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Caterpillar Switchgear

- Ferreyros
Oscar Gross
One company.

A multitude of solutions.
Generator Sets that have no equal World-Wide
One company.

A multitude of solutions.
Caterpillar Global Support
US Based Outside US

Manufacturing Locations 39 31
Remanufacturing Locations 4 10
Parts Distribution Centers 15 16
Logistics Distribution Centers 21 24
Training Centers 7 8
Dealers 64 145
Branch Stores 456 941
Rental Stores 373 903
One company.

A multitude of solutions.
Caterpillar Dealer Network
Representation in 180 Countries
Over 50,000 Trained Technicians
One company.

A multitude of solutions.
A World Leading Manufacturer of Switchboards and
Switchgear
One company.

A multitude of solutions.









Multi-billion dollar diversified
industrial manufacturer
Headquarters in Cleveland,
Ohio
50,000 employees
207 manufacturing sites
Serving customers around the
world
Eaton Corporation
Eaton World Headquarters
Cleveland, OH
One company.

A multitude of solutions.
Eaton Electrical Power Products
Load Interrupter
Switchgear
VacClad-W Medium Voltage
Switchgear
Ampgard

Medium
Voltage Starters
Excitation Control Substation Transformers
Panelboards and
Switchboards
Pow-R-WayIII

Low
Voltage Busway
Grounding Resistors
Electro/Centers
TM
Network
Protectors
Low Voltage DSII
Metal-Enclosed
Switchgear
Low Voltage
Pow-R-M-S
Switchboards
IMPACC
Communications System
One company.

A multitude of solutions.
HISTORY
ISO - Founded in 1985
Initially provided maintenance and emergency service to
UPS and standby power industry
Began manufacturing conventional generator controls
and switchgear in 1986
PowerLynx R&D 1996 to 1997
PowerLynx marketing rollout July 1998
Third largest Emergency Power Switchgear manufacturer
in 2000

One company.

A multitude of solutions.
AGENDA
Proven Products
In October 2001 Caterpillar, the World Leader in the
Engine-Generator Marketplace, decided to purchase an
Automated Switchgear Manufacturer to provide Total
Systems Solutions for its Engine-Generator Products.

After much Research, they selected the most Innovative
and Reliable Automated Switchgear Technology
available in the World Today:
CATERPILLAR SWITCHGEAR
CATERPILLAR SWITCHGEAR
One company.

A multitude of solutions.
The Intelligent Switchgear Organization


In August of 2003, Caterpillar and Eaton Electrical
partnered in the ownership of ISO.

ISO manufactures the Caterpillar Switchgear product line
with PowerLynx Technology, using Cutler Hammer power
elements.

Controls are designed to work hand in glove with
Caterpillar generators and packaged by Caterpillar
Dealers as a complete System.

THE JOINT VENTURE
One company.

A multitude of solutions.
Caterpillar Switchgear
Tomorrows Technology.. Today!!!
AGENDA
Proven Products
When the Centers for Disease Control needed Standby Power for their
Critical Operations in Atlanta and Colorado?

When McMurdough Research Station in Antarctica wanted
the most Reliable Power during the long Arctic Winters?

When the US Military looked for the most Dependable
Backup Power Source for its Missile Operations in Fort Greely, Alaska?

When the Federal Reserve Bank selected an Emergency Power System
for their newest facility in Atlanta?

When NOAA required Backup Power for its Satellite Uplinks in Hawaii?
WHO DID THEY CHOOSE?
One company.

A multitude of solutions.
WHAT IS CATERPILLAR SWITCHGEAR TECHNOLOGY?
Cat Swgr is specifically designed and manufactured for hand in
glove application with Caterpillar Generator Sets

Caterpillar Switchgear works for all applications:

Emergency Generator Paralleling
Emergency Transfer and Load Mgmt
Prime Power
Custom Applications

One company.

A multitude of solutions.
WHAT IS CATERPILLAR SWITCHGEAR?
Caterpillar Switchgear is microprocessor based, touch-screen
controlled, Generator Control Switchgear Technology with features
unavailable elsewhere in the market

Caterpillar Switchgear features a color touch-screen, with dynamic
graphical interface for intuitive system operation

Caterpillar Switchgear utilizes true distributed process to insure fault
tolerance

One company.

A multitude of solutions.
WHAT IS CATERPILLAR SWITCHGEAR?
One company.

A multitude of solutions.
System
Overview

Engine
Gauges



Generator
Meters

Generator
Control
CATERPILLAR SWITCHGEAR TOUCHSCREEN
One company.

A multitude of solutions.
Engine
Data

Annunciator




Reports


Settings
CATERPILLAR SWITCHGEAR TOUCHSCREEN
One company.

A multitude of solutions.
PowerLynx 1000 Fighting line
PowerLynx 1000 Products are designed to
compete where market conditions require a
very low cost option
PowerLynx 1000 Products do not sacrifice
reliability or fault tolerance to achieve their
low cost.
6 Monochrome TS, Limited Data Logging

PowerLynx 2000 Value line
PowerLynx 2000 Products are the standard
CAT Switchgear Product offering
PowerLynx 2000 products outperform the
RAZ offerings in all aspects
12 Color TS, Limited data Logging

PowerLynx 3000 Premium line
PowerLynx 3000 Products are the Premium
CAT Switchgear Product offering
PowerLynx 3000 Products offer your
customer features and Reliability that is
unparalleled in the industry
15 Color TS, full data Logging


PL 1000
PL 2000
PL 3000
POWERLYNX 1000 / 2000 / 3000
One company.

A multitude of solutions.
COMPETITIVE ADVANTAGES
Total System Control at Your Fingertips
The Information you need the way you want to see it
(Common interface for MV and LV applications)
Advanced Processing Technology with Remote Monitoring and
Control Capabilities
Reliability Unrivaled in the Industry
Part Count Reduction
Complete Power Solutions from a Single Source
Flawless Interface with Caterpillar gensets
Huge Global Network for Parts and Service
One company.

A multitude of solutions.
G
e
n
e
r
a
t
o
r

S
e
t
s

Caterpillar
Switchgear
On Site
Remote
Off Site
Remote
Caterpillar
ATSs
Power
Cabling
Engine
Communications
ATS
Communications
Ethernet
Communications
TOTAL SYSTEM CONTROL AT YOUR FINGERTIPS
One company.

A multitude of solutions.
REMOTE COMMUNICATIONS
Advanced Processing Technology with Remote Monitoring and
Control Capabilities
On-Site High Speed Remote Monitoring and/or Control
Off-Site Remote Monitoring and/or Control via Dial-Up, Frame
Relay or Cable Modem
All remote packages offer the same view, and level of
Monitoring and/or Control as the on-site Touch Screen Panel
Data and/or Control Export to Building Management Systems
One company.

A multitude of solutions.
Traditional System Design
RELIABILITY UNRIVALED IN THE INDUSTRY
Part Count Reduction
One company.

A multitude of solutions.
RELIABILITY UNRIVALED IN THE INDUSTRY
Part Count Reduction
Less Wiring
Smaller Footprint
Low Cost Redundancy
Better Performance
Fault Tolerance
High MTBF
Low MTTR

One company.

A multitude of solutions.
TouchScreen
ATS
Modbus Plus Supervisory Network
ATS
ATS
Caterpillar Switchgear Systems
Eliminate all these Single Points
Of Failure:
Current High Reliability System Description
MOVING MASTER TECHNOLOGY
Generator 1 executes all Main Processor
Functions.
Distribution
I/O
PB PB PB
Generator 1
PB PB
Generator 2 Generator 3
Util
Relay
Redundant Utility/Tie
EMCP
EMCP EMCP
TSP
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
MOVING MASTER TECHNOLOGY
Generator 1 executes all Main Processor
Functions.
TouchScreen
ATS
Modbus Plus Supervisory Network
ATS
ATS
Caterpillar Switchgear Systems
Eliminate all these Single Points
Of Failure:
MOVING MASTER TECHNOLOGY
If Generator 1 PLC Fails, Generator 2 PLC
takes over the Master Functions.
Distribution
I/O
PB PB PB
Generator 1
PB PB
Generator 2 Generator 3
Util
Relay
Redundant Utility/Tie
EMCP
EMCP EMCP
TSP
Current High Reliability System Description
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
MOVING MASTER TECHNOLOGY
If Generator 1 PLC Fails, Generator 2 PLC
takes over the Master Functions.
TouchScreen
ATS
Modbus Plus Supervisory Network
ATS
ATS
Caterpillar Switchgear Systems
Eliminate all these Single Points
Of Failure:
MOVING MASTER TECHNOLOGY
If Generator 2 PLC Fails, Generator 3 PLC
takes over the Master Functions, etc.
Distribution
I/O
PB PB PB
Generator 1
PB PB
Generator 2 Generator 3
Util
Relay
Redundant Utility/Tie
EMCP
EMCP EMCP
TSP
Current High Reliability System Description
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
MOVING MASTER TECHNOLOGY
If Generator 1 PLC Fails, Generator 2 PLC
takes over the Master Functions.
TouchScreen
ATS
Modbus Plus Supervisory Network
ATS
ATS
Caterpillar Switchgear Systems
Eliminate all these Single Points
Of Failure:
MOVING MASTER TECHNOLOGY
If Generator 2 PLC Fails, Generator 3 PLC
takes over the Master Functions, etc.
Distribution
I/O
PB PB PB
Generator 1
PB PB
Generator 2 Generator 3
Util
Relay
Redundant Utility/Tie
EMCP
EMCP EMCP
TSP
Current High Reliability System Description
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
TRIPLE REDUNDANT UTILITY/TIE CONTROL
If the Primary Utility/Tie PLC Fails, the
Secondary takes Control.
TouchScreen
ATS
Modbus Plus Supervisory Network
ATS
ATS
Caterpillar Switchgear Systems
Eliminate all these Single Points
Of Failure:
Distribution
I/O
PB PB PB
Generator 1
PB PB
Generator 2 Generator 3
Util
Relay
Redundant Utility/Tie
EMCP
EMCP EMCP
TSP
Current High Reliability System Description
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
TRIPLE REDUNDANT UTILITY/TIE CONTROL
If the Primary Utility/Tie PLC Fails, the
Secondary takes Control.
TouchScreen
ATS
Modbus Plus Supervisory Network
ATS
ATS
Caterpillar Switchgear Systems
Eliminate all these Single Points
Of Failure:
Distribution
I/O
PB PB PB
Generator 1
PB PB
Generator 2 Generator 3
Redundant Utility/Tie
Util
Relay
TRIPLE REDUNDANT UTILITY/TIE CONTROL
If the Secondary Utility/Tie PLC Fails, the Utility
Protective Relay calls the Generators to the Bus
through Hardwired connections.
EMCP
EMCP EMCP
TSP
Current High Reliability System Description
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
TRIPLE REDUNDANT UTILITY/TIE CONTROL
If the Primary Utility/Tie PLC Fails, the
Secondary takes Control.
TouchScreen
ATS
Modbus Plus Supervisory Network
ATS
ATS
Caterpillar Switchgear Systems
Eliminate all these Single Points
Of Failure:
EMCP
Distribution
I/O
PB PB PB
Generator 1
EMCP
PB
EMCP
PB
Generator 2 Generator 3
Redundant Utility/Tie
Util
Relay
TRIPLE REDUNDANT UTILITY/TIE CONTROL
If the Secondary Utility/Tie PLC Fails, the Utility
Protective Relay calls the Generators to the Bus
through Hardwired connections.
TSP
Current High Reliability System Description
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
REDUNDANT SUPERVISORY NETWORK
Fully Redundant Supervisory Networks are
Standard.
TouchScreen
ATS
Modbus Plus Supervisory Network
ATS
ATS
Caterpillar Switchgear Systems
Eliminate all these Single Points
Of Failure:
EMCP
Distribution
I/O
PB PB PB
Generator 1
EMCP
PB
EMCP
PB
Generator 2 Generator 3
Redundant Utility/Tie
Util
Relay
TSP
Current High Reliability System Description
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
OPTIONAL REDUNDANT DISTRIBUTION
CONTROL
Allows Fully Redundant Distribution Control for
Load Shed / Load Add.
TouchScreen
ATS
Modbus Plus Supervisory Network
ATS
ATS
Caterpillar Switchgear Systems
Eliminate all these Single Points
Of Failure:
EMCP
Distribution
I/O
PB PB PB
Generator 1
EMCP
PB
EMCP
PB
Generator 2 Generator 3
Redundant Utility/Tie
Util
Relay
TSP
Current High Reliability System Description
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
SUPER RELIABLE DC POWER

Every Caterpillar Switchgear Component is powered by 24vdc,
Including the Utility Protective Relay, Touchscreen and Touchscreen
Processor.

This DC is derived from all the Engine Batteries, as well a final Backup
Station Battery.

So if even a single Engine-Generator has a good enough Battery to
Start, PowerLynx Technology will be there to control it.
Reliability is Further Enhanced by:
Other Features
WIDE DC CONTROL POWER RANGE

Every Caterpillar Switchgear Component is built with a Separate,
Wide Range DC Power Supply.

Every Component, including the Touchscreen and Touchscreen
Processor, will accept a continuous Control Power input of 18 - 40vdc.

Many of our Competitors use DC-DC Converters or even DC-AC
Inverters to Power their Systems. These are Single Points of Failure.
The also do not operate over this wide of a voltage range.
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
Reliability is Further Enhanced by:
Other Features
SUPER RELIABLE DC POWER

Every Caterpillar Switchgear Component is powered by 24vdc,
Including the Utility Protective Relay, Touchscreen and Touchscreen
Processor.

This DC is derived from all the Engine Batteries, as well a final Backup
Station Battery.

So if even a single Engine-Generator has a good enough Battery to
Start, PowerLynx Technology will be there to control it.
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
Reliability is Further Enhanced by:
Other Features
WIDE DC CONTROL POWER RANGE

Every Caterpillar Switchgear Component is built with a Separate,
Wide Range DC Power Supply.

Every Component, including the Touchscreen and Touchscreen
Processor, will accept a continuous Control Power input of 18 - 40vdc.

Many of our Competitors use DC-DC Converters or even DC-AC
Inverters to Power their Systems. These are Single Points of Failure.
ENHANCED TEMPERATURE SPECIFICATIONS

All Components used in Caterpillar Switchgear are
Rated for 0 to 55C.
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
Reliability is Further Enhanced by:
Other Features
WIDE DC CONTROL POWER RANGE

Every Caterpillar Switchgear Component is built with a Separate,
Wide Range DC Power Supply.

Every Component, including the Touchscreen and Touchscreen
Processor, will accept a continuous Control Power input of 18 - 40vdc.

Many of our Competitors use DC-DC Converters or even DC-AC
Inverters to Power their Systems. These are Single Points of Failure.
ENHANCED TEMPERATURE SPECIFICATIONS

All Components used in Caterpillar Switchgear are
Rated for 0 to 55C.
FULL MANUAL OPERATIONS CAPABILITIES

If a Failure of all Automation should ever occur, the Engine-
Generators are Automatically switched to Pre-Calibrated Voltage and
Speed Potentiometers.

A hardware Sync Check Relay (Device 25) allows for Generators to be
paralleled without Automation.

With constant manning, a skilled Operator can run the System
manually in Parallel indefinitely.
RELIABILITY UNRIVALED IN THE INDUSTRY
One company.

A multitude of solutions.
EMCP 3.3
Controller
EMCP 3.3
Controller
VR3, KVR, DVR
(w/o PF Control)
ADEM II /PEEC
/2301A
#14 Shielded Twisted Pair
#14 Shielded Twisted Pair
#14 Shielded
Twisted Pair
4 #10 (24VDC Best source DC)
RS 485
Bipolar DC Signal
Bipolar DC SignalS
4 #12 (Discrete for start/stop)
CATERPILLAR DATA INTERFACE
One company.

A multitude of solutions.
CATERPILLAR DATA INTERFACE
Data for Display of:
RPM, DC V, Oil Press, Jacket Water Temp
Standard Engine Pre-Alarms
Standard Engine Shutdown Faults

NO CONTROL OVER THIS NETWORK

RS485
EMCP3.3




One company.

A multitude of solutions.
CATERPILLAR DATA INTERFACE




Hardware Control of:
Engine Start / Stop

Hardware Interface for:
24VDC Power
Crank Terminate
Shutdown Fault
2 Aux Alarm Input
2 Aux Shutdown Input
EMCP 3.3 Controller
One company.

A multitude of solutions.
CATERPILLAR INTERFACE TO VOLTAGE REGULATOR
Bipolar (+ & -) DC Signal
Raises and Lowers Generator Voltage Output to:
1.) Control Cross Current Compensation when in parallel
with other generators
2.) Perform VAR/PF Control when in parallel with the utility source
3.) Match Generator Voltage to Bus when synchronizing
Auto Control
Manual Control From Touchscreen
Manual Voltage Pot
VR3 /VR6
DVR w/o PF Control
KVR
Twisted Pair
One company.

A multitude of solutions.
CATERPILLAR INTERFACE TO ENGINE GOVERNOR





Bipolar (+ & -) DC Signal
Raises and Lowers Generator Speed / Frequency Output to
1.) Load Sharing Control when in parallel with other generators
2.) Perform Output Load Control when in parallel with the utility source
3.) Match Generator Frequency & Phase Angle to Bus when synchronizing
Auto Control
Manual Control From Touchscreen
Manual Speed Pot
Twisted Pair
ADEM II/III/IV Controller
PEEC Controller
2301A Controller
One company.

A multitude of solutions.
Caterpillar Switchgear
Questions