3516B Power Module Conversion Procedure

Dual Frequency Conversion (50Hz/60Hz)

3516B PM
BPD01100-up
NBR00100-up

Description
The intent of this procedure is to instruct on properly changing the operation of the
3516B 2MW Power Module from 50Hz operation to 60Hz operation or from 60Hz
operation to 50Hz operation.

Reference Publications
RENR7902 EMCP3 Systems Operation Troubleshooting Testing and Adjusting
RENR7941 Caterpillar Digital Voltage Regulator (CDVR) Systems Operation
RENR4928 Systems Operation Testing & Adjusting
RENR4929 Troubleshooting

Procedure
1. Turn off 24V DC power (key switch) and disconnect all shore power supplied to the
Power Module.
2. Open the rear doors of the trailer. The appropriate fan motor pulley will have to be
installed for the desired operation (see following steps).
3. Open the left-hand radiator door and remove it from the radiator support frame.
Remove the bolts from the right-hand radiator motor access panel and remove it
Reserve
from the radiator support frame. This will allow access to the radiator fan motor
Radiator Pulley and pulley shaft.
Mounting
Location

Radiator Fan
Pulley and
Pulley Shaft

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4. Loosen the 2 belt tension nuts to loosen the belts for removal from the currently
installed pulley (reference provided instructions below for following steps).

Note: The 50 Hz pulley will be the larger diameter pulley (Caterpillar p/n 229-8528
SHEAVE). The 60 Hz will be the smaller diameter pulley (Caterpillar p/n 293-4391
SHEAVE).

5. Remove the belts from the motor pulley.

6. Remove the 3 bolts from the motor pulley.
7. Use the 3 bolts to remove the pulley.

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

Flash File Caterpillar Part No.: 50Hz, 277-0457 SOFTWARE GP-ELEK

60Hz, 277-0456 SOFTWARE GP-ELEK

ECM Monitoring System

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

Check Engine Overspeed Setting

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 Change Trip Points for Overspeed

17. Query for the ECMs on the J1939 network.

Press this key to connect Press this key to disconnect

Query for J1939 Network

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

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

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

Note: Unless the Potential Transformers and Current Transformers in the

generator are changed, do not change their values.

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

Digital Voltage Regulator > Protection> Generator Rated Frequency

Generator Rated Frequency: 50Hz or 60Hz

Generator Rated Voltage: 50Hz, 400V

60Hz, 480V

Generator Rated Current: Current = Killowatts * 1000

Voltage * PowerFactor * 1.73

50Hz 400V, 1600 kW = 2890 Amps (0.8 PF)

60Hz 480V, 1825 kW = 2747 Amps (0.8 PF)

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

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

Generator nominal Output Voltage: 50Hz, 400V

60Hz, 480V

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

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

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

EMCP3.3 > Engine Speed Monitor > Engine Overspeed Setpoint

Engine Overspeed Setpoint: 50Hz, 1770 rpm

60 Hz, 2124 rpm

Engine Underspeed Warning Event Threshold: 50 Hz, 1290 rpm

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

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

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

EMCP3.3 > Generator AC Monitor

Generator Rated Frequency: 50Hz or 60Hz

Generator Rated Voltage: 50Hz, 400 V

60Hz, 480 V

Generator Rated Power: 50Hz, 1600 kW

60Hz, 1825 kW

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

50Hz 400V, 1600 kW = 2000 kVA (0.8 PF)

60Hz 480V, 1825 kW = 2281 kVA (0.8 PF)

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

EMCP3.3 > AVR Desired Voltage Request

Generator Nominal Output Voltage: 50Hz, 400V

60Hz, 480V

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 PARAMETER CHANGES SUMMARY
50 Hz 60 Hz
ADEM 3
Flash File Part No.* 277-0457 277-0456
Engine Overspeed 1770 2124 RPM
*Check latest flash file versions at Service Information System (SISWEB) website (contact
Caterpillar Inc. Customer Service for access).

CDVR
Monitor
Voltage Regulator Power Input Frequency Configuration 200 240 Hz
Protection
Generator Rated Frequency 50 60 Hz
Generator Rated Voltage 400 480 Volts
Generator Rated Current 2890 2747 Amps
Voltage Regulator Control Parameters
Generator Nominal Output Voltage 400 480 Volts
Voltage Regulator Corner (Knee) Frequency 49.8 59.8 Hz

EMCP 3.3
Engine Speed Monitor
Engine Overspeed Setpoint 1770 2124 RPM
Underspeed Warning Event Threshold 1290 1548 RPM
Underspeed Shutdown Event Threshold 1230 1476 RPM
Generator AC Monitor
Generator Rated Frequency 50 60 Hz
Generator Rated Voltage 400 480 Volts
Generator Rated Power 1600 1825 kW
Generator Rated Apparent Power 2000 2281 kVA
AVR Desired Voltage Request
Generator Nominal Output Voltage 400 480 Volts

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

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24. Reset any faults displayed on the EMCP3, ECM, or CDVR.
25. Go to the switchgear. Go to the “System Setup” screen on HMI and select
400V/50Hz for 50Hz operation and 480V/60Hz for 60Hz operation (light
background and dark letters means the feature is selected).

50Hz Operation
(not selected) 60Hz Operation
(selected)

26. Move the Engine Control Switch (ECS) switch to the OFF position and reset any
faults (see below).
27. Place the Sync Switch in the OFF position (see below).

OFF position
(ECS Switch) OFF position
(Sync Switch)

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

MAN Position
(ECS switch)

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

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