Caterpillar China Power System

Generator Performance
Generator Loading
When a generator is installed or reconnected, be sure the total current in one phase
does not exceed the nameplate rating. Each phase should carry the same load, allowing
the engine to work at its rated capacity. An electrical unbalance can result in an
electrical overload and overheating if one phase exceeds the nameplate amperage. Any
unbalanced load that's required should be placed on phase 2, since current sensing for
voltage regulator is on that phase.
Power Factor
Power factor may be thought of as the efficiency of the load - the ratio of apparent
power to total power. Power factor is expressed as a decimal and denotes that portion
of current supplied to a system doing useful work. The portion of current not doing
useful work is absorbed in maintaining the magnetic field in motors. This current,
although it is called the reactive load, does not require engine horsepower to maintain it.
In most applications electric motors and transformers determine the power factor of the
system. Induction motors usually have a .8 power factor. Incadescent lighting is a
resistive load to about 1.0 power factor, or unity.
The power factor of a system may be determined by a power factor meter or by
calculations. Determine the power requirement in KW by multiplying the power factor by
the KVA supplied to the system. As the power factor goes up the total current supplied
to a constant power demand will go down. A 100 KW load at a .8 power factor will draw
more current than a 100 KW load at .9 power factor. A higher power factor increases
the possibility of overloading the engine. A lower power factor increases the possibility
of overloading the generator.
Low Idle Adjustment
Electric sets require higher low idle setting than do industrial engines. Low idle must not be below 2/3 the
full load speed of 60 Hz units (4/5 full load speed of 50 Hz units).
NOTICE

Disconnect the exciter circuit by removing fuses F1 and F2 (on

SRCR) or Fuse F1 (on SR 4) before operating the engine below
the low idle rating. Failure to do this will result in generator
damage.
On electric sets with Woodward governors, there is no low idle stop. On electric sets
with mechanical governors and natural gas electric sets, the low idle is set at the
factory, and should only be adjusted by your Caterpillar dealer if adjustment is required.

Parallel Operation
Initial Start-Up
Preparing a generator for parallel operation requires special attention. Before
attempting to parallel units for the first time, all units must be checked to be sure the
following three conditions are met:
1. Same phase rotation
2. Same alternating current frequency.
3. Same voltage adjustment
Phase Rotation
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The phase rotation must be the same. A set of three light bulbs is used to determine
whether the phase rotation of the incoming unit and the phase rotation of the line are
the same.
1. Connect the light bulbs between the generator leads and the corresponding line
phase, i.e., terminal 1 to line 1 across the open circuit breaker. 2. Start the units to be
paralleled and bring them up to speed. As they approach the same speed the lights will
start to blink.
View Image

a. If the lights blink in sequence one of the units is connected backward. To correct this remove
generator leads 1 and 3 at the circuit breaker and exchange them. This reverses the direction of
phase rotation. Line 2 should always be connected to line 2.

Never attempt to work on electrically hot wiring. Stop the

electric set before rewiring generator leads. Open circuit
breakers before working on the equipment which they control.

b. If lights blink in unison the phase rotation of both engines is the same, and
condition 1 has been met.
Frequency Adjustment
The speed of units to be paralleled must be the same. Speed refers to the alternating
current frequency.
1. Allow each electric set to run under load long enough for the internal temperatures to
stabilize (about one hour). 2. Adjust the governor control to give rated frequency at full
load. 3. Remove the load and check the high idle speed; it should be approximately 3%
above full load speed. If these speeds can not be obtained, contact your Caterpillar
dealer. 4. For the most consistent results, repeat steps 2 and 3 until condition 2 has
been met.
Voltage Adjustment
The voltage level and voltage droop adjustments determine the amount of circulating
currents between generators. Carefully matched voltage regulator adjustments will
reduce the circulating currents. Loads of .8 power factor (primarily motors) require a
generator voltage droop of about 5%. Voltage droop is expressed as the percentage of

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voltage change from no load to full load. Use the same voltmeter to make adjustments
on each unit to be paralleled.
1. Adjust voltage as described for Single Unit Operation, Initial Start-Up.
2. With the engine running at high idle, turn the voltage droop clockwise about 1/2 of
full range.
If driven load is to be unity power factor, set the voltage droop control on all generators
at 1/2 of full range and proceed to Step 7. If driven load is to be normal (0.8 power
factor) proceed to Step 3.
3. Readjust the voltage level control until the voltage is about 5% above desired voltage.
4. Apply full load at .8 power factor.
NOTE: If a generator is to be paralleled with other generators, the voltage droop of
each generator must be the same to satisfactorily divide reactive load.
5. Readjust the voltage droop control to obtain desired voltage with full load at .8 power
factor.
6. Repeat Steps 3, 4 and 5 for each generator to be paralleled until line voltage is equal
to desired level at .8 power factor and no load voltage is approximately 5% above rated
voltage.
7. Parallel generators and apply the driven load (see the topic Operation/Paralleling). If the sum of the
amps of the individual generator amperes exceeds the total amps going to the load by 10% at full load,
adjust voltage droop controls to share current proportionally between generators.

NOTICE

Do NOT exceed rated ampere load on any single generator.

8. Tighten the locknuts on all controls and install the access cover. Condition 3 has been
met.
Starting Multiple Units
Starting-Units are started the same as single units.
Paralleling
Units may be paralleled at no load or paralleled with units under load. To parallel two or
more units the following conditions must be met:
1. Same phase rotation.
2. Same voltage level.
3. Same voltage droop.
4. Same frequency.
5. Voltages must be in phase.
The first three conditions have been met in the initial start-up for parallel operation.
1. Start the unit to be paralleled according to the procedure in the engine operation
section. 2. Turn the synchronizer lights on. 3. After the engine has run long enough to
warm up, bring it up to synchronous speed (the same frequency as the unit on the line).
The synchronizing lights will begin to blink. 4. Using the governor control adjust the
speed until the lights blink very slowly. 5. The lights are off when the voltages of the
two units are in phase. At this point very quickly close the breaker while the lights are
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out. 6. Use governor controls to share KW load between engines 7. After generator
temperature has stabilized (1 hr.), adjust the droop control of each generator so as to
share the reactive load and to limit the circulating currents. Less droop (moving control
CCW) increases the reactive current carried by the generator.
The frequency of the incoming unit should be slightly greater than the line frequency.
This will allow the incoming unit to assume some of the load rather than add to the
system load

Load Division-(Speed Droop)

Once two units have been paralleled their share of the load is determined by the
governor control setting. If two units of the same capacity and the same governor
characteristics have the same governor control settings they will share the load equally.
To transfer the load from one engine to the other follow this procedure:
The total load must not exceed the capacity of the engine.
1. Increase the governor speed control of one unit to increase the load. 2. Reduce
the governor speed control of the other unit to decrease the load on that unit. 3.
Raise or lower the governor speed control of both units to change system
frequency

Circulating Currents
When two units are paralleled there will be circulating currents. These currents are not
doing useful work, but are flowing between the generators. By determining the total
generator amperage and subtracting the amperage going to the load, the amount of
circulating current can be determined.
Circulating currents are caused by voltage differences between the two units.
With cold generator sets, circulating current may be as high as 25% of rated amperes,
without being considered harmful. Circulating current is part of the total generator
current and this total must not exceed the amperage rating.
As the generators warm, the circulating currents will decrease. The ammeter readings
should decrease slightly, but the voltage meter readings should remain constant.

Parallel Operation of Governors

This section is a general description of the function of the engine governor in relation to
load division between parallel electric sets. For detailed information on governor
controls and adjustments, see the Operation Guide and Service Manual for the engine.
It is very important that two basic facts be understood concerning load division between
generator sets operating in parallel. First, the power supplied to the generator and thus
to the load is a function of the engine. The engine governor settings and the positions of
the governor controls determine the amount of power delivered by the engine and the
KW load carried by the generator. If the governor control setting is advanced, the
engine and generator will assume more KW load. Likewise, decreasing the governor
control setting will result in a reduction of load on the unit. Any other units on the line
will, conversely, either reduce or gain load at the same time, assuming no change in
total load or no change in the governor settings of the other units has taken place.
Second, the division of power is not determined by generator excitation or terminal
voltage. The Power Factor at which a generator will operate when paralleled with other
generators is determined by its excitation. For more discussion on this subject, refer to
the section on Parallel Operation of generators.
Governors furnished with Caterpillar Powered Electric Sets can be either of two types,
governors with fixed speed droop or governors with adjustable speed droop. The values
of speed droop used are commonly 3% and 0%. Governors with adjustable speed droop
can be adjusted so their characteristics match quite closely the characteristics of

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governors with fixed speed droop. The operating characteristics of the following
combinations of governors on paralleled electric sets will be described.
1. Two 3% governors.
2. One 3% governor and one 0% (isochronous) governor.
Example 1-Two 3% Governors
When paralleling A.C. Generators, the engine governors must have the same speed
droop characteristics if the sets are to divide the load in proportion to their ratings
throughout the entire operating range.
The governor speed droop characteristics of these two units are similar. This is shown
by lines "A" and "B" coinciding in Figure 1. If both units are started, set for high idle
speed and paralleled at no load, the system frequency will be 61.8 cycles or 103% of
rated frequency. As load is applied to the system, the frequency will decrease along the
speed droop characteristic until the frequency at full load is 60 cycles.
View Image

PERCENT OF LOAD
Figure 1-Paralleling two units with similar speed droop characteristics.

Parallel Operation of Governors

If Unit A had been operating alone carrying full load, the system frequency would be 60
cycles as shown by Line "A" at 60 cycles and 100% load. Now, if the frequency of Unit
B is adjusted by the engine speed control to be equal to that of Unit A and the circuit
breaker of Unit B is closed, the system would be operating under the following
conditions:
1. Unit A is at 60 cycles and 100% load.
2. Unit B is at 60 cycles and 0% load. The characteristic of the governor of Unit B
at this time is shown by the dotted line B.
In order for Unit B to carry load, it is necessary to advance the speed setting of the
governor. If it is advanced to the full load position, the governor characteristic of B will
coincide with the characteristic of A. Since the load on the system was 100% of one
unit, no change was made in total load, and the available capacity is now 200%, the
system will operate at 50% load on each unit, and 60.9 cycles for two units of equal

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capacity (Point E). For units of unequal capacity, the load will be divided in proportion to
the ratio of the capacity of each to the total capacity. The system frequency will be
determined by the points on the governor characteristics corresponding to these loads.
The frequency will be the same for both units since paralleled alternators must operate
at the same speed.
If Unit A had been a 60 KW unit fully loaded and a 100 KW Unit B was paralleled with it
and the governor adjusted to the full load position, the final load division and frequency
would be determined as follows:
View Image

37.% of the capacity of either unit. Again, using Figure 1 for the governor characteristic
of the 100 KW unit and reading up from the value of load (37.5% to point F), we find the
system frequency to be 61.125 cycles.
View Image

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PERCENT OF LOAD
Figure 2-Paralleling two units, one with a 3% governor and the other with a hydraulic
governor set for isochronous operation.
Example 2-One 3% Governor and one 0% (Isochronous) Governor.
The characteristics of the 3% governor (Unit A) is shown by line A of Figure 2 and the
characteristics of the isochronous governor (Unit B) is shown by line B. Only at full
load, 60 cycles, do the frequencies of the units have the same value. It is customary to
operate a system of this type with a system load greater than the capacity of Unit A. In
this way Unit A carries its full load at 60 cycles and the additional load and load swings
are handled by Unit B, also at 60 cycles. The system can maintain constant frequency
by this method of operation. The system described in example 1 cannot maintain
constant frequency with load changes because of the speed droop characteristics of the
governors.
In the system described in this example, if the load is less than the capacity of Unit A
(which has the 3% governor) and can be carried by Unit B, the governor setting of Unit
A can be reduced to give a governor characteristic such as A, so Unit A will still carry
the steady part of the load and Unit B will carry the load swings. If the system load is
reduced to the point where Unit A is not operating at the 60 cycle point of its governor
characteristic, Unit A will try to motor Unit B and the system frequency may be greater
than 60 cycles. The reason for using an isochronous governor in a power system is to
maintain constant frequency above approximately 40% load.
Summary
The preceding discussion and examples of governor operation can be summarized as
follows:
1. The simplest governor combination for paralleled electric sets is to have a 3%
speed droop characteristic for each governor. If a constant frequency from no-
load to full-load is required, one governor can be adjusted for isochronous
operation. This is called a "lead unit".
2. In order for all paralleled units to accept their full share of the load, the
following governor adjustments are required:

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a. The same full load speed.

b. The same high idle (no-load) speed in the case of governors adjusted for speed
droop operation.
c. Governor controls set to the high idle position so the full governor range is
available.
3. Operation of an isochronous governor in parallel with speed droop governors
requires the special techniques described in example 2.
4. Any number of electric sets can be operated in parallel. However, only one
governor of the group can be adjusted for isochronous operation except in the
special cases of electronic governors with automatic load sharing.

Paralleling Multiple Units

Units may be paralleled at no load or paralleled with units under load. After the initial start-up
conditions are satisfied, verify for the following requirements.
One of the governors can be an isochronous governor. Electronic load sharing governors
are an exception.
Generators must have voltage droop compensation or cross current compensation.
1. Start the unit which will be paralleled.
2. Turn the synchronizer lights on.
3. After the engine has run a few minutes, bring the engine up to synchronous speed. This
means that the frequency of the incoming unit will be the same as the frequency of the
unit on line. The synchronizing lights will begin to blink.

Note: The frequency of the incoming unit should be slightly greater than the line
frequency. This will allow the incoming unit to assume some of the load rather than add to
the system load.
4. Using the governor control, adjust the engine speed until the lights blink very slowly.
5. The lights are off when the voltages of the two units are in phase. At this point, very
quickly close the breaker while the lights are out.
6. Use governor controls in order to share kW load between engines.
7. Generator temperature will be stabilized in approximately one hour. After the generator
temperature has been stabilized, adjust the voltage droop rheostat of each generator in
order to share the reactive load and in order to limit the circulating currents. Less droop
increases the reactive current that is carried by the generator. Adjusting the voltage droop
rheostat in a counterclockwise direction (CCW) will decrease droop. Adjusting the voltage
droop rheostat in a clockwise direction (CW) will increase droop.

Load Division - Speed Droop (If Equipped)

Once two units have been paralleled, the units share of the kW load is determined by the
governor control setting. If two units of the same capacity and the same governor characteristics
have the same governor control settings, the units will share the load equally. The total load
must not exceed the capacity of the one engine.

In order to transfer the load from one engine to another, follow the following procedure.
1. Increase the governor speed control of one unit in order to increase the load.
2. Reduce the governor speed control of the other unit in order to decrease the load on that
unit.
3. Raise or lower the governor speed control of both units to change system frequency.

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Parallel Operation Of Governors

The different governors that can be used on 3500B generator sets are shown below.

The generator set load sharing module provides either droop load sharing or isochronous load
sharing for paralleled generator applications. The load sharing module has a synchronizing
parallel module (SPM-A) input. The module provides proportional load sharing. More information
is available in the System Operation, Testing and Adjusting, SENR6565, "Generator Set Load
Sensor and Generator Load Sharing Module".

Function of The Engine Governor

This section describes the function of the engine governor in relation to load division between
parallel electric sets. For detailed information on governor controls and adjustments, refer to the
Service Manual for additional information.

It is very important to understand two basic facts about load division between generator sets
which are operating in parallel.
1. The power which is supplied to the generator and, thus, to the load is a function of the
engine. The engine governor settings and the positions of the governor controls
determine the amount of power that is delivered by the engine. Therefore, the engine
governor settings and the positions of the governor controls determine the kW load which
is carried by the generator. If the governor control setting is advanced, the engine and
generator will assume more kW load. Likewise, decreasing the governor control setting
will result in a reduction of load on the unit. Any other units on the line will, conversely,
either reduce load or gain load at the same time. These other units will assume that no
change in total load or no change in the governor settings of the other units has taken
place.
2. The division of power is not determined by generator excitation or terminal voltage. The
power factor at which a generator will operate when paralleled with other generators is
determined by the excitation.

Governors that are used with Caterpillar powered electric sets can be of two types: governors
with fixed speed droop or governors with adjustable speed droop. The values of speed droop
which are commonly used are 3 percent and 0 percent. Governors with adjustable speed droop
can be adjusted so their characteristics match quite closely the characteristics of governors with
fixed speed droop. If the governor is adjusted for 0 percent speed droop (isochronous)
operation, then the same speed from no load to full load can be obtained.

Summary on Governor Operation

The preceding discussion of governor operation can be summarized below.
The simplest governor combination for parallel generator sets is to have approximately 3
percent speed droop characteristics for each governor. If a constant frequency from no
load to full load is required, one governor can be adjusted for isochronous
operation. This isochronous unit will be called a "lead unit".
In order for all paralleled units to accept their full share of the load, the following governor
adjustments are required. The governors should have the same full load speed. The
governors should have the same high idle (no load) speed in the case of governors which
are adjusted for speed droop operation. Governor controls should be set to the high idle
position so that the full governor range is available.
Operation of an isochronous governor in parallel with speed droop governors requires
special techniques.

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Any number of electric sets can be operated in parallel. However, only one governor of
the group can be adjusted for isochronous operation. The exception will be some
special cases of electronic governors with automatic load sharing.

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