3412 Gen Set Product Description [PDF]

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Electric Power Generation Systems



3412 Package Generator Sets 50 Hz: 455 – 900 kVA 60 Hz: 455 – 800 kW



PRODUCT INFORMATION



PRODUCT INFORMATION — ELECTRIC POWER GENERATION



CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Enhancements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Air Inlet System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Governor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Starting and Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Mounting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Customer Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Generators — SR4B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 3412 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Available Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Product Comparison — Current Product vs. New 3412 . . . . . . . . . . . . . . . . . . . . . 22



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



INTRODUCTION ELECTRIC POWER GENERATION SYSTEMS 3412 Package Generator Sets 50 Hz: 455 – 900 kVA 60 Hz: 455 – 800 kW The latest Caterpillar prime and standby Package Generator Sets provide unmatched flexibility, expandability, and costeffectiveness.



These full-featured units are easier than ever to specify, order, and install. A wide range of fully assembled and connected system attachments allow systems to be configured to suit customers’ needs. Single point access for all control and low power wiring plus spacious terminal box and circuit breaker bus bar terminations reduce installation time and cost.



Sound Attenuated Weather Protective Enclosures 2



PRODUCT INFORMATION — ELECTRIC POWER GENERATION



INTRODUCTION ELECTRIC POWER GENERATION SYSTEMS 3412 Package Generator Sets 50 Hz: 455 – 900 kVA 60 Hz: 455 – 800 kW 455 kW Prime Power



700 kW Standby Power



800 kW Standby Power



Shown with Optional Equipment 3



PRODUCT INFORMATION — ELECTRIC POWER GENERATION



ENHANCEMENTS In designing the latest Cat generator set packages, Cat engineers were challenged to improve flexibility, expandability, and costeffectiveness. These challenges were met by combining traditional Caterpillar strengths with innovative system enhancements. New sales features include: • Rationalized and simplified product traits • Simplified price list which emphasizes features • Expanded sales support information • Expanded attachment offering and flexibility • All attachments installed complete and incompatibilities eliminated New product features include: • 50° C (122° F) cooling system (open set)



• Stainless steel exhaust flex and flange • Cat Extended Life Coolant • Coolant drain line with valve • Coolant Level Loss sensor • Soft mount on engine and generator • Oil drain line with valve • Broad voltage generator which handles wider voltage range without derating • Weather protective and sound attenuated enclosures are factory designed, built, and assembled • Three levels of control panels utilizing common enclosures and wiring harnesses for easy retrofit



• 43° C (110° F) cooling system (enclosed)



• Dedicated wiring box with single point for customer connections



• Installed flex fuel lines



• Optional electronic engine instrumentation



• Primary and secondary fuel filter



• Large extension box with excellent cable access



• Water separator • 45 amp charging alternator • Cat battery, rack, and cables



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• Battery disconnect switch



PRODUCT INFORMATION — ELECTRIC POWER GENERATION



COOLING SYSTEM Features • Designed for operation up to 50° C (122° F) for open units and up to 43° C (110° F) for enclosed units • Common for standby and prime • Common for open and enclosed units • Engine mounted • Caterpillar Extended Life Coolant • Coolant loss sensor • Outlet, fan, and belt guards • Coolant drain line with valve — piped to edge of baseframe Options • Radiator removal • Heat exchangers • Baseframe mounted jacket water heater which includes isolation valves • Diesel fuel fired coolant heater



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



AIR INLET SYSTEM Features • Air cleaner – Single Element (SE) — canister type, includes dust evacuator and rain cap • Completely installed • Modular design • Service indicator Options • Dual Element (DE) air cleaner, modular attachment to SE • Heavy duty air cleaner includes DE and full view precleaner (replaces rain cap) modular attachment to SE



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



LUBE SYSTEM Features • Lubricating oil • Oil drain with valve (piped to edge of baseframe) • Fumes disposal (piped to front of radiator) Options • Manual sump pump (base mounted)



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



EXHAUST SYSTEM Features • All components shipped loose • Stainless steel exhaust flex with mating weld flange, bolts, nuts, gasket, and ANSI style outlet flange Options • Engine mounted muffler • Remote mounted mufflers: – 20/25/30 dBA attenuation – Aluminized – Side in/end out option – End in/end out option • Muffler mounting kit • Through-wall installation kit • Muffler installation kit • Engine exhaust guarding



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



FUEL SYSTEM Features • Primary fuel filter/water separator • Secondary fuel filter • Fuel priming pump • Flexible fuel lines terminated on base • Fuel pressure gauge Options • Low fuel level alarm/shutdown • Fuel transfer systems: – Manual pump – Manual pump plus AC transfer pump – Automatic gravity feed system with level switch and DC motorized valve – Automatic pumped system with level switch and AC transfer pump – Automatic pumped system with level switch, AC transfer pump, and DC motorized valve



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



GOVERNOR SYSTEM Features • Hydra-mechanical governor – 50 Hz: 455-600 kVA prime 500-650 kVA standby – 60 Hz: 455-545 kW prime 500-600 kW standby • Electronic (PEEC) – 50 Hz: 635-810 kVA prime 700-900 kVA standby – 60 Hz: 591-725 kW prime 650-800 kW standby Options • Speed control motor (for hydra-mechanical governor) • Woodward 2301A electronic isochronous governor (for hydra-mechanical governor) • Load share interface module (for electronic governor)



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



STARTING AND CHARGING SYSTEM Features • Energize to run fuel shutoff solenoid • 24 V heavy-duty starting motor • Battery/rack/cables for starting down to 20° C ambient — rack designed to hold oversize batteries • 45 amp charging alternator • Battery disconnect switch Options • Remove standard battery — rack and cables provided • Oversize battery — uses same rack and cables • Ether starting aid • Jacket water heater – Automatic disconnect – Completely installed and wired – Isolation valves – Base mounted to prevent vibration • Diesel fuel fired coolant heater • Battery chargers (5 amp and 10 amp)



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



MOUNTING SYSTEM Features • Formed steel base • Linear vibration isolators between base and engine-generator Options • Fuel tank bases – Integral tanks (single/double wall) – Sub-base tanks (single/double wall)



Sub-Base Tank



• Oil field skid base – Provides dragging and lifting provisions – Mounts under base or integral fuel tank – Adds 8" height to package • Wide base



Integral Tank



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



CONTROL PANELS Features • Three levels of control panels — switchgear conversion, EMCP II, EMCP II+ — tailored to customer needs • New quick connectors for easy retrofit • Common enclosure, wiring harness • Rear mount on open set; side mount on enclosed set • Vandal door



Switchgear Conversion



Options • Accessory voltage indicator (FUW/space heater and battery charger options) • Dust proof enclosure • Common alarm/shutdown • Generator running relay • Alarm volt-free contact • Shutdown volt-free contact • Customer Communication Module (CCM) • Relay Driver Module (RDM) • Customer Interface Module (CIM)



EMCP II / EMCP II+



• Manual synchronizing module • Side mount on open set • CSA approved



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



CUSTOMER WIRING CONNECTIONS Features • Low voltage accessories box — segregated AC/DC terminal strips completely isolated from high voltage controls • Enclosed wiring channel – Improved access for customer wiring connections – Fully enclosed from environment • Large terminal box • Excellent cable access, streamlined box provides direct access • Single point customer connections: – Jacket water heater – Space heater – Battery charger • DIN rail terminal connections



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Terminal Strips (Cover Removed)



PRODUCT INFORMATION — ELECTRIC POWER GENERATION



CIRCUIT BREAKERS (PACKAGE MOUNTED) Features • UL or IEC compliant three-pole or four-pole • Rear or side mount • Top or bottom cable entry (side mount only) • 24 VDC shunt trip • IEC 100% rated • UL 80% rated • Full size neutral bar Options • Auxiliary contact • Multiple breakers (two or three)



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



ENCLOSURES Features • Sound Attenuated (SA) — sound level of: 72.1 dBA at 7 meters 83.3 dBA at 1 meter • 43° C (110° F) ambient capability • Weather Protective (WP) • Baseframe mounted • Wide base • Galvanized steel body — zinc-phosphate treated prior to paint • Durable polyester powder baked paint — yellow, standard • All hardware is zinc-plated or stainless steel • Stainless steel locks and hinges • Internally mounted exhaust system — common for WP and SA • Control panel viewing window with safety glass and lockable access door to start/stop controls • Externally mounted emergency stop • Drain lines piped to baseframe for lube oil, coolant, and fumes disposal • Single point lift • Side mounted CB and control panel Options • White, beige, or ASA61 gray paint • Interior maintenance lighting • Fuel tank base (integral) • Sub-base fuel tanks • Oil field skid base



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Sound Attenuated Weather Protective Enclosures



PRODUCT INFORMATION — ELECTRIC POWER GENERATION



GENERATORS — SR4B Features • Permanent Magnet (PM) • Broad voltage — wider voltage range without derating, upgraded excitation system, fewer generator part numbers



• Space heater — 500 watt with automatic disconnect (standard on premium generator) • Digital voltage regulator – without VAR/PF control capability – with VAR/PF control capability



• Cat 590 frame • Class H insulation (Class F temperature rise) • Certifications: UL, BS4999, BS5000, NEMA MG1, CEMA, ISO 9001 & 9002, DnV, Lloyds, BV, ABS, and VDE0530 • 12 lead except for 600 volt 60 Hz generators, which are 6 lead • Optimum pitch • Paralleling kit • Bus bar connections • 2:1 volts/Hz VR3F • Extension box – power connection area – customer wiring area Options • Self Excited (SE) • Oversize generators — two frames at each rating – 80° C, 105° C, 130° C generator at each standby rating • Premium generator – PM – Extra insulation — coastal treatment – Space heater – Winding temperature detectors – Bearing temperature detector



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



VOLTAGE REGULATOR Features • VR3F • Selectable 2:1 or 1:1 volts/Hz regulation • 3-phase sensing • Over-excitation protection • Environmentally sealed Options • Digital voltage regulator for PM or premium generator • Digital voltage regulator with kV•AR/PF for PM or premium generator



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



AUTOMATIC TRANSFER SWITCH Features • Rating: 100 to 2600 amps • Available voltage: 200/208/220/240/380/415/460/480/600 • High speed operation • Utility voltage sensor • Break-before-make transfer in less than one second • Programmable logic control • NEMA enclosure Options • In-phase monitoring • Auxiliary contacts • NEMA 3R enclosure • Manual by-pass control • Preferred source selector switch • Remote automatic control • Manual by-pass selector switch • Programmable exerciser • Elevator contact



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



3412 ENGINE Package generator sets begin with Cat 3412 V-12, 4-stroke diesel engines. These turbocharged engines demonstrate the superior quality, reliability, and fuel efficiency Cat customers have come to expect, through:



• High strength blocks • Deep-cut, gallery-cooled, three-ring aluminum pistons • Full length watercooled liners • Deep-hardened regrindable crankshafts



3412 Engine



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



SPECIFICATIONS Ratings 50 Hz Engine



Generator



3412T 3412TT 3412TTA 3412TTA 3412TTA 3412TTA 3412TTA 3412STA 3412STA 3412STA



591 592 592 593 594 594 595 596 597 598



Standby (kVA) 500 550 – 600 650 – 700 750 800 900



60 Hz Prime (kVA) 455 500 – 545 600 – 635 680 725 810



Standby (kW) 500 – 550 600 – 650 700 750 800 –



Prime (kW) 455 – 500 545 – 591 635 680 725 –



Available Voltages 50 Hz 415/240 400/230 380/220 220/127 – –



60 Hz 600 480/277 440/254 240/139 220/127 208/120



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PRODUCT INFORMATION — ELECTRIC POWER GENERATION



PRODUCT COMPARISON Current Product vs. New 3412 In summary, the following comparison reflects current package power systems versus the new 3412 package power systems. System



Current Product



New 3412



Price List



Traditional, part number based



Desktop published, emphasizing features



Smaller, user-friendly Easier and faster to quote



Product Consist



Standard equipment overview: Engine Generator Control panel Fuel filters Fuel priming pump Starting motor



Standard equipment overview: Engine Generator Control panel Fuel filters Fuel priming pump Starting motor Cat Extended Life Coolant Stainless steel exhaust flex and ANSI weld flange 45 amp charging alternator Water separator Batteries, rack, and cables Low coolant level shutdown



Full-featured and competitive product



Generator



PM standard



PM standard, SE option



Wider application



Controls



EMCP II



Three levels of control: EMCP II CSA EMCP II+ approved Switch conversion System expansion modules option



Controls matched to customer needs Meets regulatory needs Cost-sensitive options



Optional fuel tank bases: Integral tanks single/dual Sub-base tanks wall (UL)



Meets customer needs Ready-to-run systems available



Optional mufflers available with 20/25/30 dBA levels of attenuation



Wider application Meets customer needs



Mounting System Hard mount



Soft mount with nonmetallic linear vibration isolators



Meets building code



Enclosures



Weather protective



Sound attenuated and weather protective



Meeting customer requirements



Options



Wide variety of options



Expanded range of system options



Meeting customer requirements Limited incompatibility



}



Fuel Storage



(Not available)



}



Exhaust System



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Benefit



(Not available)



U.S. Sourced LEKX9517



Materials and specifications are subject to change without notice.



© 1999 Caterpillar Inc. All rights reserved. Printed in U.S.A.