EAME Power Module Conversion Procedure

Dual Frequency Conversion (50Hz/60Hz)

C32 Utility Paralleling Power Module

SYC

Description
The intent of this procedure is to instruct on properly changing the operation of the EAME C32
1000 kVA Power Module from 50Hz operation to 910 ekW prime 60Hz operation or from 60Hz
operation to 50Hz operation.

Reference Publications
SEBU 8088 Operation and Maintenance Manual EMCP3 & CDVR
EMCP3 troubleshooting manual
EMCP3 specifications
292-4084 EMCP3 wiring diagram
CDVR troubleshooting manual
CDVR specifications
RENR 9855 C32 genset wiring
RENR 7167 C32 genset specifications
RENR 9348 C32 genset troubleshooting
RENR 9968 C32 genset Systems operations testing & adjusting
RENR 8088 C32 genset Operation and Maintenance Manual

Procedure
1. Turn off 24V DC power (key switch) and disconnect all shore power supplied to the Power
Module.
2. Open the left and right service doors of the container.
3. Disassemble fan & belt guards elements. This will allow access to fan pulley group and
radiator fan.

4. Loosen belt tightener by unscrewing 1 bolt.

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5. Disassemble pulley holder to engine by unscrewing 4 bolts
6. Unscrew 6 bolts holding fan pulley to holder
7. Unscrew 6 bolts holding fan pulley to fan
8. Remove pulley and replace. When moving from 50 Hz to 60 Hz, remove 4 grooves pulley
7N8828 (25.4 cm diameter) and 4 belts 4N8218 ( 163.9 cm long) and replace by pulley
6N0597 (29 cm diameter) and 4 belts 9L6649 (174 cm long) or vice versa when moving from
60 Hz to 50 Hz.

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9. Install the desired pulley to the fan motor shaft per the above instructions. Install the
removed pulley at the reserve fan pulley mounting location located on the rail baseframe for
reversing the conversion at a later time.
10. Re-install the belts.
11. Adjust the belt tension using the tensioning rods.
12. Close the service doors.
13. Turn on 24V DC power (key switch) and reconnect all shore power supplied to the Power
Module.
14. Prepare to communicate with the EMCP 3.3 control panel via Caterpillar Engineering
Technician (ET) by connecting the ET communications cable to the EMCP 3.3
communications port.
15. Flash the ADEM with the desired flash file using the CAT Data Link and ET. After the
ADEM has been flashed, you must double-check the Engine Overspeed Setting. Go to the
Service Tab and select Monitoring System.

Please check latest available flashfile through TMI !!

Flash File Caterpillar Part No.: 50Hz, 303-1614 SOFTWARE GP-ELEK

60Hz, 302-6503 SOFTWARE GP-ELEK

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 ECM Monitoring System

16. Search for the Description Engine Overspeed and change the setting if it is not correct. The
setting is 18% over the Rated Speed (1770 rpm for 50 Hz and 2124 rpm for 60Hz).

Check Engine Overspeed Setting

Change Trip Points for Overspeed

17. Query for the ECMs on the J1939 network.

Query
Press this key to connect Press this key to disconnect for
J1939
Networ
k

Note:
Someti
mes one of the ECMs may not show up the first time you connect, so continue to disconnect
and reconnect to the J1939 until both the EMCP3.3 and CDVR appear as available. This is
a known bug within the software.

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Digital Voltage Regulator > Monitor > Voltage Regulator Power Input Freq: 4 x 60Hz = 240 Hz

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18. Click the plus sign next to Digital Voltage Regulator to see the CDVR submenus. Click on
Monitor and change the setting Voltage Regulator Power Input Frequency
Configuration. This value should be equal to four times the generator frequency for PMG
Generators. It should be equal to one times the generator frequency for Self Excited or
AREP Generators.

Note: Unless the Potential Transformers and Current Transformers in the generator are
changed, do not change their values.

19. Click on the Protection submenu and change the following parameters:

Digital Voltage Regulator > Protection> Generator Rated Frequency

Generator Rated Frequency: 50Hz or 60Hz

Generator Rated Voltage: 50Hz, 400V

60Hz, 480V

Generator Rated Current: Current = Killowatts * 1000

Voltage * PowerFactor * 1.73

50Hz 400V, 800 kW = 1443 Amps (0.8 PF)

60Hz 480V, 910 kW = 1368 Amps (0.8 PF)

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20. Click on the Voltage Regulator Control Parameters Submenu of the CDVR and change
the following parameters:

Digital Voltage Regulator > Voltage Regulator Control Parameters> Voltage Reg Corner Freq

Generator nominal Output Voltage: 50Hz, 400V

60Hz, 480V

Voltage Regulator Corner <Knee> Frequency: 50Hz, 49.8Hz

60Hz, 59.8Hz
Note: This is equal to the desired frequency
minus 0.2 Hz.

21. Click the plus sign next to EMCP3.3 to see the EMCP submenus. Find the submenu for
Engine Speed Monitor and change the following parameters:

EMCP3.3 > Engine Speed Monitor > Engine Overspeed Setpoint

Engine Overspeed Setpoint: 50Hz, 1770 rpm

60 Hz, 2124 rpm

Engine Underspeed Warning Event Threshold: 50 Hz, 1290 rpm

60 Hz, 1548 rpm
Note: This is the speed below the rated speed
that the EMCP will issue a warning to the
operator. It should be 86% of the rated speed.

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 Engine Underspeed Shutdown Event Threshold 50 Hz, 1230 rpm
60 Hz, 1476 rpm
Note: This is the speed below the rated speed
that the EMCP will initiate a shutdown of the
genset. It should be 82% of the rated speed.

22. Click on the Generator AC Monitor Submenu and change the following parameters:

EMCP3.3 > Generator AC Monitor

Generator Rated Frequency: 50Hz or 60Hz

Generator Rated Voltage: 50Hz, 400 V

60Hz, 480 V

Generator Rated Power: 50Hz, 800 kW

60Hz, 910 kW

kilowatts
Generator Rated Apparent Power: ApparentPower (kVA) =
powerfactor

50Hz 400V, 800 kW = 1000 kVA (0.8 PF)

60Hz 480V, 910 kW = 1137 kVA (0.8 PF)

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23. Click on the AVR Desired Voltage Request Submenu.
Note: This menu is currently not available for EMCP3.2 and EMCP3.1

EMCP3.3 > AVR Desired Voltage Request

Generator Nominal Output Voltage: 50Hz, 400V

60Hz, 480V

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 PARAMETER CHANGES SUMMARY
50 Hz 60 Hz
ADEM IV
Flash File Part No.* 291-8573 291-8572
Engine Overspeed 1770 2124 RPM
*Check latest flash file versions at Service Information System (SISWEB) website (contact
Caterpillar Inc. Customer Service for access).

CDVR
Monitor
Voltage Regulator Power Input Frequency Configuration 200 240 Hz
Protection
Generator Rated Frequency 50 60 Hz
Generator Rated Voltage 400 480 Volts
Generator Rated Current 1443 1368 Amps
Voltage Regulator Control Parameters
Generator Nominal Output Voltage 400 480 Volts
Voltage Regulator Corner (Knee) Frequency 49.8 59.8 Hz

EMCP 3.3
Engine Speed Monitor
Engine Overspeed Setpoint 1770 2124 RPM
Underspeed Warning Event Threshold 1290 1548 RPM
Underspeed Shutdown Event Threshold 1230 1476 RPM
Generator AC Monitor
Generator Rated Frequency 50 60 Hz
Generator Rated Voltage 400 480 Volts
Generator Rated Power 800 910 kW
Generator Rated Apparent Power 1000 1137 kVA
AVR Desired Voltage Request
Generator Nominal Output Voltage 400 480 Volts

EMCP 3.3, CDVR, and ADEM 50Hz/60Hz Frequency Conversion Chart

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24. Reset any faults displayed on the EMCP3, ECM, or CDVR.
25. Go to the PLC display HMI screen on right side of the EMCP3.3 panel. Go to the Process
Variables screen on HMI and select 400V/50Hz for 50Hz operation and 480V/60Hz for
60Hz operation.

26. Go to the EMCP3 panel on the genset and place the EMCP control panel to AUTO operation
mode. Go to the HMI and start the unit in AUTO mode (ECS switch) and check for desired
voltage and frequency.

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27. If no faults or errors are seen, the conversion procedure is complete. Otherwise, revisit steps
in conversion procedure to troubleshoot. Also, reference above publications for assistance.

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