Features & Benefits

Electric Power Marketing

C-18 Diesel Genset

Caterpillar Confidential: Yellow

 C-18 Genset Product Enhancements

• Improvements/features over 3412

– Higher Power Density (ekW / displacement)
– Linear fuel consumption as per the load
– Smaller footprint
– Significantly improved specific output
– Meet India CPCB emission requirements
– Improved fuel efficiency over 12 cylinder engines
– Improved control, monitoring and customer information interface

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 Introduction: C-18 Product – Sourced

• Standard Features
– Fully Electronic Engine
– Electronic Unit Injectors
– ADEM III controller
– EMCP 3.1 Engine Monitoring and Controls
– Standard air cleaner
– Integral Fuel Tank
– Factory built Noise enclosure
– Better Transient response
– Lesser moving parts due to EUI injection
– Environmentally responsible engine – Lower Exhaust Emission
– Isochronous / Droop mode operation
– Factory Tested Package

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 C-18 Generator Set Ratings

Prime

kVA ekW

500 400

600 480

Ratings requested per ISO 8528-1 for PRP

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 Dimensions - Open

L W

Length Width Height Footprint

Model Change
mm mm mm
3412 Former 3835 1660 1897
-25%
C-18 Current 3419 1491 2006

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 Dimensions – Enclosure

L W

Length Width Height

Model
mm mm mm
Sound Attenuated
3412 Former 7925 2438 2896
C-18 Current 7925 2438 2896

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Introduction: C-18 Generator Set - Components

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Introduction: C-18 Generator Set - Components

Fuel
Pressure
regulator Fuel
Retur
n Line

Fuel
Supply
Line

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 Introduction: C-18 Generator Set

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 Mechanical Packaging

Electric Power Marketing

C-18 Diesel Genset

Caterpillar Confidential: Yellow

 C-18 Engine

• Bore 145 mm X Stroke 183 mm

• Displacement – 18.1L
• Governor – Electronic (ADEM 3)
• Fuel System – EUI
• Aspiration – Air-to-Air After cooled
3412 C18
Compression
Ratio 14.5:1 14.5:1
C - 18 DI T ATAAC
Displacement
(liters) 27 18.1 Air to Air
Power Density After-cooled
(ekW/L) 20.4 33.1 Turbo-charged
Cylinders 12 6
Direct Injection
Engine Type Vee In-line
Tier I 18 L Displacement
Emissions Tier I Tier II “C” Series
Nomenclature
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 C-18 Engine
Cylinder Block
• Stronger block
• Increased pressure handling capability for better fuel efficiency
• Tensile strength # 32000 psi
• Deep lower skirt to increase stiffness and reduce weight
• Strengthened flywheel housing for longer life
• Heavy duty Serpentine design for lower noise
• High coolant & oil flow for long engine life

• 4 Valve, Cross flow design for excellent breathing -

reduced fuel consumption and emissions
• Robust design - stiffer structure, improved strength,
better sealing, durability & Re-usability
• Overhead Cam design eliminating the pushrods and
lifters and providing better smooth valve actuations
Cylinder Head
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 C-18 Engine
Liner, Piston, Connecting rod
• Wet replaceable liners allows higher top ring position for better fuel
consumption and reduced emission
• Compact Graphite Iron casting, Min strength – 450 mpa
• Induction Hardened, depth to 0.8 mm after finish honing
• Plateau honed, High strength grey iron for increased life
• Removable liners – for re-buildability
• Single piece steel piston, phosphate coated
• 3 ring piston design
• Gallery cooling in piston allows excellent cooling and long life of
piston and piston rings
• Steel piston and Graphite 255 coated for reduced friction, hence
excellent lubrication
• Heavy duty Forged Con’rod with oil cooling, Increased bearing
surfaces
• Con’rods are removable through top of cylinder for ease of
service -

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 C-18 Engine

Crankshaft
• Forged single piece design for increased
strength and durability
• Induction hardened journals and fillets
• Re-grindable
• Built in durability and serviceability

Bearings
• Composite material bearings with oil flow
for longer life and reduced friction

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 C-18 Engine

Turbocharger
Camshaft, Gear

• Twin turbo-chargers • Carburised and heat treated steel for

• Excellent transient response excellent durability
• Better Fuel efficiency • Overhead cam mounting
• 4 bearings for reduced friction

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 C-18 Engine

Fuel Injectors
 Mechanically actuated Electronically controlled unit
injector combines electronic actuator, pump assembly
and nozzle into a single compact unit.
 Fuel injected at 22000 PSI
 Metering & Timing variable by solenoid
 Solenoid controlled by ADEM III

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 C-18 Engine

Air to Air After cooling Advantage of ATAAC

 By using the external air for cooling the
charge air the charge air inlet air
temperatures can be reduced to approx. 50
deg C, compared to JWAC where the min
temperatures obtained are in the order of 90
deg C
 Reduced cooling pack size
 5- 7% improvement in fuel consumption
 Capability to meet emission requirements

* - Only for explanation of the cooling principle

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 C-18 Engine

Electronic Control Module – ECM

ADEM-III (Advance diesel Engine Management)

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 C-18 Engine

ADEM III

• 3 times faster processor speed

• 8 times flash memory and RAM
• Unique selectable power trim, TEL, and torque
limiting
• More reliable sensors
• 140 inputs/outputs provide growth platform for
additional future features

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 C-18 Engine

ADEM III – Information Management system

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 C-18 Engine

ADEM III
• Reliable, Durable
• All ECM controllers are designed to survive the harshest environments.
(Environmentally sealed, die-cast aluminum housing isolates and protects electronics
components from moisture and dirt contamination)
• Rigorous vibration testing ensures product reliability and durability.
• Accuracy maintained from –40° C to 120° C
• Electronic noise immunity to 100 volts/meter
• Internal circuits are designed to withstand shorts to +battery and –battery.

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 C-18 Engine

ADEM III
• Advance Features
• Isochronous or droop speed control
• Enhanced performance from variable spark ignition timing and duration
• Adjustable monitoring of vital engine parameters
• Idle/rated speed setting
• Programmable speed acceleration ramp rate
• Adjustable cooldown duration
• Data link interfaces.
• Timing Controls for primary and alternate fuel
• Integrated Temperature Sensing Module for cylinders exhaust port, turbocharger
inlet/outlet, average left/right cylinder banks. ITSM differential temperature
monitoring is especially effective for single cylinder misfires detection.
• Adjustable Air/Fuel Ratio Control for humidity and atmospheric pressure
• Electronic fuel control valve for quick response in gas flow variation

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 C-18 Engine

ADEM III
• Information can be accessed / retrieved by customer
• Maintenance information is available, which allows customer based on fuel or hours to match service intervals
• Ability to trouble shoot failures and diagnose problems
• Records information before occurrence of fault
• Instantaneous inputs for engine parameters like Speed, % load, fuel rate, temperatures, pressures & battery
voltage
• Current jobs – operating parameters like hours, fuel used, idle time, idle fuel used, average load factor
• Life time totals – Engine hours, total fuel used, total idle fuel used, total idle time, average load factor, total max.
fuel used
• Histograms - % load vs time, engine speeds vs time

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 Cooling System

• Standard:
– 50°C Ambient Clearance (Standard)
– Fan Guard
– CAT coolant
– Coolant drain with hose and valve

• Optional
– Low coolant level sensor
– Belt Guard

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 Lube System

• Standard features
– Fumes Disposal
– Spin-on CAT Oil Filter
– Oil Drain
– Lube Oil (15W-40)
• Options
– Manual sump pump

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 Air Inlet System

• Air Filtration Levels

– Dry, paper element - Standard
– Single Element (canister)

• Heavyduty Aircleaner(optional)
– Dual Element / Heavy Duty (canister)

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 Exhaust System

• Standard
– Exhaust Elbow and Stainless Steel Flexible Fitting
– Primary and Secondary mufflers with internal piping
• Sound Attenuated Enclosure
– To meets 75dB as per the norms
– Internally Mounted fuel tank

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 Fuel System

• Standard • Optional
– Primary and Secondary Fuel Filter – High level & Low Level Fuel Switch
– Fuel Priming Pump
– Flex Fuel Lines
– Water Separator
– Manual Priming Pump

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 Starting and Charging System

• Standard
– 24 VDC Heavy-duty Starting Motor
– 35 Amp Charging Alternator
– Battery, Rack, & Cables

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 Starting and Charging System

• Optional
– Jacket Water Heater
• 240 VAC
• Package mounted
• Includes isolation valves & adjustable
thermostat

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 Engine Controls and Monitoring system

• Fully Electronic Controlled Engine

• ADEM III Governor
• Electronic Control of Engine Speed
• MEUI Fuel Injectors
• EMCP 3 control and Monitoring system
• Communication thru Modbus to Building management systems using
EMCP 3.2 and 3.3 Series

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 Base Frames

• Rolled Channels with anti-vibration mounts

• Bolted Rugged Construction
• Machined for precise alignment

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 Enclosures

• Sound Attenuated to meet existing

CPCB norms

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 Sound Attenuated Enclosures

• Sound Attenuated – Enclosures designed for

access with top and bottom
– 1.6mm Cold Rolled CRCA lifting ISO corner block
– Control panel viewing window – Enclosure integral 990L fuel
tank
– Non- igniting, self-
– Interior AC / DC lighting
extinguishing acoustic
system
Mineral wool of 100mm
– Externally mounted
emergency stop button
– Durable cast steel with Teflon
bushing hinges.
– Lockable doors with seals

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 Sound Attenuated Enclosure

• Lube oil drain, coolant, drain

termination and fumes disposal lines
terminated on the enclosure
baseframe for easy access

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 Fuel Tank

Baseframe – Fuel Tank Availability

Integral Tank 990 Liter

External free floor standing- 990 Liter

Optional

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 Electrical Packaging

Electric Power Marketing

C-18 Diesel Genset

Caterpillar Confidential: Yellow

 A C Generators

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 Electrical Power Center
A C Generator
• Leroy Somer AC Generators are designed and manufactured for Caterpillar using
state-of-art manufacturing / testing equipments and well-proven processes thus
ensuring highest level of quality and reliability.
• The largest selling AC generators in Europe
• Pioneer in brushless AC generators
• 3rd generation AC generators
• ISO 9002 accreditation by DNV
• Load adjustment module (LAM) provides engine relief upon sudden block loading
• Mounting feet in the middle for better alignment,
• Closed coupled with single bearing to neutralize torque reaction
• Degree of protection - IP-23
• Better protection for the generator
• 2/3 Pitch Windings with longer core length
• Lower reactance
• Lower voltage dips
• Better motor starting capability

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 Electrical Power Center
A C Generator
• Complete class H insulation (both main and exciter windings) - higher life of
components
• AREP winding - standard
• Even under short circuit conditions, power to AVR is still retained -
selective breaker tripping.
• Generator supplies 3-4 times full-load current for 3 sec
• Power Connections
• Bus bar terminations
• Controls Packaging
• EMCP3 Operator Interface
• Control options mounting
• Annunciator
• Discrete I/O, Relays

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 Electrical Power Center

AREP Winding

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 Electrical Power Center

AREP Winding

• Two auxiliary windings provide an isolated, independent source of

power to the voltage regulator
• Provides:
300% short circuit sustaining capability
–
– Improved motor starting
– Immune from distortion of non-linear loads

Performance of a PMG at lower cost

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 Electrical Power Center

AREP Excitation System

AREP

High starting
capacity

Short-circuit
ADVANTAGES capability

No extra length

Specific
winding

Small added cost

DISADVANTAGES

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 Electrical Power Center
Automatic Voltage Regulator (AVR) (R448)
– Single phase sensing
– Lower reactance
– LAM – Load Acceptance Module – Better block load
acceptance and faster recovery
– Provides higher non-linear load capability
– 25% unbalance load capability
– R731 module – optional (3 phase sensing)

Load Acceptance Module

(LAM)

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 Load Acceptance Module

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Controls & Components

Electric Power
C-18 Generator Set
 C32: EMCP 3 Controls

EMCP 3.1 EMCP 3.2 EMCP 3.3

• Standard • Optional • Optional

• Basic Controller • Basic Controller • Enhanced Controller
• Volt adjust optional • Modbus • Modbus
• Min. Required for:
 UL 2200
 NFPA 99/110

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 Distributed J1939 Network

• Primary Networked Devices

– Engine Controller (ADEM™ III)  Standard
– Genset Controller (EMCP 3.1)  Standard
– Optional Networked Devices
– Annunciator  w/EMCP 3.2 & 3.3
– Discrete Input/Output Module  w/EMCP 3.2 & 3.3
– RTD Module  w/EMCP 3.3
– Thermocouple Module  w/EMCP 3.3

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 EMCP 3 Environmental Specifications

• IP56 front, IP22 back

• Vibration tested to 4.3G sinusoidal and 15G shock
• Passed Electromagnetic Compatibility (EMC) Testing to
USFCC & CE standards
• Monitoring Functionality & Controls Operational from -40C to
70C (-40F to 158F)
• Display Operational from -20C to 70C (-4F to 158F)
• Storable from -40C to 85C (-40F to 185F)

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 EMCP 3.1 Control System

ECM

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 EMCP 3.1 Control System

Controls
• Auto/Start/Stop
• Engine Cooldown timer
• Emergency Stop
• Engine Cycle Crank

Digital (LCD) Indication

• Generator AC Voltage - 3 phase (L-L&L-N) Local Display Languages
 True RMS Sensing • Arabic • Icelandic
 +/- 2% Accuracy
• Danish • Italian
• Dutch • Norwegian
• RPM
• Finnish • Portuguese
• Battery Voltage
• French • Russian
• Engine Hours • German • Spanish
• Generator AC Current (per phase & avg) • Greek • Swedish
• Generator Frequency • Hungarian • EU Required
• Engine Oil Pressure (in psi, kPa or bar) 33(h) x 132(w) pixel, 24mm x 95mm graphical display
• Engine Coolant Temperature

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 EMCP 3.1 Genset Controller I/O

(6) Discrete Inputs

– Emergency Stop
– Remote Start
– 4 programmable inputs
(2) Resistive Sensor Inputs
– Oil Pressure (0-2k )
– Coolant Temperature (0-2k )
(1) Magnetic Pickup Input
– Engine Speed
(1) J1939 Communications Port
(6) Relay Outputs
– For integration with Engine
(Form A, 2A @ 30VDC) Controller
–Starter Motor Relay • Can Read/Reset all Events
–Fuel Control Relay • Reads Oil Pressure & Coolant
–4 programmable relays Temp

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 EMCP 3.2 Control System

ECM

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 EMCP 3.2 – Display Features

• 33(h) x 132(w) pixel, 24mm x 95mm graphical display with positive

image, transflective LCD, with adjustable backlight and contrast

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 EMCP 3.2 – Control & Monitoring

• Same Control Features as EMCP 3.1

• Improved Metering Accuracy +/- 1%
• Added Parameters Displayed:
–Generator Power (kW) (total & per phase)
–Generator kVAR (Total & per phase)
–Generator kVARhr (Total)
–Generator % of rated (Total)
–Generator kVA (Total & per phase)
–Generator kWhr (Total)
–Generator Power Factor (Ave. & per
phase)
–Engine Successful Start Counter
–Engine Crank Attempt Counter
Protective Relaying
–Service Maintenance Interval (hrs & real- • Generator Over / Under Voltage
time) • Generator Over / Under Frequency
–Real Time Clock • Generator Overcurrent

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 EMCP 3.2 Genset Controller I/O

• Added I/O over EMCP 3.1

– 2 more programmable relay outputs
(Form C configurable for N.O. or N.C.)
– 2 more programmable discrete inputs
– 1 more programmable resistive sensor input
– 1 programmable discrete output
– An accessory J1939 data link (for options)
– MODBUS communications port for connection
to customer SCADA systems and HMI systems
with Caterpillar’s Modbus monitoring software

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 Annunciator

• Networked device only, no wiring

• 16 Points, 32 LEDs
– (12) Amber and Red LEDs
– (4) Green and Red LEDs
• Standard Label for NFPA 99 & 110
compliance
• All 16 points are configurable to any event that
can occur on the network
– Custom Label Kit available
• Local or Remote (up to 800ft w/o a repeater)

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 Discrete I/O Module

• (12) Discrete Inputs – 24Vdc

• (8) Relay Outputs
– Form C N.O. or N.C. configurable
– 2 Amps resistive up to 30Vdc, 277Vac
• For inductive loads:
› 0.5A @ 250Vac, 0.4 power factor
› 1.0A @ 250Vac, 0.8 power factor
› 1.8A @ 250Vac, 0.9 power factor
• Can remote mount up to 800 feet without a J1939
repeater

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 EMCP 3.3 Control System

ECM

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 EMCP 3 Controls
Feature EMCP 3.1 EMCP 3.2 EMCP 3.3
Display size (mm) pixels 24x95 [33 x132] 24x95 [33 x132] 28x100 [64x240]
Display Languages X X X
Generator Metering Accuracy (+/- X%) 2 1 1
RPM, Oil Press., Battery Volt, Coolant Temp, Eng Hours X X X
Modbus RTU / Remote Monitoring Software X X
Annunciator (NFPA 99-110) X X
Discrete I/O Module X X
Power Metering (kW, kVA, KVAR, etc.) X X
Engine Crank Attempt Counter X X
Engine Successful Start Counter X X
Service Maintenance Interval (hrs & Real-time) X X
Engine Oil Temperature (Degrees C or F) X X
Real Time Clock X X
Protective Relaying: O/U Volts & Freq; Overcurrent X X
Protective Relaying: Reverse Power X
Enhanced Engine Monitoring X
Voltage Adjust (on Controller) X
RTD / Thermocouple Module X
Programmable Switch Inputs 4 6 6
Programmable Relay Outputs (2A continuous DC) 4 6 6
Programmable Discrete Outputs 1 2 2
Configurable Input (0-2 kOhm resistive sender) 1 1

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 EMCP 3.3 Added Features

• Added I/O over EMCP 3.2

– 1 more programmable discrete output
• Improved Display over EMCP 3.2
– 64(h) x 240(w) pixel, 28mm x 100mm graphical
display with adjustable backlight and contrast
• System Integration with Optional
Modules
– RTD Module (Monitors Generator Temperatures)
– Thermocouple Module (Monitors Generator or
Engine Temperatures)
System Integration Means:
• View & Reset Diagnostics
• Monitor Data
• Configure from EMCP3.3

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 EMCP 3.3 – Control & Monitoring Features over EMCP 3.2

• Added Control Features :

–Generator Voltage Adjust

• Added Parameters Displayed:

–Fuel Temperature
–Fuel Pressure
–Total Fuel Used
–Engine Exhaust Temp
–Intake Manifold Temp
–Engine Oil Temp
–Crankcase Pressure
–Fuel Consumption
–Generator Temps (with optional RTD / Protective Relaying
Thermocouple Module) • Adds Reverse Power Protection

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 EMCP 3.3 – Additional Control & Monitoring Features

• Improved Metering Accuracy  +/- 1% • Additional I/O

• Added Parameters Displayed: - (1) programmable discrete output
–Power (kW) (total & per phase)
- (2) more programmable relay outputs
–kVAR (Total & per phase)
–kVAR-hr (Total) - Form C: configurable for NO or NC
–% of rated (Total) - (2) more programmable discrete inputs
–kVA (Total & per phase)
–kW-hr (Total) - (1) more programmable resistive sensor
–Power Factor (Avg & per phase) input
–Engine Successful Start Counter - (1) programmable discrete output
–Engine Oil Temperature (F or
• Accessory J1939 data link (for options)
C)
–Engine Crank Attempt Counter • MODBUS communications port for connection
–Service Maintenance Interval to customer SCADA systems and HMI systems
• hours & real-time with Caterpillar’s Modbus monitoring software
–Real Time Clock

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 EMCP 3 Remote Monitoring Software

• Remote Monitoring &

Control Software
– Single Genset
– No Charge Option
• Allows the user to:
– Monitor
– Log
– Graph
– Control
• For use on all Windows
based operating systems

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 Integral User Interface Panel

• EMCP 3.1 – standard

• Options:
• EMCP 3.2 & 3.3
• Up to 2 Local Annunciators
› 32 points / 64 LED’s
•Discrete I/O
• EMCP 3.3
• RTD, T/C modules

• Rear mounted – standard

– Options:
• Left
• Right

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