CAT Electric Power Ratings Guide: Generator Sets

Diesel Generator Sets

50 Hz Ratings

6.8 – 218 kVA (Single Phase Output* 1500 rpm)

6.8 – 218 kVA (Three Phase Output** 1500 rpm)

230 – 715 kVA (1500 rpm)

680 – 2500 kVA (1500 rpm)

2500 – 4000 kVA (1500 rpm)

1963 – 7150 kVA (Power Plants, 1000 rpm)

1963 – 7150 kVA (Power Plants, 750 rpm)

1100 – 4300 kWe (Heavy Fuel, 1000 rpm)

1100 – 4300 kWe (Heavy Fuel, 750 rpm)

1100 – 4300 kWe (Heavy Fuel, 600 rpm)

2000 – 5400 kVA (Heavy Fuel, 1000 rpm)

5520 – 16400 kWe (Heavy Fuel, 514 rpm)

5290 – 15100 kWe (Dual Fuel, 500 rpm)

5290 – 15100 kWe (Dual Fuel, 750 rpm)

60 Hz Ratings

8 – 600 ekW (Single Phase Output 1800 rpm)

8 – 600 ekW (Three Phase Output 1800 rpm)

180 – 4000 ekW (Three Phase Output 1800 rpm)

8 – 200 ekW (Available only for North America)

8 – 200 ekW (Three Phase Output** 1800 rpm)

1525 – 5320 ekW (Power Plants, 1000 rpm)

1525 – 5320 ekW (Power Plants, 750 rpm)

1500 – 4000 ekW (Heavy Fuel, 900 rpm)

985 – 4300 kWe (Heavy Fuel, 900 rpm)

985 – 4300 kWe (Heavy Fuel, 720 rpm)

985 – 4300 kWe (Heavy Fuel, 600 rpm)

5520 – 16400 kWe (Heavy Fuel, 514 rpm)

5290 – 15100 kWe (Dual Fuel, 514 rpm)

5290 – 15100 kWe (Dual Fuel, 750 rpm)

Rating Definitions

Standby Power
Output available with varying load for the duration of the interruption of the normal source power. Average power output is 70% of the standby power rating. Typical operation is 200 hours per year, with maximum expected usage of 500 hours per year.

Mission Critical
Output available with varying load for the duration of the interruption of the normal source power. Average power output is 85% of the mission critical power rating. Typical peak demand up to 100% of rated power for up to 5% of the operating time. Typical operation is 200 hours per year, with maximum expected usage of 500 hours per year.

Prime Power
Output available with varying load for an unlimited time. Average power output is 70% of the prime power rating. Typical peak demand of 100% of prime-rated ekW with 10% of overload capability for emergency use for a maximum of 1 hour in 12. Overload operation cannot exceed 25 hours per year.

Continuous Power
Output available without varying load for an unlimited time. Average power output is 70 – 100% of the continuous power rating. Typical peak demand is 100% of continuous rated ekW for 100% of operating hours.

Gas Generator Sets

50 Hz Ratings

107 – 4500 ekW (Continuous – Natural Gas, 1800 rpm)

107 – 4500 ekW (Continuous – Natural Gas, 750 rpm)

107 – 4500 ekW (Continuous – Natural Gas, 500 rpm)

107 – 4500 ekW (Continuous – Natural Gas, 1000 rpm)

6580 – 15100 kWe (Gas / Dual Fuel Ratings, 750 rpm)

6580 – 15100 kWe (Gas / Dual Fuel Ratings, 514 rpm)

60 Hz Ratings

30 – 150 ekW (Natural Gas, 1800 rpm)

30 – 150 ekW (Natural Gas, Three Phase Output* 1800 rpm)

158 – 400 kVA (Natural Gas, Three Phase Output 1500 rpm)

158 – 450 ekW (Natural Gas, Three Phase Output 1800 rpm)

30 – 140 ekW (Propane Gas Ratings, 1800 rpm)

30 – 140 ekW (Propane Gas, Three Phase Output* 1800 rpm)

150 – 2000 ekW (Standby Gas Ratings, 1800 rpm)

135 – 1900 ekW (50 – 60 Hz Gas Rental Power Ratings)

137 – 4050 ekW (60 Hz Continuous – Gas Ratings, 1800 rpm)

137 – 4050 ekW (60 Hz Continuous – Gas Ratings, 720 rpm)

137 – 4050 ekW (60 Hz Continuous – Gas Ratings, 1500 rpm)

137 – 4050 ekW (60 Hz Continuous – Gas Ratings, 1200 rpm)

137 – 4050 ekW (60 Hz Continuous – Gas Ratings, 900 rpm)

6580 – 15100 kWe (Gas / Dual Fuel Ratings, 514 rpm)

Renewable Energy Products

Photovoltaic (PV) Module

Inverter Options – UL Listed

Inverter Options – CE Mark

Inverter Options – Domestic China

[Image of solar panels and workers]

Energy Storage Systems

Grid Stability Modules

Energy Time Shift Module

Controls

Microgrid Master Controller (MMC)

MMC-S
The MMC-S is designed for residential and small business installations. It integrates the photovoltaic (PV) system, generator set, and energy storage system to provide renewable capacity penetration up to 60%.

MMC-M
The MMC-M is designed for industrial and small community installation. It integrates with the photovoltaic (PV) system, generator set, and energy storage system to provide renewable capacity penetration of greater than 60%. The MMC-M provides black start capability and performs load management functions.

MMC-L
The MMC-L is designed for large industrial, campus, and distributed resource installations. It integrates with the photovoltaic (PV) system, generator set, and energy storage system to provide renewable capacity penetration of greater than 60%. The MMC-L can control distributed assets and provides black start capability and load management functions.

Home and Outdoor Power Products

50 Hz Gasoline (50 Hz 3000 rpm)

UK and EU*

USA and Canada (60 Hz 3600 rpm)

[Image of various portable generators]

EMCP 4 Controllers

EMCP 4.1
The EMCP 4.1 provides basic engine controls – stop/run/auto push button controls, cycle crank, and cool down timer. The 3.8 inch graphical display supports multiple languages, including character languages such as Chinese, Arabic, Russian, and Japanese. The EMCP 4.1 provides monitoring of generator electrical output, including AC voltage, current, frequency, and mechanical information such as oil pressure, coolant temperature, engine speed, and battery voltage along with fuel level if a sensor is provided. It also provides a number of protective functions, such as warnings and shutdowns for over/under voltage, over/under frequency, low oil pressure, high coolant temperature, low coolant level, failure to start, and overspeed.

EMCP 4.2
The EMCP 4.2 builds on the features of the EMCP 4.1 controller, offering expanded engine monitoring based on information available from the engine ECM, along with expanded generator set protection and monitoring, such as generator kW, kVA, and kWh. Flexibility is also increased with the addition of a Modbus RTU communication port, remote annunciator modules, and expansion I/O modules to allow the EMCP 4 system to be configured to meet site specific design requirements. With the additional monitoring and expansion modules available, the EMCP 4.2 is designed to provide control and protection for critical installations, such as NFPA-110 Level 1 applications.

EMCP 4.2B
The EMCP 4.2B adds advanced features to the EMCP 4.2 controller, offering expanded generator set protection and monitoring, such as additional overcurrent protection curve selection, real (kW) load histogram, trip kWh and trip kVArh. Display screens are configurable for customer desired parameters. An integrated basic programmable logic control (PLC) function to read controller inputs and drive controller outputs is also provided with the EMCP 4.2B.

EMCP 4.3
The EMCP 4.3 further expands the EMCP 4 product line with the addition of 5.5 inch graphical display and additional context specific navigation keys. With the addition of a Modbus TCP port, the EMCP 4.3 controller can be easily integrated into complex systems requiring complete generator set monitoring.

EMCP 4.4
The EMCP 4.4 builds on the EMCP 4.3 functionality with the addition of fully automatic multi generator set paralleling. The EMCP 4.4 provides all of the functions required to automatically parallel generator sets, including dead bus arbitration, automatic or manual modes of operation, and load sharing (real and reactive). Optional provisions allow for extended parallel operation of a single generator with Utility for Base Load/Import/Export capability.

Systems Products

Paralleling Products

ATS

UPS Bypass Switches

[Image of a large electrical enclosure/switchgear]

Reference Guide

Fuel System – Diesel

Day Tank Sizing

Tank Size (gal) = Rated BSFC (lb/hp.hr) x Rated HP x Load Factor / 7.076 (lb/gal)

• Hours Between Refilling

• Reserve Requirement

Rule of Thumb for tank size with 25% reserve

0.056 x Ave. BHP demand x Hours between refills x 1.25 = ____ gal.

0.27 x Ave. BKW demand x Hours between refills x 1.25 = ____ liters.

Note: Additional tank capacity required for cooling of recirculated fuel in unit-injected engines. Tank should be located below level of injectors or nozzles.

On-Site Power Requirements

Based on 100,000 sq ft. of office building, etc. and 40°N. Latitudes

• Electric Requirements
  600 kW continuous load (Air conditioning is absorption)
  Use three - 300 kW units (2 prime and 1 standby)
• Refrigeration
  One ton refrigeration = 200 Btu/min = 12,000 Btu/h
  One Boiler hp = 33,475 Btu/h
  One ton compressor rating = One engine hp
  Auxiliary air conditioning equipment requires 1/4 hp/ton of compressor rating
• Ice Plant
  Complete power requires 4-5 hp per daily ton capacity
• Air Compressor
  hp = 1/4 x cu ft m/min at 100 psi
  Increase bhp 10% for 125 psi
  Decrease bhp 10% for 80 psi

Electrical Tables

ELECTRICAL TABLE ABBREVIATIONS:
V - voltage in volts
I - current in amperes
kW - power in kilowatts (actual power)
kVA - kilovolt-amperes (apparent power)
HP - horsepower
RPM - revolutions per minute
EFF. - efficiency as a decimal factor
FL - full load
P.F. - power factor
Note: DC kW = DC KVA

Three-Phase Connection Systems

[Diagram description: Three-Phase, Three-Wire (Wye) A]

[Diagram description: Three-Phase, Three-Wire (Delta) B]

[Diagram description: Three-Phase, Four-Wire (Wye) C]

[Diagram description: Three-Phase, Four-Wire (Delta) D]

Reduced Voltage Starters

Engine Room Ventilation

Engine room ventilation can be estimated by the following formulas, assuming 100°F (38°C) ambient air temperature:

V (cfm) = H / (0.070 x 0.24 x ΔT)

V (m³/min) = H / (1.099 x 0.017 x ΔT)

Where:

V = Ventilation air (cfm) (m³/min).
H = Heat radiation (Btu/min) (kW).
ΔT = Permissible temperature rise in engine room (°F) (°C).
Density of air at 100°F = 0.070 lb/cu ft (1.099 kg/m³).
Specific heat of air = 0.24 Btu/°F (0.017 kW/°C).

Conversion Factors

Temperature Conversion

°F = (1.8 x °C) + 32
°C = 0.5555 (°F – 32)

Angle

1 quadrant = 90 degrees
1 quadrant = 1.57 radians
1 radian = 57.3 degrees
1 degree = 60 minutes
1 minute = 2.9 x 10 radians

Identifying Code Letters on AC Motors

Note: Code letters apply to motors up to 200 HP.

Product Support

Product Support Definitions

Extended Service Coverage (ESC)

Depending on the model and application, Silver, Gold, Platinum and Platinum Plus coverage levels are available from Caterpillar with terms to meet most applications, whether prime or standby.

Platinum and Platinum Plus provide additional allowances for overtime, emergency freight, rental, crane and rigging support. Please see the registration contract for details.

Electric Power ESC reimburses covered parts at customer list price, labor at selling rates and travel and mileage charges (less any deductibles) for covered repairs.

Available worldwide for all Cat Electric Power Products, ESC provides usual and customary parts and labor costs for covered system failures due to defects in materials and workmanship on components over the duration of the covered period.

This is a brief description of Extended Coverage. See your Cat dealer for more information. The Extended Coverage contract will govern.

*Overhaul Protection Coverage.

Customer Support Agreements

• A Customer Support Agreement (CSA) is an arrangement between the end user and the Cat dealer that helps lower the cost per unit of production. Agreements are tailored to fit your business needs and can range from simple Preventive Maintenance Kits to sophisticated Total Cost Performance Guarantees.
• Qualified Factory Trained dealer technicians assist you by maintaining your Cat Electric Power Products and driving down operating costs. Perhaps the most important feature of any CSA is flexibility.
• A Preventive Maintenance (PM) agreement covers specified maintenance at a fixed cost. You maintain reliability and efficiency because the maintenance is performed by highly skilled technicians at guaranteed costs, giving you the ability to budget more accurately.
• A Total Maintenance and Repair (TM&R) agreement covers all of the maintenance and repair costs. Instead of paying for maintenance or repairs as they are needed, you pay one flat rate to cover a broad range of parts and services.

Check with your local Cat dealer for available options with each agreement.

Notes