CATERPILLAR’ ee Systems Operation Connection Diagrams: SR4 and SR4B Generators, Voltage Regulators, Optionseee Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safely rules or precautions, An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. product can be dangerous and Improper operation, lubrication, maintenance or repair of t could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions end warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. ‘The hazards are identified by the “Safety Alert Symbol" and followed by a "Signal Word" such as “DANGER’, “WARNING* or “CAUTION”. The Safety Alert “WARNING” label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. ‘The message that appears under the warning explains the hazard and can be elther written or pictorially presented. Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication, Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings In this publication and on the product are, therefore, not all inclusive. If a tool, procedure, Work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the Product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. ‘The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written, The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can aifect the service that is given to the product, Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. When replacement parts are required for this product Caterpillar recommends using Caterpil- lar replacement parts or parts with equivalent specifications including, but not limited to, phys- ical dimensions, type, strength and material. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or deathTable of Contents Systems Operation Section ‘SR4 and SR4B Generators for All Engines Except SR4B for 3500 Engines General Information (All Except SR4B for 3500 Engines) ..... 4 Main Stator and Voltage Sensing Lead Connections (All Except SR4B for 3500 Engines)... 5 Main Revolving Field Connections (All Except SR4B for 3500 Engines) «nc... 9 Selection Guide for Voltage Flegulator (All Except ‘SR4B for 3500 Engines) .. VRS Voltage Regulator Connections (All Except SR4B for 3500 Engines)... 13 VRSF Voltage Regulator Connections (All Except 12 ‘SRAB for 3500 Engines) ....... 19 V4 Voltage Regulator Connect SRAB for 3500 Engines)... 22 Digital Voltage Regulator Gonnections (All Except SR4B for 3500 Engines) ... 24 Options (All Except SR4B for 3500 Engines) ...... 28 Oil Field Generator Connections (SR4) 40 SR4B Generators for 3500 Engines General Information (SR4B for 3500 Engines) ..... 41 Main Stator and Voltage Sensing Lead Connections (SR4B for 3500 Engines) ... 4 Main Revolving Field Connections (SRB for 300 Engines) . 43 Selection Guide for Voltage Regulator (oRaB ‘or ‘3500 Engines) VR8 Voltage Reg) Engines) .. VR3F Voltage Regulator Connections (SA4B for ‘3500 Engines) ... 48 Digital Voltage Regulator Connections (SR4B for 3500 Engines)... 52 Options (SR4B for 3500 Engines) . 54 Generator Wring Diagrams (SRAB Engines) «ornare .. 67 Index Section Index . 3 Table of Contents4 Systems Operation Section _ Systems Operation Section SR4 and SR4B Generators for All Engines Except SR4B for 3500 Engines ioverseze General Information (All Except SR4B for 3500 Engines) SMCS Code: 4450 Introduction The diagrams that follow apply to the SRa Generators and the SR4B Generators (except for the SR4B used with 3500 Engines). Note: Diagrams for the SR4B used with 3500 Engines appear later in this manual5 Systems Operation Section ‘arave0s Main Stator and Voltage Sensing Lead Connections (All Except SR4B for 3500 Engines) SMCS Code: 4453 12 Lead, Wye and Delta Connection "% "4 Tap Qt 77 Tig) TH 181512 19 14 7 15 17 19, % A \.. 13 = xr T= ets T2 WYE CONNECTION Bd frame] go " ee ee tor [oun cam) aim (ATER) v0 ae [0 ws mnt | Gam gary gery | DELTA COMECTION ae] , FF wae oak iw Be A Eee CC lusteation + wonro0se26 Systems Operation Section 10 Lead Wye Connection WYE CONNECTION REGULATOR SENSING 7 “LEADS uu vourace | _u v 13 Ww TIE TOETHER vio | 1 12 (rut7)_(72.78)_ (73.19) | 18 (14,15,16.T0) 70 (14,77) (15.18) (76.79) | istration 2 o0700504 6 Lead Wye Connection " REGULATOR ye) [Pa GEN +) “SENSING see LEADS " ¢ noe: WYE CONNECTION REGULATOR SENSING TT LEADS MAY ‘NOT BE uo ob N INSTALLED. ON MEDIUM u v w ‘VOLTAGE. GENERATORS ESC CES (14,75. 76) Hustration 37 Systems Operation Section 6 Lead Delta Connection Ayn 16 \ REGULATOR ‘SENSING 13 Ji LEADS REGULATOR DELTA CONNECTION EGULATO nore L REGULATOR. SENSING u ir LEADS MAY NOT BE INSTALLED ON MEDIUM yu v VOLTAGE GENERATORS (r78) (12,14) (13.15) Bom 12 Mustration 4 ‘00700828 4 Lead Wye Connection ng Ta_GEN > "SENSING 7 “teas 3 \f 20" ce re wre CONNECTION REGULATOR SENSING ————— LEADS MAY NOT BE uous INSTALLED ON MEDIUM VOLTAGE GENERATORS Mlustration 58 Systems Operation Section 12 Lead, Single Phase Connection u 1) aT) 10 7 GENERATOR CONNECTION cE ; (12.18) (1117) (rate.ti0.t12) | (13,15,19,1) NOTE: FOR PARALLEL OPERATION, T8 LEAD GOES THROUGH WINDOW OF DROOP TRANSFORMER WITH VR-3 VOLTAGE REGULATOR, CONNECT JUMPER WIRE BETWEEN VOLTAGE REGULATOR TERMINALS 20 AND 26. WITH VR-4 VOLTAGE REGULATOR, JUMPER WIRE IS NOT REQUIRED. IMustration 6 nTOORST9 Systems Operation Section iorsao192 Main Revolving Field Connections (All Except SR4B for 3500 Engines) SMCS Code: 4457 Diode Block LS REVOLVING FIELD CRI~§ RECTIFIERS. U2 EXCITER ARMATURE GR7 SURGE SUPPRESSOR Mustration 7 Diode Block and Surge Suppressor L3 REVOLVING FIELD CRI-8 RECTIFIERS U2 EXCITER ARMATURE CRI. SURGE SUPPRESSOR ‘orate IWustration 810 Systems Operation Section Two Diode Blocks and Surge Suppressor oRa—6 L2EXITER ARMATURE CRI-6 RECTIFIERS L3 REVOLVING FIELD ORB SURGE SUPPRESSOR Rl STATIC. DISCHARGE RESISTOR nonsso? Mstration @ Three Diode Blocks and Surge Suppressor CRI-6, RECTIFIERS L3 REVOLVING FIELD GR7_SURGE SUPPRESSOR LZ EXCITER ARMATURE RI STATIC DISCHARGE RESISTOR tustration 1014 _ Systems Operation Section Six Diodes and Two Surge Suppressors L3 REVOLVING FIELD ont-§ Rectariees (2 EXCITER ARMATURE CRT. SURGE SUPPRESSOR HS HEATSINK RI STATIC DISCHARGE RESISTOR Mustration 11 oo7ass9212 Systems Operation Section Selection Guide for Voltage Regulator (All Except SR4B for 3500 Engines) SMCS Code: 4467 C sevtiror r [ N\@ | NOTE: VOLTAGES SHOWN ARE 60. He EQUIVALENTS. Wustration 12 goov0sest13 Systems Operation Section VR3 Voltage Regulator Connections (All Except SR4B for 3500 Engines) SMCS Code: 4467 Self Excited with Direct Conneci to Generator 8 of 12 sm} . on —— ae oa 310 of (6 Gen + r PP revere eve, PeeenerAtl reove ini 7) FROM 1 scion - : 7] 000 73S / > \ (cece \ vever carn / ves RESULATOR 20 GEN ol RK-R-2_ P- —| SENSING 24 Gen} |} ey aca-i_} LEADS —~ = Aut 7 wee ne Oo 0 o0o00 Newey 9 9 POO 2 2 A | u —_ Note Fa} —____________ DROOP TRANSFORMER CT1 AND DROOP RHEOSTAT RI MAY OR MAY NOT BE SUPPLIED Li EXCITER FIELD Tt DROOP TRANSFORMER Hy BRS tits 2 1 ReaOe CEE hveosrar err, sens povarity hlustration 13 ‘90070900014 Systems Operation Section Self Excited with Power Transformer 4/6 Lead Generator Mustration 14 TB oR 12 23 RaSe 10K OFM REMOTE LEVEL TF INSTALLED | (ReMove’ LINK 4-7) GENERATOR REGULATOR | ‘SENSING LEADS ¥ 20,- | 20_GEN|— L_KTEAR=12_| t | op ace} ats err | 2 22 24 6 28 30 FI FZ | 0 : eae _| Po? NOTE: DROOP TRANSFORMER CT! AND DROOP RHEOSTAT RI MAY OR MAY NOT BE SUPPLIED Li EXCITER FIELD RY DROOP RHEOSTAT R2 REMOTE LEVEL RHEOSTAT CTt DROP TRANSFORMER P12 POWER TRANSFORMER O TERMINAL NUMBERS WiRE_ NUMBERS pe POLARITY ‘oa7oso0815 _ Systems Operation Section Self Excited with Power and Sensing Isolation Transformer re on 12 ° er} ong =n nye ow voK on Cha —6 cen! - — “— ewore_ueveL eeegnerat eb (pelle NK 2) nou { centtTon Hit __ eouaTon ; Be ‘SENSING 99000000 J LEADS: 345 67 8 ao (20 ) ee VRS REGULATOR 20-22 24 26 28 30 Fl F2 2990009090 +—{F uf Fa NOTE: DROOP TRANSFORNER CTI AND OROOP RHEOSTAT RI MAY OR MAY NOT BE SUPPLIED Ht DROP TRANsroRuER UE ENCOTER FIELD Sty Poe Tener Oru BL DROOR RHEOSTAL a PrSpra" SENSING. TRANGFORUER TSOL ISOLATION TRANSFORMER © TERMINAL NUMBERS wire NUMBERS i POLARITY Iustration 15 ‘ooTaa@i16 Systems Operation Section Permanent Magnet Excitation with ect Connection to Generator 18 OR 12 ——[5 Gen }-———9— cn a 2 Son on REWOTE LEVEL {fF INSTALLED (REMOVE LINK 4~7) Frou GENERATOR Lever caIN / VR3_REGULATOR REGULATOR 7 20_ GENT 1 + SENSING << Br Fuses LEADS 2a cen KTK-R-2_ 20 22 24 26 28 30 FL FZ _ oeooo 22 GEN} + - t fii GEN} {ABC-10} | us ~ ~ fGen} {i3_cen—{ABC-10} —[13} FUSES * {ey}-__________. u £ a NOTE: F2 OO BE SUPPLIED Lt EXCITER FIELD LS PAL EXCITER STATOR RT DROOP_RHEOSTAT R2 REMOTE LEVEL RHEOSTAT itustration 16 DROOP TRANSFORMER CTT AND DROOP RHEOSTAT RI MAY OR MAY NOT CT1_DROOP TRANSFORNER © TERMINAL NUMBERS D WIRE NUMBERS POLARITY spoToT0867 Systems Operation Section Permanent Magnet Excitation with Connections to Metering Potential Transformers i mee) 10K OFM cn ! REMOTE LeveL IF INSTALLED (ReMiove LINC 4-7) FROM | ee GENERATOR se] ) LeveL om) REGULATOR SENSING , 29 ne REUATOR CONNECT To 120 voLT aeRO SECONARY. METERING POTENTATL TRANSFORNER 24 Fuses CONNECT 22 TO PT ON GEN T1 —C[arecre2 CONNECT 24 TO PT ON GEN 2 < CONNECT 20 TO PT ON GEN 13 poraiomelestonrinre PHASE RELATION WITH ROOE Rano C1 PE PELPOD 1S TMPORTANT L I t rey} ] | us el ¢ ® {cen _fec-0} {5} L FUSES ei uf 7] — NoTE: - DROOP TRANSFORWER CTI AND DROOP RHEOSTAT RI MAY OR MAY NOT BE SUPPLIED PT (CUSTOMER) METERING POTENIAL Lt EXCITER FIELD US PM excrTéR stator TRANSFORMER Rt DROOP_RHEOSTAT C11 DROOP TRANSFORNER R2 REMOTE LEVEL RHEOSTAT © TERMINAL NUMBERS WIRE NUMBERS 1 POLARITY ‘900707080, Iustration 1718 Systems Operation Section Permanent Magnet Excitation with Connections to an Isolation Transformer 18 OR 12 3 GEN yg cn 81 S48 on 1) REMOTE LEVEL © GEN ee 1b OF INSTALLED { 1 | (weMove LINK 4-7) FROM GENER REGULATOR 9900 99 OM GENERATOR ASENSING 2345 can) 7 “Leas ame \ amp (2 @ \ \ LEVEL GAIN VRS REGULATOR 207-2 u Fuses otic b>} 20 22 26 26 28 30 FI FR C oO ° oO ° 9 Pr fir Gen -[aB0-19 ub 2 EN | 13 GEN {abe 1 = | FUSES + Ah - u —_ wore a DROOP TRANSFORMER CT1 AND OROOP RHEOSTAT RI MAY OR MAY NOT BE SUPPLIED Li EXCITER FIELD C11 DROOP_ TRANSFORMER LS PAL EXCITER STATOR F123 SENSING. TRANSFORMER Ri DROP. RHEOSTAT 1S0L ISOLATION TRANSFORMER R2 REMOTE LEVEL RHEOSTAT otreruma Niners wire NuMBERS MH Potarrry IWustration 18iovarseas VRSF Voltage Regulator Connections (All Except SR4B for 3500 Engines) SMCS Code: 4467 Knee Frequency and Underfrequency Selection OTE EE SIAL swe FOR 60 HE OFERATIN,RENOWE 19 ‘Systems Operation Section Dat W7at IMBERTOUENEY LOE IMustration 19 The physical differences between the VAS and the VRSF are minor. The hole for Gain adjustment is eliminated and another terminal is added to the upper row (terminal 10) on the VR3F. All VRGF connections to the generator or external options are identical to the VR3. The additional wiring for the VR3F is shown in the previous diagram The following information is applicable to both VRGF designs: Self-Excited and Permanent Magnet Excited. © In order to determine the knee frequency, install a jumper from terminal 6 to terminal 10 on the regulator if the generator is operating at 60 Hz. If the generator is operating at 50 Hz, remove the jumper. ‘ones ® In order to determine the underfrequency slope selection, install a jumper from terminal 6 to terminal 8 on the regulator if a 1:1 Volts/Hertz undertrequency slope is desired. remove the jumper If a 2:1 VoltsiHertz underfrequency slope is needed20 Systems Operation Section Typical Permanent Magnet Excited VR3F NOTE 1 DROOP TRANSFORMER AND DROP RHEOSTAT WAY OR MAY NOT BE SUPPLIED Rh 10K OHM REMOTE LEVEL IF FITTED (REMOTE LINK 4-7) | seuoye tp a \ 8-10 FOR Bae ¢ 3 ‘yo | Copa (cen! za 23 8B $ 10] OPERATION by} veer ey 3 ott Bi reyore, une rl| f oa ae i} ely Pf ip i ali dare s a We 9 xq - ween we Or & ays i ——I 5 1s pu exert stator 1 AStARS PeaMuMEN, wae CRI-G ROTATING RECTIFIERS Rt VOLTAGE DROOP RHEOSTAT (SEE NOTE 1) Gd SAGE SRR Sones nl cane mines EiiPOstTIvERneATASINe) RS SUPPRESSION RESISTOR Es mente er a Li EXCITER FIELD (STATOR) RFA REVOLVING FIELD ASS'Y U2 EXCITER ARMATURE (ROTOR) TI VOLTAGE DROOP TRANSFORMER (SEE NOTE 1) L3 ROTATING FIELD (MAIN ROTOR) PT2 POWER TRANSFORMER ASSEMBLY L4 STATOR (MAIN STATOR) © TERMINAL BOARD NUMBER wr ours wasn Swine nneer SF cenenTOR SGRGUTIE (7 LEAD PENT AAGVET ENGTTED Ww @ Pu FIRES Note! GEEEATON STATOR LEa05 TeRUNaLs TT, 0 TS ON. BE comcrEO TS SA Me Hebd Ue ool steko eek wore llustration 2021 Systems Operation Section Typical Self Excited VR3F NOTE DROOP TRANSFORMER AND DROOP RHEOSTAT MAY OR MAY NOT BE SUPPLIED eg 1K on | REMOTE LeveL ie FITTED (REMOTE LINK 4-7) 5-10 FOR 50 HZ 10 | oPERaTIon | } eewove an REMOVE LINK 5-8 FOR | 2x vane | SLOPE 20 FUSE — KTKR-12 - Krk R12 | 20 22 24 26 28 30 FI F2 {2} — ~ er | 20y24 ae 3 3p | i d fe] i ' Som TK=R=12 i CRI-6 ROTATING RECTIF ERS RI VOLTAGE OROOP RHEOSTAT (SEE NOTE 1) GR7B SURGE SUPPRESSION DIODES R2 REMOTE LEVEL RHEOSTAT £1 POSITIVE HEAT SINK AS. SUPPRESSION RESISTOR £2 NEGATIVE HEAT SIN RFA REVOLVING FIELD ASS'Y es T1_VOLTAGE DROOP TRANSFORMER (SEE NOTE 1) U3 ROTATING FELD PT2 POWER TRANSFORWER.ASSEWBLY Ls STATOR © TERMINAL “BOARD NUMBER ia SPOUREITY warKine CL_Wike nuuper SR-4 GENERATOR SCHEMATIC (4/6 LEAD. SELF-EXCITED W/POWER TRANSFORWER) nore: GENERATOR STATOR LEADS TERMINALS T4, 15, AND T6 WILL BE INTERNALLY CONNECTED TO FORM THE NEUTRAL LEAD’ (TO) ON FOUR LEAD GENERATORS. Mustration 21 ‘coreaor222 Systems Operation Section VR4 Voltage Regulator : Connections (All Except SR4B for 3500 Engines) SMCS Code: 4467 Self Excited with Direct Connection to Generator REGULATOR SENSING LEADS u R2 REMOTE LEVEL RHEOSTAT = LY EXCITER FIELD © rerwinat Co wire nuwaer lustration 22 Om] i VRE REGULATOR & Quo 7 | REMOTE LEVEL 10k om [ __ 4 TE INSTALLED (REMOVE “LINK 4~7) ‘007021823 Systems Operation Section iorssace Digital Voltage Regulator Connections (All Except SR4B for 3500 Engines) SMCS Code: 446724 Systems Operation Section 10/12 Lead with Direct Connection to Generator NOTE & GENERATOR STATOR LEADS 110, TH, & 712 WILL BE INTERNALLY CONNECTED ON 10 LEAD GENERATORS TO FORM ONE LEAD, TO. RI 8 OHM NOTE 2: NEAT SINK FOR 1A CT NEEDS TO BE 1 on EARTH GROUNDED FOR 5A CT (see nove 4) || 6 a a) a CRI-6 ROTATING RECTIFIERS CR7,8 SURGE SUPPRESSION DIODES E1 POSITIVE HEAT SINK £2 NEGATIVE HEAT SINK Li EXCITOR FIELD (STATOR) L2 EXCITER ARMATURE(ROTOR) L3 REVOLVING FIELD(MAIN ROTOR) La MAIN STATOR LS PM EXCITOR STATOR NOTE 3: DROOP TRANSFORMER AND DROOP BURDEN RESISTOR MAY OR MAY NOT BE SUPPLIED {iS Pus [ew FUSE M ROTATING PERMANENT MAGNET Ri VOLTAGE DROOP BURDEN RESISTOR (SEE NOTE 3) RS SUPRESSION RESISTOR RFA REVOLVING FIELD ASS’Y Tl VOLTAGE DROOP TRANSFORMER (SEE NOTE 3) OQ WIRE NUNBER © TERMINAL BOARD NUMBER POLARITY MARKING NOTE 4: RI TO BE MOUNTED WITHIN 3 METERS (10 FEET) OF THE REGULATOR Iustration 23 (p006 3657625 Systems Operation Section 10/12 Lead with Sensing Isolation Transformer NOTE t GENERATOR STATOR LEADS TIO, Tit, & TI2, WILL BE INTERNALLY CONNECTED ON 10 LEAD GENERATORS TO FORM ONE LEAD, To. Rt eae NOTE 2° HEAT SINK FoR ta or NEEDS “TO BE 1 on EARTH GROUNDED FOR 5A CT (SEE NOTE 4) ORI-6 ROTATING RECTIFIERS CR7.8 SURGE SUPPRESSION DIODES El POSITIVE HEAT SINK E2 NEGATIVE HEAT SINK Li EXCITOR FIELD (STATOR) L2 EXCITER ARMATURE(ROTOR) L3 REVOLVING FIELD(MAIN ROTOR) La MAIN STATOR LS PM EXCITOR STATOR NOTE DROOP TRANSFORMER AND DROOP BURDEN RESTSTOR MAY OR MAY NOT BE SUPPLIED fis Pua Pa Fase] M ROTATING PERMANENT MAGNET Ri VOLTAGE DROOP BURDEN RESISTOR (SEE NOTE 3) R5 SUPRESSION RESISTOR RFA REVOLVING FIELD ASS‘Y T) VOLTAGE DROOP TRANSFORMER (SEE NOTE 3) PT2, PTS SENSING ISOLATION TRANSFORMERS WIRE NUMBER © TERMINAL BOARO NUMBER HM POLARITY MARKING NOTE 4: 81 10 BE MOUNTED WITHIN 3 METERS (10 FEET) OF THE REGULATOR Mustration 24 "90085952026 Systems Operation Section 4/6 Lead with Direct Connection to Generator NOTE 1: GENERATOR STATOR LEADS T4, 15, & 16 WILL BE CONNECTED ON 4 LEAD GENERATORS TO FORM ONE LEAD, TO. RI 8 onW on a cr NOTE 2: HEAT SINK NEEDS TO BE FoR 5A cT EARTH GROUNDED (SEE NOTE 4) {is Pus} pa Fuse| rican erntot Piooes Bes ae aE T1 VOLTAGE DROOP TRANSFORMER (SEE NOTE 3) L2 EXCITER ARMATURE(ROTOR) L3 REVOLVING FIELD(MAIN ROTOR) Q TERMINAL BOARD NUMBER NOTE 4: RI TO BE MOUNTED WITHIN 3 METERS (10 FEET) OF THE REGULATOR Iustration 25 ‘9005364044/6 Lead with Sensing Isolation Transformer 27 ‘Systems Operation Section RI 8 ow NOTE 1b HEAT SINK poe NEEDS To BE 1M or EARTH GROUNDED (SEE NOTE 3) CRI-6 ROTATING RECTIFIERS CR7,8 SURGE SUPPRESSION DIODES El POSITIVE HEAT SINK £2 NEGATIVE HEAT SINK L2 EXCITER ARWATURE(ROTOR) L3 REVOLVING FIELO(MAIN ROTOR) L4 MAIN STATOR NOTE 2: DROOP TRANSFORMER AND DROOP BURDEN RESISTOR MAY OR MAY NOT BE SUPPLIED ustration 26 (ery [parse] PT2, PT3 SENSING/ISOLATION TRANSFORMERS M ROTATING PERMANENT MAGNET Ri VOLTAGE DROOP BURDEN RESISTOR (SEE NOTE 2) 5 SUPRESSION RESISTOR RFA REVOLVING FIELO ASS’Y T1 VOLTAGE DRODP TRANSFORMER (SEE NOTE 2) Q WIRE NUMBER O TERMINAL BOARD NUMBER POLARITY MARKING NOTE 3: R1 TO BE MOUNTED WITHIN 3 METERS (10 FEET) OF THE REGULATOR ‘90089800528 Systems Operation Section Options (All Except SR4B for 3500 Engines) SMCS Code: 4450 Manual Control with Self Excitation VRS REGULATOR Seu aw] teaps ieakcena 9 ooo a u BOOST MODULE IF INSTALLED F2 F125 24 46 45 44 43 42 41 21 20 MANUAL CONTROL (© TERMINAL NUMBERS WIRE NUMBERS: Li EXCITER FIELD Itustation 27 eoorae0r7Manual Control with Power 29 Systems Operation Section Transformer REGULATOR SENSING LEADS [z0_cew 7 [zee = 72 GEN t [22 cen} wy o VRS REGULATOR 7 “Sot - 20 24 31 30 err L i—{Fi cen} ~ | u — 7 © {ra cen —{[ ft To series Des —_ ] Bo0ST MODULE IF INSTALLED 5 U1 EXCITER FIELD PTI POWER TRANSFORMER © TERMINAL NUMBERS 1 WaRE NuwBeRs Mustration 28 ores30 Systems Operation Section Manual Control with Permanent Magnet Exciter u Iustraton 22 REGULATOR. VR3_ REGULATOR (Fr cen F2_ GEN Lt EXCITER FIELD LS PM STATOR 6 eo 0090000 7654321 MANUAL CONTROL (© TERMINAL NUMBERS 1 WIRE NUMBERS oo7ne7ss31 Systems Operation Section Radio Interference Filter ( wom [20 20 > 20 GEN > ot} —fao] | SENSING S © 22 = 22 fro, [2 cen}—+O & FI 3 6 22] > wey GENERATOR | Fl s cS REGULATOR 8 2 | 24 24 24 GEN |} —+-O ot —_faa] / RFI RADIO INTERFERENCE SUPPRESSOR iustration 30 0070385732 Systems Operation Section Series Boost with VR3 Voltage Regulator : VRS. REGULATOR or 20 GW b—— REGULATOR ae SENSING Gren FUSES Leans KTR-R-1 22 GEN 20 22 24 26 28 30 FI F2 Fppeeere | =I} F2 ser |} [-O ES + 7 ; | 1 Lt : 0000000060 23456789 SERIES G00sT MODULE Note REMOVE LINK 6-7 FOR 50 HZ OPERATION L1_ EXCITER FIELD © TERMINAL NUMBERS SBT SERIES BOOST TRANSFORUER Co wire Noupers lustration 31 ‘goo7a202733 _ Systems Operation Section Series Boost with VR4 Voltage Regulator Fuse (Doan | 20 GEN | fp - RecuATOR VR& REGULATOR SENSING <- LEADS Queer | 6 7 fF ofp090 to | uf —r - cos £ on - sat Os £2 cet F C QO TUTTE TED SERIES BOOST MODULE NOTE: REMOVE LINK 6-7 FOR 50 HZ OPERATION Lt EXCITER FIELD © TERMINAL NUMBERS SBT SERIES BOOST TRANSFORMER wire wuuaers IMustration 32 0070208634 ‘Systems Operation Section Manual Control and Series Boost with Self Excitor SBT NOTE: - VR3 VOLTAGE REGULATOR io KTK-R=12 SME Oa a ras 22 EN 20 22 24 26 2B 30 FI F2 99000006 Ba FT eas mmc | 566 606000000686 oO 23456789 SERIES BOOST MODULE REMOVE LINK 6-7 FOR 50 HZ OPERATION Lt EXCITER FIELD SBT SERIES BOOST TRANSFORMER F2 F125 24 46 45 44 43 42.41 71 MANUAL CONTROL 0 TERMINAL NUMBERS WIRE NuMBERS IMustration 3335 ‘Systems Operation Section Remote Voltage Adjust Rheostat Connections CONNECTION WHEN REMOTE VOLTAGE CONNECTION WITH NO REMOTE ADJUST RHEOSTAT IS PROVIDED VOLTAGE ADJUST RHEOSTAT Mustration 34 Ci)36 Systems Operation Section Digital Voltage Regulator with Manual Control MANUAL CONTROL Ge Bu FORE] Ee Fuser i Mustration 35 oe37 ‘Systems Operation Section Digital Voltage Regulator with Remote Voltage Adjust Rheostat wore F igh ap res te ea SUARs eee ESS i See Be Mustration 38 Gua)38 Systems Operation Section Digital Voltage Regulator Customer Options FAULT sHurpawn ourrur oRIVER 20st} 24 VOLT ome MAX Load) ALARM ouTeUT DRIVER 2 vour domA WAX LoA0| SISABLE —————»_4 FAULT RESET at EN 52/0 ALK Conract Se uTauary. save UK ‘conTacT tJ note a. lkenore voLrace JaouusT ancostaT fo (aE , Sonus I wore a (Er TE} leewore er /xvan Jsowsr gutosrar Sons NOTE A: CONNECT SHIELD DRAIN WIRE(S) TO TERMINAL 45. INSULATE SHIELD DRAIN WIRE(S) AT RHEOSTAT END. DO NOT CONNECT SHIELD DRAIN WIRE(S) TO CHASSIS GROUND. ustration 37 ‘900539824Digital Voltage Regulator Remote Commu ns Connections 39 Systems Operation Section woo RS485 DEVICE TaANsaat (4) TRANSMIT (-1O F RECEIVE (+) No RECEIVE (-) a nore 8 |__coMMoNd SJ NOTE pezs ronneeron oa aszsz O couman REGULA Iustration 38 SUPPLY oO + 2 yoo TED POWER SREREAENG AEE APACER JI CONNECTOR IS LOCATED ON FRONT OF DVR NOTE A: NoTE 8 NOTE NOTE 0: POWER SUPPLYTOLERANGE IS +15/-S% AND WUST BE ABLE TO SUPPLY 100 WA MINIMUM. DATA CABLE SHIELDS SHOULD BE GROUNDED AT ONE END OF THE CABLE ONLY COMMON FOR THE R485 DEVICE ANDO THE REGULATED POWER SUPPLY MUST NOT BE CONNECTED TO THE GENERATOR NEUTRAL. RS4BS DATA IS NEEDED TO CONVERT R589 DATA TO R5232 FOR COMMUNICATIONS To custoMER Pc oR MopeW ‘qo0ea7az240 Systems Operation Section Oil Field Generator Connections (SR4) SMCS Code: 4450 ‘ovsaoaes Excitor Field Connection (Series or Parallel) and Voltage Sensing Leads | vourace | | REGULATOR | | (won cary | ~ SERIES : conver ION (14 OHM FIELD) * 46 VRS REGULATOR [ recurator 20 GEN 7] SENSING oa 1 mca Lee FUSES Paca 5 : 20 22 24.26 28 30 FF e g S ooo oO | fa fr € L—fo oS J Ur 1 te y - ; F3 a —B] =, t 2 ° fre agate. connec TION (3.5 OHM FIELD) lustation 3 snoTaeTSat Systems Operation Section SR4B Generators for 3500 Engines General Information (SR4B for 3500 Engines) SMCS Code: 4450 Introduction The Diagrams that follow apply to the SR4B Generators used with 3500 Engines. Note: Diagrams for the SR4 and other SR4B Generators appeat at the beginning of this manual iorsenssa Main Stator and Voltage Sensing Lead Connections (SR4B for 3500 Engines) SMCS Code: 4453 6 Lead Wye Connection YO uwQ 15. R c REGULATOR {24 GEN} SENSING — 7 LENDS " el zamees WYE CONNECTION wo W uoyvow Ts istration 40 poe722%42 Systems Operation Section 6 Lead Delta Connection 2 GEN 16 Lo REGULATOR SENSING mu LEADS [20 GEN - REGULATOR DELTA. connection ECULATO u uz is u v w 20 22 24 1) a) 3s) | BOT Lc - | " Mustraion 44 ‘e0070z20543 Systems Operation Section Main Revolving Field Connections (SR4B for 3500 Engines) SMCS Code: 4457 Two Diode Blocks and Surge Suppressor L2 EXITER ARMATURE CRI-6 RECTIFIERS U3 REVOLVING FiEl CRB SURGE SUPPRESSOR uD RY STATIC DISCHARGE RESISTOR Iustration 42 ‘go0e9sa0744 Systems Operation Section iossara1s Selection Guide for Voltage Regulator (SR4B for 3500 Engines) ‘SMCS Code: 4467 Selection Chart for SR4B Voltage Regulator RAB TYPE SELF EXCITED oF rT EXCITATION PERMANENT MAGNET GENERATOR es 60 HZ | ovreut - VOLTAGE \ 400 00 [tapeco SENSING SENSING SENSING SENSING i STATOR ISOLATION ISOLATION IS0LATION wsoation | | coRNECTION rrawsromuens | | transromuers | | rransromwess | | rransroruens | | + : + | ’ + + i ecuaror 1] recuaror | | eccutator REGULATOR recuaror | | NOTE: VOLTAGES SHOWN ARE 60 Hz EQUIVALENTS Iustration 43 (0070227845 ‘Systems Operation Section orsrera6 VR3 Voltage Regulator Connections (SR4B for 3500 Engines) SMCS Code: 446746 Systems Operation Section Self Excited with Direct Connection to Generator LW lustration 44 ‘poneass6s47 Systems Operation Section Permanent Magnet Excitation with Connections to an Isolation Transformer ustration 45 ‘90089556848 Systems Operation Section VR3F Voltage Regulator Connections (SR4B for 3500 Engines) SMCS Code: 4467 Knee Frequency Selection and Underfrequency Slope Selection station 46 ons968i249 Systems Operation Section Self Excited with Direct Connection to Generator . i Wj WT i) IMustration 47 ‘en089697750 Systems Operation Section Permanent Magnet Excitation with Connections to Isolation Transformers 022) 2 | ai Ju = ayia iustration 48 ue8s8251 Systems Operation Section ‘oraur7s Digital Voltage Regulator Connections (SR4B for 3500 Engines) SMCS Code: 446752 Systems Operation Section Permanent Magnet Excitation with Connections to Isolation Transformers 5 LE IMustration 49 ‘eon6s06753 Systems Operation Section Options (SR4B for 3500 Engines) SMCS Code: 445054 ‘Systems Operation Section VR3 with Manual Voltage Control and Self Excitation AMlustration 50 LS 2 4 2 a E ZEIE 3 z | *| 655 Systems Operation Section VR3 Manual Control with Permanent Magnet Excitation iS MAIN TERMINAL STRIP note 0 — ‘ustration 51 ‘ooneas99%56 Systems Operation Section VR3 with Radio Interference Filter with Self Excitation 9 D ‘ustration 52 sosessnes7 Systems Operation Section VR3 with Radio Interference and Permanent Magnet Excitation = ||| . i 7) 20 SENERATOR RFI STRIP MAI TEPMINAL llusteation 53 ‘088590558 Systems Operation Section Remote Voltage Adjust Rheostat Connections CONNECTION WHEN REMOTE VOLTAGE CONNECTION WITH NO REMOTE ADJUST RHEOSTAT IS PROVIDED VOLTAGE ADJUST RHEOSTAT Ilustration 54 ee59 ‘Systems Operation Section VRS3F with Manual Voltage Control and Self Excitation * (Hooeooeooe Iustration 55 0088699760 Systems Operation Section VR3F with Manual Control and Permanent Magnet Excitation =—— 2 : PS TT y —_ : = é 2 o ~ ‘goosas938 Mustation 5661 Systems Operation Section VR3F with Radio Interference Filter and Self Excitation o Iustraton 57 ‘gone856962 Systems Operation Section VR3F with Radio Interference Filter and Permanent Magnet Excitation ale 20 REGULATOR 982 + lustation 58 gonee600063 Systems Operation Section Digital Voltage Regulator with Manual Control © O ie) gs E> b= Oo o 1 2 MANUAL CONTROL eTes43 TRIP Alusiration 59 sse069e0c864 Systems Operation Section Digital Voltage Regulator with Remote VAR OTE Fs iF nue ens, Mats aes ast dona ie hd meng ess Ie rROvRED URE SE-S5N2 HADES FR Dena votiaedusitoe nie Sowce NOTE 6 SPTONAL REVOTE VOLTAGE ADWST REOSTAT LOCATED WE THE Fro eect, aa. eh me ors une YA NOL FO AG ES IMiustation 60Digital voltage Regulator Customer Options 65 Systems Operation Section zr vouT foome Max Loso] ALARM OUTPUT ORTVER 24 vOut dome ax voao| excrtatzon OTSABLE + re FAULT RESET + GEN 52/0 AUK contact utLaTy 32/0 AUT owract Spore + lreuore voutace {Soins i] wore & IRewoTe oF /kvaR [ADJUST ANEOSTAT {Px Fuse} [} NOTE A: CONNECT SHIELD DRAIN wIRE(S) TO TERMINAL 45. INSULATE SHIELD DRAIN WIRE(S) AT RHEOSTAT END. DO_NOT CONNECT SHIELD DRAIN WIRE(S) TO CHASSIS GROUND. Fos IMustration 61 0085082866 Systems Operation Section Digital Voltage Regulator Remote Communications Connections nari RS485 DEVICE TRansurt (+) a ~ ¥ gece wee Y pa commonQ. VL / NOTE © | gees connector vor aszaz — Jt : REGU ED OWER NOTE D: RS4B5 DATA IS NEEDED TO CONVERT RS485 DATA SUPPLY 10 RS252 FOR COMMUNICATIONS TO CUSTOMER Po oR MODEM Mustration 62 pos7a2Index D Digital Voltage Regulator Connections (All Except ‘SR4B for 3500 Engines) . 24 10/12 Lead with Direct Connection to Generator ses 24 10/12 Lead with Sensing Isolation Transformer. 25 4/6 Lead with Direct Connection to Generator... 26 4/6 Lead with Sensing Isolation Transformer... 27 Digital Voltage Regulator Connections (SR4B for 8500 Engines). . 52 Permanent Magnet Excitation with Connections to Isolation Transformers, 52 G ene rallnormalicn| (all scat Se 000 Engines)... —— vneen A Introduction 4 General Information (SR4B for 3500 Engines)... 41 Introduction... 7 Generator Wiring Diagrams (SR4B for 3500 Engines). . 67 Wiring Diagram for 3500 EUI Low Voltage With Digital Voltage Regulator and Permanent Magnet . 67 Wiring Diagram for 3500 EUI Low Voltage With VAG and Permanent Magnet. 69 Wiring Diagram for 3500 EU! Low Voltage With VR3 and Self-Excitation . Wiring Diagram for 3500 EUI Medium Voltage With Digital Voltage Regulator and Permanent Magnet sec 73 Wiring Diagram for 3500 EU! Medium Voltage With V8 and Permanent Magnet. weet 1 Important Safety Information m Main Revolving Field Connections (All Except SR4B for 3500 Engines) «nu 9 Diode Block 9 Diode Block and Surge Suppressor. 9 Six Diodes and Two Surge Suppressors......... 11 10 40 Three Diode Blocks and Surge Suppressor. ‘Two Diode Blocks and Surge Suppresscr...... Main Revolving Field Connections (SR4B for 3500 Engines)... Two Diode Blocks and Surge Suppressor... 77 Index Section Main Stator and Voltage Sensing Lead Connections (All Except SR4B for 3500 Engines) 10 Lead Wye Connestion.... 12 Lead, Single Phase Connection. 12 Lead, Wye and Delta Connection 4 Lead Wye Connection, . 6 Lead Delta Connection 6 Lead Wye Connection... Main Stator and Voltage Sensing Lead Connections evaoon (SR4B for 3500 Engines). 4 6 Lead Delta Connection : . 42 6 Lead Wye Connection... a ° Oil Field Generator Connections (SR4)..... 40 Excitor Field Connection (Series or Parallel) and Voltage Sensing Leads sons 40 Options (All Except SR4B for 3500 Engines)... 28 Digital Voltage Regulator Customer Options ..... 38 Digital Voltage Regulator Remote Communications Connestions. 39 Digital Voltage Regulator with Manual Control... 36 Digital Voltage Regulator with Remote Voltage ‘Adjust Rheostat... 37 Manual Control and Series Boost with Self Excitor... 34 Manual Control with Permanent Magnet Exciter. 30 Manual Control with Power Transformer sss. 29 Manual Control with Self Excitation 28 Razio Interference Filter at Remote Voltage Adjust Rheostat Connections... 35 Series Boost with VR3 Voltage Regulator... 32 Series Boost with V4 Voltage Regulator. 3378 Index Section Options (SR4B for 3500 Engines) Digital voltage Regulator Customer Options Digital Voltage Regulator Remote Communications Connections... 66 Digital Voltage Regulator with Manual Control Digital Voltage Regulator with Remote VAR...... 64 Remote Voltage Adjust Rheostat Connections. 58 V3 Manual Control with Permanent Magnet Excitation. VR@ with Manual Voltage Control and Self EXCIIAION. corn 54 VRS with Radio Interference and Permanent Magnet Excitation... VRS with Radio Interference Filter with Self Excitation... . 58 VF with Manual Control and Permanent Magnet Excitation... 60 VRSF with Manual Voltage Control and Seif Excitation. 59 VRGF with Radio Interference Filter and Permanent Magnet Excitation. senros 62, RF with Radio Interference Filter and Saif Excitation... . : 61 s Selection Guide for Voltage Regulator (All Except ‘SR4B for 3500 Engines)... Selection Guide for Voltage Regulator (SAAB for ‘3500 Engines), 44, Selection Chart for SR4B Voltage Regulator... 44 S84 and SAAB Generators for All Engines Except SR4B for 3500 Engines... 7 'SR4B Generators for 3500 Engines... oe AY 12 ‘Systems Operation Section. 4 7 Table of Contents... ssn 3 v VRS Voltage Regulator Connections (All Except ‘SR4B for 3500 Engines) 13 Permanent Magnet Excitation with Connections to an Isolation Transformer... 18 Permanent Magnet Excitation with Connections to Metering Potential Transformers screenees 17 Permanent Magnet Excitation with Direct Connection to Generator. Self Excited with Direct Connection to Generator Self Excited with Power and Sensing isolation Transformer... 15 Self Excited with Power Transformer 4/6 Lead Generator eons 14 16 13 ©2002 Caterpillar All Rights Reserved VRS Voltage Regulator Connections (SR4B for 3500 Engines)... 46 Permanent Magnet Excitation with Connections to an Isolation Transformer... 47 Self Excited with Direct Connection to Generator... 46 VRF Voltage Regulator Connections (All Except ‘SR4B for 3500 Engines) Knee Frequency and Underirequency Selection «son 19 ‘Typical Permanent Magnet Excited VAQF ........ 20 ‘Typical Self Excited VA3F. at VR3F Voltage Regulator Connections (SR4B for 3500 Engines). Knee Frequency Selection and Underirequency Slope Selection 48 Permanent Magnet Excitation with Connections to Isolation Transformers... . 50 Self Excited with Direct Connection to Generator. 49 VR4 Voltage Regulator Gonnactions (All Except ‘SR4B for 3500 Engines) eens 22 Self Excited with Direct Connection to Generator. Pere 22 Printed in U.S.A.