Gas Control Systems & Ignition

APPLICATION AND INSTALLATION GUIDE
GAS CONTROL SYSTEMS

& IGNITION
G3600 • G3500
G3400 • G3300
Contents
Gas Control Systems & Ignition ............................................... 1

Ignition Systems ................................................................ 2
Solid-State Magneto System ........................................... 2
Caterpillar Digital Ignition System (CDIS) .......................... 3
Electronic Ignition System (EIS) ....................................... 4
Electronic Control Module (ECM) ..................................... 5
Spark Plugs ................................................................... 5
Variable Timing for Dual Fuel........................................... 5
In Hazardous Locations ................................................... 6
Engine Shutdown Practice............................................... 7
Engine Control, Protection and Monitoring Systems ............... 8
G3300 and G3400 Engine Protection Systems.................. 9
Self-Powered Shutoffs ................................................ 9
Powered Shutoffs ...................................................... 9
Automatic Start/Stop Shutoff ...................................... 9
Customer Supplied Shutoff ......................................... 9
Electronic Modular Control Panel (EMCP) II ................... 9
G3500 Engine Protection System .................................. 11
Remote Control Panel ............................................... 11
Electronic Modular Control Panel (EMCP) II+ .............. 12
Alarm Modules......................................................... 13
Customer Interface Module (CIM) .............................. 14
Customer Communication Module (CCM).................... 14
Customer Supplied Shutoffs ...................................... 15
Recommended Alarms and Shutdowns ....................... 16
Advanced Digital Engine Management (ADEM)
A3 Control System................................................... 17
Electronic Control Module (ECM)................................ 17
Charge Density Feedback .......................................... 19
G3500C & E Island Mode Control System .................. 20
CDVR Initial Settings (G3520C) ................................. 24
CDVR Parameter Settings ......................................... 25
Integrated Temperature Sensing Module (ITSM) .......... 27
G3600 Engine Protection System .................................. 27
Advanced Digital Engine Management (ADEM)
A3 Control System................................................... 27
Electronic Control Module (ECM)................................ 29
Optional Control Panel .............................................. 31
Machine Information Display System (MIDS) ............... 31
Integrated Combustion Sensing Module (ICSM) ........... 32
Useful Equations from the Island Mode Sizing
and Functionality.............................................................. 33
Reference Material ........................................................... 34
Foreword
This section of the Application and Installation Guide generally describes
Gas Control Systems and Ignition for Caterpillar® engines listed on the cover
of this section. Additional engine systems, components and dynamics are
addressed in other sections of this Application and Installation Guide.
Engine-specific information and data is available from a variety of sources.
Refer to the Introduction section of this guide for additional references.
Systems and components described in this guide may not be available or
applicable for every engine.
Information contained in this publication may be considered confidential.

Discretion is recommended when distributing. Materials and specifications
are subject to change without notice.
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the

POWER EDGE trade dress, as well as corporate and product identity used
herein, are trademarks of Caterpillar and may not be used without
permission.
Gas Control Systems & Ignition Application and Installation Guide
Gas Control Systems & Ignition

Caterpillar engines have evolved from mechanically controlled workhorses
to sophisticated, electronically controlled, intelligent machines. Control
systems and ignition on Caterpillar engines have achieved industry leading
reliability and durability levels while being subjected to rigorous conditions.
SECTION CONTENTS
Ignition Systems ................. 2 Engine Control, Protection &

• Solid State Magneto System Monitoring ..........................8
• Caterpillar Digital Ignition • G3300 & G3400
System • G3500
• Electronic Ignition System • G3600
• Electronic Control Module Useful Equations from
• Spark Plugs the Island Mode Sizing
and Functionality ............... 33
• Variable Timing for Dual Fuel Reference Material ............. 34
• In Hazardous Locations • Media List
• Engine Shutdown Practice
©2008 Caterpillar®
All rights reserved. Page 1
Application and Installation Guide Gas Control Systems & Ignition
Ignition Systems
Ignition System Diagram for G3306 Engine
Figure 1
1. Spark Plug 6. Magnetic Switch
2. Ignition Transformer 7. Stop Switch
3. Ground for Magneto Case 8. Engine Oil Pressure Gauge
4. Magneto 9. Water Temperature Gauge
5. Instrument Panel
Caterpillar gas engines use a low Magneto Ignition System, currently

voltage ignition system. Individual used on G3300 engines.
ignition transformers are mounted The magneto produces low voltage
near the spark plug for each for the ignition transformers on each
cylinder. Each engine is equipped cylinder. The transformers increase
with a solid-state magneto, a the low voltage to the high voltage
Caterpillar Digital Ignition System needed to fire the spark plugs.
(CDIS), an Electronic Ignition System
Applications not having a 24 VDC
(EIS), or an Electronic Control
electrical power source, such as gas
Module (ECM). These offer a flexible
compressors at remote sights, must
ignition system that require less
find a source of electricity to power
maintenance and provide more
auxiliary panels. G3300 engines
reliability than older breaker-point
have a pin available on the magneto
magnetos.
that can be used to provide power
Solid-State Magneto System for auxiliary panels. This pin
Figure 1 is a diagram showing the provides 180 VDC with a maximum
major components of the Solid-State current draw of 20mA; however,
spark plug life will be decreased
Page 2 All rights reserved.
when the magneto is used to power that releases the low voltage to the
auxiliary panels. ignition transformers, which increase
it to the high voltage that is needed
Caterpillar Digital Ignition to fire the spark plugs.
System (CDIS) There are two options for providing
Figure 2 is a diagram showing the the electrical power for the timing
major components of the Caterpillar control:
Digital Ignition System (CDIS)
currently used on some G3400 • An engine mounted alternator
engines. enables self-powered ignition.
The CDIS uses a capacitor to store • Customer provided 12VDC or

the voltage required for ignition. The 24 VDC power source.
timing control has a relay switch
Caterpillar Digital Ignition System (CDIS) Diagram for G3400 Engine
Figure 2
1. Spark Plug 4. CDIS Module

2. Ignition Transformer 5. Speed Timing Sensor
3. Ground for CDIS Module
Electronic Ignition System (EIS)

Caterpillar Electronic Ignition System (EIS)
Figure 3
Figure 3 is a diagram showing the Gas engines with EIS incorporate a
major components of the Caterpillar control system that senses and
Electronic Ignition System (EIS) reacts to a combustion detonation
currently available on G3400 and by controlling ignition timing. An
G3500 engines. The EIS system accelerometer and electronic buffer
monitors engine operation and unit is mounted on each side of the
distributes power to the cylinder cylinder block, and is used to sense
transformers to provide the best the detonation level (if any). When a
engine performance at all engine level of detonation is reached that
speeds. EIS provides detonation might damage the engine, the
protection and precision spark electronic timing control retards the
control for each cylinder. ignition timing six degrees. If the
engine continues to detonate, the
control will provide a signal to shut For all engines with Caterpillar EIS,
the engine down. If the retarded a 24 VDC power source is
timing successfully stops the necessary. The power source
detonation, the timing control will provided for the engine's control
begin advancing the timing at a rate system can also be used to operate
of 1 degree per minute up to the auxiliary panels.
original timing. The timing control
will stop advancing if detonation Electronic Control Module
begins again. This allows the engine (ECM)
to obtain optimum fuel consumption The ignition system utilized on
by running close to detonation engines equipped with the Caterpillar
without damaging the engine. ADEM A3 control system is
The EIS control module sets engine controlled by the system’s Electronic
timing according to desired engine Control Module (ECM) described
timing, customer specified later in this section.
parameters, and the conditions in
Spark Plugs
which the engine operates. Timing
Spark plugs for Caterpillar gas
is automatically adjusted according
engines have been specifically
to speed/timing maps, manifold air
developed to meet the ignition needs
pressure, and any detonation.
of a given engine. The spark plugs
The control module also creates
must be maintained according to the
diagnostic codes if a problem
specified maintenance schedule.
develops in a component or harness.
Failure to use proper spark plugs, or
Engine sensors provide information failure to properly maintain the spark
to the EIS control module. plugs, will affect the engine's fuel
Detonation sensors are located on consumption, emissions, and
each side of the engine and stability. Good maintenance
continually monitor the engine for practices can be found in Systems
combustion detonation. A Operation Testing and Adjusting
speed/timing sensor provides Manual for your engine.
accurate spark timing and engine
speed information. An intake Variable Timing for Dual Fuel
manifold air pressure sensor provides The recommended ignition timing
engine load information. varies with fuel composition. Serious
The timing is set by connecting the engine damage could result if the
Caterpillar Digital Diagnostic Tool timing is not changed when the fuel
(DDT) or Caterpillar Electronic is changed; for example, from
Service Tool (Cat ET) to the engine natural gas to propane or digester
to electronically set the timing. The to natural gas. To allow automatic
DDT and Cat ET, which are available timing adjustment when the fuel is
through the price list, are also used changed, EIS offers a dual timing
to monitor engine speed, detonation switch. On the G3300 only, a dual
level (if any), and diagnostic codes. timing magneto is available as well.
The customer must provide the positive-pressure ventilation

contacts to signal EIS or the from a source of clean air, and
magneto to select timing. See the effective safeguards against
“Fuel Systems” section of this guide ventilation failure are
for additional information. provided.”
The basic difference between
In Hazardous Locations
Division 1 and Division 2 is:
Engines installed in hazardous
locations generally fall under the • Division 1 – flammable gases
Class I, Division 2 category of are always present.
Article 500 of the National Electrical • Division 2 – flammable gases
Code. It reads: may be present.
“A Class I, Division 2 location is a When an engine is installed in such
location: a location, shielding of the ignition
• in which volatile flammable system wiring or usage of approved
liquids or flammable gases are ignition system components may be
handled, processed, or used, required. Many Caterpillar gas
but in which the liquids, engines have attachments providing
vapors, or gases will normally an ignition system that is Canadian
be confined within closed Standards Association (CSA)
containers or closed systems approved for Class I, Division 2,
from which they can escape Group D locations. CSA approval is
only in case of accidental a Canadian requirement for engines
rupture or breakdown of such operating in hazardous locations in
containers or systems, or in Canada. CSA approval is also
case of abnormal operation of recognized in Division 2 locations
the ventilation equipment; or outside Canada. Consult factory for
availability.
• in which ignitable
concentrations of gases or The basis for the CSA attachment
vapors are normally prevented design is to prevent hazardous
by positive mechanical atmosphere from coming in contact
ventilation, and which might with arcing or sparking devices or to
become hazardous through contain an explosion within the
failure or abnormal operation engine itself. This is accomplished
of the ventilation equipment; on Caterpillar gas engines by special
or metal conduit harness assemblies for
the ignition system and engine
• that is adjacent to a Class I,
wiring harnesses. Special explosion-
Division 1 location, and to
proof transformers and cylinder head
which ignitable concentrations
components have been developed to
of gases or vapors might
contain any potential explosion in
occasionally be communicated
the head.
unless such communication is
prevented by adequate
The Caterpillar EIS system is misfiring cylinder is more of a

available in a CSA approved problem with a shielded system.
configuration. This system varies Installation of normally closed
from the standard EIS system by switches in the primary wiring is one
offering special ignition coils and a method of temporarily interrupting
terminal box located on top of the ignition to identify a misfiring
EIS control module. cylinder. If devices are incorporated
With the CSA system, no shutoffs, in the shielded system for
monitoring systems, start/stop logic troubleshooting purposes, the
or gas shutoff valves are provided. primary of the magneto must never
The functions must be provided by be grounded to interrupt the ignition.
the customer. The required shutoffs This would most likely cause failure
for jacket water temperature, oil of solid-state components within the
pressure, and overspeed can be magneto.
found in the Operation and
Engine Shutdown Practice
Maintenance Manual for each
Normal engine shutdown should be
engine.
accomplished by shutting off the
The CSA terminal box contains fuel supply. This allows the engine
warning, shutdown, and power to consume the fuel trapped
lamps and a diagnostic reset switch. between the shutoff valve and
All of these may be remote mounted cylinder. It also prevents raw fuel
by the customer. from being pumped into the exhaust
For magneto systems with the system. Raw fuel in a hot exhaust
CSA attachment, troubleshooting system presents the potential for
can be more difficult. A standard explosion. Stopping the ignition
transformer can be installed system to cause engine shutdown
temporarily so that the timing light should be utilized only for
can be triggered from the exposed emergencies.
high-tension lead. Detecting a
Engine Control, Protection and Monitoring Systems

Control, protection and monitoring details of these offerings will be
systems are a basic requirement of discussed in following sections.
all engine installations, and provide When problems occur that do not
protection to the engine as well as immediately endanger the condition
to the facility and operating of the engine or the operator, the
personnel. fuel gas valve is closed as soon as a
Many gas engines are controlled fault is detected and the ignition
using separate engine speed system remains on for 10 seconds.
governing systems, which are This allows all the gas downstream
described in the Governors section of the shutoff valve and in the intake
of the Application and Installation manifold to be consumed by the
Guide. This section of the guide engine and not dumped into the
provides basic information about the exhaust stack. When a problem
Caterpillar ADEM A3 control system occurs that can cause immediate
and the protection systems available damage to the engine or operator,
on Caterpillar non-ADEM gas such as overspeed, the gas valve is
engines. ADEM A3 is standard on closed and the ignition system is
G3600 engines and available on immediately shut off. When starting
some G3500 engines. again, the engine should be cranked
Engine protection is required for for 10 seconds with the gas valve
the lubrication, cooling, and closed and the ignition system off.
combustion systems. These systems This purges the engine of any
in turn interact with fuel and ignition unburned air/fuel mixture.
systems and in some cases, with the When designing an installation,
customer’s switchgear. consider if the engines will be
The lubrication system must attended or unattended when
maintain the oil pressure within a selecting protection equipment.
certain range; oil temperature is When attended, alarms can be
internally controlled via a thermostat provided to warn of approaching
for most arrangements. The cooling shutdown limits in each monitored
system must maintain the cooling system before an actual engine
water below a certain temperature. shutdown occurs. This allows the
Some engines have a protection attendant to decide the urgency of
system for the combustion chamber; the fault and schedule repairs before
detonation sensing that can adjust or a shutdown. Protection equipment
even shutdown the engine. for unattended applications can be
Overspeed protection is also very tailored to meet specific
important. A listing of standard and requirements.
optional protection systems can be Although most Caterpillar gas
found with each engine pricing engines are equipped with a
arrangement in the price list. The standard set of shutoffs, some
engine configurations include Powered Shutoffs

additional shutoffs and alarms. They This fully independent system
may also use different strategies for requires an external power supply of
shutdowns, annunciation and other 24 volts. The power to an ETR gas
features. Consult the Gas Engine valve (optional) is interrupted to stop
Schematics listed in the Reference the engine.
Materials at the end of this section
Automatic Start/Stop Shutoff
for additional information on how to This system is made for customers
connect to a specific engine’s safety that have switchgear that is wired to
system. the junction box in order to monitor
Gas generator set engines are shutoff parameters and control an
normally equipped with Energize-To- ETR gas shutoff valve. This system
Run (ETR) gas shutoff valves. The requires an external power supply of
diesel offers both ETR and Energize- 24 volts. The customer is required to
To-Shutoff (ETS). The gas engine supply automatic start/stop logic.
differs because there is not a
Customer Supplied Shutoff
commercially available gas shutoff
This selection provides no wiring
valve that is energize-to-shutoff with
groups or shutoffs. It is the
an automatic reset. For manual start-
customer’s responsibility to provide
stop operations, ETS gas valves are
the minimum protection required for
available as an option for G3400 and
the particular engine and application.
G3300 with a manual reset.
Electronic Modular Control Panel
G3300 and G3400 Engine (EMCP) II
Protection Systems This protection system is available
The G3300 and G3400 engines for Caterpillar EIS engines and
offer several protection system requires an external 24 volt power
options. In the price list, the desired supply. Figure 4 shows a typical
protection system is selected from a EMCP II instrument panel. The
list of mandatory options. Not all engine features provided are:
options are available for every • Emergency stop button
engine; consult the use codes for
• Energized to run gas shutoff
compatibility. Descriptions of some
valve
available options are listed below.
• Power, warning, and
Self-Powered Shutoffs
shutdown lights
These shutoffs are powered by the
ignition system when the engine is • Detonation
running; no external power is • Start, stop, run switch
required. An energized to shutoff
gas valve (manual reset) is activated The EMCP II Protection System
to stop the engine. also contains a generator set control
(GSC) and several instrument panel
switches plus optional alarm
modules and customer interface • Displays GSC programming

module. The GSC monitors and information
controls: The safeties and controls listed
• Starting and stopping of the above are all contained in the EMCP
engine II. The set points for the various
• Shows engine condition and shutoff parameters are programmed
generator output display into the EMCP II using a keypad on
the GSC.
• Engine faults, displays fault
codes
G3400 EMCP II Instrument Panel
Figure 4
1. Generator Set Control (GSC) 13. Alarm Module or Synchronizing Lights Module
10. Speed Potentiometer or Governor Switch (Optional)
(Optional) 14. Panel Light Switch (Optional)
11. Diagnostic Reset Switch 15. Emergency Stop Push Button
12. Engine Control Switch 16. Voltage Adjust Rheostat
Remote Control Panel (Status)

G3500 Engine Protection
System
G3500 engines offer an electronic
protection system that requires a
24 volt power source. The gas
shutoff valve is included and
configured as ETR. The control panel
for protection system hardware will
be one of four offerings:
• Remote Control Panel
(Status), offered on all G3500
EIS generator set and
industrial engines except
G3500 package generator
sets for COSA. A description
of the Status Control panel is
located below. Figure 5
• Electronic Modular Control 1. “Warning” indicator
Panel (EMCP II), mounted on 17. “Shutdown” indicator
the generator, standard for 18. “Power On” indicator
the 1800 rpm generator set 19. “Diagnostic Reset” switch
standby package, optional for 20. Status Control Module (SCM)
G3500 package generator 21. Engine Control Switch (ECS)
sets for COSA, and available 22. “Emergency Stop” button
via SER for other generator
set engines. The Status Control Module (SCM),
• Caterpillar Advanced Digital shown in Figure 6, displays fault
Engine Management (ADEM) conditions and key engine
A3 control system is available parameters. Information is received
on some G3500 engines. from the operator, magnetic speed
• Customer supplied control pickup, pressure/temperature
panel, safeties, shutdowns, module, and the EIS control. This
and start/stop logic, standard information is then used to control
on G3500 Package Generator the position of the fuel shutoff
sets for COSA. valve, starting system, and relay
information back to the ignition
Remote Control Panel system.
The remote control panel (Status)
is used on most engines with
Caterpillar EIS. Figure 5 shows the
remote control panel (Status) and
labels the various panel features.
II+ also contains a generator set

Status Control Module (SCM) control (GSC) and several instrument
panel switches plus optional alarm
modules and a customer interface
module. An EMCP II+ instrument
panel is shown in Figure 7.
The GSC monitors and controls the
following items.
• Starting and stopping of the
engine (This is not applicable
for ADEM A3 controlled
G3500 engines)
• Shows engine condition and
generator output display
Figure 6 • Engine faults, displays fault
1. (Liquid Crystal Display (LCD) codes
23. Switch (display hold switch) • Displays GSC programming
24. “Overcrank” indicator information
25. “Low oil pressure” indicator
The safeties and shutdowns listed
26. “Overspeed” indicator above are all contained in the EMCP
27. “Emergency Stop” indicator II+. The set points are programmed
28. “High Coolant Temperature” indicator into the EMCP II+ using a keypad
29. “Auxiliary shutdown” indicator on the GSC.
Electronic Modular Control Panel

(EMCP) II+
A second protection system,
available on G3500 generator set
engines, is the EMCP II+. The EMCP
G3500 EMCP II+ Instrument Panel
Figure 7
1. Generator Set Control+ (GSC+) 7. Speed Potentiometer (SP) (Optional) or

2. Engine Control Switch (ECS) Governor Switch (Optional)
3. Start Aid Switch (SAS) 8. Voltage Adjust Rheostat (VAR)
4. Panel Lights (PL) 9. Emergency Stop Push Button (ESPB)
5. Alarm Module (ALM) (Optional) 10. Panel Light Switch (PLS)
6. Synchronizing Lights Module (Optional) or
Custom Alarm Module (CAM) (Optional)
Caterpillar, be sure that the
Alarm Modules
module(s) includes the following
Alarm modules are optional
features.
equipment, available as an
attachment to the EMCP II+. These • Fault Light Lock-in Circuitry -
modules provide red and amber keeps fault light on when
LED’s plus an audible indicator. intermittent faults occur.
Two alarm modules are available. • Lockout of Additional Alarm
They are the NFPA 99 and NFPA Lights - prevents subsequent
110. The NFPA 99 provides alarms alarm lights from going on
for low oil pressure, low coolant after the activated engine
temperature and high coolant shutoff stops the engine. This
temperature. The NFPA 110 aids in troubleshooting.
provides alarms for low oil pressure, • Alarm Silence - allows engine
low coolant temperature and high man to acknowledge the
coolant temperature, low battery alarm without having to
voltage, battery charge malfunction continually listen to the alarm
and system not in auto. horn. Alarm light is left on.
The alarm module has a serial • If more than one engine is
connection to the SCM and must be connected to an alarm panel,
located within 305 m (1000 feet). a fault in a second engine
When using alarm modules and should activate the alarm,
panels not produced or offered by even though the alarm horn
may have been silenced after such as the switchgear. The CIM
a fault on another engine. must be located within 305 m
• Circuit Test - provides for (1000 ft) of the GSC or SCM.
periodic checking of alarm Customer Communication Module
panel functions (CCM)
Customer Interface Module (CIM) The Customer Communication
The Customer Interface Module Module (CCM) provides a
(CIM) provides an interface (separate communication link between the
relay contacts) between the GSC electronic control system of an
and switchgear on EMCP II+ engine and a host device. A typical
equipped engines and between the CCM is shown in Figure 8. The
SCM and switchgear on RCP communication link is established
equipped engines. with the CAT Data Link and the
industry standard RS-232C. The
The two major components of the
host device can be one of the
CIM are the relay board and the
following items:
electronic control. The electronic
control connects to the serial data • Personal Computer (PC)
link and decodes the information into • Programmable Logic Controller
discrete outputs. The output drives (PLC)
relays to sound a horn, flash a lamp • Any other device with an
or trigger some other action. The RS-232C port
following information is available
from the serial data link. The host device can be connected
directly to the CCM and can be used
• High coolant temperature with a modem.
alarm
If the host device is a PC, software
• High coolant temperature that is compatible with the CCM is
shutdown available from Caterpillar.
• Low coolant temperature The host device will usually be a
alarm PLC and the CCM can be used with
• Low coolant temperature customized software. Refer to the
shutdown Operation and Maintenance Manual
• Low oil pressure alarm for each engine for further
information on this subject.
• Low oil pressure shutdown
• Overcrank
• Overspeed
• Engine control switch not in
auto
• Diagnostic failure
The CIM is normally shipped loose
for installation in a convent location,
• Detonation
Customer Communication Module
• Start, stop, run switch
When the high temperature cooling
option is selected, the following are
used:
For engines operating above a
jacket water temperature of 110°C
(230°F), a Caterpillar pump may not
be used. When using a customer
supplied pump, Caterpillar requires
that a shutdown be provided for low
jacket water flow. This can be done
with a pressure switch or a pressure
differential switch across the engine
block, triggering below 27 kPa (4
psig) delta.
Figure 8
Customer Supplied Shutoffs

Customer supplied shutoffs must
meet all Caterpillar and other local
requirements. Caterpillar requires at
a minimum a duplication of the
safeties and shutdowns that would
have been provided by Caterpillar for
the particular engine. These safeties
and their limiting values are shown
for each engine in the product
description section of the price list
and in the Operation and
Maintenance Manual for each
engine. For a typical standard
cooling G3500 LE, the Caterpillar
system provides:
• Emergency stop button
• Energized to run gas shutoff
valve
• Power, warning, and
shutdown lights
Recommended Alarms and suggests various alarms and

Shutdowns shutdowns to be considered and
The engine shutoff systems how they might be applied. This
discussed above are the standard chart is frequently modified to fit the
systems. Customers routinely add site, application, and maintenance
alarms and shutdowns to meet the personnel preferences.
needs of the application. Table 1
Gas Engine Controls and Safety Devices

Malfunction Unattended Attended
Low oil pressure S S
High oil pressure S A
Excessive vibration S S
Overspeed I I
High inlet air temperature S S
Alarm shutdown S S
Detonation I I
Overcrank S S
High jacket water temperature S S
High water level A A
Low water level S A
Reverse power S S
Overcurrent S S
High steam pressure A A
Overloaded S A
Under frequency S S
Over/under voltage S S
Battery charger failure (AC) A A
Battery failure (DC) A A
Low condensate level S S
Low tower water level S A
I – Immediate shutdown – close gas valve and terminate ignition immediately
S – Staged shutdown – close gas valve immediately and terminate ignition after 10 second time
delay
A – Alarm only
Table 1
Advanced Digital Engine • Electronic Control Module

Management (ADEM) A3 Control (ECM) and emergency stop
System button in an engine mounted
The Caterpillar Advanced Digital junction box
Engine Management (ADEM) A3 • Integrated Temperature
electronic controls integrate Sensing Module (ITSM)
start/stop controls, governing,
• Gas Shutoff Valve (GSOV)
engine sensing/monitoring, air/fuel
ratio control, ignition timing and • Ignition system controlled by
detonation control into one ECM
comprehensive engine control • Detonation sensor for each
system for optimum performance two cylinders
and reliability. • Electronically controlled
The ADEM A3 control system is actuators for fuel, throttle and
shown in Figure 9 and includes the turbocharger bypass
following components:
G3500 ADEM A3 Control System
Figure 9
of the engine. The module is an
Electronic Control Module (ECM)
environmentally sealed unit that is in
The Electronic Control Module
(ECM) controls most of the functions an engine-mounted junction box.
The ECM monitors various inputs detonation. The detonation sensors

from sensors in order to activate (one for each two adjacent
relays, solenoids, etc. at the cylinders) monitor the engine for
appropriate levels. The ECM excessive detonation and provide
supports the following five primary this data to the ECM. If detonation
functions: reaches an unacceptable level, the
• Governing of the engine ECM will retard the ignition timing of
the affected cylinder or cylinders. If
• Control of ignition
retarding the timing does not limit
• Air/fuel ratio control the detonation to an acceptable
• Start/stop control level, the ECM will shut down the
engine.
• Engine monitoring and
protection A normal engine shutdown is
accomplished by shutting off the
The ECM control parameters are all
fuel supply. The ignition system
preset at the factory with any site
continues to operate until the engine
specific reprogramming done by
is below 60 rpm. This allows the
Caterpillar service personnel during
engine to consume the fuel that is
the commissioning process utilizing
trapped between the shutoff valve
Cat ET service tool. The following is
and the cylinder. The ignition system
a brief description of these five
is disabled for engine overspeed and
functions:
emergency stop shutdowns.
Governing of the Engine The ECM provides extensive
The ECM monitors the actual diagnostics for the ignition system.
engine speed, and calculates the The ECM also provides a switch for
difference between this and the ignition timing in order to allow
desired engine speed. The ECM then operation with alternate fuels that
adjusts the air/fuel flow by require a timing offset.
controlling the throttle to maintain
the desired engine speed. Levels of detonation can be
displayed by the MIDS on the
Control of Ignition Optional Control Panel. Alternatively,
Each cylinder has an ignition the “Cylinder X Detonation Level”
transformer. To initiate combustion, screen on the Cat ET service tool
the ECM sends a pulse of can also be used. The “X”
approximately 108 volts to the represents the cylinder number.
primary coil of each ignition
transformer at the appropriate time Air/Fuel Ratio Control
and for the appropriate duration. The ECM provides control of the
The transformer increases the air/fuel mixture for performance and
voltage, which creates a spark for efficiency at low emission levels
across the spark plug electrode. utilizing the fuel valve and oxygen
sensor. The system has three modes
The ECM provides variable ignition of operation for the air/fuel ratio:
timing that is sensitive to
• Start-up charge, exhaust oxygen levels are a

• No feedback direct result of the air/fuel ratio
being provided. An oxygen sensor in
• Exhaust oxygen feedback the exhaust stack measures the
or Charge density feedback oxygen level in the exhaust. This
Note: The engine uses either information is provided as feedback
exhaust oxygen or charge density. to the AFRC, which compares the
In each of these modes, the air/ measured oxygen level to that of the
fuel ratio is controlled by the fuel correct air/fuel ratio for the desired
valve. emissions setting.
Exhaust Oxygen Feedback
Because most, if not all, of the
oxygen in the combustion chamber
comes from the air in the inlet
Figure 10
of inlet manifold air temperature and

Charge Density Feedback
Charge density is the density of the air inlet pressure and compares it to
the desired charge density. Desired
air/fuel mixture in the air inlet
manifold. The ECM calculates the charge density is dependant on
actual charge density from the values engine speed and real engine load.
For standard G3500C and E Percentage" causes a large change

packages the real engine load is in the actual exhaust emissions. For
calculated and sent to the ECM by example, an adjustment of one
the EMCPII+. However, for G3500C percent in the parameter's value will
and E packages with the Island Mode result in a change of 20 to 40 ppm
control system (Coal Mine Methane, in the actual level of NOx.
Island Mode and 50Hz Landfill) the
G3500C & E Island Mode Control
ECM requires a continuous and System
instantaneous measurement of the Island mode applications are
real engine load to adequately adjust defined as stand-alone applications
for load and fuel transients. For this without any connection to the utility
reason Caterpillar provides a kilowatt grid, parallel with other units not
transducer, which supplies the ECM connected to the utility grid,
with a 0.2-4.8V DC analog signal connected to a small utility grid
proportional to the measured real which can experience frequency and
power. voltage changes, or paralleled to
To achieve the desired charge grid, but when grid is "down", the
density, the ECM sends a command genset must operate stand-alone
signal to the fuel metering valve. with minimum freq/voltage variation.
This is a continuous process during The island mode control system
operation with loads that are greater provides additional sensors, controls
than 25 percent. The same and software to permit improved
customer's inputs that are required transient operation. Check the
for operation in the open loop are appropriate product update
used for the feedback mode. The (LEXE7567) on the PowerNet for
following additional configuration detailed transient information.
parameter must be programmed into Caution: Gas engine gensets
the ECM via the "Configuration" cannot accept transient conditions
screen of Cat ET: equal to a diesel genset or a large
"Desired Emissions Gain utility grid. It is the dealer's
Adjustment Percentage" - This is an responsibility to be sure the
adjustment for the charge density. customers' needs are matched to
To richen the air/fuel mixture, this product's capability.
increase the gain adjustment. To
Kilowatt Transducer – Island Mode
lean the air/fuel mixture, decrease
Control System
the gain adjustment. This increases
The Island Mode control system
the charge density and lowers NOX.
utilizes a kilowatt (kW) transducer to
The ECM uses the gain adjustment
provide a real time, real power signal
to help determine the FCF. The FCF
to the engine control system (Figure
varies during operation in the
10). The kilowatt transducer
feedback mode.
measures the electrical power
Note: A small change in the delivered to a load and converts that
"Desired Emissions Gain Adjustment measurement to a DC Voltage
proportional to the power measured. transducer to accurately monitor the

The kW transducer monitors both power. Applications utilizing three-
the voltage and current using phase three-wire balanced
potential transformers (PT’s) and connection only require a two-
current transformers (CT’s) and element transducer to accurately
calculates the power based on the measure the power.
circuits PT and CT outputs. The PT
Kilowatt Transducer Output Voltage
and CT ratios directly impact the PT and CT ratios should be
output voltage of the kW transducer selected to maximize the kilowatt
and need to be sized to maximize transducer output voltage at genset
the kW transducer output voltage. full load. A full scale output less
At a minimum the kW transducer than 4.0V DC will degrade the
full-scale output voltage needs to be transient capability of the engine due
4.0V, however it should not exceed to the increased kW/V range and
4.8V. If the voltage at the load input increased susceptibility of noise. The
on the ECM ever exceeds 4.8 volts following calculations are used to
then the ECM will trigger a “Kilowatt determine the kilowatt transducer
Sensor Open or Shorted high” output at the full load of the Genset
diagnostic and the engine will based on PT and CT ratios.
shutdown. If the voltage is ever less
than 0.2 volts and the engine is Caution: The kW transducer should
above 20% load (based on be selected such that the maximum
traditional load calculation) then the is 110% of the generator's rated
ECM will trigger a “Kilowatt Sensor output. For example, if the generator
Shorted Low Diagnostic.” has a rated output of 1700 ekW, the
maximum output is 1870 ekW.
Selecting a transducer When the generator's output is
For accurate power measurement, 1870 ekW, the kW transducer will
kW transducers must measure the provide a signal of approximately
power in each branch of the circuit, 4.8 VDC. In addition, the kW
which depending on the load transducer output voltage at 100%
requires either a two or three of the generator’s rated output
element kW transducer. The kW needs to be no less than 4.0V. For
transducer provides the following many packages a kW transducer
measuring function: with an output voltage range of
Power (Two Element, Three-Phase, 0-10VDC is used to meets the 4.0V
Three-Wire) = VL-N x I x 1.732 x pf minimum output voltage required by
Power (Three Element, Three- the ECM. PT’s and CT’s should be
Phase, Four-Wire) = VL-L x I x 3 x pf sized so the output voltage does not
exceed 4.8V at 110% of the
Applications with three-phase,
generator’s rated output even
four-wire power, which utilize line-
though the kW transducer has a 10V
to-line and line-to-neutral loads that
range.
could produce unbalanced loading,
require a three-element kW
KW Transducer output Voltage at 100% Rated Genset output:
PT ( ratio) × CT ( ratio) × (transducer full scale Watts )

= Ratio of Tranducer Output ’
Genset Rated Output Power
(Transducer Full Output Voltage)

= Transducer Output Voltage @ Full Rated Genset Power
Ratio of Transducer Output
Example:
PT ratio = 14,400:120 CT ratio = 200:5
120( PT ratio) × 40 (CT ratio) ×1000(transducer full scale Watts )

= 2.336 ( Ratio of Tranducer Output )
2055000 (Genset Rated Output Power in Watts )
10V (Transducer Full Output Voltage)

= 4.281 (Transducer Output @ Full Rated Genset Power )
2.336 ( Ratio of Transducer Output )
KW Transducer output Voltage at 110% Rated Genset output:
PT ( ratio) × CT ( ratio) × (transducer full scale Watts )

= Ratio of Tranducer Output
Genset Rated Output Power * 1.10
(Transducer Full Output Voltage)

= Transducer Output Voltage @ Full Rated Genset Power
Ratio of Transducer Output
Example:
PT ratio = 14,400:120 CT ratio = 200:5
120( PT ratio) × 40 (CT ratio) ×1000(transducer full scale Watts )

= 2.123 ( Ratio of Tranducer Output )
2055000 (Genset Rated Output Power in Watts ) * 1.10
10V (Transducer Full Output Voltage)

= 4.709 (Transducer Output @ Full Rated Genset Power )
2.123 ( Ratio of Transducer Output )
Selecting Potential Transformers small that it can generally be

(PT’s) ignored). A CT is most accurate at
PT’s are precision transformers rated current with a low burden
that step the voltage down to a (load). Accuracy decreases with
voltage range that is suitable to the increased burden (load) or low line
kW transducer input. The kW current. In sizing CT's the conductor
transducers are self-powered and size and distance is important.
have a specific input voltage range Improper sizing of current
that needs to be met to guarantee transformers or long secondary
performance. PT’s should be conductor runs with undersized
selected so that the secondary cable can result in poor accuracy.
voltage does not drop below the The burden can be expressed in
minimum input requirement of the volt-amperes:
kW transducer during load VA = I2 x Z
transients. A two-element watt
transducer monitoring a three-phase, Z = Total CT secondary
three-wire load are rated for line-to- impedance
line voltage and a three-element I = 5A
watt transducer monitoring a three- Sizing CT’s Example:
phase, four-wire load is rated for
If the peak load is 500 kW, the
line-to-neutral voltage. Any load
peak current on a 480V three-phase
connected to the PT including the
system would be:
kW transducer have an associated
burden on the PT, therefore care 500,000 / (480 x 1.73 x 0.9 pf) =
should be taken not to exceed the 669 amps
transformer burden rating. This assumes a 0.9 power factor.
Selecting and Sizing Current (Peak current would be higher with a
Transformers (CT’s) lower power factor.) Since the CT
The kW transducers supplied by should be about 10% to 20% larger
Caterpillar have a current input range than the calculated current and
of 0-5A, and therefore CT’s should 800:5 CT would be a good
be selected so that the maximum selection.
secondary current of the CT does Caution: Current transformers can
not exceed 5A. Connect the loads and will develop a lethal voltage and
on current transformers in series possibly self-destruct if the
being careful not to exceed the secondary is open when the primary
burden rating. The total burden is current is present. Never disconnect
the sum of the transducer, the secondary or leave it open when
interconnecting leads (calculated by there is the possibility of primary
using the below formula. Use current.
conductor resistance (total to the
device and back), and internal
burden of CT windings (usually so
Watt Transducer Location and CDVR Initial Settings (G3520C)

Wiring Guidelines The Caterpillar Digital Voltage
The kW transducer should be Regulator (CDVR) is a
mounted near the CT’s and PT’s for microprocessor based voltage
accurate power measurement. In regulator. The main purpose of a
addition it is strongly recommended digital voltage regulator is to
that the output signal of the kW regulate the output voltage of a
transducer be a Shielded Twisted generator that is used with an
Pair Cable of 22 Gauge or larger engine generator set. The following
wire to connect the transducer section lists the parameter default
output to the engine. The shield of settings that have been found to be
the transducer output cable should stable in most cases, however they
be grounded at the receiving end are far from optimal and should be
only (ECM). In addition it is used as a base line and to just get
recommended that the shielded the system functioning.
twisted pair output cable be kept as
short as possible and should not
exceed 100ft due to the
susceptibility of noise onto the
system. For applications in noisy
environments the following things
can be done to help improve signal
quality.
• Connect a 0.01mfd, 200 volt
capacitor between the
negative terminal and case
• Ground the case
CDVR Parameter Settings

o System Configuration
• Rated Voltage (90 – 15,000V) 120V default
• Rated Current (1 – 9,999A) 600A default
• Frequency (Sensing 50 or 60Hz) 60Hz default
• PT Primary (90 – 15,000V) 120V default
• PT Secondary (90 – 600V) 120V default
• CT Primary (1 – 9,999A) 600A default
• Power Input Freq (50 – 400Hz) 60Hz default
• Sensing Mode (1F or 3 F) 3 F default
o Settings
• Setpoint
o AVR Voltage (limited by Volt Adj Band) 120V default
o VAR (% of rated, +/- 100%) 0% default
o Power Factor (+/- 0.6) 1.0 default
o AVR Voltage Control (CAN / Switch) CAN default
o VAR/PF Control (CAN / Switch) Switch default
o Load Compensation Mode (Off, Droop, LDC) Off default
o Load Comp Setpoint (0 to +/-10%) 0% default
o Voltage Adjustment Band (0 to +/- 15%) 15% default
o Settings
• Startup
o Soft Start Mode
Soft Start Bias (0 – 90%) 10% default
Soft Start Time (0 – 120s) 5s default
o Under Frequency Mode
Knee Frequency (45 – 64Hz) 50Hz default
Freq. Dev. From Knee Freq.(5Hz - fixed)
Slope #1 and #2 (0 – 10Hz) 2Hz default for both
Min Voltage (50 – 100%) 50% default
Min Frequency (20 – 40Hz) 25Hz default
o Settings
• Control Gain
o PID Pre-Settings
1 – 20 pre-programmed, 1 custom PID settings
PID Calculator
o AVR
Kp, Ki, Kd (0 – 1000) 200/600/50 defaults
Td (0 – 1s) 0 default
Kg (0 – 1000) 50 default
o VAR/PF
Ki, Kg (1 – 1000) 5/2.5 & 5/3 defaults
o PID Gains
• PID Calculator
o T’do & Te required (2.0 & 0.33s defaults

o Adjust Kg to achieve desired response
• Good generic values: PID = 80,20,10 then adj Kg as needed
• var / PF Integral and Loop Gain Settings
o Use factory defaults as a staring point
o Increase Kg to increase speed of response
(suggest keeping it slow)
o Increase Ki if var/PF regulation not acceptable
o Protection
• Shutdown Override (Enable to override shutdowns)
Disabled is default value
o Function not affected:
Gen. Overvoltage
Gen. Undervoltage
Reverse VAR
Fault Reset too long
o Cannot be saved in EEPROM – Cycling power causes function
to become disabled on power up
• Generator Overvoltage (105 – 135%, 2 – 30s, 135%, 2s default)
• Generator Undervoltage (60 – 95%, 10 – 120s, 60%, 30s default)
• Over Excitation – Threshold is default (0 – 12A, 0 – 10s, 12A
& 10s default)
• Over Excitation – Inv Time(0 – 12A, TD = 0 – 10, 12A
& TD = 10 default)
• Reverse VAR (10 – 100%, 0.1 – 9.9s, 10% & 3s to be defaults soon)
• Fault Reset Too Long
• Exciter Diode Monitor (1 – 10A, 2A default)
• Loss Of Sensing (0 – 25s, 2A default)
o Settings
• Metering
o Gen Voltage
o Gen Current
o Gen Freq
o Gen Power
o Aux DC Input
o Exciter Field
o Operating Mode
o Fine Adjustment
o Setpoint
o Status
o Alarms
o Contact Inputs
Start/Stop Control factory. To accommodate unique

The ECM contains the logic and applications and sites, many of the
outputs for control of engine starting parameters may be reprogrammed
and shutdown. The customer with the Cat ET service tool. The
programmable logic responds to screens of the Cat ET provide
signals from the engine control guidance for the changing of trip
switch, emergency stop switch, points. The Cat ET can be used to
remote start switch, data link and perform the following activities:
other inputs, and the ECM controls • Select the available
the starting motor, and the gas responses.
shutoff valve (GSOV) at the
• Program the level of
appropriate times.
monitoring.
Engine Monitoring and Protection
• Program delay times for each
The ECM monitors both the engine
response.
operation and the electronic system.
Any problems with the engine Service Publications listed in the
operation will cause the ECM to Reference Materials at the end of
generate an event code that can this section list default examples
either issue a warning or cause a for the values of the parameters,
shutdown, depending on the severity however, the values may vary.
of the condition. Problems with the The Cat ET service tool must be
electronic system produce a used to determine the programming
diagnostic code that can be for each specific engine.
processed using the Cat ET service
G3600 Engine Protection
tool.
System
Integrated Temperature Sensing
Module (ITSM) Advanced Digital Engine
The ITSM monitors the Management (ADEM) A3 Control
temperatures of the cylinder exhaust System
ports, the inlets of the turbocharger The Caterpillar Advanced Digital
turbines, and the outlets of the Engine Management (ADEM) A3
turbocharger turbines. system is specifically designed for
the G3600 Family of Caterpillar
If a temperature exceeds an Engines. The ADEM A3 electronic
acceptable range, the ITSM can controls integrate start/stop
initiate a warning or a shutdown.
controls, governing, engine
Both responses are available for all sensing/monitoring, air/fuel ratio
of the parameters. control, ignition timing and
Note: To initiate the responses, the detonation control into one
ITSM sends commands to the ECM comprehensive engine control
via the Cat Data Link. system for optimum performance
The default settings for the and reliability.
parameters are programmed at the
The ADEM A3 Control System • Gas Shutoff Valve (GSOV)

includes the following components: • Ignition system controlled by
• Electronic Control Module ECM
(ECM) and emergency stop • Detonation sensor for each
button in an engine mounted two cylinders
junction box
• Prelube system that includes
• Optional remote control panel solenoid and prelube pump
with a Machine Information
Display System (MIDS) • Electronically controlled
hydraulic actuators for fuel,
• Integrated Combustion air choke and exhaust bypass
Sensing Module (ICSM) (wastegate) (Hydrax)
G3600 ADEM A3 Control System
Figure 11
Electronic Control Module (ECM) • Start/stop control

The Electronic Control Module • Engine monitoring and
(ECM) controls most of the functions protection
of the engine. The module is an The ECM control parameters are all
environmentally sealed unit that is in preset at the factory with any site
an engine-mounted junction box. specific reprogramming done by
The ECM monitors various inputs Caterpillar service personnel during
from sensors in order to activate the commissioning process utilizing
relays, solenoids, etc. at the the Cat ET service tool. The
appropriate levels. The ECM following is a brief description of
supports the following five primary these five functions:
functions:
Governing of the Engine
• Governing of the engine The ECM monitors the actual
• Control of ignition engine speed, and calculates the
• Air/fuel ratio control difference between this and the
desired engine speed. The ECM then
adjusts the fuel flow by controlling The ECM provides extensive

the fuel actuator to maintain the diagnostics for the ignition system.
desired engine speed. The ECM also provides a switch for
The Hydrax actuator requires ignition timing in order to allow
proper oil pressure to function operation with alternate fuels that
reliably. Refer to service information require a timing offset.
listed in the Reference Material Levels of detonation can be
section for specifics. displayed by the MIDS on the
Optional Control Panel. Alternatively,
Control of Ignition
the “Cylinder X Detonation Level”
Each cylinder has an ignition
screen on the Cat ET service tool
transformer. To initiate combustion,
can also be used. The “X”
the ECM sends a pulse of
represents the cylinder number.
approximately 108 volts to the
primary coil of each ignition Air/Fuel Ratio Control
transformer at the appropriate time The ECM provides control of the
and for the appropriate duration. The air/fuel mixture for performance and
transformer increases the voltage, for efficiency at low emission levels
which creates a spark across the utilizing the fuel actuator, air choke
spark plug electrode. actuator, exhaust bypass actuator
The ECM provides variable ignition (wastegate), ICSM, thermocouples
timing that is sensitive to and combustion sensors. The
detonation. The detonation sensors system has five modes of operation
(one for each two adjacent for the air/fuel ratio:
cylinders) monitor the engine for • Start-up
excessive detonation and provide • No feedback
this data to the ECM. If detonation
• Exhaust port temperature
reaches an unacceptable level, the
ECM will retard the ignition timing of feedback
the affected cylinder or cylinders. If • Combustion feedback
retarding the timing does not limit • Prechamber calibration
the detonation to an acceptable
In each of these modes, the
level, the ECM will shut down the
air/fuel ratio is controlled by either
engine.
the air choke actuator or the
A normal engine shutdown is wastegate actuator, but only one
accomplished by shutting off the actuator operates at any time. Both
fuel supply. The ignition system of the actuators regulate air flow,
continues to operate until the engine and the active actuator is
is below 50 rpm. This allows the determined by the ability to provide
engine to consume the fuel that is the desired inlet manifold air
trapped between the shutoff valve pressure.
and the cylinder. The ignition system
The software is also programmed
is disabled for engine overspeed and
to correct the fuel flow according to
emergency stop shutdowns.
the temperature of the jacket water processed using the Cat ET service
and the engine speed. tool.
The modes of operation, their Optional Control Panel
relationship to the engine load and Figure 11 illustrates the optional
the transitions between the modes control panel that is available as part
are described in the Systems of the ADEM A3 system.
Operation documents listed in the
Reference Materials at the end of Optional Control Panel
this section. However, in general,
at loads less than 40 percent, the
air/fuel ratio is controlled by the air
choke actuator. The air choke
controls the flow of air during engine
start-up, and continues to control
the air flow during the increase of
engine speed and load, until it
becomes fully open. At this point,
the wastegate becomes the active
actuator.
Start/Stop Control
The ECM contains the logic and Figure 12
outputs for control of engine 1. Display for the Machine Information Display
prelubrication, starting, shutdown System (MIDS).
and postlube. The customer 30. Keypad for the MIDS.
programmable logic responds to 31. “EMERGENCY STOP” button.
signals from the engine control 32. “ENGINE ON” indicator.
switch, emergency stop switch, 33. “ACTIVE ALARM” indicator.
remote start switch, data link and 34. “ENGINE FAILURE” indicator.
other inputs, and the ECM controls 35. “MANUAL PRELUBE” switch and “PRELUBE
the prelube pump, the starting ACTIVE” indicator.
motor, and the gas shutoff valve 36. Mode control switch.
(GSOV) at the appropriate times. 37. “DESIRED SPEED” potentiometer.
Engine Monitoring and Protection Machine Information Display System
The ECM monitors both the engine (MIDS)
operation and the electronic system. The MIDS is a device which
Any problems with the engine enables the operator to monitor
operation will cause the ECM to engine operation. The MIDS receives
generate an event code that can information from the ECM and is
either issue a warning or cause a provided with a screen display and a
shutdown, depending on the severity keypad for operator interface;
of the condition. Problems with the however, the MIDS cannot be used
electronic system produce a for programming.
diagnostic code that can be
Integrated Combustion Sensing with the Cat ET service tool. The

Module (ICSM) screens of the Cat ET provide
The ICSM monitors the guidance for the changing of trip
temperatures of the cylinder exhaust points. The Cat ET can be used to
ports, the inlets of the turbocharger perform the following activities:
turbines, and the outlets of the • Select the available
turbocharger turbines. The ICSM responses.
also monitors the combustion
• Program the level of
sensors.
monitoring.
If a temperature exceeds an
acceptable range, the ICSM can • Program delay times for each
response.
initiate a warning or a shutdown.
Both responses are available for all Service Publications listed in the
of the parameters. Reference Materials at the end of
Note: To initiate the responses, the this section list default examples for
the values of the parameters,
ICSM sends commands to the ECM
via the Cat Data Link. however, the values may vary. The
Cat ET service tool must be used to
The default settings for the determine the programming for each
parameters are programmed at the specific engine.
factory. To accommodate unique
applications and sites, many of the
parameters may be reprogrammed
Useful Equations from the Island Mode Sizing

and Functionality
1.)
Genset Rated Output (in Watts )
Generator Amps per Phase =
3 × Generator Output Voltage
Example:
2055000 W Genset Rated Power
Generator Amps per Phase = = 95.15 Amps
3 × 12470 V
2.)
Phase Amps
Full Load CT Amps =
CT Ratio
Example:
95.15 ( Phase Amps )
Full Load CT Amps = = 2.378 (CT Full Output Amps )
40 (CT Ratio )
3.)
Generator Rated Voltage
Generator Volts per Phase =
3
Example:
12470 (Generator Rated Voltage)
Generator Volts per Phase = = 7199.8Volts per Phase
3
4.)
Volts per Phase
PT Output Voltage =
PT Ratio
Example
12470 (Volts per Phase )
PT Output Voltage = = 71.998Volts ( PT Full Output Volts )
100 ( PT Ratio)
Reference Material
The following information is
provided as an additional reference
to subjects discussed in this manual.
Operation and Maintenance
Manuals
Systems Operation Manuals
Installation and Initial Start-up
Procedures
Electrical System Schematics
LEBW4982-01 ©2008 Caterpillar® Printed in U.S.A.
All rights reserved.

Gas Control Systems & Ignition

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APPLICATION AND INSTALLATION GUIDE

GAS CONTROL SYSTEMS

Gas Control Systems & Ignition ............................................... 1

Information contained in this publication may be considered confidential.

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the

Gas Control Systems & Ignition

Ignition Systems ................. 2 Engine Control, Protection &

Caterpillar gas engines use a low Magneto Ignition System, currently

The CDIS uses a capacitor to store • Customer provided 12VDC or

Caterpillar Digital Ignition System (CDIS) Diagram for G3400 Engine

1. Spark Plug 4. CDIS Module

Electronic Ignition System (EIS)

The customer must provide the positive-pressure ventilation

The Caterpillar EIS system is misfiring cylinder is more of a

Engine Control, Protection and Monitoring Systems

engine configurations include Powered Shutoffs

modules and customer interface • Displays GSC programming

G3400 EMCP II Instrument Panel

Remote Control Panel (Status)

II+ also contains a generator set

Electronic Modular Control Panel

G3500 EMCP II+ Instrument Panel

1. Generator Set Control+ (GSC+) 7. Speed Potentiometer (SP) (Optional) or

Customer Supplied Shutoffs

Recommended Alarms and suggests various alarms and

Gas Engine Controls and Safety Devices

Advanced Digital Engine • Electronic Control Module

G3500 ADEM A3 Control System

The ECM monitors various inputs detonation. The detonation sensors

• Start-up charge, exhaust oxygen levels are a

of inlet manifold air temperature and

For standard G3500C and E Percentage" causes a large change

proportional to the power measured. transducer to accurately monitor the

KW Transducer output Voltage at 100% Rated Genset output:

PT ( ratio) × CT ( ratio) × (transducer full scale Watts )

(Transducer Full Output Voltage)

120( PT ratio) × 40 (CT ratio) ×1000(transducer full scale Watts )

10V (Transducer Full Output Voltage)

KW Transducer output Voltage at 110% Rated Genset output:

PT ( ratio) × CT ( ratio) × (transducer full scale Watts )

(Transducer Full Output Voltage)

120( PT ratio) × 40 (CT ratio) ×1000(transducer full scale Watts )

10V (Transducer Full Output Voltage)

Selecting Potential Transformers small that it can generally be

Watt Transducer Location and CDVR Initial Settings (G3520C)

CDVR Parameter Settings

o T’do & Te required (2.0 & 0.33s defaults

Start/Stop Control factory. To accommodate unique

The ADEM A3 Control System • Gas Shutoff Valve (GSOV)

G3600 ADEM A3 Control System

Electronic Control Module (ECM) • Start/stop control

adjusts the fuel flow by controlling The ECM provides extensive

Integrated Combustion Sensing with the Cat ET service tool. The

Useful Equations from the Island Mode Sizing

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