59330788 Cummins PCC3 3 Technical Training

7/30/2019 59330788 Cummins PCC3 3 Technical Training

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Participant Guide

Controller

PowerCommand 3.3

Phase 1 Release

CMT6068-EN-PG

Created 10/2008



Revision History

v1.00 (10/2008)1. Initial draft for product launch QTQ 2008

Cummins, Onan, and PowerCommand are all registered trademarks of Cummins Inc. InPower is a trademark of

Cummins Inc. Windows is a trademark of Microsoft Corporation.

Copyright 2006−2007 by Cummins Power Generation



PowerCommand Control 3300 & HMI 320

Table of Contents

Preface: I

This generation of Genset controls will use a new naming system. The preface will identify the various controls and combinations that make up the new controlfamily.

Introduction: II

The introduction describes the audience, the purpose, and the structure of thetraining module.

Introduction to the PowerCommand Control 3.3, the PowerCommand

Control 3300 control board and its standard options: 1

This lesson presents an overview of the PowerCommand Control 3300. Theparticipant will learn to identify the main features and components of thePowerCommand Control 3300, its standard features and options.

PowerCommand 3.3 & HMI 320 Operation and Service Menus: 2

This lesson presents the Setup and Calibration menu system used in the PCC3.3and HMI 320

PowerCommand Control 3.3 Sequence of Operation: 3

This lesson presents sequence of operation and feature operation andperformance information about the PowerCommand Control 3300.

PowerCommand Control 3300 Installation: 4

This section provides installation information, procedures, and requirements forthe PowerCommand Control 3300.

PowerCommand Control 3300 Control Setup and InPower: 5This lesson covers the basic adjustments and configuration details using InPoweras the setup tool. This section addresses the non-paralleling functions.

PCCNet Network for the PC3.3: 6

This lesson presents an overview of the PCCNet network and an introduction tothe unique PCCNet network and components used with the PCC 3300,



PowerCommand Control 3300 ModBus: 7

This lesson presents the ModBus communications feature on the PCC 3300, andintroduces some of the advanced ModBus abilities offered in this control.

PowerCommand Control 3300 PGICAN: 8

This section provides familiarization with the J1939 CAN communicationsavailable on the PCC 3300, for use with Full Authority Engine controls.

PowerCommand Control 3300 Paralleling Introduction: 9

This lesson introduces the various paralleling features and abilities offered inthis control.

PowerCommand Control 3300 Paralleling - Standalone: 10

This lesson covers setup, operation and configuration of PCC 3300, and HMI

320 when applied in a single unit non paralleled configuration.

PowerCommand Control 3300 Paralleling - Synchronizer: 11

This lesson covers the synchronizer operation and configuration of PCC 3300,and HMI 320 when applied in a paralleled and non paralleled configuration.

PowerCommand Control 3300 Paralleling – Isolated Bus: 12

This lesson covers setup, operation and configuration of PCC 3300, and HMI320 when applied in a multiple unit paralleled configuration that is completelyseparated from any utility (Mains) connection.

PowerCommand Control 3300 Paralleling Troubleshooting: 13

This lesson presents tools, problem scenarios, and solutions that are commonlyencountered when encountering operation problems with the PC 3.3.

Glossary: 14

This section lists the most common terms used throughout this training modulepertaining to the PowerCommand family of Controls.

Activities: 15

Copies of Participant In-class and Homework Activities, and each Section Quizare found in this section.

Appendix: 16

This section contains several useful guides and lists, including the ModBusregister list.



Diagrams: 17

This section has copies of all prints used in the course.

Module Comment Sheet: 18

Participants are requested to turn in the Comment Sheet at the end of the courseto help update the course materials as needed.

Participants have a copy of this sheet as the last page in their Participant Guide,but if you need a master we provide one here.



Participants’ Guide Title & Introduction Page6

Preface:

The new generation of PowerCommand Controls will use a new easier to understand namingsystem. The new controls are modular and therefore it can be confusing to know what feature are

being used it the genset control system is only referred to by the control board model. There areseveral combinations of control boards and HMIs

3

Naming System

PCC 1302 PCC 2300 PCC 3300

PowerCommand 1.X PowerCommand 3.3PowerCommand 2.X

PowerCommand 1.1HMI 211



HMI 112(w/PF) or HMI 114, HMI 113

Phase 1 (FAE)


Phase 1 (FAE)


PowerCommand 2.3

HMI 320HMI 112 or HMI 114, HMI 113

AUX 101/102, AUX 104

Phase 2 (Hydra Mech.)


HMI 112 or HMI 114, HMI 113

AUX 101/102, AUX 104Phase 2 (Hydra Mech.)

Naming Chart - PCC 1.X, 2.X, 3.X Naming System

The above naming chart shows the naming system for the new series of controls, PowerCommandControl 1.X, 2.X, and 3.X. The X represents the HMI Operator Panel you have with the series of

control board.

Here is a list showing how they are structured:

1.X = PCC 1302 control board






X.1 = HMI 211

X.2 = HMI 220

X.3 = HMI 320

The PCC 2.X and 3.3 will be released in a couple of different phases. These phases will supportcertain devices as depicted in the visual above and in more detail throughout this training course.

The 2.X, & 3.X series designation will identify the high level of control ability however, there willbe several subcategories of different control board features. The first category of 2.X, & 3.3controls will only work on FAE controlled engines. The next category will be used with hydramechanical engine applications. As new features and categories develop, additional trainingcourses will also develop.

Series 2.X with FAE control training and 3.3 with FAE control training will be the most

comprehensive training programs about the PCC 2300 and PCC 3300 controls. The trainingprograms that follow will concentrate on the specific feature enhancements, HMI, or accessorydevelopments relative to the specific Series. The Series 2.X & 3.3 FAE training will be aprerequisite to any future training program

It has been planned that the PCC 3300 & HMI320 combination will be the only combinationavailable for the high level paralleling gensets. The plan is to only have a PC 3.3 control and nevera PC 3.2 or PC 3.4.




Introduction

Welcome!

Welcome to the Particpants Guide for the PC 3.3 & PowerCommand Control 3300 module! Thisguide was written by the Cummins Power Generation Technical Training department for your use

and reference.

We suggest you read through the entire Introduction to become familiar with the guide’s

structure. Then, just follow the step-by-step instructions for each lesson.

Module Purpose

The purpose of the PC 3.3 & PowerCommand Control 3300 module is to help you, the Cummins

Power Generation distributor service technician, understand the PC 3.3 & PowerCommand Control 3300 which is going to replace the specialized gen set control modules. It is also expected that the

PowerCommand Control 3300 will be used on many of the Cummins−powered gensets with Full

Authority Engines (FAE) and the hydro−mechanical fuel systems.

With this information, our technical force will be better prepared to meet our customers’

varying needs.

Module Audience

The primary audience for this module is Cummins Power Generation distributor power

generation technicians. We assume participants have previous experience with or knowledge of

integrated generator set AC and DC control operation, troubleshooting, and repair procedures. It

is a prerequisite to attend a PC 2.X course prior to attending this course.

Module Structure

This module contains lessons on related topics. Each lesson follows a carefully designed training

format, including a warm up, presentation, and activity (or exercise).

Lesson Format

Warm ups help participants focus and begin thinking about the lesson topic. The presentation

portion of the lesson is where participants receive new information. The activity & Quiz follows

the presentation; it gives participants the chance to practice new skills or work with new ideas.




Module Assessment

After completing all the lessons in the module, participants will complete a module assessment .The module assessment lets us evaluate the level of knowledge participants have on the topic after

completing the module.

Module Comment Form

Participants will also complete a module comment form. This form gives participants the chance to

comment on the usefulness and effectiveness of the training module and make suggestions for

improvements.

We will use the results from the module assessments and module comment forms to help us

determine if there is a need to modify the module.

Please mail the module assessments and comment forms to Cummins Power Generation’s Sales

and Technical Training department as soon as possible after the training session. The address is:

Cummins Power Generation

Technical Training OUJ3

1400 73rd Avenue NE

Minneapolis, MN 55432

Preview the lessons−−Review the lesson objectives and read through the trainer’s instructions. Usethe Notes column to write any comments or additional information you want to include.



PCC 3.3 & PowerCommand Control 3300 Section last page

Participants’ Guide Section Last Page

THIS PAGE IS INTENTIONALLY LEFT BLANK



PCC 3.3 & PowerCommand Control 3300 Introduction and Options

Participants’ Guide Section 1 Page1

PowerCommand

3.3

Section 1 Introduction to the

PowerCommand Control 3300

Visual 1-1 PowerCommand Control





Section 1

Introduction to the PCC 3.3, the PowerCommand

Control 3300 control board and its options.

Estimated Time: 2.5 hours





Warm Up

In this lesson we are going to learn about the PowerCommand Control 3300 and itscomponents

We will see the standard and optional components, and learn their functions.

Objectives

After completing this lesson, the participants should be able to:

• Identify the PCC 3.3 standard components.

• Identify the PCC 3.3 & PowerCommand Control 3300 optional components.

• Describe the main functions of the PowerCommand Control 3300 and its features.

• Describe the standard operator interface (switch and LED).

• Use the Operator menus on the optional control panel.





2

PowerCommand Control 3300

Premium Paralleling Genset Control

Integrated J 1939 CAN Link for FAE sets

Optional governor amp. for non-FAE sets (Phase 2)

Separate module for AVR (Voltage Regulation)

Common wiring harness with “3-series”controls

Visual 1-2 Introduction to the PowerCommand Control 3300

Participant’s Text

The PowerCommand Control 3300 is ahighly integrated control providingcomplete genset control and protection.

The Phase 1 release of this new control willsupport Lean Burn Natural Gas (LBNG)

gensets and Diesel FAE engine-drivensets

The phase 2 release will support a governordrive module which is needed for dieselsets equipped with electric actuator.

Notes:





3

PCC 3300 Control Boards

PCC 3300 Base Board

AUX 103 Power Stage

Visual 1-3 The PCC 3300 Control Board


The PCC 3300 board uses the same largepotting shell as used in the MCM3320and PCC 2300.

The control board provides many connectorsfor input and output information.

• Many of the connectors are common

among all “3-series” controls.This is the primary board of the control

system and is call the Base board.

Notes:






There are14 connection points on the PCC3300:

• J Connections−

Common Connectors.• TB Connections − Customer

Connections and Feature inputs.

3 CT connection on the PCC 3300:

3 connection points on the AUX 103 PowerStage:

• J17 − Excitation Output (X1, X2)

• J18 − AVR Power (PMG)

• J19−

AVR Control Communications

Notes:





4

PCC 3300 Connectors

TB7- Bus Voltage Sense

TB-15 – ModBus/RS485

J 20- GensetConnections

J 12- Genset CT Input

J 26- AUX 103

Connector

J 22- GensetVoltage Sense

Onboard BUS CTs

TB-1 – CustomerConnections

J -25 DisplayConnections

DSx LED Status Indicators

TB10 – Breaker StatusConnections

TB-9 – Analog I/O

TB-3 – CustomerInput/Output

TB-5 – Breaker ControlConnections

TB-8 CustomerConnections

J 14 – Service Tool Port

Visual 1-4 Control Board Connectors

Participant’s Guide

DSx − Status indicators: DS3 flashes to let

you know the control board is operating

properly.

CT1, 2, & 3 − Onboard Bus CTs

J12 − Generator CT inputs

J14 − Connection port for InPower.

J20 − Genset Accessories connection

J22 − Genset voltage sense

J25 − Operator Panel (HMI) connection

J26 − AUX 103 & Interconnect

Notes:





4

PCC 3300 Connectors

TB7- Bus Voltage Sense

TB-15 – ModBus/RS485

J 20- GensetConnections

J 12- Genset CT Input

J 26- AUX 103

Connector

J 22- GensetVoltage Sense

Onboard BUS CTs

TB-1 – CustomerConnections

J -25 DisplayConnections

DSx LED Status Indicators

TB10 – Breaker StatusConnections

TB-9 – Analog I/O

TB-3 – CustomerInput/Output

TB-5 – Breaker ControlConnections

TB-8 CustomerConnections

J 14 – Service Tool Port

Visual 1-4A Control Board Connectors


TB1 − Customer I/O connections


TB5 − Circuit breaker control connection

TB7 − Bus/utility voltage sense


TB9 − Analog control I/O connections

TB10−

Circuit breaker control connectionTB15 − RS485 / ModBus Communicationconnection

Notes:





5

AUX103 AVR Power Stage

J 18 – Power Input

J 19 – Interconnectionto PCC 3300Base Board

J 17 – Field Output

Chassis GroundWire

Visual 1-5 Automatic Voltage Regulator Module


The AVR Module is used with all PC 3.3gensets.

There are 3 connectors on the board.

J17 provides the excitation output.

J18 provides the power input

J19 connects to J26 on the 3300 ControlBoard.

Notes:





6

HMI 320 Operator Panel

Visual 1-6 Optional operator panel


HMI 320 Operator Panel is also highlypopulated with display and controlfeatures.

Multiple LEDs for status and operatorinformation

Large graphical display for menus andinformation display.

Multiple buttons for operation andcontrol.

Same physical size and layout as the HMI220 but has a much larger display.

Notes:





7

Operator Panel Menus

Visual 1-7 Operator Panel Menus


The panel allows easy navigation throughmultitudes of monitoring screens. Thereare also a great many screens available forsetup of the control and the accessoryfeatures.

There is a HOME screen that providesguidance and access to many screens.

The number of screens available will depend

on features activated and the type of applications chosen.

Instead of menu screens, we now have menuchoices. The menu choice will provideaccess to a single or multiple pages of information or setup functions.

Notes:





8

HMI Display Navigation

Multiple Combinations of buttonpushing will allow navigation to

various messages, data, andadjustment screens.

Participant Guide Visual 1-7 shows anexample of some of the navigationchoices.

Visual 1-8 HMI screen navigation


Navigating the many different screensrequires practice. There is a DEMO modeon the screen that enables an operator tolearn many of the button sequencesrequired for screen navigation.

Some screens allow you to view data in eithera graph mode or in a table of data.

There are a series of soft keys, and hard keys.The soft keys change function dependingon the screen being viewed. This will bediscussed more in the next section.

All of the keys provide tactile feed back.

Notes:





9

PCCNet Components

(Common @ Phase 1)

0300-6315-02 HMI 320 Operator Panel (Local)

0300-6315-03 HMI 320 Operator Panel (Remote)

0300-5929-01 HMI 113 Annunciator (No Box)

0300-5929-02 HMI 113 Annunciator (With Box)

0300-6366-02 HMI 114 Horizontal lamp Bargraph (kW & PF)

0300-6050-01 HMI 112 Vertical lamp Bargraph (kW & PF)

Visual 1-9 PCCNet Components


0300-6315 HMI320 Operator Panel Thisis the Operator Panel for the PCC 3300.There is one for local control and anoptional one, 0300-63115-03 for remotemounting.

0300-5929-01 or -02 Annunciator This isthe same Universal Annunciator that isused with many other CPG products. The

-01 kit contains the Annunciator only, -02kits contain a mounting box too.

0300-6366-02 & 0300-6050 Bargraph

Module These modules allow thecustomer to have a graphical readout of alternator information.

Notes:





10

PowerCommand 3.3

Quiz 1-1: Intro to PowerCommand 3300,

Operator panel, and PC 3.3 system.

Visual 1-10 Quiz for Lesson 1


Turn to Section 15 and complete Quiz 1-1.

At this time I would like you to work ingroups to complete the quiz. It shouldtake about 20 minutes.

Notes:





Wrap-Up

In this lesson we have learned about the PCC 3300 control boards.

First we talked about the PCC 3300 Control, where it is used, and where it may be used

in the future.

Next we talked about the control board and a little bit about the connectors that join the harness tothe board:

Next we talked about the HMI 320 operator interface to the PCC 3.3 control.

After introduction of the operator panel we talked about the Operator Panel Menus and took a littlepeek at the vast array of menu choices.

Then we looked at a drawing of the Optional Governor Drive stage for Diesel gensets.

Finally, we introduced the optional PCCNet components

Are there any questions that you have about the PCC 3.3 controls we have not yet covered? The

following sections will delve deeper into all of the items introduced here.








PCC 3.3 & PowerCommand Control 3300 Service Menus


PowerCommand 3.3

HMI 320

Section 2: PC 3.3 HMI 320 Panel, Operation,and Menus

Visual 2-1





Section 2

PCC 3.3 HMI 320 Service Menus:

Estimated Time: 2 hours

Materials Needed

PowerCommand Control 3300 Participant’s Guide Guide CMT6068-EN-PG

Operator Installation Manual – 3300 Series Genset Control 0900-0670





Warm Up

In this lesson we are going to learn about the Service and Setup Menus for thePCC3.3

You will have a chance to go through the menus as an in-class activity after we complete the lessonmaterial. Please don’t get lost in the menus as we are trying to go through the Participant’s Guidematerial.

First, let’s look at the objectives for this lesson:

Objectives


• Locate and identify the front panel buttons used in navigating the PCC 3.3 HMI 320 menus.

• Identify the menu choices accessible without using the Application password.

• Access and use the Setup menu − Genset Service to view and/adjust Service menus.

• Use the Setup menu − Genset Setup to view and/adjust Setup menus.





2


Local Control Panel0300-6315-02

Remote Control Panel0300-6315-03

Slide 2-2


We were introduced to the HMI 320 OperatorPanel in lesson 1.

This view is of a local version HMI which isstandard, and the optional remote HMI.

Local HMI 320 = 0300-6315-02

Remote HMI 320 = 0300-6315-03

The remote version will not allow changes tothe mode of operation.

The Participant’s Guide contains some of thebasic familiarization with the HMI 320, but we will reference the 900-0670 ServiceManual for most of the lesson.

Notes:

.





3

Standard HMI 320 Operator Panel

LargeGraphicalDisplay

MenuSelection

Buttons

ScreenNavigationButtons Breaker

ControlButtons

ControlFunction

Buttons

Functionindicationlamps

Slide 2-3 Setup Menu Access.


The HMI 320 layout is very similar to theHMI 220 with several added features..

Function indicator lamps and control functionbuttons are located in the same locations asthe HMI 220 and they operate the same.

Breaker control buttons are available toprovide breaker control during manualparalleling operation.

Screen navigation buttons (Hard Keys)provide control of screen viewing functions.They are laid out and operate vary similar tocell phone navigation buttons.

Notes:





4

Display ScreenLine 1

Controller ModeLine 2

Fault Data

Line 3Screen Name

Data & StatusScreen

Soft Button Options

Data & StatusScreen

Slide 2-4 Display Screen


Top three lines of display are reserved for:

Line 1 will always display the ControllerMode or Status information.

Line 2 will always display the gensetfault popup message.

Line 3 will always display the screen

name or menu description of what isviewable in the Data & Status screen.

The Data & Status Screen section can show avast amount of data or menu choices.

There are 9 lines of display in 2 columns for atotal of 18 viewable parameters.

Notes:





4

Display ScreenLine 1

Controller ModeLine 2

Fault Data

Line 3Screen Name

Data & StatusScreen

Soft Button Options

Data & Status

Screen

Page &Pages available

Slide 2-4B Display screen continued.


Soft keys are labeled across the bottom of thescreen. The manual refers to them asFunction Selection Buttons.

Some of the soft keys are used for Previous and Next screen selection.

The up arrow indicates navigation to a

previous screen.

The down arrow indicates navigationto a next screen.

Other soft buttons are used to directlynavigate to other data screens

Notes:





5

HMI Hard Keys

Pressing these buttons simultaneouslyfor 3 seconds will cause the screen toenter a DEMO mode if PCCNet isdisconnected.

The HOMEbutton

Previous ScreenButton

These hard keys enable navigationbetween various menu screens

Slide 2-5 Hard Keys.


The seven buttons at the bottom of the PCC3300 Operator Panel lead to menus andprovide control of menu navigation.

• – pressing it will return you to theHome screen menu from any other screen.

• - will return you to the previousmenu or to the Home screen

• OK – will engage the highlighted menu

choice and advance to that screen.

• The 4 -will advance, back up onescreen, or highlight menu choice

Notes:





6

Setup Menu and Passwords

There are 4 levels of passwords available for adjustments,setup and control.

Slide 2-6 Genset Setup


The HMI 320 Setup Screens are accessibleand viewable without a password. If youattempt to change a setting that requires apassword, you will be prompted to supplya password. The passwords must beentered for the appropriate level as thescreen requests.

There are various levels of authority formaking changes or adjustments.

• Level 0 = minor adjustments only -anyone can access.

• Level 1 = minor adjustments and somecalibrations

Notes:






• Level 2 = high level adjustments,calibrations, and configurations.

• Level 3 = very high level configurationand reserved for engineering or factoryaccess.

As an example:

• If you access the setup screen for PCCNetSetup, you will not be asked for apassword. This is an example of a Level 0password setup parameter.

• If you attempt to access the Adjust

Voltage screen, you will be prompted fora Level 1 (574) or higher password.

• If you attempt to access the OEM setupparameters, you will be prompted for aLevel 2 (1209) or higher password.

• The Level 3 password is reserved forengineering and factory configuration andis not shared for field access or setup.

If a password is entered, it will remain activeuntil a higher level password is entered or

the HMI is INACTIVE for 5 minutes.

Notes:





7

Mode Change Password

Mode Change Password

ProtectionIf enabled, many of the HMI buttons will be

disabled. The operator MUST havethe password f or them to become

operational.

Slide 2-7 Mode Change Password


Look at page 5-1 of 0900-0670 servicemanual. MODE CHANGE PASSWORDcan be confusing to many.

MODE refers to the operation mode suchas – running in Manual, running in Automatic, Manual parallel, etc... I

If Mode Change Password Protection isenabled, the buttons are disabled so an

unauthorized operator cannot switchfrom one mode to another.

If Enabled, any button push on the HMI willprompt a password request screen toappear.

Additional Participant’s Text

This is a feature to protect a piece of customer equipment, or to protectequipment from the customer. Thisfeature prevents someone fromaccidentally or unknowingly changing thecontrol from Automatic Mode to ManualMode or from sending a breaker closecommand when they shouldn’t. It is to

prevent an unauthorized person frommaking unauthorized changes.

Field technicians may want to use this featurefor protection from inadvertent buttonactuations during service work.

The Password is 121





8

Adjust Menus

The HMI has a Adjustment screenfor minor adjustment of operation setpoints.

Setting of the Keyswitchoveride to Active will allowfor service connection tothe engine ECM.

Slide 2-8 Adjust Screen


Turn to page 5-30 in the 900-0670 ServiceManual

Table 5-22 provides a slight description of each ADJUST function.

IMPORTANT: Keyswitch Status. The enginemust be stopped to activate the KeyswitchOverride.

The Keyswitch Override is provided tosupport control service. This setting existsto allow ECM to power down and it willnot trigger a “CAN Link Degrade” fault.

Notes:






What is the purpose of having a Keyswitchoverride? When servicing an ECM on an

automotive application, the ignition key isturned to the on position which providesthe input to the ECM to turn on andoperate its program. This is the mode you want the ECM to be in during service. Ona generator set, we use the E-Stop buttonas the Keyswitch.

The Keyswitch Override will return toINACTIVE if the E-Stop button ispushed, and/or you will not be able to

switch the override to INACTIVE if thelocal or remote E-Stop is activated.

The control must be in the Manual mode tochange the override from INACTIVE to ACTIVE.

Switching the control from Manual to Automatic while the override is in the ACTIVE state will cause a Data LinkError fault to be generated.

Additional Participant Text & Notes

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

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_________________________________

_________________________________

_________________________________

_________________________________

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_________________________________ _________________________________

_________________________________

_________________________________





9

Setup Genset Menus The HMI has a series of 5 screensthat allow for detailed setup of amultitude of operation set points.

Slide 2-9 Genset Setup


From the Home (2) screen, navigate to andhighlight the “Genset Setup” menu and

press Pressing the button will takeyou to a series of screens where you canadjust and change various gensetconfiguration settings.

If you attempt to make any change, you willbe prompted for a Password.

Some parameter can be changed if you usethe 574 password; however, using thelevel 2 password will allow you to adjustany of the parameters.

Notes:





10

Paralleling Setup Menus

The HMI has a series of 6 screensthat allow for detailed setup of amultitude of Paralleling operation setpoints.

Slide 2-10 Paralleling Setup


From the Home (2) screen, navigate to andhighlight the “Paralleling Basic Setup”

menu and press Pressing thebutton will take you to a series of 6 setupscreens where you can adjust and changevarious genset configuration settings.

PTC (Power Transfer Control) is a featurethat will become available at the Phase 2

release.Pressing the “Status” soft key will jump you

out of setup and take you to monitoring of the Paralleling mode.

Future chapters will cover the Parallelingfunctions.

Notes:





11

OEM Setup Menus The OEM Setup provides accessto genset configuration settings.

Slide 2-11 OEM Setup


OEM (Original Equipment Maker [orManufacture]) setup menu provide accessto a multitude of settings.

These settings are mostly gensetconfiguration settings; a Level 2 passwordis required for almost all adjustments.

Notes:

OEM Setup Menus duplicate the setupfunctions found in InPower. InPower willbe covered in later lessons.





Participant’s Text (OEM GENSET

SETUP)

It is possible to completely configure a newgenerator control from the HMI, howeverit is not recommended or you probably donot want to expend the effort. The task of inputting a 10 character genset serial

number can take as many as 970 buttonpushes. The HMI buttons are rated forhundreds of thousands of button pushes,but your finger most likely is not.

If you try to input Serial Numbers or ModelNumbers, you will find 96 charactersavailable to scroll through, including theentire alphabet in upper case and again inlower case, numerals 0 through 9, 33symbols and even a blank character.

In the OEM GENSET SETUP, you will findreference to “Input Factory Lock ”functions. You will notice there are morethan 3 dozen inputs affected by this setup.

When the factory configures a genset with allits option, some inputs are consumed andare “Locked”.

Factory Lock prevents causal operatorchanges to the genset setup. Password1209 is required to change any input fromLock to Unlock or Unlock to Lock. Onceunlocked, the input configuration can bechanged.

Notes:





Participant’s Text (OEM ENGINE

SETUP)

There are 2 pages to Engine Setup. Thistraining course will only address some of the FAE application points. Other PC 3.3control courses will address other engine

setup functions.

ECM CAN ENABLE turns on the SAE J1939CAN communications to the engineECM. Changing the setup to Disable willlead to communication and Operationproblems. There may be times when you want to Disable this such astroubleshooting the ECM, but it must beEnabled for genset operation.

Fault 1117 Enable is a ECM warning that can

be Enabled or Disabled, the setup criteriafor this setting will be discussed in moredetail several lessons ahead.

Prelube Enable is a newer feature option thatis available with some engines. There arecontrol provisions to allow for either arolling Prelube or Prelube pumpengagement. Setting this up correctly isdependent on engine and gensetconfiguration.

Page 2 offers several setup parameters thatshould be familiar to technicians.

Notes:





Participant’s Text (OEM

ALTERNATOR SETUP)

There are 3 pages to Alternator Setup. Like inother OEM SETUP screens, there is acombination of Level 1 and Level 2password authorized settings.

OEM ALTERNATOR SETUP is differentfrom OEM GENSET SETUP. Alternatorsetup concentrates on voltage regulationperformance and on alternator protectionsetting. Most settings require a Level 2password.

On page 1 you will notice an option forchoosing the Excitation Source. You areable to choose between PMG (PermanentMagnet Generator) or SHUNT. Shunt is a

term unique to Cummins PowerGeneration excitation systems and it issynonymous with the industry commonterm Self Excitation.

Scroll through the Alternator Setup pages andyou will notice some of the protectionsettings are very high level protectionsand these settings if improperly set cancontribute to serious damage of thealternator or system. Be VERYCAUTIOUS about sharing the level 2password with others.

Notes:





12

PCCNet & ModBus Setup Menus

The PCCNet and ModBus Setupscreens will be covered ingreater detail in upcominglessons.

The PCCNet and ModBus Setup screens use Level 1 passwords.

Slide 2-12 PCCNET & ModBus Setup


PCCNet and ModBus setup menus will becovered in detail in upcoming lessons.

All of the navigation choices and functionsfound in these menus have beenexperienced. Using your simulator,navigate to, and open the PCCNet andModBus menu screens.

Later Lessons will cover the detailed setup of both these features.

Notes:





13

Setup Menus

The remaining Setup screensDisplay Options, Clock Setup,Configurable IO, and Calibrationalso contain multiple screenswith many setup parameters.

Slide 2-13 Operator Setup Menus


The remaining setup menus on this screen

utilize the same navigation buttons andsequences covered previously.

The Configurable IO menu contains manyconfiguration settings and labels. Asmentioned in previous screens, wheninputting lots of character data, it can takea long time to input descriptions. If youare only changing a couple of descriptionsit is ok to attempt it from the HMI menus,but some people may prefer to us InPower

for this configuration. InPower setupmenus will be covered in upcominglessons.

Notes:





14

DEMO MODE Operation

The HMI has a DEMO MODE of operation that allows for practice atnavigation through the variousscreens. There is a series of 5screens that allow for detailed setupof a multitude of operation set points.

The DEMO MODE is accessed bypressing these buttons simultaneouslyfor a few seconds will cause the screento enter a DEMO mode if PCCNet isdisconnected.

Slide 2-14 Demo Mode Menus


Demo mode is very useful for trainingcustomers and site operators onnavigation skills.

You must remove the PCCNetcommunication connector before youattempt to enter Demo Mode.

Notes:





15

Activities

2-1 Menu Hands On Activity



Section 2 Activities are found in Section 15 of the Training Guide.

Slide 2-15 Activities Listing for Lesson 2


At this time I would like you to work asteams to complete these activities.

These activities should be fairly easy for you,but take your time to become comfortable with the button pushing sequences.

Notes:

When everyone is done with the activities, we will discuss the correct answers.





Wrap-Up

In this lesson we have learned about the Service Menus for the PCC 3.3 and PCC3300/HMI 320control.

We talked about the Service Menu password: 5−

7−

4

We talked about the Service Setup Menu Password: 1 − 2 − 0 − 9

We also talked about the Setup Menus:

Genset Service Menus

• Genset

• Customer I/O

• Meter Calibration

• Annunciator

Genset Setup Menus

• Genset

• Voltage Protection

• Current Protection

• Engine Protection

View Setup Menus

• No Adjustments

We then went through the choices available in these menus. We covered the some factory defaultsettings, minimum, and maximum values available.

Lastly we worked through the menus and recorded the settings in the controls you have at your workstations, and took a quiz on the Service Menus.

Are there any questions we have not yet covered on the Operator Panel Menus?

In the next lesson we will cover the use of InPower software with the PCC 3300 control.



PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 Sequence of Operation


PowerCommand

3.3

Section 3 Sequence & Operation

PCC 3300 & HMI 320

Visual 3-1





Section 3

PowerCommand Control 3300 Sequence & Operation.


Materials Needed

• PowerCommand Control 3300 Participant’s Guide Guide (CMT6068-EN-PG)

• PC with InPower v 7.0 or later installed

• PowerCommand 3.3 Service Manual #900-0670





Warm Up

In this lesson we are going to learn the operating features and sequence for the PowerCommandControl 3300.

What we learn in this lesson will be applied in the troubleshooting lesson and in both the writtenand performance examinations.


Objectives


• Create an understanding of the operation and functions of modes, sequences, and connections

used during the sequence of operation from start command to shutdown.• Describe how to isolate a failure in the operation of the PCC 3.3 and find the failed part.

• Use the PC 3.3 Service Manual #900-0670 to understand the function of various modes of operation.





2




Fixed buttons

Visual 3-2 Local and Optional Remote Operator Panel


There are 2 Operator Panels. The Localversion is considered standard and theRemote version is optional.

The HMI 320 Local allows greater control of the control and setup functions. It offersoperator interface to the digital voltageregulation, engine speed governing, andremote start/stop control, and protective

functions.

The obvious difference between each HMI isnoticeable when to look at the fixedbuttons.

Notes:





3

Modes of Operation

Each mode of operation has multiple choicesaffecting sequence of operation.

Off Mode

Auto Mode

Manual Mode

Parallel Mode

Visual 3-3 PCC 3.3 Operation Modes


As with so many things about this control, adifferent style of thinking is required tounderstand how this control operates.

Modes of Operation: Off Mode

On most controls we think of OFF as acondition when no power is being used forany purpose. That is not what this control isdoing.

In OFF MODE, this control is activelymonitoring communications, enginecondition, and generator conditions, but itdoes NOT allowing the engine to run. Thecontrol is not operating in Manual nor is itoperating in Automatic. The Control is veryhard at work making the genset do nothing.

Notes:






Modes of Operation: Auto Mode

Auto Mode operates the same as previouscontrols. The unit is in a state of readinessawaiting a remote start signal via digitalcommutations or a remote discrete contact startcommand.

Auto Mode also supports start commands initiatedby Exercise and the exercise signal.

In Auto Mode when auto start commands areremoved, the PCC will enter a shutdown withcooldown sequence.

The Exercise Signal can originate from any of

these sources. ModBus signal command.

Operator panel exercise command

Exerciser Schedule. (The control has a built inexercise scheduler much like transferswitchcontrols)

InPower exercise command.

Exercise switch PCCNet input

Modes of Operation: Manual Mode

At the HMI pressing the will engage theManual mode if the HMI is configured to allowthis.

If the engine is already running when this button ispushed, it will continue to run if the START button is pressed again within 250ms -- yes thatis ¼ of a second. If you are not fast enough, theunit will go into a Shutdown WITHOUTcooldown

If the unit is not running and the button ispushed, the unit will be available for Manualstart & stop commands.

If you engage the Manual mode, you must pushthe manual button again within 10 seconds orthe control will enter the OFF MODE.

Notes:






Modes of Operation: Manual Mode

If the HMI button has been engaged withthe engine off, normal start functions will beavailable and take place with a idle warm upif needed. Once the engine ramps to rated,the control can operate in Parallel Mode if the control is configured to allow this. If thecontrol is configured for a Parallel Modeand you are operating in Manual Mode the

buttons will allow control of theparalleling circuit breakers.

Modes of Operation: Paralleling Mode

There are 7 states of paralleling operation of which 5 are associated with applicationperformance modes.

Dead Bus Close First Start Arbitration Droop Synchronization Load Share

Load Govern Power Transfer Control

Dead bus close and 1st start arbitration aresequence modes that are incorporated intosome of the other paralleling modes, butthey merit recognition at this point.

The operation of the various modes involved with Paralleling will be covered in detail inlater lessons.

Notes:





4

Modes of Operation - Starting

Multiple START sequences available.

Emergency Start

Non-emergency StartNon-emergency Start With Idle Warm upNon-emergency Start Without Idle Warm up

Manual StartManual Start With Idle Warm upManual Start Without Idle Warm up

Load Demand Start

Visual 3-4 PCC 3300 Starting Mode & Sequence


Starting Modes of operation

The control operates the generator differentlydepending on the operation mode and thedesired start type.

Refer to Section 3-12 of 900-0670 ControlService Manual for more information.

Notes:







Manual Start:

The PCC3.3 Control System can be place in Manual Run bypressing the Manual button and then the Start button on theHMI320. When the control system is transferring into Manual

Run mode the Green LED above the manual button will flash, once the control system hassuccessfully transferred into Manual Run Mode the Green LED will be lit solid.

If the Manual button is pressed, but the Start button is not, the control system will not start and thecontrol system will revert back to ‘Off’ after 10 seconds.

After the Start button is pressed on the HMI320, the PCC3.3 Control system enters Manual Runmode which begins with the start sequence. The start sequence begins with the engine Pre-LubeCycle Prelube Cycle Enable if Enabled.

After the Pre-Lube cycle is complete, the PCC3.3 control system commands the genset to startcranking by turning on the starter Low-Side Relay driver on Pin J20 -15. At this point, thecontrol system verifies the engine is rotating by monitoring the Average Engine Speedparameter coming from the ECM.

If the engine speed is zero after two seconds from engaging the starter the control system turns off the starter, waits two seconds and then re-engages the starter. At this point, if engine speed isstill zero the control issues a Fail To Crank (1438) shutdown fault.

Once the engine speed is greater then the Start Disconnect speed, the starter is disengaged. ForStart Mode = Emergency engine will accelerate to rated speed and voltage and bypass all theidle warm-up delays. At this point, an engine is allowed will warm-up at idle speed until the Idle Warmup Time delay has expired or the engine coolant temperature is greater then the Idle

Warmup Coolant Temperature. Upon completing the warm-up sequence, the engine will becommanded to accelerate to rated speed and the genset to rated voltage. Upon reaching ratedspeed and voltage the ‘Ready To Load’ command will become active.

Once the PCC3.3 receives a stop command by placing the control system in Off mode, it will gointo cool-down at rated speed if the genset was running with load that is greater than 10% of genset rating. The genset will run in cool-down at rated mode for the Rated Cooldown Time trim setting. The purpose of the cool-down at rated is to cool-down and preserve the engine.

After the cool-down at rated is completed the genset will cool-down at Idle speed. After the cooldown at Idle speed time expires, the genset is shut down via a normal stop.





6

Modes of Operation - StoppingMultiple STOP sequencesavailable.

Controlled ShutdownWith Idle Cool DownWithout Idle Cool Down

Emergency Stop WithIdle Cool Down

Automatic ShutdownWith Idle Cool DownWithout Idle Cool Down

B+

PCC3300Control

Remote E-

STOP

Contact 1

RemoteE-

STOPContact

2

Local E-STOP

Contact 2

To RelayContacts

Local E-STOP

Contact 1

Emergency Stop

Visual 3-6 PCC 3300 Shutdown Sequence


For operation of the genset, a short betweenTB1-15 and TB1-16 must be present. Thecontrol enters an emergency stop mode when the short is removed. Before thegenset can be restarted, the control mustbe manually reset by re-applying the shortand acknowledging the fault.

Local Emergency Stop:

For operation of the genset, a short betweenJ25-2 and J25- 6 must be present. Thecontrol enters an emergency stop mode when the short is removed.

Notes:






Before the genset can be restarted, the controlmust be manually reset by re-applying theshort and acknowledging the fault.

It is also required to have physicalinterruption of the Keyswitch, FSO andStarter relays when emergency stop(either local or remote) is active. In orderto achieve this, a second NC switchcontact should be added to the Estopswitch such that when a Estop button ispressed, this second NC contact isopened. The second NC contact should be wired in series with B+ and the

Keyswitch, FSO, and Starter relay coils.Thusly, when the Estop button is pressed,power is removed from the Keyswitch,FSO, and Starter relay coils which inturns de-energizes the relays and preventsfurther genset operation.

Notes:





7

Prelube Cycle

The PCC 3300 is able to initiate a Prelube cycle periodallowing the engine to circulate engine oil pressure.

Prelube Cycle is adjustable. Adjustments are available for:Prelube Cycle Enable.Prelube Cycle Time.Prelube Oil Pressure ThresholdPrelube Timeout Period

Prelube ModeEmergency start: Crank relay and Oil Priming Pump relay is energizedduring start.

Visual 3-7 PCC 3.3 Prelube


Prelube pumps can be controlled by the PCC3300 control and they can be cycled asdesired to maintain an oil coating on thebearing surfaces during times of inactivity.

The Prelube relay is optional per gensetdesign requirements. The Prelube pump isoptional and types may vary.

The relay will engage when the engine is notrunning, so be aware of unanticipatedpump engagement.

Prelube will usually be found with largerengines since long & heavy crankshaftsand heavy flywheels need to be supportedby a sufficient film of oil on bearings.

Notes:






InPower supports the setup functionsassociated with Prelube.

Prelube Cycle Enable – turns the Prelubefunction on or off.

Prelube Cycle Time – Sets the amount of time between Prelube cycles. Default 168hours (7 days)

Prelube Oil Pressure Threshold – this asan adjustable setting so that when thepredetermined oil pressure is achievedduring Prelube Cycle pumping, the cycle will disengage.

Prelube Timeout Period – this is anadjustable setting determining how longthe Prelube pump should run.

Charging the engine lube system with Prelubekeeps internal engine components coated with oil and keeps the oil galleriescharged with oil supply. With CyclePrelube you can set a schedule when thepump will recharge the lube system withpressurized oil.

Prelube will also engage at the beginning of an Emergency start command to helpcharge the lube oils system and bring thesystem up to safe oil pressure levels assoon as possible.

The Prelube cycle is disabled and does notoperate while the engine is running.

Notes:





8

Power Down Mode The PC 3.3 also uses the same Bi-directional wakeup

scheme found in the PC 1.X and PC 2.X controlsystems.

PCC Current Draw (base board) HMI– Normal Operation ---- (750 mA) 150 mA

– Power Down (Sleep) --- (5 mA) 1 mA

If one PCCNet device awakens, it will wake up theother PCCNet devices by driving the Bi-directionalsystem wakeup pin.

When all devices are satisfied, the PCCNet will go tosleep as one system.

Visual 3-8 PCC 3.3 Power Down


The PCC 3300 power consumption changesdepending which of mode of sleep or wake it is in.

The current draw of the HMI changes duringpower down mode. Look at Table 3-11 inSection 3 (page 11) of the 900-0670Service Manual.

The system Power Down Mode Time Delaytimer is adjustable under the GenSetSetup of InPower or the HMI setupscreens.

Notes:





9

PCC 3300 AVR Operation

The PC 3.3 AUX103 Power Stage (AVR) providesa PWM signal to the generator Exciter

AUX 103 Current Output– Normal Operation 0 to 4 amp

– Maximum continuous operation 4 amp

– Surge ` 6 amp for 10 seconds

AUX 103 does not provide output during:– Normal startup @ idle

– Normal shutdown @ idle

– Emergency Stop (local, remote or fault shutdown)

Visual 3-9 PCC 3300 Power Stage


The AUX 103 Power Stage AVR is separate fromPCC 3300 main control board to helpdissipate the heat being rejected from the AVR circuits.

The AUX 103 MUST be mounted with the

heat sink fins vertical so convective airflowcan help carry heat up and away from theboard.

Processors on board this module communicate tothe rest of the control to optimize Volt/Hzperformance and to shut down the AVRoutput during idle.

The AUX 103 also communicates Backup StartDisconnect information.

Notes:





10

PWM and Self Excitation

The PCC3300 collects main alternator output power at J 18 1 & 2 which isgenset rated frequency.

The PCC 3300 regulates the DC power and then controls the amountof on timefor the signal sent back to the exciter field winding. The Pulse duration of DCsignal is controlled for the needed excitation rate. Pulse Width Modulation

The PCC3300 rectifies the incoming phases for a ripple DC power signal.

Visual 3-10 PCC 3300 and Self Excitation


Self Excitation uses 2 phases of power comingoff the main output leads of the generator forpowering the voltage regulation process. andthe voltage could be as low as 100 volts to ashigh as 240 volts RMS.

PWM provides very high performance forvoltage regulation response. One of the mainshortcomings of a self excited system is the

lack of supply power to the excitation system when very heavy loads are applied to themain windings. Motor start performance isnot as good with self excitation as you get with PMG power supply.

Notes:





11

The PCC3300 collects 3 phase PMG output power at J 18 which is twice gensetrated frequency.

The PCC 3300 regulates the DC power and then controls the amountof on timefor the signal sent back to the exciter field winding. The Pulse duration of DCsignal is controlled for the needed excitation rate. Pulse Width Modulation

The PCC3300 rectifies the incoming phases for a nearly smooth DC signal.

PWM and PMG Excitation

Visual 3-11 PCC 3300 PMG Excitation


PMG Excitation offers many advantages overSelf Excitation.

PMGs are not affected by harmonics orloading on the main windings and canprovide a clean source of the neededpower to the voltage regulation system asneeded when needed.

As can be noticed in the above image of thePWM signal, the on time (red) and the off time will vary. If the on time increases,the voltage will increase. The variation of this relationship is called the “% DutyCycle” on previous controls. Now it istermed AVR PWM Software

Command.

Notes:





12

PCC 3300 Start Disconnect

The PC 3.3 can use multiple signal or inputs forstarter disconnect.

Primary Start Disconnect:– ECM speed reference

– Battery Charging Alternator output

Alternator Frequency

AUX 103 Provides Backup Start Disconnect:– If PMG – PMG voltage (105 volt AC)

– If Self Excited – Alternator frequency

Visual 3-12 Start Disconnect


The PCC 3300 provides for multiple formsand options for starter disconnect.

The PCC control provides control of thestarter control relay, but in FAEapplications the ECM is the one whodecides when the primary starterdisconnect should take place. On FAEapplications the EPS (Speed Reference) is

determined by the ECM and theinformation is communicated throughCAN to the genset PCC control.

If PMG is used, the AUX 103 determinesbackup start disconnect when PMGvoltage achieves 105 volts.

Notes:





13

Quiz: PCC 3300 Sequence of Operation

Activities:

Visual 3-13 PCC 3300 Activities - Sequence of Operation


Work through the Quiz found in the Activityportion of Section 15.

Notes:





Wrap-Up

In this lesson we have learned about the operation information about the PCC 3300 control board.

First we talked about the PCC 3300 Control board connections and the HMI 320 Operator Panel as

a quick review.

Next we talked about the control operation sequence during a engine start through shutdown.

Next we talked about the start modes available on the PCC 3.3 control.

Next we looked at the excitation operation possibilities. Finally, we mentioned the start disconnect.

Are there any questions that you have about the operation of PC 3.3 controls we have not yet

covered? The following section will look at installation, and connections details.








PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 Installation


PowerCommand

3.3

Section 4: Control Installation

Visual 4-1





Section 4

PowerCommand Control 3300 Installation


Materials Needed

Wiring Diagram 0630-3440 (A007M115 D) Sheets 1 to 18 or diagrams in 900-0670

PowerCommand Control 3300 Participant’s Guide Guide (CMT6068-EN-PG)

PC 3.3 Controller Service Manual #900-0670





Warm Up

In this lesson we are going to look at the installation and connections that can be used with thePowerCommand Control 3300.

We will also give you a chance to work with some optional devices and controls at your workstations.

Objectives


• Understand options for the PowerCommand Control 3300.

• Identify the correct connection points on options and the PCC 3300 control module.

• Connect and install options for the PowerCommand Control 3300.





2

Control and Option Installation

Physical Installation Requirements

Identify each of the connectors

Input and Output Connections

Visual 4-2 Control and Option Installation.

Control Installation


Most technicians will encounter the PCC3300 when it is already installed onto a factorybuilt generator set. However, there will besituations when technicians will need toknow about proper installation of the PCC3300, such as instances when an

old/obsolete control needs to be replacedor when troubleshooting, or if addingmore features or options.

Attaching to and utilizing the I/O features will be the most common reason tobecome familiar with the connectors onthis control.

Notes:

Adding options in the field will most likelybe a common occurrence





3

Installation Steps for Options

Place Genset in OFF Mode & Press E-Stop

Turn Battery Charger Off

Disconnect Battery (Lock-out & Tag-out)

Static Wrist Strap (Not if AC power present possible

600v present)

Install Option, (Bargraph, Sensor, Harness, etc.)

Install Wiring Harness

Battery Connected (Remove Lock-out) Download Proper Calibration

Turn on Battery Charger

Test Generator Set

Visual 4-3 Installation Steps for PowerCommand Control 3300 Options


Installing Options

The PowerCommand Control 3300 cannot bepowered down except by disconnecting thebattery cable.

IMPORTANT! Press the local EmergencyStop button and wait approximately 30seconds before removing battery power.

The ECM needs to save data in

memory before power down.Pressing the E-Stop (Keyswitch)

initiates the save process. If the

ECM experiences an

unanticipated power down, ECM

files may be corrupted.

Notes:






Disable the battery charger FIRST! thendisconnect the battery − Negative cablefirst. Remember to remove the chassis

end of the negative battery cable toprevent sparking and possible batteryexplosions. In class we will power downthe simulator to remove power from thecontrol. Remove control-housing cover(s)and connect your wrist strap.

Static wrist straps are recommended toprevent static discharge damage to the

control boards, but this control may

have up to 600vac bus power

connected. For safety reasons, it is bestNOT to use a wrist strap, but antistatichandling measures must be employed.

Install the new option or card or othermodules, etc.

Install the wiring harness for the option.

Reconnect battery and enable the batterycharger. Remove Lock-out Tag-out.

If necessary, use InPower service software to

enable the feature(s) or set the requiredparameters.

Test the generator set with the new option toverify proper operation.

Notes:

Additional Notes or Comments _______________________________________________________________________________





4

Baseboard Connector LocationJ12- Gen CT Inputs

TB15- Service / MODBUS

J22- Gen Voltage

J25- Display Connections

TB7- Bus Voltage

TB5- Circuit Breaker Control

TB10- Circuit

Breaker Status

J26- Engine Interconnect

TB3 - Customer I/O

J14- Service Interface

TB8- Customer I/O

TB1 – Customer I/O

J20- Genset input/outputs

TB9- Analog I/O

Bus CT Inputs

Visual 4-4 Connector Location -r PowerCommand Control 3300


Like the PC 1.X & 2.X, the PowerCommand3.3 also uses the new common connectorscheme.

All connectors use a tension or mechanicallatch to hold the harness jack in place.

All connectors are keyed so the harness jack

will not be inserted incorrectly.

Notes:





5

Bus CT Connections

CT1 CT2 CT3

Visual 4-5 Control Board CT Connections


There are 3 donut style CTs mounted to theboard and they are used for monitor of Bus current, not Genset current.

These CTs are polarity sensitive and arelimited to a maximum of 5 amp pass-through.

These CTs are looking for a signal from thebus primary CT mounted in the

switchgear bus. Passing the output loopfrom the bus CT through the center of each CT will induce a signal for the PCCto measure.

Make sure each CT is monitoring the properphase as the voltage sense!

Notes:





6

J12 Connections

Pin 4

Pin 1

Pin 6

Pin 3

Visual 4-6 J12 Inputs


J12 provides input from the genset mountedCT and monitor genset output current.

Input is limited to a standard 0 to 5 amp. CT.

The plug is keyed so incorrect insertion willbe minimized.

The genset harness will be prewired and it isunlikely that the plug can be inserted

wrong. However, the wires at the otherend of this plug are susceptible tomiswire.

Do Not unplug this connector while

the genset is operating! Shortingblocks or some sort of shorting systemmust be used to protect the Gen CTs fromopen circuit when unplugged.

Notes:





7

J22 Gen Voltage Connections

Pin 1 Pin 4

Visual 4-7 J22 Gen Voltage Inputs


J22 provides voltage sensing inputs to thecontrol. The control uses this informationfor voltage regulation and other protectionfunctions.

There are 4 pins on this connection. 1 pin foreach phase plus neutral.

J22 is rated to accept up to 600 volt AC. Forvoltages greater than 600, a PotentialTransformer (PT) must be used to lowerthe voltage down to an acceptable level.

Refer to Service Manual 900-0670 Section 2for proper PT Sizing Rules.

Notes:





8

J20 Gen I/O Connections

Pin 22

Pin 1Pin 12

Pin 11

Visual 4-8 J20 Genset I/O Connections


J20 provides connection for most gensetfeatures.

Notice J20-16 is the Oil Priming Pump Driver which was discussed previously in lesson3.

J20-9 & 10 are Fused B+ inputs and need tobe fused for a maximum of 20 amp.

Low Side IS NOT THE SAME ASBATTERY GROUND!

B+ RETURN = Battery Negative

B+ RETURN IS NOT EQUAL TO

GROUND

Notes:





9

J25 Display Connections

Pin 1

Pin 6

Pin 7

Pin 12

Visual 4-9 J25 Display Connections


J25 uses the exact same connection points atused on PC 1.X and 2.X controls.

J25 provides connection for PCCNET displayconnection.

Notes:





10

J26 Engine Interconnect

Pin 18

Pin 10

Pin 9

Pin 1

Visual 4-10 J26 Engine Interconnect


J26 is used for engine and AVR Power Stageconnection.

Standard SAE J1939 communications can beconnected at J26-1, 10, & 11. On thechart, this may seem spread outhaphazardly, but if you look at theconnector you will notice they areconsolidated neatly.

J26 – 7 & 14 provide F1 & F2 informationfrom the AVR Power Stage to the PCC3300 processor to so it can properlymonitor and protect the excitation system.

Notes:





11

J14 Data / Service Interface

Pin 9

Pin 5

Pin 6

Pin 1

J14 DATA LINK (RS232)

Visual 4-11 J14 Data/Service Interface


This communication port is used tocommunicate with a computer running aPC based service tool. This port can alsobe used to communicate with the externaldevices via the MODBUS protocol.

InPower service cable #0338-3277 can beused to communicate direct into the boardusing RS232 communication from your

computer port.

Notes:





12

TB1 Customer I/O ConnectionsPin 16 Pin 1

Visual 4-12 TB1 Customer Connections


PCCNet connections on TB1-1, 2, & 3duplicate the PCCNet functions andconnections of J25.

Ready to Load on TB1-4 becomes active when the genset achieves 90% voltageand/or frequency during startup.

Look at page 9 of print 0630-3440. At the topof the page next to TB1 – Basic you will

see , this is thepart number for the connector terminalblock that is missing on the above visual.

Remote Start is between TB1-10 & 11.

Notes:





13

TB3 Customer I/O ConnectionsPin 12 Pin 1

Visual 4-13 TB3 Customer I/O connection


TB3 has many inputs that will be utilized with the PTC functions to be released inPhase 2.

TB3-11 & 12 are utilized in many parallelingapplications for First Start arbitration.

Notes:





14

TB5 Circuit Breaker ControlPin 9 Pin 1

Visual 4-14 TB5 Breaker connections


TB5 is reserved for connections devoted tocontrolling Genset breakers and Utility(Mains) breakers.

More details about these connections will becovered in later lessons.

Refer to print 630-3440 page 13 through 17or Appendix A page A-7, through A-11 of

the 900-0670 Service Manual.

Notes:





15

TB8 Customer ConnectionsPin 13 Pin 1

Visual 4-15 TB8 Customer Connections


TB8 is used in paralleling applications forseveral control functions. Mostconnections will be shown in CPGparalleling interconnect drawings.

The inputs are used for parallelingperformance commands.

More details about these connections will be

covered in later lessons.

Refer to print 630-3440 page 13 through 17or Appendix A page A-7, through A-11 of the 900-0670 Service Manual.

In the PC 2.X course, this connector was

referred to as the Premium Connector .

Notes:





16

TB10 Breaker Status Connections

Pin 17 Pin 1

Visual 4-16 TB10Breaker status connections


TB10 accepts breaker status for both utility(Mains) and genset breaker. There arealso a couple paralleling performancecommand inputs.

print 630-3440 page 12 through 17 or Appendix A page A-6, through A-11of the 900-0670 Service Manual.

Notes:





17

TB15 Data / Service Interface

Pin 5

Pin 1

Visual 4-17 TB15 Service tool connection


TB15 is the standard service tool connectionport.

This port can be used for InPower connectionor it can be used for ModBuscommunications, but it cannot be used forboth simultaneously.

Notes:





18

TB9 Analog I/O Connections

Pin 11

Pin 1

Visual 4-18 TB9 Analog connections


TB9 provides analog paralleling loadmanagement input and output.

Look at Section 2 page 15 through 18 of theService Manual 900-670 for details aboutthe connection made to this terminalblock.

The analog voltage is 0 to 5 volt. TB9 does

not have any 4 to 20 milliamp signalterminals.

The details about connection to this TB willbe covered in later paralleling lessons.

Notes:





19

TB7 Gen Bus/Utility Voltage SensePin 4Pin 1

Visual 4-19 TB7 Bus sense connection


TB7 provides the bus voltage sense input tothe control.

This connection will sense up to 600 vac. If the bus voltage exceeds 600 vac, a PT/VT(Potential Transformer/VoltageTransformer) must be used to lower thebus voltage to a value less than 600 volts.

More details about this connection and

InPower setup will be covered in laterlessons.

Notes:





20

AVR Power Stage Connectors

Pin 1

Pin 2

Pin 1

Visual 4-20 J17 - 18 Inputs and Outputs

J17 Excitation Field Power


J17-1 supplies excitation positive to X1 (F1)

J17-2 supplies excitation negative to X1 (F1)

Notes:





J18 Voltage Regulation Power Supply - maximum input is 240 VAC


The PCC 3300 will operate in either a self excited (Shunt excitation) mode or inPMG excitation mode.

J18 can receive input from either thealternator output, or from phase 1 & 2 of aPMG.

J18 has 3 connector pins; however, only 2 of them are used in Self Excitedapplications.

The J18-1 & 2 inputs are limited to amaximum input of 240 VAC.

CGT (Cummins Generator Technologiessupplies 600 VAC alternators with aspecial winding tap that supplies theproper voltage for voltage regulator input.If these taps are not available, propertransformers must supply 240 VAC orless to the J18 inputs.

Notes:





21

AVR J19 Interconnect

Pin 14

Pin 1

Visual 4-22 Operator Panel Installation


The AVR J19 connector is expected to beused on all applications.

There is a short connection harness from the AUX 103 J19 terminal that plugs into theJ26 interconnect harness.

J19 – 4 & 10 are reserved for future plans tomonitor field current. This is not

supported during the Phase 1 program.

Notes:





22




Visual 4-22 Operator Panel Installation


The HMI320 Local Control is required and isexpected to be used on all applications.

The HMI320 Remote is optional and is notused on all applications.

Optional languages can be loaded(programmed) into the HMI

Environmental installation requirements arelisted on this visual.

Notes:





23


Visual 4-23 Installation HMI320


Refer to Service Manual #900-0670 Section2-24 for proper connection information.

LED11 blinks at a 1 second rate to indicate aHeartbeat. If it is not blinking it is dead,or the control is in a Power Down Mode.

TB15 is a connection for InPower and is usedfor calibration updates.

Inserting a jumper across J36 will prevent theHMI from entering Power Down Mode,thereby engaging the Bi-directionalWakeup mode for the entire PCCNetcontrol system.

Notes:





24

Common Connector Scheme 0630-3440


The PC 1, 2, & 3 generation of PowerCommand Controls will use a newCommon Connector Scheme.

Genset connections are displayed on print0630-3440, pages 1 through 11.Pages 12through 18 concentrate on parallelingconnections.

The same basic “J” connectors are used on all3 series and phases of controls allowingfor simplified control upgrades withoutchanging engine harnesses.

There are many new features imbedded in theprint. Look at each Legend, and you willnotice valuable information.

Notes:





25

Activities

Section 4: In-Class Quiz

Visual 4-14 Quiz Listing for Section 4


At this time I would like you to work alone tocomplete the quiz.

Notes:



PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300Installation


Wrap-Up

In this lesson, we have learned about installation of the PCC 3300 genset control andimportant connection locations.

We talked about each individual connector and the connections available from the controlto the genset components and why each is important.

We also encountered the Common Connector Scheme diagrams.

Q. Are there any questions we have not yet covered about installation of the PCC 3300?



PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 Setup and InPower


PowerCommand

3.3

Section 5: Control Setup and InPower

Visual 5-1 Control Setup & InPower





Section 5

PowerCommand Control 3300 Control Setup and

InPower


Materials Needed

PowerCommand Control 3300 Participant’s Guide (CMT6068-EN-TG)

PC with InPower v 7.0 or later installed

Registered Dongle or authorization code.

InPower Connection Cable Kit #0541-1199





Warm Up

In this lesson we are going to learn about the InPower parameters for the PowerCommandControl3300.

You will have a chance to use InPower with the training controls as an in-class activity after wecomplete the lesson material.

Objectives

After completing this lesson, participants should be able to:

• Connect a PC running InPower service tool software to a PowerCommand Control 3300.

• Download a capture file from the control to your PC.

• Identify the parameters used in setting up a PowerCommand Control 3300.

• Identify the parameters used in troubleshooting a PowerCommand Control 3300.

• Identify the parameters used in testing a PowerCommand Control 3300.





2

Connecting to a PCC 3300

Visual 5-2 Connecting to a PCC 3300 with InPower software


Connect your hardware lock (dongle) to theUSB port of your PC and start the PC.Log in to your PC using one of thesecurity schemes discussed in theInPower class or on the Power GenerationUniversity training program.

The converter and cable of Communication

Kit #0541-1199 is also used whenconnecting InPower to a PC 3.3 controlsystem.

Notes:










3

InPower Service Tool Software

Visual 5-3 In-Power service software connected to a PCC 3300 control


The screen structure is different for thePCC3300 than some other controls. Thereare several new features.

• Advanced Status allows you to monitor avast amount of engine, alternator, gensetand fuel system performance and data.

• Alternator Data contains monitoring

points for alternator performance dataonly.

• Engine Data contains monitoring pointsfor engine performance data only.

Notes:






• Setup is a folder containing functions thatused to be found in the Adjustmentsfolder

• Faults contains information and faultconfigurations

• Test provides access to a great many testfeatures such as Witness Test Folder

Notes:

Additional Notes:





4


This choice will take you to asetup screen

A simple right mousebutton click on theSETUP folder willbring up the dialogbox with the

Genset OEM Setup

choice

Visual 5-4 InPower Setup


The PCC 2300 and 3300 both have a specialGenset OEM Setup function choice. Thisfeature facilitates easy setup of all of thesame OEM setup functions we looked atin Lesson 2 about the HMI screens.

Just like on the HMI, there are setup screensfor:

• OEM Alternator Setup (2 screens)

• OEM Engine Setup (6 screens)

• OEM Genset Setup (4 screens)

Notes:





5

InPower: Genset OEM Setup

Screen 1Radio buttonsaccept asimple click toactivate ordeactivate

Adjustablerating withlisting of possible range

Text boxesaccept upper

and lowercase

alphabet,numerals,

and specialcharacters.

Visual 5-5 Genset OEM Setup


The first default screen is page 1 of the OEMGenset Setup. This screen offers the exactsame setup functions as found on thispage in the HMI OEM Genset Setupscreen.

Notice the “Setup Mode Disabled” button inthe lower left corner. If it is highlighted,you are prevented from implementing

changes. Click on the “Enable SetupMode” to activate all of the adjustmentchoices.

InPower must be connected to the control toenter the Enable Setup Mode. You cannotmake changes to a capture file.

Notes:





6

Setup Screen: Genset Screen 2

Check boxesaccept asimple click toactivate or

deactivate

Visual 5-6 Battle Short


Battle Short setup procedures are morecomplex than placing a simple check inthis screens checkbox. Refer to theService Manual 0900-0670 Section 7 fordetails on the proper mode configurationprocess. There are approximately 6 pagesdevoted to the procedures involved withactivating the mode.

Removing the check in a Factory Lock checkbox will allow the input or output to beused for a different purpose.

Notes:





7


Radio buttonsaccept a simpleclick to changeresponse to:None,Warning, orShutdown

Text boxesonly use

upper casealphabet,numerals,

and specialcharacters.

Response must

be set to:Warning, orShutdownto enter text intothe Fault Textbox.

Visual 5-7 Configurable Switch Settings


Screen 3 allows you to set these ConfigurableInputs:

• Input #1, #2, #13 & #14

• Response of None, Warning, orShutdownEvent

• Names for display at the HMI displayscreen (s), or transmission via a ModBusregister (16 characters of text maximum)

Notes:





8


Visual 5-8 Genset Settings


These settings allow for easy configuration of premium genset options available fromthe factory. The genset wire harness haspreconfigured inputs for factory gensetoptions such as a sub base fuel tank or anoptional coolant level sensor.

These items would be Factory Lock functions

if enabled at the factory. They are premapped for communications toannunciator lamps and for fault display.

Notes:





9

Setup Screen: Engine Screen 1

Visual 5-9 Engine Setup Screen 1


The PCC 3300 phase 1 release supports Full Authority Electronic Engines, and phase 2 will support mechanical control engines.

Oil Priming Pump enabling requires otheradjustments to be made on other screensfor Time & Pressure requirements.

Fuel System settings support Diesel & several

spark ignited engines.Glow Plug options will be available on some

engines. Time & Temperature settings will be made on other screens.

Starter Owner designates if the ECM or thegenset control sends the start engagementcommand to the starter.

Notes:





10


Visual 5-10 Engine Setup Screen


These parameters are almost all related toHydra mechanical applications.

Watt Sentry is a function for Gas fuel systems.It is described in Section 3 (3 – 19) of Service Manual 0900-0670. It is supposedto help protect large turbocharged gasgenset engine.

Mag Pickup and Flywheel Teeth, functiontogether, Flywheel ring tooth count is usedto calculate RPM.

Notes:





11


Visual 5-11 Engine OEM Setup Screen.


All parameters on Screen 4 support Hydramechanical application. These functions will be covered in Phase 2 training.

Notes:





12


Visual 5-12 Engine Setup Screen 5


The settings in Screen 5 are intended tosupport Hydra Mechanical applications, just like the adjustments we saw in Screen4.

Screens 2 and 6 will also support Hydramechanical functions. The content of screens 2 and 6 will be available when

Phase 2 is complete.

Notes:





13

Setup Screen: Alternator Screen 1

There is no

SHUNT involvedwith the excitationsystem, it is just aterm loosely usedby CPG to describea self excitedregulation system.

Pay attention tothis Note:

Voltages less than600 volts can besensed directly

without a PT.

There are usefulNotes found onthis page. Followthe directions to

properly set upthe CTs.

Visual 5-13 Alternator Setup


Do not confuse the notes on this screen asimplying that a PT/CT module is used with this control. Remember – this controlcan handle direct 600 volt AC into the J22connection. Refer to page 2-8 of the 0900-0670 Service Manual for PT info.

For CT setup and calibration refer to page 2-5

of the 0900-0670 Service Manual. Do notconfuse these CT settings with Bus CTsettings. This Screen supports the GensetCTs only.

Notes:





14

Setup Screen: Alternator Screen 2

This controlwill support

single and 3phase

generator

output. .

This control isable tomonitor totalKWH output.

You can alsoreset the

KWH meter.

Visual 5-14 Alternator Setup.


The K factors adjust the tuning for regulationperformance. Refer to page 5-51 and 5-52for an explanation of the K1, 2, 3, & 4settings.

• K1 – is similar to GAIN adjustments.

• K2 – is similar to Integral settings forovershoot & undershoot.

• K3 – is similar to a stability setting forresponse.

• K4 - is a calculation value dependent onthe alternator hysterisis characteristics andusually should not be changed.

• Shunt Gain Multiplier should remain at1.5

Notes:





15

InPower Service Tool SoftwareA standard left

mouse button click ontheSETUP folder willprovide a standarddrop down list of more adjustmentfolder.

Choosing the OEM

GENSET SETUPfolder will give you

setup choices in adifferent format fromthe previous visuals –It is your choice howyou prefer to view thescreens.

Visual 5-15 Setup Folders


If you prefer not to use the OEM SetupScreens that we just covered, you canexecute the same functions usingconventional InPower screens for settingup the PCC 3300 control. There arefolders for:

• OEM Alternator Setup• OEM Engine Setup

• OEM Genset Setup

Notes:





16


SETUP containsa folder for setupof the real timeclock. This clockis referenced fortime stamps onfaults and isused forexerciseprograms.

Visual 5-16 Setup Clock


This folder contains a clock setup foradjusting the real time clock. The clock isused for time stamps on faults and for theexerciser scheduler.

If the battery is disconnected, the clock will

continue running for about 4 hour.

Look in Section 5 of the 0900-0670 ServiceManual for details about setting the clock.

Also look at Appendix B of this guide for

detailed info about setting the clock andexerciser.

Clock Year shows 2 digits for the year,however it does not show a 0 before theyear, so 8 is all that will be shown for2008.

Notes:





17

InPower Service Tool - FAULTS

Visual 5-17 Fault Screens


The FAULTS folder convenientlyconsolidates all fault information in onelocation. There are 3 main folders for:

• Active Faults

• Events and Faults

• Fault History

In the Events and Faults folder, under theSnapshot column it is possible to select afault that will record data for thepreceding few seconds before a faultbecomes active. The memory of the PCC3300 holds a limited amount of snapshotdata, so only turn on snapshots of important points.

Notes:





18

InPower: History & About

The History/Aboutfolder containsseveral adjustmenttrims that allowkeyboard insertionof Serial and Modelnumbers

Visual 5-18 History & About


In an earlier section you discovered that serialand model numbers could be inserted viathe HMI setup using many consecutivebutton pushes. InPower allows you to usethe computer keyboard to type thecharacter.

Notes:





19

Activities

5-1 PC 3.3 Setup and InPower Quiz

5-2 Real Time Clock Setup

Visual 5-15Activities Listing for Lesson 1


You will find Section 5 Activities in Section15 of your guide.

Please find the Activities and at this time and work as teams to complete theseactivities.

Notes:





Wrap-Up

In this lesson we have reviewed using InPower version 7.0 or later with the PCC 3300. First wetalked about connecting to the PCC 3300 control at TB15 with the RS-485 to RS-232 adapter and

the Cummins cable.We then discussed the main InPower folders and parameters available when connected.

Q. Are there any questions we have not yet covered that you may have?

In the next lesson we will learn about the PCC 3300PCCNet Communications.



PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 PCCNET

Participants’ Guide Section6 Page1

PowerCommand

3.3

Section 6: PC 3.3 & PCCNet

Visual 6-1 PCCNet





Section 6

PCCNet Network for the PCC 3300


Materials Needed

PowerCommand Control 3300 Participant’s Guide (CMT6068-EN-PG)

Universal Annunciator Operator’s Manual (optional) (900-0301)

Universal Annunciator Quick Reference Card (optional) (900-0304) Instructor’s Note: This lesson presents information on the PCCNet modules used with thePowerCommand Control 3300: Universal Annunciator, and HMI Control Panel. The Phase 1release of the PC 3.3 supports only a few PCCNet devices, Phase 2 will support more.

Warm Up

In this lesson, we are going to look at the optional devices that communicate with thePowerCommand Control 3300.

We will also give you a chance to work with the optional devices with the controls at your workstations.

First, let us look at the objectives for this lesson:





Objectives


Understand the basic operation of PCCNet communications

Identify the PCCNet devices common to PCC 3300 installations. Connect the Universal Annunciator and/or HMI114 to the PCC 3300 genset control and

simulator.

Configure the Universal Annunciator and/or HMI114 used with PCCNet and the simulator.

Test the Universal Annunciator and/or HMI114 with the PCC 3300 genset control andsimulator.

Participants will use InPower and gain more experience with the setup process and screensfound in InPower.





2

PCCNET Overview

PCCNET is a flexible communication system thatuses a standardized proprietary protocol unique toCummins Power Generation

PCCNET provides device to device connectivity andis supported by many of the PowerCommandgenset controls. It is a dynamic system that supportstwo way communications between many devices.

The list of available devices is subject to changefrom time to time with the addition or subtraction of devices, or device availability differences fromregion to region or application to application.

Visual 6-2


PCCNet is a proprietary communicationsystem used on PCC 3300 and severalother PowerCommand controls anddevices.

PCCNet is a low cost communication systemdeveloped as a solution for simplenetworking. A simple network is limitedto only 1 generator set control.

PCCNet provides functional communication

from device to device and it is not formonitoring or building managementsystems. The ModBus feature is bettersuited to support this.

Notes:





3

PowerCommand PCCNET Overview

2-Wire RS-485 Data Connection

2-Wire Power Connection

Recommended wire: Beldin #9729

Up to 4,000 feet network data wire length

No Termination Required

Total of 20 PCCNET devices on one network.

Visual 6-3


PCCNet Basics on the PCC 3300:

Two Data Wires and Two Power wiresneeded. Beldin #9729 shielded data cableis recommended.

DATA TERMINALS ARE

POLARITY SENSITIVE!

A = + = 1 & B = - = 2

Power Terminals are TB1-5 (+) and TB1-3 (B+ Return)

Up to 4,000 feet maximum networklength with no terminations needed.

PCCNet data connections MUST use adaisy chain topology

Maximum is 20 devices. This countincludes the HMI display and bar graph.

Notes:





4

PCCNET Communication Operation

PCCNet is a Token Passing Network

The authority (Token) to speak (broadcast) passes fromdevice to device on schedule.

Sequence of this schedule is determined during arbitration(Initializing Communication) at power up.

Each device knows who is next in line.

The Token holder is the only device allowed to speak.

If there are no communications from a device, and thisexceeds 10 seconds, ALL other devices arbitrate again.

Visual 6-4 PCCNet Operation


Broadcast Messages are output messages from adevice that has a hard-wired input. Broadcastmessages are sent out:

• every time the input changes, or

• every five seconds.

Gensets broadcast NFPA-110 data to thenetwork. Annunciators listen for thesemessages. Annunciators will also broadcastupdates of their hard-wired inputs.

The token is passed from device to device insequence and each device reports its status within the 5 seconds it takes to pass thetoken throughout the group.

If a device is unplugged or if it fails, the rest of the network will notice the absence and willre-negotiate the communication sequence.

Notes:





5

PCCNET Devices – PCC 3300

PCC 3300 communicates with these devices

HMI 320 plus Remote HMI 320

HMI 220 (Specific applications only)

AUX101 & 102 Module (Max. 2 set) (Available @ Phase 2)

HMI 112 (Bar Graph) (9 Bar Display only)

HMI 114 (Horizontal Bar Graph)

HMI 113 (Universal Annunciator)MCM 3320 (Someday)

This list may change with the addition of new or special devices

Visual 6-5 PCCNet Devices


These are the most common devices that youcan expect to encounter on a PCC 3300application.

HMI 320 – Previously called a display,touch screen, or customer interface.

HMI 220 – For special productapplications only. Special programmingof the HMI is needed for it tocommunicate to the PCC 3300

AUX 101 & 102 – Remote relay device with expansion module. The PCC 3300 will not communicate to the AUX 101until the release of Phase 2.

HMI 112 –Bar graph display. PCC 3300calculates power factor, so only the 9column display P/N 0300-6050-01 will befound with PCC 3300 controls.

Notes:






HMI 113 – Universal Annunciator. Thisitem was the original PCCNet device andit was first used with the PCC 2100

control. It is primarily used in the North American market, but it is sometimesfound in some global projects.

Notes:

6

PC 3.3 PCCNet Architecture

PCCNetNetwork(4 wire)

HMI113

OptionOption

AVR Power Stag e

HMI114

Remote HMI320

HMI320

Option

PCC3300

AUX101&102 (Future)

Not aPCCNetdevice

AUX 103

Visual 6-6 PCCNet Architecture





7

Configuring with InPower

This value is determined during initial arbitrations.

Visual 6-7 PCCNet setup with InPower


There is one folder devoted for configuringPCCNet devices in InPower.

Phase 1 of the PC 3.3 control will notcommunicated to the AUX 101/102 soInPower will only show setup for theHMI 113 and the other supported PCCNetdevices.

The Annunciator configuration process isexactly the same between PC 2.X and PC3.X

There is a ModBus annunciator for use inParalleling Master Control systems. Somedetails about that annunciator will becovered in the ModBus lesson.

Notes:






InPower allows you to configure some of the

PCCNet device to launch a fault that willtell you if a device is no longer able tocommunicate on the network.

You have the option to configure a device toignore a device that is no longercommunicating by leaving at the default Non-Critical Device Response, or you canset it to a Critical Device Response.

If you have multiple HMI 320s in the systemand only 1 fails its communications, the

other HMI 320s will display a PCCNetfailure alarm.

The “PCCNet Device Failure Time Delay”is adjustable from 0 seconds to amaximum of 250 seconds. If the PCCNetsystem cannot re-establishcommunication to the device set toCritical Device Response by the end of this set time, a fault will be generated.

Notes:





8

HMI 113 Universal Annunciator

Visual 6-8 Universal Annunciator


The PCCNet Annunciator has Network andPhysical inputs.

This annunciator supports both Network wiring and discrete wiring terminals

There can be up to four annunciators in anetwork. If their configuration modes aredifferent, they will display different

information.There is a Universal Annunciator Operator’s

Manual available (900-0301) that coversinstallation and service topics, and there isa quick reference card (900-0304) thatprovides configuration notes.

Notes:

REMEMBER! The annunciator only works with PCCNet or hard-wired installations,and cannot be used in a LonWorks basednetwork.





9

PCCNet HMI 113 Switch Settings

Setup ModeMust beENABLED towrite changesto the PCCNetsetup.

Inputs at theAnnunciator canbe configuredas faults to bedisplayed onthe HMI 320

screen.

Output relays atthe Annunciatorcan be set up toactuate for anyfault codeoriginating fromthe PC 3.3

Visual 6-9 Annunciator Switch Settings


InPower is used for changing PCCNet Annunciator Switch Settings and can onlybe changed when the device iscommunicating with the PCC Gensetcontrol

Faults 1, 2, & 3 are fault inputs FROM theannunciator TO the PCC 3300 anddisplayed on the HMI 320.The text

inserted into the Value box will bedisplayed when the input is active.

The PC 3.3 can control four (4) output relayslocated on the Annunciator. Insert thegenset fault/event code number you desireinto the value area and when it becomesactive at the control, the control will send arelay close command to the Annunciator.

Notes:





10

HMI 112 Bargraph

Visual 6-10 Vertical display Bargraph


The HMI 112 is optional and in rareoccasions, it may be encountered on a PC3.3 system. It has previously been referredto as the Bar Graph display.

The PCC 3300 is able to and does calculatePower Factor, therefore only the optionalP/N 0300-6050-01 HMI112 version that

has 9 bars is used.

There are no setup parameters for this devicein InPower or in the HMI 320 setupscreens.

The device is truly and completely Plug &Play

Notes:





10

HMI 114 Bargraph

0300-6366-02

J 1

J 6

J 3

J 6 J 1

2 1 5 4 3 2 1

J 3

1

8

Visual 6-11 Configuring the Universal Annunciator


The HMI 114 is a new bargraph and is anoptional device.

There are no setup parameters for this deviceas it is truly a plug & play device.

The J3 connection on the back of the HMI114 is the same as J29 connection of theHMI 320. If this jumper is in placebetween J3-4 & 5, it will keep the system

awake at all times and will not allow it togo into power-down mode (Sleep).

Notes:





12

PCCNET Troubleshooting

The HMI fault response type feature provides a way todeduce PCCNet communication problems.

HMI display capabilities also allow checking of thenetwork integrity.

Visual 6-12 Troubleshooting PCCNet systems.


Troubleshooting PCCNet networks can be

easy ---- if you want it to be! As mentioned previously, PCCNet is based

on an EIA communication standardreferred to as RS485. This standardizedindustrial protocol has been in use sincethe 1960s and is well understood in theelectronics industry. There are manycommercially available testing tools suchas protocol analyzers, signal strength &interference testing equipment and mediatest equipment. If you are experienced with and/or have access to such tools, usethem. If you are unfamiliar with suchitems, there is no need to invest inadditional equipment beyond your usualPowerCommand troubleshootingequipment.

Notes:






InPower is an excellent troubleshooting tool when working with PCCNet networks.Use it to check if a device is enabled. The

InPower communication system that isused on the PCC 3300 is actually aPCCNet system so if you are able toconnect to the HMI or to TB15, then youknow PCCNet is operational on thoseitems.

The most common and best tool available isyour own ingenuity. Here are somesuggestions that my help you reason andfigure out the cause for a networkproblem:

Shut down power to the entire PCCNetNetwork. When power is restored, each of the devices will try to reestablishcommunication and “arbitrate”. If one ormore of the devices was confused, it maybegin working properly after cyclingpower.

Wire problems are the most commonfailure. Check continuity of each of thecomm.. wires and check if B+ and B- isavailable at each of the modules.

If the wires check out ok, trydisconnecting the device at the far end of the network. Keep doing this as you workyour way back to the PCC 3300, or untilthe Network begins to work again.

Retrieve all the devices in the Networkand bring them all close to the 3300 andconnect them with very short sections of good wire and see if the system works.

Start connecting each device 1 at a time tosee if one causes the Network to fail. Thistechnique also helps identify if there areproblems with an environment that causescommunication problems. This helpsidentify if the wire is incompatible withthe installation, or if EMI noise is present.

Notes:






Check the wire installation throughout thefacility. The communication wire shouldcross power lines/conduits or any AC

power in a perpendicular fashion andshould never be run parallel to a linecarrying AC power.

Pay attention to the facility! Look aroundyou.

During troubleshooting, it is common forsomeone to assume the device they knowthe least about is the problem component.Resist this temptation. Check the thingsyou know the most about and reach a

conclusion about a failed component aftera process of elimination trial.

Sometimes a device will fail, but mostimportantly, do not ASSUME that thedevice failed – try to prove it! Look for areason for it to fail too.

Notes:





13

Activities

6-1 Universal Annunciator Connections

6-2 Configure Annunciator for Fault Inputs

6-3 Configure Annunciator for Relay Outputs

6-4 Quiz

Visual 6-13 Activities


The Activity Guide for Section 6 PCCNetexercises is found in Section 15.

At this time, please work as teams tocomplete these activities.

Notes:



PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300PCCNET


Wrap-Up

In this lesson we have learned about the PCCNet network and devices used with the PCC3300.

This lesson gave us the opportunity to learn about the about installation of the PCC 3300PCCNet communication system. We covered the connections that must be made from thegenset control to the various components/devices and why each is important.

Q. Are there any questions we have not yet covered on PCCNet for the PCC 3300?








PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 ModBus

Participant’s Guide Section 7 Page1

PowerCommand

3.3

Section 7:PCC 3300 ModBus Communication

Visual 7-1 ModBus Communications





Section 7:

ModBus and the PCC 3300.


Equipment Needed

Materials Needed

PowerCommand Control 3300 Participant’s Guide (CMT6068-EN-PG)

PC 3.3 SERIES MODBUS REGISTER MAP MANUAL 900-0670 (APPENDIX D)

Appendix B – Using ModScan Software (CMT6068-EN-PG)

Computer: must meet system requirement to effectively operated InPower 7.0 or higher.

InPower Connection Cable (P/N: 0541-1199)





Warm Up

In this lesson, we are going to look at the on board ModBus system that communicates informationfrom the PowerCommand Control 3300.

First, let us look at the objectives for this lesson:

Objectives


Understand the basic operation of ModBus communications

Identify the ModBus port on the PCC 3300 control.

Connect to the ModBus port on the PCC 3300 control.

Configure and setup the ModBus port on the PCC 3300 control using InPower or the HMI320.

Test the ModBus communications.





2

ModBus Overview

ModBus is a industrial communication protocolsystem that is not controlled by or influenced byCummins Power Generation. It is considered a“Open Protocol”

ModBus is not related to PowerCommand Networksor PCCNet.

ModBus operates using industry standards and in

the case of Cummins Power Generation gensetcontrols, it is usually used as a communicationprotocol that enables others to gain communicationaccess to the generator set control.

Visual 7-2 ModBus overview


ModBus is an open communication systemavailable onboard the PCC 3300

ModBus was developed in the 1970’s as anindustrial protocol to work with ModiconPLCs (Programmable Logic Control)

Unlike PCCNet, ModBus does providefunctional communication for monitoringor building management systems. TheModBus feature is well suited to support

this. All of the content of the ModBus

communication messages arepredetermined and cannot be changed inthe field.

(The term message has a very specificmeaning in ModBus, so from now on we willcall these packets of info Registers.)

Notes:





3

ModBus Overview

CPG uses ModBus over Serial Line Protocol.

ModBus Serial Line protocol is a Master - Slave protocol.

A Master-slave type system can have only one master node and multipleslave nodes.

The PC1.X, 2.X & 3.3 controls are a Slave Node.

A bus can accommodate 32 devices without repeaters, but up to amaximum of 247 slave nodes can exist on a large ModBus network bus.

ModBus can communicate using many different physical media. The PCC1302 uses EIA-485 (RS485) two-wire (2 wire) interface.

ModBus can use two different serial transmission modes: RTU mode orASCII mode.

All ModBus transmissions are verified for CRC errors.

Visual 7-3 ModBus overview


The PCC 3300 ModBus port is a serial port.It follows EIA standards and isconfigured for rs485:

ModBus is comprised of multiple differenttransmission modes. The most commonmodes encountered on CPG systems are:

RTU. (modern & most common)

ASCII (considered old & rare and isnot used on the PCC 3300)

ModBus is a Master – Slave communication

system There can only be 1 master.

There can be up to 247 slave devices.

The PCC 3300 can ONLY be a slavedevice.

The slave address can be assigned inthe field.

Notes:






In a master – slave system, the master devicerequests data from a particular slavedevice. This is called a poll. The register

sent back from the slave device is called aresponse.

The slave device does not send any dataunless it is polled by the master. If themaster device sends a command such as aengine start command the slave device will still send back a responseacknowledging that it received thecommand register (poll)

Many communication systems use a CRC

error checking scheme. ModBus does too,and it is highly effective.

CRC stands for Cyclical Redundancy Check, which is a way of checking if a messageis corrupted or damaged during itstransmission. Sometimes this check iscalled a Check Sum.

CRC errors do NOT indicate that a device ishaving trouble or is faulty; it indicatesthat the register created by the device is

good at origination, but it is corrupt at thedestination.

Serial communication systems are verysusceptible to electro-magneticinterference and other electronic noise, soit is not considered the best choice forinstallation into a power generationenvironment. Therefore the CRC errorchecking feature built into ModBus isvery important.

The PCC 3300 is not able to warn you of CRC errors, but the master device in thesystem will. Since the master device isusually the responsibility of a 3rd party,you will need to work with them toidentify and resolve the problem.

Notes:





4

TB15 Data / Service Interface

Pin 5

Pin 1

Visual 7-4 ModBus Connection


TB15 serves a dual function:

• When connected to InPower, it serves as aservice port connection.

• When connected to a ModBus masterdevice and enabled, it will serve as acommunication port connection.

TB15 can also transmit PCCNet, but the porthas to be configured for one or the other, itCAN NOT serve both communicationsystems simultaneously.

For wire connection details, refer to wiringdiagram 0630-3440.

Notes:





5

ModBus wire and PCC 3300

The ModBus network wire type and length is specified byModBus standards, not by Cummins Power Generation.

Use stranded wire to endure the vibration present on gensets.

Refer to www.modbus.org for details and wire specification.

The responsibility for meeting these standards belong to theintegrator who is attaching to the control.

If installing the iWatch product to communicate with the PC3.3, refer to the iWatch installation guide for information aboutthe proper wire.

Visual 7-5 ModBus Cable


Remember the previous statement about

serial communications being susceptibleto EMI and other noise. The type of communication cable used can affectcommunication reliability too.

Designers of Building Management Systems(BMS) usually have a specification for thecable used in their system. It is rare thatCPG installing technicians will berequested to supply the ModBuscommunication cable.

If installing an iWatch to monitor a PCC3300, try to keep the ModBus cable asshort as possible or practical. Details of the installation will be found in theiWatch installation guide.

A 120Ω, ¼ watt terminator resistor iscommonly installed in long bus applicationsto suppress signal reflections.

Notes:





6

ModBus Setup with InPower

Visual 7-6 InPower Configuration of the ModBus port


There is a ModBus Setup folder locatedunder the Setup folder of InPower.

There are 8 adjustments found in the ModBusSetup folder along with 11 monitorfunctions, and 10 switch functions:

Connect InPower using the normal 541-1199tool connected to TB15. The Setup Mode

Enable must be set to “ Enable” foradjustments to take effect.

Notes:





7

InPower – Setup - ModBus

J 14 and TB15 provide ModBus communications

Setup functions specific to the J 14 connection are labeled

Setup Mode must be ENABLED

Visual 7-7 InPower Configuration of the ModBus port


Refer to section 5-57, “ModBus Setup” of theService Manual #900-0670.

On page 5-58, all the ModBus submenus arepresented.

There are setting for the TB15 connector andthere are adjustments for the J14connector.

Many of the adjustment parameters have adrop box in the value field; a few allowdirect entry of a value.

Notes:






The ModBus Node Address is default as 1;however it may need to change.

The J14 ModBus Node Address is default as

1 also; however it can be changed to adifferent address than the TB15 address.

Recall that a ModBus network may containup to 247 nodes. The node addressidentifies to the ModBus Master which of those 247 devices is the PCC 3300.

The ModBus Baud Rate adjusts the speed of communication that the PCC 3300 mustbe set at to communicate in the Network.

The ModBus Parity setting changes theregister structure per the requirements of

the network design. The default is Even.

The Parity adjustment for TB15 can be setdifferently than the Parity adjustment forJ14.

ModBus Failure Time Delay can trigger fault2939 – ModBus Failure if the Masterresponse time exceeds the set amount of time.

The ModBus Communications Lost ResponseMethod can be set to reset in case there isa loss of communication.

The ModBus settings are usually requested

by the network installer. The Failure

Time Delay and Lost Response Method settings are usually chosen by the CPGinstaller.

Notes:





8

InPower - Monitor - ModBus

Monitor Points

Monitor Points

Visual 7-8 ModBus Monitor Participant’s Text



The visual shows the monitor points.

The appropriate setup values will bedetermined by the system integrator, or

they will be called out by the appropriateinstallation guide provided with the CPGcommunication kit.

Trainers Text






InPower

Of course, it is not possible to monitor acommunicating ModBus network with

InPower since the TB-15 port is used forModBus communication and forconnection to InPower.

The data displayed in the Monitor screens isrecorded data.

Bus Message Count – this is the numberof times that the PCC 3300 has beenpolled by the Master.

Slave Message Count – this is the numberof times the PCC 3300 has responded to

polls. No Response Count – this is the number

of times the PCC 3300 HAS NOT beenable to respond.

CRC Error Count – this is the number of times the network has seen a faultyregister.

Exception Count – this is the number of times the system has seen a correctedversion of a faulty register.

CRC errors are encountered when a register issent correctly, but the receiving deviceviews it and finds errors in it. Thereceiving device will automaticallyrequest that the register be sent again.This error count is very valuable to you if you are troubleshooting ModBuscommunications. It indicates that thedevices are trying to send or receivemessages, but someplace along thetransmission stream, the register is being

damaged. Start inspecting the wiring andconnections. The problem could becaused by poor quality or inadequate wire, poor connections, or environmentalissues such as electromagneticinterference.

Trainers Text





9

ModBus Settings

The ModBus adjustments and settings are alsoaccessible through the HMI 320.

Visual 7-9 HMI Participant’s Text



The visual shows the HMI screen layout.

Trainers Text





10

ModBus Testing & Troubleshooting

ModBus Register Map – Provided by CPG

ModScan – Available as freeware

InPower – Has some minor test capability.

Visual 7-10 Testing ModBus systems.


The ModBus register map is available fromCPG. A copy is attached to the ServiceManual, and is found in Appendix D.

ModScan is 3rd party software that can beused to prove to customers that theModBus port is operational.

InPower can be used to assist withtroubleshooting a ModBus installationthat may not be communicating reliably.

Notes:





11

ModBus Register Map

NFPA110 bitmap (Register 40016)

(LSB)15Low Fuel Level14Low Coolant Level13Overspeed12Low Oil Pressure11Pre–Low Oil Pressure10High Engine Temperature9Pre–High Engine Temperature

8Low Coolant Temperature

7Fail to Start6Charger AC Failure5Low Battery Voltage4High Battery Voltage3Not in Auto2Genset Running1Genset Supplying Load

(MSB)0Common AlarmBitDescription

NFPA 110

MSB = Most Significant Bit

LSG = Least Significant Bit

Visual 7-11 ModBus Register Map


Register maps are specific to the product. Theregister map for a PCC 3300 control is thesame as the map for the PCC 2300control. Other generator sets and systemsmay use different maps, be sure you arereferencing the proper map.

The map provides details about the differenttypes of individual registers. It can tell

you the many details about how to poll it,calibration details about a specificregister, or the combinations of information contained within a particularregister.

Notes:





12

ModScan testing

Registeraddress to

begin polling

Number of registers

to bepolled

Slave addressRegister Type

ModScan

requests tocommunicate

Deviceresponses

toModScanrequests

ModBus register and the datacommunicated from the device

Visual 7-12 ModScan Software


ModScan is not a Cummins product. It isavailable as freeware from WinTech viaWeb download or through several otherfree sources. The free version limitsconnection time to an active ModBusnetwork to 3 minutes, and then it stopspolling. A code to enable unlimitedconnection time is available for purchase

from WinTech.CPG encourages the use of ModScan as a

testing tool to prove to customers andintegrators that the ModBus port iscommunicating properly. There are othersoftware products that can be used too, butModScan is considered a simple to use.

Notes:






ModScan Software.

Once connected, ModScan will poll registersand will allow write registers. Writeregisters will send a command to thegenerator set. A common command is toSTART the genset. The genset must be in Auto for the command to take effect.

It is a simple process to configure ModScanto communicate with PCC 3300, but if you need assistance with proper setup andoperation, refer to the details found in Appendix B

The standard InPower communication cablefrom the computer com port to the PCC3300 TB-15 port can be used. TheRS232/RS485 converter must be usedtoo.

Refer to the ModBus register map to help youidentify the register that you may wish topoll.

The 2 most common register types to checkare:

1. Coil Status – this is an on/off statue indication. 1=ON & 0=OFF

2. Holding Register – thisindicates a message indicating up to 16bits of information. Example in visual7-9 shows register #40016. It willappear 0000000000000000

A common test is to “Write” bit “1” toregister 40300, the genset should start if

the control is in automatic mode.(Remote)

Register 40302 can activate the EmergencyStop. If this is activated via ModBus, youcannot reset the shutdown at the gensetcontrol until the ModBus command is setto 0.

Notes:





13

ModScan Troubleshooting

This message indicates the device sent a response,but the message string had problems.

This shows that ModScan is trying to talk to thedevice but it is not getting proper responses.

Visual 7-13 ModScan software


Refer to the Appendix about operatingModScan.

Notice the message line in Visual 11 and inVisual 12. The line in Visual 11 indicatesthat ModScan is not able to communicateto anything, but the line in Visual 12indicates that ModScan is talking to a

device but the information is notunderstandable.

Try to keep the length requests as short aspossible, and do not attempt to poll acrossempty registers.

Notes:

.





14

Quiz & Activities

7-1 Quiz (found in section 15)

7-2 Connect InPower and Configure

7-3 Configure at the HMI

7-4 Connect with ModScan (optional)



Find the Section 7 activities in the Section 15.Work with partners to complete eachactivity.

Notes:





Wrap-Up

In this lesson we have learned about the ModBus communication system and the ModBus featurebuilt into the PCC 3300.

First we talked about the basics of ModBus communications and some of the specific informationabout how the system works.

Next we talked about ModBus connection requirement on the PCC 3300, its connectors and wireinformation.

Next we talked about the setup and configuration using InPower and the HMI320 setup.

Then we talked about the testing and troubleshooting. This was separated into 3 separate areas thatrequired additional information.

Lastly we went through each of the testing and troubleshooting tools and information available to

technicians.

This lesson gave us the opportunity to learn some basics of ModBus and a little about thiscommunication feature on the PCC 3300. This section is a basic introduction to ModBuscommunications with PCC control and communication systems. We will continue delving deeperinto ModBus communications with more advanced controls. This section serves as a prerequisitefor training on some of the more advanced PCC controls

Q. Are there any questions we have not yet covered on ModBus for the PCC 3300?








PCC 3.3 & PowerCommand Control 3300 PGI

Participants’ Guide Section 8 Page 1

PowerCommand

3.3

Section 8: PGI CAN

Communication

Visual 8-1 PGI CAN Communications





Section 8

PowerCommand Control 3300 & PGI


Materials Needed

• PowerCommand Control 3300Participant’s Guide Guide (CMT6068-EN-PG)

• PC with InPower v7.0 or higher installed

• Registered Dongle

• InPower Connection Cable Kit #541-1199

• INSITE v7.1 or higher installed

• Peak System Adapter and associated software/drivers installed

• Inline Adapter Kit w/Software and Drivers Installed





Warm Up

In this lesson we are going to learn about the Power Generation Interface (PGI) for thePowerCommandControl 3300.


Objectives

After completing this lesson, participants should be able to:

• Identify the system architecture of a PGI system.

• Locate components of the PGI system.

• Determine how a PGI system is working with the PowerCommand Control 3300.

• Develop general troubleshooting skills.

• Identify test equipment for troubleshooting PGI system.

• Set-up software and drivers for test equipment usage.

• Working knowledge and usage of test equipment to hook up to a PGI system.





2

Cummins Power Generation is moving away from the Full

Authority Engine & Genset controller as found on the PCC

3200 and PCC 3201 (governing, engine protection, features,

etc) and towards communicating with the EBU controllers

like the Motorola CM850, CM876 etc.

New Cummins Power Generation software and hardware

interface has been developed for this purpose. This newinterface is referred to as the Power Generation Interface

(PGI)

What Is PGI?

Visual 8-2 What is PGI?


The Power Generation Interface (PGI)Specification is intended to drivecommonality in the On-Engine Controls(diesel and gas) across the entire CPGproduct line.

Two of the main areas that make up PGI are:

• Physical Datalink

• Electrical Datalink

Datalinks are a way to communicateinformation between systems.

CPG uses Multiplexing Datalinks to send orreceive multiple messages amongelectronic modules using a serial bus.

Notes:





3

FAE / Mech. Engine Alternator

PCC3200 (1 Box)

PCC3201 (1 Box & 2Box)

PCC2100 (1 Box & 2 Box)

PCC1301 (1Box)

Past Control Product

AVR

CorporateGenset

G-Drive

OEM

FAE / Mech.

Engine Alternator

PCC3300 w/ CAN

PCC2300 w/ CAN

PCC1302 w/ CAN

AVR

CMxxx

PCC 1.x, 2.x and 3.x

Product

FAE / Mech.

Engine

GCS

FAE / Mech.

Engine

CMxxx

OEM

Control

No GCS !!!

OEM Control OEM Control

w/ CAN

GCSCMxxx CMYYY

I n t e r f a

c e C A N / J 1 9 3 9

CMxxx With PGI CMYYY W/o PGI

Visual 8-3 PGI Architecture


In Visual 8-3 you see a graphic representationof how the past product lines operate(PCC 2100, 3200, 3201, and 1301). Theyoperate by direct engine control or withthe use of a Genset Controller (GCS).

PCC 3300 can communicate directly with aCummins Engine Controller Module

(ECM) using PGI or to other enginemanufacturers ECM using CANstandards. This training covers PGI basicsand communication to Cummins engines.

Notes:





4

Required Hardware/Software

Inline 4/5 Datalink Adapter (note: Inline 2 will work withCPG products and you do not need to install drivers with thisproduct)

- INLINE 4 Kit P/N - 4918190

- INLINE 5 USB Kit P/N – 4918416

INSITE V6.5.1 – INCAL Calibration Download

InPower V6.0 – CM850/CM876 Products

– All Except QSX15, QSL9-IND

Peak System Adapter – USB CAN adapter

– PCAN Explorer, PCAN View

Visual 8-4 Hardware/Software


In order to view/change parameters andperform certain tests, technicians willneed InPower, INSITE, and Inlinesoftware/hardware/drivers in order toconnect to the engine ECM and PCC3300 control.

An easy and cost effective way to viewsignals and perform simpletroubleshooting tasks is to use the Peak

System Adapter. While the Peak Sys Adapter does not allow you to performcalibrations, it is an easy tool to operateand see if the system ECM and PCC arecommunicating properly.

Trainer’s Guide





5

INSITETM - Monitor & adjust parameters and features

Visual 8-5 INSITE


INSITE is an engine tool that allowstechnicians to perform a variety of enginediagnostic checks as well as calibrationsand adjustments.

With the introduction of the PGI, PowerGentechnicians are needed to understand thistool for troubleshooting as well as setupof the engine. With the increased usageof ECM operated engines for emissionsstandards, technicians should attend acourse on INSITE to gain morefamiliarity than this course will offer.

You can get INSITE information from:insite.cummins.com

Notes:





6

INPOWER TM – Adjustments

Visual 8-6 InPower


With InPower you are able to click on theCORE II ECS icon and perform a varietyof different tests on the system. Youcannot perform these tests whileconnected to the controller and you mustbe connected to the engine harness 9-pinDeutsch plug.

Most notably you are able to perform theWitness Testing Procedures as seen in theInstallation Section of this guide.

Notes:





7

Peak System Adapter

Visual 8-7 Peak System Adapter


The Peak System Adapter allows techniciansto view CAN messages broadcasted onthe system. Here is an example:

Message Interpretation: 18FE7C00h

18 – Priority of the Message

FE7C – PGN (Parameter Group Number)

00 – Source Address (ECM- Parent – Source Address 00, Child 1 – Source Address 01, Child 2 – Source Address 90;

PCC Source Address is DC)

Notes:






You can purchase the Peak Adapter from theCummins Hardware Shelf or from www.gridconnect.com/usbcanin.html

Not only will you need to order the adapteritself, but you will need to buy an inlineCAN terminator. You will also need aCAN cable that allows you to connectfrom the 9-pin plug on your Peak System Adapter to the 3-pin Deutsch connectoron the genset.

After you have all of the required hardware,you will need to download the softwareand associated drivers.

Drivers to operate the Peak System Adaptercan be ordered from the CumminsSoftware Shelf. You will need to orderthese software tools:

• Peak All In One Driver

• PCAN Explorer (optional)

Once you have the hardware and softwareinstalled, you can connect to a device and

read the messages. The software willhave a default baud rate of 500Kbit/sec.This needs to be changed to 250Kbit/secin order to communicate with the PGIsystem.

You do not need the engine running to seemessages transmitted on the system.Once you have the Peak System Adaptersetup properly you will be able to connectand read the messages sent. This tool

provides an easy way to help determine whether the ECM (s), PCC, or backboneis faulty.

Notes:

http://www.gridconnect.com/usbcanin.html

http://www.gridconnect.com/usbcanin.html





8

Location: Engine Harness:

3-Pin Plug Cummins P/N – 3164635 (detail 1), Deutsch DT06-3S-E008

3-Pin Receptacle with 120Ω resistor Cummins P/N – 3163051, Deutsch DT04-3P-P006

Location: Genset Harness:

3-Pin Receptacle Cummins P/N – 3163918 (detail 2) Deutsch DT04-3P-E008

The 3-Pin connectors ONLY supply the SAE J 1939 support (no battery voltage supply)

J1939 Datalink Connector

J1939 Datalink (Shield)C

J1939 Datalink (-)B

J1939 Datalink (+) A

SignalPin

Physical Datalink

Visual 8-8 J1939 Connector


The first portion of PGI we will cover is the PHYSICAL datalink. There are threemain parts of the physical datalink:Backbone, Plugs, and Stubs.

The Backbone consists of a three-wire systemthat has a high, low and a shield wire. Invisual 8-5 above you can see the pinout of this system.

There are two different types of Plugs that areused on this system. The first is the plug

that has orange keys inserted into theDeutsch connector. The second is atermination plug. This is verified by ablue key and is capped with a 120ohmresistor receptacle.

Notes:





9

Basic J1939 Backbone and Stub Configuration

Visual 8-9 J1939 Backbone


The total length of the backbone is not toexceed 40m (approx 131 ft) in length.This is a J1939 SAE standardrequirement.

The Stubs are depicted in Visual 8-6. Thesestubs need to be kept to 1m (approx 3 ft)in length.

There are a maximum of 30 different devicesthat can be installed on the backbone atonce.

To minimize message reflections (echo) onthe data link, a 120ohm terminatingresistor is needed at each end of thebackbone.

Notes:





10

Extending length of J1939 backbone

Visual 8-10 Extending J1939


If you need to extend the length of thebackbone, you can do so by removing theterminating resistor on the end you wishto extend, add the required length of backbone (remember this extension plusthe original backbone can not exceed 40meters in length) and reinstall theterminating resistor at the end of theextended piece.

As an example, you may want to extend the

backbone if you are removing thecontroller pedestal from the genset andmount it elsewhere.

Notes:





11

J1939 Topology

Fuel/Water

Separator

Coolant Level

Switch

Visual 8-11 J1939 Typology


Visual 8-8 shows a typical J1939 topology.You can see that some of the stubs aregoing to such devices as the Fuel/WaterSeparator and Coolant Level Switch.

All stubs that are unused must havereceptacles installed on them.

Ensure you ground the shield at one pointonly.

You must also connect shield at each device.

Notes:





12

Engine Harness Genset Harness PCC Harness

Extension

Harness

16-pin power

connector

(Receptacle)

Starter relay

Alternator Battery ‘X-pin’ Connector to mate

with extension harness

16-pin power

connector (Plug)

Controller

harness

‘Y -pin’

connector

J1939 3-pinconnector

(Receptacle)

ECM

power

ECM

Coolant level 4-pin

connector (Plug)3-pin J1939

connector

with 120 Ohm

resistor

9-pin service

connector

60-pin engine

connector

50-pin OEM

connector

J1939 3-pin

connector

(Plug)

Engine harness

connector

Pedestal

HMI

PCC

Board

3-pin J1939

connector

with 120 Ohm

resistor

Harness Block Diagram

Visual 8-12 Harness Block Diagram


Visual 8-9 show the different components andconnections made on a genset. It is brokendown into the Engine Harness, GensetHarness and PCC Harness.

Notes:





13

Unconnected J

UnconnectedH

UnconnectedG

UnconnectedF

Datalink ShieldE

J1939 Datalink (-)D

J1939 Datalink (+)C

Datalink PowerB

Datalink ReturnA

IDPin

9-Pin Deutsch

Service connector

9-pin Receptacle Cummins P/N: 3163295Deutsch HD10-9-1939PLocation: Engine Harness

Visual 8-13 9-Pin Deutsch


The 9-pin Deutsch connector is where you will connect with your Inline adapter kit.It is also a location where you canperform some testing of the system. Pins A and B should have battery voltagepresent. Battery voltage present at thisconnector is needed to power-up yourInline adapter.

Notes:





14

Troubleshooting Datalinks

Check Topology

Check Back Bone is not longer than 40m

Check there is 120 Ohm resistor at each end of the back bone. 55 - 65 Ohm

Check each Stub is not longer than 1m

Check that stubs are located appropriately on the datalink (not opposite each other)

Check Continuity

Check that the J1939 high and J1939 low are not open ciruit < 10 ohms

Check that the J1939 high and J1939 low are not shorted to ground > 100k ohms

Check that the ground wire is not open circuit < 10 ohms

Check that sheiding wire is not open ciruit < 10 ohms

Check that all grounds are the same

Check all ECM are commu nicating

If you have a Inline II, connect it and look at J1939 light on the adaptor. If the J1939 light

is flashing, connect one ECM at a time to determine which ones are communicating.

Visual 8-14 Troubleshooting Datalinks


This is a simple chart to follow in order tocheck the physical datalink.

If you are having communication errors theseare good points to start with thetroubleshooting process.

Keyswitch should be cycled every timethere is an engine shutdown in order tosave important ECM data (Ex: fault codes,ECM run time etc.). Wait 30 secs or more

before engine restart.

There are NO Fault Acknowledge inputs tothe ECM to reset active faults. The ECM will broadcast an active fault as long as thecondition is true.

Notes:






You can remove one terminating resistorand you should be able to see the otherresistor of 120 ohms. You can replace that

terminating resistor and remove the otherone to check for 120 ohms on that resistor.

While both terminating resistors areinstalled, remove J11 from base board.Check resistance between J11-19 and J11-20. Resistance should be approximately 60ohms if the backbone is ok. If you haveless than 55 or more than 65 ohms there isa potential problem with an open or groundon the datalink.

Here are some rules to apply for an open orshorted CAN circuit.

CAN_H is Shorted to VBat - Datacommunication is not possible if VBat isgreater than the maximum allowedcommon mode bus voltage.

CAN_L is Shorted to GND - Datacommunication is possible, because thebus voltages are within the allowed

common mode voltage range. Signal-to-noise ratio is reduced and radiation isincreased. The electromagnetic immunityis decreased.

CAN_H is Shorted to GND - Datacommunication is not possible.

CAN_L is Shorted to VBat - Datacommunication is not possible.

CAN_H is Shorted to CAN_L - Data

communication is not possible.

Loss of Termination Resistor - Datacommunication via the bus may bepossible, but with reduced signal-to-noiseratio.

Notes:






Loss of Termination Resistor - Datacommunication via the bus may bepossible, but with reduced signal-to-noise

ratio.

Topology Parameter Violations (i.e., BusLength, Cable Stub Length, NodeDistribution) - Data communication via thebus may be possible, but with reducedsignal-to-noise ratio

Notes:





15

J2

J1

J3

J34 Pin

P/N 3165121

Battery

Power

J250 Pin

P/N 3163071

OEM

J160 PinEngine

Connector

Name

Connector

Type

Connector

Function

CM850 – QSB5/7, QSL9,

QSK19/38/50/60

J2

J1

J3

* Please Refer to the appropriate Harness Wiring

Diagram for Pinouts of J1, J2, and J3

Note: J3 only required for QSB 5/7 and

QSL 9

Visual 8-15 CM850 ECM


The CM850 is one of the basic ECM’s thatyou will see on our gensets. The ECM will:

• Perform all Engine Protection with theexception of Low Coolant Level & LowCoolant Temperature

• All metering of engine pressures,temperatures, speed, flow, etc.

• All fueling and emissions control

• Engine Speed Governing

• Control of Idle speed and ramping to Idlefrom rated speed

Notes:





16

CM876 – QSM11 T3

J34 Pin

P/N 3165121

Battery

Power

J250 Pin

P/N 3163071

OEM

J160 PinEngine

Connector

Name

Connector

Type

Connector

Function

Visual 8-16 CM876 ECM


The CM876 is another one of the basicECM’s that you will see on our gensets.It consists of three connectors. It is verysimilar to the CM850, with the exceptionof the keyways on the connectors.

You will see the CM210 and CM2250 in thefuture. These ECM’s will have similarphysical characteristics.

Notes:





17

The J1939 datalink carries a series of 1’s and 0’s in each

message. A 1 is a HIGH voltage differential between the J1939 high and the J1939 low.

A 0 is a LOW voltage differential between the J1939 high and the J1939 low.

At a Baud Rate of 250k it is possible for the voltages on the J1939 high and

low wires to change from 0 to 1 250 thousand times per second. Hence a

high resolution oscilloscope is required to be able to view these voltages.

Shield

Electrical Datalink

Visual 8-17 J1939 Messages


The second portion of the CAN system is the

ELECTRICAL datalink.

Cummins communication is at a speed of 250Kbit/sec.

Connecting an oscilloscope can help you withsome advanced troubleshooting, but it isbeing mentioned here to illustrate thatcommon electronics tools can be used tohelp identify problems. This is not a

recommended check.

Notes:





18

Since the messages are sent by a voltage differential, it isessential that all devices are on the same ground plain. – If the grounds of two ECM’s are different, then a low voltage

differential of one ECM may appear to be a high voltagedifferential to another. Hence messages get corrupted andcommunication is lost.

2 v0 vV

differential

1.5v2.5 vJ1939 low

3.5v2.5 vJ1939 high

10

Nominal Values

Signals

Visual 8-18 J1939 Voltages


The properties of the J1939 datalink messageare broken down into bits. A “bit” takes,at most, 0.0000002secs to travel down a40m datalink.

And an entire message (110bits) takes0.00044secs to be transmitted. That’s apossible 2000 messages per second.

If two devices attempt to broadcast at thesame time, the message with the highest

priority wins and the other device “waits”.

Notes:





19

Activities

8-1 PGI Written Quiz



Find the Section 8 Quiz in Section 15. Work with partners to complete each activity.

Trainer’s Guide





Wrap-Up

In this lesson we introduced the Power Generation Interface (PGI) usage with the PCC 3300 forFAE engines. We covered the basics of what constitutes a PGI system, associated hardware andsoftware, troubleshooting tools, and some adjustments that can be made on the ECM.

Q. Are there any questions we have not yet covered that you wrote down as you went through

the CBT?

In the next lesson we will learn about the PCC 3300 support materials.








PCC 3.3 & PowerCommand Control 3300 Paralleling Introduction


PowerCommand

3.3

Section 9: Paralleling Introduction

Visual 9-1





Section 9

PPC 3.3 Paralleling Introduction


Materials Needed








Warm Up

In this lesson we will introduce connections and operation options that can be used with the PC 3.3in a paralleling environment.

This lesson will not delve into the operation and setup for each of the paralleling modes, but it willintroduce the paralleling abilities of this control.

Objectives


• Understand the different paralleling setups and modes available in the PowerCommand Control3300.

• Find and understand the paralleling configuration information in the service manual, InPower

and the HMI320.





2

What is Paralleling?

Paralleling is the synchronous operation of two or more generator sets connected to acommon bus in order to provide power to acommon load

Engines Produce kW

Alternators Make kVAR

kW Demanded by Load kVar Demanded by Load

Visual 9-2 What is paralleling.


The Power Command 3.3 control providesparalleling functionality for several modesof parallel operation.

Parallel operation is not a new or uniquefeature. It has been offered with many of the predecessors to the PCC3300,however: this control provides anydesired mode of paralleling operation as

standard. The control is fully configurablein the field AT WILL. You no longer haveto contact the factory and purchase newcodes or added features. They are all here.

Notes:





3

PC 3.3 Paralleling Modes

Standalone

Synchronization

Droop

Load Share

Load Govern

Power Transfer Control

Visual 9-3 Paralleling Modes


Standalone:

Standalone mode is more like a non parallelingcontrol configuration. There are a coupleof added features that make thisconfiguration more desirable than justusing a PC2.X control.

Synchronization:

This is a mode designed to allow the genset tomatch frequency and voltage with anothersource. In some modes of this operationthe PCC does not control connection to thesource and in some modes the PCC is infull control of all connection functions.

Notes:






Sync. Cont: Synchronization is utilized in allthe different paralleling modes beyond theStandalone mode.

Droop:

Droop is an adjustable feature that can beturned on as the application requires. Theunit is able to operate in speed droop,and/or voltage droop.

Load Share:

In Load Share, the PCC is in parallel withother gensets while isolated from theutility. The PCC adjusts the speed

reference and the voltage set point so thatthe genset takes its fair share of the load.The genset should run at the samepercentage of its rated load at which othergensets run.

Load Govern:

In Load Govern, the PCC is in parallel withthe utility. Since the utility frequency andvoltage are fixed, the PCC regulates thegenset kW output and genset kVAR

output, instead of the genset frequencyand genset voltage.

Power Transfer Control:

Power Transfer Control (PTC) is a featurethat will be available during the Phase 2launch. This feature allows the PCC to actas the transferswitch control in addition toacting as the genset control.

Notes:





4

PC 3.3 Modes of Paralleling

Visual 9-4 Modes of PowerCommand Control 3300 Paralleling


Modes are a set of operating configurationsthat are determined by a setup choice.

This chart is mostly self explanatory.

As you look at the modes from left to right,the hookup, setup, calibration, andoperation become progressively morecomplex.

The following training guide sections willdiscuss each mode in detail.

Notes:





5

Paralleling Connector LocationTB7- Bus Voltage


TB10- CircuitBreaker Status

TB3 - Customer I/O

TB8- Customer I/O

TB1 – Customer I/O

TB9- Analog I/O

Bus CT Inputs

Visual 9-5 Control Board Connections


The previous sections only introduced thefunction of each of these connectors.

All of these connectors are reserved forcustomer or site connections. You mayencounter some factory connections on acouple of these connectors, but they areonly for options or accessories ordered with the generator set.

Each connector listed on this visual will bediscussed in the section which uses aconnection on it.

Notes:





6

Wire diagram Connections

Visual 9-6 Common Connection for paralleling


The common connector scheme wire diagramprovides connection information for eachof the paralleling modes.

Beginning on page 12 the CommonConnector Diagram changes focus fromshowing genset connection to showing theparalleling connections.

Page 18 is devoted to showing a table of optional inputs, outputs and configurationavailable on connectors TB3, TB9, andTB10.

Dotted lines on these diagrams representoptional connections for the mode of operation

Notes:





7

InPower Configuration

Status screensMonitor thefunctions

Setup screensprovide completeconfiguration andadjustment for allparalleling functions.

(OEM Setup - Paralleling

Not available in Phase 1)

Visual 9-7 InPower


In previous sections we have covered setupfunctions for the genset only. InPoweralso has configuration abilities for all theparalleling functions.

InPower has a large section for monitoringthe paralleling functions. Under the Paralleling Status folder you will not

find any adjustments.

There are many adjustments and only a few

monitor screens in the Paralleling Setup folder.

OEM Setup will contain paralleling setupfunctions in later releases.

Notes:





8

HMI Paralleling Setup Menus

Any Paralleling operation setupfunction available in InPower is alsoavailable through the HMI.

Most HMI operation setup functionrequire the Level Password.

Visual 9-8 HMI Setup


The HMI will allow complete configurationof the paralleling setups.

Just like with InPower, the first phase release will not support OEM Setup of theparalleling functions.

There are 6 setup screens available in theParalleling Basic Setup menu.

Notes:





7

Parallel Intro Activities


Visual 9-9 Quiz for Section 9


At this time I would like you to work alone tocomplete the quiz.

Notes:





Wrap-Up

This is an introduction section. This section should encourage discussion.

There are several different state features that were discussed. They were Standalone,

synchronization, Droop, Load Share, Load Govern and Power Transfer Control.

Q. Are there any questions we have not yet covered about this lesson?








PCC 3.3 & PowerCommand Control 3300 Standalone Mode


PowerCommand

3.3

Section 10: Standalone Mode

Visual 10-1





Section 10

PPC 3.3 Standalone Mode


Materials Needed








Warm Up

In this lesson we will cover the Standalone mode operation. We will experience the setup processand configuration of the control in addition to the physical connections that can be used with thePC 3.3.

Objectives

This is the first lesson in the series introducing participants to the paralleling features or options.

These lessons will not teach the theory and science of paralleling. It will cover the basics about

connecting, configuring and adjusting the features of this control to optimize unit performance.

Understanding the operation of these features provides a solid base for troubleshooting if

performance problems should ever occur.

Standalone operation will be covered first because it is the most basic. Later lessons will provide

the details about more complex configurations.


• Understand the reason for operating the PC 3.3 in Standalone mode.

• Find and understand the configuration information in the service manual, InPower and theHMI320.





2

Standalone is a mode that does not parallel, it does notsynchronize with any other genset or system.

In Standalone the PCC does not control a breaker forconnection or disconnect from load, but can provide abreaker trip signal, and it can monitor breaker position.

Is Standalone Paralleling?

kW Demanded by Load

kVar Demanded by Load

In Standalone mode operation, a single generator set isconnected to a bus in order to provide power to a commonload.

Visual 10-2 What is Standalone paralleling.


Standalone is a mode of operation that allowsthe generator set to be used in a singlepower supply situation and still providesome added feature for monitoring andprotecting the genset AND theinstallation.

In Standalone mode the power capacity of thepower system is regulated by the capacity

of the single generator set and it alone isresponsible for maintaining voltage andfrequency. In paralleling systems, all of the units in the system contribute andshare this function.

Notes:





3


Visual 10-3 Common Connector diagram


Standalone:

There are few connections to the PCC 3300 inthe Standalone mode. The dotted linesdesignate the connection is optional.

IMPORTANT! The information bulletsfound on the diagram provides valuableinformation. Read them!

Notes:






The above bullet describes operating featuresthat are affected by the connection of thebreaker information and control.

The genset is not able to read 3 phase buscurrent when configured for Standalone

mode. It is able to monitor the Neutralcurrent but not for any protective purposesuch as the noted Ground Fault.

.

Greater detail about the bullet references canbe found in Service Manual 900-0670

Section 4 and Section 2.

Notes:





4

InPower Modes of Paralleling

Genset Application Type Setup – Modes of Operation

Visual 10-4 InPower


InPower has a specific folder (Paralleling

Setup) devoted to the setup andconfiguration of the paralleling features.No more hunting and searching fordifferent folders for individual setupfeatures. .

This visual highlights the specific adjustmentfor placing the control into any one of thevarious modes of paralleling.

Unlike previous controls were customers were charged for different levels of paralleling capability, this controlprovides all the levels for one basic price.

Notes:





5

HMI320 Paralleling Setup

The HMI paralleling setupfunctions are the same withInPower. This screenshows the GensetApplication Type is set toIsolated Bus. Use theproper password code tochange the type.



InPower is an easy tool for configuring thecontrol, but the HMI has all the setupfeatures built in too. There will be manysituations when it will be moreconvenient to make adjustments andchanges from the HMI then to try andconnect with InPower.

There are 6 screens of adjustment.

As you saw in the previous visual, the first

adjustment under Basic Setup is Genset

Application Type. It is also in the HMIBasic Setup screen.

To change the Gen App Type, use the Level 1or Level 2password.

Notes:





6

Paralleling Connector Use in

Standalone Mode


TB10- Circuit

Breaker Status

Bus CT #2

Visual 10-6 Connector


There are 3 connections used in StandaloneMode for providing input/output andmonitoring functions.

Important!: Only CT #2 is used forStandalone mode. It is polarity sensitiveand limited to a maximum of 5 amp pass-through.

Notes:





7

Bus CT Connections

CT2

Optional: Only Provides Metering of Neutral Current

Visual 10-7 Bus Connection


Only CT #2 is used in Standalone mode and itcan only be used to monitor bus NeutralCurrent.

Remember, this control can be used in asingle phase application and Deltaconfiguration too. Even in theseapplications, neutral current is all this CTshould be employed to monitor.

Input is limited to a standard 0 to 5 amp CToutput.

The tables in section 2 of service manualprovide information about setting andcalibrating this input.

Shorting blocks or some sort of shortingsystem must be used to protect the CT.

Notes:





8

TB5 Circuit Breaker Control

MB+

B+Return

Visual 10-8 Breaker connection


TB5 provides the hookup points to controlbreakers. Standalone mode supports only1 contact point on this connector.

Pins 1 and 2 provide limited output to drive abreaker open or shunt trip command. It isvery important to know the inrush coilspecifications of the breaker shunt trip or

motor. If you suspect the 5A, 30VDCinductive loading will exceed 7milliseconds, use a pilot relay.

DO NOT overload this driver, overloading

may lead to and require boardreplacement.

Notes:





9


Pin 10 Pin 2

Return: TB10 - 2

CB Tripped Status: TB10 - 10

In Standalone Mode, Breakertripped connections are optional.

Visual 10-9 Breaker status


This is Customer Input #27 so an excellenttime to learn about the FUNCTIONPOINTER setup in InPower.

In the SETUP folder – Configurable I/O youfind dozens of configurable settings

If you scroll down the list, at approximatelythe 105th trims down the list you will

notice several settings for Genset CB.

Open the Genset CB Tripped/Configurable

Input #27 Function Pointer Value. You will see a dropdown list of all theconditions that can be used to close thiscontact. This will trip fault code 1454.

Notes:





10

Standalone Mode Activities




At this time I would like you to complete thequiz.

The Quiz is found in Section 15.

Notes:





Wrap-Up

In this lesson, we have learned about installation of the PCC 3300 genset control andimportant connection locations.

First, we talked about the procedure for installing options to the control on a genset.

Then, we used the Common Connector Scheme diagrams and visuals to view eachindividual connector and the connections available from the control to the gensetcomponents and why each is important.

Q. Are there any questions we have not yet covered about installation of the PCC 3300?



PCC 3.3 & PowerCommand Control 3300 Synchronizer Only Mode


PowerCommand

3.3

Section 11: Synchronizer Only Mode

Visual 11-1





Section 11

PPC 3.3 Synchronize Only Mode


Equipment Needed

Materials Needed








Warm Up

Differences and similarities between Standalone mode operation and Synchronize Only will becovered in this lesson. We will experience the setup process and configuration of the control inaddition to the physical connections that can be used with the PC 3.3.

Objectives

These early lesson in the paralleling lesson series introduce participants to the paralleling features

or options. These lessons will not teach the theory and science of paralleling. It will cover the

basics about connecting, configuring and adjusting the features of this control to optimize unit

performance. Understanding the operation of these features provides a solid base for

troubleshooting if performance problems should ever occur.

Synchronize is a very basic introduction to paralleling functions and it prepares everyone for

encounters with more complex modes of paralleling operation.


• Understand the reason for operating the PC 3.3 in Synchronize Only mode.


• Execute a control setup and configuration for a genset or simulator to operate in this mode.





2

Synchronize Only

Synchronize Only is a mode that does not parallel, however: itdoes synchronize with other gensets or systems.

In Synchronize Only, the PCC does not control a breaker forconnection or disconnect from load, but like Standalone it canprovide a breaker trip signal, and it can monitor breakerposition.

Synchronize Only is very useful for hard transfer ATSsystems.

Visual 11-2 Synchronize only


The operating features of Synchronize Onlyare the same as those used in moreadvanced paralleling modes.

The control will not command breakerclosure in this mode but it will monitorthe position of the Gen breaker and it canalso provide a generator breaker open orshunt trip command.

This feature is well suited to work with thePLTH product and it will work with hardand bump-less transferswitch systems.

Notes:






The frequency/phase matching control

provides for two methods of automaticfrequency synchronizing. The first isPhase Match which will attempt to drivethe phase error to zero. A phase offsetadjustment is included for cases where aphase shift exists due to a delta / wyetransformer for example. The secondmethod of synchronizing is Slip

Frequency which will attempt to drive afixed frequency difference between thetwo sources. In some cases this is used to

insure that power will flow in the desireddirection at the initial time the sources areparalleled, or with a genset whosegoverning cannot be accurately enoughcontrolled to phase match (such as gasgensets).

The control provides one method of automatic voltage synchronizing which isvoltage match. This method will attemptto drive the voltage error to zero.

In most cases synchronizing is automaticallyinitiated by the control when necessary.This is done by connecting syncenable/configurable input #30 on TB10 toa return.

Notes:





3




Notice the same dotted lines on this diagram asyou found on the Standalone diagram. Again, the dotted lines designate theconnection is optional.

IMPORTANT! The information bulletsfound on the diagram provides valuableinformation. Read them!

Bus voltage input is needed for synchronizing,but bus CT input is not needed for thisfunction.

Notes:





4

InPower Modes of Paralleling

Genset Application Type SetupModes of Operation

Choose Synchronize

The setupprocessencountered inInPower is thesame as thatused withStandaloneMode.

Visual 11-4 InPower


InPower has a specific folder (Paralleling

Setup) devoted to the setup andconfiguration of the paralleling features.No more hunting and searching fordifferent folders for individual setupfeatures. .

This visual repeats the same information that was covered in the Standalone section. Itis repeated to reinforce the point that thiscontrol is easily configured. One place – you choose the setup – no more huntingthrough many InPower folders to find theproper adjustments.

Notes:





5

HMI320 Paralleling Setup

The HMI paralleling setupfunctions are the same withInPower. This screenshows the GensetApplication Type is set toIsolated Bus. Use theproper password code tochange the type.



Are you catching on yet? Hopefully you arenoticing a repeating pattern about howyou can configure this control. YOU havea choice for your preferred method of setup of a control, you can use InPower oryou can use the HMI.

As you saw in the previous visual, the firstadjustment under Basic Setup is Genset

Application Type. It is also in the HMIBasic Setup screen.

To change the Gen App Type, use the Level 1or Level 2password.

Notes:





6

TB7- Bus Voltage


TB10- Circuit

Breaker Status

TB8- Customer I/O

Bus CT Inputs

Paralleling Connector Used in

Synchronize Mode

Visual 11-6 Connector


Now there are 5 connections (potentially 7 if you use all CTs) used in Standalone Modefor providing input/output and monitoringfunctions.

Important!: Only CT #2 is used to monitorneutral current .

The connection diagram does not showinstallation of shorting blocks for the CTconnections, but it is stronglyrecommended.

TB7 Voltage inputs are rated to accept up to600 volts

Notes:





7

Bus CT Connections

CT2CT1 CT3

OR

CT2

Optional: Only ProvidesMetering of Neutral Current

Visual 11-7 Bus CT Connection


Remember, this control can be used in asingle phase application and Deltaconfiguration too. Even in theseapplications, neutral current is all that thisCT should be employed to monitor.

Input is limited to a standard 0 to 5 amp CToutput.

The tables in section 2 of service manualprovide information about setting andcalibrating this input.

Shorting blocks or some sort of shortingsystem must be used to protect the CT.

Notes:





8


MB+

B+Return



TB5 hookup is optional. Synchronize Onlymode and Standalone mode support only1 contact point on this connector.

Pins 1 and 2 provide limited output to drive abreaker open or shunt trip command. It isvery important to know the inrush coilspecifications of the breaker shunt trip or

motor. If you suspect the 5A, 30VDCinductive loading will exceed 7milliseconds, use a pilot relay.

Notes:






This is an excellent time to learn about theFUNCTION POINTER setup in InPower.

In the SETUP folder – Configurable I/O youfind dozens of configurable settings

If you scroll down the list, at approximatelythe 105th trims down the list you willnotice several settings for Genset CB.

Open the Genset CB Tripped/Configurable

Input #27 Function Pointer Value. You will see a dropdown list of all theconditions that can be used to close thiscontact. Chose the appropriate one that will open the breaker as your application would require.

The trim Function Pointer is used to set whatconditions the configurable outputbecomes active.

Associated with the Input #27 Function

Pointer is the Active State Selection choice. This can be set for “ Active

Closed”, or “ Active Open”.

Notes:





9


17 210

7

8

10

8&7

13

13

#2 Return

#17 Return

optional



TB10 provides breaker status information andit provides the Sync Enable input.

The Sync Enable input is required forSynchronize Only Mode. It is thecommand the causes the genset tosynchronize to Source 1.

The breaker status inputs are optional. Thereis no breaker control function with thismode, so this would be used for reportingthe status of the breaker over ModBus orgenerally for reporting the position.

Notes:





10

Activities

Activity 11-1: In-Class Quiz



At this time I would like you to complete thequiz and the activity. The quiz is locatedin Section 15

Notes:





Wrap-Up

This lesson is not only supposed teach you about the synchronizing feature of thiscontrol, but it is also supposed to prepare you for lesson 12: Isolated Bus Paralleling.

In this lesson, we have learned about synchronizing, installation connections, and setupof the PCC 3300 genset control for operating in Synchronize Only mode.

Q. Are there any questions we have not yet covered about Synchronize Only Mode of the

PCC 3300?








PCC 3.3 & PowerCommand Control 3300 Isolated Bus Mode


PowerCommand

3.3

Section 12:Isolated Bus Paralleling

Visual 12-1





Section 12

PPC 3.3 Isolated Bus Mode


Materials Needed








Warm Up

What you have learned about Standalone mode operation and Synchronize Only will be applied inthis lesson. We will experience the setup process and configuration of the control in addition to thephysical connections that can be used with the PC 3.3.

Objectives

This lesson will provide a very basic introduction to Isolated bus paralleling functions and it will

prepare everyone for encounters with more complex utility/mains paralleling operation.


• Understand the configuration of various Isolated Bus systems, and the reason for operating thePC 3.3 in droop or isochronous mode.


• Execute a control setup and configuration for a genset or simulator to operate in this mode.





2

Isolated Bus Paralleling

Multiple units connected to a common supply bus.

All units are connected to the bus in a synchronousway with matched frequency and voltage.

Units may be set to operate in Droop or they may be

set for Isochronous operation

Visual 12-2 Isolated bus


All units operate at the same frequency(speed) and voltage.

Generally speaking, the units can operate invarious modes which will determine howindividual units will react to loadconditions, but all units will worktogether on line to share the load.

Droop and Isochronous modes are available. ,

The bus system may consist of switchgear with bus work or it may consist of cableconnections between gensets andbreakers.

Notes:





3

Isolated Bus Paralleling

Dead Bus Close

First Start Arbitration

Synchronizing

Load sharing between units

Visual 12-3 Isolated bus


Dead Bus Close & First Start Arbitration:First start arbitration is used in a multi-genset system to control which genset gets to close to a dead

bus. Only one genset is allowed to close to a dead bus. All others must synchronize. Thegenset controls arbitrate with each other through an interconnected first start signal. Once agenset has reached the ready to load state and the bus is sensed as being dead, it can join in thearbitration. When the arbitration completes, one genset has "won" permission to close and willbe allowed to command its breaker to close. At the same time this genset puts theinterconnected arbitration signal into an inhibit state which tells all other gensets that they do

not have permission to close. Once the permitted genset has closed to the dead bus, then theother gensets will see the genset bus go live and begin synchronizing to it.

If a genset has been waiting to win permission to close to a dead bus and it has not received thatpermission within a set amount of time, it will assume that the first start system has failed and will close its breaker to the dead bus. This is the First Start Backup function. This prevents asituation where no genset closes to the bus due to a failed first start system.





WARNING! --- This does present a risk of multiple gensets closing to the dead bus, but this risk isreduced by setting the first start backup time delays to be significantly different on each genset.E.G. 10 sec, 20sec, 30 sec, etc. Then the assumpt ion is that all gensets were started at the sametime.

Synchronizing:The frequency/phase matching control provides for two methods of automatic frequency

synchronizing. The first is Phase Match which will attempt to drive the phase error to zero. A phase offset adjustment is included for cases where a phase shift exists due to a delta / wyetransformer for example. The second method of synchronizing is Slip Frequency which willattempt to drive a fixed frequency difference between the two sources. In some cases this isused to insure that power will flow in the desired direction at the initial time the sources areparalleled, or with a genset whose governing cannot be accurately enough controlled to phasematch (such as gas gensets). The control provides one method of automatic voltagesynchronizing which is voltage match. This method will attempt to drive the voltage error tozero.

In most cases synchronizing is automatically initiated by the control when necessary. This is doneby connecting sync enable/configurable input #30 to a return.

Load Share:The load share function manages the genset’s kW and kVAR production when it is connected to a

common bus with other gensets while isolated from the utility bus. Each genset must determinehow much of the total bus load to take. The desired result is for each genset to take its equalshare of the load relative to its own rating while maintaining the bus frequency and voltage atthe nominal values. (i.e. Each would end up taking the same % load.) The sharing of kW is

controlled by fuel (speed). The sharing of kVAR is controlled by excitation (voltage).

IsochronousIn order to share load while maintaining fixed frequency and voltage, some form of communication

between the gensets must occur. (The other option with no communication is speed and voltagedroop.) This is accomplished via the “load share lines”. There is a pair for kW and a pair forkVAR.

Controller compatibility for Paralleling must b considered. When a paralleling system consists of different models of PCC3XXX genset controls, some adjustments are necessary in order toinsure comparable load sharing performance. These adjustments are NOT necessary if thecontrols are all identical control models.

What are the symptoms or issues if these adjustments are not made or are made improperly?

1. Reverse kVAR (Loss of Field) shutdowns may occur.

2. Bus Voltage may shift from nominal. (I.E. It may look like voltage droop.)

3. With the control default kVAR balance settings, the kVAR sharing will not be balanced.





4. Even after balancing the kVAR sharing at one kVAR load condition, the kVAR sharingmay not be balanced at a different kVAR load.

5. kVAR sharing will not be equal when V/Hz is acting (e.g. during a large kW transient oroverload condition).

6.

Reverse kW or Reverse kVAR shutdowns may occur during Master Synchronizing withMCM3320

DroopDroop is a passive means of having paralleled gensets share kW (via speed droop) and kVAR (via

voltage droop). In the case of speed droop, as kW load increases, speed (i.e. fueling) isreduced, forcing other gensets to pick up more kW thus resulting in a balance. In the case of voltage droop, as lagging kVAR increases, voltage (i.e. excitation) is reduced, forcing othergensets to pick up more lagging kVAR thus resulting in a balance. Droop can be used on anisolated bus for passive sharing among gensets.

All gensets may be operated in droop, but this leads to a frequency which changes with load.

Another alternative is to operate one of the sets as a “lead” unit in the isochronous mode. Theother sets operating in droop will be forced to go to the isochronous speed and thus they will beeffectively base-loaded. The lead unit then takes up all the changes in load that occur whilemaintaining a fixed frequency bus. As an example, if the genset set to operate in isochronousmode at a frequency of 57Hz were run in parallel with a genset operating in droop set as shownin Figure 1 with a nominal frequency of 60Hz the genset in droop would be loaded at 50% kW.If it were desired to run both gensets at 60Hz and still load the genset operating in droop to 50%set the Frequency Adjust trim on the genset operating in droop to 3 to increase the 0% kWoutput frequency to 63Hz.

Figure 1 Load Share – Droop kW is a graphical representation of speed droop. In this case the

Speed Droop Percentage trim has been set to 10%. As can be seen from the graph at 100% kWouput the genset will be operating at 90% of nominal frequency. In other words for a nominalfrequency of 60Hz the genset will be running at 54Hz at full load.

Figure 2 Load Share – Droop kVAR is a graphical representation of voltage droop. In this casethe Voltage Droop Percentage trim has been set to 5%. As can be seen from the graph at 100%kVAR ouput the genset will be operating at 95% of nominal voltage. In other words, for anominal voltage of 480VAC the genset will be running at 456VAC at full load.





Load Share - Droop kW

87

88

89

90

91

92

93

94

95

96

97

98

99

100

101

0 20 40 60 80 100 120 140% kW Output

% N

o m i n a l F r e q u e n c y

Figure 1 Load Share DROOP kW

Load Share - Droop kVAR

93

94

95

96

97

98

99

100

101

0 20 40 60 80 100 120 140

% kVAR Output

% N

o m i n a l V o l t a g e

Figure 1 Load Share DROOP kVAR





4

Isolated Bus Paralleling Sequence

Visual 12-4 Sequence diagram


The PCC control is acting on many inputsand actions that must take place in aparticular sequence for the PCC toparallel with other generator sets.

This diagram provides a basic sequence of operation and graphically shows eachevent that must happen. A large fold outsheet is available in Appendix B:

Sequence Diagrams of the ServiceManual.

Notes:





5

Wire Diagram Connections



This is the first diagram when full connectionand control of the genset breaker isencountered.

This is the first diagram when connections tothe TB9 analog connection areencountered. The connections are polaritysensitive and must be connected betweeneach generator so each unit will share load

correctly.

Notes:






There will be a 52G for each generator set.(52G is the standard ANSI designation fora motor actuated breaker for a generator

set.)

A Contact =

B Contact =

C Contact =

MEDIUM VOLTAGE & HIGH VOLTAGE – Potential of 600voltAC is generallyconsidered the threshold to Mediumvoltage. Systems operating at potentialabove 600voltAC must use PTs (PotentialTransformers) VT =VoltageTransformer---- a common term in manyof the global regions to lower thevoltage.

Notes:

Additional Notes or Comments _______________________________________________________________________________





6

Isolated Bus Paralleling Connectors

TB7- Bus Voltage


TB10- Circuit Breaker

Status

TB3 - Customer I/O

TB9- Analog I/O

Bus CT Inputs

Visual 12-6 Connectors


Customer connections must be made at eachof these connection points.

The next few pages will highlight theconnections required at each of theterminal blocks.

In addition to the connections that were madeon the Synchronize Only Mode,

connections must also land at TB3Customer I/O, TB9 Analog I/O, and theTB7 Bus Voltage.

Notes:





7

Bus CT Connections

CT1 CT2 CT3

Visual 12- 7 Bus CTs


Bus CT connections are polarity sensitive andthe sense wire must be routed through theCT in the proper direction.

If the CTs wires are installed backwards, thecontrol will sense a phase shift and thecontrol may not parallel correctly or there will be erroneous readings of load or PF.

Most Switchgear manufacturers build theirgear with CT shorting blocks in place. Itis the responsibility of the installationdesigner to make certain there areshorting blocks in the system. Questionthe maker if you do not find any.

Notes:





8

TB3 Customer I/O ConnectionsPin 12

Pin 12

First StartArbitration

Return

First StartArbitration

Supply

Gen 1

Gen 2

Visual 12-8 Connection TB3 Participant’s Text

In this paralleling mode, the only connectionto TB3 is the optional First Start Statussignal.

The connections are considered polaritysensitive with output from the first gensetconnected to the next genset.

TB3-11 to TB3-11 on all gensets

TB3-12 to TB3-12 on all gensets

Notes:





9


M

B+

MB+

B+Return

B+Return



TB5 provides the hookup points to controlbreaker open and another for breakerclose control.

Breaker motors can consume a large amountof energy during actuation. The powerconsumption is so great that damage toPCC control can take place if you attemptto drive the breaker directly from this

connector.

Use a pilot relay of sufficient size to run thebreaker, but be aware that relay motorscan sometimes consume a large amount of energy. Make sure the relay motor doesnot exceed the specification listed on thisvisual.

Notes:





10


17 210

7

8

1011

7

14

15

14

#2 Return

#9 Return

#17 Return

#16 Return



TB10 provides information to the controlabout breaker position, and it alsoprovides control input from a MasterControl.

There are 3 discrete input points. These areoptional, but they are available to be usedas Customer Inputs #28, #31, & #32.

#28 is Genset CB Inhibit. It uses TB10-9and TB10-11.

#31 is Load Demand Stop. It uses TB10-14 and TB10-17.

#32 is Ramp Load/Unload. It uses TB10-15 and TB10-16.

Notes:






There are 3 breaker status indications

Terminal #7 input indicates Genset CBPosition It uses “A” contact inputfromTB10-2 and TB10-7.

Terminal #8 input indicates Genset CBPosition It uses “B” contact inputfromTB10-2 and TB10-8.

Terminal #10 input indicates Genset CBtripped It uses “A” contact inputfromTB10-2 and TB10-10.

Notes:







12

TB7 Gen Bus Voltage Sense

Pin4

Pin1

Pin4

Pin1

Pin4

Pin1

Unconnected

Neutral UU

U

W

VV

V WW

N e u t r a l

Delta

WYE 1 Phase

Visual 12-12 Connection TB7 Participant’s Text

TB7 can monitor voltage of 600 voltAC orless.

Fuses listed are optional and provided byothers. The fuse rating should be

appropriate to protect the wire system.

=

Notes:

Unconnected





13

InPower Trim Adjustments

Genset Application Type Setup – First step

Visual 12-13 InPower Participant’s Text

It has been pointed out in previous lessonsthat all paralleling setup functions andadjustments are found under the

Paralleling Setup – Basic section of InPower.

The first and most important adjustment tocheck when configuring a parallelingsetup is Genset Application Type.

Notes:





14


InPower Adjustment Screen Service Manual Menu Description

Visual 12-14 Trims Participant’s Text

Within the InPower Setup ---- Paralleling

Setup ----- Basic folder you will see thedozens of adjustments for parallelingfunctions. All adjustments for all themodes of paralleling are intermingled in

this Basic folder. This is represented onthe left of this visual.

The right side of this visual shows an

extraction from Section 5 SETUP &CALIBRATION of the 0900-0670Service Manual.

You will notice the sequence of the InPowerlist matches the Service Manual list. This will help you find descriptions andadjustments.

Notes:





15


OOR =Out Of Range

Visual 12-15 InPower Participant’s Text

These highlighted adjustments affectUtility/mains connections andperformance. They are listed in the basicsetup section and may cause someconfusion.

OOR is a common acronym that can beencountered in many control systems, but

it may be a new term for those in thePower Generation service field.

Notes:





16

Quiz & Activities


Visual 12-16 Quiz


At this time I would like you to complete thequiz and the activity

Notes:





Wrap-Up

In this lesson, we have learned about Isolated Bus Paralleling configuration of the PCC3300 genset control and important connection locations.

Q. Are there any questions we have not yet covered about Isolated Bus installation of the PCC 3300?



PCC 3.3 & PowerCommand Control 3300 Troubleshooting & Service Manual.


PowerCommand

3.3

Section 13: Troubleshooting &Service Manual

Visual 13-1





Section 13

PC 3.3 Troubleshooting


Materials Needed



Wiring Diagram 0630-3440 (A007M115 D) Sheets 1 to 18 or use diagrams in 900-0670





Warm Up

This is the last lesson and if everyone is not warmed up by now, they never will be.

Objectives

Troubleshooting is a skill that comes from experience and training can only enhance the

proficiency of the individual practicing the skill. This section will provide guidance on finding

resources to support troubleshooting efforts.


• Use the Troubleshooting guide in the Service Manual.

• Find fault codes and sequence of operation information in the Service Manual.





2

Troubleshooting Tools & Resources

#1 = Brains

Service Manual 0900-0670

Quality VOM

Common Connector Scheme Diagram

InPower

ModScan

InSite

InLine IV or V Adapter or PEAK Adapter

Visual 13-2 Troubleshooting Tools.


Brain:

Don’t leave your brains at home. If you

remembered to bring it to the jobsite, Use

It!

This course has been pouring lots and lots of information into your heads but it is onlya small fraction of information about this

control. We have provided you withguidance and an overview about howmajor features operate. Not only have youbeen learning how to properly configurethe control, you have been learning how itis supposed to work. Now that you havethis knowledge, please use it.

Notes:





3

Service Manual #0900-0670

Concise Table of Contents

Seven Section• System Overview

• Hardware

• Control Operation

• Paralleling Operation

• Setup and Calib ration

• Parameters

• Troubleshooting

Appendix•Schematics

•Sequence Diagrams

•Parts List

•ModBus Register Mapping

Visual 13-3 Service Manual.


The Service Manual table of contents is 12pages long and it provides detailed andexplicit directions about where to find anyparticular piece of information.

The manual is separated into the listed 7sections of information and is set up insuch a way that you will find informationaccording to the type of activity you areengaged in as opposed to which part of the machine you are working with.

The Appendix is also divided into sectionslabeled A, B, C, & D. Each sectionprovides reference information such asthe ModBus Register Map or a parts list.

Notes:






Section 7 of the Service Manual provides acomprehensive troubleshooting guide.

Before opening to Section 7, please look at

the Table of Content information aboutSection 7 Troubleshooting beginning onpage vii of the Service Manual.

Notice the fault codes are listed in sequence with a description of the fault and areference to a page in section 7.

Assume that the HMI displays fault #1438.

Open the Table of Contents to page viii.

Code 1438 - Fail to Crank……….. 7-39

Open to Section 7. Troubleshooting

Open to page 39 of the section.

You should see the heading for this code.

There are Logic, Possible Cause and Diagnosis and Repair headings.

The Logic & Possible Cause will helpyou understand the conditions of the fault.

Diagnosis and Repair will guide you topossible or probable solutions.

Read and understand the Diagnosis andRepair suggestions. SRT (Standard RateTables) are based on thesetroubleshooting suggestions.

Notes:





4

Quality VOM

$4.95 @ Amazon



There are many makers of quality meters.CPG does not endorse any one maker, but we do encourage use of tools that are safeto use and provide accurate and reliablereadings.

Look for these features & Accuracy:

Measure 1000 V ac & dc

True RMS ac voltage & current Frequency to 200kHz and % Duty cycle Min/Max Averaging Peak Capture Diode Test +/- .1% ac Volt +/- .4% Ω +/- .2% per kHz - DutyCycle.

Notes:




Particpants’ Guide Section 13 Page8

5


Testlocationsare clearlynoted oneachdiagram.

Visual 13-5 Connector diagram


Now that you have a good VOM to work with, where do you connect it? The CommonConnector Diagram tells us

IMPORTANT! The information bulletsfound on the diagram provides valuableinformation. Troubleshooting data can befound on many of them!

Notes:






The bullet below identifies a reason why theOil Priming Pump does not start. If someone put too large of a relay motor on

the genset, could this fuse burn out?

Many of the bullets provide specificationinformation that can help with

troubleshooting. Using your VOM youcould check your exciter field. In earliersections we learned this AVR output is aPWM signal so with a quality meter youcould check duty cycle OR you couldcheck the current draw.

Notes:





6

InPower Troubleshooting Tips

InPower continues to havethe Snapshot feature. ThePhase 1 PCC3300 does notrecord Snapshots,

InPower has a quicknavigation to the Fault List.

InPower is able to recordMonitor information and itcan create a viewableStripchartof performance.

Visual 13-6 InPower


InPower has been a valuable troubleshootingtool for many years. It is most likely themost important troubleshooting toolavailable for servicing a PC 3.3 control.

Most of the features shown on this visualhave been around a long time. Some of them may have been forgotten about.Such as the quick link to view the faultlist..

Phase 2 of the PCC3300 control board isplanned support fault Snapshots. ThePhase 1 release (this training session)does not support the Snapshot function.

Notes:





7

ModScan Troubleshooting Tips

ModScan is not aconfiguration tool, itis a troubleshootingand testing tool.

Holding Registersdisplay data.

Registers 43517is the PrelubeState parameter.

This middle digit reportsPrelube ON state.



ModScan was covered in detail in Section 7of this Training guide.

Consider using ModScan as a troubleshootingtool to test some of the operatingfunctions. The ModBus register map in

the Appendix Dof the Service Manual

lists many different control functions.

If you command the genset to enter Prelube Mode On and this Prelube ON statechanges to 00100, but the Prelube relaydoes not pick up, this could help youunderstand that the internal fuse may havefailed.

Notes:





8

InSite

Visual 13-8 InSite


InSite is a valuable service tool fortroubleshooting engine related problems.

CPG does not train or certify technicians touse this tool, but if a PowerGentechnician is trained to use this tool andhas it available, by all means – use it!

InSite connects to the CAN communication

system through the InLine tool. InLine IVand InLine V tools are the currentconnection tools available at the Phase 1launce of the PC 3.3 control.

Notes:





9

Troubleshooting Activities


Visual 13-9 Quiz & Activity


At this time I would like you to complete thequiz and the activity

Notes:



PCC 3.3 & PowerCommand Control 3300 Troubleshooting & ServiceManual.


Wrap-Up

In this lesson, we covered tools and multiple ways to troubleshoot the PC 3.3 control.

Q. This is the last training Section before the final test. Are there any questions we have

not yet covered about the PC 3.3?



PCC 3.3 and PowerCommand Control 3300 PowerCommand Control 3300 Glossary

Training Guide Section 14 Page1

AC Alternating Current (AC) is electric current that alternates between a positive maximum value and anegative maximum value at a characteristic frequency, usually 50 or 60 cycles per second (Hertz).

AlarmUsed generically to indicate either a warning or a shutdown fault.

ANSI American National Standards Institute.

Acoustic Material Acoustic material is any material considered in terms of its acoustic properties, especially itsproperties of absorbing or deadening sound.

Active PowerActive power is the real power (kW) supplied by the generator set to the electrical load. Activepower creates a load on the generator set's engine and is limited by the horsepower of the engine.Active power does the work of heating, turning motor shafts, etc.

Air Circuit BreakerAn air circuit breaker automatically interrupts the current flowing through it when the currentexceeds the trip rating of the breaker. Air is the medium of electrical insulation between electricallylive parts and grounded (earthed) metal parts.

Alternator Alternator is another term for AC generator.

Alternator Rating EffectSome of the alternator protections are inherently related to the alternator capabilities rather than

GenSet power rating. For example, Reverse VARs (Loss of Field), is inherently a function of alternator capability. Overcurrent is inherently a function of alternator capability. If data to analternator’s capability in these areas is not available, the PowerCommand Control will default tobasing the limits on the on the GenSet rating — as the previous version of the PowerCommandControl did. (GenSet rating is either engine limited or alternator limited — normally enginelimited.)

SECTION 14 -- Glossary





Amortisseur WindingsThe amortisseur windings of a synchronous AC generator are the conductors embedded in the polefaces of the rotor. They are connected together at both ends of the poles by end rings or end plates.Their function is to dampen waveform distortion during load changes.

Ampacity Ampacity is the safe current-carrying capacity of an electrical conductor in amperes as defined bycode.

AmpereThe ampere is a unit of electric current flow. One ampere of current will flow when a potential of one volt is applied across a resistance of one ohm.

Annunciator An annunciator is an accessory device used to give remote indication of the status of an operating

component in a system. Annunciators are typically used in applications where the equipmentmonitored is not located in a portion of the facility that is normally attended. The NFPA hasspecific requirements for remote annunciators used in some applications, such as hospitals.

Apparent Power Apparent power is the product of current and voltage, expressed as kVA. It is real power (kW)divided by the power factor (PF).

ArmatureThe armature of an AC generator is the assembly of windings and metal core laminations in which

the output voltage is induced. It is the stationary part (stator) in a revolving-field generator.

Authority Having JurisdictionThe authority having jurisdiction is the individual with the legal responsibility for inspecting afacility and approving the equipment in the facility as meeting applicable codes and standards.

Automatic (Exciter) Paralleling Automatic (Exciter) Paralleling describes a system where two or more generator sets can be startedand paralleled while coming up to rated frequency and voltage. Because the generator excitationsystem is not turned on until the generator set is started (thus the term "dead field"), the generatorsets automatically synchronize as they come to rated speed and voltage.

B+ ReturnSimilar to battery negative (B-). This may be an isolated battery negative circuit and may not bedirectly connected to chassis ground or the battery negative. In some circumstances it may float at adifferent potential than chassis ground.





Backup ProtectionBackup protection consists of protective devices, which are intended to operate only after otherprotective devices have failed to operate or detect a fault.

BandwidthThe amount of data that can be transmitted in a fixed amount of time. For digital devices, it isexpressed as bits per second, or bytes per second. For analog devices, it is usually expressed ascycles per second, or Hertz.

Bar Graph A metering panel which is optional a PowerCommand Control. This optional panel is referred to asthe HMI112 and it allows the operator to view a display of Amperes, KVA, Frequency, andVoltage provided by the generator set. There is also a version that will display KVA and PowerFactor in addition to the other listed functions.

Base CardThe main processor board of the PowerCommand Control. This board contains the main powersupply for the control, microprocessor, flash memory for updates to the operating system(calibration download), interface to the optional HMIs, PCCNET and Modbus connections, andinputs for engine sensor data.

Base LoadBase load is that portion of a building load demand which is constant. It is the "base" of thebuilding demand curve.

Baud RateThe speed of data transmission in serial data communications approximately equal to the number of code elements (bits) per second (BPS). Bits per second are also termed BPS, with the prefix (k)denoting thousands.

BindingThe process of making the logical connections to the network (also called connecting). Thisinvolves connecting network variable outputs to network variable inputs using LonWorks software.

BitBinary Digit.

Black StartBlack Start refers to the starting of a power system with its own power sources, without theassistance from external power supplies.

Boolean A logical system used to express one of two states, such as on or off (yes or no, 1 or 0, etc.)





Bound A network communication technique whereby a node automatically receives a network variablefrom a sender node whenever the sender node sends it out. Whenever this condition exists, the nodeis said to be "bound".

Bumpless TransitionBumpless transition is make-before-break transfer of an electrical load from one source to another where voltage and frequency transients are kept to a minimum.

BusBus can refer to the current-carrying copper bars that connect the AC generators and loads in aparalleling system, to the paralleled output of the AC generators in a system or to a feeder in anelectrical distribution system.

Bus Bars

Bus Bars are rectangular copper or aluminum bars that connect the output of the generator setcircuit breakers to the transfer switches, circuit breakers, or fusible switches that transfer power tothe load. The bus bars are sized and assembled in multiples according to the current they must carryunder load. A typical sizing criteria for copper bus bars rated from 500-5,000 amps is to maintain acurrent density of 1,000 amps per square inch of cross-sectional area. This results in a bustemperature rise at full load that is within acceptable limits.

Bus CapacityBus capacity is the maximum load that can be carried on a system without causing degradation of the generator frequency to less than a prescribed level (usually 59 Hz in a 60 Hz system).

CT (Current Transformer)Current transformers are instrument transformers used in conjunction with ammeters, controlcircuits and protective relaying. They usually have 5 ampere secondaries.

CalibrationNon-volatile adjustment made on the factory floor. A data set downloaded to a G-Drive or GenSetcontrol to update the operation of the control.

CellularRefers to a communication system that divides geographic regions into sections called cells. Thepurpose of this division is to make the most use of the limited number of transmission frequencies.

Channel A Channel is the physical communications media that connects the devices and the properties of these media (such as transmission speed). Most PowerCommand network installations will haveonly one channel (UTP cable and 78 KBPS transmission speed). In a large network, there may be





multiple channels and each channel may or may not be of the same media type. Typically, channelsare linked together using routers.

Channel TerminatorThis is used to terminate networks on devices that do not have terminate switches. These are

devices such as Gateways, RCI's, Routers, etc. that do not terminate circuits built into their design.

Circuit A circuit is a path for an electric current across a potential (voltage).

Circuit Breaker A circuit breaker is a protective device that automatically interrupts the current flowing through it when that current exceeds a certain value for a specified period of time. See Air Circuit Breaker,Main Breaker, Molded Case Circuit Breaker and Power Circuit Breaker.

Circulating Harmonic CurrentsCirculating Harmonic Currents are currents that flow because of differences in voltage waveformsbetween paralleled power sources, or induced by operation of non-linear loads.

Comma Separated Value (CSV) A record layout that separates data fields with a comma and usually surrounds character data withquotes. PowerCommand for windows uses the CSV record format.

Connecting DevicesConnecting to refers to the process of assigning connections--linking an output variable of one

device to an input variable of another device. This process is also called "binding".

Contactor A contactor is a device for opening and closing an electric power circuit.

Continuous Load A continuous load is a load where the maximum current is expected to continue for three hours ormore (as defined by the NEC for design calculations).

Cross Current

Cross currents are currents that circulate between paralleled generator sets when the internal(excitation) voltage of one genset is different from the other genset(s). The genset with the higherinternal voltage supplies reactive power (kVAR) to the other genset(s). The amount of cross currentthat flows is a measure of this reactive power. Cross currents are 90 degrees out of phase (lagging)compared to the current that the generator would supply at 1.0 (unity) power factor.





Cross Current CompensationCross current compensation is a method of controlling the reactive power supplied by ACgenerators in a paralleling system so that they share equally the total reactive load on the bus without significant voltage droop.

Cross Current Transformer (CCT)Cross Current Transformers are used to step down the higher line current to a lower current that thecontrol system was designed for.

CurrentCurrent is the flow of electric charge. Its unit of measure is the ampere.

Current Limiting Fuse A current limiting fuse is a fast-acting device that, when interrupting currents in its current-limitingrange, will substantially reduce the magnitude of current, typically within one-half cycle, that

would otherwise flow.

Cycle A cycle is one complete reversal of an alternating current or voltage from zero to a positivemaximum to zero again and then from zero to a negative maximum to zero again. The number of cycles per second is the frequency.

CRC ErrorThis is a digital communication test. It is a acronym for Cyclical Redundancy Check. An errorindicates that a digital message did not arrive at its destination with all of the original data intact.

Dead BusDead Bus refers to the de-energized state of the power connections between outputs of paralleledgenerator sets. The term bus in this usage can either be rigid solid bus bars or insulated flexiblecables.

Dead Field Paralleling Automatic (Exciter) Paralleling

Delta Connection

Delta connection refers to a three phase connection in which the start of each phase is connected tothe end of the next phase, forming the triangle-shaped Greek letter Delta. The load lines areconnected to the corners of the triangle.

Demand Mode Standby Unit(s) (DMSU)Demand Mode Standby Units are generator sets that can be shut down by the system when there isa low load level on the system.





Deviation FactorThe deviation factor is the maximum instantaneous deviation, in percent, of the generator voltagefrom a true sine wave of the same RMS value and frequency.

Dielectric StrengthDielectric strength is the ability of insulation to withstand voltage without breaking down.

Differential Relay A differential relay is a protective device that is fed by current transformers located at two differentseries points in the electrical system. The differential relay compares the currents and picks up when there is a difference in the two, which signifies a fault in the zone of protection. Thesedevices are typically used to protect windings in generators or transformers.

Digital Display A small display board that communicates with the Base Board. This item is now sysnonomis with

the HMI. This display module shows menus, adjustment information, alarms, and statistics of events. This module is optional on some products.

Digital Master Control (DMC)This device is designed to control the power systems in a facility. It is offered as an option onCummins switchgear.

Direct Current (DC)Direct current is current with no reversals in polarity.

Distributed Control System A collection of nodes that interact to control a system whose components are spread out over somedistance. Each node has intelligence for operating its own particular component of the system.Different parts of the system communicate status and control information with one another to forma distributed control system. Typically, they communicate on a peer-to-peer level. This is differentfrom a type of system where all control and interaction between components is dictated by onecentral control. This is a common master/slave arrangement.

Distribution Circuit Breaker A distribution circuit breaker is a device used for overload and short current protection of loadsconnected to a main distribution device.

Distribution SwitchgearDistribution switchgear may include automatic transfer switches, drawout air frame circuitbreakers, fusible switches, or molded case breakers.





Domain A domain is a network concept that allows independently functioning networks to share resourcessuch as transmission media. A domain designation provides an ID number to identify the devicesthat can communicate within that domain. A network must have at least one domain.PowerCommand Network installations will usually have only one specified domain.

Draw Out Unit A draw out unit is a structure that holds a circuit breaker in an enclosure. It has a movable carriageand contact structures that permit the breaker to be removed from the enclosure without manuallydisconnecting power cables and control wires.

Droop Load SharingDroop load sharing is a method of making two or more parallel generator sets share a system kWload. This is accomplished by having each governor control adjusted so that the sets have the samedroop (reduction of speed). Typical droop is two cycles in frequency from no load to full load.

Earth Fault Protection A grounding bar is a copper bar that electrically joins all the metal sections of the switchgear. Thisbar is connected to the earth or ground connection when the system is installed. The grounding orearthing protects personnel from stray currents that could leak to the metallic enclosures.

ECM Acronym for Engine Control Module. This term usually refers to the control that is supplied onCummins FAE engines, but it is also used when referring to PCC series controls that are used tocontrol engine speed and engine protection.

EEPROMElectrically Erasable Programmable Read Only Memory. This memory holds data after the powerhas been removed, but can be changed by writing new data on top of old data. This is where thePowerCommand Control stores its calibration data. InPower, the service software, can write a newcalibration into the control flash memory.

Efficiency (EFF)Efficiency is the ratio of energy output to energy input, such as the ratio between the electricalenergy input to a motor and the mechanical energy output at the shaft of the motor.

Electrical Operator An electrical operator is the electric motor driven closing and tripping (opening) devices that permitremote control of a circuit breaker.





Emergency Bus An emergency bus is the silver-plated copper bus bars or flexible cable used to connect theparalleling breakers to the emergency system feeder breakers, and ultimately to automatic transferswitches or other distribution devices.

Emergency System An emergency system is independent power generation equipment that is legally required to feedequipment or systems whose failure may present a life safety hazard to persons or property.

EnergyEnergy is manifest in forms such as electricity, heat, light and the capacity to do work. It isconvertible from one form to another, such as in a generator set, which converts rotatingmechanical energy into electrical energy. Typical units of energy are kW/h, Btu (British thermalunit), Hp/h, ft/lbf, joule and calorie.

EPSEngine Position Sensor. Serves the similar function as an MPU (Magnetic Pick Up) however it usesHall Effect sensing and provides input to the ECM (Engine Control Module)

Exciter An exciter is a device that supplies direct current (DC) to the field coils of a synchronous generator,producing the magnetic flux required for inducing output voltage in the armature coils (stator). SeeField.

Exciter Paralleling Control

An exciter paralleling control initiates the start of generator excitation in generator sets used inautomatic paralleling systems.

FAE Acronym for Full Authority Engine. These engines typically employ high tech electronic fuelinjection and control systems.

Fault A condition occurred which caused a warning or shutdown alarm.

Feeder Circuit BreakerSee Distribution Circuit Breaker.

Fiber Optic Cable A technology using glass or plastic threads (fibers) to transmit data. A fiber optic cable is a bundleof either glass or plastic threads capable of transmitting messages modulated into light waves.Typically, fiber optic cable has greater bandwidth allowing them to carry more data than metal wires. Fiber optic cable is lighter and less susceptible to interference than metal wires. Also, data





can be transmitted digitally rather being transformed into analog data for transmission as is the case with metal wires when used for computer data transmission. Fiber optics are becoming increasinglymore common for use with Local-Area Networks (LANs).

FieldThe generator field (rotor) consists of a multi-pole electromagnet which induces output voltage inthe armature coils (stator) of the generator when it is rotated by the engine. The field is energizedby DC supplied by the exciter.

Field Breaker with Auxiliary SwitchThis is the circuit breaker (usually mounted in the generator control panel) that monitors thealternating current input to the automatic voltage regulator. If a malfunction occurs in the excitationsystem, the circuit breaker trips on overcurrent-closing the auxiliary switch, shutting down thegenerator set, and energizing the alarm circuit.

First Start Sensor A first start sensor is an electronic device within some paralleling equipment that senses generatorset and bus voltage and frequency, and determines whether or not a generator set is the first unitready to close to the bus following a call to start under "black start" conditions.

Form - C RelayRefers to a type of relay that has a normally closed contact and a normally closed contact. The relaycoil must be energized for the contacts to switch position.

Free Field (Noise Measurements)

In noise measurements, a free field is a field in a homogeneous, isotropic medium (a mediumhaving the quality of transmitting sound equally in all directions) which is free of boundaries. Inpractice, it is a field in which the effects of the boundaries are negligible in the region of interest. Inthe free field, the sound pressure level decreases 6 dB for each doubling of the distance from apoint source.

FrequencyFrequency is the number of complete cycles per unit of time of any periodically varying quantity,such as alternating voltage or current. It is usually expressed as (Hz) Hertz or CPS (cycles persecond).

Frequency Adjust Potentiometer A frequency adjust potentiometer is used to manually bring the frequency (speed) of the incomingset to that of the bus for synchronizing purposes. When the generator set is paralleled, operation of this potentiometer will adjust the kW load assumed by the generator set.





Frequency RegulationFrequency regulation is a measure that states the difference between no-load and full-loadfrequency as a percentage of full-load frequency.

FT-10 NetworkFT-10, sometimes described as FTT-10, is the large network transceiver system used withCummins Power Generation systems employing the LonWorks protocol. FTT-10 stands for “FreeTopology Type - 10Mbaud.” The Free Topology protocol allows multiple topologies to be used inone network. The maximum network cable length in a free topology network is 500 meters. If thenetwork is designed and installed using a multi-drop bus topology the maximum distance is 4,000feet.

Fusible Switch A fusible switch is an isolating switch and overcurrent protective device used for feeder or transferswitch isolation and protection. It is typically a manually operated, stored energy opening and

closing, bolted compression blade switch, with provisions for installing current limited fuses.

Gateway A device that acts as an interface between two different communication protocols. The NetworkGateway Module (NGM) provides a communication protocol that a PC can understand. Othergateway devices may be used to interface between our Lontalk protocol and other systems such as aSCADA or Building Automation System. Typically, a gateway becomes necessary when a SCADA or BAS does not have a driver developed for Lontalk.

Generator

A generator is a machine which converts rotating mechanical energy into electrical energy.

Genset Communication Module (GCM)The GCM provides a communication gateway between the Model 3100 PowerCommand Control(PCCI) and the network. The GCM communicates with the PCCI control over a serial data link.The GCM gets data from the PCCI controls such as voltage, current, engine speed, oil temperature,etc. and then sends it out on the network if another network node is bound to it or requesting data.

GCS Acronym for Genset Control System. This is usually found on generator sets built by other, yetthey use engines and controls built by Cummins.

Governor A governor is a device on the engine which controls fuel to maintain a constant engine speed undervarious load conditions. The governor must have provision for adjusting speed (generatorfrequency) and speed droop (no load to full load).





GridThe utility-owned power distribution system.

Ground A ground is a connection, either intentional or accidental, between an electrical circuit and the earthor some conducting body serving in place of the earth.

Ground Fault ProtectionThis function trips (opens) a circuit breaker or sounds an alarm in the event that there is anelectrical fault between one or more of the phase conductors and ground (earth). This ground faultprotection function may be incorporated into a circuit breaker.

Ground ReturnGround return is a method of ground fault detection that employs a single sensor (CT) encirclingthe main bonding jumper between the power system neutral and ground. This device in itself is not

capable of locating the faulted circuit but when used in conjunction with ground fault sensors on allfeeders and source connections, can provide bus fault protection when properly coordinated(delayed).

Grounded Neutral A grounded neutral is the intentionally grounded center point of a Y-connected, four-wiregenerator, or the mid-winding point of a single phase generator.

Hall Effect Sensor A Hall effect sensor is a transducer that varies its output voltage in response to changes in

magnetic field. Hall sensors are used for proximity switching, positioning, speed detection, andcurrent sensing applications.

Harmonic Distortion (Total Harmonic Distortion)Total harmonic distortion is an expression of the total harmonic content of a voltage waveform. Theharmonic distortion (or harmonic content) of a waveform is usually expressed as the square root of the sum of the squares of each of the harmonic amplitudes (with amplitudes as a percent of thefundamental voltage amplitude).

HarmonicsHarmonics are voltage or current components which operate at integral multiples of thefundamental frequency of a power system (50 or 60 Hertz). Harmonic currents have the effect of distorting the shape of the voltage wave form from that of a pure sine wave.

Hertz (Hz)The term Hertz is the preferred designation for cycles per second (CPS) and is used to describefrequency.





HMIHuman Machine Interface: Commonly referred to as touch panel, or control display, and nowincludes reference to the annunciator and bargraph .

Hub A common connection point for devices or nodes in a network or sub-network. Hubs are commonlyused to connect segments of a LAN and contain multiple ports.

HuntingHunting is a phenomenon that can occur upon load changes in which the frequency or the voltagecontinues to rise above and fall below the desired value without reaching a steady-state value. It iscaused by insufficient damping.

Incoming SetThis is the generator set that is about to be connected to (paralleled with) the energized bus.

Initial CalibrationDownloading a data set to a PowerCommand Control to set up the operation of the control. In thistype of calibration the technician has to manually enter the dataplate information for the genset intoInPower software. If a capture file is not downloaded into the control after this type of calibration isperformed, all parameters will be reset to their “factory settings”.

Insulated Case Circuit Breaker An insulated case circuit breaker is a power circuit breaker that is provided in a preformed case,similar to a molded case breaker.

InsulationInsulation is non-conductive material used to prevent leakage of electric current from a conductor.There are several classes of insulation in use for generator construction, each recognized for amaximum continuous-duty temperature.

Internal VoltageThe internal voltage is the voltage a generator would develop at no load if it were not connected ina parallel operation. Excitation of the generator field controls internal voltage.

InteroperabilityDesign to allow one product to work with another product without modification.

InterruptibleThis refers to the practice of operating on-site power systems, at the request of a utility, to reduceelectrical demand on the utility grid during periods of high consumption. Interruptible facilitiesmay also be disconnected from all electrical service in the event of high demand on the utility grid,even if no on site power system is available.





Interrupting CapacityInterrupting capacity is the magnitude of electrical current that a device can safely interrupt (openagainst), without failure of the component.

kW Load SensorThe kW load sensor is an electronic device provided to sense kW level at various points in asystem, for use in control functions within the system, such as kW load alarms, or load demand.

kVA (kilo-Volt-Amperes)kVA is a term for rating electrical devices. A device's kVA rating is equal to its rated output inamperes multiplied by its rated operating voltage. In the case of three-phase generator sets, kVA isthe kW ouput rating divided by 0.8, the rated power factor. kVA is the vector sum of the activepower (kW) and the reactive power (kVAR) flowing in a circuit.

kVAR (kilo-Volt-Amperes Reactive)

kVAR is the product of the voltage and the amperage required to excite inductive circuits. It isassociated with the reactive power which flows between paralleled generator windings and betweengenerators and load windings that supply the magnetizing currents necessary in the operation of transformers, motors and other electromagnetic loads. Reactive power does not load the generatorset's engine but does limit the generator thermally.

kWThis is an abbreviation for kilowatt, an alternate term for rating electrical devices. Generator sets inthe United States are usually rated in kW. Sometimes called active power, kW loads the generatorset engine.

kW-h(kilo-Watt-hour)This is a unit of electric energy. It is equivalent to one kW of electric power supplied for one hour.

Lagging Power FactorLagging power factor in AC circuits (a power factor of less than 1.0) is caused by inductive loads,such as motors and transformers, which cause the current to lag behind the voltage. See PowerFactor.

Lead UnitIn a paralleling system that has a load demand feature, the lead unit is the last unit to be shut downin the event that load demand mode is in operation.

Leading Power FactorLeading power factor in AC circuits (0.0 to -1.0) is caused by capacitive loads or overexcitedsynchronous motors which cause the current to lead the voltage. See Power Factor.





Leg A leg is a phase winding of a generator, or a phase conductor of a distribution system.

Line-To-Line VoltageLine-to-line voltage is the voltage between any two phases of an AC generator.

Line-To-Neutral VoltageIn a 3-phase, 4-wire, Y-connected generator, line-to-neutral voltage is the voltage between a phaseand the common neutral where the three phases are tied together.

Load DemandLoad Demand is a paralleling system operating mode in which the system monitors the total kWoutput of the generator sets, and controls the number of operating sets as a function of the total loadon the system. The purpose of load demand controls is to reduce fuel consumption and limitproblems caused by light load operation of reciprocating diesel generator sets.

Load DumpSignal output from a genset which is activated by the genset when it enters an overload and/orunderfrequency condition. In today’s systems, this tells the master control that it needs to shedsome load.

Load FactorThe load factor is the ratio of the average load to the generator set power rating.

Load Management

Load management is the overall control of load connected to match available generator capacity.Priority control and load shedding are the two features required for load management.

Load SheddingLoad shedding is the process by which the total load on a paralleling system is reduced, onoverload of the system bus, so that the most critical loads continue to be provided with reliableelectrical service.

Local Loop A method of branching out or creating a stub on the network. The maximum distance this stub can

be is 10ft. (3m) from the main network bus. Effectively the node is "daisy-chained" into thenetwork. This involves two wires, one that goes to the node and another that returns to the mainnetwork bus. The total local loop distance must be added to the total network length. This becomesimportant when the main network bus nears the 4,600 ft. length and requires the use of Routers.

Local-Area Network (LAN) A computer network that spans a relatively small area. Most LANs are confined to a single buildingor group of buildings.





LocationsLocations are subdivisions of a network that can be selected for easier organization. Locations maydesignate physical places, but are not required to do so. For example, network devices in onelocation may communicate with network devices in another location when requested to do so.

Low Side DriverDC loads have a positive side and a negative side. On the PCC 1302, the Low Side Driver is theswitched negative side of a load when the circuit operates because of a internal power supply. Itmay not have direct connection to chassis ground or battery negative.

Low Voltage AC system operating voltages from 120 to 600 VAC.

Main Breaker A main breaker is a circuit breaker at the input or output of the bus, through which all of the bus

power must flow. The generator main breaker is the device, usually mounted on the generator set,that interrupts the genset's power output. Main breakers provide overcurrent protection and a singledisconnect point for all power in a switchboard or device.

MainsMains is a term used extensively outside of the United States to describe the normal power service(utility).

Master Control A control section in a typical paralleling system that provides total system metering and the

interface point between the paralleling system and the facility.

MediaThe main network bus defined by two characteristics: 1) The electrical signal level and 2) thecharacteristics of the wiring they will travel over. Typically, our standard PowerCommand Networkuses 22 AWG Unshielded Twisted-Pair (UTP) wire operating at 78 KBPS.

Medium Voltage AC system operating voltages from 601 to 15000 VAC.

MODBUSMODBUS®Protocol An industrial networking system that uses RS-232 serial master-slavecommunications at data transfer rate of up to 19.2 KBPS and is a messaging structure developed byModicon in 1979, used to establish master-slave/client-server communication between intelligentindustrial devices. There are multiple variations of the protocol.





Modbus II An industrial networking system that uses token-passing peer-to-peer communications at datatransfer rates of five megabits per second (MBPS). The network medium is coaxial cable.

Modbus Plus An industrial networking system that uses token-passing peer-to-peer communications at datatransfer rates of one megabit per second (MBPS). The network media is shielded twisted-pair cable.

ModulesModules are also called nodes or devices. These are devices such as Genset CommunicationModules (GCMs), Control Communication Modules (CCMs), and Digital Input/Output Modules(DIMs).

Molded Case Circuit Breaker A molded case circuit breaker automatically interrupts the current flowing through it when the

current exceeds the trip rating of the breaker. Molded case refers to the use of molded plastic as themedium of electrical insulation for enclosing the mechanisms, and for separating conductingsurfaces from one another and from grounded (earthed) metal parts. Molded case circuit breakersusually contain thermal-magnetic trip units, although larger sizes can be equipped with solid statetrip sensors.

MotoringIn paralleling applications, unless a generator set is disconnected from the bus when its engine fails(usually as a result of a fuel system problem), the generator will drive (motor) the engine, drawingpower from the bus. Reverse power protection which automatically disconnects a failed set from

the bus is essential for paralleling systems. Also, in certain applications such as elevators, the loadcan motor the generator set if insufficient additional load is present.

Multi-drop Bus TopologyThe wiring arrangement used for the network data. The bus starts at one point and ends at another.Both the start and end of a network must be terminated through the use of a terminate switch. Themaximum stub length (See Definition of Local Loop) must not exceed 10ft. and must be includedin the total length of the main network bus.

NEC (National Electrical Code)This document is the most commonly referenced general electrical standard in the United States.

NEMANational Electrical Manufacturers Association

NEMA 1 EnclosureThis enclosure designation is for indoor use only-where dirt, dust, and water are not aconsideration. Personnel protection is the primary purpose of this type of enclosure.





NFPANational Fire Protection Association

NFPA 110National Fire Protection Agency Section 110 (NFPA 110) deals with the regulations concerningEmergency Power Systems (EPS). This section deals with regulations on installation, operation,and monitoring of EPS.

Network A collection of Nodes that communicate with one another over a common medium.

Network Annunciator Module (NAM) A device providing LED indication in the event of an alarm condition on a PowerCommandNetwork device. For example, we can provide NFPA 110-alarm annunciation for gensets with theuse of a NAM.

Network BusThe main "backbone" of the network data wire. It must be terminated at both the start and end of the network. Stubs off the main bus wire cannot exceed 10ft. (3m.). The wire is "daisy-chained"from one node to the next. The bus cannot exceed 4,600ft. without the use of a router. Bus can alsorefer to the devices that connect the generators and loads to a system.

Network Communication Module (NCM ATS) An optional module located inside the OTPC PowerCommand Control. This module allows thetransferswitch to be a node on the network and communicate with the rest of the network devices.

Network Communication Module (NCM Gen) An optional module located inside the PowerCommand Control 2100. This module allows the PCC2100 to be a node on the network and communicate with the rest of the network devices.

Network Data A signal that carries messages between nodes. PowerCommand Networks use ManchesterEncoding that makes the signal insensitive to polarity. The signal is transformer-coupled to thenetwork data wire at a rate of 78 KBPS.

Network Data WireUnshielded-Twisted Pair (UTP) cable that carries the network data over the main network bus. Themaximum network length is 4,600 ft. without the use of routers.

Network Gateway Module A device acting as an interface between a modem or PC and the network wire. The Gateway takesthe UTP wire and then provides an RS-232 port for connection to either a modem or PC.





NeutralNeutral refers to the common point of a Y-connected AC generator, a conductor connected to thatpoint or to the mid-winding point of a single-phase AC generator.

Neutral CurrentNeutral current is the current that flows in the neutral leg of a paralleling system. Often, this term isused in reference to circulating currents or cross currents.

Node A module that can communicate over the network data to other modules. A module contains aNeuron Chip. Certain devices are nodes such as Genset Communication Modules (GCMs) andControl Communication Modules (CCMs). Other devices are not nodes, as they cannotcommunicate with other devices, but only receive messages. An example is the Network Annunciator Module (NAM).

Nominal Value A value which has not been trimmed. An example would be normal line frequency of 60.0 Hz. Thenominal value is 60.0 Hz.

Nonlinear Load A nonlinear load is a load for which the relationship between voltage and current is not a linearfunction. Some common nonlinear loads are fluorescent lighting, SCR motor starters and UPSsystems. Nonlinear loads cause abnormal conductor heating and voltage distortion.

Normal Standby Mode

In the normal standby mode, power to the load is supplied by the utility. The paralleling system isready to provide power to the load in the event of utility failure.

Octave BandIn sound pressure measurements (using an octave band analyzer), octave bands are the eightdivisions of the measured sound frequency spectrum, where the highest frequency of each band istwice that of its lowest frequency. The octave bands are specified by their center frequencies,typically: 63, 125, 250, 500, 1,000, 2,000, 4,000 and 8,000 Hz (cycles per second).

OhmThe ohm is a unit of electrical resistance. One volt will cause a current of one ampere to flowthrough a resistance of one ohm.

On-Set ParallelingOn-set paralleling is a manual paralleling system that is built onto the generator set, no additionalswitchboards are required.





One-Line Diagram A one-line diagram is a schematic diagram of a three-phase power distribution system which usesone line to show all three phases. It is understood when using this easy to read drawing that one linerepresents three.

Operating Source An operating source is a source of electrical power that is delivering power to a load. The operatingsource can be either a generator set or a commercial (utility bus) power line.

Out-Of-PhaseOut-Of-Phase refers to alternating currents or voltages of the same frequency which are not passingthrough their zero points at the same time.

OvercrankOvercrank is an alarm function provided with most generator sets that indicate that the generator

set has failed to start.

Overload RatingThe overload rating of a device is the load in excess of the nominal rating the device can carry for aspecified length of time without being damaged.

OvershootOvershoot refers to the amount by which voltage or frequency exceeds the nominal value as thevoltage regulator or governor responds to changes in load.

Parallel OperationParallel Operation is the operation of two or more sources of AC electrical power whose outputleads are connected to a common load. Connection of the power sources is made so that the sourceselectrically function as a single source of power. Parallel Operation requires that the two sources of electrical power must match in voltage, frequency, and number of phases.

Paralleling Breaker A paralleling breaker is the circuit breaker that connects the generator set to the emergency bus,and across which all the individual generator synchronizing functions occur.

Paralleling Control A paralleling control contains the electrical equipment provided in a paralleling system for controlof a single generator set.

Paralleling SuppressersParalleling suppressors are semiconductor devices that protect the silicon diodes on a brushlessexcitation system from damaging overvoltages. Overvoltages, usually of short duration, occur whena generator is paralleled out of phase with the energized bus.





ParameterMonitored values or settings in the PCC or the Operator Panel that can be looked at and, in somecases, adjusted. Some parameters are protected by passwords.

ParityIn error detecting schemes, a Bit (even or odd) that represents the binary sum of the datatransmitted. Primarily used when transmitting data over a long distance. For example, whentransmitting information using modems.

Pass ThruRefers to a junction box connection where the network bus comes to a connector and thencontinues straight on through. In most Pass Thru connections, very little input and output is done. An example of this connection is the Junction Box/Terminator (JBT).

PC 1.X

Acronym designationfor PowerCommand Control 1302 with one of several HMI versions. 1.1 =HMI 211, 1.2 = HMI 220.

PCC Acronym for PowerCommand Control.

PCCNet An RS-485 based networking scheme that allows PowerCommand gensets, transfer switches,paralleling switchgear, and monitoring/control modules to work without operator intervention onsetup or restart.

Per Unit (PU)Definition #1: A unitless quantity that is the ratio of the current operating value to therated/nominal value. For example, a standby rated genset of 250 kW, 0.8 power factor with a loadof +260 kW, −50 kVAR would have +1.04pu kW, −0.26pu kVAR.

Definition #2: Alternator capability curves calculate per unit kW as the ratio of kW to rated kVA.Per unit kVAR is calculated as the ratio of rated kVAR to rated kVA.

PETS Acronym for Production Engine Test System.

Peak LoadPeak load is the highest point in the kilowatt demand curve of a facility. This is used as the basisfor the utility company's demand charge.





Peer-To-Peer A network operating system where any device on the main network bus can initiatecommunication.

PhasePhase refers to the windings of an AC generator. In a three-phase generator there are three windings, typically designated as A-B-C, R-S-T or U-V-W. The phases are 120 degrees out of phase with each other. That is, the instants at which the three phase voltages pass through zero orreach their maximums are 120 degrees apart, where one complete cycle is considered 360 degrees. A single-phase generator has only one winding.

Phase AnglePhase angle refers to the relation between two sine waves which do not pass through zero at thesame time. Considering one full cycle to be 360 degrees, the phase angle expresses how far apartthe two waves are in relation to each other in degrees.

Phase RotationPhase rotation (or phase sequence) describes the order (A-B-C, R-S-T, or U-V-W) of the phasevoltages at the output terminals of a three-phase generator. The generator phase rotation mustmatch the facility phase rotation. This must be checked prior to operation of the electrical loads in afacility with an on-site generator.

PGI CAN Acronym for Power Generation Interface to Cummins J1939 CAN communication systems.

Pilot Relay A Pilot Relay is a simple relay which uses a low current coil that activates high current contacts.The PCC 1302 control board has limited output power and it can be damage if it is connecteddirectly to high power DC loads such as fuel shut off solenoids or starter solenoids.

PitchPitch is a mechanical design characteristic of a generator that indicates the ratio of the number of winding slots per generator pole to the number of slots enclosed by each coil. The generatordesigner may use the pitch of a machine to optimize the generator cost versus the quality of thevoltage waveform generated.

PolePole is used in reference to magnets, which are bipolar. The poles of a magnet are designated Northand South. Because magnets are bipolar, all generators have an even number of poles. The numberof poles determines how fast the generator will have to be turned to obtain the specified frequency .For example, a generator with a 4-pole field would have to be run at 1800 rpm to obtain afrequency of 60 Hz (1500 rpm for 50 Hz). Pole can also refer to the electrodes of a battery or to thenumber of phases served by a switch or breaker.





PortThe external connector on a device at which the network cable or medium is attached.

PowerPower refers to the rate of performing work or of expending energy. Typically, mechanical poweris expressed in terms of horsepower and electrical power in terms of kilowatts. One kW equals 1.34hp.

Power Circuit Breaker A power circuit breaker is a circuit breaker whose contacts are forced closed via a spring-charged,over-center mechanism to achieve fast closing (5-cycle) and high withstand and interruptingratings. A power circuit breaker can be an insulated case or power air circuit breaker.

PowerCommand Control 1302The base line control developed by Cummins Power Generation which will be used to replace the

“One-Off” controls used on Cummins Power Generation sets. The smaller kW range setscommonly have non-Cummins engines. The PCC 1302 control operates on 12 Volt or 24 Voltbattery systems. It can be used without extra componentry on gaseous fuel gensets. When used onsome Diesel gensets, an external governor signal amplifier is needed. The PCC 1302 is intended tobe available for use on all non-paralleling Cummins gensets up to 1,500 kW in 2008.

PowerCommand Network A communication network for moving information electrically among various Onan on-site powergeneration modules. The PowerCommand Network will utilize Echelon LonWorks for systemmodule interconnection.

Power FactorPower factor is the cosine of the angle between the active power (kW) and apparent power (kVA)in a circuit.

Prime PowerPrime Power describes an application where the generator set(s) must supply power on acontinuous basis and for long periods of time between shutdowns. No utility service is present intypical prime power applications.

Priority ControlPriority control is the process by which the total loads on the bus is limited to the most criticalloads in the system until adequate generation capacity is available to serve all loads.

Protocol A set of rules used mutually by two or more devices to communicate. Also, known as the"language" used in a network.





Pulse AlarmsPulse alarms are alarm logic systems that allow all alarms to be annunciated, even if a previousalarm has been silenced but is still present in the system.

RAMRandom-Access Memory. This is the memory that the PowerCommand Control uses to actuallyoperate the generator set. This memory requires power to maintain its content.

Radio Frequency (RF) Any frequency within the electromagnetic spectrum associated with radio wave propagation.

Radio InterferenceRadio interference refers to the interference with radio reception caused by a generator set.

Radio Interference SuppressionRadio interference suppression refers to the methods employed to minimize radio interference.

Random Access ParallelingRandom access paralleling is a paralleling operation where any generator may be the first unit toclose to the bus on startup of the system. Random access systems use active synchronizing to forcethe second and all subsequent generator sets to close to the bus as fast as possible.

Rated CurrentTo be calculated based on rated power (kW) and nominal voltage.

Rated kWDefinition #1: This is set by the end application — standby, limited time prime, unlimited timeprime, or continuous.

Definition #2: Determined by the rated current and voltage programmed into the Base card by theManufacturing Tool or calibration downloaded by InPower software. This is the maximum kilowattload the generator set can provide.

Reference Value A value in a control loop which determines to what value the control loop is attempting to drive theoutput. An example situation would be when a synchronizing control loop is attempting to drive thegenset frequency to match the bus frequency. Perhaps the genset nominal frequency is 60.0 Hz, thegenset set point frequency is 61.5 Hz, but the bus frequency is 59.0 Hz because it is overloaded.Prior to closing the circuit breaker, the genset will set its reference frequency to 59.0 to allow it tomatch the bus. At this time, the reference value is 59.0 Hz.





Register A ModBus communication packet of information. Cummins Power Generation uses 40000 leveldesignations for most genset data.

RMS(Root Mean Square)The RMS values of a measured quantity such as AC voltage, current and power are considered the"effective" values of the quantities. See Watt.

RPMRevolutions Per Minute.

ReactanceReactance is the opposition to the flow of current in AC circuits caused by inductances andcapacitances. It is expressed in terms of ohms and its symbol is X.

Reactive Differential CompensationReactive differential compensation (also called cross current compensation)is a method of controlling the reactive power supplied by generators in a paralleling system so that they equallyshare the total reactive load on the bus, without inducing significant voltage droop in the system.

Reactive Droop CompensationReactive droop compensation is one method used in paralleled generator sets to enable them toshare reactive power supplied to a load. This system causes a drop in the internal voltage of a set when reactive currents flow from that generator. Typically, at full load, 0.8 PF, the output voltageof a set is reduced by 4% from that at no load when reactive droop compensation is used.

Reactive PowerReactive power is power that flows back and forth between the inductive windings of the generatorand the inductive windings of motors, transformers, etc., which are part of the electrical load. Thispower does no useful work in the electrical load nor does it present load to the engine. It does applyload to the generator and limits the capacity of the generator.

Reactor A reactor is an electrical device that applies only reactive load to a system.

Real PowerReal power is the product of current, voltage and power factor (the cosine of the angle by whichcurrent leads or lags voltage) and is expressed as W (watts).

ResistanceResistance is the opposition to the flow of current in DC and AC circuits. It is expressed in ohmsand its symbol is R.





Reverse Power Relay A reverse power relay is a relay with a wattmeter movement that senses the direction of powerflow. In paralleled sets, a flow of reverse power (i.e., power flow into set) will actuate the reversepower relay and disconnect the set from the system. If one set stops and reverse power protection isnot provided, the set still running will drive the set that has stopped. The generator on the set that

has stopped will act as a motor.

RisersRisers are rectangular copper or aluminum bars that connect circuit breakers, fusible switches, andtransfer switches with the main system bus. As with bus bars, they are sized and assembled inmultiples according to the current they must carry.

Rotor A rotor is the rotating element of a motor or generator.

Router A device for passing network messages over another media and sometimes protocol. Our networkrouter is programmed as a "repeater" to create another channel on the main network bus. Eachchannel can have a 4,600 ft. network bus and is capable of having 44 nodes. The PowerCommandNetwork can have up to twenty (20) channels.

Save and Restore CalibrationDownloading a data set to the PCC 2100 to update the operation of the control. In this type of calibration, the data plate information for the genset comes from the stored data in the Base board. All previous settings are restored.

SCRSilicon Controlled Rectifier -- a three-electrode solid-state device which permits current to flow inone direction only, and does this only when a suitable potential is applied to the third electrode,called the gate.

Selective CoordinationSelective coordination is the selective application of overcurrent devices such that short circuitfaults are cleared by the device immediately on the line side of the fault, and only by that device.

Self Excitation A method whereby the output of the AC alternator is utilized for powering the voltage regulationcircuit. Sometimes the term “Shunt Excitation” will be found in some product literature.

Separately Derived A separately derived on-site power system has no direct neutral connection with the neutral of thenormal electrical service.





Sequential ParallelingSequential paralleling is a type of automatic paralleling system where the generators in a systemclose to the bus in a prescribed order, typically by use of a single synchronizer.

Service EntranceThe service entrance is the point where the utility service enters the facility. In low voltage systemsthe neutral is grounded at the service entrance.

Set point Value A value which is the result of a trim made to a nominal value. An example would be if the operatoradjusted a nominal frequency of 60.0 Hz to 61.5 Hz. The set point value is 61.5 Hz.

Short Circuit A short circuit is generally an unintended electrical connection between current carrying parts.

Shunt TripShunt trip is a feature added to a circuit breaker or fusible switch to permit the remote opening of the breaker or switch by an electrical signal.

Shutdown A type of fault that causes the Genset to shut off immediately or prevents it from starting.

Sine Wave A sine wave is a graphical representation of a sine function, where the sine values (usually the yaxis) are plotted against the angles (x axis) to which they correspond. AC voltage and current wave

shapes approximate such a curve.

Site A single instance where a network has been installed.

Slave A networked device that is controlled by another device. Slave devices do not initiate datatransmission. They respond to commands or requests initiated by a master device. In digitalcommunication systems such as ModBus, this would be a device that is not capable of originatingor initiating communications. It can only respond when asked for information.

Soft LoadingSoft loading refers to the ramping of load onto or off of a generator in a gradual fashion for thepurpose of minimizing voltage and frequency transients on the system.





SoundSound is considered both in terms of the sound pressure waves travelling in air (pressuressuperimposed on the atmospheric pressure) and the corresponding aural sensation. Sound can be"structure-borne", that is, transmitted through any solid elastic medium, but is audible only atpoints where the solid medium "radiates" the pressure waves into the air.

Sound Level Meter A sound level meter measures sound pressure level. It has several frequency-weighted decibel (dB)scales (A, B, C) to cover different portions of the range of measured loudness. Sound level metersindicate RMS sound, unless the measurements are qualified as instantaneous or peak sound level.

Sound Pressure Level (SPL)Sound pressure level is a measurement of the pressure fluctuations of a sound wave as it propagatesthrough the air. Because of the wide range of pressures to which the ear responds, a logarithmicscale is used and is expressed as a ratio of the measured pressure referenced to a pressure of 2x10-5

N/m2 (20 m Pa) which is the threshold of human hearing at 1000 Hz. The measure is expressed indecibels (dB). The Bel unit is named after Alexander Graham Bell.

Standby System A standby system is an independent power system that allows operation of a facility in the event of normal power failure.

Star ConnectionSee Wye Connection.

Star Topology A topology where all the devices must connect to a central hub. Star topologies are relatively easyto install and manage, but can have bottlenecks occur as all the information must pass through thehub.

Starting CurrentThe initial value of current drawn by a motor when it is started from standstill.

StatorThe stator is the stationary part of a generator or motor. See Armature.

Status An indication of state used for informative purposes only — not a warning or shutdown alarm.Typically a status indication does not require any action to be taken.

Steady State RatingSteady state rating is the maximum load that a generator set or paralleling system can carry, on acontinuous basis, for the duration of a utility power outage.





SurgeSurge is the sudden rise in voltage in a system, usually caused by load disconnect.

Surge RatingSurge rating is the rating of a machine, usually in excess of its normal operating level, for which itcan provide power for a very short time.

Surge SuppressorSurge suppressors are devices capable of conducting high transient voltages. They are used forprotecting other devices that could be destroyed by the transient voltages.

Switching HubShort for port-switching hub, a special type of hub that actually forwards information to theappropriate port based on the IP address assigned. Conventional hubs simply rebroadcastinformation to every port. Switching hubs forward information only to the required port.

Sync Check Relay A sync check relay is an electrical device that monitors the phase relationship between two voltagesources and provides a signal when the voltage sources are within specific preset parameters.

SynchronizationIn a paralleling application, synchronization is obtained when an incoming generator set is matched with and in step to the same frequency, voltage, and phase sequence as the operating power source.

Synchronizer

A synchronizer is an electronic device that monitors the phase relationship between two voltagesources and provides a connection signal to an engine governor, to force the generator set tosynchronize to the system bus.

Synchronizing LightsSynchronizing lights are lamps connected across the line contactor of the incoming generator set.The lights indicate when the voltage waveforms of the incoming and operating power sourcescoincide and paralleling can be completed.

Synchronous Generator

A synchronous generator is an AC generator having a DC exciter. Synchronous generators are usedas stand-alone generators for emergency power and can also be paralleled with other synchronousgenerators and the utility system.





Synchroscope A synchroscope is a meter that indicates the relative phase angle between an incoming set voltageand the bus voltage. The synchroscope pointer indicates whether the set is faster or slower than thebus and allows the operator to adjust the frequency (speed) accordingly before manually parallelingto the bus.

Telephone Influence Factor (TIF)The higher harmonics in the voltage wave shape of a generator can cause undesirable effects ontelephone communications when power lines parallel telephone lines. The telephone influencefactor is calculated by squaring the weighted RMS values of the fundamental and the non-tripleseries of harmonics, adding them together and then taking the square root of the sum. The ratio of this value to the RMS value of the no-load voltage wave is called the Balanced TIF. The ratio of this value to three times the RMS value of the no-load phase-to-neutral voltage is called theResidual Component RIF.

TerminationBoth ends of the main network bus must be terminated to avoid transmission reflections. Theeffective network data bus may be made up of several different physical buses. The Terminator is aRC circuit that matches the impedance of the physical media.

Terminator A resistive load placed at the end of a cable to prevent data signals from reflecting back into thedata path.

Token

In digital data transmission communications, this is a “permission to speak” bit that passes fromnetwork member to member in a specific sequence at specific intervals.

Token-Ring Topology All of the devices or nodes are connected to one another in the shape of a closed loop. Ringtopologies are relatively expensive to install, but they offer high bandwidth and can span largerdistances.

TopologyThe physical shape of a network. There are three principal topologies: multi-drop bus, token-ring,and star.

Transfer Switch A transfer switch is an electrical device for switching loads between alternate power sources. Anautomatic transfer switch monitors the condition of the sources and connects the load to thealternate source if the preferred source fails.





TrimNon-volatile adjustment made in the field by an operator, user, or service technician. It is a subsetof parameters that can be adjusted, as opposed to parameters that can only be monitored.

TP/XF-78 Network An older transceiver system used in PowerCommand Networks. TP/XF-78 stands for “Twisted-Pair, Transformer-Coupled, 78 kbaud speed network.” The TP/XF-78 network has been replacedby PCCNet network in small systems and by the FT-10 network in larger systems.

UtilityThe primary producer/distributor of electric power. In some countries it’s called the utility source;in some others it is called the mains or “hydro.”

UndershootUndershoot refers to the amount by which voltage or frequency drops below the nominal value as

the voltage regulator or governor responds to changes in load.

VoltThe volt is a unit of electrical potential. A potential of one volt will cause a current of one ampereto flow through a resistance of one ohm.

Voltage ControlThe voltage control is a rheostat that sets the operating point of the voltage regulator and thereforecontrols the output voltage of the generator set, within its design limits.

Voltage DipVoltage dip is the dip in voltage that results when a load is added, occurring before the regulatorcan correct it, or resulting from the functioning of the voltage regulator to unload an overloadedengine-generator.

Voltage RegulationVoltage regulation is a measure that states the difference between maximum and minimum steady-state voltage as a percentage of nominal voltage.

Warning

A type of fault which does not shut down the engine or generator set, but is meant to warn the useror operator of an out of normal condition which could eventually adversely affect operation of theGenset (i.e. could shut it down or prevent it from starting or operating properly).





WattThe watt is a unit of electric power. In direct current (DC) circuits, wattage equals voltage timesamperage. In alternating current (AC) circuits, wattage equals effective (RMS) voltage timeseffective (RMS) amperage times power factor times a constant dependent on the number of phases.1,000 watts equal one kW.

Watt-Hour Demand Meter A watt-hour demand meter is similar to a watt-hour meter except that it also provides an indicationof the highest kW load level achieved during operation.

Watt-Hour Meter A watt-hour meter records the total power output at a specific point in a system. Typical recordingincrement is in kW-hours.

Wattmeter

A wattmeter records power being delivered from a source to the load. Wattmeters for parallelingsystems are calibrated in kilowatts (kW).

Wide-Area Network A system of LANs connected over a large distance via a fiber optic line, telephone line, or radio wave.

Wye Connections A Wye connection is the same as a star connection. It is a method of interconnecting the phases of athree-phase system to form a configuration resembling the letter Y. A fourth (neutral) wire can be

connected at the center point.

Zero SequenceZero sequence is a method of ground fault detection that utilizes a sensor (CT) that encircles all thephase conductors as well as the neutral conductors. The sensor will produce an output proportionalto the imbalance of ground fault current in the circuit. This output is then measured by a relay toinitiate circuit breaker tripping or ground fault alarm.

Zones of ProtectionZones of protection are defined areas within a distribution system that are protected by specificgroups.



PCC 3.3 & PowerCommandControl 3300 Participants’ Activity Section 15I

_____________________________________________________________________

Participants’ Guide Section 15 - 1

PC 3.3 & PCC 3300 Activities

This section provides Activities and Quiz’s to the previous 13 Sections.

Section 1 Introduction Quiz. 15-3

Section 2 - 1 Menu Activities 15-5



Section 3 Sequence of Operation Quiz 15-17

Section 4 Installation Quiz 15-19

Section 5 - 1 Setup and InPower Quiz 15-21

Section 5 - 2 Setup and InPower Activities 15-23

Section 6 - 1 PCCNet Quiz 15-25

Section 6 - 2 PCCNet Activities 15-26

Section 7 ModBus Activities 15-27

Section 8 PGI Quiz 15-29

Section 9 Paralleling Intro Quiz 15-31

Section 10 Standalone Quiz 15-33

Section 11 Synchronize Only Quiz 15-35

Section 12 Isolated Bus Quiz 15-37

Section 13 Troubleshooting Quiz 15-39

Final Test will be distributed by trainer at end of Module 15-41

Section 15:




_____________________________________________________________________






_____________________________________________________________________


Section 1 Quiz:

Introduction to the PC 3.3 & PCC 3300 Quiz

Match and identify the image and components; use the Service Manual or Participants’

Guide. Images are located on the next page

_____ 1) TB-5 Breaker Control Connection

_____ 2) J19 Control Board Interconnection _____ 3) TB-7 Bus Voltage Sense

_____ 4) AUX 105 Power Stage

_____ 5) J14 Service Tool Port

_____ 6) J12 Genset CT Input

_____ 7) TB-8 Customer Connections

_____ 8) J20 Genset Connections

_____ 9) TB-1 Customer Connections

_____ 10) J17 – Field Output

_____ 11) TB-15 ModBus/RS485 Service Port

_____ 12) DSx LED Status Indicators

_____ 13) Onboard CT’s _____ 14) J26 AUX105 Connections

_____ 15) J22 Genset Voltage Sense

_____ 16) TB-9 Analog I/O

_____ 17) TB-10 Breaker Status Connections

_____ 18) J18 – Power Input

_____ 19) Chassis Ground Wire

_____ 20) TB-3 Customer Input/Output

_____ 21) J25 Display Connections

_____ 22) PCC 3300

Activity 1-1:



PCC 3.3 and PowerCommand Control 3300 Participants’ Activity Section 15


R

T

Q

S

U

A CB

G

F

E

D

N

M

L K J I

H

P

O

V





PC3.3 Menu Navigation

Work through the Menus on the Operator Panel

1. Press the Home button and begin this activity from the Home Menus.

2. History / About

____________________ Number of Starts

____________________ Engine Hours

____________________ Control Hours

____________________ Genset Model Number

____________________ Kw Hours

____________________ ECM Code

____________________ Wye/Delta

____________________ Control Type

____________________HMI Boot Version

____________________ %kW Hours @ 40% @ 50Hz

____________________ “ Relative load % x 10” is displayed on which page?

____________________ %kW Hours @ 4% @ 60 Hz

3. Faults Screens

____________________ Number of Active Shutdowns

____________________ Number of Active Warning

____________________ First listed Fault History fault code

Activity 2-1:





4. Fault History

Fault Index 1

__________ Fault Number

__________ Fault History at # Hours

_____________________Fault Name

Fault Index 3



____________________ Fault Name

Fault Index 2



______________________ Fault Name

Fault Index 4



______________________ Fault Name

5. Paralleling Status

____________________ How many Paralleling Status screens exist

________________________ What screen appears if you press “Basic” soft key?

6. Genset Data

____________________ How many Genset Data screens are available?

____________________ % Torque /Duty

____________________ Genset Standby Rated Current?





PC3.3 Set Up Menus

Work through the Menus on the Operator Panel

1. Navigate to the HOME 2/2 Level to Setup Menus

________________________________________________________________________ ______________________________ List the menu choices on the HOME 2/2 screen.

2. Adjust

____________________ Exercise Switch

____________________ Keyswitch override

____________________ Governor Gain

____________________ Stop Delay

3. Genset Setup

____________________ Nominal Voltage

____________________ Auto Sleep Enable

____________________ Start Delay

____________________ Disconnect Speed

____________________ Prelube Timeout

____________________ Controlled Shutdown Unload Time

____________________ Scheduler Program Run Mode

____________________ Exception Program Repeat Interval

____________________ Load Dump UF Set Time

____________________ Delay off FSO

Activity 2-2:





4. Paralleling Setup - Basic

____________________ Gen Application Type

____________________ Voltage Match Kp

____________________ Sync Check Phase

____________________ Load Share Speed Droop Frequency Adjust

____________________ Load Share kVAR Gain

____________________ Load Govern kVAR Kp

____________________ Frequency Match Kp

5. OEM Setup Genset

Insert Serial Number GenSet _____5A124a_______________

Set Prime Standby to ______Prime______________

____________________ Fault Reset/#10 (locked or unlocked)

____________________ Backup Start disconnect/#33 (locked or unlocked)

____________________ Utility Energy Meter - Reset

____________________ Delay Shutdown Delay

____________________ Standby KVA Rating 3PH/60Hz

____________________ Reset Runs

____________________ Genset CB Tripped/#27

____________________ Load Demand Stop/#31

____________________ Voltage Bias Output/AO #2 (locked or unlocked)

____________________ Remote Fault Reset

6. OEM Setup Engine





____________________ Keyswitch Retries

____________________ V/Hz Slope

____________________ Data Save Delay

____________________ Weak Battery Set Time

____________________ Fault 1117 Enable

____________________ V/Hz Knee

____________________ Nominal Battery Volt

____________________ Freq/Speed

____________________ Prelube Enable

7. OEM Setup Alternator

____________________ Excitation Source

____________________ Max Field Time

____________________ AVR Enable

____________________ PT Primary

____________________ PT Secondary

____________________ AVR 60Hz Gains – K1

____________________ AC Voltage Fault High Threshold

____________________ Over frequency Fault Threshold

____________________ Under frequency Fault Threshold

____________________ Speed / Frequency Fault Threshold

____________________ CT Secondary





8. PCCNetSetup

____________________ PCCNet Failure Response – HMI320

____________________ PCCNet Failure Response – HMI113

____________________ HMI113 Output #2 Fault/Event

____________________ HMI113 Faults #3 Text

9. ModBus Setup

____________________ Baud Rate

____________________ Lost Response

____________________ CRC Response

____________________ Clear Counters

10. Display Options

____________________ Language

____________________ Sleep Timer

____________________ Mode Change

____________________ Temperature

____________________ Fluid Pressure

____________________ Fluid Volume

11. Clock Setup

___Present time of day___ Set the real time clock

___Present day, month, year___ Set the real time calendar

____________________ Daylight Saving Time

____________________ Daylight Saving Time End

12. Configurable I/O





___Louvers Open___ Change Configurable Input Fault#1 – Text

____________________ Low Fuel #6 - Response

____________________ Start Type/Input #11 - Active

____________________ Configurable Output #2 – Event Code

____________________ Oil Priming Pump/Output #6 - Invert Bypass

____________________ Genset CB Inhibit/Input#28 - Active

____________________ Speed Bias/AO#1 – Output High Setpoint

____________________ Voltage Bias/AO #2 – Function Output Low Setpoint

13. Calibration

____________________ Genset 1 Phase Voltage Cal – L1-N Calibration

____________________ Genset Bus Voltage Cal – L2-L3 Calibration

____________________ Utility Voltage Cal – L1-L2 Calibration

14. Save/Restore

Report all that you are able to view: ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________










Using the Soft Keys at the bottom of the Home screen, work through the Menus on the

Operator Panel

1. Genset Data

____________________ Avg Current

____________________ Coolant Temp

____________________ %Torq?Duty

____________________ Total Fuel Consumption

____________________ Genset Standby KVA rating

2. Alternator Data

____________________ Frequency

____________________ AVR Duty Cycle

3. Engine Data

____________________ Oil Pressure

____________________ Ambient Pressure

____________________ Coolant Temperature

____________________ Aftercooler Temperature

____________________ Engine Hours

____________________ Battery Voltage

4. Paralleling

Activity 2-3: Soft Key Menu Navigation





____________________ Gen breaker position

____________________ Load Demand Stop:

____________________ Synchronizer Bus Status

____________________ Genset CB Status - Tripped

____________________ Bus Metering - Frequency

____________________ Bus Energy Metering – Net kWhr

____________________ Phase Difference – L1-L2

5. %Alternator

____________________ Standby %Load – Total KW

____________________ Genset Energy Metering – Net kWhr

____________________ % Standby Current – L2

____________________ Prelube Mode

____________________ Number of Bargraphs

____________________ Phase Rotation

6. Advance Control

____________________ Exercise Time Remaining

____________________ High Alternator Temp

____________________ Active Start Type InPuts

____________________ Load Dump/#11

____________________ Analog Input – Speed Bias

____________________ Active External Parallel Inputs

7. Advance Engine

____________________ Turbo 1 Speed - RPM:





____________________ Exhaust Port Temp #2

____________________ Exhaust Port Temp #20

____________________ Governor Ramp State

____________________ Battery Charger Voltage










PC3.3 Sequence of Operation Quiz Answer the following questions about functions and components; use the

demonstrator, Participants’ Guide or Operator Manual 900-0670.

1. The PMG can provide the backup start disconnect. At what voltage does it activate? AC or DC?

_______________________________________________________________________

2. In order to keep the devices awake at all times, what jumper do you make on the HMI320?

_______________________________________________________________________

3. If the genset is running and then enters Manual operation, how long do you have topush the Manual Button before it will do a hard shutdown?

_______________________________________________________________________

4. What is the Prelube Cycle Time default setting?

_______________________________________________________________________

5. Start Time Delay can be set to what range of values?

_______________________________________________________________________

6. What terminal block and pin will the ground input remote start signal enter thePowerCommand 3.3?

_______________________________________________________________________

7. Is motor starting performance better using self excitation? Why?

_______________________________________________________________________

8. When running in Parallel Mode @ idle, what button push will cause the breaker toclose?

_______________________________________________________________________

Activity 3-1:










PC3.3 Installation Quiz Answer the following questions about functions and components; use the


1. When powering down the PCC 3300, it is important to press the local EmergencyStop button and wait approximately 30 seconds before removing battery power.Why?

A. To ensure that the ECM has time to cool down before power downB. To ensure that the ECM has had enough time to save data in memory before

power down.C. To prevent static discharge damage to the control boards. .D. All of the above

2. The PCC3300 processor receives alternator field information (F1 and F2) through

A. J17-1 and J17-2B. J20-11 and J20-22C. J26-7 and J26-14D. None of the above

3. Which of the following is a true statement?

A. Low side is the same as battery groundB. B+ return is the same as battery negativeC. B+ return is the same as groundD. None of the above

Match each of the following components in column A to its corresponding function incolumn B

Column A (Component) Column B (Function)

4. _______CT1, CT2, CT3 A. Provides analog paralleling load management inputand output

5. _______J26 B. Monitor the Bus current6. _______TB5 C. Monitor the genset current7. _______HMI320 D. Connection to the engine and AVR Power Stage8. _______TB9 E. Connection to the circuit breaker controls

F. Interface to the generator and controller functions

Activity 4-1:










PC3.3 Setup and InPower Quiz Answer the following questions about functions and components; use the


1. Kit 0541-1199 allows the technician to connect InPower to both the Operator Paneland the Base Board at the same time.

A. TrueB. False

2. Which of the following is true with regard to connecting InPower to the HMI?

A. The HMI needs to powered by a DC source via connector 15B. Communication takes place through J28 on the HMIC. The HMI can be powered through the control board via connector 15D. None of the above

Match each of the following feature folders in column A to its corresponding function incolumn B

Column A (Component) Column B (Function)3. _______Advanced Status A. Allows the user to view fault information and setfault configurations

4. _______Alternator Data B. Allows the user set and perform tests such as witness testing

5. _______Engine Data C. Allows the user to monitor engine, alternator, gensetand fuel system performance and data

6. _______Faults D. Allows the user to monitor engine performance data

only

7. _______Test E. Contains functions that used to be found in theadjustments folder.

F. Allows the user to monitor alternator performancedata only

Activity 5-1:





8. The snapshot feature allows the user to select a particular fault and then view data forthe preceding few seconds before that fault becomes active.

A. True

B. False

9. Why is it important to save a capture file before making any changes or adjustments?

_______________________________________________________________________

________________________________________________________________________

10. When viewing the setup wizard, the Enable Setup Mode button seen on the setupscreens must be highlighted in order to be able to make any adjustments/changes.

A. TrueB. False





PC3.3 Setup Activity

Work through the Menus on the Operator Panel to adjust the Real Time Clock

and Exercise setup. Use Appendix C of the Participants’ Guide and/or Operator

Manual 900-0670.

1. Set the Real Time Clock to the present time.

2. Set the Calendar to the present Day, Month, and Year

3. Set the Daylight Savings time, day, month and hour and all settings for the year.

4 . Set the exerciser Scheduler to exercise the genset every Thursday morning at10:00AM for 30 minutes and on Friday afternoon at 12:30 for 10 minutes.

5. Set the Exception for Thursday & Friday November 27 & 28 beginning in the year2008.

6. Can all of these setting be achieved? YES______ NO_______

7. If InPower is available, check all the setting that were been made during this exercise.

Activity 5-2:










PC3.3 PCCNet Quiz

Answer the following questions about functions and components; use the


1. The recommended data cable for the data and power wires used with PCCNET isBeldin #9729.

A. TrueB. False

2. The maximum number of devices in the network is 20 and should not span more than4000ft of data wire.

A. TrueB. False

3. Which of the following is NOT true about PCCNET?

A. It is a flexible communication system that provides device to device connectivity.B. It is a communication system that uses a proprietary protocol unique to CPG

products.C. It is a system for monitoring or building management systemsD. It is a token passing network

4. List 4 devices that the PCC 3300 communicates with

Activity 6-1:





5. Which of the following is true about the Universal Annunciator?

A. PCCNET allows for up to four annunciator’s in a networkB. The Annunciator supports both network and discrete wiring terminalsC. PCCNet Annunciator Switch Settings can only be changed when the device is

connecting with the PCC GensetD. Both A and BE. All of the above

PC3.3 PCCNet Activity

It is optional to include configuration of the HMI 113 - Universal Annunciator. This

activity is not required. The setup procedures are exactly the same as found in

the PC 2.X training course.

More activities will be offered in the PHASE 2 training. MorePCCNet devices will be available at that time. The skills andexperience of setup and installation of the PHASE 2 devices willbe more valuable at that time.

Activity 6-2:





PC3.3 ModBus Quiz



1. Since the PowerCommand 3.3 follows the master-slave protocol, would thePowerCommand 3.3 be configured as a master or a slave? Why?

__ ____________________________________________ __________________________

2. Does the PowerCommand 3.3 use ModBus RTU or ModBus ASCII?

__ _______________ _______________________________________________________

3. On what PCC 3300 connector would you make your ModBus connections?

__ __________________ ____________________________________________________

4. Can you change the communication Baud rate on the PCC 3300 base board?

__ ______ ________________________________________________________________

5. Via the HMI 320, what screens would you use/navigate to find the ModBus setup

information?

________________________________________________________________________

6. What is the Fasted Baud Rate available for the PowerCommand 3.3?

__ _______________ _______________________________________________________

7. With the PowerCommand 3.3 ModBus Register Map, what ModBus Address is GensetLL Average Voltage?

________________________________________________________________________

8. What software can be used to help troubleshoot the PowerCommand 3.3 ModBuscommunication?

________________________________________________________________________

Activity 7-1:










PC3.3 PGI CAN Communication Quiz



1. What connector and pins would you check the backbone for proper resistance values?What should be the value between those pins if the circuit is good?

_______________________________________________________________________

2. What is the maximum length of a PGI backbone?

_______________________________________________________________________

3. Can you perform Witness Testing Procedures if you are connected to the PCC 2300base board with InPower?

_______________________________________________________________________

4. If you were connected with a Peak System Adapter and did not see DC as part of anysource address, what would this mean?

_______________________________________________________________________

5. Do you need to ground your backbone shield? If so, where?

_______________________________________________________________________

6. Where would you find B+ on the 9-Pin Service Tool connector?

_______________________________________________________________________

7. Can your system communicate with only one terminating resistor?

__ ____________________________________________________ __________________

8. What is the communication speed of the PGI system?

_______________________________________________________________________

Activity 8-1:










PC3.3 Parallel Intro Quiz



1. The PC3.3 comes fully configurable and there is no requirement to purchase newcodes or additional features.

_____True

_____False

2. In what mode would you use Load Govern?

A. StandbyB. Isolated BusC. Utility SingleD. Utility MultipleE. C & D

3. Load Share is a feature that allows?

A. The amount of KVAR sharingB. the generator to supply a portion of KW power.

C. the unit to operate in speed droop.D. synchronization in all paralleling modes.

4. Which connector is not used when configuring the control for paralleling modes?

A. TB10B. TB1C. TB5D. TB3

5. There are many adjustments and few monitor screens in the paralleling setup folder.

_____True

_____False

Activity 9-1:










PC3.3 Standalone Paralleling Quiz



1. The password used for changing the Genset Application Type from the HMI is?

A. 121B. No password is requiredC. 574D. 1209

2. CT1 can only read Neutral Bus current in Standalone Mode.

_____True

_____False

3. The fault code generated when Genset CB Tripped is active is?

A. 1213B. 1454C. 1456D. 1209

4. Configurable Input #27 is commonly used for Ground Fault Protection.

_____True

_____False

5. TB10-2 & 10 must be connected to the:

A. Utility disconnect breaker.B. it is an optional connection and does not need to be attached to anything.C. the ground fault relayD. breaker trip relay.

Activity 10-1:










PC3.3 Synchronize Only Quiz



1. Synchronize only mode cannot be used with a transferswitch.

_____True

_____False

2. CT2 can only read Neutral Bus current in Synchronize only Mode.

_____True

_____False

3. Which ModBus register will initiate the Synchronizer when in Synchronize onlymode?

A. 40954B. 43954C. The synchronizer can only be enabled through TB10 – 13 & 19.D. The Synchronizer is always enabled when in Synchronizer only mode.

4. In Synchronize only mode, the breaker close command is connected to?

A. TB10 – 13 &17B. It is not connected anywhere because the PCC does not close the breaker in

Synchronizer only mode.C. TB10 – 13 & 19.D. TB 5 – 1 & 2.

5. Slip Frequency synchronizing is initiated how?

A. ModBus input commandB. InPowerC. Configurable Input #30.

D. after the control fails to Phase Match synchronizes for 10 consecutive seconds.

Activity 11-1:










PC3.3 Isolated Bus Paralleling Quiz

Answer the following questions about functions and components; use thedemonstrator, Participants’ Guide or Operator Manual 900-0670.

1. The genset circuit breaker close control output is provided at terminals?

A. TB10 – 8 & TB10 - 2B. TB5 – 1 & TB5 - 2C. TB10 – 9 & TB10 - 11.D. None of the above

2. Which connector is used for circuit breaker control?

A. TB3B. TB7C. TB5D. None of the above

3. Which connector inputs are used for First Start Arbitration?

A. TB3-9 & TB3-1B. TB10 - 13 & TB10 - 17C. TB10 – 13 & TB10 - 19.D. TB3 – 12 & TB3 - 11.

4. Which of the following statements is true for the Bus CTs?

A. The wire may be looped through the CT twice.B. The wire may be routed through the CT in either direction.C. There should be shorting blocks installed in the system.D. All of the above.

5. For a 120/240 volt 3 phase installation, where do the generator bus inputs land on thePCC3300 control board?

A. TB9- pins 7, 8, 10, & 11B. TB7 – pins 1, 2, 3, and 4C. TB7 – pins 5, 6, 7, and 8.D. TB7 – pins 1, 2, and 3

Activity 12-1:










PC3.3 Troubleshooting Quiz

Answer the following questions about functions and components; use thedemonstrator, Participants’ Guide or Operator Manual 900-0670.

1. The InPower Snapshot feature can only be used for alternator fault codes?

_____True

_____False

2. InPower cannot monitor the control during the Prelube cycle?

_____True

_____False

3. All faults codes available from the PCC3300 control can be reset by the ModBus reset register.

_____True

_____False

4. Exciter Field voltage limits are listed on the Common Connector Wire Diagram ?

_____True

_____False

5. is found on which page in the servicemanual?

A. A-5B. A-7

C. A-5, 6, 7, and 8.D. A-12

Activity 13-1:








PCC 3.3 and PowerCommand Control 3300 Appendix Section 16

Participants’ Guide Section 16 Appendix

PC 3.3 Appendix

This section provides additional technical information to assist with understanding

several sections.

Appendix A Setting the Real Time Clock . . 16-3

Appendix B Using ModScan Software 16-10

Section 16:



PCC 3.3 and PowerCommand Control 3300 Appendix Section 16

Participants’ Guide Section 16 Appendix




PC 3.3 REAL TIME CLOCK & EXERCISE Appendix A

PC 3.3 Training Guide Appendix A Page1

The PCC3300 control system includes a real time clock function. The Real Time Clock (RTC) is used for

calculating controller on time, recording fault occurrence times, supporting factory test, and for the automatic

scheduler feature. Once programmed, the real time clock accurately* calculates seconds, minutes, hours,

date of the month, month, day of the week, and year with leap year compensation valid up to 2100. The

clock operates in 24 hour format and automatically adjusts the end of the month for months fewer than 31

days.

When battery power is removed from the PCC3300, the RTC remains powered via internal circuitry on the

PCC3300. The internal circuitry will provide power to the RTC for about one hour, after which the RTC will

become reset to 0 Seconds, 0 Hour, 0 Minutes, 0 Month, 0 Date, 0 Year. Under this condition, the “RTC

Power Interrupt” Fault (1689) will become active indicating that the clock needs to be reset.

The RTC also has supports Daylights Savings Time, which is a convention used to advance the time by one

hour so afternoons have more daylight then mornings. The DST logic adds the DST Adjustment time to the

current time when the current time is equal to the DST Start Time. The DST logic subtracts the DST

Adjustment time from the current time when the current time is equal to the DST End Time. To Enable DST,

the trim Daylight Savings Enabled needs to be set to Enabled. To setup DST, specify the values for the

following trims.

Trim Value Meaning

Daylight Savings End Day Monday - Sunday Calendar Day in which DST Ends

Daylight Savings End Hour 02 – 19 hours Hour (24 Hr) in which DST Ends

Daylight Savings End Month 1 – 12 months Month in which DST Ends

Daylight Savings End Week

Occurrence in Month

First Occurrence – Last

Occurrence

Occurrence of Daylight Savings End

Day in which DST Ends

Daylight Savings Start Day Monday - Sunday Calendar Day in which DST Starts

Daylight Savings Start Hour 02 – 19 hours Hour (24 Hr) in which DST Starts

Daylight Savings Start Month 1 – 12 months Month in which DST Starts

Daylight Savings Start Week

Occurrence in Month

First Occurrence – Last

Occurrence

Occurrence of Daylight Savings End

Day in which DST Starts

Daylight Savings Time Adjustment 0 – 120 minutes Amount of time to be added or

subtracted from current time for DST

adjustment.

PC 3.3Real Time Clock





For Example: If DST Ends on the 1st Wednesday in April at 02:00 AM every year, and DST Starts on the 2nd

Thursday in September at 3:00 PM every year, and DST Adjusts the clock by 1 hour each time, the

parameters should be set to the following values.

Trim Value

Daylight Savings End Day Wednesday

Daylight Savings End Hour 02

Daylight Savings End Month 4

Daylight Savings End Week

Occurrence in Month

First Occurrence

Daylight Savings Start Day Thursday

Daylight Savings Start Hour 15

Daylight Savings Start Month 9

Daylight Savings Start WeekOccurrence in Month

Second Occurrence

Daylight Savings Time Adjustment 60

*The real time clock is accurate with 30 minutes over the course of 1 calendar year.

The exercise scheduler is a feature that automatically starts the genset for exercise. This feature prevents

common problems which result from mechanical equipment sitting for long periods of time. In order for the

automatic exerciser to work, the PCC3.3 control system needs to be in ‘Auto’ mode, the RTC needs to be

set (Fault 1689 is not active), and the trim Exercise Scheduler Enable needs to be set to Enable.

The PCC3.3 can be programmed to run up to 12 independent programs, all which can either be one time

events or repeating events. Furthermore, each program can be programmed to exercise the genset in two

run modes, no load and with Load.

Each independent program has the following trims which establish its behavior. “X” can have a value from 1

thru 12, once for each available program.

PC 3.3Exercise Scheduler





Trim Value Meaning

Scheduler Program x Enable Enable – Disable Enables or Disables Schedule X

Scheduler Program x Start Minute 0 – 59 Specifies at what minute Program X

with start.

Scheduler Program x Start Hour 0 – 23 Specifies at what hour Program X will

start.

Scheduler Program x Start Day Monday – Sunday Specifies at what day Program X will

start.

Scheduler Program x Run Mode No Load / Load Specifies if Program X will exercise

the genset with Load or No Load.

Scheduler Program x Repeat

Interval

Once, Twice… Specifies the repeating behavior of

Program X

Scheduler Program x Duration

Hours

0 – 23 Specifies how many hours Program X

will run.Scheduler Program X Duration

Minutes

1 – 59 Specifies how many minutes Program

X will run.

For example, if it was desired to have a Program that ran on every Monday at 8:12 AM for 1 Hour and 30

Minutes with Load the trims should be defined like this

Trim Value

Scheduler Program x Enable Enable

Scheduler Program x Start Minute 12

Scheduler Program x Start Hour 8

Scheduler Program x Start Day Monday

Scheduler Program x Run Mode Load

Scheduler Program x Repeat

Interval

Every Week

Scheduler Program x Duration

Hours

1

Scheduler Program X Duration

Minutes

30





The following table is the Exercise Scheduler table which contains the information for Programs 1 thru 12.

Start Time Scheduler

Program

Duration

Schedule Repeat

Interval

Scheduler

Program

Enable

Scheduler

Program

Start Day

Hr Min Hr Min

Scheduler

Program

Run Mode

Week

Program 1

Program 2

Program 3

Program 4

Program 5

Program 6

Program 7

Program 8

Program 9

Program 10

Program 11

Program 12

Another sub-feature of the Exercise Scheduler is the ability to program exceptions to the scheduler

programs. Exceptions are anti-programs and can either be on time events or repeating. The PCC3.3 can

have up to 6 independent exceptions. The following are the trims needed to define an exception.

Each independent program has the following trims which establish its behavior. “X” can have a value from 1

thru 12, once for each available program.

Trim Value Meaning

Scheduler Exception x Enable Enable – Disable Enables or Disables Exception X

Scheduler Exception x Minute 0 – 59 Specifies at what minute Exception X

with start.

Scheduler Exception x Hour 0 – 23 Specifies at what hour Exception X

will start.

Scheduler Exception x Date 0 - 31 Specifies the date in which Exception

X will start.Scheduler Exception x Month 0 - 12 Specifies which Month Exception X

will start.

Scheduler Exception x Repeat Once, Every Year. Specifies the repeating behavior of

Exception X

Scheduler Exception x Duration

Hours

0 – 23 Specifies how many hours Exception

X will be valid for.





Scheduler Exception X Duration

Minutes

1 – 59 Specifies how many minutes

Exception X will be valid for.


Days

0 – 44 Specifies how many days Exception X

will be valid for.

For example, if it was desired to have an Exception that stopped all programmed activity from December

25th

at 1:00 AM until J an 2nd

the trims should be defined like this

Trim Value

Scheduler Exception x Enable Enable

Scheduler Exception x Minute 0

Scheduler Exception x Hour 1

Scheduler Exception x Date 25

Scheduler Exception x Month 12

Scheduler Exception x Repeat Every Year.

Scheduler Exception x Duration

Hours

23


Minutes

1


Days

7

The following is the Exercise Scheduler which contains all the exceptions 1 - 6.

Scheduler

Exception

Enable

Scheduler

Exception

Scheduler

Exception Time

Scheduler Exception

Duration

Month Date

Hour Minute Days Hours Minute

s

Schedul

er

Exceptio

n Repeat

(Interval)

Exception 1

Exception 2

Exception 3

Exception 4

Exception 5

Exception 6





The following are a set of rules used to define schedules and exceptions –

1. If there is a running program and the next programmed program(s) overlap with the existing

running program, the existing program will run as it is and next overlapping program(s) will not

start even, if the first program is expires before the next overlapping program is scheduled to

stop.2. If program is running and exception becomes active, the PCC3.3 control system will ignore the

newly activated exception(s) and will continue to run the active program expires.

3. If there is an active exception and the next exception(s) overlap with the existing active

exception, the existing exception will continue to be active as it is and the next exception(s) will

be ignored.

4. If an exception and program are scheduled to become active at the same time, then the

exception will become active and the program will be ignored.

5. If a program is active and running (or an exception is active) and control system loses power

before the program or exception can expire, the active program or exception will not be startedagain when power is restored to the control system even if there is time remaining in the

program/exception.

Remote Start command behavior on exercise scheduler –

While in exercise scheduler mode, ie a scheduled program is active and control system is in ‘Auto’ mode, if the

PCC3.3 control system receives a remote start command, the genset will continue to run. If remote start

command is removed and the exercise scheduler program is still active, the genset will continue to run until

scheduler time lapses.



Appendix B PC 3.3 ModBus

Page 1

USING MODSCAN SOFTWARE

ModScan is a software tool that can help you verify ModBus communications from thePowerCommand control. It is not a Cummins Power Generation product, it is a product designedby WinTech for general use in any ModBus serial communication system. The use of ModScan

enables a CPG technician to prove ModBus communications from a CPG controls system to aneutral third party software.

The following directions and examples apply to using ModScan with PCC 1301 and 1302 gensetcontrols.

Refer to the appropriate register map for specific registers available.

FIGURE 1. MAIN MODSCAN SCREEN

Use ModScan software after you have enabled your ModBus setup in the control. A standardPCC 1300 series service cable must be installed between the PC serial port and the TB-15connector on the PCC 1302 control board. PC serial ports communicate using RS232 so aRS485 converter must be used. Figure 1 show the initial screen displayed upon launching the

program.




Page 2

FIGURE 2. MAIN MODSCAN SCREEN

1. From the tool bar, select:

Connection

Connect.

The Connection Details dialog box is displayed (see Figure 3). The “Connect Using” is used to designatethe proper communication port on your computer.

2. Use the pull down menu under “Connect Using” to select the comm port you wish to use.

A typical configuration would be set to:

Baud Rate: 19200,Word Length:8,Parity: None,Stop Bits: 1,

(as shown in Figure 3.)

Use the pull down menus to change these settings as necessary.






Page 4

4.Click “OK” on the two open dialog boxes.

You should notice in the upper right of the dialog box, the “Number of Polls” counterincrementing.

Notice the message at the top of the register list captured by **____**. In Figure 4-2 themessage **MODBUS Exception Response from Slave Device ** is indicating the device hasresponded, but there is a problem with one or more messages in the poll length.

If the **____** line states **MODBUS Message TIME-OUT** ModScan is not able to findanything at the other end of the communication wire. There could be many reasons for this.Check your computer comm.. port, the wire, if the PCC 1302 is powered up, if ModBus is“Enabled”, or if the PCC 1302 “ModBus Setup” matches the Protocol settings on Figure 3 & 4.

FIGURE 4-2. MODBUS DIALOG BOX INFORMATION

5. On the main ModScan screen (see Figure 5), Change the Address to 0064, the Length to 1.

WARNING ModScan is not satisfied if it polls a group of registers and finds one in thesequence that is not programmed, it will d isplay a “ Exception Response” as in Figure 4-2.Minimize the number of registers polled to a sequential length as listed in the register map.

6. From the MODBUS Point Type pull down menu, select “03: HOLDING REGISTER.”

The PCC 1300 series communicates all registers as a HOLDING REGISTER. Refer to any of thepreceding mapping registers to view different pieces of data.

The “Valid Slave Responses” should now be incrementing as the data on the screen is updated. You should see a single register displayed with a 5 digit value. Poll the following registeraddresses for the Genset.

40061 is Battery voltage at the control.

40064 is Coolant Temp. (This value will be displayed in Celsius ONLY)

40070 is Eng Runtime (value will be displayed in seconds)



Page5

FIGURE 5. MODBUS POINT TYPE = HOLDING REGISTER

7. On the main ModScan menu (see Figure 6), change the Length to 1. Refer to the warning instep 5.

WARNING Accidental starting of the generator set can cause severe personal injury or death. During step 8, a “ start” command is sent to the genset. If the genset is in the Automode, the genset WILL start.

8.To output a value to the genset control, poll the desired address, (In this case we want to test

the start command which is register #40300) double click on register 40300. The Write Registerdialog box is displayed (see Figure 6).

If you enter a value of “1” and select “Update,” Genset #1 starts and runs. If you double click onregister 40300 again, enter a value of “0,” and selecting “Update;” the Genset stops.

9. Review the mapping register information for other coils that you can manipulate.




Page 6

FIGURE 6. WRITE COIL DIALOG BOX

ModScan Read & Write Commands

ModScan has more ability to test and command ModBus devices than is presented in this guide. Thereare other features used on some of the other PowerCommand ModBus systems, but the processes andexamples so far listed will enable a technician prove to a customer or system integrator that the PCC 1301or 1302 will communicated properly.




Page 7

Notes

The following notes apply to using ModScan with PCC 1301 and 1302 genset controls.

Refer to the appropriate register map for specific registers available.

Genset Control

Start/Stop - When this register is set to “1,” the genset starts, and ramps to operating speed.As long as this register remains a “1,” the genset will continue to run. When this register is setto “0,” the genset stops.

Fault Reset - This should be a momentary signal of about 2 seconds duration. Entering a “1” inthe fault reset register resets any non–active warning and, If there is not a remote start on thegenset, it resets any non–active shutdown except the Emergency Stop.

Emergency Stop - When this register is set to “1,” the emergency stop is active at the

PowerCommand control. The emergency stop cannot be rest until this register is set to “0.”After the register is reset to “0,” the emergency stop must be reset at the PowerCommandcontrol. It cannot be reset remotely.

Miscellaneous

Fault State - As part of Gen Status State, digital value 4 (Fault State 1) = shutdown with anactive run command (cannot be remotely reset) and digital value 5 (Fault State 2) = shutdownwith no active run command (can be remotely reset).

Fault Code - This register contains the fault code number of the currently active fault. Seeservice manual for list of supported fault codes.

Fault Type - This register contains the fault type of currently active fault

0=Normal1=Warning2=Derate (this is a feature NOT currently supported by the PCC 1300 series)3=Shutdown with Cool down4=Shutdown

Fault bypass (battle short) feature enable – Activation of battle short via ModBus is just asserious as any other activation of battle short.




Page 8




PCC 3.3 and PowerCommand Control 3300 Diagrams Section 17

Participants’ Guide Section 17 Sequence Diagrams

PC 3.3 Sequence Diagrams

This section contains Common Connector wire diagrams and Sequence

Diagrams.

Diagram 630-3440 Rev D Sheet 1 - 11

Diagram 630-3440 Rev D Sheet 12 - 19

Parallel Mode Sequence Diagram Symbols

Parallel Mode Sequence Diagram Synchronize Only

Parallel Mode Sequence Diagram Isolated Bus Only

Section 17:








Sheet 1 of 1



Sheet 2 of 2



Sheet 3 of 3



Sheet 4 of 4



Sheet 5 of 5



Sheet 6 of 6



Sheet 7 of 7



Sheet 8 of 8



Sheet 9 of 9



Sheet 10 of 10



Sheet 11 of 11



Sheet 12 of 12



Sheet 13 of 13



Sheet 14 of 14



Sheet 15 of 15



Sheet 16 of 16



Sheet 17 of 17



Sheet 18 of 18



B-3

PARALLELING SEQUENCES LEGEND



B-4

SYNCHRONIZE ONLY



B-5

ISOLATED BUS ONLY








________________________________________________________________

Participants’ Guide Section 18

PowerCommand 3.3 & PowerCommand Control 3300 Section 18

PC 3.3 & PCC 3300 Module Comment Sheet

Participants are requested to turn in the Comment Sheet at theend of the course to help update the course materials asneeded.

Section 18:



________________________________________________________________






________________________________________________________________



Module Comment Form

Now that you have completed the PC 3.3 & PowerCommand Control 3300 training module, we would like you to assess your skills before and after the training program.

Circle the appropriate number on both scales for each performance area.

Performance Area

Your Skill level

Before the program

No skill High Skill

Your Skill level

After the program

No skill High Skill

Understanding the CPG model andcomponent naming system.

0 1 2 3 4 5 0 1 2 3 4 5

Selection of proper Section topics andSection content.

0 1 2 3 4 5 0 1 2 3 4 5

Use of Installation guides, InstructionSheets, Guides, and Appendix Material. 0 1 2 3 4 5 0 1 2 3 4 5

Operating the HMI, and navigating thecontrol system.

0 1 2 3 4 5 0 1 2 3 4 5

Operation of the HMI for configurationprocesses and setup. 0 1 2 3 4 5 0 1 2 3 4 5

Operation and connection of InPowerfor configuration processes and setup. 0 1 2 3 4 5 0 1 2 3 4 5

Understanding Common ConnectorScheme and new schematics. 0 1 2 3 4 5 0 1 2 3 4 5

Understanding connector locations andfunctions. 0 1 2 3 4 5 0 1 2 3 4 5

Understanding features andcommonality of options. 0 1 2 3 4 5 0 1 2 3 4 5

Setup various PCCNet components andinstall them. 0 1 2 3 4 5 0 1 2 3 4 5

Setup the ModBus feature, test it andunderstand its basic operation. 0 1 2 3 4 5 0 1 2 3 4 5

Identify PGI CAN system components

and understand their operation. 0 1 2 3 4 5 0 1 2 3 4 5

Troubleshoot CAN genset controlsystems. 0 1 2 3 4 5 0 1 2 3 4 5

Converse about genset communicationability with Building ManagementSystem installers.

0 1 2 3 4 5 0 1 2 3 4 5



________________________________________________________________



We are interested in your opinion about the effectiveness and usefulness of this trainingmodule. We will use the results of your response to help improve and modify trainingmodules and the effectiveness of their delivery. Please fill out the form by placing a mark onthe scale next to each statement.

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1. The Purpose of the module was clearto me.

2. The lesson objectives wereappropriate.

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4. The module content was at anappropriate level for my backgroundand experience

5. The visuals were helpful inexplaining the topic.

6. The module followed a logical andmeaningful sequence.

7. The module activities gave me achance to practice new skills or work with new ideas.

8. I will be able to apply what I havelearned from this module.

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________________________________________________________________ PowerCommand 3.3 & PowerCommand Control 3300 Section 18

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