MPU (+)838 (16 AWG)

807 (16 AWG)

839 (16 AWG)RH MPU-B

ELECTRONIC GOVERNOR ACTUATOR (+) 25

16

838 (16 AWG)

839 (16 AWG)

27

26

LH MPU-SH

RH MPU-SH

IC GEN IN

PHASE B CURRENT SENSING (1)

PHASE B CURRENT SENSING (2)

PMG PHASE C

EXCITER (-)

EXCITER (+)

CHASSIS GND

PMG PHASE B

PMG PHASE A

I AC COMMON

SENSING BOLTAGE PHASE B

SENSING VOLTAGE PHASE C

SENSING VOLTAGE PHASE A

IB GEN IN

IA GEN IN

22

21

BATT -

BATT +

M755 (18 AWG)

M756 (18 AWG)

M757 (18 AWG)

36

35

34

CAN DATA LINK -

CAN DATA LINK +

CAN DATA LINK SHIELD

101 (16 AWG)

200 (16 AWG)POWER (-)

POWER (+)

2

1

P7A J7AJ7 P7

ENGINE INTERCONNECTION

WALL MOUNTED EMCP 3.2/3.3

3

4

9

11

12

13

14

15

16

20

23

25

30

31

ENGINE CONNECTOR (DC) GENERATOR CONNECTOR (AC)

5

8

10

6

17

27

26

319

GND

315

316

321

317

318

320

To CT's

To PT's

29

28

18

2

1

CR2

SM1

A3 - ELECTRONIC GOVERNOR

AI - ANOLOG INPUT

ALT - ALTERNATOR

ASOS - AIR SHUTOFF SYSTEM

AS1 - AIR SHUTOFF SOLENOID (RH)

AS2 - AIR SHUTOFF SOLENOID (LH)

AUX - AUXILLARY CONTACT

BATT+ - BATTERY POWER +24V

BATT- - BATTERY POWER - 24V

BDS - BATTERY DISCONNECT SWITCH

CB - CIRCUIT BREAKER

CDVR - CATERPILLAR DIGITAL VOLTAGE REGULATOR

CONN - CONNECTOR

CR2 - CONTROL RELAY 2 (SHORE POWER)

DIN RTN - DIGITAL INPUT RETURN

DI - DIGITAL INPUT

DI 2 - DISCRETE INPUT#2 (REMOTE INITIATE)

DO 2 - DISCRETE OUTPUT#2

DR SUP - DRIVER SUPPLY

EMCP 3.3 - ELECTRONIC MODULAR CONTROL PANEL 3.3

ENA - ENABLE

ES - ETHER START

ESPB - EMERGENCY STOP PUSH BUTTON

ESV1 - ETHER START VALVE 1

ESV2 - ETHER START VALVE 2

GEN - GENERATOR

KR - KEY REMOVABLE

MES - MANUAL ETHR SWITCH

MPU - MAGNETIC PICKUP

PDB - POWER DISTRIBUTION BOX

PL - PANEL LIGHT

PLS - PANEL LIGHT SWITCH

PMG - PERMENANT MAGNET GENERATOR

PP - PRELUBE PRESSURE

PPM - PRELUBE PUMP MOTOR

PPR - PRELUBE PUMP RELAY

PPS - PRELUBE PRESSURE SWITCH

PS - PINION SOLENOID

GND - GROUND

RO1 (NO) - RELAY OUTPUT #1 NORMALLY OPEN (STARTER MOTOR RELAY)

R08 (NO) - RELAY OUTPUT #8 NORMALLY OPEN (PRELUBE)

RTD/THERMO - RTD/THERMO COUPLE MODULE

SC - SERVICE CONNECTOR

SH - SPACE HEATER

SHDWN - SHUT DOWN

SMMS - STARTING MOTOR MAGNETIC SWITCH

SM - STARTER MOTOR

PF - POWER FACTOR

SMR - STARTER MOTOR RELAY

SP - SPEED POTENTIOMETER

SPA - SPARE

STC - SHUNT TRIP COIL

STR - SHUNT TRIP RELAY

ST+ - SHUNT TRIP+

V- - ADD CONTACT VOLTAGE LOWER

V+ - ADD CONTACT VOLTAGE HIGHER

VAR - VOLTAGE ADJUST REMOTE

V COM - CONTACT SENSE COMMON

- GENERATOR TERMINAL STRIP

- CONTROL PANEL TERMINAL STRIP

- RELAY COIL

- RELAY CONTACT NORMALLY OPEN

- MOTOR

- DIODE

- NORMALLY CLOSED CONTACT

- SWITCH CONTACT

- NORMALLY OPEN CONTACT

- EMERGENCY STOP PUSH BOTTON

- CIRCUIT BREAKER

- RELAY CONTACT NORMALLY CLOSED

- CONTROL PANEL WIRING/ GENERATOR WIRING

- INTERCONNECT WIRING

- OPTIONS WIRING

- NORMALLY CLOSED CONTACT

- CUSTOMER WIRING

SHEET 1

SHEET 3

SHEET 3

SHEET 4

SHEET 5

SHEET 6

Page 3

EMCP3

CONNECTOR(L-C36)

FRONT VIEW

DETAIL BSCALE 2:1

E487-MV2

E486-MV1

E488-MV3

200-MV4

SH1 C-5

E486-V1_REFE487-V2_REFE488-V3_REF

200-MV4

E488-MV3 E487-MV2 E486-MV1

E486-V4_REF

Y910-AC54

Y911-AC53

Y915-AC52

Y916-AC50

Y917-AC40

F408-AC62

G487-AC61

G488-AC60

G490-AC55

R955-AC64

N713-AC21

N714-AC20

N752-AC22

J904-AC23

J905-AC24

N716-AC25

N720-AC26

N719-AC27

N717-AC29

N715-AC30

N718-AC28

Y912-AC59

Y913-AC72

Y914-AC56

DETAIL ASCALE 2:1SH2 D-5

101-AC17

101-AC3

229-AC18

200-AC49

838-AC19

Y903-AC69

E565-AC57

F407-AC58

F405-AC66

F406-AC63

G429-AC1

F411-AC2

R951-AC48

R952-AC46R953-AC47

Y794-RE30

Y795-RE32

Y796-RE34

220-AC70

A235-AC71

229-AC4

Y903-AC68

229-SJ6

229-SJ7

229-SJ7

229-SJ6

229-SJ5

Y794-AC33

Y795-AC39

Y796-AC36

229-SJ5

CB1-1-SJ1

CB1-2-SJ2

CR2-12-SJ3

CR2-22-SJ4

CR2-12-SJ3

CR2-22-SJ4

CB1-1-SJ1

CB1-2-SJ2

101-AC16

F709-AC65

N704-GEN9

N703-GEN6

N702-GEN5

N705-GEN7

N706-GEN8

AC-PMG-C

AC-PMG-B

AC-PMG-A

AC-F1

AC-F2

DETAIL CSCALE 2:1SH2 D-8

RE

NR

9844-0

2 V

ol 2

20

Pa

ge

©2012 CaterpillarAll Rights Reserved

Printed in U.S.A.

Volume 2 - EMCP 3.1

RENR9844-02July 2012

3500B GeneratorElectrical SystemZAB1-UPZAF1-UPYAK1-UPYAL1-UPZAL1-UPZBL1-UPYAS1-UPYBS1-UPYAX1-UP1JZ1-UP1LZ1-UP

Page 4

This schematic is for a 3500 MUI Generator with EMCP 3.1270-9008

RE

NR

9844-0

2 V

OL

22

0 P

ag

e,

Bla

ck

& W

hit

e

CUSTOMER AC CONNECTIONS

ENGINE INTERCONNECTION

J20P20

J20 P20

J9 P9

J12 P12

J6 P6

GND

SMMS2SMMS1

ALT

PPRS

EMCP 3.1

REMO

TE I

NITI

ATE

SPARE

PPM

PPRM

SM1 SM2

PS1 PS2

-

24V

+

ASR

(3E5239)

AS1AST

AS2

ASRSTR SMR

ASRLH RH

(3E5239)

IRSS

ES

(3E5239)

SHR

8T-9834

FCR

CONTROL PANEL

GND

CHASSISGROUND

2

GND

GND

1

8T-9834

ENG CONN

ENG CONN

GNDD-8SEE

2 2

101371 1

S1

L1 L2

11

2

9X-1339

1

H3

H1

H4

H4L2

L1

GND

H2

H3

1 36

P7A J7AJ7 P7

CR2

CONTROL GP

+-

CONTROL GP

+-

T

(9X3207)

(9X3207)

4P2729

GEN

13

77

99

1111

13

3939

5757

4747

EMCP 3.1

3131

8

9

6

4

5

7

5

9

4

2

1

10

12

11

6

CDVR

1

3

3

2

4

6

5

1

1

1

2

2

2

EMCP 3.1

(OPTIONAL)LSM

13 11 9 31 47 57

EMCP3.1

CONN9-PIN

12-PINDVR II

CONN

ENG CONN

5

2

4

3

1

66

5

4

3

2

1

J

I

H

G

E

F

D

C

B

A

XX

P16

>

>

>

>

>

>

>

>

>

>

J10

J16

8T-9834 9X-1339

Engine

11

12

4

3

15

17

20

9

24

7

18

38

23

13

ENGINE COOLANT LEVEL SENSOR C

ELECTRONIC GOVERNOR ACTUATOR (+)

ENGINE OIL TEMP SENSOR C

ENGINE OIL TEMP SENSOR A

LH MPU (-)

ENGINE COOLANT TEMP SENSOR A

ELECTRONIC GOVERNOR ACTUATOR-SH

ENGINE COOLANT LEVEL SENSOR B

CRANK SIGNAL CONNECTOR

AIR SHUT OFF RELAY

POWER (-)

POWER (+)

708 (16 AWG)

306 (16 AWG)

F411 (16 AWG)

838 (16 AWG)

220 (16 AWG)

709 (16 AWG)

807 (16 AWG)

221 (16 AWG)

C527 (16 AWG)

807 (16 AWG)

G429 (16 AWG)

31

37

ENGINE OIL PRESSRE SENSOR C

POWER (-)/LO200 (16 AWG)

382 (16 AWG)

RH MPU-A 6839 (16 AWG)

10

ENGINE OIL PRESSURE B

ENGINE OIL PRESSURE A799 (16 AWG)

19ENGINE COOLANT TEMP SENSOR BA235 (16 AWG)

LH MPU (+)838 (16 AWG)

807 (16 AWG)

839 (16 AWG)RH MPU-B

ELECTRONIC GOVERNOR ACTUATOR (+) 25

16

838 (16 AWG)

839 (16 AWG)

27

26

LH MPU-SH

RH MPU-SH

IC GEN IN

PHASE B CURRENT SENSING (1)

PHASE B CURRENT SENSING (2)

PMG PHASE C

EXCITER (-)

EXCITER (+)

CHASSIS GND

PMG PHASE B

PMG PHASE A

I AC COMMON

SENSING BOLTAGE PHASE B

SENSING VOLTAGE PHASE C

SENSING VOLTAGE PHASE A

IB GEN IN

IA GEN IN

22

21

BATT -

BATT +

M755 (18 AWG)

M756 (18 AWG)

M757 (18 AWG)

36

35

34

CAN DATA LINK -

CAN DATA LINK +

CAN DATA LINK SHIELD

101 (16 AWG)

200 (16 AWG)POWER (-)

POWER (+)

2

1

T3

EXCITER

C

B APMG

-

+

T2

N

T1

BATT LOW (-)

F-T1

F-T2

F-T3

2 SP3 2 1

LOADSHARELINES

301 302 303

SENSING VOLTAGE PHASE A

SENSING VOLTAGE PHASE C

SENSING VOLTAGE NEUTRAL

SENSING VOLTAGE PHASE B

I AC COMMON

IC GEN IN

IB GEN IN

IA GEN IN

CONN9 PIN

EXCITATION DISABLE

FAULT RESET

VAR/PF ENABLE

CONTACT SENSE - LOWER

CONTACT SENSE - RAISE

CONTACT SENSE - COMMON

ALARM OUTPUT DRIVER

FAULT SHUTDOWN DRIVER

DRIVER SUPPLY

PHASE B CURRENT SENSING (2)

PHASE B CURRENT SENSING (1)

GEN VOLTAGE SENSING C

GEN VOLTAGE SENSING B

GEN VOLTAGE SENSING A

+/- 10Vdc INPUT (A)

CONN12 PIN

CONN6 PIN

+/- 10Vdc INPUT (B)

PMG PHASE A

PMG PHASE C

PMG PHASE B

CHASSIS GND

EXCITER (+)

EXCITER (-)

CAN1 -

CAN1 SH

CAN1 +

CAN1 SH

CAN1 -

CAN1 +

BATT -

BATT +

BATT +

BATT -

CAN1 +

CAN1 -

BATT -

BATT +

CAN1 SH

M755

M757

M756

42

41

40

1

2A

101

200

M756

M755

M757

M756

M755

M757

200

101

200

101

M756

M755

M757

101

200

CAN1 SH

BATT +

BATT -

101

200

CAN1 -

CAN1 +

M755

M757

M756

200

101

M755

M757

M756

200

101

200

101

2A

BATT -

-

M757

M755

M756

200

MPU

MPU

A B

COOLANT

SENSORTEMP

SENSORPRESS OIL

ESV2 ESV1

(189-5746)

LOW COOLANTLEVEL

A B

(189-5746)

BATT +

BATT -

NC

CAN1 SH

CAN1 -

CAN1 +

E486A

E488A

E487A

F453

F452

F450

F448

N717

N715

N718

N720

N716

N719

F454

N752

F455

J905

J904

N713

E488B

E487B

E486B

N714

N703

N704

N705

N706

N702

200

F453

F453

F450

F453

F452

E488

E487

E486

C

B

BUSBARS

F448

F455

A

B

F2

11

13

12

N704

N703

N705

N702

N706

F1

F454

NT1 T2 T3

H3

H2

H1X1

X2

X3E488

E487

E486

CHASSISGROUND

100 - 240 VAC50 - 400 HzPOTENTIAL

A0

Batt +

1

F448A

F448

2 3

10WB0 C0

4 5

CTA0

F450A

F450

76

CTB0

F452A

F452

8 9

CTC0

Batt -

10W24 Vdc+ -15 16

488C

487C

486C

488A

487A

486A

IC GEN IN

IB GEN IN

IA GEN IN

VC GEN IN

VB GEN IN

VA GEN IN

23 24

RED

BK

WH

22

BK

RD SH

10 11 12

CHARGINGALTERNATOR

(OPTIONAL)AIR SHUTOFF

ASR

AND CONTROL (OPTIONAL)PRELUBE PUMP

PPRS

AIR

(OPTIONAL)START

PPRM

PREL

UBE

PRESSURE SWITCH

51

6561 70

33

41

(OPTIONAL)ETHER

200

30

87

200

304

32

40

35

43 55 45

#4 #5 #1#3

DI 1

DI 2

DI 5

46

AI 1

(-)

6766

MPU

(-)

MPU

(+)

839

AI 1

(+)

56

PPRMPPRMB

A

NOTE:BREAK CONNECTIONA & B FOR OPTIONALPRELUBE PUMP

AI 2

(-)

37

AI 2

(+)

38

MOTOR #1

DISCONNECT

REMOVABLEKEY

SWITCH

(IF REQUIRED)STARTER MOTOR #2STARTER

BATTERY

PS1 PS2

SMMS1 SMMS2

(40A)

RD-6

CB1

101

CB3(25A) (30A)

104

CB4

139

(60A)CB2

(+)2

GOV3 5

(-)1

11 12 (+) (-) 8 7

SP

213

EGA

85

86

2301A

109

87ASR

30

CB5(20A)

CB6(20A)

852

852

200

14ES

11

85

86

A2

A1

MANUAL ETHERSWITCH

#6

27

26

52

6 162010199341772523 2

#2

48

58

101

54

DI 3

44

DI 6

18 3831

31 12623 14 4 93 25 13 10 58 15 17 2

839

11

24 27

27 P7A/J7A

P7/J7

>> >> > > >> > > > > > >J20/P20

J20/P20< < < << < < < < < <

101

101H

Y918

101D

101C

101E

382

382

12 2

15

J7P7

1

1

220

799

A235

709

995

B482

220

799

A235

709

C527

221

708

838

838

838

807

807

807

852

852

>

26

26

839

839

839

G487

F406

7 17

412

5

8

AA

BB

33

44

1

1

Y918

101D

(8C-9812)

101F

Y910

306

Y911

Y909

306

L11

L12

L21

L22

R11

R12

<

F408

>

53

DI 4

31

34

32

25

26

23

24

4 3

2

11

3330 2A

ACT SH

ACT +

ACT -

MPU SH

MPU +

MPU -

29

30

37

382

101E

200

807

807

807

838

838

838

708

200

200

C527

306

221

A235

709

799

220

839

839

839

200

200

E560

F405

Y905

Y903LIGHTS

(8D2676)

103

SWITCH

(25A)CB7

200 200 200

200

200

2

AUTO

MAN.

(7G-9730)

PANEL

101

38

Y919

34

42

50

3

2

1

7

8

36

34

35

52

65

ANNUNCIATOR#1

CONN(155-2273)

(9W-1951)

SERVICECONN

GENERATOR

22

21

(174-0502)

C

BA

A B

CCONN

TERMINATING

(134-2540)RESISTOR #21

120

OHMS

>

>

>

>

>

P12

P9

42

34

50

52

65

<

<

<

<

<

P20

PRIMARY

J12

J9

J20

J7/P7 J7A/P7A

5

1

4

MODULERTD/THERMO

2

3

TERMINATING

(134-2540)

CONN(169-8670)

C

C

A

A

B

B

120

OHMS

RESISTOR

37

11

37

21

22

18

29

28

12

SEE SHEET 6 FORINTERCONNECTION

2

HEATERWATERJACKET

3

1L2

1

4

1L1

CR1

CR1

CR2

CR2

A

CHARGERBATTERY

B

H2

H4

H1

H3

SPACE HEATER

P

10AMP

CR2

A2A1CR1

T

9KW

240V AC SUPPLY

CUSTOMER

L2

L1

240

N

1211

21 22

3231

L4 T4

T3L3

AMP50

CR1L2 T2

CR1L1 T1

2

3

1L2

1

4

1L1

ALM

166 167

170170169

173173172

176176175

C210C210

802

806806

804 803 803

807

N725

N728

802

801801800

805 806 808806 807

N725

N728

C987

C988

801

167

A1CR2 A2

TO EMCP 3.1TERM 15

SHEET 3, D-4

F709101TO SHT 3E-6

325

324

323

322

TO DIGITAL INPUTEMCP3

326

323

322

- RELAY COIL

- RELAY CONTACT NORMALLY OPEN

- MOTOR

- DIODE

- NORMALLY CLOSED CONTACT

- SWITCH CONTACT

- NORMALLY OPEN CONTACT

- EMERGENCY STOP PUSH BOTTON

- CIRCUIT BREAKER

- RELAY CONTACT NORMALLY CLOSED

- CONTROL PANEL WIRING/ GENERATOR WIRING

- INTERCONNECT WIRING

- OPTIONS WIRING

- NORMALLY CLOSED CONTACT

- CUSTOMER WIRING

304

305

306

307

308

309

GND

T1

T2

T3

310

311

312

313

314

IA1

IB1

IC1

IN

319

318

317

316

315

321

320

T3

T2

T1

IB

IC

IA

T1

T2

T3

IA IB

IA1 IB1

IC

IC1

NOTE: SEE SHEET 6 FOR INTERCONNECTION

NOTE: SEE SHEET 6 FOR INTERCONNECTION

WALL MOUNTED EMCP 3.1

3

4

9

11

12

13

14

15

16

20

23

25

30

31

ENGINE CONNECTOR (DC) GENERATOR CONNECTOR (AC)

5

8

10

6

17

27

26

319

GND

315

316

321

317

318

320

To CT's

To PT's

29

28

18

2

1

SM1

A3 - ELECTRONIC GOVERNOR

AI - ANOLOG INPUT

ALT - ALTERNATOR

ASOS - AIR SHUTOFF SYSTEM

AS1 - AIR SHUTOFF SOLENOID (RH)

AS2 - AIR SHUTOFF SOLENOID (LH)

AUX - AUXILLARY CONTACT

BATT+ - BATTERY POWER +24V

BATT- - BATTERY POWER - 24V

BDS - BATTERY DISCONNECT SWITCH

CB - CIRCUIT BREAKER

CDVR - CATERPILLAR DIGITAL VOLTAGE REGULATOR

CONN - CONNECTOR

CR2 - CONTROL RELAY 2 (SHORE POWER)

DIN RTN - DIGITAL INPUT RETURN

DI - DIGITAL INPUT

DI 2 - DISCRETE INPUT#2 (REMOTE INITIATE)

DO 2 - DISCRETE OUTPUT#2

DR SUP - DRIVER SUPPLY

EMCP 3.3 - ELECTRONIC MODULAR CONTROL PANEL 3.3

ENA - ENABLE

ES - ETHER START

ESPB - EMERGENCY STOP PUSH BUTTON

ESV1 - ETHER START VALVE 1

ESV2 - ETHER START VALVE 2

GEN - GENERATOR

KR - KEY REMOVABLE

MES - MANUAL ETHR SWITCH

MPU - MAGNETIC PICKUP

PDB - POWER DISTRIBUTION BOX

PL - PANEL LIGHT

PLS - PANEL LIGHT SWITCH

PMG - PERMENANT MAGNET GENERATOR

PP - PRELUBE PRESSURE

PPM - PRELUBE PUMP MOTOR

PPR - PRELUBE PUMP RELAY

PPS - PRELUBE PRESSURE SWITCH

PS - PINION SOLENOID

GND - GROUND

RO1 (NO) - RELAY OUTPUT #1 NORMALLY OPEN (STARTER MOTOR RELAY)

R08 (NO) - RELAY OUTPUT #8 NORMALLY OPEN (PRELUBE)

RTD/THERMO - RTD/THERMO COUPLE MODULE

SC - SERVICE CONNECTOR

SH - SPACE HEATER

SHO- SHORE POWER

SMMS - STARTING MOTOR MAGNETIC SWITCH

SM - STARTER MOTOR

PF - POWER FACTOR

SMR - STARTER MOTOR RELAY

SP - SPEED POTENTIOMETER

SPA - SPARE

STC - SHUNT TRIP COIL

STR - SHUNT TRIP RELAY

ST+ - SHUNT TRIP+

V- - ADD CONTACT VOLTAGE LOWER

V+ - ADD CONTACT VOLTAGE HIGHER

VAR - VOLTAGE ADJUST REMOTE

V COM - CONTACT SENSE COMMON

SHDWN - SHUT DOWN

- GENERATOR TERMINAL STRIP

- CONTROL PANEL TERMINAL STRIP

SHEET 2

SHEET 1

SHEET 3

SHEET 4

SHEET 5

SHEET 6