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RENR2477-01 December 2001

GENERATOR SET CONTROL PANEL LIGHT ALARM MODULE OR MANUAL SYNC MODULE PUMP STOP PUSHBUTTON START AID SWITCH PANEL LIGHT PUMP RUN PUSHBUTTON VOLTAGE ADJUST RHEOSTAT ENGINE MONITORING SYSTEM SCROLL SWITCH
ABBREVIATIONS

MODE CLEAR SWITCH

AFTS ALM ALR ALT

AUTOMATIC FUEL TRANSFER SYSTEM ALARM MODULE ALARM RELAY ALTERNATOR AIR SHUT-OFF RELAY AC TRANSFORMER BOX ALTERNATOR TEMPERATURE RELAY

KWR

KILOWATT RELAY

L LFLS LFSR

LOAD LEADS LOW FUEL LEVEL SWITCH LOW FUEL SHUTOFF RELAY

WARNING
SCROLL

ASR ATB ATR


HIGH COOLANT TEMP

PUMP STOP

STARTING AID

PUMP RUN

DISPLAY

LOW COOLANT TEMP

CLEAR

LOW OIL PRESSURE EMERGENCY STOP HIGH WATER TEMP ENGINE OVERSPEED LOW COOLANT LEVEL OVERCRANK

LOW OIL PRESSURE

BATT BC BCF

BATTERY BATTERY CHARGER BATTERY CHARGER FAILURE SWITCH BEARING TEMPERATURE RELAY

MAN MPU MV

MANUAL MAGNETIC SPEED PICKUP MOTOR VALVE/SOLENOID VALVE

MODE

LOW FUEL LEVEL

DISPLAY

SYSTEM NOT IN AUTO

PANEL LIGHTS

LH

BTR

LOW BATTERY VOLTAGE

RH

LH/RH SELECT

CAM
STOP
EMERGENCY STOP
R R

CUSTOM ALARM MODULE CIRCUIT BREAKER CUSTOMER COMMUNICATION MODULE CUSTOMER INTERFACE MODULE CRANK RELAY CURRENT TRANSFORMER CRANK TERMINATION RELAY

FAULT SHUTDOWN FAULT ALARM

OFF RESET

CB CCM
AUT

NC NO

NORMALLY CLOSED NORMALLY OPEN

OL

OVERLOAD CONTACTOR

PHASE SELECT

ENGINE METER

LAMP TEST

ALARM CODES

EXIT

SERVICE MODE

ALARM SILENCE

COOLDOWN STOP

AUTO

CIM CR

MAN

START
560-642 154-3045

CT CTR

PC PL PLS

PUMP CONTACTOR PANEL ILLUMINATION LIGHT PANEL LIGHT SWITCH POTENTIOMETER PUMP RELAY PUMP RUN LIGHT PUMP RUN PUSHBUTTON PINION SOLENOID PUMP STOP LIGHT PUMP STOP PUSHBUTTON PULSE WIDTH MODULATED

D DVR

DIODE DIGITAL VOLTAGE REGULATOR

SPEED ADJUST POTENTIOMETER EMERGENCY STOP PUSHBUTTON PANEL LIGHT SWITCH

ENGINE CONTROL SWITCH

3456 Generator Set with EMCP II Electrical System


CCB1-UP CAH1-UP CBX1-UP 8AZ1-UP

POT PR PRL PRPB PS PSL PSPB PWM

ECLS ECM ECS ECTS EFR EGR EOPS EOTS EPIR ESPB ESTS EXC

ENGINE COOLANT LOSS SENSOR ELECTRONIC CONTROL MODULE ENGINE CONTROL SWITCH ENGINE COOLANT TEMPERATURE SENSOR ENGINE FAILURE RELAY ELECTRONIC GOVERNOR RELAY ENGINE OIL PRESSURE SENSOR ENGINE OIL TEMPERATURE SENSOR ETHER PULL-IN RELAY EMERGENCY STOP PUSH BUTTON EMERGENCY STOP SWITCH ON ENCLOSURE EXCITOR

RAN RDM RFI RR

REMOTE ANNUNCIATOR RELAY DRIVER MODULE RADIATED FREQUENCY IMMUNITY RUN RELAY

SASV SAS SEC SHTC

START AID SOLENOID VALVE START AID SWITCH SECOND CIRCUIT BREAKER SHUNT TRIP COIL STARTING MOTOR STARTING MOTOR MAGNETIC SWITCH STARTING MOTOR RELAY SPEED ADJUST POTENTIOMETER SLAVE RELAY

F FCR FRBS

FUSE FUEL CONTROL RELAY FUEL RUPTURE BASIN SWITCH

SM SMMS SMR SP SR

GFR GNDFCT GNDFR GRR GSC

GENSET FAULT RELAY GROUND FAULT CT GROUND FAULT RELAY GENERATOR RUN RELAY GENERATOR SET CONTROL T TDR TSC GENERATOR LINE LEADS TIME DELAY RELAY TRANSFER SWITCH POSITION INDICATING CONTACT

HC

HEATER CONTACTOR VAR VOLTAGE ADJUST RHEOSTAT VOLTAGE REGULATOR VR

IC

REMOTE START/STOP INITIATE CONTACT

PWM MODULE

GENERATOR RUNNING RELAY TIME DELAY RELAY CRANK RELAY ETHER START RELAY

FUSE BLOCKS

LOW FUEL LEVEL SHUTDOWN RELAY

AC TRANSFORMER BOX

DIODES

Volume 1: Electronic & AC/DC Panel Group and Schematic


2001 Caterpillar All Rights Reserved
F11 F12

Printed in U.S.A.

+ ~

A1

B1

15

6 3

4 1

6 3

4 1

6 3

4 1

F13

1
A

CATERPILLAR
-B S D +B

AB

FSM3U

1mn

.8

.4

A 8 7
16 18 A2
~ -

.2

EPIR

CR

TDR GRR

DC TERMINAL STRIP

GND5 50 50 50 T0 101 108 109 110 131 136 137 202 203 206 207 157 159 51 52 53

57 57 59 62 62 63 67 67 90 99 DD+ CCMCCM+ SP1 SP1A SP2 SP2 SP3 SP4 21 GND2 22

GND1 1 1 1 1 2 2 2 2 5 5 46 45A 45 3

GND3 GND4

GND6

HC1 HC4 2 2 2 2 SV SV SV SV BO ER EL MT FP

87 88 89 ES

4 34 6 10 10

17 18 19 20 20 30 30 30 30 37 38

80 82

DC TERMINAL STRIP (TBD1)

5 70 83 85 77

B
ABCDEFGHIJ ABCDEFGHIJ
adjust set point read

DC CHASSIS

6 3

4 1

6 3

4 1

6 3

B 9 8

A 7

B 9 8

A 7

B 9 8

KWR

ALR

PR

ATR
ABCDEFGHIJ
adjust set point read

ATR
ABCDEFGHIJ
adjust set point read

12

567

12

567

ABCDEFGHIJ
adjust set point read

ABCDEFGHIJ
adjust set point read

12

567

12

567

BTR

ATR

AC

DC TERMS

GND1 101 108 109 110 133

AC 40 PIN CONNECTOR

AC TERMS

(TBD 2)

132 131 131 139 148 GND

(TBA 2)
GND 2 2 2 3 6 10 10 30 30 36 71 72 74 81 81 84 SP1 SP2 SP3 SP4

GROUND
7W-9799

VOLTAGE REGULATOR

GND GND 133 131 132

(TBD 2) VIEW B-B CHASSIS ONLY SHOWN

154 156

CUSTOMER GROUND BAR

MARSHALLING BOX (FRONT VIEW)

CUSTOMER TERMINAL STRIP (TBC)

GND2

GND 140 142 209 210 EF1 EF2 120 122 124

133 136 137 157 159 202 203 206 207 132

GND 148 139 131 131 132

.6
4 1 A 7

1.0

B 9 8

A 7

B 9 8

A 7

TBC

F15 F23

LFSR

50

50

51

51

61

61

52

52

53

53

L1

L1

L3

L3

80

80

82

82

KILOWATT RELAY

ALARM RELAY

AC TERMINAL STRIP

DC TERMINAL STRIP

DC PANEL

PUMP RELAY

AC TERMINAL STRIP

FUSE BLOCKS

AC PANEL
6 3 5 4 1 6 3 5 4 1 6 3 5 4 1

GROUND FAULT RELAY


F50 F51 F52

B 9 8

A 7

B 9 8

A 7

B 9 8

A 7

WINDING TEMPERATURE RELAYS


B 9 8 A 7 6 3 5 4 1

KWR

ALR

PR

PUMP CONTACTOR

ATR
ABCDEFGHIJ

ATR
ABCDEFGHIJ
adjust set point read

AR

GNDFR

ARMING RELAY

MERLIN GERIN

PC

multi 9

C60N

AC TERMINAL STRIP (TBA1)


12

OFF

adjust set point read

567

12

567

F16 F17 F18 MCB1 F21 F22 F32 F33

HC

FUSE BLOCKS HEATER CONTACTOR


BC

CIRCUIT BREAKER DC PANEL


GND 2 2 3 6 6 10 30 57 61 63 87 88 89 90 99 D+ DCCM+ CCMATA+ ATARDM 47 48 49 231A 232A 233A 231B 232B 233B 231C 232C 233C 64 65 66
adjust set point read

AC PANEL
F50 F51 F52

12

567

12

567

BTR
6 3 5 4 1

ATR
AC TERMINAL STRIP

BATTERY CHARGER

BEARING
B 9 8 A 7

O/UVR

AR

GNDFR

TEMPERATURE
PC

RELAY

MERLIN GERIN

multi 9

C60N

OFF

OFF

F16 F17 F18

MCB1

F21 F22 F32 F33

HC

DC 40 PIN CONNECTOR
DC

DC TERMINAL STRIP
BC

KILOWATT RELAY

ALARM RELAY

PUMP RELAY

6 3

4 1

6 3

4 1

6 3

4 1

CUSTOMER TERMINAL STRIP

(TBA 2)
B A B A B A

FUSE BLOCKS

RFI

132 131 133 GND GND

18

17
CUSTOMER 240V AC SUPPLY 240

16

15

14

13

12

11

10

L1

L2

K
GND

C 132

C 133

NOTE Q
17 38

CR 136 2 8 137

66

19

132

F16 2A

136

136

137 A1

HC
A2

141

VOLTAGE REGULATOR TERMINAL CHART REGULATOR A B 6A 45 45 C 44 TERMINAL DESTINATION CROSS REFERENCE D 4 E 8 F 9 8 8 G B+ B+ H BBJ 5A 5 5 K 22 22 22 L 24 24 24 M 20 20 20 N F1 F1 F1 O F2 F2 F2 P 26 26 26 Q 28 28 28 R 30 30 30 S 6 6 6

141 HC 132 F17 8A 135 1 2 A B H2 HC 133 F18 8A 141 3 4 142 142 142 H4 140 140 240 VAC 140 H1 H3

SPACE HEATER

VR6-B DIGITAL PF/KVAR

7 7 7

SLR CHART
VOLT LINE TO LINE 1600 OHM 208 A B 240 300 380 640 OHM C 400 416 480 E SYNCHRONIZING RESISTOR TAP SETTING CHART USE E-D 1760 OHM USE E-C 2400 OHM USE E-B 5600 OHM USE E-B 5600 OHM USE E-B 5600 OHM USE E-A 7200 OHM USE E-A 7200 OHM

BATTERY CHARGER
SEE CHART BELOW NOTE P

240 VAC NOTE L

MCB1
16 AMP 132 1 2 138 5 HC 6 14 AWG 14 AWG 148 148

NOTE K 1L1

BATTERY
40 BATTERY DISCONNECT SWITCH NOTE BL

CB1 60A 2 BATTERY CHARGER DESIGNATION A 10 AMP NON-UL 0 L B 240 N CB2 20A 1 24 PS1

NOTE N

ALT

SM1

HC 133 3 4 134 7 8 139 139

3 1L2

5 AMP NON-UL

SMMS1 25 2 1

PS1

NOTE AE

GENERATOR WINDING OVERTEMPERATURE ALARM/SHUTDOWN


3 +D -E 2 2 2 30

1760 OHM

JACKET WATER HEATER

240 VAC BATTERY CHARGER TERMINAL CHART

BATTERY CHARGER UL

3200 OHM

LAMP 1
132 138 5 HC 6 148 1 10 AMP ELS 2 4 TC4 T1 T2 T3 WH RD WH
57

GOVERNOR TERMINAL CHART GOVERNOR TERMINAL DESTINATION CROSS REFERENCE A PWM LOADSHARE S 19 B D C B21 D B16 E B+ 15 F 3 28 G 2 27 H 1 26 J 14 K 13

ATR1
1 171 172 173 174 P 3 Q 6 5 7 75 74
37
21

F19 10A

30

240V BLOCK HEATER


133 F20 10A 134 7 HC 8

GENERATOR RUNNING RELAY


NOTE BK NOTE R GRR 139 7 GND GRR 7 1
59

LAMP 2 ENCLOSURE LIGHTING


30 TC1

87

31 87 C

RD

NOTE BG 2 11

4
58

C SP2

MANUAL

88

88

OFF/RESET

CONTACTS

32

AUTO

133

131 89

33 89 C 2

1 2 3

X X

X X

STOP

OFF RESET

X
AUT

AUTOMATIC FUEL TRANSFER SYSTEM


5 36

PSPB
207 1A 2A 206

64

24

PR 206 9 6 205 95

OL 204 96 A1

INTERNAL
CIRCUITRY
RM32 F4 10A

FLYBACK 27 RM5 ASR

RM27 RM19

132

F22 2A

207

207

PC
A2

131
33

+D

-E 2

4 5 6 X X X X

X X X X

COOLDOWN STOP

AUTO

COMMON ALARM SHUTDOWN


NOTE U ALR 64 7
70

37 181 TC5 182 WH 183 184 P

ATR2
1 30 74 A B 12 3 Q 6 5 7 75

7 8 9 10

MAN

4 ALR 65

1 RM30 F1 10A RM3 CTR CTR

RM16

START
X X

38

GRR

PC 207 61 62 203 203

42

PSL
203

7 131

1 66

RM17 TC2 NOTE R

RD

C 99

PC 207 53 54 202 202

40

PRL
202 NOTE M

RM36 131

RM23 F7 10A RM9 RR 1 21 22 2 3 +D -E 2 2 1 BK RD

OUTPUT LOAD SPECIFICATIONS FOR GSC RELAY MODULE RELAY MODULE TERMINAL NO. RATING FOR RESISTIVE LOADS 0-.45A, 24VDC 10A, 24VDC RATING FOR INDUCTIVE LOADS *N/A 10A, 24VDC

AUXILIARY CIRCUIT BREAKER CONTACT


FIRST CIRCUIT BREAKER BREAKER AUX NOTE AR 233 C 233A 1

CUSTOMER 120V AC SUPPLY 120

PC 132 F21 15A 133 212 3 4 208 1 PC F24 15A 210 2 209

OL 209 2 OL 210 4

GSC
NOTE X

MPU

13, 15, 17, 19, 22, 23,

14, 16, 18, 21, 20, 24, 36,

T1 T2,T3 T4 P

FUEL TRANSFER PUMP


3/4 HP, 1, 2 POLE 115/110-230-208 50/60 HZ 8 GPM 9.2/11.2 FLA

11

14 231

BREAKER AUX 11 12

231A

ATR3
232 RM35 C 232A F6 10A RM33 C 233B F3 10A RM6 SMR SMR 17 17 1L3 1L4 NOTE S 30 30 46 46 45 NOTE S RM28 C 231C 30 28 C 232C E-STOP SWITCH 1 39 39 5 E-STOP SWITCH 2 CB3 15A SR A+ 30 87 B+ 1 2 1 BATT. (+) 2 BATT. (+) (SWITCH) 32 ATA DATA LINK (-) 31 ATA DATA LINK (+) 9 29 40 START/RUN/STOP 2 83 1 2 83 2 DIGITAL SENSOR RETURN D START/RUN/STOP 1 2 40 32 C 31 C K J E C C NOTE J 28 30 4 CLR SRV 45 86 45A NOTE Z SP2 T1 T2 T3 1R2 1R1 45 17 RM8 RR RM18 RM21 14 RM24 39

L1

SECOND CIRCUIT BREAKER BREAKER AUX 233 C GND 132 C 131 C 11 14 231 BREAKER AUX 11 NOTE Q THIRD CIRCUIT BREAKER
17 38

ESPB
6 1L1 1L2 34 4

A 4

CR
B 4

2 34

ESTS
1L1 1L2 TC6 4 WH TC3 1L3 1L4 RD 193 194

1 191 192 P 3 Q 6 5 7

30 74

10A, 24VDC OR 110VAC

5A, 24VDC 7.5A,110VAC

SMM 3 S1

* DO NOT CONNECT INDUCTIVE LOADS TO THESE TERMINALS

75

231B

12 232 C 232B 1 RM28 233 45 C 233C 2R2 2R1 RM B+ 38

30

CR 136 2 8 137

66

19

132

F16 2A

136

136

137 A1

HC
A2

131

BREAKER AUX 11 14 231

BREAKER AUX 131 HC 132 F17 8A 135 1 2 L 140 140 120 VAC 140 H1 H3 131 11 12

232

SR
85

MCS SCS
2 3 3 2 1 6 8 C
33 23

ENGINE INSTRUMENTATION

G
131 MCB1 32 AMP 132 138 5 HC 6 4 148 148 NOTE K 1L1

N H2 142 H4

ELECTRONIC LOADSHARE
AUX

NOTE AV 4

GENERATOR BEARING OVERTEMPERATURE ALARM/SHUTDOWN


2 3 +D -E 2 2

NOTE AF

99

1+

REMOTE CUSTOM 8 LIGHT

30 8 9 10 SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT 30 LED #1 LED #2 LED #3 LED #4 LED #5 LED #6 LED #7 LED #8

SPACE HEATER
NOTE L

20 41 1

PR 7 4

CAT MONITORING SYSTEM

BATTERY CHARGER JACKET WATER HEATER


NOTE N

120 VAC

AUTOMATIC FUEL TRANSFER SYSTEM 1 FUEL SUPPLY FROM BELOW FLOOR LEVEL BULK TANK

NOTE AN EGR

RM14 RM13

10

9 29

BTR
1 RD BT1 RTD PT100 163 P 3 S WH 164 Q R 6 5 7 76 13 SILENCE 14 HORN 71
16 1

30

11 3 4 12 TEST 5 6 -7

PSPB
F23 2 AMP 211 1B 2B 84

10 84

10 AWG

LFLS
3 4

LFLS
81

PWM
NOTE T 21 10 A 12 B C L 86 NOTE BF 85 3 H G F 1 2

PR
A B 6 NOTE AT NOTE AS

131

CAT DATA LINK (+) 7 CAT DATA LINK (-) ETHER START RELAY21 THROTTLE 10

EPIR

3 1L2

PRPB
81

18

GND 3 HC 5 6
4

9 81

ETHER START AID


NOTE T

Engine ECM

SP

MCB1 16 AMP 132 138 148

4 1 2 NOTE AP 10 84

SAS
AUTO 3 MAN

DROOP 12 START AID SWITCH 38 ES 38 20

SP2 NOTE AW REMOTE NFPA 99 8 LIGHT 3 HORN INPUT 1

99

4
28 24 6 16 22 12 3 31 2

HORN INPUT 2

120V BLOCK HEATER

NOTE BJ

F23 2 AMP

84

LFLS
3 4

LFLS
81 1 2 83 83 2

ER SV HC5 HC4 HC3

ER SV 2

ER SV 2

C A B

12

90 2 DATA NOTE BG 12 TEST 13 SILENCE 14 HORN R8 8 7 6 R7 5 5 14 R6 6 7 13 12 8 11 9 10 10 9 11 8 2 C 30 C 69 23 3 4 3 2 2 1 99 B+ NOTE AX REMOTE NFPA 110 2 LIGHT TSC 22 -7 30 12 R9 11 10 9

PR
A B RM31 F2 10A RM4 FCR RM15 13 6 CR 9 3 3 3 3 3 C
1

EXHAUST TEMPERATURE
LOW COOLANT TEMP ALARM

15 13 14 18

F
131

131 GND 84

NOTE AT PR 7 4

NOTE AS

81

10

ETHER START AID


85 85 2 3 1 NOTE T

HC2 HC1 HC0 2 2 SYSTEM NOT IN AUTO ALARM 90 C HIGH COOLANT TEMP FAULT 22 23 19 20 24 LOW OIL PRESS ALARM 16 17 21

84

PR 8 5

AUTOMATIC FUEL TRANSFER SYSTEM


5 36

AUTOMATIC FUEL TRANSFER SYSTEM 2 FUEL SUPPLY FROM ABOVE GROUND BULK TANK PSPB
207 1A 2A 206
64 24

PR 206 9 6 205 95

OL 204 96 A1

MV
30

EPIR 87

SASV
2

59

132

F22 2A

207

207

PC
A2

131
33

2 D+ D-

14

NOTE T

ELECTRONIC CONTROL GROUP 7 6 5 1 4

PR
70

PC 207 61 62 203 203

42

PSL
203

AUTOMATIC FUEL TRANSFER SYSTEM 3 FUEL SUPPLY FROM FREESTANDING BULK TANK

85 5

SPARE 36 63 63

6 63 5 C 5 90

27 LOW OIL PRESS FAULT 25 26 4 30 3 OVERCRANK FAULT 28 29 33


44

MV
131 7 PR 4 35 90 90

R5

12

NFPA ALARM MODULES


PC 207 53 54 NOTE M NOTE AT NOTE AS NOTE W
18
1 40

30 -B

PRL
202

PSPB
131 F23 2 AMP 211 1B 2B 84

10 84

LFLS
3 4

LFLS
81 1 2 83 83 2

A1

202

202

TDR

A2 10 1+

NOTE AA -7 30 NOTE AH 36 70 LFLS 5 LOW FUEL LEVEL ALARM 2 6 NOTE AF 20 68 1 30 69 12 TEST 13 SILENCE 14 HORN 11 300 NOTE AC 10 301 SEE ALARM CHART 38 6 NOTE AL
35

R4

2 1 NOTE AY REMOTE CUSTOM 16 LIGHT 8 9 10 11 SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT 30 LED #1 LED #2 LED #3 LED #4 LED #5 LED #6 LED #7 LED #8

PR
A B

1 RM2 1

B1 1

99

PC 132 F21 15A 131 3 4 208 1 PC 210 2 209

OL 209 2 OL 210 4

T1,T3 FUEL TRANSFER PUMP P T2,T4


3/4 HP, 1, 2 POLE 115/110-230-208 50/60 HZ 8 GPM 9.2/11.2 FLA

PRPB
81 3 4

ALM ECS
90

OVERSPEED FAULT

31 32 36

R3

99

1+

9 81 NOTE AQ CTR FCR RM1 7 15 TDR 54 OFF/RESET 39 COOLDOWN/STOP 32 55 58 56 57 16 5 22


48

5 10 9 8 7 2 5 3 4

HIGH COOLANT TEMP ALARM

34 35 39

R2 3 4 12 TEST R1 5

SEE ALARM CHART 99

ALARM INPUT CHART


ALM INPUT TERMINAL NFPA 99 NFPA 110 8 SPARE SPARE 10 SPARE SPARE 11

EMCP DIAGNOSTIC FAULT

37 38 40

LOAD

AUTO 40

CIM

CUSTOMER INTERFACE MODULE

13 SILENCE 14 HORN

6 -7

L0

L1

L2

L3

START 33

NOTE AD

SPARE BCF

RUPTURE BASIN ALARM


SP3 77

1 NOTE AU 99 8 99 90 1+ 9 10 SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT 30 LED #1 LED #2 LED #3 LED #4 LED #5 LED #6 LED #7 LED #8

FRBS
2 1 2 NOTE BM
30

57

30 57 C

IC C

30

15

16

30

MANUAL SYNCHRONIZING MODULE


156 C 3 OR 4 POLE OPTIONAL MOLDED CASE CIRCUIT BREAKER 154 C F32 2 AMP NOTE BC 4 1 F33 2 AMP
11
23

15

51

159

SL2
160 162

SLR2
110 RM39 F10 10A
45

PL1
2 RM12

CUSTOM ALARM MODULE


NOTE AB 8 2 74 NOTE AE GEN WINDING OVERTEMP ALARM NOTE AF 9 71 GEN BEARING OVERTEMP ALARM 12 15 12 R9 11 10 9 R8 8 7 6 R7 5 5 14 R6 6 7 8 9 10 10 9 11 8 12 TEST 1 2 13 SILENCE 90 2 DATA NOTE BG 99 1+ NOTE AZ REMOTE NFPA 99 16 LIGHT 20 68 69 12 13 14 TEST SILENCE HORN 1

11 3 4 5 6 -7

PLS
10 10 3 2 9

157

161

163

108

PL2
2 1

SL1

SLR1

D
GROUND FAULT RELAY
NOTE E

SS
10

12 10 C 10 6 C
15

AR
AR B 4 120 108 T1 K GNDFR T2 F12 F11 PR1 T12 H2 X2 T11 H1 T1 X1 J1-1 91 10 A 122 7 A1 118

RM34 F5 10A

RM7 GFR

RM22

10

73

GNDFR 14 11

NOTE E GROUND FAULT NOTE AH 36 70 LFLS 5 6 NOTE AL R8 OUTPUTS R9 OUTPUTS

13 14 18 16 17 21

T0
GNDFCT

T1

T2

T3
EF2 EF1 L

CAM COMMON ALARM SHUTDOWN


NOTE U A
44

A2

ALR

B 35 10 1+

11

HORN INPUT 1

LOW FUEL LEVEL ALARM

T1

32 J1-2 92 11 32

SH TC SH TC SH TC

-7 SHUNT TRIP CB 3 SHUNT TRIP CB 4 SHUNT TRIP CB 5

30 75 NOTE AE GEN WINDING OVERTEMP SHUTDOWN

R7 OUTPUTS

19 20 24

HORN INPUT 2

T2

13 12 11

T3

T3 F13

T13

H1 PR1

T2

X1 32 a

NOTE AF 76 GEN BEARING OVERTEMP SHUTDOWN

R6 OUTPUTS

22 23 27

ELECTRONIC CONTROL GROUP 7 6 5 1 4 4 3 3 2

TO

14

38

TO

101

101 110

H2

X2

J1-3

93 12

NOTE V

30 R5 4 12 14 HORN -7

SPARE FAULT INPUT

LED #7

R5 OUTPUTS

25 26 30

50 CT 1

12 DC CONN 1 1 11 61 2 10 3 4 52 51 62 67 18 8 11 152 52 52 12 5 10 7 9 SENSOR V+ PU COOLANT LOSS 9 13 62L 67L 18 B A 20 68 12 TEST 13 SILENCE 14 HORN R3 OUTPUTS LOW FUEL LEVEL SHUTDOWN 6 7 H1 PR1 BK T4 BR J1-5 95 67O 62O A B 86 6 NOTE BD ONLY FOR DVR BK PU 6 9 LFSR 4 53 1W 8 9 153 53 53 H1 PR1 BK 50 50 50 BK T5 BR J1-7 PU J1-8 98 17 97 16 20 J1-6 96 6 19 D+ D+
20 19

3 R4 OUTPUTS 28 29 33 31 32 36 RDM LFSR R2 OUTPUTS 34 35 39 R1 OUTPUTS 17 72 A NOTE AM NOTE AJ LFSR B 2 37 38 40 1 R1 R2 C 68 69 2 20 12 13 14 TEST 5 SILENCE HORN 6 -7 30 R3 1 R4 2 8 99 1+ 9 10 11 3 4 SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT LED #1 LED #2 LED #3 LED #4 LED #5 LED #6 LED #7 LED #8

51

51

151

51

PR1

C
50 CT 2 52 50 CT 3 53

H1 BK

T3 BR

J1-4

94 4

SENSOR V-

31

ECLS
C

COOLANT LOSS
NOTE AK

69

LOADSHARE MODULE

BK

19

D2 DROOP CT D1

19 D20 D+ C D+ DC

LFLS 8 7

72

17

RELAY DRIVER MODULE RDM


NOTE BA REMOTE NFPA 110 16 LIGHT NOTE BG 3 HORN INPUT 1

D-

D-

T1 U

T2 V

T3 W

99 1+

ATB
VOLTAGE REGULATOR
NOTE D 122 30 RDM 90
7

HORN INPUT 2

7 RDM

DATA

T4

T5

T6 5A J A B 82 80 82 80 3 3 1 2 S

VAR
124

12 TEST NOTE Y 13 SILENCE 120 21


32

B
30 -7

6A

VOLTAGE ADJUST POTENTIOMETER

8 CCM+ CCM18 CCM4 SP1 C CCM+ 99 B+ 99 2 B99 1+ DDATAC D+ DATA + 14 HORN

CCM+

CCM+
33

NOTE A

NOTE C

NOTE B

T7

T8

T9
22 24 20

RFI FILTER
NOTE F
GENERATOR REGULATOR 22 24 20

K L M

PF/KVAR
2 C NOTE J 1

22 1 2 3 SPARE 1 23

CCM-

CCM60

ADJUST

CCM
8 9 10 SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT SPARE FAULT INPUT 30 LED #1 LED #2 LED #3 LED #4 LED #5 LED #6 LED #7 LED #8

RFI

SP1A

SP1

GOV
NOTE AG

F2GEN EXC T10 T11 T0 N T12 F1GEN

O N

E F 10 G

LOADSHARE MODULE
NOTE H 10 11 12 NOTE J

61

SPARE 2

24

SP2

SP2
62

14 SP2 24 SP3

+
11 PMG 12 PMG P Q 2 R NOTE BH

SPARE 3

25

SP3

SP3

CUSTOMER COMMUNICATION MODULE

11 3 20 12 TEST 68 5 13 SILENCE 14 HORN 6 -7 4

2
49

11 36 + NOTE P

69

1 NOTE:

VR

H 122

F15

36

GEN

SHIELD TO BE GROUNDED AT CONTROL END ONLY

BATTERY CHARGER NON-UL

PM GENERATOR
NOTE G

PHASE ROTATION 1-2-3

L5 F51 2 AMP F52 S M N 13 PMG 2 AMP F50 2 AMP 124

122 S LS2 120 120 LS1

A
NOTE BS

18

17

16

15

14

13

12

11

10

9
NOTE V: SHUNT TRIPS ARE INSTALLED WITH EACH OPTIONAL CIRCUIT BREAKER INSTALLED ON PACKAGE. NOTE W: REMOVE THIS JUMPER WIRE IF IT IS DESIRABLE TO TURN OFF THE GSC AND ALARM VIA THE ENGINE CONTROL SWITCH (ECS) "OFF" POSITION IN ORDER TO LIMIT BATTERY DRAIN. NOTE X: SEE GSC RELAY RATING CHART.

5
NOTE AL: "LOW FUEL ALARM" 40% DECREASING NOTE AM: "CRITICAL LOW" 5% DECREASING

1
NOTE BM: CONTACT WIRED WITH OPTIONAL RUPTURE BASIN ALARM. NOTE BN: SET TOP DIAL ON TIMER TO "E", SET MIDDLE DIAL TO "3s", AND SET BOTTOM DIAL TO "0.7".

SYMBOLS
Standard Wiring Customer Wiring Package Options Alternative Wiring Shielded Wire Engine Mounted Component Relay Contact (Normally Open) Relay Contact (Normally Closed) Generator Frame (Chassis) Ground Earth Ground Solenoid Resistor Temperature Switch Liquid Level Switch Lamp Breakdown Diode (Bi-directional) Diode Fuse Emergency Switch Relay Coil Circuit Breaker
19

NOTES
23

NOTE L: COMPONENTS INSTALLED ONLY WITH OPTIONAL SPACE HEATERS. NOTE M: COMPONENTS INSTALLED WITH EITHER THE AUTOMATIC FUEL TRANSFER SYSTEM 1 OR THE AUTOMATIC FUEL TRANSFER SYSTEM 3 OPTIONS. NOTE N: COMPONENTS INSTALLED WITH OPTIONAL UL BATTERY CHARGER. UL BATTERY CHARGERS WIRED 120 VAC. NOTE P: COMPONENTS INSTALLED WITH OPTIONAL NON-UL BATTERY CHARGERS. IEC BATTERY CHARGERS WIRED 240 VAC. FUSE F15 IS A 6 AMP FUSE SUPPLIED WITH 5 AMP BATTERY CHARGER. FUSE F15 IS A 10 AMP FUSE SUPPLIED WITH 10 AMP BATTERY CHARGER. NOTE Q: COMPONENTS INSTALLED WITH ANY COMBINATION OF THE SPACE HEATER, BATTERY CHARGERS, JACKET WATER HEATER, OR BLOCK HEATER OPTIONS. NOTE R: COMPONENTS INSTALLED WITH OPTIONAL GENERATOR RUNNING RELAY. NOTE S: EMERGENCY STOP PUSHBUTTON INSTALLED WITH OPTIONAL PACKAGE ENCLOSURE. JUMPERS BETWEEN 4 & 34 AND 45 & 46 ARE REMOVED WITH THIS OPTION. NOTE T: COMPONENTS INSTALLED WITH OPTIONAL ETHER START AID. NOTE U: COMPONENTS INSTALLED WITH OPTIONAL COMMON ALARM RELAY.

ATB Terminal Marshalling Box DC Terminal Marshalling Box AC Terminal GSC 40 Way Harness Connector GSC Relay Module Terminal Control Panel Terminal Engine 40 Way Connector

Panel 70 way Connector DC Connector No. 1 (Black) DC Connector No. 2 (Grey) AC Connector From Gen (Green) Marshalling Box 40 Way DC Connector Marshalling Box 40 Way AC Connector SASV 2 Way Connector

Marshalling Box Customer DC Term. Marshalling Box Customer AC Term.


2

NOTE AC: CONNECT ALARM TERMINAL POINT 7 TO POINT 6 FOR NFPA 110 ALARM MODULE OPERATION MODE. NO CONNECTION REQUIRED FOR NFPA 99 OPERATION. NOTE AD: TERMINALS 12, 13 & 14 ARE WIRED FROM AN OPTIONAL CUSTOM ALARM MODULE TO TERMINALS 12, 13 & 14 RESPECTIVELY, OF THE FIRST ALARM MODULE WHEN ORDERED IN ADDITION TO EITHER AN NFPA 99, NFPA 110 OR CUSTOM ALARM MODULE. NOTE AE: COMPONENTS INSTALLED WITH OPTIONAL GENERATOR WINDING OVERTEMPERATURE RELAY. ALARM OVERTEMPERATURE FACTORY SET TO 130C FOR PRIME POWER, 160C FOR STANDBY POWER. SHUTDOWN OVERTEMPERATURE FACTORY SET TO 135C FOR PRIME POWER, 165C FOR STANDBY POWER. NOTE AF: COMPONENTS INSTALLED WITH OPTIONAL GENERATOR BEARING OVERTEMPERATURE RELAY ALARM OVERTEMPERATURE FACTORY SET TO 70C. SHUTDOWN OVERTEMPERATURE FACTORY SET TO 90C. NOTE AG: THE INPUT TO THE GSC SPARE SHUTDOWN INPUTS MUST BE A B- SIGNAL APPLIED FOR 250mSEC OR LONGER TO ASSURE PROPER OPERATION. CUSTOMER PROVIDED SWITCH TO BE RATED FOR 4mA, 12VDC OPERATION. NOTE AH: CONTACT WIRED WITH OPTIONAL LOW FUEL LEVEL ALARM. NOTE AJ: LOW FUEL LEVEL SHUTDOWN WIRED WHEN OPTIONAL FUEL TANK BASE IS ORDERED. NOTE AK: TERMINAL 23 OF REMOTE ANNUNCIATOR TO BE WIRED TO TERMINAL 14 OF THE THE LOCAL ALARM MODULE.

NOTE BA: OPTIONAL NFPA 110, (16) LIGHT REMOTE ANNUNCIATOR INSTALLED BY CUSTOMER NOTE BB: UP TO 3 ALARM MODULES WITH A COMBINED WIRE LENGTH OF 300 METERS MAY BE DRIVEN FROM THE DATA LINK. WIRE 30 AND WIRE 99 TO BE MINIMUM WIRE SIZE 12 AWG. ALL OTHER WIRES TO BE MINIMUM 16 AWG. NOTE BC: COMPONENTS INSTALLED WITH MANUAL SYNCHRONIZING OPTION. SEE SLR TABLE FOR RESISTOR CONNECTIONS. NOTE BD: COMPONENTS INSTALLED ONLY WITH LOADSHARE OPTION. NOTE BE: LOADSHARING LINES ARE COMMON TO ALL UNITS. NOTE BF: REFER TO GOVERNOR TERMINAL CHART TO DETERMINE THE ACTUAL TERMINAL DESIGNATION FOR SPECIFIC GOVERNORS. NOTE BG: COMPONENTS INSTALLED WITH OPTIONAL ENCLOSURE LIGHTING NOTE BH: FOR VR6-B VOLTAGE REGULATOR ONLY: REMOVE JUMPERS BETWEEN: TERMINALS 20 & 28, 22 & 30, AND 24 & 26 FOR OPTIONAL PM GENERATORS. NOTE BJ: COMPONENTS INSTALLED ONLY WITH 120 VAC BLOCK HEATER OPTION. NOTE BK: COMPONENTS INSTALLED ONLY WITH 240 VAC BLOCK HEATER OPTION. NOTE BL: COMPONENT INSTALLED ONLY WITH BATTERY DISCONNECT OPTION.

NOTE A: FOR VR6-B VOLTAGE REGULATOR ONLY: JUMPER TERMINALS FOR THREE PHASE SENSING, REMOVE JUMPER FOR SINGLE PHASE SENSING. NOTE B: FOR VR6-B VOLTAGE REGULATOR ONLY: INSTALL JUMPER FOR 1:1 V/HZ SLOPE, REMOVE FOR 2:1 V/HZ UNDERFREQUENCY SLOPE. (STANDARD IS TO REMOVE JUMPER) NOTE C: FOR VR6-B VOLTAGE REGULATOR ONLY: REMOVE JUMPER WHEN VOLTS ADJUST POT FITTED. NOTE D: REFER TO THE VOLTAGE REGULATOR TERMINAL CHART TO DETERMINE THE ACTUAL DESIGNATION FOR THE SPECIFIC VOLTAGE REGULATOR. NOTE E: COMPONENTS INSTALLED WITH THE GROUND FAULT RELAY OPTION. NOT AVAILABLE WITH OPTIONAL DELTA CONNECTED GENERATORS. NOTE F: OPTIONAL RFI FILTER INSTALLED ONLY WITH VR6-B REGULATOR NOTE G: OPTIONAL PM CONNECTIONS. STANDARD SE GENERATORS REQUIRE NO CONNECTIONS. NOTE H: 24VDC POWER SUPPLIED ONLY WITH OPTIONAL DIGITAL VOLTAGE REGULATOR. NOTE J: PF/KVAR ADJUSTABLE POTENTIOMETER ONLY AVAILABLE WITH DVR WITH PF/KVAR CONTROL. NOTE K: COMPONENTS INSTALLED ONLY WITH JACKET WATER HEATER OPTION. NOT USED WITH FUEL FIRED JACKET WATER HEATER.

NOTE AN: COMPONENTS INSTALLED FOR OPTIONAL FUEL TRANSFER SYSTEM #1. NOTE AP: COMPONENTS INSTALLED FOR OPTIONAL FUEL TRANSFER SYSTEM #2. NOTE AQ: COMPONENTS INSTALLED FOR OPTIONAL FUEL TRANSFER SYSTEM #3. NOTE AR: OPTIONAL AUXILLIARY CIRCUIT BREAKER CONTACTS RATED FOR 6 AMPS AT 240/480VAC, 50/60HZ; 3 AMPS AT 600VAC, 50/60HZ; 2.5 AMPS AT 48VDC; 0.8 AMPS AT 125VDC; 0.3 AMPS AT 250VDC: NOTE AS: "PUMP OFF" 90% INCREASING NOTE AT: "PUMP ON" 50% DECREASING NOTE AU: CUSTOMER INTERFACE MODULE INSTALLED BY CUSTOMER. NOTE AV: OPTIONAL CUSTOM (8) LIGHT REMOTE ANNUNCIATOR INSTALLED BY CUSTOMER. NOTE AW: OPTIONAL NFPA 99, (8) LIGHT REMOTE ANNUNCIATOR INSTALLED BY CUSTOMER. NOTE AX: OPTIONAL NFPA 110, (2) LIGHT REMOTE ANNUNCIATOR INSTALLED BY CUSTOMER. NOTE AY: OPTIONAL CUSTOM (16) LIGHT REMOTE ANNUNCIATOR INSTALLED BY CUSTOMER NOTE AZ: OPTIONAL NFPA 99, (16) LIGHT REMOTE ANNUNCIATOR INSTALLED BY CUSTOMER

Magnetic Pick-up Engine Connector Coolant Loss Engine Connector (ECLS) Oil Temp Engine Connector (EOTS)
CAT MONITORING SYSTEM 40 Way Connector

NOTE Y: CUSTOMER COMMUNICATION MODULE INSTALLED BY CUSTOMER. WIRES 2 & 99 MUST BE A MINIMUM OF 16 AWG SHIELDED TWISTED PAIR CABLE. MAXIMUM DATA AND BATTERY WIRE LENGTH IS 457 METERS, INCLUDING RUNS BETWEEN MULTIPLE GENSETS. NOTE Z: COMPONENTS INSTALLED WITH OPTIONAL ENGINE MONITORING SYSTEM. NOTE AA: COMPONENT INSTALLED FOR NFPA 99 OR NFPA 110 ALARM MODULE. SWITCHED INPUT TERMINALS 10 AND 11 ON THE ALARM MODULE MUST BE JUMPERED TO TERMINALS 3 AND 4 RESPECTIVELY, IF IT IS DESIRED TO SOUND HORN IN CONJUNCTION WITH FLASHING LAMP. NOTE AB: COMPONENT INSTALLED FOR OPTIONAL CUSTOM ALARM MODULE. MODULE CONTAINS SPARE INPUTS FOR CUSTOMER DESIRED USE WITH CUSTOMER PROVIDED SWITCH. (RATED FOR 4mA, 12 VDC OPERATION)

36

11

ATB
75-CAM-3 76-CAM-4 GND-REAR COVER T1-AC CONN-7 T2-AC CONN-5 T3-AC CONN-9
L1 L1
F11

108-TBA1-108T
131-PSL-X2 131-70 WAY-70 136-CR-2 136-70 WAY-38 137-CR-8 137-70 WAY-66 202-PRL-X1 202-70 WAY-40 203-PSL-X1 203-70 WAY-42 206-PSPB-2A 206-70 WAY-64 207-PSPB-1A 207-70 WAY-36 157-SS-4 157-70 WAY-23 159-SS-6 159-70 WAY-51 51-TBC-51 OR 51-LSGOV-4 51-AC CONN-1 52-TBC-52 OR 52-LSGOV-6 52-AC CONN-2 53-TBC-53 OR 53-LSGOV-8 53-AC CONN-3

RENR2477-01 December 2001


GND-70 WAY-68 GND-CHASSIS STUD

NOTE E 1-TBD1-1CT 1-TBD1-1DT 1-TBD1-1CL 54-ECS-7

F12

SP2-TBD1-SP2BB

7-RM-1

50-TBC-50 50-AC CONN-11

50-AC CONN-12

F13

136-TBA1-136T

87-TBD1-87T

88-TBD1-88T

86-CAM-6

T0-AC CONN-8

101-70 WAY-14

110-TBA1-110T

50-TBA1-50AT GND-AC CONN-4 50-TBA1-GND5T 50-AC CONN-10

13-RM-15

108-F11

59-TBD1-59T

1-TBD1-1AL

43-SP-1

44-SP-2

42-SP-3

TBC
50-TBA1-50BT 50 51 61 52 53 L1 L3
U1 U1

+ ~

A1

B1

15

EPIR

6 3

5 2

4 1

TDR
A

6 3

5 2

4 1

6 3

5 2

4 1

D2

D3

AB

FSM3U

CR
3 2 1

1mn

GRR
.8

F15

F23

51-TBA1-51T OR 151-LSGOV-5 52-TBA1-52T OR 152-LSGOV-7 53-TBA1-53T OR 153-LSGOV-9

110-F13

LFSR
B A 8 7 SP2-TBD1-SP2BT

TBA1

B 9 3-TBD1-3B 2-GRR-B 2-TBD1-2AB 2-LFSR-B 8 137-TBA1-137T

A 7 39-RM-24

.2

.4

16

18

36-70 WAY-49

211-PSPB-1B OR 84-70 WAY-4

CATERPILLAR
-B S D +B

30-TBD1-30DT

2-TBD1-2AL

5-TBD1-5AB

8-ECM-21

L2

SP2-TBD1-SP2BT

89-TBD1-89T

38-TBD1-38B

2-CR-B

30-LFSR-9 30-TBD1-30DB

30-LFSR-7

2-CR-B

72-70 WAY-17

GND5

101

110

159

75-ATR-7

76-BTR-7

91-GSC-10 92-GSC-11 93-GSC-12 94-GSC-4 95-GSC-5 96-GSC-6 97-GSC-16 98-GSC-17

D-SPD-ECM-12

S-SPD-ECM-10

30-TBD1-30CT

10-PLS-3

108-SLR1

20-RM14 20-DC CONN2-10 20-ESPB-1R2 20-SAS-2 30-70 WAY-16 30-DC CONN2-4 30-ESPB-1L4 30-RM-28 30-PWM-B(-) OR 30-LSGOV-16 30-ECS-1 30-TDR-A2 30-LFSR-7

110-SLR2

HC4-EMSII CONN-16 2-EMSII CONN-2 2-EMSII CONN-31 2-SCS-2 2-EMSII CONN-12

59-EPIR-87 59-DC CONN2-3 62-DC CONN1-10 62-DC CONN1-7 62-GSC-31 63-GSC-36 63-70 WAY-6 67-DC CONN1-12 67-DC CONN1-9 67-GSC-9 90-GSC-35 90-70 WAY-5 99-RM-9 99-70 WAY-35 D(-)-GSC-20 D(-)-70 WAY-20 D(+)-GSC-19 D(+)-70 WAY-19 CCM(-)-GSC-22 CCM(-)-70 WAY-33 CCM(+)-GSC-21 CCM(+)-70 WAY-32 SP1-70 WAY-60

GND-CHASSIS STUD

CHASSIS STUD
GND-DOOR STUD GND-GSC-GND

HC1-EMSII CONN-3

SV-EMSII CONN-24

45A-DC CONN1-5

17-ESPB-1L3 17-GSC-38 18-GSC-13 18-DC CONN1-8 19-DC CONN1-11

2-TBD1-2DT GND-70 WAY-47 1-DC CONN2-1 1-DC CONN2-2 1-RM-30 1-RM-36 1-F15-T 1-ECS-6 1-F23-T 1-RM-2 2-DC CONN2-11 2-CR-B 2-70 WAY-15 2-DC CONN2-12 2-PL2-1 2-RM-27 2-TBD1-GND1T 2-PL1-1 5-70 WAY-48 5-TDR-16

45-DC CONN1-4 3-70 WAY-3 3-CR-9

10-DC CONN2-8 10-PLS-3

SP1A-GSC-23 SP2-GSC-24 SP2-70 WAY-61 SP2-D2-U2 SP2-D3-U2 SP2-LFSR-4 SP3-GSC-25 SP3-70 WAY-62

4-DC CONN2-6

34-ESPB-1L2 6-RM-22 6-70 WAY-2 10-RM-39 10-70 WAY-45

57-ECS-4 57-GSC-33 57-70 WAY-30

38-RM-16 38-GRR-A

21-GSC-1

22-GSC-2

80-VAR-3

37-RM-19

82-VAR-1

5-ECS-9

2-EMSII CONN-6

46-ESPB-1R1

MPU-SHIELD VAR-SHIELD

ER-EMSII CONN-8

2-EMSII CONN-22

87-GRR-4 87-70 WAY-57 88-GRR-1 88-70 WAY-58 89-GRR-7 89-70 WAY-59 ES-SAS-3

GND6

206

202

108

109

131

203

207

136

137

157

51 52 53

50 50 50 T0

TBD1
CHASSIS STUD

GND-REAR COVER GND-TBA1-GND6B

B
GND-BODY STUD GND-TBD1-GND3T

B B

B B

GND1

CCM+

GND2

HC1

GND3

L L

SP1A-TBD1-SP1AL

SP1A-TBD1-SP1L

30-TBD1-GND2L

46-TBD11-46L

20-LSGOV-20

1-TBD1-1DL

10-EMSII CONN-1

30-TBD1-30DL

82-VR6B-7 OR 82-DVR-7

80-VR6B-6A OR 80-DVR-45

46-TBD1-45L

2-TBD1-2DL

1-TBD1-5AL

2-TBD1-2EL

4-TBD1-4L

4-TBD1-34L

1-EPIR-30

1-TDR-A1

2-EPIR-85

90-ALM-2

21-MPU-1

22-MPU-2

D(-)-EMSII-14

D(+)-EMSII-5

ET(-)-EMT-B

ET(+)-EMT-A

BODY STUD

GND-CHASSIS STUD

D(+)-TBD1-D(+)B

D(-)-TBD1-D(-)B

ES-ECM-38

207-TBA1-207B

157-TBA1-157B

72-LFSR-A 84-F23-B OR 84-PRPB-3 81-PRPB-4

62-TBD1-62AB

20-TBD1-20AB

67-TBD1-67AB

50-TBA1-50CB

50-TBA1-50BB

67-TBD1-67AT

62-TBD1-62AT

50-TBA1-50AB

10-TBD1-10BT

18-TBD1-18B

19-TBD-19B

T0-TBA1-T0T

2-TBD1-2BB

2-TBD1-2AT

T3-F13

T1-F11

12

11

10

12

11

10

12

11

10

10

11

12

13

203-TBA1-203B

30-TBD1-30AT

RDM-GSC-30

90-TBD1-90B

2-TBD1-2BT

6-TBD1-6B

3-TBD1-3T

71-CAM-9

14

DC CONN 1 (BLACK)
1 2 3 4 5 6 1 2

DC CONN 2 (GREY)
3 4 5 6 1 2

AC CONN (GREEN)
3 4 5 6

15

16

17

18

19

20

21

22

23

24

25

26

27

28

101-TBA1-101B

57-TBD1-57BB

63-TBD1-63B

74-CAM-8

ET-EMT-C

70 WAY
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

57 GND-TBA1-GND5B 45A-TBD1-45AT 45-TBD1-45T 1-TBD1-1AT 59-TBD1-59B 41-RM 13 41-RM 13 1-TBD1-1AB 30-TBD1-30AB 51-TBA1-51B 52-TBA1-52B 53-TBA1-53B 4-TBD1-4B T2-F12

58

59

60

61

62

63

64

65

66

67

68

69

70

GND4

SP1A

CCM-

SP2

SP2

SP3

SP4

45A

SV SV SV SV BO ER EL MT FP

HC4

SP1

57 57 59 62 62 63 67 67 90 99 DD+

4 34 6 10 10

17 18 19 20 20 30 30 30 30 37 38

1 1 1 1 2 2 2 2 5 5 46

45 3

80 82

22

87 88 89

ES

21

2 2 2 2

136-TBA1-136B

137-TBA1-137B

202-TBA1-202B

SP1-TBD1-SP1B

SP3-TBD1-SP3B

CCM(+)-TBD1-CCM(+)B

CCM(-)-TBD1-CCM(-)B

206-TBA1-206B

159-TBA1-159B

NOTE D

GND-TBD1-GND1B

GND-TBA1-GND6T

SP2-TBD1-SP2AB

131-TBA1-131B

10-TBD1-10AB

87-TBD1-87B

88-TBD1-88B

89-TBD1-89B

99-TBD1-99B

5-TBD1-5AT

36-F15-B

GND-TBD1-GND4B

46-TBD1-46B

30-TBD1-30BT

5-ECS-9 5-ECS-8 54-TDR-B1

5-TBD1-5BT 5-ECS-10

5-ECS-10

10-TBD1-10AT

1-TBD1-1BB

20-TBD1-20BT

1-TBD1-1BT

17-TBD1-17T

ALM 1-TBD1-1DB 7-TDR-15


-

30-TBD1-30CB

57-TBD1-57AT

CAM

34-TBD1-34B

10-ALM-1

14-RM-18

1-TBD1-1CB

56-GSC-40

55-GSC-39

58-GSC-32

13-CR-6 38-TBD1-38T 14-ESPB-1L1 37-TBD1-37B

15 16 17 18 19 20 21 22 23 24 25 26 27 28
RM

B+ 29 30 31 32 33 34 35 36 37 38 39 B-

NOTE B

6-TBD1-6T 39-CR-A

F10

GND-TBD1-GND4T SP-SHIELD

F1 F2 F3 F4 F5 F6 F7 F8 F9

1 2 3
99-TBD1-99T

30-TBD1-30CT

S-SPD-ECM-10

20-TBD1-20BL

4 5 6 7 8 9 10 11 12 13 14

69-CAM-14 68-CAM-13 60-CAM-12 70-70 WAY-44

14 13 12 11 10 9 8

42-SP-3

44-SP-2

76-D3-L2 75-D2-L2 10-ALM-1

32

22 21

12 11

2 1

90-TBD1-90L 10-CAM-1 10-RM-39

2-TBD1-2EB

31

2-TBD1-2ET 2-TBD1-2FB 10-TBD1-10BL

43-SP-1

DOOR STUD

10-PLS-3

2-TBD1-2CB 30-TBD1-30BB

SP-SHIELD-DOOR STUD

20-TBD1-20AT 41-DC CONN1-1 41-DC CONN1-2

42-PWM-1 OR 42-LSGOV-26 44-PWM-2 OR 44-LSGOV-27

10-PWM-B(+) OR 10-LSGOV-15

30-ALM-7

43-PWM-3 OR 43-LSGOV-28

10-TBD1-10BB

159-TBA1-159T

157-TBA1-157T

110-TBA1-110L

108-TBA1-108L

80-TBD1-80B

82-TBD1-82B

21-TBD1-21B

22-TBD1-22B

94-ATB J1-4

95-ATB J1-5

96-ATB J1-6

9-PL1-2

9-PL2-2

160

B C SLR1

161

162

1 7
67-TBD1-67BB 18-TBD1-18T D(-)-TBD1-D(-)T D(+)-TBD1-D(+)T SP2-TBD1-SP2AT SP1A-TBD1-SP1AB

2 8

3 9

6
91-ATB J1-1 93-ATB J1-3 92-ATB J1-2 97-ATB J1-7 98-ATB J1-8

SLR 2 C D

10 11 12 16 17 18

13 14 15

2 1

163

122-TBA2-122U

124-TBA2-122U

120-TBA2-120U

51-TBA1-51T

52-TBA1-52T

53-TBA1-53T

151-TBC-51

19 20 23 24 25

21 22 26 27 28

SLM CCM(-)-TBD1-CCM(-)T CCM(+)-TBD1-CCM(+)T 203-TBA1-203T 20-TBD1-20BB 202-TBA1-202T

152-TBC-52

153-TBC-53

207-TBA1-207T

206-TBA1-206T

131-PSL-X2

ES-TBD1-ES

SP3-TBD1-SP3T

131-TBA1-131T

84-PSPB-2B 84--70 WAY-4

81-70 WAY-18

131-PRL-X2

84-PRPB-3

211-F23-B

29 30 31
RDM-70 WAY-7 62-TBD1-62BB 90-TBD1-90T 63-TBD1-63T

32 33 34 38 39 40

58-ECS-5 57-TBD1-57AB

35 36 37

PSL 17-TBD1-17B 55-ECS-2 56-ECS-3


X1 X2

PRL
3 NO 4

1600 OHM

1A NC 2A 1B NC 2B

3200 OHM

640 OHM

1760 OHM

PL1 2-TBD1-2DB
1 2

9-PLS-2

.6
A2

1.0

B
~ -

A 8 7

NOTE D

80 82

B B

B B

L2

3456 Generator Set with EMCP II Electrical System


CCB1-UP CAH1-UP CBX1-UP 8AZ1-UP

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B B

B B

B B B

B B

B B

B B

Volume 2: Control Panel & Marshalling Box


2001 Caterpillar All Rights Reserved

Printed in U.S.A.

COMPONENTS INSIDE CONTROL PANEL

CONTROL PANEL DOOR

CAT MONITORING SYSTEM

Failure Mode Identifiers (FMI)


FMI No. Failure Description
Data valid but above normal operational range. Data valid but below normal operational range. Data erratic, intermittent, or incorrect. Voltage above normal or shorted high. Voltage below normal or shorted low. Current below normal or open circuit. Current above normal or grounded circuit. Mechanical system not responding properly. Abnormal frequency, pulse width, or period. Abnormal update. Abnormal rate of change. Failure mode not identifiable. Bad device or component. Out of calibration. 0 1
ER-TBD1-ERT

40 39 38 37 36

30 29 28 27 26

20 19 18 17 16

10 9 8 7 6

2 3 4

10

8 6

2-TBD1-2HT HC4-TBD1-HC4T

1L1 1L3 1R1

NC NO NC

1L2 1L4 1R2

CONTROL PANEL REAR SUB PANEL

5 6 7 8 9 10 11 12 13

35

25 24 23

15 14 13

5 4 3

D(+)-TBD1-D(+)L

ESPB

7 6 5 4 3 2 1

30-CAM-7 30-RM-B-

69-ALM-14 68-ALM-13 60-ALM-12 70-70 WAY-44 73-GNDFR-14 71-70 WAY-1 74-70 WAY-21

14 13 12 11 10 9 8

7 6 5 4 3 2 1

SV-TBD1-SVAT
34

30-ALM-7 86-LFSR-6 ECS

SRV-SCS-3 CLR-MCS-6 2-TBD1-2GT

33

D(-)-TBD1-D(-)L HC1-TBD1-HC1T

CLR-MCS-4 CLR-CAT MONITORING SYSTEM CONN-33 2-MCS-2 CLR-MCS-6

MCS
6 5 4 3 2 1

The FMI is a diagnostic code that indicates what type of failure has occurred.
SRV-SCS-3 2-MCS-5 2-SCS-2

NOTE A

SCS
3 2 1

SRV-MCS-3 SRV-CAT MONITORING SYSTEM CONN-23 2-MCS-2 2-TBD1-2FT

15 16 17 18 19 20 21 22 23 24 25 26 27 28

WOODWAR D
PART NO. REV.

WOODWAR D
R

SERIAL NO.

LOAD SHARING MODULE

SP 6 3 5 SS 2 4 1

PLS
2

VAR

LOAD SHARING MODULE


DROOP

LOAD GAIN

NOTE A: ALL WIRE IS STRANDED 16 AWG UL & CSA, 90C, 600 VAC INSULATION WIRE UNLESS OTHERWISE INDICATED.
10 = 10 AWG = COMPONENT LOCATED ON ENGINE OR BASE
1 2 3 4 5 6 7 8 9

10

10

WARNING

SL2
2 1

10 11 12 13

14

= COMPONENT LOCATED IN MARSHALLING BOX

Component Identifiers (CID'S) For (EMCP II )


CID
100 110

NOTE B: WIRE JUMPER FROM TERMINAL 6 TO 7 IS PROVIDED ONLY FOR OPTIONAL NFPA 110 ALARM MODULE. NOTE C: WIRES 108 AND 110 CONNECT TO THE SYNCHRONIZING LIGHT RESISTORS (SLR1 & SLR2) OF THE SYNCHRONIZING MODULE REFER TO SLR CHART BELOW FOR PROPER CONNECTIONS. NOTE D: WIRES 51, 52, AND 53 ARE CONNECTED TO TERMINAL STRIP "TBC" UNLESS OPTIONAL LOADSHARE GOVERNOR IS PROVIDED. NOTE E: SET TOP DIAL ON TIMER TO "E", SET MIDDLE DIAL TO "3s", AND SET BOTTOM DIAL TO "0.7".

DESCRIPTION
Pressure Sensor (Engine Oil) Temperature Sensor (Engine Coolant) Fluid Level Sensor (Engine Coolant) Electrical System Voltage Speed Sensor (Engine) CAT Data Link EMCP Electronic Control (Generator Set) Sensor Power Supply Alarm Module Control Spare Output Switch (Engine Control) Electronic Governor Relay Generator Fault Relay Crank Termination Relay Starting Motor Relay Run Relay Air Shutoff Relay Fuel Control Relay Relay Driver Module EMCP Electronic Control (Generator Set) Unexpected Shutdown Engine Electronic Control Module

SL1

GND

111 168 190 248 268 269


REAR COVER

SLR CHART
VOLT LINE TO LINE 208 A B 240 300 380 C 400 416 480 E SYNCHRONIZING RESISTOR TAP SETTING CHART USE E-D 1760 OHM USE E-C 2400 OHM USE E-B 5600 OHM USE E-B 5600 OHM USE E-B 5600 OHM USE E-A 7200 OHM USE E-A 7200 OHM

333
GND-TOP COVER GND-CHASSIS STUD

334 336 441 442 443 444 445 446 447 475 500 566

SAS

2 3

X1

X2

CONTROL PANEL REAR SUB PANEL

PSPB

PRPB

PL2 2-TBD1-2CT
1 2

590
9-PLS-2

The CID is a diagnostic code that indicates which component is faulty.

CONTROL PANEL DOOR

DC CHASSIS STUD

GND-TBD2-GNDT GND-DC CONN-21

TBD2

5
T B

5-KWR-B 5-DC CONN-22

70
T B

GND
U
2-BTR-E 2-ATR1-E 2-MV-1

U B

83-LFLS-2

83
T B T B

85-MV-2

85
T B U T B

30-TBD2-30BB 30-BTR-5

70-DC CONN-36 70-LFLS-5 GND-DC CHASSIS STUD GDN-PANEL GND 83-PR-A 2-TBC-2T 2-PR-B 85-PR-5 2-DVR-(B-) 77-TBD2-SP3T

77-FRBS-1

77
T B B T U
3-BTR-D 3-ATR1-D

1 2 3 4

71-TBD2-71T 3-TBD2-3U 2-TBD2-2AU 30-BTR-1

adjust set point read


T B

@ 76-D3-L2

T B U

A B C D E F G H I J

30-TBD2-30BB 30-ATR1-5 74-TBD2-74T 74-ATR2-3


1 2 3 4

30-ATR1-1

3-TBD2-3U 3-ATR2-D

2-DC CONN-35 2-ALR-B 2-BC-(-) 3-DC C0NN-3 3-TBC-3T 6-DC CONN-2 6-TBC-6T 10-DC CONN-12 10-TBC-10T 10-LFLS-8

T B U

adjust set point read


2-TBD2-2AU 2-ATR2-E

T B U
30-LFLS-6 30-FRBS-2

30-ATR2-1 @ 75-D2-L2 75-ATR2-7

T B U

A B C D E F G H I J

K L M N O P Q R S

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

163-BT1-RD 164-BT1-WH

T T B

10-DVR-B(+) 30B-DC CONN-15 30-TBC-30T 30-GNDFR-11 30-ATR1-1 30-BTR-1 36-BC-(+) 36-DC CONN-11 71-BTR-3 71-DC CONN-16

K L M N O P Q R S

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

BTR
T B
72-DC CONN-17

U
72-LFLS-7

171-TC4-WH 172-TC4-RD

T
81-LFLS-1 81-LFLS-4 84-LFLS-3

74-ATR1-3 74-DC CONN-37 81-PR-4 81-DC CONN-9

ATR1
U T T U B B
84-PR-7 84-DC CONN-10 5-TBD2-5T

2 2 2 3 6 10 10 30 30 36 71 72 74 81 81 84

DC CHASSIS
30-ATR2-5 30-ATR3-5
1 2 3 4 1 2 3 4

74-ATR2-3 3-ATR2-D 2-ATR2-E 2-ATR1-E 2-ATR3-E

30-ATR1-5 30-ATR2-5 74-ATR1-3 74-ATR3-3 3-ATR1-D 3-ATR3-D

adjust set point read

adjust set point read

30-ATR3-1

9 3 6

75-ATR2-7

30-ATR2-1 30-ATR3-1 75-ATR1-7 75-ATR3-7

A B C D E F G H I J

A B C D E F G H I J

KWR
49-TBC-49T

A 1 4

7
47-TBC-47T

48-TBC-48T

K L M N O P Q R S

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

K L M N O P Q R S

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

191-TC6-WH 192-TC6-RD

181-TC5-WH 182-TC5-RD

61-TBC-61B

ATR2
2-TBD2-2CT

22
22-GEN A ATA(-)-TBC-ATA(-)B D(+)-TBC-D(+)B D H
D2

ATR3

3 2

6 5

ALR

5A-DVR-5

D(-)-TBC-D(-)B

22-VR6B-22

66-TBC-66T

64-TBC-64T

22 24
C 24-GEN J B ATA(+)-TBC-ATA(+)B 10-TBC-10B 6-TBC-6B

NOTE C

RFI FILTER

24-VR6B-24

65-TBC-65T

24 20
20-GEN
D1

20

SERVICE CONNECTOR

20-VR6B-20

2-TBD2-2AB

DROOP RESISTOR

2-TBC-2AB 206-TBA2-206T 84-PR-7 6A-DVR-6

B 9 8

205-OL-95

3 2

6 5

PR

85-TBD2-85B

275-DVR-45
3 2 1

A 7

PF/KVAR 276-DVR-44

6A-DROOP-D1 5A-DROOP-D2

84-TBD2-84T 84-PR-8

124-F52-B 122-F51-B 120-F50-B

81-TBD2-81T

MARSHALLING BOX DC CHASSIS


83-TBD2-83T
3

SP1-DC CONN-4

SP1
T B

GND-AC CHASSIS STUD

131-TBA2-131AB

101-TBA2-101B

206-TBA2-206B

J1

40 41 42 43 5

B+ B- 20 22 24 26 28 30 F1 F2

10-TBD2-10U 2-TBD2-2BT 20-GEN 22-GEN 24-GEN 26-GEN PM 28-GEN PM 30-GEN PM F1-GEN FIELD LEAD F2-GEN FIELD LEAD NOTE E

SP2
T B
SP2-DC CONN-14 77-TBD2-77T SP3-DC CONN-24

DVR

SP3
T B
40
SP4-DC CONN-34

31

32

33

34

35

36

37

38

39

46 47 48 49 50 44 45

SP4
29 30

AC CONN (40 WAY)

21 11 2 3 4 5 6 1 12 13 14 15 16 17 7

22

23

24

25

26

27

28 18 8

19 9

20 10

82-TBD1-82L @ 276-PF/KVAR-1 80-TBD1-80L @ 275-PF/KVAR-3 157-TBA2-157B 202-TBA2-202B 203-TBA2-203B 207-TBA2-207B 159-TBA2-159B

136-TBA2-136B

PANEL GND

124-F52-B 122-F51-B 120-F50-B

GND-TBC-GNDT GND-TBA2-GND1B GND-TBD2-GNDB

137-TBA2-137B

DEVICE ABBREVIATION

NOTE G

10 14

WIRING EXAMPLE

WIRE NO.

= 8 AWG

= 10 AWG

= 14 AWG

SP4-TBD2-SP4B

SP3-TBD2-SP3B

2-TBD2-2BB

99-TBC-99T

70-TBD2-70B

74-TBD2-74B

87-TBC-87T

88-TBC-88T

89-TBC-89T

57-TBC-57T

VR6-B

5-TBD2-5B

DEVICE TERMINAL NUMBER

NOTE E

NOTE C 20-GEN-20 OR 20-RFI-20 22-GEN-22 OR 22-RFI-22 24-GEN-24 OR 24-RFI-24 26-GEN PM 28-GEN PM 30-GEN PM F1-GEN FIELD LEAD F2-GEN FIELD LEAD 5A-DROOP CT 6A-DROOP CT 80-TBD1-80L @ 82-TBD1-82L @

2 - TBD1 - 2 F T

= COMPONENT LOCATED ON ENGINE OR BASE

NOTE E: WIRES 26, 28, AND 30 WILL NOT BE CONNECTED WITH A STANDARD SE GENERATOR.

NOTE D: WIRES 5A AND 6A AR TO BE SOLDERED TO RESISTOR.

= COMPONENT LOCATED IN THE CONTROL PANEL

NOTE A: ALL WIRE IS STRANDED 16 AWG UL & CSA, 90C, 600 VAC INSULATION WIRE UNLESS OTHERWISE INDICATED.

NOTE B: CONNECT WIRES 2, 3, AND 30 FROM ATR2 TO ATR3 IF BTR IS NOT PROVIDED. IF BTR IS PROVIDED, CONNECT WIRES 2, 3, AND 30 FROM ATR2 TO BTR AS INDICATED.

NOTE F: UL LISTED BATTERY CHARGER WILL BE ENGINE MOUNTED. NOTE G: REMOVE JUMPERS FOR OPTIONAL PM GENERATOR.

31 21 11 1

32 22 12 2

33 23 13 3

34 24 14 4

35 25 15 5

36 26 16 6

37 27 17 7

38 28 18 8

39 29 19 9

40 30 20 10

DC CONN (40 WAY)

(IF REQUIRED) SPECIFIC TERMINAL BLOCK FOR WIRE NO. I.E.: 'A' IS THE FIRST BLOCK, 'B' IS THE SECOND BLOCK,...,'F' IS THE SIXTH BLOCK

NOTE C: WIRES 20, 22, AND 24 ARE CONNECTED FROM THE GENERATOR UNLESS AND RFI FILTER IS PROVIDED.

(IF REQUIRED) TERMINAL CONNECTION POINT T=TOP B=BOTTOM U=UPPER

120-GNDFR-A2 132-F17-T 132-TBA2-132AT 136-TBA2-136T

36-TBD2-36B GND-DC CHASSIS STUD

D(-)-TBC-D(-)T

D(+)-TBC-D(+)T

SP1-TBD2-SP1B

SP2-TBD2-SP2B

RDM-TBC-RDMT

CCM(-)-TBC-CCM(-)T CCM(+)-TBC-CCM(+)T

6-TBD2-6T

61-TBC-61T 3-TBD2-3T

90-TBC-90T

63-TBC-63T

10-TBD2-10T

71-TBD2-71B

72-TBD2-72B

81-TBD2-81B

84-TBD2-84B

30-TBD2-30AT

AC CHASSIS STUD

GND-TBA2-GND1T GND-AC CONN-21

TBA2
T B

GND-AC CHASSIS STUD GND-PANEL GND 101-AC CONN-38

GND1
T T B B

101

F16

108

B 9

109

F17

135-HC-1

132-F16-T

110

AR

5
133
OFF

multi 9

C60N

MERLIN GERIN

10 138-HC-5

132-TBA2-132BB 10

MCB1

2
208-PC-1 207-PC-61 207-TBA2-207T 157-TBA2-157T 159-TBA2-159T 2

A 7
118-GNDFR-A1 132-TBA2-132AB 132-F22-T 132-F21-T 122-TBA2-122B 122-AR-4

122-AR-A

10 133-TBC-133B
T B

133 136-F16-B 136-AC CONN-17 136


T B

120V AC OPTIONS

F21 F22 F32 F33


1

137
T B

157 154-TBC-154T A1 M+ 118-AR-7 A2 M156-TBC-156T EF1-TBA2-EF1B EF2-TBA2-EF2B


T T T B B B

159 202 120-TBA2-120B 120-AR-B (K) (L) T/R 21 22 24 203


T T T B B B

206 207 T/R 132 11

137-HC-A1 137-AC CONN-19 157-F32-B 157-AC CONN-11 159-F33-B 159-AC CONN-15 202-PC-54 202-AC CONN-1 203-PC-62 203-AC CONN-3 206-PR-9 206-AC CONN-24 207-F22-B 207-AC CONN-5 132-F16-T 132-F21-T

GNDFR

8
30-TBD2-30BT 12 14 73-CAM-10 135-F17-B 140-TBA2-140B 4 6 3 5 138-MCB1-2 10 137-TBA2-137T A1 @

132-TBC-132B 10 132-MCB1-1 131-PC-3 131-AC CONN-33

132

131

131-BC-N 131-TBA2-142B

8 131-TBC-131T 131-HC-A2

131

131-JWH-IL2 OR 131-BLH 139

10

10 148-TBA2-148B
8 7

10 148-HC-6
GND 2 B B U 2 3 6 B B B U 6 10 30 57 61 63 87 88 89 90 99 B B B B B B B B B B B T T T T T T T T T T T T T T T T GND-PANEL GND A2

MARSHALLING BOX AC CHASSIS

148

148-JWH-IL1 OR 148-BLH

10

HC

131-TBA2-131BB

GND-TBC-GNDB
T B

GND GND 207-PC-61 202-TBA2-202T 98 208-F21-B 204-OL-96 2 A1 1 3 209-TBA2-209B


U T B

GND-JWH-GND OR GND-BLH

10

2-SHUNT TRIP3-C1

GND-BC-GND 140-BC-L 140-HC-2 131-TBA2-131AT 209-OL-2 54 53 97 131-TBA2-131AT 131-PC-A2 210-OL-4 4 5

140
T T B B

140-SPH-H1
U U

140-SPH-H3 142 209


T B

6-SHUNT TRIP3-C2

131-SPH-H2 131-SPH-H4 209-PUMP-T1/T3


U

14
210 210-PUMP-T2/T4

14
62 61

PC

OL
95

2-TBD2-2AT 2-SERVICE CONN-B 2-SHUNT TRIP1-C1 2-SHUNT TRIP2-C1 3-TBD2-3B 3-GNDFR-A1 6-TBD2-6B 6-ALR-A 6-SHUNT TRIP1-C2 6-SHUNT TRIP2-C2 10-TBD2-10B 10-SERVICE CONN-A 30-TBD2-30AB 57-DC CONN-30

210-TBA2-210B 205-PR-6

EF1-GNDFR-K A2 13 6 204-PC-A1 203-TBA2-203T 87-DC CONN-31 88-DC CONN-32 89-DC CONN-33 207-F22-B 207-PC-53 14 96 131-PC-3 61-DC CONN-13 61-KWR-A 63-DC CONN-6 EF2-GNDFR-L

EF1
T T T B B B

EF2
U

120 122
T B

120-LSGOV-3 @
U

120-F50-T 120-GNDFR-A2 122-F51-T 122-AR-A 124-F52-T

122-LSGOV-1 @
U

124

124-LSGOV-2 @

90-DC CONN-5 99-DC CONN-38

GND2

GND-PUMP-GND

14

F50

120-VR6B-20 OR 120-DVR-20 D(+)-ADEM-7 D(-)-ADEM-6 U U D+ DCCM+ CCMATA+ ATA-

120-TBA2-120T B B B B B B RDM 47 48 49
231A 232A 233A 231B 232B 233B 231C 232C 233C

T T T T T T B B B B B B B B B B B B B 64 65 66 B B B T T T T T T T T T T T T T T T T

D(+)-DC CONN-19 D(+)-SERVICE CONN-D D(-)-DC CONN-20 D(-)-SERVICE CONN-E CCM(+)-DC CONN-8 CCM(-)-DC CONN-18

F51

AC TERMS

122-VR6B-22 OR 122-DVR-22

122-TBA2-122T

F52

ATA(+)-ADEM-31 ATA(+)-SERVICE CONN-J ATA(-)-ADEM-32 ATA(-)-SERVICE CONN-H RDM-DC CONN-7 47-KWR-1 48-KWR-7 49-KWR-4 CB1-AUX-12 CB1-AUX-11 CB1-AUX-14 CB2-AUX-12 CB2-AUX-11 CB2-AUX-14 CB3-AUX-12 CB3-AUX-11 CB3-AUX-14 64-ALR-4 65-ALR-1 66-ALR-7
GND-TBA2-GND1T GND-AC CONN-21

124-VR6B-24 OR 124-DVR-24

124-TBA2-124T

TBA2
T B

AC CHASSIS STUD

F16

136-TBA2-136T

132-F17-T 132-TBA2-132AT 120-GNDFR-A2 135-HC-1 132-F16-T

GND-AC CHASSIS STUD GND-PANEL GND 101-AC CONN-38

GND1
T T B B

101 108

B 9

F17 F18

MARSHALLING BOX CUSTOMER TERMINAL BLOCK


DC TERMS

141-HC-A2 141-HC-3

133-TBA2-133AT

109
T B

110

AR

F19

138-HC-5

132-TBA2-132BB

132

132-TBA2-132BT

8
138-HC-7

133

133-TBA2-131BT

F20

133-TBA2-133BB

118-GNDFR-A1

122-AR-A

10 133-TBC-133B
131 131-TBA2-131BT

(This Terminal Block is common for both 120V AC and 240V AC Options.)

133

133-MCB1-3 14

8
multi 9

MERLIN GERIN

14 138-HC-5

132-TBA2-132BB

14

136-F16-B 136-AC CONN-17


C60N OFF

136
T B

133

133-TBA2-133BT

10

122-TBA2-122B 122-AR-4

137

2
OFF

14 134-HC-7

133-TBA2-133BU 14

157

MCB1

GND

GND-TBA2-GNDAT

159 A1 M+ 208-PC-1 118-AR-7 132-TBA2-132AB 132-F22-T A2 MT B

240V AC OPTIONS

202

GND 154-F32-T 154 156 B B T T 156-F33-T

120-TBA2-120B 120-AR-B 207-PC-61 207-TBA2-207T 132-F21-T EF1-TBA2-EF1B EF2-TBA2-EF2B 212-PC-3 133-TBA2-133AB (K) (L)

F21 F22 F24

203
T T T B B B

206 207 T/R T/R 132

F32

MARSHALLING BOX AC CHASSIS


14 14

157-TBA2-157T

154-TBC-154T

137-HC-A1 137-AC CONN-19 157-F32-B 157-AC CONN-11 159-F33-B 159-AC CONN-15 202-PC-54 202-AC CONN-1 203-PC-62 203-AC CONN-3 206-PR-9 206-AC CONN-24 207-F22-B 207-AC CONN-5 132-F16-T 132-F21-T

GNDFR

21 22

11 30-TBD2-30BT 12

F33

159-TBA2-159T

156-TBC-156T

8 132-TBC-132B 14 132-MCB1-1
24 14 73-CAM-10 @ 135-F17-B 2 1 137-TBA2-137T 140-TBA2-140B 4 3 141-F18-B 142-TBA2-142B 5 6 148-TBA2-148B 7 138-MCB1-2 14 OR 138-F19-B A1 131-PC-A2 131-AC CONN-33

132

131

8 131-TBC-131T

131

133-TBA2-133AU

14 148-HC-8

139

139-JWH-IL2 OR 139-BLH

14

14 148-HC-6
8 A2

148

148-JWH-IL1 OR 148-BLH

14

HC

TBC

139-TBA2-139B

141-F18-B 134-MCB1-4 14 OR 134-F20-B 202-TBA2-202T 98 2

GND-TBC-GNDB
T B

GND GND 207-PC-61 208-F21-B 204-OL-96 A1 1 3 209-TBA2-209B


U T T B U

GND-JWH-GND OR GND-BLH

14

140-BC-L 140-HC-2

140
T B B

140-SPH-H1
U

142 209-OL-2 54 53 212-F24-B 97


T B

142-SPH-H4 209 210-OL-4 210 4 95 5 209-PUMP-T1


U

14
210-PUMP-T4

14

PC
62

61

OL

210-TBA2-210B 205-PR-6 NOTE F

EF1-GNDFR-K A2 13 6 204-PC-A1 203-TBA2-203T 207-F22-B 207-PC-53 96 14 131-TBA2-131AT EF2-GNDFR-L

EF1
T T T B B B

EF2
U

120 122
T B

120-LSGOV-3 @
U

120-F50-T 120-GNDFR-A2 122-F51-T 122-AR-A 2-TBD2-2CB 36-TBD2-36T 124-F52-T

122-LSGOV-1 @
U

142-TBA2-142T N

140-TBA2-140T L

124

124-LSGOV-2 @

+ -

F50

120-VR6B-20 OR 120-DVR-20

F51

122-VR6B-22 OR 122-DVR-22

F52

124-VR6B-24 OR 124-DVR-24

GND2

GND-PUMP-GND

14

120-TBA2-120T

122-TBA2-122T

124-TBA2-124T

BC

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