CAT SWITCHGEAR TIME REQUIREMENT GUIDE (TRG) This warranty repair time requirement guide is designed to: Provide detailed guidance on troubleshooting Determine possible solutions Guide the technician to seek assistance, based on the individuals level of qualification Establish the amount of time that will be reimbursed under warranty PLEASE BE SURE TO SEEK ASSISTANCE APPROPIATE FOR YOUR LEVEL OF QUALIFICATION means that the technician not only attends classroom training, but also performs on an actual job startup, to demonstrate his epertise. W/ Assist means that the time will be reimbursed provided the technician calls for assistance. If the technician does not seek assistance, the troubleshooting and solution may require more time, and may not be reimbursed. Self means that the technician can perform the troubleshooting and repair independently and will be reimbursed for the specified time. If the troubleshooting and repair is epected to take more time than noted, please contact the Product Support Center for guidance and authorization. To qualify for allowable hours, the technician must also have the required PLC download () or access to () tools and associated hardware. The Cat switchgear Product Support Center can be reached at: U.S. Toll Free: 866-883-3879 U.S. Direct: 678-746-5000 EMAIL: HELPDESK@CAT-ISO.COM If the Cat switchgear has a Caterpillar serial number beginning with the prefi SWG, the Dealer Solution Network (DSN) can also be contacted for assistance with product issues. Please refer to most current Warranty Bulletin (Cat Switchgear) for additional information.
Table of Contents Component Codes... 3 Segmented Repair Times... 4 Generator Breaker Fails to Close... 5 Generator Breaker Fails to Open... 6 Utility Breaker Fails to Close... 7 Utility Breaker Fails to Open... 9 Tie Breaker Fails to Open... 10 Distribution Breaker Fails to Close... 11 Distribution Breaker Fails to Open... 12 NOTE: For touchscreen and communication issues in the U.S. call (866) 883-3879 or for Int l (678) 746-5000 or by email to HELPDESK@CAT-ISO.COM
SWITCHGEAR INFORMATION DESCRIPTION MEANING Switchgear High level general troubleshooting switchgear code. Use when a more appropriate code does not eist. Software 449S Processor Concept programming software 449L PL 1000 & PL 2000 HMI Proface programming software 449H PL 3000 HMI RSView programming software 449R Remote RSView remote software 449B MB+ Communications Modbus+ intra-switchgear communications 449G Generator Communications Communications between switchgear and generator Hardware 449T Touchscreen Display for user control, interface and monitoring 449P Touchscreen Processor Contains user project and graphics for user control, interface and monitoring 449C Programmable Logic Controller Circuit Breaker 4494 Protective Relay 1417 Fuse 4493 Control Relay 4495 25 Relay Sync. check relay 4459 Wiring 4475 Control Power Transformer (CPT) 449M Metering Monitors switchgear and generator 1904 Transducer 4476 Current Transformer (CT) 4475 Potential Transformer / Voltage Transformer Page 3 of 12
CAT SWITCHGEAR SEGMENTED REPAIR TIMES HOURS ALLOWED PER EXPERTISE LEVEL JOB L1* L1 L2* L2 NONE TRAINED QUALIFIED TRAINED QUALIFIED TROUBLESHOOTING Software 035 X X X 1.0 4.0 MB+ Communications 449B 035 X X X 1.0 1.0 Generator Communications 449G 035 X X 0.3 0.3 1.0 Hardware 035 X 1.0 2.0 1.0 4.0 Circuit Breaker 035 X X 0.5 0.5 1.0 Metering 449M 035 X X X X 1.5 REPAIRS Job Set Up 587 0.3 0.3 0.3 0.3 0.3 Download Processor 449S 591 X X X 1.0 1.0 Download PL 1000 & PL 2000 HMI 449L 591 X X X 0.5 0.5 Download PL 3000 HMI 449H 591 X X X 1.0 1.0 Download Remote 449R 591 X X X 1.0 1.0 Replace Touchscreen 449T 010 X 0.5 0.5 0.5 0.5 Replace Touchscreen Processor 449P 010 X X 2.0 2.0 2.0 Replace PLC** 449C 010 X X 1.0 1.0 1.0 Replace Transducer 1904 010 X X X X 0.5 Replace 25 Relay 4495 010 X X 0.6 0.6 0.6 Reports 030 0.5 0.5 0.5 0.5 0.5 Site Clean Up 071 0.3 0.3 0.3 0.3 0.3 * To qualify for allowable hours, technician must also have the required PLC download () or access () tools and associated hardware. ** If there are multiple PLC's, Multiply "Hours Allowed" times the number of PLC's Page 4 of 12
SYMPTOM - Generator Breaker Will Not Close Automatically A. Generator not running Start gen, at touchscreen to verify PLC output. Be certain it's not being held out on a previous shutdown that has not been cleared. B. Generator running but not 1. Generator mounted CB is open Shut CB producing voltage as indicated 2. Metering problem on touchscreen a. Sensing fuses blown (primary) Investigate reason for blowing fuses, repair and replace fuses 449M b. Sensing fuses blown (secondary) Investigate reason for blowing fuses, repair and replace fuses 449M c. Faulty PLC block Troubleshoot PLC block and replace if necessary 1904 3. Generator problem Troubleshoot voltage regulator and speed regulator. Verify wiring File on Genset to generator Claim C. Generator running and producing voltage, but breaker will not close 1. Synchronizing selector switch on touchscreen not in auto Place sync. switch in auto 2. System not in auto Place system switch in auto 3. Generator removed by gen demand No problem 4. Gen breaker tripped / locked out by 86 Investigate reason for breaker trip and repair. Reset breaker, reset 86. 5. Gen not syncing to bus a. Check bias to speed / voltage regulator Follow 5.a. 449G b. Gen in sync window? (+/-6 degrees) YES Proceed to net step NO Tune gen to get it near 12 O'clock. If breaker still won't close, proceed to net step. 449G 6. Bad sync check relay a. Check wiring on terminals 1&2, 3&4 1) Wiring OK? YES Proceed to 6.b. 449M NO Correct wiring 449M b. Check relay portion of device 1) Relay on red light is illuminated when YES Check relay with meter. When off, should have 24 VDC on synchroscope is near 12 O'clock? (IF terminal 5, 0 VDC on terminal 6. When on, should have 24 VDC lighting someplace else, then phasing is on both terminals 5 & 6. If you don't get these readings replace the 4495 probably incorrect) Verify Phasing 25 device. NO Replace 25 device. 4495 7. PLC sending close signal, but breaker is not closing (indicated by LED's on PLC base) a. Output row plugged in? YES Proceed to 7.b. NO Plug in output row. (Note: equipment may operate when this step is performed) b. CBCL (circuit breaker close) relay pickup? YES Note: for LV systems, control power comes from a control power transformer which requires the bus to be energized. Voltage on the primary and secondary should be checked. Be sure to check PT ratios if you are unsure of your readings. Check control power (120VAC, 48VDC, or 125VDC) available. Check fuses and wiring up to closing coil on breaker. If control power is reaching coil, but breaker will still not close, breaker problem. Call Product Support Center for guidance and to report the issue. 8. Metering problem (see B.2. above) 9. Gen PLC problem NO Verify 24VDC at terminal 13. If 24VDC is present here, replace closing coil. (NOTE: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately) a. PLC run light lit? YES Proceed to 9.b. NO PLC has lost its program. Re-download program, or replace with a 449S / 449B pre-programmed PLC from Product Support Center. b. MB+ light flashing fast and steady? YES No problem with PLC. Troubleshoot other causes. NO PLC has a communication problem. Verify address of PLC and 449B network integrity. Page 5 of 12
SYMPTOM - Generator Breaker Will Not Open A. Breaker already open No problem. B. System mode will not allow opening No problem. C. Sync control switch not in auto Place switch in auto D. Disconnect KW not reached No problem. E. PLC problem 1. PLC run light illuminated? YES Proceed to E.2. NO PLC has lost its programming. Re-download program, or replace with a pre-programmed 449S / 449B PLC from Product Support 2. MB+ light flashing fast & steady? NO YES PLC has a communication problem. Verify No problem with PLC. Troubleshoot other address of PLC and network integrity causes 449B F. PLC sending open signal, but breaker is not opening (indicated by LEDs on PLC base) 1. Output row plugged in? YES Proceed to F.2. NO 2. CBOP (circuit breaker open) relay pickup? YES Plug in output row. (Note: equipment may Check control power (120VAC, 48VDC or operate when this step is performing) 125VDC) available Note: For low voltage systems, control power Check fuses and wiring up to closing coil on comes from a control power transformer which breaker. If control power is reaching coil, but requires the bus to be energized. Voltage on the breaker will still not close, breaker problem. primary and secondary should be checked. Be Call Product Support Center for guidance sure to check PT ratios if you are not sure of and to report the issue. your readings. NO Verify 24VDC at terminal 13. If VDC is present here, replace closing coil. (Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately) Page 6 of 12
SYMPTOM - Utility Breaker Will Not Close Automatically A. Utility not energized Energize utility B. Mode will not allow breaker closure 1. Mode eit timer timing out? YES Press "Immediate Transfer" to bypass timer. NO Proceed to net step 2. System in E-Mode? (as indicated on YES No problem. System will restore from E-Mode automatically. NO Proceed to net step 3. Utility Re-close Switch in LOCKOUT? YES Coordinate with end user, determine why switch was placed in LOCKOUT, then, if safe, place switch in the AUTO position. NO Proceed to net step C. Multifunction relay see fault on utility, resulting in a breaker trip D. Breaker function interlocked with another breaker E. Utility synchronizer selector switch not in auto F. Metering problem 1. Sensing fuses blown (primary) 2. Sensing fuses blown (secondary) Clear fault on utility, reset 86 and close breaker. 4494 Ensure all breakers in lineup are installed and the At Utility control screen, place SYNC SEL correct position to meet any interlocks. SWITCH in AUTO, or use INSTANT AUTO. 4490 Investigate reason for blowing fuses, repair and replace fuses. Investigate reason for blowing fuses, repair and replace fuses. 3. Faulty PL block Troubleshoot block and replace if necessary 1904 449M 449M G. Bad sync check relay 1. Check wiring on terminals 1 & 2, 3 & 4 a. Wiring OK? YES Proceed to G.1. 449M NO Correct wiring 449M 2. Check relay portion of device a. Relay on red light illuminates when Synchroscope near 12 O'clock (if illuminated someplace else, then phasing is probable incorrect) Verify phasing YES Check relay with meter. When off, should have 24VDC on terminal 5, 0VDC on terminal 6. When on, should have 24VDC on both terminals 5 & 6. If you don't have this, replace 25 device. NO Replace 25 device 4495 4495 Page 7 of 12
H. PLC problem 1. PLC run light illuminated? YES Proceed to H.2. NO PLC has lost its program. Re-download program or replace with a pre-programmed PLC from the 449S / 449B Product Support Center. 2. MB+ light flashing fast and steady? YES No problem with PLC, troubleshoot other causes NO PLC has a communication problem. Verify address of PLC and network integrity. 449B I. PLC sending close signal, but breaker is not closing (indicated by LEDs on PLC base) 1. Output row plugged in? YES Proceed to I.2. NO Plug in output row. (Note: equipment may operate when this step is performed) 2. CBCL (circuit breaker close) relay pickup? Note: For low voltage systems, control power comes from a control power transformer which requires the bus to be energized. Voltage on the primary and secondary should be checked. Be sure to check PT ratios if you are unsure of your readings. YES Check control power (120VAC, 48VDC, 125VDC) available Check fuses and wiring up to closing coil on breaker. If control power is reaching coil, but breaker will still not close, there is a problem with the breaker. Call the Product Support Center for guidance and to report the issue. NO Verify 24VDC at terminal 13. If VDC is present here, replace closing coil. (Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately) Page 8 of 12
SYMPTOM - Utility Breaker Will Not Open A. Breaker already open No Problem B. System mode will not allow opening No Problem C. Sync control switch not in auto Place switch in auto D. Disconnect KW not reached No Problem E. PLC problem 1. PLC run light illuminated? YES Proceed to E.2. NO PLC has lost its program. Re-download program or replace it with a pre-programmed PLC front the Product Support Center 449S / 449B 2. MB+ light is flashing fast and steady YES No problem with PLC. Troubleshoot other causes. F. PLC is sending open signal, but breaker not opening (indicated by LEDs on PLC base) 1. Output row plugged in? YES Proceed to F.2. NO 2. CBOP (circuit breaker open) relay YES Plug in output row. (Note: equipment may Check control power (120VAC, 48VDC or operate when this step is performed) 125VDC) available Note: For low voltage systems, control power comes from a control power transformer which requires the bus to be energized. Voltage on the primary and secondary should be checked. Be sure to check PT ratios if you are unsure of your readings. NO Check fuses and wiring up to closing coil on breaker. If control power is reaching coil, but breaker will still not close, breaker has a problem. Call the Product Support Center for guidance and to report the issue. Verify 24VDC at terminal 13. If 24VDC is present here, replace closing coil. (Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately.) G. Utility breaker electrically interlocked with another breaker Meet interlock conditions according to drawings and sequence of operation. If interlock conditions are met, verify wiring between the breakers for interlock circuit. Page 9 of 12
SYMPTOM - Tie Breaker Will Not Open A. Breaker already open No Problem B. System mode will not allow opening No Problem C. Sync control switch not in auto Place switch in auto D. Disconnect KW not reached No Problem E. PLC problem 1. PLC run light illuminated? YES Proceed to E.2. NO PLC has lost its program. Redownload program, or replace it with a pre-programmed PLC from 449S / 449B the Product Support Center. 2. MB+ light is flashing fast and steady? YES No problem with PLC. Troubleshoot other causes. NO PLC has a communication problem. Verify address of PLC 449B and network integrity. F. PLC is sending open signal, but breaker is not opening (indicated by LEDs on PLC base) 1. Output row plugged in? Yes Proceed to F.2. NO Plug in output row. (Note: equipment may operate when this step is performed.) 2. CBOP (circuit breaker open) relay pickup? YES Check control power (120VAC, 48VDC or 125VDC) available. Note: For low voltage systems, control power Check fuses and wiring up to comes from a control power transformer closing coil on the breaker. If the which requires the bus to be energized. control power is reaching the coil, Voltage on the primary and secondary should but the breaker still will not close, be checked. Be sure to check PT ratios if you there is a breaker problem. are unsure of your readings. Contact the Product Support Center for guidance and to report the issue. NO Verify 24VDC at terminal 13. If 24VDC is present here, replace the closing coil. )Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately.) Page 10 of 12
SYMPTOM - Distribution Breaker Won't Close Automatically A. Breaker has been shed by the system B. Breaker has been manually overridden to OPEN C. Breaker is tripped D. PLC problem No Problem Place breaker in AUTO on Load Shed Control Screen. Correct the reason for breaker tripping, reset the breaker and reclose. 1. PLC run light illuminated? YES Proceed to D.2. NO PLC has lost its program. Redownload program, or replace with a pre-programmed PLC from 449S / 449B the Product Support Center. 2. MB+ light is flashing fast and steady? YES No problem with PLC. Troubleshoot other causes. NO PLC has a communication problem. Verify address of PLC 449B and network integrity. E. PLC is sending close signal, but breaker is not closing (indicated by LEDs on PLC base) 1. Output row plugged in? YES Proceed to E.2. NO Plug in output row. (Note: equipment may operate when this step is performed.) 2. CBCL (circuit breaker close) relay pickup? YES Check control power (120VAC, 48VDC or 125VDC) available. Note: For low voltage systems, Check fuses and the wiring up to control power comes from a control closing coil on the breaker. If power transformer which requires control power is reaching the coil, the bus to be energized. Voltage on but the breaker will still not close, the primary and secondary should be there is a breaker problem. Call checked. Be sure to check PT ratios the Product Support Center for if you are unsure of your readings. guidance and to report the issue. NO Verify 24VDC at terminal 13. If 24VDC is present here, replace the closing coil. (Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately.) Page 11 of 12
SYMPTOM - Distribution Breaker Will Not Open A. Breaker has been added to the system B. Breaker has been manually overridden to CLOSE C. Breaker is tripped D. PLC problem No Problem Place breaker in AUTO on Load Shed No automation problem. Cause of breaker Control Screen. trip should be corrected. 1. PLC run light illuminated? YES Proceed to D.2. NO PLC has lost its program. Re-download program, or replace with a pre-programmed PLC from the Product Support Center. 449S / 449B 2. MB+ light flashing fast and steady? YES NO No problem with PLC. Troubleshoot other causes. PLC has a communication problem. Verify address of PLC and network integrity. 449B E. PLC sending open signal, but breaker not opening (indicated by LEDs on PLC base) 1. Output row plugged in? YES Proceed to E.2. NO Plug in output row. (Note: equipment my operate when this step is performed.) 2. CBOP (circuit breaker open) relay pickup? YES Check control power (120VAC, 48VDC or 125VDC) available. Note: For low voltage systems, control power comes from a control power transformer which requires the bus to Check fuses and the wiring up to closing coil on the breaker. If control power is reaching the coil, but the breaker will still not close, be energized. Voltage on the primary and secondary should be checked. Be sure to check PT ratios if you are unsure of your readings. there is a breaker problem. Call the Product Support Center for guidance and to report the issue. NO Verify 24VDC at terminal 13. If 24VDC is present here, replace the closing coil. (Note: 24VDC is applied by pulsing to the relay. You should see it come on and go off alternately.) Page 12 of 12