RENR7941-05

March 2009

SpeciÞcations
Systems Operation
Testing and Adjusting
Caterpillar Digital Voltage Regulator
(CDVR)

SAFETY.CAT.COM
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identiÞed by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identiÞed by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not speciÞcally recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, speciÞcations, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The speciÞcations, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
speciÞcations including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
RENR7941-05 3
Table of Contents

Table of Contents
SpeciÞcations Section
Electrical ................................................................. 4
Dimensions ............................................................. 7

Systems Operation Section

General Information ................................................ 8
Startup ProÞle Function ........................................ 10
Loading and Stopping ProÞle ................................. 11
Voltage Regulation ................................................ 12
Line Loss Compensation ...................................... 12
Reactive Voltage Droop ........................................ 13
Cross Current Compensation ............................... 14
KVAR Regulation .................................................. 14
Power Factor Regulation ...................................... 15
Parameters ........................................................... 16
Remote Communication ....................................... 17

Testing and Adjusting Section

Testing and Adjusting
General Information .............................................. 20
Service Tools ........................................................ 20
Startup Procedure ................................................. 21
Parameter Viewing and ConÞguration (Caterpillar PC
Software) ............................................................. 23
Parameter Viewing and ConÞguration (Caterpillar
Electronic Technician) ......................................... 57
Gain Setting - Adjust ............................................. 61
Troubleshooting .................................................... 62
No Voltage - Troubleshoot .................................... 62
Low Voltage - Troubleshoot .................................. 65
High Voltage - Troubleshoot ................................. 66
Unstable Voltage - Troubleshoot ........................... 66
Generator Overcurrent - Troubleshoot .................. 67
Reverse VAR Condition - Troubleshoot ................ 68
Poor Voltage Regulation - Troubleshoot ............... 68
No Line Loss Compensation - Troubleshoot ......... 69
No Voltage Droop - Troubleshoot ......................... 69
Wiring Diagrams ................................................... 71

Index Section
Index ..................................................................... 85
4 RENR7941-05
SpeciÞcations Section

SpeciÞcations Section
i03213848

Electrical
SMCS Code: 4467

Table 1
SpeciÞcations
Regulation 0.25% from no load to full load.
Regulator temperature drift Less than ±1% for any 40 °C (72 °F) change over the ambient operating
temperature range.
ConÞgurable Volts/Hz characteristic Two slope ranges adjustable from 1 to 10 V/Hz. See the Regulation
Characteristic Illustration.
Regulator response time Maximum of 10 milliseconds.
Regulator sensing True RMS 3-phase sensing is standard. Single phase sensing is available.
Variable sense range: 90 to 600 volts.
Regulator stability The regulator maintains stable output voltage within 0.25% for total
harmonic distortion of the generator output voltage waveform up to 30%,
and within 0.50% for total harmonic distortion of the generator output
voltage waveform up to 40%. These values are based on a typical 6 SCR
bridge.
Telephone inßuence factor (TIF) Less than 50. Complies with MIL STD 461C Part 9 and VDE 0875 level N.
Fine voltage adjust range ± 10% of regulator sensing voltage.
Regulator voltage gain (Line loss compensation) Adjustable from 0 to 10%.
Fault detection and identiÞcation Diagnostics identify operation outside of programmed limits. SpeciÞc
fault information is available even after the unit has been powered down.
CANBUS only.
Harmonic tolerance For total harmonic distortion of the generator output voltage waveform up
to 30%, the regulator maintains stable output voltage within 0.25%. For
total harmonic distortion of the generator output voltage waveform up to
40%, the regulator maintains stable output voltage within 0.50%. These
values are based on a typical 6 SCR bridge.
Reactive droop adjustment Adjustable from 0 to 10%.
Overexcitation protection Shuts off generator output when excitation current exceeds normal
operating currents for 10 seconds or instantaneous shutoff if output current
exceeds approximately 28 Amperes.
Ambient operating temperature í40 °C (í40 °F) to +70 °C (+ 158 °F).
Storage temperature range í40 °C (í40 °F) to +85 °C (+ 185 °F).
Power dissipation 5 watts at idle, 55 watts at rated output.
Shock Withstands up to 20 g's in three mutually perpendicular planes .
Vibration Withstands 4.5 g's at frequencies between 18 and 2000 Hz in three
mutually perpendicular planes.
Salt fog 5% salt spray for 48 hours at 38 °C (100.4 °F) at 115% of the nominal
operating voltage.
Weight 1.47 kg (3.24 lb.).
Electromagnetic compatibility Meets 89/336/EEC Electromagnetic Compatibility Directive.
Power supply 24 ± 6 volt DC power supply required (0.5 amp).
(continued)
RENR7941-05 5
SpeciÞcations Section

(Table 1, contd)
SpeciÞcations
Conformity UL UL Recognized per Standard 508, UL File No. E97035.
CSA CertiÞed per Standard CAN/CSA-C22.2 No. 14-95, CSA Dile No. LR
23131.
CE Conforms to the following standards: Radiated Emissions EN50081-2,
Radiated Immunity (electric Þeld) EN61000-4-3 (10 V/m), Radiated
Immunity (conducted) EN61000-4-6 (10 VRMS), Conducted Emissions
EN50081-2 (EN55011, Class A), ESD Immunity EN50082-2 (4 KV contact,
8 KV air), EFT Immunity EN50082-2 (2 KV coupling clamp), Magnetic
Immunity EN50082-2 (30ARMS, 50 Hz), Safety EN61010-1.

g01040043
Illustration 1
Regulation Characteristic
6 RENR7941-05
SpeciÞcations Section

Table 2
Summary of Operating Parameters
Parameter SpeciÞcations
Voltage Regulation 120 to 15000 Volts
Rating
Generator Type PM
SE
Internal Excitation (IE)
Power Input Voltage(1) Frequency Burden (Continuous)
80 to 264 Volts (3Ø) 50 to 400 Hz 1150 VA (63 VDC applications) or 1900
100 to 280 Volts (1Ø) VA (125 VDC applications)
Output Rating Maximum Continuous Maximum Forcing (10 Seconds)
Voltage Current Voltage Current
63 or 125 Volts 12 or 10 Amperes 125 or 250 Volts 25 or 20 Amperes
Sensing Voltage Maximum VA Burden per Ø
90 to 600 Volts 1 VA
Reactive Droop Maximum Current Maximum VA Burden
5 Amperes 1 VA
Exciter Field Minimum Resistance Maximum Resistance
Resistance
3 Ohms 39 Ohms
(1) As the CDVR input voltage increases, the PWM duty cycle decreases. As PWM duty cycle decreases, system stability may decrease as
well. Powering the CDVR with a voltage closer to the low end of this range is preferred.
RENR7941-05 7
SpeciÞcations Section

i02852265

Dimensions
SMCS Code: 4467

g01415745
Illustration 2
Dimensions of the Caterpillar Digital Voltage Regulator
(A) 276.4 mm (10.88 inch)
(B) 190.5 mm (7.50 inch)
(C) 139.7 mm (5.50 inch)
(D) 162.1 mm (6.38 inch)
(E) 72.9 mm (2.87 inch)
(F) 71.4 mm (2.81 inch)
(G) 15.0 mm (0.59 inch)
(H) 4.06 mm (0.16 inch)
8 RENR7941-05
Systems Operation Section

Systems Operation Section

i02787221

General Information
SMCS Code: 4467

g01118951
Illustration 3
(1) “P6” Connector (3) “P12” Connector (5) “J4” Connector
(2) LED Indicator (4) “P9” Connector

The Caterpillar Digital Voltage Regulator (CDVR) is Connector “P6” is a six-pin header that mates with
a microprocessor based voltage regulator. The main a six-pin connector. Connector “P9” is a nine-pin
purpose of a digital voltage regulator is to regulate header that mates with a nine pin connector.
the output voltage of a generator that is used with an Connector “P12” is a twelve pin header that mates
engine generator set. Control power for the Digital with a twelve pin connector.
Voltage Regulator is supplied from an external 24
DCV source. The power stage of the Digital Voltage The regulator has a nine pin D sub connector that is
Regulator can be supplied from a multi-pole, high labeled “J4”. This connector is used for interface with
frequency, permanent magnet generator (PMG), IBM compatible personal computers.
from the generator output (shunt excitation), or
from auxiliary windings that are included on some Note: The Caterpillar Digital Voltage Regulator
generators. Connections to the Digital Voltage should be hard wired to earth ground with at least a
Regulator are made through three multi-pin, plug type 16 AWG copper wire that is attached to the ground
connectors. The communication between the Digital terminal “P6-6”.
Voltage Regulator and a service tool is accomplished
using a CANBUS protocol. Note: When the unit is conÞgured in a system with
other devices, a separate lead should be used to
The Caterpillar Digital Voltage Regulator has three ground the bus from each device.
multiple-pin, plug-type connectors. These connectors
are labeled “P6”, “P9”, and “P12”. See illustration 3.
RENR7941-05 9
Systems Operation Section

Note: When the digital voltage regulator is installed Connector “P9”

remotely from the generator, special care should be
given during installation to ensure proper engineering
procedures are followed to prevent electromagnetic
noise from reducing the performance of the regulator
or other system components.

Note: When mounting the regulator remotely, the

sensing wires, PMG wires, and exciter Þeld wires
should each be routed in their own separate tray
or conduit. The optional customer wiring should be
separated from all other signals in a control wiring
conduit. The voltage sensing wires must be twisted
together. The exciter Þeld wires must also be twisted
together.
g01013761
Illustration 5
Connectors Pin out for the “P9” Connector on the CDVR

Connector “P6” Table 4

P9 Terminal Functions
Terminal Function
P9-1 CANbus - High
P9-2 CANbus - Low
P9-3 CANbus - Drain (Shield)
P9-4 Contact Sense - Lower
P9-5 Contact Sense - Raise
P9-6 Contact Sense - Common
P9-7 Contact Sense - Excitation Disable
P9-8 Contact Sense - Fault Reset
g01013614
Illustration 4
P9-9 Contact Sense - Var/PF Enable
Pin out for the “P6” Connector on the CDVR

Table 3
Connector “P12”
P6 Terminal Functions
Terminal Function
P6-1 Power Input (single phase)
P6-2 Power Input (single phase)
P6-3 Power Input
P6-4 F-
P6-5 F+
P6-6 Chassis Ground

g01013628
Illustration 6
Pin out for the “P12” Connector on the CDVR
10 RENR7941-05
Systems Operation Section

Table 5 • Generator Rated Voltage

P12 Terminal Functions
• Knee Frequency
Terminal Function
P12-1 B-phase generator current sensing (CT1) • Underfrequency Point
P12-2 B-phase generator current sensing (CT2) The digital voltage regulator will begin to build
P12-3 ±10 DCV Input (B), -
voltage following the “Soft Start” settings before the
conÞgurable underfrequency point has been reached.
P12-4 Alarm Output Driver (24V, 100mA) After the conÞgurable underfrequency point has
P12-5 Fault Shutdown Driver (24V, 100mA)
been reached, the digital voltage regulator will begin
to build voltage following a volts per hertz proÞle.
P12-6 ±10 DCV Input (A), + When the speed reaches the knee frequency point,
P12-7 18 to 30 V Control Power Input (B-)
the loading/stopping proÞle takes effect. The startup
proÞle function will not be initiated again unless
P12-8 18 to 30 V Control Power Input (B+) the frequency drops below the underfrequency
P12-9
point. The underfrequency point is defaulted to 25
Driver Supply (50) (24V, 100mA)
Hz, with a range of 20 to 40 Hz. This is the same
P12-10 Generator Voltage Sensing - C (T3), lead 20 underfrequency set point that is used by the loading
for SR4 and SR4B generators)(1) and stopping set point. The knee frequency point is
P12-11 Generator Voltage Sensing - B (T2), lead 24 the point at which the digital voltage regulator will
for SR4 and SR4B generators)(1) regulate to the voltage speciÞed by the generator
output voltage parameter.
P12-12 Generator Voltage Sensing - A (T1), lead 22
for SR4 and SR4B generators)(1)
(1) Refer to the generator set wiring diagrams.

The Caterpillar Digital Voltage Regulator has the

following features:

• Three control modes:

1. Automatic voltage regulation (AVR)

2. Power factor (PF) regulation

3. Reactive power (VAR) regulation

• Programmable stability settings

• Soft start control with an adjustable time setting
in AVR mode

• Dual slope voltage versus frequency (V/Hz)

characteristic

• Three-phase or single-phase voltage sensing

• Single-phase current sensing
• Field current and Þeld voltage sensing
• Ten protection functions

i02848546

Startup ProÞle Function

SMCS Code: 4467

The parameters that are related to the startup proÞle

function are listed below.
RENR7941-05 11
Systems Operation Section

i02847653

Loading and Stopping ProÞle

SMCS Code: 4467

g01012488
Illustration 7

The parameters that are related to the loading and When the generator is running and if a large load is
stopping proÞle are listed below. applied, the frequency and voltage will drop. The
loading/stopping function minimizes the amount of
• Generator Output Voltage time that it takes the engine and generator to recover
and increases the ability to pick up large loads.
• Knee Frequency
As a large load is applied, the engine speed will begin
• Decreasing V/Hz Slope 1 to drop (frequency decreases). As the frequency
decreases below the knee frequency, the voltage
• Decreasing V/Hz Slope 2 reference will decrease on a Volts/Hz slope according
to the decreasing slope 1 value. If the frequency
• Minimum Voltage decrease continues beyond the knee frequency
minus 5 Hz, then the voltage reference will decrease
• Underfrequency Point on a Volts/Hz slope according to the decreasing
slope 2 value until the minimum voltage level is
Voltage regulators are generally of the volts per hertz reached. The digital voltage regulator will try to
type or the constant voltage type. The digital voltage regulate the generator output voltage at the minimum
regulator can perform as a constant voltage regulator voltage, unless the underfrequency point is reached
or a volts per hertz type regulator depending on where the generator output voltage will decrease to a
user conÞguration. Volts per hertz type regulators minimum value.
are commonly used with reciprocating internal
combustion engine driven generator sets because As the engine recovers from the load increase,
they provide an automatic means for the engine to the voltage will increase in the reverse order as it
recover from a large block load. In the digital voltage decreased, unless the frequency dropped below
regulator, the block load recovery performance is the underfrequency point. If the frequency dropped
conÞgurable so that it may be Þeld optimized for each below the underfrequency point, the startup proÞle
speciÞc application. will be used for the recovery.
12 RENR7941-05
Systems Operation Section

In some applications it is desirable to maintain Once startup has been achieved and the generator
a constant voltage at the possible sacriÞce of a output frequency is above the corner frequency, the
larger frequency dip during load transients. The regulator will normally act to keep the generator
digital voltage regulator can accommodate these output voltage constant. As changes in generator
applications if the knee frequency is conÞgured for loading cause the voltage to sag or rise, the regulator
a lower value than normal. The actual value will will automatically adjust generator excitation to
depend on the speciÞc application. When used in this maintain the output voltage. If loading causes
application, the load transients must be kept small in the generator frequency to drop below the knee
order to allow the engine to recover without dropping frequency, the loading and stopping proÞle as
below the knee frequency. previously described will be followed. See System
Operation, “Loading And Stopping ProÞle”.
When a large block load is switched on to the system,
the engine speed temporarily decreases as the The CDVR can be connected to a “Manual
engine produces the additional power requirement Voltage Control”. For a wiring diagram of “Manual
by burning more fuel. If the regulator is set to act Voltage Control” see Testing and Adjusting, “Wiring
as a volts per hertz type, it will reduce the output diagrams”.
voltage according to the slope of the V/Hz curve. The
reduction in voltage reduces the power requirement A remote voltage adjust toggle switch may be used
of the load, thus allowing the engine to recover faster to Þne tune the generator output voltage. When
for a given block load. If the regulator is set to act as used, the active value of voltage reference may be
a constant voltage type, the regulator will not reduce adjusted ±10%.
the output voltage for a change in speed (addition of
block load). Therefore, it will take the engine a longer Voltage can be changed in the software.
time to regain speed and supply the total power
requirement of the load. If the regulator is set to act 1. The voltage can be changed at the “Settings”
as a constant voltage type, care must be taken to screen or the “Metering” screen in the CDVR.
keep block load applications small enough so that
the engine can recover in acceptable time. 2. The voltage can be changed at the “Voltage
Regulator Control Parameters” screen with the
use of Cat ET.
i02848560

Voltage Regulation Note: In order to change the new voltage set point,
the “EEPROM” button must be pressed in the CDVR
SMCS Code: 4467 PC software, or the “Enter” key must be pressed in
Cat ET after the new set point is entered.
The parameters that are related to voltage regulation
are listed below. i02847614

• Rated Generator Voltage Line Loss Compensation

• Generator PT Primary Voltage Rating SMCS Code: 4467

• Generator PT Secondary Voltage Rating In some installations where a single generator is

used with long feeder lines to the load, it may be
• Voltage Setpoint advantageous to provide line loss compensation.
Line loss compensation is commonly referred to as IR
• Generator Frequency compensation. In this mode, a CT must be provided
in order to measure the generator current.
• Knee Frequency
The parameters that are related to line loss
• Integral Gain compensation are listed below.

• Derivative Gain • Rated Generator Voltage

• Proportional Gain • Generator PT Primary Voltage Rating
• Loop Gain • Generator PT Secondary Voltage Rating
• Voltage Set point
• Generator Frequency
• Knee Frequency
RENR7941-05 13
Systems Operation Section

• Integral Gain • Derivative Gain

• Derivative Gain • Proportional Gain
• Proportional Gain • Loop Gain
• Loop Gain • Generator CT Current Primary Rating
• Generator CT Current Primary Rating • Generator CT Current Secondary Rating
• Generator CT Current Secondary Rating • Load Compensation Mode
• Load Compensation Mode • Droop Percentage
• IR Compensation • Rated Generator Current
• Rated Generator Current When generators operate in parallel, two primary
objectives are for the generators to share both
Current ßowing through a long conductor causes the real power requirements and the reactive
a voltage drop due to the resistance of the wire. power requirements of the system electrical load.
Therefore, the voltage at the load end of the The engine governors will control sharing of the
conductor will be lower than the voltage at the real power requirements (kW) and the voltage
generator end due to the voltage drop along the regulator will control sharing of the reactive power
conductor. This condition is commonly referred to as requirements (KVAR) of the total system load. If the
line losses. In order to improve the power quality, output voltage of one generator is slightly higher than
the digital voltage regulator can compensate for the other generators, it will supply lagging reactive
this phenomenon. As generator load increases, the current to the other generators connected in the
regulator will cause the output voltage to rise slightly group. This current will circulate between generators,
at the generator terminals in order to compensate possibly causing ampere overloading. One method
for line losses. Line drop percentage controls the of minimizing this effect is to cause an individual
amount of compensation. It should be adjusted to generator's output voltage to sag, or “droop”, in
yield a constant voltage at the location of the load. proportion to the lagging reactive current ßow from it
as measured with a current transformer (CT). For
Line loss compensation is mutually exclusive to proper reactive load sharing, the regulator must know
reactive voltage droop. These two functions work the rated generator output current, the CT current at
opposite of one another and can not be used at rated generator current and the desired percentage
the same time. If a CT is provided but line loss of output voltage droop when the generator is at
compensation is not desired, the set point percent rated reactive output current.
must be set to zero.
As reactive lagging generator output current
increases, the regulator will cause the output voltage
i02848359
to droop (lower the voltage) proportionally. If the
Reactive Voltage Droop measured reactive output current is leading, the
output voltage will rise. In either case, this action
SMCS Code: 4467 will tend to reduce the reactive current for better
KVAR sharing with other units. The droop percentage
The parameters that are related to voltage regulation controls how much the generator output voltage
with reactive droop are listed below. will vary for a given amount of reactive current. It is
important that the connected CT polarity is correct for
the voltage to droop with lagging current ßow. The
• Rated Generator Voltage CT must be installed on phase B. Reactive droop
compensation is mutually exclusive to line droop
• Generator PT Primary Voltage Rating compensation. These two functions work opposite of
one another and can not be used at the same time.
• Generator PT Secondary Voltage Rating
• Voltage Setpoint
• Generator Frequency
• Knee Frequency
• Integral Gain
14 RENR7941-05
Systems Operation Section

i02848575 When all generators share the same current, in

magnitude and phase (according to the CT ratio),
Cross Current Compensation there will be no signiÞcant current output on the
secondary of any generator CT. If one of the
SMCS Code: 4467 generators carries more current or the current that
the generator carries is lagging or leading relative
The parameters that are related to voltage regulation to the others, a net difference current signal will be
with “Cross Current Compensation” (CCC) are listed created in that CT. If that generator is supplying more
below. reactive (lagging) current than other generators,
the phase polarity and the magnitude of the signal
• Rated Generator Voltage returned to the digital voltage regulator will be
such to cause a slight decrease in the generated
• Generator PT Primary Voltage Rating voltage, reducing the amount of reactive current.
Less reactive (or more leading) current will cause the
• Generator PT Secondary Voltage Rating generator voltage to rise.

• Voltage Set point The net result is that the generated voltage and the
output current of each generator is trimmed toward
• Generator Frequency an operating point where all generators will share
the same load current in proportion to the CT ratio,
• Knee Frequency with the little or no circulating current between them.
Droop percentage controls the amount of individual
• Integral Gain generator voltage droop (or rise) for a given amount
of CT signal.
• Derivative Gain
However, because the CT secondary circuits are all
• Proportional Gain interconnected, the CT signal seen by any individual
regulator is not representative of the actual current
• Loop Gain ßowing in that particular generator. Any display or
calculations that might use that signal as if it were
• Generator CT Current Primary Rating the actual generator current will provide erroneous
results.
• Generator CT Current Secondary Rating
Reactive voltage droop needs to be selected and an
• Load Compensation Mode enable contact needs to be closed in order to enable
cross current compensation. Refer to the Testing and
• Droop Percentage Adjusting, “Wiring Diagrams” section for a wiring
diagram of the cross current compensation circuit.
• Rated Generator Current
Cross current compensation is often used in i02847603
order to minimize circulating current ßow between
the generators that are connected in parallel. KVAR Regulation
The advantage of this operating mode is that all
generators contribute in order to establish the SMCS Code: 4467
same output voltage to the load. Cross current
compensation is only used for paralleling multiple Parameters that are related to KVAR regulation are
generator sets. Cross current compensation is not listed below.
used when paralleling with a utility.
• Rated Generator Voltage
Operation is similar to the reactive voltage droop
mode except that the secondary circuits of the current • Generator PT Primary Voltage Rating
transformers of all generators are interconnected in
a series string. Each generator is initially adjusted in • Generator PT Secondary Voltage Rating
order to provide the same output voltage.
• Voltage Setpoint
• Generator Frequency
• Knee Frequency
• Integral Gain
• Derivative Gain
RENR7941-05 15
Systems Operation Section

• Proportional Gain Note: The KVAR/PF (Aux breaker) contact does

not specify if the CDVR is in KVAR or PF mode
• Loop Gain speciÞcally. KVAR mode must be selected in software
(at the “Metering” screen in the CDVR PC software,
• Rated Generator Current or under the “VAR/PF Mode Selection” screen in Cat
ET.
• Generator CT Current Primary Rating
Note: When operating in parallel operations, make
• Generator CT Current Secondary Rating sure that “Droop” mode is selected in the “Settings”
screen in the PC software. A 0% droop may be
• Operating Mode selected.

• VAR Set point In KVAR mode, the generator will supply a constant
amount of reactive power to the system as set by the
• VAR Integral Gain reference (KVAR) regardless of the real power output
(kW) of the generator set. The generator will supply
• VAR Loop Gain real power (kW) to the system. This is determined by
the engine governor and/or the device that is used for
When the generator is connected in parallel with sharing the load. Due to the amount of reactive power
an inÞnite bus (utility), the voltage of the generator on the utility, current overloading of the system (due
is controlled by the inÞnite bus. The voltage of the to large reactive current requirements) is possible. In
generator will change as the inÞnite bus voltage the KVAR mode, the generator can supply a Þxed
changes. It is not possible to control the system amount of reactive power to the system.
voltage when the generator is connected to an inÞnite
bus. In this instance, it is necessary for the digital For stable operation of the generator in the KVAR
voltage regulator to regulate the reactive power regulating mode, the generator must be connected
output which is supplied by the generator. There are to a utility or a system that is much larger than the
two methods for regulating the reactive power output. generator. When the breaker (tie) is closed to the
utility, connect terminal “P9-9” and terminal “P9-6” in
• KVAR Regulation order to enable the KVAR mode. When the terminal
“P9-9” and terminal “P9-6” are disconnected from
• Power Factor (PF) Regulation each other, the regulator will be in a voltage control
operating mode with the following or without the
Note: KVAR stands for Kilo-Volt-Ampere-Reactive, following: droop and line loss compensation.
which is the unit of measurement for reactive power.
i02848334
When the digital voltage regulator is in the KVAR
operating mode, the digital voltage regulator works
to produce a constant KVAR output, regardless
Power Factor Regulation
of the real power output of the generator. In this SMCS Code: 4467
case, the power factor (generator) will change when
the real power output of the generator changes. A Parameters that are related to PF regulation are
current transformer (CT) is necessary for this mode listed below.
to work. KVAR mode must be selected in software
(at the “Metering” screen in the CDVR PC software,
or under the “VAR/PF Mode Selection” screen in
• Rated Generator Voltage
the Caterpillar Electronic Technician (Cat ET). The
contact for the KVAR/PF enable must also be closed.
• Generator PT Primary Voltage Rating
Refer to the following contacts: “P9-6” and “P9-9”.
• Generator PT Secondary Voltage Rating
A remote KVAR/PF adjust toggle switch may be used
in order to Þne-tune the KVAR set point. Refer to
• Voltage Set point
the following contacts: “P9-4”, “P9-5”, and “P9-6”.
This switch may be the same switch used for remote
• Generator Frequency
voltage adjustment. When the contact for KVAR/PF
is closed, and the KVAR mode is selected, the switch
• Knee Frequency
will not affect voltage.
• Integral Gain
• Derivative Gain
• Proportional Gain
• Loop Gain
16 RENR7941-05
Systems Operation Section

• Rated Generator Current A remote KVAR/PF adjust toggle switch may be used
in order to Þne tune the PF set point. Refer to the
• Generator CT Current Primary Rating following contacts: “P9-4”, “P9-5”, and “P9-6”. The
remote KVAR/PF switch may be the same switch
• Generator CT Current Secondary Rating used for remote voltage adjustment. Raising the
PF set point will make the PF more lagging. The
• Operating Mode lagging PF is a positive PF. Lowering the PF set
point will make the PF more leading. The leading PF
• PF Set point is a negative PF. When the contact for KVAR/PF is
closed, and the PF mode is selected, then the switch
• PF Integral Gain will not adjust the voltage setting.

• PF Loop Gain Note: The KVAR/PF contact does not specify if the
CDVR is in KVAR or PF mode speciÞcally. PF mode
• Reactive Droop must be selected in software.

When the generator is connected in parallel with Note: When operating in parallel operations, make
an inÞnite bus (utility), the voltage of the generator sure that “Droop” mode is selected. The “Droop”
is controlled by the inÞnite bus. The voltage of the mode must be selected in the “Settings” screen. A
generator will change as the inÞnite bus voltage 0% droop may be selected.
changes. It is not possible to control the system
voltage when the generator is connected to an inÞnite
i02847681
bus. In this instance, it is necessary for the digital
voltage regulator to regulate the reactive power
output which is supplied by the generator. There are
Parameters
two methods for regulating the reactive power output. SMCS Code: 4467
• KVAR Regulation
General Information
• Power Factor Regulation
Parameters are pieces of information which are used
Note: KVAR stands for kilo-Volt-Ampere-Reactive, within the memory of the digital voltage regulator.
which is the unit of measurement for reactive power. Each parameter has a speciÞc range of values.
Parameters tell the digital voltage regulator how to
When the digital voltage regulator is in the power operate. Service personnel can conÞgure certain
factor operating mode, it works to produce a constant parameters to the requirements of a speciÞc site.
power factor, regardless of the real power output of ConÞguration changes the value of a particular
the generator. In this case, the reactive current will parameter. There is an upper and lower limit for
change when the real power output of the generator the value of each parameter. The limits can not be
changes. A current transformer (CT) is necessary exceeded.
for this mode to work. PF operating mode must be
selected. In order to view or conÞgure the values of the
parameters see Testing And Adjusting, “Parameter
For stable operation of the generator in the PF Viewing And ConÞguring Procedure”.
regulating mode, the generator must be connected
to a utility or system that is much larger than the
generator. When the tie breaker is closed to the
utility, connect terminals “P9-9” and “P9-6” in order
to enable the PF mode. When the terminals “P9-9”
and “P9-6” are disconnected from each other, the
regulator will be in a voltage control operating mode
with or without droop or line loss compensation as
previously described. “PF” mode must be selected in
software and the “KVAR/PF” contact must be closed.
Refer to the following contacts: “P9-6” and “P9-9”.
When the contact is not closed the regulator operates
in AVR mode.
RENR7941-05 17
Systems Operation Section

i02787341

Remote Communication
SMCS Code: 4467

The digital voltage regulator has the capability to

communicate with a remote personal computer or
programmable logic controller. The J4 connector
of the digital voltage regulator provides an RS-232
port necessary for communication. The RS-232 port
is a 9-pin communication media including a wire
for Receive, a wire for Transmit, and a common
Signal Ground. The common signal ground is NOT a
bonding ground and should not be grounded to the
case or frame. It is to be connected to the RS-232
device Signal Ground connection point. Cable length
should be limited to 15 m (50 ft) maximum for the
RS-232 signal wiring. Caterpillar 1U-9484 Cable is
recommended.

g01008946
Illustration 8

Table 6
Pin Function Name Direction
1 - - N/A
2 Transmit Data TXD From Regulator
3 Receive Data RXD To Regulator
4 - - N/A
5 Signal Ground GND N/A
6 - - N/A
7 - - N/A
8 - - N/A
9 - - N/A
18 RENR7941-05
Systems Operation Section

g01136853
Illustration 9

Note: Battery power (24 VDC) must be available at Establishing Communication

“P12-8” (B+) and “P12-7” (B-) in order for the remote
communications port to operate. Communication between the voltage regulator
and the PC software must be established before
A Windows based program is available to viewing the metering values, reading settings, or
communicate with the digital voltage regulator. The changing settings. PC software screen settings are
Windows program is called Caterpillar PC Software. updated only after communication is opened or the
The part number for the program is 252-7515 communication settings have been changed. Open
Software. The Windows program is available on the voltage regulator communication port by clicking
SisWeb. “Communications” on the menu bar, hovering the
mouse pointer over “Open Comm Port” and clicking
Caterpillar PC Software allows the user to perform “RS-232 Port”.
the following operations.

• Viewing and modifying the parameters in a

windowed PC environment

• Sending the parameters to the digital voltage

regulator

• Saving the existing digital voltage regulator settings

to a Þle

• Viewing the metering and fault information

• Upgrade embedded Þrmware
g01392570
For information on changing and viewing the Illustration 10
parameters of the voltage regulator, see Testing
and Adjusting, “Parameter Viewing and ConÞguring When “RS-232 Port” is selected, the “Password”
Procedure”. dialog box appears and prompts you to enter a
password. Refer to illustration 10.

Note: Each voltage regulator is delivered with

“cat” as the password.
RENR7941-05 19
Systems Operation Section

Terminating Communication
Voltage regulator communication is terminated
by clicking “Communications” on the menu bar
and clicking “Close Comm Port”. The user will be
prompted to save the settings to the EEPROM. This
question is asked even if no changes were made
to the voltage regulator settings. When the close
command is executed (with a Yes or No to save
settings to the EEPROM), communication with the
voltage regulator is terminated. If the PC software is
exited the (by clicking “File” on the “Menu” bar and
then “Exit”) without Þrst closing communication, the
option will still be given to save the settings to the
g01392575 EEPROM.
Illustration 11

After the correct password is entered, the “Comm

Port” screen is displayed. Refer to Illustration 11.
Select “Comm 1”, “Comm 2”, “Comm 3”, or “Comm
4” as the active communication port on your PC and
click the “Initialize” button. The PC software initializes
communication by obtaining the conÞguration
settings from the voltage regulator.

g01392576
Illustration 12

Note: The Caterpillar PC software may display the

“Please wait...” dialog box that is shown in Illustration
12 when initializing communication, obtaining
conÞguration settings, or performing other tasks. It
is important to wait until the box disappears before
trying to execute communication commands. Issuing
commands while the “Please wait...” dialog box is
present may disrupt communication between the PC
software and the voltage regulator.
20 RENR7941-05
Testing and Adjusting Section

Testing and Adjusting i03470083

Section Service Tools

SMCS Code: 0785

Testing and Adjusting

i02847378

General Information
SMCS Code: 4467

g01425366
Illustration 14

The Cat Digital Voltage Regulator presents an

electrical shock/electrocution hazard. This hazard
will cause serious injury or death.

g01425354 Service by trained personnel only.

Illustration 13

The terminals and heat sinks are live at hazardous

voltages when power is applied and for up to 8
minutes after power is removed.
The Cat Digital Voltage Regulator presents an
electrical shock/electrocution hazard. This hazard
will cause serious injury or death.

Service by trained personnel only.

The terminals and heat sinks are live at hazardous

voltages when power is applied and for up to 8
minutes after power is removed.

Preventive Maintenance
The only preventive maintenance that is required
on the voltage regulator is to periodically check
the connections between the voltage regulator and g00241203
Illustration 15
the system. The connections must be clean and
tight. Voltage regulator units are manufactured 6V-7070 Caterpillar Digital Multimeter
using state-of-the-art, surface-mount technology.
Caterpillar recommends that no repair procedures be Caterpillar digital multimeters can be used in order
attempted by anyone other than Caterpillar dealer to measure voltage, resistance or current up to 10
technicians. amperes. RectiÞers can also be checked by using the
diode function. See Special Instruction, SEHS7734,
“Use Of The 6V-7070 And 6V-7800 Multimeter”
for the correct operation of the 6V-7070 Digital
Multimeter.
RENR7941-05 21
Testing and Adjusting Section

1. Connect the digital voltage regulator. Refer to

Testing and Adjusting, “Wiring Diagrams” for a
proper illustration. Take care to follow notes and
observe polarities.

2. Apply battery power only to the regulator.

3. Connect serial cable between CATV and PC. Start

the CATV PC Software. Establish communication
between the CATV and the PC. For more details,
refer to “Establishing Communications” located in
the “Remote Communication” section.

4. Verify that all of the parameters are properly

g00538441
adjusted for the application. The following Þelds
Illustration 16 may need to be entered for Þrst conÞguration. For
8T-0900 AC/DC Clamp-On Ammeter more details, refer to “Settings DeÞnitions” located
in the “Parameter Viewing and ConÞguration
The 8T-0900 Ammeter may be used to measure (Caterpillar PC Software)” section.
current up to 1200 amperes. When you are
measuring line current on multiple lead units, a. System ConÞguration
measure the current in each conductor per phase and
add the currents together. See Special Instruction, • Rated Voltage (V)
SEHS8420, “Using the 8T900 AC/DC Clamp On
Ammeter 0651” for the correct operation of the • Rated Current (A)
8T-0900 Ammeter.
• Frequency
i02848479
• PT Primary (V)
Startup Procedure
• PT Secondary (V) - A PT is required if the
SMCS Code: 4467 generator is rated at more than 600 VAC. If
no PT is installed, set the PT Primary and PT
Secondary to rated voltage.

• CT Primary
• Power Input Frequency (Hz) - Refer to
Table 7.

• Sensing Mode - Three phase is the typical

Caterpillar setting.

Table 7

Operating Frequency 50HZ 60HZ

Self Excited Generators 50HZ 60HZ
g01425354
Illustration 17 Permanent Magnet 200HZ 240HZ
Generators
Low and Medium Voltage
6 Pole Generators 133HZ 160HZ
The Cat Digital Voltage Regulator presents an
electrical shock/electrocution hazard. This hazard High Voltage 2600 Frame 200HZ 240HZ
will cause serious injury or death. Generators
High Voltage 2400 and 2800 150HZ 180Hz
Service by trained personnel only. Frame Generators

The terminals and heat sinks are live at hazardous

voltages when power is applied and for up to 8 b. Setting Adjustments
minutes after power is removed.
• AVR Voltage (V) - Desired voltage for AVR
mode.
22 RENR7941-05
Testing and Adjusting Section

• VAR (percent of rated) - For VAR mode. 6. Start the engine. Make the Þnal adjustments, as
required.
• Power Factor - Must select Droop under
“Load Compensation Mode” for PF control. 7. Press the EEPROM button to save the settings in
the CATV.
• Soft Start Bias (percent) - A starting value
for the regulator on startup. 8. Record all settings. For more details, refer to
“Settings File” located in the “Parameter Viewing
• Soft Start Time (sec.) - For emergency and ConÞguration (Caterpillar PC Software)”
applications, this value may need to be set section.
to 2 seconds, or less.
9. Press “Get From Unit” to verify that the settings
• Knee Frequency (Hz) - Select a value that were saved.
is 0.2 to 2 Hz below rated frequency.
10. Disable communications (if desired). For more
• Slope 1 (V/Hz) - 2V per Hz suggested. details, refer to “Terminating Communications”
located in the “Remote Communication” section.
• Slope 2 (V/Hz) - Refer to Illustration 18.
c. Control Gain Settings

• For applications that require special PID

settings, refer to the “Gain Setting - Adjust”
section.

d. Protections Settings

• "Shutdown Override" Button - Leave

disabled.

• Generator Overvoltage - ConÞgure as

required by the application.

• Generator Undervoltage - ConÞgure as

required by the application.

• Reverse VAR - ConÞgure as required by the

application.

• Fault Reset Too Long - ConÞgure as

required by the application.

• Over Excitation - ConÞgure as required by

the application.

• Exciter Diode Monitor - ConÞgure as

required by the application.

• Loss of Sensing - ConÞgure as required by

the application.

• Over Excitation: Type - Threshold is the

default setting. If “Inverse Time” is selected,
the time setting must be changed to a
suggested value of 2 (based on the time dial
settings for the SR4B Generator curve). If
this value is not changed, over excitation
protection may not exist.

5. Press the EEPROM button to save the settings

in the CDVR.
RENR7941-05 23
Testing and Adjusting Section

g01012488
Illustration 18

i03213853 Caterpillar PC Software operates with an IBM

compatible personnel computer using a Microsoft
Parameter Viewing and Windows 95 or later operating system. The minimum
ConÞguration (Caterpillar PC recommended operating requirements are listed
below:
Software)
• IBM compatible PC, 486DX2 or faster (100 MHz or
SMCS Code: 4467-NQ higher microprocessor is recommended)
In order to view and conÞgure the parameters of the • CD-ROM drive
digital voltage regulator, a PC with the Caterpillar PC
software is required. • One available serial port
Note: Before performing this procedure, study the
list of parameters in order to determine the desired Installing the Caterpillar PC
parameter and the corresponding range of values. Software
The value of some parameters are only for viewing
by the user and may not be conÞgurable. Caterpillar PC software contains a setup utility that
installs the program on the PC. An uninstall utility is
Note: It will be convenient to have the entire loaded with the program that can be used to remove
list of parameters available while performing this the application from the PC. Use the following
procedure. See System Operation, “Parameters”. procedure to install the PC software.

The Caterpillar PC software provides the 1. Insert the CD-ROM into the CD-ROM drive of the
communication link between the voltage regulator PC.
and the user. All voltage regulator settings are
entered and read through this software. Within this 2. Click the Windows Start button and then select
software, voltage regulator settings can be saved in “Run”. In the “Open:” Þeld, enter “D:/Setup.exe”,
a computer Þle and used later in order to conÞgure where “D” is the designator letter for your PC
other units with the same settings. CD-ROM drive. Then click “OK”.
24 RENR7941-05
Testing and Adjusting Section

When Caterpillar PC software is installed, a folder

with the name Caterpillar is added to the Windows
program menu. This folder is accessed by clicking
the “Start” button and pointing to “Programs”.

Starting Caterpillar PC Software

g01393986
Illustration 19

The PC software is started by clicking the Windows Changing Settings

“Start” button, pointing to “Programs”, the “Caterpillar”
folder, and then clicking the voltage regulator icon. The settings are arranged into the following Þve
At startup, a dialog box with the program title and groups:
version number is displayed brießy. After this dialog
box is displayed, the “System ConÞguration” screen • System conÞguration
is displayed. See Illustration 19.
• Setting Adjustments
Establishing Communication
• Control Gain Settings
Communication between the voltage regulator and
the PC must be established before any settings • Protections Settings
can be viewed or changed. For more information
on establishing communications, see Systems • Metering/Operation and Alarms
Operation, “Remote Communication”.
RENR7941-05 25
Testing and Adjusting Section

g01393989
Illustration 20
Systems ConÞguration screen
(1) System ConÞguration button (4) Protection Setting button (7) EEPROM button
(2) Setting Adjustment button (5) Metering/Operation button
(3) Control Gain Button (6) Get From Unit button

Each setting group has a corresponding button that Sending and Receiving Settings
can be selected to access that group of settings. See
Illustration 20. The Þve setting groups can also be When communication is enabled, voltage regulator
accessed by clicking “Screens” on the menu bar and settings can be sent or received through the PC
then selecting the desired setting group from the list. software.
Once a setting group is accessed, the individuals
settings of the group can be viewed and changed. Sending Settings
A setting is changed by clicking within the setting Settings changes are sent to the voltage regulator
Þeld and typing the setting. The minimum, maximum by two methods:
and increments (steps) for a setting are displayed on
the status bar when the cursor is placed within that 1. Type a value in the setting screen Þeld, then press
setting Þeld. A changed setting is sent to the voltage the “Enter” key.
regulator when the “Enter” key on the PC is pressed.
A setting in a Þeld with the pull down menu is sent Note: Just typing a value in the setting screen Þeld
to the voltage regulator when the setting is selected WILL NOT send that value to the CDVR. When a
from the pull down menu. value is typed in the setting screen Þeld, the “Enter”
key must also be pressed.

2. Select a value from the setting screen pull down

menu.
26 RENR7941-05
Testing and Adjusting Section

Note: When a selection is made from the pull down

menu, the selected setting that is displayed on the
setting screen will automatically be sent to the CDVR
and will become the voltage regulator setting. There
is NO need to press the “Enter” key.

Receiving Settings
Voltage regulator settings are retrieved by clicking the
“Get From Unit” button (6). This causes the current
settings of the voltage regulator to be displayed on
the “settings” screen.

Saving Settings to the Memory of the

Voltage Regulator
Settings are saved in nonvolatile memory (EEPROM).
In the event of a power loss, these are the settings
that will be active at start up. If the settings are
changed and sent to the voltage regulator, but the
settings are not sent to the EEPROM, the changed
settings will be lost if the operating power to the
voltage regulator is lost. When exiting an application
or closing communication, the software will prompt
the user to save the settings to the EEPROM. This
question is asked even if no changes were made
to the settings. When communication is enabled,
setting changes are saved to the EEPROM by
clicking the “EEPROM” button (7). The opportunity
to save the settings to the EEPROM is also given
through a dialog box when the application is exited or
communication is closed.

Setting DeÞnitions
Each of the Þve setting groups have a corresponding
screen in the PC software. The setting of each
screen are categorized by one or more tabs. In
the following paragraphs, setting are arranged and
deÞned according to the organization of the PC
application screens and tabs.

System ConÞguration
The “System ConÞguration” screen consists
of one tab labeled “ConÞguration”. Click the
“ConÞgure” button (1) in order to access the “System
ConÞguration” screen or click “Screens” on the menu
bar and click “System ConÞguration”.
RENR7941-05 27
Testing and Adjusting Section

ConÞguration Tab

g01393995
Illustration 21

Rated Voltage (V) – The rated AC generator voltage PT Secondary (V) – The secondary AC voltage
is entered in this Þeld. Voltages within the range of 90 rating of the PT is entered in this Þeld. Voltages
to 15000 VAC may be entered in 1 VAC increments. within the range of 90 and 600 VAC may be entered
in 1 VAC increments. Note: A PT is required if the
Rated Current (A) – The maximum rated AC generator is rated at more than 600 VAC. If no PT is
generator current is entered in this setting Þeld. installed, set the PT primary and PT secondary to the
Current values that are up to 9999 amperes may be expected sensed voltage.
entered in 1 ampere increments.
CT Primary – The AC current rating of the primary
Rated kVAR – This Þeld is a read-only Þeld that winding of the CT is entered in this Þeld. Current
displays the rated, calculated reactive power, based values that are up to 9999 amperes may be entered
on the values that are entered in the Rated Voltage in 1 ampere increments.
and Rated current Þelds.
CT Secondary – This Þeld is a read-only Þeld that
Frequency – This setting is used to select a nominal displays the rated value of the current that is present
system operating frequency of 50 Hz or 60Hz. at the secondary winding of the CT. This regulator is
designed for a 5 ampere secondary winding only.
PT Primary (V) – The primary AC voltage rating of
the potential transformer (PT) is entered in this Þeld. Power Input Frequency (Hz) – The frequency
Voltages within the range of 90 and 15000 VAC may value of the operating power applied to the voltage
be entered in 1 VAC increments. regulator is entered in this Þeld. This would be the
frequency of the permanent magnet generator or the
frequency of the generator in the case of self-excited
generator. Frequencies within the range of 50 to 400
Hz may be entered in 1 Hz increments. Refer to table
8 for the correct frequency values.
28 RENR7941-05
Testing and Adjusting Section

Table 8
Operating Frequency 50HZ 60HZ
Self Excited Generators 50HZ 60HZ
Permanent Magnet Generators 200HZ 240HZ
Low and Medium Voltage
6 Pole Generators 133HZ 160HZ
High Voltage 2600 Frame 200HZ 240HZ
Generators
High Voltage 2400 and 2800 150HZ 180Hz
Frame Generators

Sensing Mode – This setting is used to conÞgure the

voltage regulator for the single-phase or three-phase
voltage sensing. Note: For single phase sensing,
ensure the “C” phase sensing input is connected to
pins P12-10 and P12-11 with the “A” phase sensing
input connected to pin P12-12.

PC Software Part Number – This is a read-only

Þeld that displays the version of the PC software part
number.

Embedded Software Part Number – This is a

read-only Þeld that displays the version of the
embedded software part number.

Hardware Part Number – This is a read-only

Þeld that displays the version of the Hardware part
number.

Serial Number – This is a read-only Þeld that

displays the serial number of the voltage regulator
connected to the PC. Communication between the
voltage regulator and the PC must be enabled in
order to read the Þrmware version.

Setting Adjustments
The “Setting Adjustments” screen consists of two
tabs labeled “Setpoint” and “Startup”. Click the
“Settings” button (2) in order to access the “Setting
Adjustments” screen or click “Screens” on the menu
bar and click “Setting Adjustments”.
RENR7941-05 29
Testing and Adjusting Section

Setpoint Tab

g01009341
Illustration 22
Set point tab as seen without AVR Voltage Control and VAR/PF Control Desired Input ConÞguration (for original Þrmware).
30 RENR7941-05
Testing and Adjusting Section

g01418840
Illustration 23
Setpoint tab with AVR Voltage Control and VAR/PF Control Desired Input ConÞguration

AVR Voltage (V) – This setting Þeld is used to enter Power Factor – The Power Factor set point
the desired generator output terminal voltage. The determines the level of generator power factor
range of voltages is dependent on the value in the that is maintained by the voltage regulator when
“Voltage Adjustment Band (percent of rated)” Þeld. the voltage regulator is in the power factor mode.
Values may be entered in increments of 0.1 VAC. Settings within the range of 0.600 lagging to 0.600
leading may be entered in increments of 0.001. A
VAR (percent of rated) – The VAR set point setting in the lagging direction will have a positive
determines the level of generator VARs that are value and a setting in the leading direction will have
maintained by the voltage regulator when the digital a negative value. Before setting a leading power
voltage regulator is in the VAR mode. Percentage factor, consult the reactive capability curve for
values within the range of -100 to 100 percent may the generator being used.
be entered in increments of 0.1 percent. A setting in
the overexcited direction will have a positive value
and a setting in the under excited direction will have
a negative value.
RENR7941-05 31
Testing and Adjusting Section

AVR Voltage Control: Desired Input When operating in parallel operations, make sure
ConÞguration – “CAN Input” and “Switch” Droop mode is selected.
are the two settings that can be selected from the
drop down menu for this conÞguration. Selecting “Reactive Droop Compensation” and “Line Drop
“CAN Input” conÞgures the voltage regulator to accept Compensation” are brießy described below:
changes to the AVR voltage set point only from the
“CANbus”. If an attempt is made to change the AVR Reactive Droop Compensation - The voltage
set point with this conÞguration, from the “Settings” regulator provides a “Reactive Droop Compensation”
screen, with the use of the “Raise” or “Lower” buttons feature for three phase generators in order to
while at the “Metering” screen, and with the “Raise” assist in the sharing of reactive load during parallel
or “Lower” contacts, then the adjustment will have generator operation. The voltage regulator calculates
no effect. Selecting “Switch” conÞgures the voltage the reactive portion of the generator load using
regulator to accept changes to the AVR voltage the sensed generator output voltage and current
set point from the “Settings” screen, the “Raise” or quantities. The voltage regulator then modiÞes the
“Lower” buttons in the “Metering” screen, or by the voltage regulation set point accordingly.
use of the “Raise” or “Lower” contacts. The CANbus
will have no effect. If “CAN Input” is selected and the • A unity power factor generator load results in
CANbus communication is not available, the voltage almost no change in generator output voltage.
regulator will not automatically change to the “Switch”
setting. The user must use software to manually • A lagging power factor generator load (inductive)
change this setting to “Switch” in order to have AVR results in a reduction of generator output voltage.
voltage set point control. However, changing the
AVR set point from the “Settings” screen or using the • A leading power factor generator load (capacitive)
“Raise” or “Lower” buttons in the “Metering” screen results in an increase of generator output voltage.
will allow for changes to the AVR set point.
Droop is adjustable up to 10 percent with rated “B
VAR/PF Control: Desired Input ConÞguration – phase” line currents and 0.8 power factor. The “B
“CAN Input” and “Switch” are the two settings that phase” line currents are 5 amperes applied through
can be selected from the drop down menu for this terminals P12-1 and P12-2. The droop is adjustable
conÞguration. Selecting “CAN Input” conÞgures the with the use of the communication port(s).
voltage regulator to accept changes to the VAR/PF
voltage set point only from the “CANbus”. If an “Reactive Droop Compensation” is mutually exclusive
attempt is made to change the VAR/PF set point with to line drop compensation. These two functions work
this conÞguration, from the “Settings” screen, with opposite of one another and, therefore, cannot be
the use of the “Raise” or “Lower” buttons while at the used at the same time.
“Metering” screen, and with the “Raise” or “Lower”
contacts, then the adjustment will have no effect. In addition, the “Reactive Droop Compensation”
Selecting “Switch” conÞgures the voltage regulator to feature allows paralleling of three phase generators
accept changes to the VAR/PF voltage set point from when connected for “Cross Current Compensation”
the “Settings” screen, with the use of the “Raise” or (CCC). The CCC method of connection allows
“Lower” buttons while at the “Metering” screen, and reactive load shared between generators with very
with the “Raise” or “Lower” contacts. The CANbus little voltage droop. The droop level adjustment acts
will have no effect. If “CAN Input” is selected and the as the sensitivity adjustment when connected for
CANbus communication is not available, the voltage CCC.
regulator will not automatically change to the “Switch”
setting. The user must use software to manually Verify that the system works in reactive droop mode
change this setting to “Switch” in order to have before connecting in CCC mode.
VAR/PF voltage set point control. However, changing
the VAR/PF set point from the “Settings” screen or Note: When in CCC mode, kW and/or kVAR may
using the “Raise” or “Lower” buttons in the “Metering” indicate negative values in the “Metering” screen.
screen will allow for changes to the VAR/PF set point.

Load Compensation Mode: Mode – Three settings

may be selected from the drop down menu for this
operating mode: “Off”, “Droop”, or “Line Drop” (Line
Loss). Selecting “Off” disables all load compensation.
Selecting “Droop” enables the reactive droop
compensation feature of the voltage regulator.
Selecting “Line Drop” enables the voltage regulator
to compensate for a line drop by increasing the
generator output voltage as the generator load
increases.
32 RENR7941-05
Testing and Adjusting Section

Line Drop Compensation - The voltage regulator

provides a “Line Drop Compensation” feature
for three phase generators in order to assist in
compensating for voltage drops in the lines between
the generator and the load. The voltage regulator
calculates the magnitude of generator output current
and modiÞes the voltage set point accordingly. An
increase in generator output current results in an
increase in generator output voltage. “Line Drop
Compensation” is adjustable up to 10 percent with
rated “B phase” line currents and 0.8 power factor.
The “B phase” line currents are 5 amperes applied
through terminals P12-1 and P12-2. The droop is
adjustable with the use of the communication port(s).
“Line Drop Compensation” is mutually exclusive to
“Droop”. “Line Drop Compensation” and “Droop”
work opposite of one another and, therefore, cannot
be used at the same time.

Load Compensation Mode: Setpoint (percent) –

The “Load Compensation Mode” setting Þeld is
enabled only when “Droop” or “Line Drop” is selected
as the “Load Compensation” mode. A percentage of
zero to 10.00 percent may be entered in increments
of 0.01.

Voltage Adjustment Band (percent of rated) –

The “Voltage Adjustment Band” setting is entered as
a percentage of the rated generator voltage. “Voltage
Adjustment Band” is used to limit the range of the
AVR set point. A percentage value of zero to 15.00
percent may be entered in increments of 0.01.

Note: Adjusting the voltage using the DC bias input

or the “Fine Adjustment” buttons in the CDVR PC
software will only change the voltage set point.
Adjusting the voltage using the DC bias input or the
“Fine Adjustment” buttons will not change the voltage
adjustment band.
RENR7941-05 33
Testing and Adjusting Section

Startup Tab

g01393997
Illustration 24
34 RENR7941-05
Testing and Adjusting Section

g01012488
Illustration 25

Soft Start Bias (percent) – The Soft Start Bias Knee Frequency (Hz) – The “Knee Frequency”
setting determines the generator voltage offset setting deÞnes the value of frequency that causes
during start up as a percentage of the generator the voltage regulator to adjust the voltage set point
rated voltage. The CDVR will raise output voltage to so that the generator terminal voltage follows the
this percentage as quickly as possible. A percentage selected volts per hertz slope. A value of 45.00 to
value of 0.00 to 90.00 may be entered in increments 65.00 hertz may be entered in increments of 0.01
of 0.01 percent. hertz. “Knee Frequency” should typically be set
from 0.2 to 2 Hz less than the generator operating
Soft Start Time (sec.) – The Soft Start Time frequency. The knee frequency should be adjusted
establishes the length of time for the generator closer to the nominal frequency in applications
terminal voltage to increase to the generator rated where the generator engine and governor is slow in
voltage level from the “Soft Start Bias” percent. A recovering frequency during a transient load event.
value of 0.00 to 120.00 seconds may be entered in
increments of 0.01 seconds. If the “Under Frequency Frequency Deviation from Corner Frequency
Point” is reached before the CDVR reaches the (Hz) – This Þeld is a “read-only” Þeld. The Þxed value
“Soft Start Bias” percent, voltage will build from the is subtracted from the “Corner Frequency” value
“Soft Start Bias” percent, in a linear manner, for in order to determine when the generator under
the duration of the “Soft Start Time”. If the “Under frequency operation changes from slope 1 to slope 2.
Frequency Point” is reached after the CDVR reaches
the “Soft Start Bias” percent, voltage will build from Slope 1 (V/Hz) – When the generator frequency
the “Soft Start Bias” percent, in a linear manner, until is between the corner frequency and the corner
the “Under Frequency Point” is reached. From there, frequency minus 5 hertz, the voltage set point is
voltage will build following a “volts-per-hertz” proÞle. automatically adjusted so that the generator voltage
Refer to Illustration 25. follows volts per hertz slope 1. Slope 1 is adjusted by
this setting Þeld. A setting of zero to 10.00 may be
entered in increments of 0.01.
RENR7941-05 35
Testing and Adjusting Section

Slope 2 (V/Hz) – When the generator frequency is

between the corner frequency minus 5 hertz and the
“Minimum Frequency” setting, the voltage set point is
automatically adjusted so that the generator voltage
follows volts per hertz slope 2. Slope 2 is adjusted by
this setting Þeld. A setting of zero to 10.00 may be
entered in increments of 0.01.

Note: Volts per Hz slope value can be used to

improve transient response time.

Minimum Voltage (percent of rated) – The

“Minimum Voltage” setting deÞnes the voltage level
where the voltage regulator transitions from the
under frequency characteristic to a constant voltage
characteristic. The “Minimum Voltage” setting is
expressed as a percentage of nominal generator
voltage. A value of 50.00 to 100.00 percent may be
entered in increments of 0.01.

Minimum Frequency (Hz) – The “Minimum

Frequency” setting deÞnes the value of the generator
frequency where the excitation is removed. A
frequency value of 20.00 to 40.00 hertz may be
entered in increments of 0.01 hertz.

Control Gain
The “Control Gain” screen consists of a single tab
labeled “Control Gain”. Click the “Gain” button (3)
in order to access the “Control Gain” screen or click
“Screens” on the menu bar and click “Control Gain”.
36 RENR7941-05
Testing and Adjusting Section

Control Gain Tab

g01009752
Illustration 26

Proportional Gain Kp – This setting selects the Increasing the value of Ki decreases the time
proportional constant stability parameter. The voltage required to reach steady state.
regulator supplies a value that is equivalent to Kp
multiplied by the error between the voltage set point Derivative Gain Kd – This setting selects the
and the actual generator output voltage. Kp values of derivative constant stability parameter. The voltage
0 to 1,000 may be entered in increments of 0.01. regulator provides an output value that is equivalent
to Kd multiplied by the derivative of the error between
If the transient response has too much overshoot, the voltage set point and the actual generator output
then Kp may be decreased. If the transient response voltage. Kd values of 0 to 1,000 may be entered in
is too slow, then Kp may be increased. increments of 0.01.

Integral Gain Ki – This setting selects the integral Increasing the value of Kd reduces transient
constant stability parameter. The voltage regulator response ringing.
supplies a value that is equivalent to Ki multiplied by
the integral of the error between the voltage set point Noise Filter Time Constant Td – This setting
and the actual generator output voltage. Ki values of selects the noise Þlter time constant and is used in
0 to 1,000 may be entered in increments of 0.01. order to reduce high frequency noise. Values of 0.00
to 1.00 may be entered in increments of 0.01.
RENR7941-05 37
Testing and Adjusting Section

Loop Gain Kg – This setting adjusts the loop-gain

level of the PID algorithm. Loop gain values of 0
to 1,000 may be entered in increments of 0.01.
Loop gain Kg is an overall gain multiplier affecting
all gain parameters, and should be used as a Þrst
gain adjustment. Increasing loop gain may be used
to increase transient response and reduce time
to steady state. Decreasing loop gain will reduce
overshoot but will lengthen time to steady state. For
self excited machines, a low value may be required
for stability. This value may be as low as 5. Refer to
the “Poor Voltage Regulation - Troubleshoot” section.

VAR Integral Gain Ki – This setting adjusts the

integral gain and determines the characteristic of the
voltage regulator dynamic response to a changed
VAR setting. Ki values of 0 to 1,000 may be entered
in increments of 0.01.

VAR Loop Gain Kg – This setting adjusts the loop

gain level of the PI algorithm for VAR control. Values
of 0 to 1,000 may be entered in increments of 0.01.

PF Integral Gain Ki – This setting adjusts the

integral gain and determines the characteristic of the
voltage regulator dynamic response to a changed
power factor setting. Values of 0 to 1,000 may be
entered in increments of 0.01.

PF Loop Gain Kg – This setting adjusts the loop

gain level of the PI algorithm for power factor control.
Values of 0 to 1,000 may be entered in increments
of 0.01.

PID Pre-Settings – One of 20 preset stability ranges

within the voltage regulator can be selected from this
pull down menu. Selection of one of the 20 preset
stability ranges disables the “Proportional Gain”
(Kp), “Integral Gain” (Ki), and “Derivative Gain” (Kd)
settings of the “Control Gain” tab. Selecting “Custom
PID Settings” from the “PID Pre-Settings” menu
enables the Kp, Ki, and Kd settings. Caterpillar does
not recommend using the current “PID Pre-Settings”
in the list except the “Custom PID Settings”. The
default settings from the “Custom PID Settings”
will work well for most SR4 and SR4B generator
applications. If an adjustment is to be made, the
“Loop Gain Kg” should be used as a Þrst adjustment
approach.

“PID” Button – Press the PID button in order to

open the PID “Calculator” screen. See illustration 27.
The PID “Calculator” is used in order to calculate
proportional gain (Kp), integral gain (Ki), and
derivative gain (Kd) for a PID type controller. The
generator and the exciter time constant values are
entered into the “PID Calculator” in order to calculate
these values. AVR overall gain (Kg) and derivative
Þlter time constant (Td) can be entered and saved
in a Þle. Refer to the “PID Calculator” section for
additional information.
38 RENR7941-05
Testing and Adjusting Section

PID Calculator

g01009819
Illustration 27

The PID parameters are calculated for the desired Exciter Time Constant (Te) - (Seconds) – The
system response with a settling time of about one exciter time constant (Te) can be selected from this
third of the generator time constant and about 10 pull down menu. The value displayed in this menu
percent overshoot. depend on the generator time constant (T'do) that
is selected. Available values range from one Þfth to
Excitation Control Data one half of (T'do) in 0.01 second increments. The
maximum possible exciter time constant is 3 seconds.
Gen. Information – Up to 20 characters of
descriptive text for the generator can be entered in Default Exciter Time Constant – When this box
this Þeld. When a PID record is created, this text is checked, manual selection of the exciter time
identiÞes the record. constant is disabled and Te is set at one-sixth the
value of the generator time constant (T'do). This is
Gen Time Constant (T'do) - (Seconds) – The open not recommended for SR4 and SR4B generators.
circuit generator time constant (T'do) can be selected
from this pull down menu. Time constant values AVR Control Parameters
of 1 to 15 seconds can be entered in 0.05 second
increments. Proportional Gain (Kp) – This is a read only value.
The value is calculated from the values that are
Note: Values for speciÞc generators can be obtained selected from the generator time constant (T'do) and
from the “Technical Marketing Information System”. exciter time constant (Te) pull down menus.

Integral Gain (Ki) – This is a read only value. The

value is calculated from the values that are selected
from the generator time constant (T'do) and exciter
time constant (Te) pull down menus.
RENR7941-05 39
Testing and Adjusting Section

Derivative Gain (Kd) – This is a read-only value.

The value is calculated from the values selected from
the generator time constant (T'do) and exciter time
constant (Te) pull down menus.

Time Constant (Td) – The time constant value

entered in this Þeld is used to reduce high frequency
noise. The Td value entered is recommended to be
less than 0.2 (Kd, Kp). Td values from zero to 1.00
may be entered in 0.01 increments. Entering a value
of “zero” disables the Þltering.

AVR Overall Gain (Kg) – The AVR overall gain is

entered in this Þeld. A Kg value of zero to 1000.00
may be entered. Note: If the “Update CDVR PC
Software” button is pressed, a default value of 1.00 is
loaded into this Þeld. Make sure to adjust this value
as needed.

PID Record List

This area of the PID “Calculator” screen lists all of the

saved PID records that are available.

Remove Record Button – Records in the “PID

Record List” can be selected and deleted by clicking
this button.

Add Record Button – A record containing the

excitation control data and AVR control parameters
can be added to the “PID Record List” by clicking this
button. The “Save” button must be pressed in order
to save the record in the list.

Update CAT PC Software Button – Transfers

the AVR control parameters calculated in the PID
calculator and recorded to the “Control Gain” screen.

Close Button – Clicking this button closes the “PID

Calculator” and returns to the “Control Gain” screen.
40 RENR7941-05
Testing and Adjusting Section

Table 9
Power Input to Voltage Regulator (PM /
Power Input to Exciter
SE / IE systems)
Full Forcing
Nominal Requirements
Requirements
Exciter Exciter Exciter
Number Full Full
SE/PM Input to Frequency Nominal Nominal Exciter Time
of Forcing Forcing
Voltage Regulator Range Voltage Current Resistance Constant
Phases Voltage Current
Input Input Te
Kato
70
2600/
PM to 240 Hz 3 35V 10A 3.7 ohms 0.22 sec 65V 15A
2700
105V
Frame
Kato
2800 PM 120V 90 Hz 1 50V 5A 10 ohms 0.18 sec 90V 10A
Frame
6100 PM 140V 120 Hz 3 40V 4A 10 ohms 0.22 sec 60V 10A
6100 SE 140V 60 Hz 1 40V 4A 10 ohms 0.22 sec 60V 10A
6100 IE 140V 50/180 Hz 2x1 40V 4A 10 ohms 0.22 sec 60V 10A
1400
PM 180V 200/240 Hz 3 45V 4.5A 11 ohms 0.06 sec 80V 10A
/4P
1400
IE 140V 50/180 Hz 2x1 45V 4.5A 10 ohms 0.06 sec 80V 10A
/4P
1600
PM 180V 200/240 Hz 3 60V 6A 10 ohms 0.094 sec 150V 15A
/4P
1600
IE 240 V 50/180 Hz 2x1 60V 6A 10 ohms 0.094 sec 150V 15A
/4P
1800
PM 180V 240 Hz 3 84V 4A 11 ohms 0.26 sec 190V 8.5A
/4P
1800
AREP 240V 60 Hz 1 84V 4A 11 ohms 0.26 sec 190V 8.5A
/4P
70
SR4/
PM to 240 Hz 3 35V 10A 3.7 ohms 0.22 sec 65V 15A
SR4B
105V
SR4/
SE 240V 60 Hz 1 35V 10A 3.7 ohms 0.22 sec 65V 15A
SR4B

Protection Settings
The “Protection Settings” screen consists of a single
tab labeled “Protection”. Click the “Protection” button
to access the “Protection Settings” screen or click
“Screens” on the menu bar and click “Protection
Settings”.
RENR7941-05 41
Testing and Adjusting Section

Protection Tab

g01009884
Illustration 28

“SHUTDOWN OVERRIDE” Button – This button is Generator Over voltage: Enabled – Selecting the
used to prevent excitation shutdown for any protected “Enabled” check box enables generator over voltage
function. The button displays “ENABLED” when protection. Deselecting the “Enabled” check box
selected and the button displays “DISABLED” when disables generator over voltage protection and the
the button is deselected. Enabling this button does associated settings.
not disable output drivers or “CANbus” messages.
The following protections do not rely on disabling Generator Over voltage: Fault Type – Two
excitation to cause a shutdown and, therefore, are options can be selected from this pull down menu,
not affected by the “Shutdown Override” button. “Alarm” or “Shutdown”. When “Alarm” is selected
and a generator over voltage condition is detected,
• Generator Over voltage the alarm output driver energizes, a J1939 alarm
message is sent via the “CAN” communication port,
• Generator Under voltage and the “Fault LED” will be lit constantly. For units
equipped with an RS-232 communication port, an
• Loss of Excitation (Reverse Var) Alarm fault will be annunciated via the PC software.
When “Shutdown” is selected and a generator over
• Fault Reset too long voltage condition is detected, the “Fault Shutdown”
output driver energizes, a J1939 shutdown message
Note: The position of this button cannot be saved is sent, and the “Fault LED” will ßash. For units
into the EEPROM. The default value of “Disabled” is equipped with an RS-232 communication port, a
loaded when power is cycled on the CDVR. “Shutdown” fault will be annunciated via the PC
software. The voltage regulator does NOT disable
excitation when a “Generator Over Voltage” fault
is detected.
42 RENR7941-05
Testing and Adjusting Section

Generator Over Voltage: Trip Value (percent) – Generator Under Voltage: Fault Type – Two
This setting determines the voltage threshold where options can be selected from this pull down menu,
an over voltage trip will occur. Voltage values of 105 “Alarm” or “Shutdown”. When “Alarm” is selected and
to 135 percent of the rated voltage may be entered in a generator under voltage is detected, the “Alarm”
increments of 1 percent. output driver will energize. A J1939 alarm message
is sent via the “CAN” communication port. Also,
Generator Over Voltage: Time Delay (Sec.) – This the “Fault LED” is on constantly. For units that are
setting assigns the length of time from when an equipped with an RS-232 communication port, an
over voltage condition is detected until the voltage “Alarm” fault will be annunciated via the PC software.
regulator issues an alarm or shuts down excitation. When “Shutdown” is selected and a generator
A time value of 2.0 to 30 seconds may be entered in under voltage is detected, the “Shutdown” output
0.1 second increments. driver will energize. A J1939 shutdown message is
sent via the CAN communication port. The “Fault
Reverse VAR: Enabled – Selecting the “Enabled” LED” will ßash. For units that are equipped with an
check box enables reverse VAR protection. RS-232 communication port, a “Shutdown” fault will
Deselecting the “Enabled” check box disables be annunciated via the PC software. The voltage
reverse VAR protection and the associated settings. regulator does NOT disable excitation when a
“Generator Under Voltage” fault is detected.
Note: If “Reverse VAR” protection is enabled and the
CT connections are reversed, a reverse VAR alarm Generator Under Voltage: Trip Value (percent) –
or shutdown will occur. This setting determines the level of voltage. The
value is expressed as a percentage of nominal
Reverse VAR: Fault Type – Two options can generator voltage when a generator under voltage
be selected from this pull down menu, “Alarm” or trip occurs. A value of 60 to 95 percent may be
“Shutdown”. When “Alarm” is selected and loss entered in 1 percent increments.
of excitation is detected, the alarm output driver
energizes, a J1939 alarm message is sent via Generator Under Voltage: Time Delay (Secs) –
the “CAN” communication port, and the “Fault This setting assigns the length of time from when a
LED” is lit constantly. For units equipped with an generator under voltage condition is detected until
RS-232 communication port, an alarm fault will be the voltage regulator issues an alarm or shuts down
annunciated via the PC software. When “Shutdown” excitation. A time value of 10.0 to 120.0 seconds may
is selected and loss of excitation is detected, be entered in 0.1 second increments.
the “Fault Shutdown” output driver energizes, a
J1939 shutdown message is sent via the “CAN” Over Excitation: Type – Two options can be
communication port, and the “Fault LED” ßashes. selected from this pull down menu. “Inv Time” (for
For units equipped with an RS-232 communication inverse curves) or “Threshold” (for a Þxed time delay)
port, a shutdown fault will be annunciated via the PC can be selected. The voltage regulator disables
software. The voltage regulator does NOT disable excitation when an over excitation fault is detected
excitation when a Loss of Excitation (Reverse unless a global “Shutdown Override” command is
Var) fault is detected. in effect.

Reverse VAR: Trip Value (percent) – This setting Note: Selecting “Inv Time” requires changing the
determines the level of reverse VAR ßow, expressed time setting to a suggested value of 2 (based on
as a percentage of nominal, positive VAR ßow, where the time dial settings for the SR4B Generators
a loss of excitation trip occurs. A value of 10 to 100 curve). If this value is changed, over excitation
percent may be entered in increments of 1 percent. protection may not exist.

Reverse VAR: Time Delay (Secs) – This setting

assigns the length of time from when the reverse
VAR trip value is exceeded until the voltage regulator
issues an alarm or shuts down. A time value of
0.1 to 9.9 seconds may be entered in 0.1 second
increments.

Generator Under Voltage: Enabled – Selecting

the “Enabled” check box enables generator under
voltage protection. Deselecting the “Enabled” check
box disables generator under voltage protection and
the associated settings.
RENR7941-05 43
Testing and Adjusting Section

Over Excitation: Trip Value (Amps) – This setting

determines the level of Þeld current that will cause
an over excitation trip. Values of 0 to 12.0 amperes
may be entered in 0.1 ampere increments. When in
“Threshold” mode, the suggested value for the SR4
and SR4B generators is 12 amperes. When in “Inv
Time” mode, the value entered should be determined
by the full load excitation level of the generator and
application. This entered value becomes a “per
unit” value. For example, if a value of 12 is entered
and a time setting of 2 is chosen, then 2.0 on the
“Field Current” axis of the “Inverse Time” curve
corresponds to 24 amps, that is, 2.0 x 12. This will
give the CDVR approximately 17 seconds before
shutdown (provided the same level of current exists).
If a trip value lower than the full load excitation level
is entered, the CDVR will allow less time before
shutdown for a given current level. Excitation will
be disabled instantly if the Þeld current reaches
28 amps, regardless of the “Over Excitation” time
setting. This event will indicate in the “Metering”
screen as “Field Over Current” and is separate
from the “Over Excitation” alarm.

Over Excitation: Time Setting – This setting

assigns the length of time from when an over
excitation condition is detected and when the
voltage regulator issues an alarm or shuts down the
excitation. A time value of 1.0 to 10.0 seconds may be
entered in 0.1 second increments. The required value
for the SR4 and SR4B generators is 10 seconds. If
“Inv Time” is selected, this value becomes the time
dial setting for the generator. See Illustration 29.

g01119160
Illustration 29
Inverse Time Characteristic for Over Excitation Limiter
44 RENR7941-05
Testing and Adjusting Section

Exciter Diode Monitor (EDM): Trip Value (Amps) –

This setting determines the level of current that is
indicative of a failed exciter diode. The RMS ripple
current of the Þeld is measured. If the current level
exceeds the diode fault threshold set point for Þve
seconds, a diode fault is detected. The voltage
regulator disables excitation when a diode fault
is detected unless a global “Shutdown Override”
command is in effect. A value of 1.0 to 10.0 amperes
may be entered in 0.1 ampere increments. If the
regulator shuts down on instantaneous “Field Over
Current” of 28 amps or more, then the EDM alarm
LED will not illuminate in the “Metering” screen.

Loss of Sensing (LOS): Time Delay (Secs) –

The value of this setting determines the time
delay between the time a loss of sensing voltage
is recognized and the time the voltage regulator
responds by removing the Þeld excitation. For single
phase sensing, 50 percent of voltage set point is
interpreted as an LOS. For three phase sensing,
a total loss of one of the phases or an imbalance
totaling 20 percent of the voltage set point is
interpreted as an LOS. A time value of zero to 25.0
seconds may be entered in 0.1 second increments.
The voltage regulator disables excitation when a loss
of “Generator Sensing” fault is detected unless a
global “Shutdown Override” command is in effect.

Fault Reset Too Long: Enabled – Selecting the

“Enabled” check box enables the voltage regulator to
issue an alarm or a shut down fault if the fault reset
input is closed longer than 10 seconds.

Fault Reset Too Long: Fault Type – Two options

can be selected from this pull down menu, “Alarm” or
“Shutdown”. When “Alarm” is selected and the “Fault
Reset” contact input remains closed for more than 10
seconds, the alarm output driver energizes, a J1939
alarm message is sent via the “CAN” communication
port, and the “Fault LED” lights constantly. For units
that are equipped with an RS-232 communication
port, an alarm fault will be annunciated via the
PC software. When “Shutdown” is selected and
the “Fault Reset” contact input remains closed for
more than 10 seconds, the “Fault Shutdown” output
driver energizes, a J1939 alarm message is sent
via the “CAN” communication port, and the “Fault
LED” will ßash. For units that are equipped with an
RS-232 communication port, the voltage regulator
will attempt to annunciate the “Shutdown” fault via
the PC software. The voltage regulator does NOT
disable excitation when a “Fault Reset Closed
Too Long” condition is detected.

Metering, Operation, and Alarms

The “Metering, Operation, and Alarms” screen
consists of a single tab labeled “Metering”. Click the
“Metering” button to access the “Metering, Operation,
and Alarms” screen or click “Screens” on the menu
bar and click “Metering/Operation”.
RENR7941-05 45
Testing and Adjusting Section

Metering Tab

g01010266
Illustration 30

Note: When communication is established, a GEN VOLTAGE (V): Vca – This Þeld is a read-only
“Metering” choice becomes available in the menu Þeld that displays the phase-to-phase voltage of
bar. Metering can be disabled by selecting “Disable phase C and phase A.
Metering” from this choice. When metering is
disabled, contact inputs will still work normally, but GEN VOLTAGE (V): Vavg – This Þeld is a read-only
will not indicate. “Alarms” will still work normally Þeld that displays the average value of the three
and indicate. The raise and lower buttons will still phase-to-phase voltages.
work and show a changed set point. If another tab
is selected when metering is disabled, then the GEN CURRENT (A): Ib – This Þeld is a read-only
“Metering” tab is selected, metering will become Þeld that displays the value of the current on the B
enabled automatically. phase of the generator.

GEN VOLTAGE (V): Vab – This Þeld is a read-only GEN FREQ (Hz): Freq – This Þeld is a read-only
Þeld that displays the phase-to-phase voltage of Þeld that displays the value of the frequency of the
phase A and phase B. generator voltage.

GEN VOLTAGE (V): Vbc – This Þeld is a read-only GEN POWER: kWatts – This Þeld is a read-only
Þeld that displays the phase-to-phase voltage of Þeld that displays the value of real power that is being
phase B and phase C. output from the generator.
46 RENR7941-05
Testing and Adjusting Section

GEN POWER: kVA – This Þeld is a read-only Þeld FINE ADJUSTMENT – The “Raise” and “Lower”
that displays the value of apparent power that is buttons control the Þne adjustment of the operating
being output by the generator. set point. These buttons perform the same function
as closing the appropriate set of contacts connected
GEN POWER: kVAR – This Þeld is a read-only Þeld to the “Contact Sense – Raise” input (terminal P9-5)
that displays the value of reactive power that is being and “Contact Sense - Lower” input (terminal P9-4) of
output by the generator. the voltage regulator. Each click of the “Raise” button
increases the voltage set point by 0.1 V, each click
GEN POWER: PF – This Þeld is a read-only Þeld of the “Lower” button decreases the voltage set point
that displays the value of the power factor that the by 0.1 V.
generator is operating at.
Note: The PT ratio will affect this setting.
AUX DC INPUT (V): Vaux – This Þeld is a read-only
Þeld that displays the level of dc control voltage Note: An alternate method of adjusting voltage is to
that is applied from a remote device to the voltage adjust the DC voltage between terminals “P12-3” and
regulator terminals “P12-3” (B) and “P12-6” (A). “P12-6”.

Note: The “Aux DC Input” terminals can be used as SET POINT: AVR (V) – This setting Þeld is used to
an alternate method of adjusting voltage in “AVR” enter the desired generator terminal voltage. The
mode or adjusting PF or VAR in PF or VAR mode background color of this Þeld is green when the
when used with an existing remote VAR/PF controller. voltage regulator is in AVR mode.
A DC input on these pins acts as a DC bias. When
the CDVR is in “AVR” mode, a 1 VDC change on the Note: The PT ratio will affect this setting.
terminals corresponds to a 1 percent change in the
voltage set point. A 1 VDC change gives a 10 percent SET POINT: VAR (percent of nom.) – This setting
VAR change (in “VAR” mode) and a 0.04 PF change determines the level of generator VARs maintained
(in “PF” mode). If the DC voltage is removed from by the voltage regulator when operating in VAR
the ±10 VDC control input, the operating set point mode. The background color of this Þeld is green
will return to the original value regardless of pressing when the voltage regulator is regulating the VAR set
the EEPROM button. point. A percentage value of zero to 100.0 may be
entered in 0.1 percent increments.
Note: Adding a DC voltage when the operating set
point is near the voltage adjust band limit may allow SET POINT: Power Factor – This setting determines
the regulator to operate outside of the voltage adjust the level of power factor regulation maintained by the
band. voltage regulator. The background color of this Þeld
is green when the voltage regulator is regulating the
EXCITER FIELD: Vfd (V) – This Þeld is a “read-only” power factor set point. A power factor value of –0.600
Þeld that displays the value of the exciter Þeld voltage. to 0.600 may be entered in 0.001 increments.

EXCITER FIELD: Ifd (A) – This Þeld is a “read-only” STATUS – Four indicators indicate the operating
Þeld that displays the value of the exciter Þeld current. status of the voltage regulator: “Droop”, “Line Drop”,
“Under Frequency”, and “Soft Start”.
OPERATING MODE – One of three operating modes
may be selected as active: “AVR”, “VAR”, or “PF”. The “Droop” indicator turns red when the “Reactive
When an operating mode is active, the corresponding Droop Compensation” feature is selected. The
indicator color changes from black to red for “AVR” “Reactive Droop Compensation” feature is used
mode. When an operating mode is active, the during parallel generator operation to assist in the
corresponding indicator color changes from black to sharing of reactive load.
green for the “VAR” mode and the “PF” mode.
The “Line Drop” indicator turns red when the “Line
Note: When either KVAR or PF mode are selected, Drop Compensation” feature is selected The “Line
the appropriate button must be selected and the Drop Compensation” feature is used to compensate
auxiliary breaker contact that is connected to “P9-6” for voltage drops in the lines between the generator
(KVAR/PF enable contact) and “P9-9” (contact sense and the load.
common) must be closed.
The “Under Frequency” indicator turns red when the
Note: “Droop” should be enabled whenever the generator frequency decreases below the “Knee
CDVR is operated in PF or VAR mode. The newest Frequency” setting and excitation is terminated.
version of the CDVR PC Þrmware will not allow the
operator to select PF or VAR mode unless “Droop” The “Soft Start” indicator turns red when the “Soft
is selected in the “Settings” menu Þrst. The “Droop” Start” feature is active to control the time for generator
setting can be set to 0 percent. voltage to ramp up during startup.
RENR7941-05 47
Testing and Adjusting Section

CONTACT INPUTS – Five indicators provide the • real time clock Þrst
status of the voltage regulator switch inputs: “Raise”,
“Lower”, “VAR / PF”, “Excitation Disable”, and “Fault • real time clock last
Reset”.
• occurrence count
The “Raise” indicator turns red when contact closure
at terminals “P9-5” “Contact Sense - Raise” and Note: The CDVR does not know the actual time.
“P9-6” “Contact Sense - Common” is detected. The CDVR only knows the elapsed time from CDVR
power up.
The “Lower” indicator turns red when contact closure
at terminals “P9-4” “Contact Sense - Lower” and Settings Files
“P9-6” “Contact Sense - Common” is detected.
Caterpillar PC software enables you to print a list of
The “Var/PF” indicator turns red when contact closure voltage regulator settings, save voltage regulator
at terminals “P9-9” “Contact Sense - Var/PF Enable”
settings in a Þle, and open a settings Þle in order
and “P9-6” “Contact Sense - Common”is detected.
to upload those settings to a voltage regulator. A
settings Þle may also be opened and edited with any
The “Excitation Disable” indicator turns red when
text editing software.
contact closure at terminals “P9-7” “Contact Sense
– Excitation Disable” and “P9-6” “Contact Sense -
Common” is detected.

The “Fault Reset” indicator turns red when contact

closure at terminals “P9-8” “Contact Sense - Fault
Reset” and “P9-6” “Contact Sense - Common”is
detected.

ALARMS – Ten indicators annunciate alarm

conditions. Alarm indicators include the following
alarms: “Internal Memory Failure”, “Internal Watchdog
Failure”, “Exciter Diode Monitor”, “Excitation Loss”,
“Generator Over voltage”, “Generator Undervoltage”,
“Over excitation”, “Loss of Sensing”, “Field Over
current (28 Amps instantaneous shutdown)”, and
“Fault Reset Too Long”. When the voltage regulator
detects an alarm condition, the appropriate indicator
changes from black to red.

ALARMS: Shutdown Override Status – This

indication provides the status (position) of the
“Shutdown Override Button”. The button displays
“ENABLED” when selected and “DISABLED” when
deselected.

The CDVR does some diagnostic code logging

and diagnostic code broadcasting. These codes
are transmitted over CANbus. When the CDVR
is operating, any active diagnostic codes will be
transmitted along with a description of that code and
the occurrence count.

If power is removed from the CDVR, the nonvolatile

memory will retain the following information for each
of the 10 alarms if any codes have been logged:

• code
• description
• service meter hours Þrst
• service meter hours last
48 RENR7941-05
Testing and Adjusting Section

Printing the Settings Files

g01394300
Illustration 31
Print Icon

g01016740
Illustration 32
RENR7941-05 49
Testing and Adjusting Section

g01016741
Illustration 33

A printout of voltage regulator settings can be useful

for record keeping or comparison purposes. The
voltage regulator settings can be printed by clicking
the print icon (1) or clicking “File” on the menu bar
and then clicking “Print”. When the print command
is given, a dialog box provides the opportunity to
add a title and comments to the settings list. See
illustration 32. Each entry is limited to a maximum
of 54 characters. After this information is entered,
click on “OK”. The “Print Settings” box will appear.
See illustration 33. This dialog box is used in order
to select the desired printer, change and verify the
printer settings, and preview the printed settings list.
Click on the “Print” button in order to print the settings
list.
50 RENR7941-05
Testing and Adjusting Section

Saving the Settings Files

g01394035
Illustration 34
Save Icon

It is recommended that the settings for the voltage Uploading the Settings Files to the
regulator be saved to a Þle. In order to save setup Voltage Regulator
time when conÞguring multiple units with the same
settings, the saved settings can be uploaded to other A voltage regulator settings Þle downloaded from a
voltage regulator units. voltage regulator or created within the PC software
can be uploaded to multiple voltage regulator units.
A settings Þle can also be created in the PC software Only a voltage regulator settings Þle with a “.dv2”
without being connected to a voltage regulator. The extension can be uploaded to a voltage regulator
settings of the desired screens can be changed. The unit. Before uploading a Þle, communication must be
settings can then be saved to a Þle. Once a settings initiated with the voltage regulator that is to receive
Þle is created, the Þle can be edited with the use of the settings. See Systems Operation, “Remote
any text editing software. The Þle can then be saved Communication”.
for uploading.
The upload process is started by clicking the open
A settings Þle is created by clicking the save icon icon or clicking “File” on the menu bar and then
(1) or by clicking “File” on the menu bar and then clicking “Open”. An “Open” dialog box is then
clicking “Save”. When the command is given, a “Save displayed where the desired settings Þle is navigated
As” dialog box is displayed where the settings are to and selected. Clicking “Open” uploads the settings
assigned a Þle name and then saved. All voltage Þle. The default settings for the CDVR are stored in a
regulator settings Þles are automatically given a Þle called “Defaults.DV2” in the “CDVR PC Software”
“.dv2” extension. folder on the PC.

The defaults are displayed here for reference.

RENR7941-05 51
Testing and Adjusting Section

Table 10
CDVR PC Software Settings
Rated kVAR (@ 0.8 Power Factor): 75
Sensing Mode: 1 (0=Single-Phase, 1=Three-Phase)
Rated Generator Frequency: 0 (0=60 Hz, 1=50 Hz)
Rated Generator Voltage: 120 (Volts)
Generator PT Primary Voltage Rating: 120 (Volts)
Generator PT Secondary Voltage Rating: 120 (Volts)
Generator CT Primary Current Rating: 600 (Amps)
Generator CT Secondary Current Rating: 5 (Amps)
Rated Generator Current: 600 (Amps)
Power Input Frequency: 60 (Hz)

Load Compensation Mode: 0 (0=Off, 1=Droop, 2=Line Drop)

Operating Mode: 2 (0=AVR[Off], 1=PF, 2=VAR)

AVR Setpoint: 120.0 (Volts)

AVR Minimum Setpoint: 102.0 (Volts)
AVR Maximum Setpoint: 138.0 (Volts)
VAR Setpoint: 0.0 (%)
PF Setpoint: 1
AVR Voltage Control: 0 (0=CAN Input, 1=Switch)
VAR/PF Control: 1 (0=CAN Input, 1=Switch)

Soft Start Bias: 10.00 (%)

Soft Start Time: 5.00 (Seconds)
Knee Frequency: 50.00 (Hz)
Decreasing Slope 1: 2.00 (Volts/Hz)
Minimum Voltage: 50.00 (% of rated)
Frequency Deviation from Knee Frequency: 5.00 (Hz)
Decreasing Slope #2: 2.00 (Volts/Hz)
Minimum Frequency: 25.00 (Hz)

AVR Proportional Gain: 200

AVR Integral Gain: 600
AVR Derivative Gain: 30
Noise Filter Time Constant: 0.00 (Seconds)
Regulator Loop Gain: 50
Pre-deÞned PID Gains: 21 (1-20 or Custom)
Voltage Adjustment Band Limit: 15.00 (% of rated)

Overexcitation Type: 0 (0=Threshold, 1=Inverse Time)

(continued)
52 RENR7941-05
Testing and Adjusting Section

(Table 10, contd)

Overexcitation Trip Value: 12.0 (Amps)
Overexcitation Time Setting: 10
Excitation Loss (Reverse VAR): 1 (0=Disabled, 1=Enabled)
Excitation Loss (Reverse VAR) Fault Type: 0 (0=Alarm, 1=Shutdown)
Excitation Loss (Reverse VAR) Trip Value: 10 (%)(1)
Excitation Loss (Reverse VAR) Time Delay: 3 (Seconds)(1)
Generator Overvoltage: 1 (0=Disabled, 1=Enabled)
Generator Overvoltage Fault Type: 0 (0=Alarm, 1=Shutdown)
Generator Overvoltage Trip Value: 135 (%)
Generator Overvoltage Time Delay: 2.0 (Seconds)
Generator Undervoltage: 1 (0=Disabled, 1=Enabled)
Generator Undervoltage Fault Type: 0 (0=Alarm, 1=Shutdown)
Generator Undervoltage Trip Value: 60 (%)
Generator Undervoltage Time Delay: 30.0 (Seconds)
Loss of Sensing Time Delay: 2.0 (Seconds)
Exciter Diode Monitor Trip Value: 2.0 (Amps)
Fault Reset Too Long: 1 (0=Disabled, 1=Enabled)
Fault Reset Too Long Fault Type: 0 (0=Alarm, 1=Shutdown)
Shutdown Override Flag: 0 (0=Disabled, 1=Enabled)

VAR Integral Gain: 5

VAR Loop Gain: 2.5
PF Integral Gain: 5
PF Loop Gain: 3
(1) The default settings for software 279-0916 Generator Set Software Gp and before are 40 (%) and 0.5 (Seconds).

Uploading Embedded Firmware • CDVR

Using the CDVR PC Software
• CDVR PC software
Embedded Þrmware is the operating program that
controls the actions of the CDVR. The CDVR stores • Firmware as a .s19 Þle
Þrmware in nonvolatile ßash memory that can be
reprogrammed through the RS-232 communication • Computer with communication port
port. It is not necessary to replace EPROM chips
when replacing the Þrmware with a newer version. • A “pass through” 1U-9484 Cable or equivalent
RS-232 “pass through” cable with one end that has
a male connector and the other cable end with a
NOTICE female connector
If power is lost or communication is interrupted during
Þle transfer, the CDVR will not recover and will cease • 24 V power to the CDVR
to be operational.
Flash the CDVR
Note: Communication must be closed prior to
uploading embedded Þrmware to the CDVR. Refer 1. Apply power to the CDVR.
to the “Terminating Communication” section for
information about closing CDVR communication. 2. Connect a communication cable between the
RS-232 connector (J4) of the CDVR and the
In order to ßash the CDVR, the following materials appropriate communication port of your PC.
are needed:
RENR7941-05 53
Testing and Adjusting Section

3. Start the CDVR PC software.

4. Click “Upgrade” on the “Menu” bar. Click “Upload

Embedded Software”. Refer to Illustration 35.
If this menu selection is grayed out, close
CDVR communication. Refer to the “Terminating
Communication” section for information about
closing CDVR communication.

g01408125
Illustration 35
Upload Embedded Software

5. When “Upload Embedded Software” is clicked,

a dialog box appears and veriÞes your intent to
update the Þrmware. Click “Yes” to proceed. When
“Yes” is clicked, the “CDVR Embedded Program
Loader” screen will appear. Refer to Illustration 36.

Note: Uploading Þrmware may replace some user

adjusted settings with factory default settings.

g01408132
Illustration 37

7. Click the “Start Transfer Data” button in order

to proceed with software uploading. Illustration
38 will appear. Illustration 38 recommends that
the CDVR settings be saved in a Þle that can
be uploaded to the CDVR after the embedded
Þrmware is updated.
g01408128
Illustration 36

6. Click the “Get Device Information” button. The

“CDVR Embedded Program Loader” will retrieve
and will display the CDVR model number. The
information will be displayed in the left hand
column as shown in Illustration 37.
54 RENR7941-05
Testing and Adjusting Section

g01408133
Illustration 38

8. Click “No” in order to exit the upload process and

in order to create a CDVR settings Þle. Refer to
the “Settings Files” section for information about
creating a settings Þle. Click “Yes” in order to
continue with the upload process and in order to
display the “Open” dialog box that is shown in
Illustration 39. The “Open” dialog box is used in
order to locate and select the appropriate Þle for
uploading to the CDVR. Only Þles with the .s19
extension are displayed in the “Open” dialog box.

g01408135
Illustration 39

9. Select the appropriate Þle for uploading. Click the

“Open” button in order to start the Þle transfer. If
the dialog box appears that is shown in Illustration
40, then software is asking for the serial number
of the CDVR. Enter the eight (8) numerical digits
of the serial number exactly as they appear on
the upper right hand corner of the label on the
CDVR. Ignore the letters GD. Do not use the
CDVR serial number that is shown in the PC
software. Do not use spaces, dashes, or any
other symbols. Press “Enter”.

g01408137
Illustration 40
Serial Number Change

10. A dialog box will appear in order to indicate the

progress of the Þle transfer. Refer to Illustration 41.
RENR7941-05 55
Testing and Adjusting Section

• Computer with a serial port

• Communication Adapter II (171-4400
Communication Adapter Group)

Follow the steps below to ßash the CDVR with Cat

ET:

1. Follow steps 1 through 6 in the “Parameter

Viewing and ConÞguration-Caterpillar Electronic
Technician” section.

2. Disconnect communication if necessary.

g01408138
3. Click on the “Flash Memory” button. Refer to
Illustration 41 Illustration 43.
11. Once the transfer is complete, the device
information is displayed in the right hand column
of the “Embedded Program Loader”. Refer to
Illustration 42. The displayed program version
number indicates the version and the date of the
Þrmware that was just loaded.

g01408140
Illustration 42
CDVR Information After Upload

12. Close the “Embedded Program Loader”. The

default settings are loaded into the CDVR and
are checked.

If desired, the settings can be reloaded into the

regulator from the saved settings Þle. Refer to
the “Settings Files” section for information about
loading a settings Þle.

Flash the CDVR Using Cat ET

Software
The following items are needed in order to ßash the
CDVR with Cat ET:

• CDVR
• Caterpillar Electronic Technician software (Cat ET)
• Power to the CDVR
56 RENR7941-05
Testing and Adjusting Section

g01425391
Illustration 43

4. The “WinFlash” screen will appear. Refer to

Illustration 44.

g01425392
Illustration 44
RENR7941-05 57
Testing and Adjusting Section

5. Select the CDVR in the list. Click “Browse” that

is located in the upper right corner of the screen.
Browse to the appropriate .ßs Þle. Select “Open”.

6. When the “Winßash” screen appears, select

“Begin Flash” in order to ßash the selected Þle into
the CDVR. “Begin Flash” is located in the lower
right corner of the screen.

i02848566

Parameter Viewing and

ConÞguration (Caterpillar
Electronic Technician)
SMCS Code: 4467-NQ

The following materials are needed to program the

voltage regulator with Cat ET:
g01112515
• CDVR Illustration 45
ECM's detected screen
• Cat ET Software
3. Wait for the software to recognize the ECM's. See
• 24 VDC control power to the voltage regulator illustration 45.

• IBM compatible PC with serial port, 486DX2 or

faster (100 MHz or higher microprocessor is
recommended)

• Communication Adapter II
Follow the steps below in order to program the
voltage regulator with Cat ET:

1. Apply 24 VDC control power to the voltage

regulator.

2. Connect the “Communication Adapter II” module

between the computer and the primary “CANbus”
port and start the Cat ET software. Select the
appropriate communication port, if prompted.
58 RENR7941-05
Testing and Adjusting Section

g01112560
Illustration 46
Connect button

4. If the software does not automatically connect,

click on the “CONNECT” button at the top of the
screen as shown in illustration 46.

g01113063
Illustration 47
ConÞguration tool

5. The “Service” menu contains a drop down menu

containing the “ConÞguration Tool” button as
shown in illustration 47. Click on the “ConÞguration
Tool” button. Select the CDVR from the list by
clicking on it once.

g01113076
Illustration 48
Available ECM's

6. Verify that the CDVR is listed in the left panel under

“AVAILABLE ECM(S)” as shown in illustration 48.
RENR7941-05 59
Testing and Adjusting Section

g01113082
Illustration 49
ConÞguration group

7. Select the conÞguration group that is to be viewed

by clicking on the group in the left panel. Refer
to illustration 49. If necessary, expand the CDVR
folder in the left panel by clicking the “+” symbol
next to the CDVR label. The various parameters
to be programmed or viewed in that particular
conÞguration group become visible in the right
panel.

g01113121
Illustration 50
Parameter selection

8. In order to program a parameter, double click

that parameter in the right panel or highlight the
parameter by single clicking the parameter, then
press “ENTER”. Refer to illustration 50.
60 RENR7941-05
Testing and Adjusting Section

g01113102
Illustration 51
Change Parameter Value

9. Type the new value or select a new value from the

drop down menu if the “CHANGE PARAMETER
VALUE” window is available. Click on “OK”. Click
on “YES” in order to conÞrm. Refer to illustration
51.

10. Repeat steps 7 through 9 for each parameter to

be programmed.

g01113109
Illustration 52
Disconnect button

11. In order to disconnect communication, click the • Power to the CDVR

“DISCONNECT” button. Refer to Illustration 52.
• Computer with serial port
Viewing Metering Parameters
• Communication Adapter II (171-4400
Using Cat ET Software Communication Adapter Group)

The following items are needed to view metering Follow the steps below in order to view metering
parameters in the CDVR with Cat ET: parameters in the CDVR with Cat ET.

• CDVR 1. Follow steps 1 through 6 in “Parameter Viewing

and ConÞguration - Caterpillar Electronic
• Caterpillar Electronic Technician software (Cat ET) Technician” section.
RENR7941-05 61
Testing and Adjusting Section

2. Click on the “Status Tool” button in order to view i02847372

the metering parameters. Refer to Illustration 53.
Gain Setting - Adjust
SMCS Code: 4467

The following steps should only to be used as a

guide if the default settings in the CDVR do not give
acceptable performance. Each generator has its own
requirements that are application speciÞc.

1. Starting with the factory defaults (Kp = 200, Ki =

600, Td = 0, and Kg = 50), adjust Kg to achieve
the desired response. If that response is not
achievable, proceed to Step 2.

2. Perform a “step of reference” test by recording the

generator terminal voltage with a chart recorder or
similar device. Limit the step sizes to 5% or less of
terminal voltage, that is, from 480V to 504V.

a. If the response is too slow, increase Ki.

g01425537
b. If the response is oscillatory or has a large
Illustration 53 amount of overshoot, decrease Ki or Kd.
3. Various status groups will be available. Refer to c. If the desired response is still not achievable,
Illustration 54. Click on a status group in order to proceed to Step 3.
display the parameters in that group.
3. If T'do and Te are known, use the PID calculator in
order to obtain the starting PID values. If T'do is
known but Te is not known, use the PID calculator
with the default exciter time constant (Te = T'do/6).
If the desired response is not obtainable with
these PID values, proceed to Step 4.

4. Start with Kp = 10, Ki = 2, Kd = 2, Td = 0, and

Kg = 30. If the voltage set point is not achieved,
increase Kg until the machine terminal voltage is
approximately equal to the set value. Reduce Ki
to 0.01. The terminal voltage should decrease.
Adjust Kg in order to obtain 90% of set terminal
voltage, for example, if the voltage set point is
480V, adjust Kg to achieve 432V.

5. With Kg set as determined in Step 4, set Kp = 40,

Ki = 10, Kd = 10, and Td = 0. Perform a “step of
reference” test, with no more than 5% per step, for
example, from 480V to 504V. Adjust Kp to achieve
80% of the Þnal value (403V in the example) in
Illustration 54
g01425538 the desired time frame.

4. In order to set up custom groups, double click The desired rise time should be based on how
on “Temporary Group”. Double click on the fast you want the combined generator and CDVR
parameters that are desired in order to add them to respond. In most application, this will be in the
to the group. range of 0.5 seconds to 1 second. Once Kp is
adjusted, increase Ki in order to get the desired
5. Click “OK” again to enable the group. response. If overshoot or if ringing occurs, reduce
Ki and then increase Kp, Ki, and Kd. Keep the
ratio constant.
62 RENR7941-05
Testing and Adjusting Section

Note: Many people use a load application or If a “Generator Undervoltage” fault has occurred, a
rejection test in order to adjust the voltage regulator. generator undervoltage condition has been detected
If available, use an inductive load. A resistive load at the generator voltage sensing input(s) of the
is not the best way to adjust the voltage regulator's voltage regulator in excess of the programmed
PID values. If the only load available is a resistive threshold for longer than the programmed time delay.
load, beware that the engine governor's or speed Refer to the Testing and Adjusting, “Low Voltage -
governor's response will signiÞcantly affect the Troubleshoot” section.
voltage regulator's performance.
If the“ Fault Reset” contact input is closed for more
than 10 seconds, a “Fault Reset Too Long” fault has
i02848548
occurred. Remove the short across the “Fault Reset”
Troubleshooting contact input.

SMCS Code: 4467 Resetting the voltage regulator may be achieved

either by momentarily closing the “Fault Reset”
If the voltage regulator does not operate as contact input or by cycling the 24 VDC control power.
expected, Þrst check the programmable settings
for the appropriate function. Use the following i02822506
troubleshooting procedures when difÞculties are
encountered in the operation of the excitation system. No Voltage - Troubleshoot
SMCS Code: 4467-035
Alarm or Shutdown Faults
Faults that are discussed in this section will not cause
excitation to be turned off unless some external
means of removing excitation is wired into the “Alarm”
output driver or is wired into the “Shutdown Fault”
output driver. Shutdown faults that always cause
excitation to be turned off are discussed in the Testing
and Adjusting, “No Voltage - Troubleshoot” section.
Open communication with the voltage regulator in
order to determine which fault condition has occurred.

If the “Fault” LED is lit constantly, this indicates that

the “Alarm” output driver is active. If the Fault LED is
ßashing, this indicates that the “Shutdown” output
driver is active. Illustration 55
g01425620

If an “Excitation Loss” (reverse VAR) fault has

occurred, a reverse VAR condition has been detected
in excess of the programmed threshold for longer
The Cat Digital Voltage Regulator presents an
than the programmed time delay. If an incorrect fault
electrical shock/electrocution hazard. This hazard
detection is suspected, verify that the programmed
will cause serious injury or death.
settings are compatible with the application. If settings
are correct, it is possible to get an incorrect fault
Service by trained personnel only.
detection if the generator voltage and the generator
current sensing inputs to the voltage regulator are
The terminals and heat sinks are live at hazardous
not properly wired for ABC rotation. Verify correct
voltages when power is applied and for up to 8
wiring of the generator voltage and generator current
minutes after power is removed.
sensing inputs to the voltage regulator. Refer to the
Testing and Adjusting, “Wiring Diagrams” section.
1. Verify that all of the wiring is properly connected.
If a “Generator Overvoltage” fault has occurred, a Refer to Testing and Adjusting, “Wiring Diagrams”.
generator overvoltage condition has been detected at
the generator voltage sensing input(s) of the voltage OK – If the wiring connections are correct, go to
regulator in excess of the programmed threshold for step 2.
longer than the programmed time delay. Refer to the
Testing and Adjusting, “High Voltage - Troubleshoot” NOT OK – If the wiring is improperly connected or
section. the wiring is loose, reconnect the wiring properly.

STOP.
RENR7941-05 63
Testing and Adjusting Section

2. Verify that the generator is running at rated speed. 8. Verify that the common alarm/Shutdown LED
indicator on the voltage regulator is not ßashing.
OK – If the generator is spinning at rated speed,
go to step 3. OK – If no protective fault has caused the
excitation to be turned off, go to step 15.
NOT OK – If the generator is not at rated speed,
increase generator speed to the rated value. NOT OK – If the LED indicator is ßashing, open
communications with the voltage regulator to
STOP. determine if a protective shutdown fault has
occurred that would cause excitation to be turned
3. The digital voltage regulator is PMG power or off. If protective shutdown fault has occurred that
Shunt powered. would cause excitation to be turned off, go to step
9.
PMG power – Proceed to step 4.
9. If an Exciter Diode Monitor (EDM) fault has
Shunt Powered – Proceed to step 5. occurred, stop the machine, insure that the power
input to the voltage regulator is removed, and
4. Check for correct input power to the voltage unplug “P6” on the voltage regulator.
regulator. Refer to SpeciÞcation, “Electrical”, for
input power requirements. a. Refer to the generator manual for instructions
on checking the rotating exciter diodes. Have
OK – If voltage is present, go to step 5. the rotating exciter diode assembly checked for
open or shorted diodes. If an open or shorted
NOT OK – If PMG voltage is not present, refer to diode is present in the rotating exciter diode
the generator manual for the repair procedures assembly, refer to the generator manual for
and check for an open circuit. instructions on how to replace the rotating
rectiÞer assembly.
STOP.
b. After repairs are complete, reset the voltage
5. Verify that the residual voltage applied to the regulator by momentarily closing the Fault
power input is at least 6 VAC. Reset contact or by cycling 24 VDC control
power.
OK – If the applied voltage is 6 VAC or greater,
go to step 6. c. The generator may be restarted. If there is
no problem with the rotating exciter diode
NOT OK – If the applied voltage is less than 6 assembly, the EDM trip value may be set
VAC, refer to the generator manual and ßash the too low. An EDM fault may occur with good
generator Þeld. Install blocking diodes in series rotating exciter diodes under varying loads if
with the battery in order to prevent damage to the the trip level is set too low. Set the EDM trip
voltage regulator and/or the battery. level to a value greater than the RMS ripple
current present in the exciter Þeld under normal
STOP. operating conditions in order to prevent a false
trip.
6. Verify that the fuse is not open.
d. Reconnect “P6”. Reset the voltage regulator by
OK – If no fuses are open, go to step 8. momentarily closing the Fault Reset contact or
by cycling 24 VDC control power.
NOT OK – Replace any fuses that are open.
e. The generator may be restarted. If an Exciter
STOP. Diode Monitor (EDM) fault has not occurred,
go to step 10.
7. Verify that the CDVR is connected to 24VDC
control power. 10. If an Over Excitation fault has occurred, stop
the machine and have the generator and/or load
OK – If CDVR is connected to 24VDC control conditions checked for a generator or load fault
power, go to step 8. that could cause excessive exciter Þeld current to
ßow. Also have the system checked for loose or
NOT OK – Connect CDVR to 24VDC control open connections to the voltage regulator sensing
power. inputs. Any faults must be repaired.

STOP.
64 RENR7941-05
Testing and Adjusting Section

a. After repairs are complete, reset the voltage 12. If a Field Overcurrent fault has occurred, stop
regulator by momentarily closing the Fault the machine and have the generator and/or load
Reset contact or by cycling 24 VDC control conditions checked for a generator or load fault
power. that could cause excessive exciter Þeld current to
ßow. Also have the system checked for loose or
b. The generator may be restarted. If no generator open connections to the voltage regulator sensing
or load fault has occurred and there are no inputs. A Field Overcurrent fault is detected when
loose or open connections to the sensing output current from the voltage regulator exceeds
inputs of the voltage regulator, verify that the approximately 28 A.
Over Excitation trip level and the delay settings
are properly adjusted for the generator. OK – If a Field Overcurrent fault has not occurred,
go to step 13.
c. Set the Over Excitation trip level slightly above
the requirement of the application but not so NOT OK – Any fault must be repaired. After
high as to render the protection ineffective or repairs are complete, reset the voltage regulator
damage the system. by momentarily closing the Fault Reset contact or
by cycling 24 VDC control power. The generator
d. Reset the voltage regulator by momentarily may be restarted.
closing the Fault Reset contact or by cycling
24 VDC control power. STOP.

e. The generator may be restarted. If the Over 13. If an Internal Memory Failure fault has occurred,
Excitation fault still exists, the instantaneous try resetting the voltage regulator by momentarily
trip value of 28 Amperes may have been closing the Fault Reset contact or by cycling 24
reached by a faulty diode. The EDM virtual fault VDC control power.
LED will not indicate in this case since there is
a 5 second delay associated with the EDM fault STOP. – If an Internal Memory fault has not
protection. Go to Step 9. If an Over Excitation occurred, go to step 14.
fault has not occurred, go to step 11.
NOT OK – If after resetting the voltage regulator
Note: SR4 and SR4B generators may require up another Internal Memory Failure occurs, replace
to 12 Amperes for full load excitation. A 10 second the voltage regulator.
delay is needed in order to insure 300 percent short
circuit current requirements. STOP.

11. If a Loss of Sensing fault has occurred, stop the 14. If an Internal Watchdog Failure fault has occurred,
machine and have the system checked for loose reset the voltage regulator by momentarily closing
or open connections to the voltage sensing inputs the Fault Reset contact or by cycling 24 volt
of the voltage regulator. control power.

a. Have the generator and/or load conditions OK – If an Internal Watchdog Failure fault has not
checked for a generator or load fault that could occurred, go to step 15.
cause the sensed voltage to be low.
NOT OK – If after resetting the voltage regulator
b. If the generator is equipped with voltage another Internal Watchdog Failure fault occurs,
transformers for stepping the generator voltage replace the voltage regulator.
down to levels usable by the voltage regulator,
verify that the transformers are functional and STOP.
that any transformer fuses are not open.
15. Replace the voltage regulator unit. If replacing
c. If transformer fuses are found to be open, the voltage regulator unit does not correct the
replace the fuses. problem, go to step 16.

d. Any faults must be repaired. After repairs 16. There is a problem with the generator. Refer to
are complete, reset the voltage regulator by the generator manual to troubleshoot the problem.
momentarily closing the Fault Reset contact or
by cycling 24 VDC control power.

e. The generator may be restarted. If a Loss of

Sensing fault has not occurred, go to step 12.
RENR7941-05 65
Testing and Adjusting Section

i02847657 NOT OK – If the generator is not at rated speed,

increase the generator speed to the rated level.
Low Voltage - Troubleshoot
STOP.
SMCS Code: 4467-035
4. PMG power or Shunt powered regulator

PMG power – Proceed to step 5.

Shunt powered – Proceed to step 6.

5. Check for the correct input power to the voltage

regulator. Refer to SpeciÞcation, “Electrical” for
input power requirements.

OK – If the voltage is at the required level, go to

step 7.

NOT OK – If the voltage regulator input voltage is

g01425622 low, refer to the generator manual for PMG repair.
Illustration 56

STOP.

6. Verify that the potential transformer (if used) has

The Cat Digital Voltage Regulator presents an the correct turns ratio and is supplying the correct
electrical shock/electrocution hazard. This hazard voltage to the power input.
will cause serious injury or death.
OK – If the turns ratio of the power potential
Service by trained personnel only. transformer is correct, go to step 7.
The terminals and heat sinks are live at hazardous NOT OK – If the turns ratio of the potential
voltages when power is applied and for up to 8 transformer is incorrect, is sized too small, or the
minutes after power is removed. transformer is not supplying the correct power,
replace the potential transformer.
1. Verify that the voltage adjustment is not set too
low. STOP.

OK – If the voltage adjustment is correct, go to 7. Verify that the sensing potential transformer (if
step 2. used) has the correct turns ratio and is operating
correctly.
NOT OK – If the voltage adjustment is too low,
adjust the voltage to the correct setpoint. OK – If the sensing potential transformer is
operating correctly, go to step 8.
STOP.
NOT OK – If the turns ratio of the sensing
2. Verify that the underfrequency setpoint (knee potential transformer is incorrect, replace the
frequency) is not greater than the generator sensing potential transformer.
frequency.
STOP.
OK – If the underfrequency setpoint is correct,
go to step 3. 8. Low generator output voltage may occur when
operating in droop mode with an inductive load.
NOT OK – If the underfrequency setpoint is too If the low voltage condition is not caused by the
high, adjust the setpoint below the rated generator droop function, go to step 9.
frequency.
9. Replace the voltage regulator.
STOP.

3. Verify that the generator is running at rated speed.

OK – If the generator is running at rated speed,

go to step 5.
66 RENR7941-05
Testing and Adjusting Section

i02847591 4. High generator output voltage may occur when

operating in line drop compensation mode with a
High Voltage - Troubleshoot large generator load. If the high voltage condition
is not caused by the line drop compensation
SMCS Code: 4467-035 function, go to step 5.

5. Verify that the fuses for the sensing potential

transformer (if used) are not open.

OK – If the fuses for the sensing potential

transformer are correct, go to step 6.

NOT OK – If the fuses for the sensing potential

transformer are open, replace the fuses.

STOP.

6. Verify that the auxiliary input voltage going to

the voltage regulator is present or abnormally
g01425625 high. Higher than normal voltage at this input will
Illustration 57
cause a higher than normal generator voltage. If
voltage is present on the auxiliary input, remove
the input by removing the wiring going to the
voltage regulator. If the wire is removed and the
The Cat Digital Voltage Regulator presents an generator voltage returns to the desired level,
electrical shock/electrocution hazard. This hazard investigate where the voltage is coming from,
will cause serious injury or death. possible a VAR/PF controller or another source of
control. If the auxiliary input voltage is not present
Service by trained personnel only. or abnormally high, go to step 7.
The terminals and heat sinks are live at hazardous 7. Replace the voltage regulator.
voltages when power is applied and for up to 8
minutes after power is removed.
i02848556

1. Verify that the voltage adjustment is not set too Unstable Voltage -
high.
Troubleshoot
OK – If the voltage adjustment is correct, go to
step 2. SMCS Code: 4467-035

NOT OK – If the voltage adjustment is too high,

adjust the voltage to the correct set point.

STOP.

2. Verify that the sensing potential transformer (if

used) has the correct turns ratio.

OK – If the sensing potential transformer is

correct, go to step 3.

NOT OK – If the turns ratio of the sensing

potential transformer is incorrect, replace the
sensing potential transformer with the correct one. Illustration 58
g01425628

STOP.

3. High generator output voltage may occur when

operating in droop mode with a capacitive load. If
the high voltage condition is not caused by the
droop function, go to step 4.
RENR7941-05 67
Testing and Adjusting Section

2. Is there a difference between sensed voltage and

rated voltage, that is, the voltage that is sensed off
The Cat Digital Voltage Regulator presents an of the wye center tap?
electrical shock/electrocution hazard. This hazard
will cause serious injury or death. OK – If yes, go to Step 3.

Service by trained personnel only. NOT OK – If no, go to Step 4.

The terminals and heat sinks are live at hazardous 3. Verify the following parameters are programmed
voltages when power is applied and for up to 8 as follows:
minutes after power is removed.
• Rated voltage (V) equals the generator rated
voltage
1. Verify that the governor for the engine is operating
properly. • PT primary (V) equals the generator winding
rated voltage
OK – If the governor is operating properly, go to
step 2. • PT secondary (V) equals the generator sensed
voltage
NOT OK – If the governor is not operating
properly, refer to the engine manual in order to Go to step 5.
troubleshoot the problem.
4. Verify the following parameters are programmed
STOP. as follows:

2. Verify that the sensing and input power leads are • Rated voltage (V) equals the generator rated
connected securely. voltage

OK – If the sensing or input power lead • PT primary (V) equals the generator rated
connections are secure, go to step 3. voltage

NOT OK – If the sensing or input power leads are • PT secondary (V) equals the generator rated
not connected securely, tighten the connections. voltage

STOP. Go to step 5.

3. Verify that the voltage regulator stability range is 5. Verify that the Þeld winding inputs to the CDVR
set to the proper range. are not partially or completely shorted.

OK – If the stability range setting is correct, go OK – If winding inputs are ok, go to Step 6.
to step 4.
NOT OK – If winding inputs not ok, repair winding
NOT OK – If the stability range setting is incorrect, input fault. Check the system again.
reset the stability range.
STOP.
STOP.
6. Check exciter for proper resistance value.
4. Verify that the stability level is properly set. If the
stability level is not properly set, reset the stability OK – If exciter resistance value is ok, go to Step
level. 7.

NOT OK – If exciter resistance value is not ok,

i02826583
repair exciter fault. Check the system again.
Generator Overcurrent -
STOP.
Troubleshoot
7. If all of the previous steps fail to correct the
SMCS Code: 4467-035 malfunction, replace the voltage regulator.
1. Verify that the PTs are installed correctly. STOP.
68 RENR7941-05
Testing and Adjusting Section

i02847363

Reverse VAR Condition - The Cat Digital Voltage Regulator presents an

Troubleshoot electrical shock/electrocution hazard. This hazard
will cause serious injury or death.
SMCS Code: 4467-035
Service by trained personnel only.
The switchgear or the generator set control panel will
initiate “Reverse Var Tripping”. The terminals and heat sinks are live at hazardous
voltages when power is applied and for up to 8
1. Operate the generator in “Stand-Alone” mode. minutes after power is removed.

2. Start the CDVR PC software, establish

communication, and then go to the “Metering” 1. Verify that the chassis of the voltage regulator is
screen. properly grounded.

3. Apply a small reactive load. OK – If the voltage regulator is properly grounded,

go to step 2.
4. Check the kWatts and Kvar values in the
“Metering” screen. NOT OK – If the voltage regulator is not properly
grounded, connect a dedicated ground wire to
5. If both kWatts and Kvar are negative, the CT may terminal P6-6 on the voltage regulator.
be wired backwards. Check the wiring to the CT.
Alternately, the “A” and “C” sensing leads may STOP.
be reversed. Physically check the connections
from the bus bars to the sensing inputs for correct 2. Check for grounded Þeld leads.
ordering (12-10, 12-11, and 12-12 are C-B-A
respectively). OK – If the Þeld leads are not grounded, go to
step 3.
6. If either kWatts or Kvar is negative, and the other
is positive, the “A” and “B”, or “B” and “C” sensing NOT OK – If the Þeld leads are grounded, isolate
leads may be reversed. Physically check the the Þeld leads from ground.
connections from the bus bars to the sensing
inputs for correct ordering (12-10, 12-11, and STOP.
12-12 are C-B-A respectively).
3. Check for grounded PMG leads.

i03213881 OK – If the PMG leads are not grounded, go to

step 4.
Poor Voltage Regulation -
Troubleshoot NOT OK – If the PMG leads are grounded, isolate
the PMG leads from ground.
SMCS Code: 4467-035
STOP.

4. Verify that the generator frequency is not dropping

below the voltage regulator underfrequency
setpoint when load is applied to the generator.

OK – If poor regulation is not related to voltage

regulator underfrequency operation, go to step 5.

NOT OK – If the generator frequency is dropping

below the underfrequency setpoint, reduce the
setpoint if possible. Also check the engine and
generator for proper sizing in relation to the
applied load.
g01425632 STOP.
Illustration 59

Note: Measure the PMG voltage from line to line.

RENR7941-05 69
Testing and Adjusting Section

5. Verify that regulation is not being affected by 2. Verify that the voltage regulator line drop setting
normal droop operation. If droop operation is not is not adjusted to 0%. If the line drop setting is
affecting regulation, go to step 6. adjusted to 0%, increase the set point above 0%.
If the line drop setting is adjusted to above 0%,
6. Verify that regulation is not being affected by go to step 3.
normal line loss compensation. If line loss
compensation is not affecting regulation, then 3. Check for an open in the circuit connected to
replace the voltage regulator. voltage regulator terminals P12-1 and P12-2
and CT2. If there is an open circuit, repair as
On new applications and when commissioning, check necessary. If there is not an open circuit, go to
the PID value. If the voltage ßuctuates at steady-state step 4.
“No Load” or “Full Load”, reduce Kg or if at 1.0 reduce
Kp. Recalculate PID in calculator. 4. Verify that all connections are correct according
to Testing and Adjusting, “Wiring Diagrams”. If
Note: Self Excited (shunt powered) generators connections are incorrect, correct the problem. If
will have a greater input power voltage than PMG connections are correct, go to step 5.
generators. This will require lower gain settings (Kg
Þrst then Kp if necessary) on comparably sized 5. Verify that the load that is being applied to the
machines. Adjust the Kg values Þrst, then Kp values generator for droop testing is not a purely resistive
to reach acceptable steady-state and transient load. If only a resistive load is being applied to the
responses. generator, apply an inductive load and retest. If the
load being applied to the generator is inductive,
go to step 6.
i02847675

No Line Loss Compensation - 6. Verify that the current sensing transformer that
is being used is compatible with the voltage
Troubleshoot regulator. For example, a current sensing
transformer with a 1 ampere output rating would
SMCS Code: 4467-035 produce very little droop since the voltage
regulator has a 5 ampere current transformer
input. If the current transformer input is incorrect,
replace the current sensing transformer for
compatibility. If the current transformer input is
correct, go to step 7.

7. If all of the previous steps fail to correct the

malfunction, replace the voltage regulator.

i02822626

No Voltage Droop -
Troubleshoot
g01425633
Illustration 60 SMCS Code: 4467-035

The Cat Digital Voltage Regulator presents an

electrical shock/electrocution hazard. This hazard
will cause serious injury or death.

Service by trained personnel only.

The terminals and heat sinks are live at hazardous

voltages when power is applied and for up to 8
minutes after power is removed.

1. Verify that the voltage regulator is programmed for

line loss compensation. If the voltage regulator Illustration 61
g01425634
is programmed for line loss compensation, go to
step 2.
70 RENR7941-05
Testing and Adjusting Section

The Cat Digital Voltage Regulator presents an

electrical shock/electrocution hazard. This hazard
will cause serious injury or death.

Service by trained personnel only.

The terminals and heat sinks are live at hazardous

voltages when power is applied and for up to 8
minutes after power is removed.

1. Verify that the voltage regulator is programmed

for droop mode. If the voltage regulator is
programmed for droop mode, go to step 2.

2. Verify that the voltage regulator droop setting is

not adjusted to 0% droop. If the droop setting is
adjusted to 0% droop, increase the setpoint above
0%. If the droop setting is adjusted to above 0%,
go to step 3.

3. Check for an open in the circuit connected to

voltage regulator terminals P12-1 and P12-2
and CT2. If there is an open circuit, repair as
necessary. If there is not an open circuit, go to
step 4.

4. Verify that all connections are correct according to

Testing and Adjusting, “Wiring Diagrams”. Verify
that the “Curren Transformer” (CT) is not installed
backwards, or on the wrong phase. Verify that
the “Potential Transformer” (PT) phase rotation
is correct. If connections and installations are
correct, go to step 5.

5. Verify that the load that is being applied to the

generator for droop testing is not a purely resistive
load. If only a resistive load is being applied to the
generator, apply an inductive load and retest. If the
load being applied to the generator is inductive,
go to step 6.

6. Verify that the current sensing transformer that

is being used is compatible with the voltage
regulator. For example, a current sensing
transformer with a 1-ampere output rating would
produce very little droop since the voltage
regulator has a 5 ampere current transformer
input. If the current transformer input is incorrect,
replace the current sensing transformer for
compatibility. If the current transformer input is
correct, go to step 7.

7. If all of the previous steps fail to correct the

malfunction, replace the voltage regulator.
RENR7941-05 71
Testing and Adjusting Section

i03213854

Wiring Diagrams
SMCS Code: 4467; 7566

g01425818
Illustration 62
Math Model - Per Unit Block Diagram for Rotating RectiÞer Excitation System.

Vs – Sensing Voltage

Vc – Compensated Terminal Voltage

Vref – Reference Voltage

Kg – Programmed Gain

Kp – Proportional Gain

Ki – Integral Gain

Kd – Derivative Gain

Td – Derivative Time

Vp – Input From The Power Source For The

Excitation System

Vrlmt – Forcing Limit

Ta – Alternator Time Limit

Vr – Regulated Voltage

Te – Exciter Time Constant

Ke – Exciter Gain

Efd – Exciter Field

72 RENR7941-05
Testing and Adjusting Section

g01015474
Illustration 63
Typical Connections for PMG Power Input, ABC Rotation, and Three Phase Voltage Sensing
Notes:
(A) 52a contact required only for Var/PF (F) The ±10 VDC input provides adjustment (I) When generator rotation is ACB, the
control. Var/PF enabled only when 52a of output. connections for the CTB should be
is closed, inactive when open. (G) Three-phase PMG is shown. For reversed.
(B) When excitation disable switch is open, single-phase, remove P6-3 connection.
excitation is enabled. For HV machines using 2 single phase
(C) When fault reset switch is momentarily PMGs in series, connect PMG leads
closed, any shutdown fault is reset. 2 and 3 together, and connect leads 1
(D) S1 (SPST, spring return to center-off and 4 to CDVR pins P6-1 and P6-2,
position) adjusts CAT Digital Voltage respectively.
Regulator setpoint. (H) Sensing potential transformer is required
(E) Alarm Driver and Shutdown Fault Driver if line voltage exceeds 600 VAC.
are normally off.
RENR7941-05 73
Testing and Adjusting Section

g01015488
Illustration 64
Typical Connections for Shunt Power Input, ABC Rotation, and Single Phase Voltage Sensing
Notes:
(A) 52a contact required only for Var/PF (D) S1 (SPST, spring return to center-off (G) Sensing potential transformer is required
control. Var/PF enabled only when 52a position) adjusts CAT Digital Voltage if line voltage exceeds 600 VAC.
is closed, inactive when open. Regulator setpoint. (H) When generator rotation is ACB, the
(B) When excitation disable switch is open, (E) Alarm Driver and Shutdown Fault Driver connections for the CTB should be
excitation is enabled. are normally off. reversed.
(C) When fault reset switch is momentarily (F) The ±10 VDC input provides adjustment
closed, any shutdown fault is reset. of output.
74 RENR7941-05
Testing and Adjusting Section

g01408526
Illustration 65
Typical Connections for a SE, L-N Directly Connected Power Input, ABC Rotation, and Single Phase Voltage Sensing (Generator less than 480V)
Notes:
(A) 52a contact required only for Var/PF (D) S1 (SPST, spring return to center-off (G) Sensing potential transformer is required
control. Var/PF enabled only when 52a position) adjusts CAT Digital Voltage if line voltage exceeds 600 VAC.
is closed, inactive when open. Regulator setpoint. (H) When generator rotation is ACB, the
(B) When excitation disable switch is open, (E) Alarm Driver and Shutdown Fault Driver connections for the CTB should be
excitation is enabled. are normally off. reversed.
(C) When fault reset switch is momentarily (F) The ±10 VDC input provides adjustment
closed, any shutdown fault is reset. of output.
RENR7941-05 75
Testing and Adjusting Section

g01015546
Illustration 66
Typical Connections for Shunt Power Input, ABC Rotation, and Three Phase voltage Sensing
Notes:
(A) 52a contact required only for Var/PF (D) S1 (SPST, spring return to center-off (G) Sensing potential transformer is required
control. Var/PF enabled only when 52a position) adjusts CAT Digital Voltage if line voltage exceeds 600 VAC.
is closed, inactive when open. Regulator setpoint. (H) When generator rotation is ACB, the
(B) When excitation disable switch is open, (E) Alarm Driver and Shutdown Fault Driver connections for the CTB should be
excitation is enabled. are normally off. reversed.
(C) When fault reset switch is momentarily (F) The ±10 VDC input provides adjustment
closed, any shutdown fault is reset. of output.
76 RENR7941-05
Testing and Adjusting Section

g01015576
Illustration 67
Typical Connections for PMG Power Input, ABC Rotation, and Single Phase Voltage Sensing
Notes:
(A) 52a contact required only for Var/PF (F) The ±10 VDC input provides adjustment (I) When generator rotation is ACB, the
control. Var/PF enabled only when 52a of output. connections for the CTB should be
is closed, inactive when open. (G) Three-phase PMG is shown. For reversed.
(B) When excitation disable switch is open, single-phase, remove P6-3 connection.
excitation is enabled. For HV machines using 2 single phase
(C) When fault reset switch is momentarily PMGs in series, connect PMG leads
closed, any shutdown fault is reset. 2 and 3 together, and connect leads 1
(D) S1 (SPST, spring return to center-off and 4 to CDVR pins P6-1 and P6-2,
position) adjusts CAT Digital Voltage respectively.
Regulator setpoint. (H) Sensing potential transformer is required
(E) Alarm Driver and Shutdown Fault Driver if line voltage exceeds 600 VAC.
are normally off.
RENR7941-05 77
Testing and Adjusting Section

g01425819
Illustration 68
Typical Connections for PMG Power Input, ABC Rotation, and Single Phase Voltage Sensing
Notes:
(A) 52a contact required only for Var/PF (F) The ±10 VDC input provides adjustment (I) When generator rotation is ACB, the
control. Var/PF enabled only when 52a of output. connections for the CTB should be
is closed, inactive when open. (G) Three-phase PMG is shown. For reversed.
(B) When excitation disable switch is open, single-phase, remove P6-3 connection.
excitation is enabled. For HV machines using 2 single phase
(C) When fault reset switch is momentarily PMGs in series, connect PMG leads
closed, any shutdown fault is reset. 2 and 3 together, and connect leads 1
(D) S1 (SPST, spring return to center-off and 4 to CDVR pins P6-1 and P6-2,
position) adjusts CAT Digital Voltage respectively.
Regulator setpoint. (H) Sensing potential transformer is required
(E) Alarm Driver and Shutdown Fault Driver if line voltage exceeds 600 VAC.
are normally off.
78 RENR7941-05
Testing and Adjusting Section

g01112935
Illustration 69
Typical Connections for Internal Excitation Power Input, ABC Rotation, and Three Phase Voltage Sensing
Notes:
(A) 52a contact required only for Var/PF (D) S1 (SPST, spring return to center-off (G) Sensing potential transformer is required
control. Var/PF enabled only when 52a position) adjusts CAT Digital Voltage if line voltage exceeds 600 VAC.
is closed, inactive when open. Regulator setpoint. (H) When generator rotation is ACB, the
(B) When excitation disable switch is open, (E) Alarm Driver and Shutdown Fault Driver connections for the CTB should be
excitation is enabled. are normally off. reversed.
(C) When fault reset switch is momentarily (F) The ±10 VDC input provides adjustment
closed, any shutdown fault is reset. of output.
RENR7941-05 79
Testing and Adjusting Section

g01112701
Illustration 70
Typical Connections for PMG Power Input, ABC Rotation, and Single Phase Voltage Sensing (Generator Less Than 600 Volts)
Notes:
(A) 52a contact required only for Var/PF (F) The ±10 VDC input provides adjustment (I) When generator rotation is ACB, the
control. Var/PF enabled only when 52a of output. connections for the CTB should be
is closed, inactive when open. (G) Three-phase PMG is shown. For reversed.
(B) When excitation disable switch is open, single-phase, remove P6-3 connection.
excitation is enabled. For HV machines using 2 single phase
(C) When fault reset switch is momentarily PMGs in series, connect PMG leads
closed, any shutdown fault is reset. 2 and 3 together, and connect leads 1
(D) S1 (SPST, spring return to center-off and 4 to CDVR pins P6-1 and P6-2,
position) adjusts CAT Digital Voltage respectively.
Regulator setpoint. (H) Sensing potential transformer is required
(E) Alarm Driver and Shutdown Fault Driver if line voltage exceeds 600 VAC.
are normally off.
80 RENR7941-05
Testing and Adjusting Section

g01112717
Illustration 71
Typical connections for PMG power input and three phase direct voltage sensing
(generator less than 600 volts)
Notes:
(A) 52a contact required only for Var/PF (D) S1 (SPST, spring return to center-off (H) Sensing potential transformer is required
control. Var/PF enabled only when 52a position) adjusts CAT Digital Voltage if line voltage exceeds 600 VAC. For HV
is closed, inactive when open. Regulator setpoint. machines using 2 single phase PMGs
(B) When excitation disable switch is open, (E) Alarm Driver and Shutdown Fault Driver in series, connect PMG leads 2 and 3
excitation is enabled. are normally off. together, and connect leads 1 and 4 to
(C) When fault reset switch is momentarily (F) The ±10 VDC input provides adjustment CDVR pins P6-1 and P6-2, respectively.
closed, any shutdown fault is reset. of output. (I) When generator rotation is ACB, the
(G) Three-phase PMG is shown. For connections for the CTB should be
single-phase, remove P6-3 connection. reversed.
RENR7941-05 81
Testing and Adjusting Section

g01429193
Illustration 72
Typical connections for cross current compensation
82 RENR7941-05
Testing and Adjusting Section

g01429203
Illustration 73
Typical connections for cross current compensation (two CDVR's).
RENR7941-05 83
Testing and Adjusting Section

g01429204
Illustration 74
Typical connections for cross current compensation (one CDVR and one DVR).
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Testing and Adjusting Section

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Illustration 75
Typical connections for a manual voltage control
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Index Section

Index
C Parameter Viewing and ConÞguration (Caterpillar PC
Software) ............................................................. 23
Cross Current Compensation ................................ 14 Changing Settings.............................................. 24
Flash the CDVR Using Cat ET Software ........... 55
Installing the Caterpillar PC Software ................ 23
D Sending and Receiving Settings ........................ 25
Setting DeÞnitions .............................................. 26
Dimensions.............................................................. 7 Settings Files ..................................................... 47
Starting Caterpillar PC Software ........................ 24
Uploading Embedded Firmware Using the CDVR
E PC Software ..................................................... 52
Parameters ............................................................ 16
Electrical .................................................................. 4 General Information ........................................... 16
Poor Voltage Regulation - Troubleshoot................ 68
Power Factor Regulation ....................................... 15
G

Gain Setting - Adjust.............................................. 61 R

General Information........................................... 8, 20
Connectors........................................................... 9 Reactive Voltage Droop......................................... 13
Preventive Maintenance .................................... 20 Remote Communication ........................................ 17
Generator Overcurrent - Troubleshoot .................. 67 Establishing Communication.............................. 18
Terminating Communication .............................. 19
Reverse VAR Condition - Troubleshoot................. 68
H

High Voltage - Troubleshoot .................................. 66 S

Service Tools ......................................................... 20

I SpeciÞcations Section ............................................. 4
Startup Procedure ................................................. 21
Important Safety Information ................................... 2 Startup ProÞle Function ......................................... 10
Systems Operation Section ..................................... 8

K
T
KVAR Regulation................................................... 14
Table of Contents..................................................... 3
Testing and Adjusting ............................................ 20
L Testing and Adjusting Section ............................... 20
Troubleshooting..................................................... 62
Line Loss Compensation ....................................... 12 Alarm or Shutdown Faults.................................. 62
Loading and Stopping ProÞle ................................. 11
Low Voltage - Troubleshoot................................... 65
U

N Unstable Voltage - Troubleshoot ........................... 66

No Line Loss Compensation - Troubleshoot ......... 69

No Voltage - Troubleshoot..................................... 62 V
No Voltage Droop - Troubleshoot .......................... 69
Voltage Regulation ................................................ 12

P
W
Parameter Viewing and ConÞguration (Caterpillar
Electronic Technician).......................................... 57 Wiring Diagrams .................................................... 71
Viewing Metering Parameters Using Cat ET
Software ........................................................... 60
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Index Section
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Index Section
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