59330788 Cummins PCC3 3 Technical Training
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Description
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 control family. Introduction:
II
The introduction describes the audience, the purpose, and the structure of the training 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. The participant will learn to identify the main features and components of the PowerCommand 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 PCC3.3 and HMI 320 PowerCommand Control 3.3 Sequence of Operation:
3
This lesson presents sequence of operation and feature operation and performance information about the PowerCommand Control 3300. PowerCommand Control 3300 Installation:
4
This section provides installation information, procedures, and requirements for the PowerCommand Control 3300. PowerCommand Control 3300 Control Setup and InPower:
5
This lesson covers the basic adjustments and configuration details using InPower as the setup tool. This section addresses the non-paralleling functions. PCCNet Network for the PC3.3: This lesson presents an overview of the PCCNet network and an introduction to the unique PCCNet network and components used with the PCC 3300,
6
PowerCommand Control 3300 ModBus:
7
This lesson presents the ModBus communications feature on the PCC 3300, and introduces some of the advanced ModBus abilities offered in this control. PowerCommand Control 3300 PGICAN:
8
This section provides familiarization with the J1939 CAN communications available 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 in this 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 HMI 320 when applied in a multiple unit paralleled configuration that is completely separated from any utility (Mains) connection. PowerCommand Control 3300 Paralleling Troubleshooting:
13
This lesson presents tools, problem scenarios, and solutions that are commonly encountered when encountering operation problems with the PC 3.3. Glossary:
14
This section lists the most common terms used throughout this training module pertaining to the PowerCommand family of Controls. Activities:
15
Copies of Participant In-class and Homework Activities, and each Section Quiz are found in this section. Appendix: This section contains several useful guides and lists, including the ModBus register list.
16
Diagrams:
17
This section has copies of all prints used in the course. Module Comment Sheet: Participants are requested to turn in the Comment Sheet at the end of the course to 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.
18
Preface: The new generation of PowerCommand Controls will use a new easier to understand naming system. 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 are several combinations of control boards and HMIs
Naming System PowerCommand 1.X
PowerCommand 2.X
PCC 1302
PCC 2300
PowerCommand 1.1 HMI 211 PowerCommand 1.2 HMI 220
PowerCommand 2.2 HMI 220 HMI 112(w/PF) or HMI 114, HMI 113
Phase 1 (FAE) PowerCommand 2.2 HMI 220 PowerCommand 2.3 HMI 320 HMI 112 or HMI 114, HMI 113 AUX 101/102, AUX 104
PowerCommand 3.3
PCC 3300
PowerCommand 3.3 HMI 320 Phase 1 (FAE)
PowerCommand 3.3 HMI 320 HMI 112 or HMI 114, HMI 113 AUX 101/102, AUX 104
Phase 2 (Hydra Mech.)
Phase 2 (Hydra Mech.) 3
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, PowerCommand Control 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 2.X = PCC 2300 control board 3.X = PCC 3300 control board Participants’ Guide
Title & Introduction Page6
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 support certain 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 will be several subcategories of different control board features. The first category of 2.X, & 3.3 controls will only work on FAE controlled engines. The next category will be used with hydra mechanical engine applications. As new features and categories develop, additional training courses 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 training programs that follow will concentrate on the specific feature enhancements, HMI, or accessory developments relative to the specific Series. The Series 2.X & 3.3 FAE training will be a prerequisite to any future training program It has been planned that the PCC 3300 & HMI320 combination will be the only combination available for the high level paralleling gensets. The plan is to only have a PC 3.3 control and never a PC 3.2 or PC 3.4.
Participants’ Guide
Title & Introduction Page7
Introduction Welcome! Welcome to the Particpants Guide for the PC 3.3 & PowerCommand Control 3300 module! This guide 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.
Participants’ Guide
Title & Introduction Page8
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. Use the Notes column to write any comments or additional information you want to include.
Participants’ Guide
Title & Introduction Page9
PCC 3.3 & PowerCommand Control 3300
Section last page
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Participants’ Guide
Section Last Page
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
PowerCommand 3.3 Section 1 Introduction to the PowerCommand Control 3300
Visual 1-1 PowerCommand Control
Participants’ Guide
Section 1 Page1
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
Section 1 Introduction to the PCC 3.3, the PowerCommand Control 3300 control board and its options. Estimated Time: 2.5 hours
Participants’ Guide
Section 1 Page2
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
Warm Up In this lesson we are going to learn about the PowerCommand Control 3300 and its components 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.
Participants’ Guide
Section 1 Page3
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
PowerCommand Control 3300 Premium Paralleling Genset Control Integrated J1939 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 2
Visual 1-2 Introduction to the PowerCommand Control 3300
Participant’s Text
Notes:
The PowerCommand Control 3300 is a highly integrated control providing complete genset control and protection. The Phase 1 release of this new control will support Lean Burn Natural Gas (LBNG) gensets and Diesel FAE engine-driven sets The phase 2 release will support a governor drive module which is needed for diesel sets equipped with electric actuator.
Participants’ Guide
Section 1 Page4
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
PCC 3300 Control Boards
AUX 103 Power Stage PCC 3300 Base Board 3
Visual 1-3 The PCC 3300 Control Board
Participant’s Text
Notes:
The PCC 3300 board uses the same large potting shell as used in the MCM3320 and PCC 2300. The control board provides many connectors for 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.
Participants’ Guide
Section 1 Page5
PCC 3.3 & PowerCommand Control 3300 Participant’s Text
Introduction and Options Notes:
There are14 connection points on the PCC 3300: •
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 Power Stage: •
J17 − Excitation Output (X1, X2)
•
J18 − AVR Power (PMG)
•
J19 − AVR Control Communications
Participants’ Guide
Section 1 Page6
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
PCC 3300 Connectors TB7- Bus Voltage Sense
Onboard BUS CTs J12- Genset CT Input DSx LED Status Indicators J22- Genset Voltage Sense
TB-9 – Analog I/O TB-15 – ModBus/RS485
J20- Genset Connections J14 – Service Tool Port J26- AUX 103 Connector TB10 – Breaker Status Connections
TB-8 Customer Connections
J-25 Display Connections
TB-5 – Breaker Control Connections
TB-3 – Customer Input/Output
TB-1 – Customer Connections
4
Visual 1-4 Control Board Connectors
Participant’s Guide
Notes:
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
Participants’ Guide
Section 1 Page7
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
PCC 3300 Connectors TB7- Bus Voltage Sense
Onboard BUS CTs J12- Genset CT Input DSx LED Status Indicators J22- Genset Voltage Sense
TB-9 – Analog I/O TB-15 – ModBus/RS485
J20- Genset Connections J14 – Service Tool Port J26- AUX 103 Connector TB10 – Breaker Status Connections
TB-8 Customer Connections
J-25 Display Connections
TB-5 – Breaker Control Connections
TB-3 – Customer Input/Output
TB-1 – Customer Connections
4
Visual 1-4A Control Board Connectors
Participant’s Guide
Notes:
TB1 − Customer I/O connections TB3 − Customer I/O connections TB5 − Circuit breaker control connection TB7 − Bus/utility voltage sense TB8 − Customer I/O connections TB9 − Analog control I/O connections TB10 − Circuit breaker control connection TB15 − RS485 / ModBus Communication connection
Participants’ Guide
Section 1 Page8
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
AUX103 AVR Power Stage J19 – Interconnection to PCC 3300 Base Board
J17 – Field Output
J18 – Power Input
Chassis Ground Wire 5
Visual 1-5 Automatic Voltage Regulator Module
Participant’s Text
Notes:
The AVR Module is used with all PC 3.3 gensets. There are 3 connectors on the board.
J17 provides the excitation output.
J18 provides the power input
J19 connects to J26 on the 3300 Control Board.
Participants’ Guide
Section 1 Page9
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
HMI 320 Operator Panel
6
Visual 1-6 Optional operator panel
Participant’s Text
Notes:
HMI 320 Operator Panel is also highly populated with display and control features.
Multiple LEDs for status and operator information
Large graphical display for menus and information display.
Multiple buttons for operation and control. Same physical size and layout as the HMI 220 but has a much larger display.
Participants’ Guide
Section 1 Page10
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
Operator Panel Menus
7
Visual 1-7 Operator Panel Menus
Participant’s Text
Notes:
The panel allows easy navigation through multitudes of monitoring screens. There are also a great many screens available for setup of the control and the accessory features. There is a HOME screen that provides guidance 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 menu choices. The menu choice will provide access to a single or multiple pages of information or setup functions.
Participants’ Guide
Section 1 Page11
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
HMI Display Navigation Multiple Combinations of button pushing will allow navigation to various messages, data, and adjustment screens.
Participant Guide Visual 1-7 shows an example of some of the navigation choices.
8
Visual 1-8 HMI screen navigation
Participant’s Text
Notes:
Navigating the many different screens requires practice. There is a DEMO mode on the screen that enables an operator to learn many of the button sequences required for screen navigation. Some screens allow you to view data in either a graph mode or in a table of data. There are a series of soft keys, and hard keys. The soft keys change function depending on the screen being viewed. This will be discussed more in the next section. All of the keys provide tactile feed back.
Participants’ Guide
Section 1 Page12
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
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) 9
Visual 1-9 PCCNet Components
Participant’s Text
Notes:
0300-6315 HMI320 Operator Panel This is the Operator Panel for the PCC 3300. There is one for local control and an optional one, 0300-63115-03 for remote mounting. 0300-5929-01 or -02 Annunciator This is the same Universal Annunciator that is used with many other CPG products. The -01 kit contains the Annunciator only, -02 kits contain a mounting box too. 0300-6366-02 & 0300-6050 Bargraph Module These modules allow the customer to have a graphical readout of alternator information.
Participants’ Guide
Section 1 Page13
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
PowerCommand 3.3 Quiz 1-1: Intro to PowerCommand 3300, Operator panel, and PC 3.3 system.
10
Visual 1-10 Quiz for Lesson 1
Participant’s Text
Notes:
Turn to Section 15 and complete Quiz 1-1. At this time I would like you to work in groups to complete the quiz. It should take about 20 minutes.
Participants’ Guide
Section 1 Page14
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
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 to the 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 little peek 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.
Participants’ Guide
Section 1 Page15
PCC 3.3 & PowerCommand Control 3300
Introduction and Options
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Participants’ Guide
Section 1 Page16
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
Participants’ Guide
Section 2 Page1
PCC 3.3 & PowerCommand Control 3300
Service Menus
Section 2 PCC 3.3 HMI 320 Service Menus: Estimated Time: 2 hours
Materials Needed PowerCommand Control 3300 Participant’s Guide Operator Installation Manual – 3300 Series Genset Control
Participants’ Guide
Guide CMT6068-EN-PG 0900-0670
Section 2 Page2
PCC 3.3 & PowerCommand Control 3300
Service Menus
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 lesson material. Please don’t get lost in the menus as we are trying to go through the Participant’s Guide material. First, let’s look at the objectives for this lesson:
Objectives After completing this lesson, the participants should be able to: • 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.
Participants’ Guide
Section 2 Page3
PCC 3.3 & PowerCommand Control 3300
Service Menus
HMI 320 Operator Panel
Remote Control Panel 0300-6315-03
Local Control Panel 0300-6315-02
2
Slide 2-2
Participant’s Text
Notes:
We were introduced to the HMI 320 Operator Panel in lesson 1.
.
This view is of a local version HMI which is standard, and the optional remote HMI.
Local HMI 320 = 0300-6315-02
Remote HMI 320 = 0300-6315-03
The remote version will not allow changes to the mode of operation. The Participant’s Guide contains some of the basic familiarization with the HMI 320, but we will reference the 900-0670 Service Manual for most of the lesson.
Participants’ Guide
Section 2 Page4
PCC 3.3 & PowerCommand Control 3300
Service Menus
Standard HMI 320 Operator Panel Function indication lamps
Large Graphical Display Menu Selection Buttons
Control Function Buttons
Screen Navigation Buttons
Breaker Control Buttons
3
Slide 2-3 Setup Menu Access.
Participant’s Text
Notes:
The HMI 320 layout is very similar to the HMI 220 with several added features.. Function indicator lamps and control function buttons are located in the same locations as the HMI 220 and they operate the same. Breaker control buttons are available to provide breaker control during manual paralleling operation. Screen navigation buttons (Hard Keys) provide control of screen viewing functions. They are laid out and operate vary similar to cell phone navigation buttons.
Participants’ Guide
Section 2 Page5
PCC 3.3 & PowerCommand Control 3300
Service Menus
Display Screen Line 1 Controller Mode
Line 2 Fault Data
Line 3 Screen Name Data & Status Screen
Data & Status Screen
Soft Button Options 4
Slide 2-4 Display Screen
Participant’s Guide
Notes:
Top three lines of display are reserved for:
Line 1 will always display the Controller Mode or Status information.
Line 2 will always display the genset fault popup message.
Line 3 will always display the screen name or menu description of what is viewable in the Data & Status screen.
The Data & Status Screen section can show a vast amount of data or menu choices. There are 9 lines of display in 2 columns for a total of 18 viewable parameters.
Participants’ Guide
Section 2 Page6
PCC 3.3 & PowerCommand Control 3300
Service Menus
Display Screen Line 1 Controller Mode
Line 2 Fault Data
Line 3 Screen Name Page & Pages available Data & Status Screen
Data & Status Screen
Soft Button Options 4
Slide 2-4B Display screen continued.
Participant’s Guide
Notes:
Soft keys are labeled across the bottom of the screen. The manual refers to them as Function Selection Buttons. Some of the soft keys are used for Previous and Next screen selection. arrow indicates navigation to a The up previous screen. The down arrow indicates navigation to a next screen. Other soft buttons are used to directly navigate to other data screens
Participants’ Guide
Section 2 Page7
PCC 3.3 & PowerCommand Control 3300
Service Menus
HMI Hard Keys
The HOME button
These hard keys enable navigation between various menu screens
5
Previous Screen Button
Pressing these buttons simultaneously for 3 seconds will cause the screen to enter a DEMO mode if PCCNet is disconnected.
Slide 2-5 Hard Keys.
Participant’s Text
Notes:
The seven buttons at the bottom of the PCC 3300 Operator Panel lead to menus and provide control of menu navigation. •
– pressing it will return you to the Home screen menu from any other screen.
•
- will return you to the previous menu or to the Home screen
•
OK – will engage the highlighted menu choice and advance to that screen.
•
The 4 -will advance, back up one screen, or highlight menu choice
Participants’ Guide
Section 2 Page8
PCC 3.3 & PowerCommand Control 3300
Service Menus
Setup Menu and Passwords
There are 4 levels of passwords available for adjustments, setup and control.
6
Slide 2-6 Genset Setup
Participant’s Text
Notes:
The HMI 320 Setup Screens are accessible and viewable without a password. If you attempt to change a setting that requires a password, you will be prompted to supply a password. The passwords must be entered for the appropriate level as the screen requests. There are various levels of authority for making changes or adjustments. • Level 0 = minor adjustments only anyone can access. • Level 1 = minor adjustments and some calibrations
Participants’ Guide
Section 2 Page9
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
Service Menus
Notes:
• Level 2 = high level adjustments, calibrations, and configurations. • Level 3 = very high level configuration and reserved for engineering or factory access. As an example: • If you access the setup screen for PCCNet Setup, you will not be asked for a password. This is an example of a Level 0 password setup parameter. • If you attempt to access the Adjust Voltage screen, you will be prompted for a Level 1 (574) or higher password. • If you attempt to access the OEM setup parameters, you will be prompted for a Level 2 (1209) or higher password. • The Level 3 password is reserved for engineering and factory configuration and is not shared for field access or setup. If a password is entered, it will remain active until a higher level password is entered or the HMI is INACTIVE for 5 minutes.
Participants’ Guide
Section 2 Page10
PCC 3.3 & PowerCommand Control 3300
Service Menus
Mode Change Password
Mode Change Password Protection If enabled, many of the HMI buttons will be disabled. The operator MUST have the password for them to become operational. 7
Slide 2-7 Mode Change Password
Participant’s Text
Additional Participant’s Text
Look at page 5-1 of 0900-0670 service manual. MODE CHANGE PASSWORD can be confusing to many.
This is a feature to protect a piece of customer equipment, or to protect equipment from the customer. This feature prevents someone from accidentally or unknowingly changing the control from Automatic Mode to Manual Mode or from sending a breaker close command when they shouldn’t. It is to prevent an unauthorized person from making unauthorized changes.
MODE refers to the operation mode such as – running in Manual, running in Automatic, Manual parallel, etc... I
If Mode Change Password Protection is enabled, the buttons are disabled so an unauthorized operator cannot switch from one mode to another.
If Enabled, any button push on the HMI will prompt a password request screen to appear.
Field technicians may want to use this feature for protection from inadvertent button actuations during service work.
The Password is 121
Participants’ Guide
Section 2 Page11
PCC 3.3 & PowerCommand Control 3300
Service Menus
Adjust Menus The HMI has a Adjustment screen for minor adjustment of operation set points.
Setting of the Keyswitch overide to Active will allow for service connection to the engine ECM. 8
Slide 2-8 Adjust Screen
Participant’s Text
Notes:
Turn to page 5-30 in the 900-0670 Service Manual Table 5-22 provides a slight description of each ADJUST function. IMPORTANT: Keyswitch Status. The engine must be stopped to activate the Keyswitch Override. The Keyswitch Override is provided to support control service. This setting exists to allow ECM to power down and it will not trigger a “CAN Link Degrade” fault.
Participants’ Guide
Section 2 Page12
PCC 3.3 & PowerCommand Control 3300
Service Menus
Participant’s Text
Additional Participant Text & Notes
What is the purpose of having a Keyswitch override? When servicing an ECM on an automotive application, the ignition key is turned to the on position which provides the input to the ECM to turn on and operate its program. This is the mode you want the ECM to be in during service. On a generator set, we use the E-Stop button as the Keyswitch.
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
The Keyswitch Override will return to INACTIVE if the E-Stop button is pushed, and/or you will not be able to switch the override to INACTIVE if the local or remote E-Stop is activated. The control must be in the Manual mode to change 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 Link Error fault to be generated.
Participants’ Guide
Section 2 Page13
PCC 3.3 & PowerCommand Control 3300
Service Menus
Setup Genset Menus The HMI has a series of 5 screens that allow for detailed setup of a multitude of operation set points.
9
Slide 2-9 Genset Setup
Participant’s Text
Notes:
From the Home (2) screen, navigate to and highlight the “Genset Setup” menu and button will take press Pressing the you to a series of screens where you can adjust and change various genset configuration settings. If you attempt to make any change, you will be prompted for a Password. Some parameter can be changed if you use the 574 password; however, using the level 2 password will allow you to adjust any of the parameters.
Participants’ Guide
Section 2 Page14
PCC 3.3 & PowerCommand Control 3300
Service Menus
Paralleling Setup Menus The HMI has a series of 6 screens that allow for detailed setup of a multitude of Paralleling operation set points.
10
Slide 2-10 Paralleling Setup
Participant’s Text
Notes:
From the Home (2) screen, navigate to and highlight the “Paralleling Basic Setup” menu and press Pressing the button will take you to a series of 6 setup screens where you can adjust and change various genset configuration settings. PTC (Power Transfer Control) is a feature that 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 Paralleling functions.
Participants’ Guide
Section 2 Page15
PCC 3.3 & PowerCommand Control 3300
Service Menus
OEM Setup Menus The OEM Setup provides access to genset configuration settings.
11
Slide 2-11 OEM Setup
Participant’s Text
Notes:
OEM (Original Equipment Maker [or Manufacture]) setup menu provide access to a multitude of settings. These settings are mostly genset configuration settings; a Level 2 password is required for almost all adjustments. OEM Setup Menus duplicate the setup functions found in InPower. InPower will be covered in later lessons.
Participants’ Guide
Section 2 Page16
PCC 3.3 & PowerCommand Control 3300 Participant’s Text (OEM GENSET SETUP)
Service Menus Notes:
It is possible to completely configure a new generator control from the HMI, however it is not recommended or you probably do not want to expend the effort. The task of inputting a 10 character genset serial number can take as many as 970 button pushes. The HMI buttons are rated for hundreds of thousands of button pushes, but your finger most likely is not. If you try to input Serial Numbers or Model Numbers, you will find 96 characters available to scroll through, including the entire alphabet in upper case and again in lower case, numerals 0 through 9, 33 symbols and even a blank character.
In the OEM GENSET SETUP, you will find reference to “Input Factory Lock” functions. You will notice there are more than 3 dozen inputs affected by this setup. When the factory configures a genset with all its option, some inputs are consumed and are “Locked”. Factory Lock prevents causal operator changes to the genset setup. Password 1209 is required to change any input from Lock to Unlock or Unlock to Lock. Once unlocked, the input configuration can be changed.
Participants’ Guide
Section 2 Page17
PCC 3.3 & PowerCommand Control 3300
Participant’s Text (OEM ENGINE SETUP)
Service Menus
Notes:
There are 2 pages to Engine Setup. This training course will only address some of the FAE application points. Other PC 3.3 control courses will address other engine setup functions. ECM CAN ENABLE turns on the SAE J1939 CAN communications to the engine ECM. Changing the setup to Disable will lead to communication and Operation problems. There may be times when you want to Disable this such as troubleshooting the ECM, but it must be Enabled for genset operation. Fault 1117 Enable is a ECM warning that can be Enabled or Disabled, the setup criteria for this setting will be discussed in more detail several lessons ahead. Prelube Enable is a newer feature option that is available with some engines. There are control provisions to allow for either a rolling Prelube or Prelube pump engagement. Setting this up correctly is dependent on engine and genset configuration. Page 2 offers several setup parameters that should be familiar to technicians.
Participants’ Guide
Section 2 Page18
PCC 3.3 & PowerCommand Control 3300
Participant’s Text (OEM ALTERNATOR SETUP)
Service Menus
Notes:
There are 3 pages to Alternator Setup. Like in other OEM SETUP screens, there is a combination of Level 1 and Level 2 password authorized settings. OEM ALTERNATOR SETUP is different from OEM GENSET SETUP. Alternator setup concentrates on voltage regulation performance and on alternator protection setting. Most settings require a Level 2 password. On page 1 you will notice an option for choosing the Excitation Source. You are able to choose between PMG (Permanent Magnet Generator) or SHUNT. Shunt is a term unique to Cummins Power Generation excitation systems and it is synonymous with the industry common term Self Excitation. Scroll through the Alternator Setup pages and you will notice some of the protection settings are very high level protections and these settings if improperly set can contribute to serious damage of the alternator or system. Be VERY CAUTIOUS about sharing the level 2 password with others.
Participants’ Guide
Section 2 Page19
PCC 3.3 & PowerCommand Control 3300
Service Menus
PCCNet & ModBus Setup Menus The PCCNet and ModBus Setup screens will be covered in greater detail in upcoming lessons.
The PCCNet and ModBus Setup screens use Level 1 passwords.
12
Slide 2-12 PCCNET & ModBus Setup
Participant’s Text
Notes:
PCCNet and ModBus setup menus will be covered in detail in upcoming lessons. All of the navigation choices and functions found in these menus have been experienced. Using your simulator, navigate to, and open the PCCNet and ModBus menu screens. Later Lessons will cover the detailed setup of both these features.
Participants’ Guide
Section 2 Page20
PCC 3.3 & PowerCommand Control 3300
Service Menus
Setup Menus The remaining Setup screens Display Options, Clock Setup, Configurable IO, and Calibration also contain multiple screens with many setup parameters.
13
Slide 2-13 Operator Setup Menus
Participant’s Text
Notes:
The remaining setup menus on this screen utilize the same navigation buttons and sequences covered previously. The Configurable IO menu contains many configuration settings and labels. As mentioned in previous screens, when inputting lots of character data, it can take a long time to input descriptions. If you are only changing a couple of descriptions it is ok to attempt it from the HMI menus, but some people may prefer to us InPower for this configuration. InPower setup menus will be covered in upcoming lessons.
Participants’ Guide
Section 2 Page21
PCC 3.3 & PowerCommand Control 3300
Service Menus
DEMO MODE Operation The HMI has a DEMO MODE of operation that allows for practice at navigation through the various screens. There is a series of 5 screens that allow for detailed setup of a multitude of operation set points.
14
The DEMO MODE is accessed by pressing these buttons simultaneously for a few seconds will cause the screen to enter a DEMO mode if PCCNet is disconnected.
Slide 2-14 Demo Mode Menus
Participant’s Text
Notes:
Demo mode is very useful for training customers and site operators on navigation skills. You must remove the PCCNet communication connector before you attempt to enter Demo Mode.
Participants’ Guide
Section 2 Page22
PCC 3.3 & PowerCommand Control 3300
Service Menus
Activities 2-1 Menu Hands On Activity 2-2 Menu Hands On Activity 2-3 Menu Hands On Activity
Section 2 Activities are found in Section 15 of the Training Guide. 15
Slide 2-15 Activities Listing for Lesson 2
Participant’s Text
Notes:
At this time I would like you to work as teams to complete these activities.
When everyone is done with the activities, we will discuss the correct answers.
These activities should be fairly easy for you, but take your time to become comfortable with the button pushing sequences.
Participants’ Guide
Section 2 Page23
PCC 3.3 & PowerCommand Control 3300
Service Menus
Wrap-Up In this lesson we have learned about the Service Menus for the PCC 3.3 and PCC3300/HMI 320 control. 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 default settings, 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.
Participants’ Guide
Section 2 Page24
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
Participants’ Guide
Section 3 Page1
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Section 3 PowerCommand Control 3300 Sequence & Operation. Estimated Time: 2 hours
Materials Needed •
PowerCommand Control 3300 Participant’s Guide
•
PC with InPower v 7.0 or later installed
•
PowerCommand 3.3 Service Manual
Participants’ Guide
Guide (CMT6068-EN-PG)
#900-0670
Section 3 Page2
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Warm Up In this lesson we are going to learn the operating features and sequence for the PowerCommand Control 3300. What we learn in this lesson will be applied in the troubleshooting lesson and in both the written and performance examinations. First, let’s look at the objectives for this lesson: Objectives After completing this lesson, the participants should be able to: •
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.
Participants’ Guide
Section 3 Page3
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
HMI 320 Operator Panel Local Control Panel
Remote Control Panel
0300-6315-02
0300-6315-03
Fixed buttons 2
Visual 3-2 Local and Optional Remote Operator Panel
Participant’s Text
Notes:
There are 2 Operator Panels. The Local version is considered standard and the Remote version is optional. The HMI 320 Local allows greater control of the control and setup functions. It offers operator interface to the digital voltage regulation, engine speed governing, and remote start/stop control, and protective functions. The obvious difference between each HMI is noticeable when to look at the fixed buttons.
Participants’ Guide
Section 3 Page4
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Modes of Operation Each mode of operation has multiple choices affecting sequence of operation.
Off Mode Auto Mode Manual Mode Parallel Mode
3
Visual 3-3 PCC 3.3 Operation Modes
Participant’s Text
Notes:
As with so many things about this control, a different style of thinking is required to understand how this control operates. Modes of Operation: Off Mode On most controls we think of OFF as a condition when no power is being used for any purpose. That is not what this control is doing. In OFF MODE, this control is actively monitoring communications, engine condition, and generator conditions, but it does NOT allowing the engine to run. The control is not operating in Manual nor is it operating in Automatic. The Control is very hard at work making the genset do nothing.
Participants’ Guide
Section 3 Page5
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Participant’s Text
Notes:
Modes of Operation: Auto Mode Auto Mode operates the same as previous controls. The unit is in a state of readiness awaiting a remote start signal via digital commutations or a remote discrete contact start command. Auto Mode also supports start commands initiated by Exercise and the exercise signal. In Auto Mode when auto start commands are removed, the PCC will enter a shutdown with cooldown 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 in exercise scheduler much like transferswitch controls) InPower exercise command. Exercise switch PCCNet input Modes of Operation: Manual Mode will engage the At the HMI pressing the Manual mode if the HMI is configured to allow this. If the engine is already running when this button is pushed, it will continue to run if the START button is pressed again within 250ms -- yes that is ¼ of a second. If you are not fast enough, the unit will go into a Shutdown WITHOUT cooldown button is If the unit is not running and the pushed, the unit will be available for Manual start & stop commands. If you engage the Manual mode, you must push the manual button again within 10 seconds or the control will enter the OFF MODE.
Participants’ Guide
Section 3 Page6
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Participant’s Text
Notes:
Modes of Operation: Manual Mode If the HMI button has been engaged with the engine off, normal start functions will be available and take place with a idle warm up if needed. Once the engine ramps to rated, the control can operate in Parallel Mode if the control is configured to allow this. If the control is configured for a Parallel Mode and you are operating in Manual Mode the buttons will allow control of the paralleling circuit breakers. Modes of Operation: Paralleling Mode There are 7 states of paralleling operation of which 5 are associated with application performance modes.
Dead Bus Close First Start Arbitration Droop Synchronization Load Share Load Govern Power Transfer Control
Dead bus close and 1st start arbitration are sequence modes that are incorporated into some of the other paralleling modes, but they merit recognition at this point. The operation of the various modes involved with Paralleling will be covered in detail in later lessons.
Participants’ Guide
Section 3 Page7
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Modes of Operation - Starting Multiple START sequences available.
Emergency Start Non-emergency Start Non-emergency Start With Idle Warm up Non-emergency Start Without Idle Warm up Manual Start Manual Start With Idle Warm up Manual Start Without Idle Warm up Load Demand Start 4
Visual 3-4 PCC 3300 Starting Mode & Sequence
Participant’s Text
Notes:
Starting Modes of operation The control operates the generator differently depending on the operation mode and the desired start type. Refer to Section 3-12 of 900-0670 Control Service Manual for more information.
Participants’ Guide
Section 3 Page8
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Flow diagram of the normal start modes of the PCC3.3 Control system in A uto M ode & rem ote start = 1 (hardw ired or netw ork)
start m ode = em erg (hardw ired or netw ork)
start m ode = non-em erg (hardw ired or netw ork)
REM OTE ST A R T
EM ERGENCY REM OTE ST A R T
N O N -E M E R G E N C Y REM OTE ST A R T
T IM E D E L A Y T O ST A R T
T IM E D E L A Y T O ST A R T
O IL PR E LUBE tim er expires C ranking Is D elayed till Prelube C om pletes
O IL PR E LU BE
N O R M A L ST A R T /R U N /ST O P SE Q U E N C E S
C ranking Is N ot D elayed
tim er expires W ARMUP @ ID L E
in M anual M ode & “m anual” run is initiated (= 1)
*
COOLDOW N @ RATED
rem ote start = 0
*
load tim er expires
RATED TO ID L E DELAY tim er expires COOLDOW N @ ID L E tim er expires ST O P
COOLDOW N @ RATED
tim er expires
RATED SPE E D & VOLTAGE "m anual" = 0
*
COOLDOW N @ RATED
RATED TO ID L E DELAY tim er expires COOLDOW N @ ID L E tim er expires ST O P
load dem and stop = 1
E xercise T im e E xpires
*
*
COOLDOW N @ RATED
**
T IM E D E L A Y T O ST O P
COOLDOW N @ ID L E tim er expires ST O P
tim er expires
RATED TO ID L E DELAY
tim er expires
COOLDOW N @ RATED
load tim er expires
tim er expires RATED TO ID L E DELAY
**
RATED TO ID L E DELAY
tim er expires COOLDOW N @ ID L E tim er expires
tim er expires COOLDOW N @ ID L E tim er expires
ST O P
ST O P
*N O T E : C ooldow n at R ated does not necessarily increase the T im e D elay to Stop. See the requirem ents for details. **N O T E : R ated to Idle delay does not necessarily occur. See the requirem ents for details.
Participants’ Guide
C ranking Is N ot D elayed
RATED SPE E D & VOLTAGE
T IM E D E L A Y T O ST O P
**
O IL PR E LU BE
(tim er expires or coolant tem p)
load tim er expires
tim er expires
**
W ARM UP @ ID L E
O IL PR E LUBE C ranking Is D elayed till Prelube C om pletes
RATED SPE E D & VOLTAGE
T IM E D E L A Y T O ST O P
tim er expires
**
LOAD DEM AND ST A R T
ID L E (tim er expires or coolant tem p)
load tim er expires
T IM E D E L A Y T O ST O P
E X E R C ISE LOCAL ST A R T
T IM E D E L A Y T O ST A R T
O IL PR E LU BE C ranking Is D elayed W ARMUP till Prelube @ C om pletes
RATED SPE E D & VOLTAGE
rem ote start = 0
in A uto M ode & rem ote start = 1 load dem and stop = 0 (hardw ired or netw ork)
MANUAL LOCAL ST A R T
(tim er expires or coolant tem p) RATED SPE E D & VOLTAGE
T o -->A uto M ode transition & “exercise” button (hardw ired or netw ork) =1
Section 3 Page9
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Manual Start: The PCC3.3 Control System can be place in Manual Run by pressing the Manual button and then the Start button on the HMI320. When the control system is transferring into Manual Run mode the Green LED above the manual button will flash, once the control system has successfully 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 the control 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 Run mode which begins with the start sequence. The start sequence begins with the engine Pre-Lube Cycle Prelube Cycle Enable if Enabled. After the Pre-Lube cycle is complete, the PCC3.3 control system commands the genset to start cranking by turning on the starter Low-Side Relay driver on Pin J20 -15. At this point, the control system verifies the engine is rotating by monitoring the Average Engine Speed parameter 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 is still 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. For Start Mode = Emergency engine will accelerate to rated speed and voltage and bypass all the idle 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 be commanded to accelerate to rated speed and the genset to rated voltage. Upon reaching rated speed 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 go into 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 cool down at Idle speed time expires, the genset is shut down via a normal stop.
Participants’ Guide
Section 3 Page10
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Modes of Operation - Stopping Emergency Stop
Multiple STOP sequences available.
Controlled Shutdown With Idle Cool Down Without Idle Cool Down Emergency Stop With Idle Cool Down
Automatic Shutdown With Idle Cool Down Without Idle Cool Down
B +
Local ESTOP Contact 2 Local ESTOP Contact 1
Remot e ESTOP Contac t1 Remote ESTOP Contact 2
PCC3300 Control
To Relay Contacts
6
Visual 3-6 PCC 3300 Shutdown Sequence
Participant’s Text
Notes:
For operation of the genset, a short between TB1-15 and TB1-16 must be present. The control enters an emergency stop mode when the short is removed. Before the genset can be restarted, the control must be manually reset by re-applying the short and acknowledging the fault. Local Emergency Stop: For operation of the genset, a short between J25-2 and J25- 6 must be present. The control enters an emergency stop mode when the short is removed.
Participants’ Guide
Section 3 Page11
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Participant’s Text
Notes:
Before the genset can be restarted, the control must be manually reset by re-applying the short and acknowledging the fault. It is also required to have physical interruption of the Keyswitch, FSO and Starter relays when emergency stop (either local or remote) is active. In order to achieve this, a second NC switch contact should be added to the Estop switch such that when a Estop button is pressed, this second NC contact is opened. 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 in turns de-energizes the relays and prevents further genset operation.
Participants’ Guide
Section 3 Page12
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Prelube Cycle The PCC 3300 is able to initiate a Prelube cycle period allowing the engine to circulate engine oil pressure.
Prelube Cycle is adjustable. Adjustments are available for: Prelube Cycle Enable. Prelube Cycle Time. Prelube Oil Pressure Threshold Prelube Timeout Period
Prelube Mode
Emergency start: Crank relay and Oil Priming Pump relay is energized
during start.
7
Visual 3-7 PCC 3.3 Prelube
Participant’s Text
Notes:
Prelube pumps can be controlled by the PCC 3300 control and they can be cycled as desired to maintain an oil coating on the bearing surfaces during times of inactivity. The Prelube relay is optional per genset design requirements. The Prelube pump is optional and types may vary. The relay will engage when the engine is not running, so be aware of unanticipated pump engagement. Prelube will usually be found with larger engines since long & heavy crankshafts and heavy flywheels need to be supported by a sufficient film of oil on bearings.
Participants’ Guide
Section 3 Page13
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Participant’s Text
Notes:
InPower supports the setup functions associated with Prelube.
Prelube Cycle Enable – turns the Prelube function on or off.
Prelube Cycle Time – Sets the amount of time between Prelube cycles. Default 168 hours (7 days)
Prelube Oil Pressure Threshold – this as an adjustable setting so that when the predetermined oil pressure is achieved during Prelube Cycle pumping, the cycle will disengage.
Prelube Timeout Period – this is an adjustable setting determining how long the Prelube pump should run.
Charging the engine lube system with Prelube keeps internal engine components coated with oil and keeps the oil galleries charged with oil supply. With Cycle Prelube you can set a schedule when the pump will recharge the lube system with pressurized oil. Prelube will also engage at the beginning of an Emergency start command to help charge the lube oils system and bring the system up to safe oil pressure levels as soon as possible. The Prelube cycle is disabled and does not operate while the engine is running.
Participants’ Guide
Section 3 Page14
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
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 control systems.
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 the other PCCNet devices by driving the Bi-directional system wakeup pin.
When all devices are satisfied, the PCCNet will go to sleep as one system. 8
Visual 3-8 PCC 3.3 Power Down
Participant’s Text
Notes:
The PCC 3300 power consumption changes depending which of mode of sleep or wake it is in. The current draw of the HMI changes during power down mode. Look at Table 3-11 in Section 3 (page 11) of the 900-0670 Service Manual. The system Power Down Mode Time Delay timer is adjustable under the GenSet Setup of InPower or the HMI setup screens.
Participants’ Guide
Section 3 Page15
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
PCC 3300 AVR Operation The PC 3.3 AUX103 Power Stage (AVR) provides a PWM signal to the generator Exciter
AUX 103 Current Output – Normal Operation – Maximum continuous operation – Surge `
0 to 4 amp 4 amp 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) 9
Visual 3-9 PCC 3300 Power Stage
Participant’s Text
Notes:
The AUX 103 Power Stage AVR is separate from PCC 3300 main control board to help dissipate the heat being rejected from the AVR circuits. The AUX 103 MUST be mounted with the heat sink fins vertical so convective airflow can help carry heat up and away from the board. Processors on board this module communicate to the rest of the control to optimize Volt/Hz performance and to shut down the AVR output during idle. The AUX 103 also communicates Backup Start Disconnect information.
Participants’ Guide
Section 3 Page16
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
PWM and Self Excitation The PCC3300 collects main alternator output power at J18 1 & 2 which is genset rated frequency.
The PCC3300 rectifies the incoming phases for a ripple DC power signal.
The PCC 3300 regulates the DC power and then controls the amount of on time for the signal sent back to the exciter field winding. The Pulse duration of DC signal is controlled for the needed excitation rate. Pulse Width Modulation 10
Visual 3-10 PCC 3300 and Self Excitation
Participant’s Text
Notes:
Self Excitation uses 2 phases of power coming off the main output leads of the generator for powering the voltage regulation process. and the voltage could be as low as 100 volts to as high as 240 volts RMS. PWM provides very high performance for voltage regulation response. One of the main shortcomings of a self excited system is the lack of supply power to the excitation system when very heavy loads are applied to the main windings. Motor start performance is not as good with self excitation as you get with PMG power supply.
Participants’ Guide
Section 3 Page17
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
PWM and PMG Excitation The PCC3300 collects 3 phase PMG output power at J18 which is twice genset rated frequency.
The PCC3300 rectifies the incoming phases for a nearly smooth DC signal.
The PCC 3300 regulates the DC power and then controls the amount of on time for the signal sent back to the exciter field winding. The Pulse duration of DC signal is controlled for the needed excitation rate. Pulse Width Modulation 11
Visual 3-11 PCC 3300 PMG Excitation
Participant’s Text
Notes:
PMG Excitation offers many advantages over Self Excitation. PMGs are not affected by harmonics or loading on the main windings and can provide a clean source of the needed power to the voltage regulation system as needed when needed. As can be noticed in the above image of the PWM 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 “% Duty Cycle” on previous controls. Now it is termed AVR PWM Software Command.
Participants’ Guide
Section 3 Page18
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
PCC 3300 Start Disconnect The PC 3.3 can use multiple signal or inputs for starter 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 12
Visual 3-12 Start Disconnect
Participant’s Text
Notes:
The PCC 3300 provides for multiple forms and options for starter disconnect. The PCC control provides control of the starter control relay, but in FAE applications the ECM is the one who decides when the primary starter disconnect should take place. On FAE applications the EPS (Speed Reference) is determined by the ECM and the information is communicated through CAN to the genset PCC control. If PMG is used, the AUX 103 determines backup start disconnect when PMG voltage achieves 105 volts.
Participants’ Guide
Section 3 Page19
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
Activities: Quiz: PCC 3300 Sequence of Operation
13
Visual 3-13 PCC 3300 Activities - Sequence of Operation
Participant’s Text
Notes:
Work through the Quiz found in the Activity portion of Section 15.
Participants’ Guide
Section 3 Page20
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Sequence of Operation
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.
Participants’ Guide
Section 3 Page21
PCC 3.3 & PowerCommand Control 3300
Section last page
THIS PAGE IS INTENTIONALLY LEFT BLANK
Participants’ Guide
Section Last Page
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
PowerCommand 3.3 Section 4: Control Installation
Visual 4-1
Participants’ Guide
Section 4 Page1
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
Section 4 PowerCommand Control 3300 Installation Estimated Time: 3 hours
Materials Needed
Wiring Diagram 0630-3440 (A007M115 D)
PowerCommand Control 3300 Participant’s Guide
PC 3.3 Controller Service Manual
Participants’ Guide
Sheets 1 to 18 or diagrams in 900-0670 Guide (CMT6068-EN-PG) #900-0670
Section 4 Page2
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
Warm Up In this lesson we are going to look at the installation and connections that can be used with the PowerCommand Control 3300. We will also give you a chance to work with some optional devices and controls at your workstations. Objectives After completing this lesson, the participants should be able to: •
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.
Participants’ Guide
Section 4 Page3
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
Control and Option Installation Physical Installation Requirements Identify each of the connectors Input and Output Connections
2
Visual 4-2 Control and Option Installation.
Control Installation Participant’s Text
Notes:
Most technicians will encounter the PCC3300 when it is already installed onto a factory built generator set. However, there will be situations when technicians will need to know about proper installation of the PCC 3300, such as instances when an old/obsolete control needs to be replaced or when troubleshooting, or if adding more features or options.
Adding options in the field will most likely be a common occurrence
Attaching to and utilizing the I/O features will be the most common reason to become familiar with the connectors on this control.
Participants’ Guide
Section 4 Page4
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
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 3
Visual 4-3 Installation Steps for PowerCommand Control 3300 Options
Participant’s Text
Notes:
Installing Options The PowerCommand Control 3300 cannot be powered down except by disconnecting the battery cable. IMPORTANT! Press the local Emergency Stop button and wait approximately 30 seconds 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.
Participants’ Guide
Section 4 Page5
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
PowerCommand Control 3300 Installation
Notes:
Disable the battery charger FIRST! then disconnect the battery − Negative cable first. Remember to remove the chassis end of the negative battery cable to prevent sparking and possible battery explosions. In class we will power down the simulator to remove power from the control. Remove control-housing cover(s) and connect your wrist strap. Static wrist straps are recommended to prevent static discharge damage to the control boards, but this control may
have up to 600vac bus power connected. For safety reasons, it is best NOT to use a wrist strap, but antistatic handling measures must be employed.
Install the new option or card or other modules, etc. Install the wiring harness for the option. Reconnect battery and enable the battery charger. Remove Lock-out Tag-out. If necessary, use InPower service software to enable the feature(s) or set the required parameters. Test the generator set with the new option to verify proper operation.
Additional Notes or Comments _______________________________________________________________________________
Participants’ Guide
Section 4 Page6
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
Baseboard Connector Location Bus CT Inputs
J12- Gen CT Inputs
TB7- Bus Voltage
J22- Gen Voltage
J20- Genset input/outputs TB9- Analog I/O
J25- Display Connections TB15- Service / MODBUS
J26- Engine Interconnect J14- Service Interface TB3 - Customer I/O TB10- Circuit Breaker Status TB8- Customer I/O
TB1 – Customer I/O TB5- Circuit Breaker Control
4
Visual 4-4 Connector Location -r PowerCommand Control 3300
Participant’s Text
Notes:
Like the PC 1.X & 2.X, the PowerCommand 3.3 also uses the new common connector scheme. All connectors use a tension or mechanical latch to hold the harness jack in place. All connectors are keyed so the harness jack will not be inserted incorrectly.
Participants’ Guide
Section 4 Page7
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
Bus CT Connections
CT1
CT2
CT3
5
Visual 4-5 Control Board CT Connections
Participant’s Text
Notes:
There are 3 donut style CTs mounted to the board and they are used for monitor of Bus current, not Genset current. These CTs are polarity sensitive and are limited to a maximum of 5 amp passthrough. These CTs are looking for a signal from the bus primary CT mounted in the switchgear bus. Passing the output loop from the bus CT through the center of each CT will induce a signal for the PCC to measure. Make sure each CT is monitoring the proper phase as the voltage sense!
Participants’ Guide
Section 4 Page8
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
J12 Connections Pin 4
Pin 6
Pin 1
Pin 3
6
Visual 4-6 J12 Inputs
Participant’s Text
Notes:
J12 provides input from the genset mounted CT and monitor genset output current. Input is limited to a standard 0 to 5 amp. CT. The plug is keyed so incorrect insertion will be minimized. The genset harness will be prewired and it is unlikely that the plug can be inserted wrong. However, the wires at the other end of this plug are susceptible to miswire. Do Not unplug this connector while the genset is operating! Shorting blocks or some sort of shorting system must be used to protect the Gen CTs from open circuit when unplugged. Participants’ Guide
Section 4 Page9
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
J22 Gen Voltage Connections
Pin 1
Pin 4
7
Visual 4-7 J22 Gen Voltage Inputs
Participant’s Text
Notes:
J22 provides voltage sensing inputs to the control. The control uses this information for voltage regulation and other protection functions. There are 4 pins on this connection. 1 pin for each phase plus neutral. J22 is rated to accept up to 600 volt AC. For voltages greater than 600, a Potential Transformer (PT) must be used to lower the voltage down to an acceptable level. Refer to Service Manual 900-0670 Section 2 for proper PT Sizing Rules.
Participants’ Guide
Section 4 Page10
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
J20 Gen I/O Connections
Pin 22 Pin 11
Pin 1
Pin 12 8
Visual 4-8 J20 Genset I/O Connections
Participant’s Text
Notes:
J20 provides connection for most genset features. Notice J20-16 is the Oil Priming Pump Driver which was discussed previously in lesson 3. J20-9 & 10 are Fused B+ inputs and need to be fused for a maximum of 20 amp. Low Side IS NOT THE SAME AS BATTERY GROUND! B+ RETURN = Battery Negative B+ RETURN IS NOT EQUAL TO GROUND
Participants’ Guide
Section 4 Page11
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
J25 Display Connections Pin 1
Pin 7
Pin 6
Pin 12
9
Visual 4-9 J25 Display Connections
Participant’s Text
Notes:
J25 uses the exact same connection points at used on PC 1.X and 2.X controls. J25 provides connection for PCCNET display connection.
Participants’ Guide
Section 4 Page12
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
J26 Engine Interconnect Pin 18
Pin 10
Pin 9
Pin 1
10
Visual 4-10 J26 Engine Interconnect
Participant’s Text
Notes:
J26 is used for engine and AVR Power Stage connection. Standard SAE J1939 communications can be connected at J26-1, 10, & 11. On the chart, this may seem spread out haphazardly, but if you look at the connector you will notice they are consolidated neatly. J26 – 7 & 14 provide F1 & F2 information from the AVR Power Stage to the PCC 3300 processor to so it can properly monitor and protect the excitation system.
Participants’ Guide
Section 4 Page13
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
J14 Data / Service Interface Pin 6
Pin 9
Pin 5
J14 DATA LINK
Pin 1
(RS232)
11
Visual 4-11 J14 Data/Service Interface
Participant’s Text
Notes:
This communication port is used to communicate with a computer running a PC based service tool. This port can also be used to communicate with the external devices via the MODBUS protocol. InPower service cable #0338-3277 can be used to communicate direct into the board using RS232 communication from your computer port.
Participants’ Guide
Section 4 Page14
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
TB1 Customer I/O Connections Pin 16
Pin 1
12
Visual 4-12 TB1 Customer Connections
Participant’s Text
Notes:
PCCNet connections on TB1-1, 2, & 3 duplicate the PCCNet functions and connections of J25. Ready to Load on TB1-4 becomes active when the genset achieves 90% voltage and/or frequency during startup. Look at page 9 of print 0630-3440. At the top of the page next to TB1 – Basic you will , this is the see part number for the connector terminal block that is missing on the above visual. Remote Start is between TB1-10 & 11.
Participants’ Guide
Section 4 Page15
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
TB3 Customer I/O Connections Pin 1
Pin 12
13
Visual 4-13 TB3 Customer I/O connection
Participant’s Text
Notes:
TB3 has many inputs that will be utilized with the PTC functions to be released in Phase 2. TB3-11 & 12 are utilized in many paralleling applications for First Start arbitration.
Participants’ Guide
Section 4 Page16
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
TB5 Circuit Breaker Control Pin 9
Pin 1
14
Visual 4-14 TB5 Breaker connections
Participant’s Text
Notes:
TB5 is reserved for connections devoted to controlling Genset breakers and Utility (Mains) breakers. More details about these connections will be covered in later lessons. Refer to print 630-3440 page 13 through 17 or Appendix A page A-7, through A-11 of the 900-0670 Service Manual.
Participants’ Guide
Section 4 Page17
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
TB8 Customer Connections Pin 13
Pin 1
15
Visual 4-15 TB8 Customer Connections
Participant’s Text
Notes:
TB8 is used in paralleling applications for several control functions. Most connections will be shown in CPG paralleling interconnect drawings. The inputs are used for paralleling performance commands. More details about these connections will be covered in later lessons. Refer to print 630-3440 page 13 through 17 or 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.
Participants’ Guide
Section 4 Page18
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
TB10 Breaker Status Connections
Pin 17
Pin 1
16
Visual 4-16 TB10Breaker status connections
Participant’s Text
Notes:
TB10 accepts breaker status for both utility (Mains) and genset breaker. There are also a couple paralleling performance command inputs. print 630-3440 page 12 through 17 or Appendix A page A-6, through A-11 of the 900-0670 Service Manual.
Participants’ Guide
Section 4 Page19
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
TB15 Data / Service Interface Pin 5
Pin 1
17
Visual 4-17 TB15 Service tool connection
Participant’s Text
Notes:
TB15 is the standard service tool connection port. This port can be used for InPower connection or it can be used for ModBus communications, but it cannot be used for both simultaneously.
Participants’ Guide
Section 4 Page20
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
TB9 Analog I/O Connections
Pin 11
Pin 1 18
Visual 4-18 TB9 Analog connections
Participant’s Text
Notes:
TB9 provides analog paralleling load management input and output. Look at Section 2 page 15 through 18 of the Service Manual 900-670 for details about the connection made to this terminal block. The analog voltage is 0 to 5 volt. TB9 does not have any 4 to 20 milliamp signal terminals. The details about connection to this TB will be covered in later paralleling lessons.
Participants’ Guide
Section 4 Page21
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
TB7 Gen Bus/Utility Voltage Sense Pin 1
Pin 4
19
Visual 4-19 TB7 Bus sense connection
Participant’s Text
Notes:
TB7 provides the bus voltage sense input to the control. This connection will sense up to 600 vac. If the bus voltage exceeds 600 vac, a PT/VT (Potential Transformer/Voltage Transformer) must be used to lower the bus voltage to a value less than 600 volts. More details about this connection and InPower setup will be covered in later lessons.
Participants’ Guide
Section 4 Page22
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
AVR Power Stage Connectors Pin 1
Pin 1 Pin 2
20
Visual 4-20 J17 - 18 Inputs and Outputs
J17 Excitation Field Power Participant’s Text
Notes:
J17-1 supplies excitation positive to X1 (F1) J17-2 supplies excitation negative to X1 (F1)
Participants’ Guide
Section 4 Page23
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
J18 Voltage Regulation Power Supply - maximum input is 240 VAC Participant’s Text
Notes:
The PCC 3300 will operate in either a self excited (Shunt excitation) mode or in PMG excitation mode. J18 can receive input from either the alternator output, or from phase 1 & 2 of a PMG. J18 has 3 connector pins; however, only 2 of them are used in Self Excited applications. The J18-1 & 2 inputs are limited to a maximum input of 240 VAC. CGT (Cummins Generator Technologies supplies 600 VAC alternators with a special winding tap that supplies the proper voltage for voltage regulator input. If these taps are not available, proper transformers must supply 240 VAC or less to the J18 inputs.
Participants’ Guide
Section 4 Page24
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
AVR J19 Interconnect
Pin 14
Pin 1 21
Visual 4-22 Operator Panel Installation
Participant’s Text
Notes:
The AVR J19 connector is expected to be used on all applications. There is a short connection harness from the AUX 103 J19 terminal that plugs into the J26 interconnect harness. J19 – 4 & 10 are reserved for future plans to monitor field current. This is not supported during the Phase 1 program.
Participants’ Guide
Section 4 Page25
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
HMI 320 Operator Panel Local Control Panel
Remote Control Panel
0300-6315-02
0300-6315-03
22
Visual 4-22 Operator Panel Installation
Participant’s Text
Notes:
The HMI320 Local Control is required and is expected to be used on all applications. The HMI320 Remote is optional and is not used on all applications. Optional languages can be loaded (programmed) into the HMI Environmental installation requirements are listed on this visual.
Participants’ Guide
Section 4 Page26
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
HMI 320 Operator Panel
23
Visual 4-23 Installation HMI320
Participant’s Text
Notes:
Refer to Service Manual #900-0670 Section 2-24 for proper connection information. LED11 blinks at a 1 second rate to indicate a Heartbeat. 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 used for calibration updates. Inserting a jumper across J36 will prevent the HMI from entering Power Down Mode, thereby engaging the Bi-directional Wakeup mode for the entire PCCNet control system.
Participants’ Guide
Section 4 Page27
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
24
Common Connector Scheme 0630-3440
Participant’s Text
Notes:
The PC 1, 2, & 3 generation of PowerCommand Controls will use a new Common Connector Scheme. Genset connections are displayed on print 0630-3440, pages 1 through 11.Pages 12 through 18 concentrate on paralleling connections. The same basic “J” connectors are used on all 3 series and phases of controls allowing for simplified control upgrades without changing engine harnesses. There are many new features imbedded in the print. Look at each Legend, and you will notice valuable information.
Participants’ Guide
Section 4 Page28
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Installation
Activities Section 4: In-Class Quiz
25
Visual 4-14 Quiz Listing for Section 4
Participant’s Text
Notes:
At this time I would like you to work alone to complete the quiz.
Participants’ Guide
Section 4 Page29
PCC 3.3 & PowerCommand Control 3300 Installation
PowerCommand Control 3300
Wrap-Up In this lesson, we have learned about installation of the PCC 3300 genset control and important connection locations. We talked about each individual connector and the connections available from the control to 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?
Participants’ Guide
Section 4 Page30
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
Participants’ Guide
Section 5 Page1
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Section 5 PowerCommand Control 3300 Control Setup and InPower Estimated Time: 2.5 hours
Materials Needed
PowerCommand Control 3300 Participant’s Guide
PC with InPower v 7.0 or later installed
Registered Dongle or authorization code.
InPower Connection Cable Kit
Participants’ Guide
(CMT6068-EN-TG)
#0541-1199
Section 5 Page2
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Warm Up In this lesson we are going to learn about the InPower parameters for the PowerCommandControl 3300. You will have a chance to use InPower with the training controls as an in-class activity after we complete 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.
Participants’ Guide
Section 5 Page3
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Connecting to a PCC 3300
2
Visual 5-2 Connecting to a PCC 3300 with InPower software
Participant’s Text
Notes:
Connect your hardware lock (dongle) to the USB port of your PC and start the PC. Log in to your PC using one of the security schemes discussed in the InPower class or on the Power Generation University training program. The converter and cable of Communication Kit #0541-1199 is also used when connecting InPower to a PC 3.3 control system.
Participants’ Guide
Section 5 Page4
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
THIS PAGE IS INTENTIONALLY LEFT BLANK
Participants’ Guide
Section 5 Page5
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
InPower Service Tool Software
3
Visual 5-3 In-Power service software connected to a PCC 3300 control
Participant’s Text
Notes:
The screen structure is different for the PCC3300 than some other controls. There are several new features. •
Advanced Status allows you to monitor a vast amount of engine, alternator, genset and fuel system performance and data.
•
Alternator Data contains monitoring points for alternator performance data only.
•
Engine Data contains monitoring points for engine performance data only.
Participants’ Guide
Section 5 Page6
PCC 3.3 & PowerCommand Control 3300
Participant’s Text •
Setup is a folder containing functions that used to be found in the Adjustments folder
•
Faults contains information and fault configurations
•
Test provides access to a great many test features such as Witness Test Folder
PowerCommand Control 3300 Setup and InPower
Notes:
Additional Notes:
Participants’ Guide
Section 5 Page7
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
InPower Service Tool Software
This choice will take you to a setup screen
A simple right mouse button click on the SETUP folder will bring up the dialog box with the Genset OEM Setup choice 4
Visual 5-4 InPower Setup
Participant’s Text
Notes:
The PCC 2300 and 3300 both have a special Genset OEM Setup function choice. This feature facilitates easy setup of all of the same OEM setup functions we looked at in Lesson 2 about the HMI screens. Just like on the HMI, there are setup screens for: •
OEM Alternator Setup (2 screens)
•
OEM Engine Setup (6 screens)
•
OEM Genset Setup (4 screens)
Participants’ Guide
Section 5 Page8
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
InPower: Genset OEM Setup Screen 1 Radio buttons accept a simple click to activate or deactivate Text boxes accept upper and lower case alphabet, numerals, and special characters.
Adjustable rating with listing of possible range
5
Visual 5-5 Genset OEM Setup
Participant’s Text
Notes:
The first default screen is page 1 of the OEM Genset Setup. This screen offers the exact same setup functions as found on this page in the HMI OEM Genset Setup screen. Notice the “Setup Mode Disabled” button in the lower left corner. If it is highlighted, you are prevented from implementing changes. Click on the “Enable Setup Mode” to activate all of the adjustment choices. InPower must be connected to the control to enter the Enable Setup Mode. You cannot make changes to a capture file.
Participants’ Guide
Section 5 Page9
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Setup Screen: Genset Screen 2
Check boxes accept a simple click to activate or deactivate
6
Visual 5-6 Battle Short
Participant’s Text
Notes:
Battle Short setup procedures are more complex than placing a simple check in this screens checkbox. Refer to the Service Manual 0900-0670 Section 7 for details on the proper mode configuration process. There are approximately 6 pages devoted to the procedures involved with activating the mode. Removing the check in a Factory Lock check box will allow the input or output to be used for a different purpose.
Participants’ Guide
Section 5 Page10
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Setup Screen: Genset Screen 3 Radio buttons accept a simple click to change response to: None, Warning, or Shutdown
Text boxes only use upper case alphabet, numerals, and special characters.
Response must be set to: Warning, or Shutdown to enter text into the Fault Text box.
7
Visual 5-7 Configurable Switch Settings
Participant’s Text
Notes:
Screen 3 allows you to set these Configurable Inputs: •
Input #1, #2, #13 & #14
•
Response of None, Warning, or ShutdownEvent
•
Names for display at the HMI display screen (s), or transmission via a ModBus register (16 characters of text maximum)
Participants’ Guide
Section 5 Page11
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Setup Screen: Genset Screen 4
8
Visual 5-8 Genset Settings
Participant’s Text
Notes:
These settings allow for easy configuration of premium genset options available from the factory. The genset wire harness has preconfigured inputs for factory genset options such as a sub base fuel tank or an optional coolant level sensor. These items would be Factory Lock functions if enabled at the factory. They are pre mapped for communications to annunciator lamps and for fault display.
Participants’ Guide
Section 5 Page12
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Setup Screen: Engine Screen 1
9
Visual 5-9 Engine Setup Screen 1
Participant’s Text
Notes:
The PCC 3300 phase 1 release supports Full Authority Electronic Engines, and phase 2 will support mechanical control engines. Oil Priming Pump enabling requires other adjustments to be made on other screens for 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 the genset control sends the start engagement command to the starter.
Participants’ Guide
Section 5 Page13
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Setup Screen: Engine Screen 3
10
Visual 5-10 Engine Setup Screen
Participant’s Text
Notes:
These parameters are almost all related to Hydra 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 supposed to help protect large turbocharged gas genset engine. Mag Pickup and Flywheel Teeth, function together, Flywheel ring tooth count is used to calculate RPM.
Participants’ Guide
Section 5 Page14
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Setup Screen: Engine Screen 4
11
Visual 5-11 Engine OEM Setup Screen.
Participant’s Text
Notes:
All parameters on Screen 4 support Hydra mechanical application. These functions will be covered in Phase 2 training.
Participants’ Guide
Section 5 Page15
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Setup Screen: Engine Screen 5
12
Visual 5-12 Engine Setup Screen 5
Participant’s Text
Notes:
The settings in Screen 5 are intended to support Hydra Mechanical applications, just like the adjustments we saw in Screen 4. Screens 2 and 6 will also support Hydra mechanical functions. The content of screens 2 and 6 will be available when Phase 2 is complete.
Participants’ Guide
Section 5 Page16
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Setup Screen: Alternator Screen 1 Pay attention to this Note: Voltages less than 600 volts can be sensed directly without a PT.
There are useful Notes found on this page. Follow the directions to properly set up the CTs.
There is no SHUNT involved with the excitation system, it is just a term loosely used by CPG to describe a self excited regulation system. 13
Visual 5-13 Alternator Setup
Participant’s Text
Notes:
Do not confuse the notes on this screen as implying that a PT/CT module is used with this control. Remember – this control can handle direct 600 volt AC into the J22 connection. Refer to page 2-8 of the 09000670 Service Manual for PT info. For CT setup and calibration refer to page 2-5 of the 0900-0670 Service Manual. Do not confuse these CT settings with Bus CT settings. This Screen supports the Genset CTs only.
Participants’ Guide
Section 5 Page17
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Setup Screen: Alternator Screen 2
This control is able to monitor total KWH output. You can also reset the KWH meter.
This control will support single and 3 phase generator output. .
14
Visual 5-14 Alternator Setup.
Participant’s Text
Notes:
The K factors adjust the tuning for regulation performance. Refer to page 5-51 and 5-52 for an explanation of the K1, 2, 3, & 4 settings. •
K1 – is similar to GAIN adjustments.
•
K2 – is similar to Integral settings for overshoot & undershoot.
•
K3 – is similar to a stability setting for response.
•
K4 - is a calculation value dependent on the alternator hysterisis characteristics and usually should not be changed.
•
Shunt Gain Multiplier should remain at 1.5
Participants’ Guide
Section 5 Page18
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
InPower Service Tool Software A standard left mouse button click on the SETUP folder will provide a standard drop down list of more adjustment folder.
Choosing the OEM GENSET SETUP folder will give you setup choices in a different format from the previous visuals – It is your choice how you prefer to view the screens.
15
Visual 5-15 Setup Folders
Participant’s Text
Notes:
If you prefer not to use the OEM Setup Screens that we just covered, you can execute the same functions using conventional InPower screens for setting up the PCC 3300 control. There are folders for: •
OEM Alternator Setup
•
OEM Engine Setup
•
OEM Genset Setup
Participants’ Guide
Section 5 Page19
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
InPower Service Tool Software
SETUP contains a folder for setup of the real time clock. This clock is referenced for time stamps on faults and is used for exercise programs.
16
Visual 5-16 Setup Clock
Participant’s Text
Notes:
This folder contains a clock setup for adjusting the real time clock. The clock is used for time stamps on faults and for the exerciser scheduler. If the battery is disconnected, the clock will continue running for about 4 hour. Look in Section 5 of the 0900-0670 Service Manual for details about setting the clock. Also look at Appendix B of this guide for detailed info about setting the clock and exerciser. Clock Year shows 2 digits for the year, however it does not show a 0 before the year, so 8 is all that will be shown for 2008.
Participants’ Guide
Section 5 Page20
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
InPower Service Tool - FAULTS
17
Visual 5-17 Fault Screens
Participant’s Text
Notes:
The FAULTS folder conveniently consolidates all fault information in one location. There are 3 main folders for: •
Active Faults
•
Events and Faults
•
Fault History
In the Events and Faults folder, under the Snapshot column it is possible to select a fault that will record data for the preceding few seconds before a fault becomes active. The memory of the PCC 3300 holds a limited amount of snapshot data, so only turn on snapshots of important points.
Participants’ Guide
Section 5 Page21
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
InPower: History & About The History/About folder contains several adjustment trims that allow keyboard insertion of Serial and Model numbers
18
Visual 5-18 History & About
Participant’s Text
Notes:
In an earlier section you discovered that serial and model numbers could be inserted via the HMI setup using many consecutive button pushes. InPower allows you to use the computer keyboard to type the character.
Participants’ Guide
Section 5 Page22
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Activities 5-1 PC 3.3 Setup and InPower Quiz 5-2 Real Time Clock Setup
19
Visual 5-15Activities Listing for Lesson 1
Participant’s Text
Notes:
You will find Section 5 Activities in Section 15 of your guide. Please find the Activities and at this time and work as teams to complete these activities.
Participants’ Guide
Section 5 Page23
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 Setup and InPower
Wrap-Up In this lesson we have reviewed using InPower version 7.0 or later with the PCC 3300. First we talked 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 3300 PCCNet Communications.
Participants’ Guide
Section 5 Page24
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
PowerCommand 3.3 Section 6: PC 3.3 & PCCNet
Visual 6-1 PCCNet
Participants’ Guide
Section6 Page1
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
Section 6 PCCNet Network for the PCC 3300 Estimated Time: 3 hours Materials Needed (CMT6068-EN-PG)
PowerCommand Control 3300 Participant’s Guide 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 the PowerCommand Control 3300: Universal Annunciator, and HMI Control Panel. The Phase 1 release 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 the PowerCommand 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:
Participants’ Guide
Section6 Page2
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
Objectives After completing this lesson, the participants should be able to:
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 and simulator.
Participants will use InPower and gain more experience with the setup process and screens found in InPower.
Participants’ Guide
Section6 Page3
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
PCCNET Overview PCCNET is a flexible communication system that uses a standardized proprietary protocol unique to Cummins Power Generation
PCCNET provides device to device connectivity and is supported by many of the PowerCommand genset controls. It is a dynamic system that supports two way communications between many devices.
The list of available devices is subject to change from time to time with the addition or subtraction of devices, or device availability differences from region to region or application to application. 2
Visual 6-2
Participant’s Text
Notes:
PCCNet is a proprietary communication system used on PCC 3300 and several other PowerCommand controls and devices. PCCNet is a low cost communication system developed as a solution for simple networking. A simple network is limited to only 1 generator set control. PCCNet provides functional communication from device to device and it is not for monitoring or building management systems. The ModBus feature is better suited to support this.
Participants’ Guide
Section6 Page4
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
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. 3
Visual 6-3
Participant’s Text
Notes:
PCCNet Basics on the PCC 3300:
Two Data Wires and Two Power wires needed. Beldin #9729 shielded data cable is recommended.
DATA TERMINALS ARE POLARITY SENSITIVE! A=+=1&B=-=2
Power Terminals are TB1-5 (+) and TB13 (B+ Return)
Up to 4,000 feet maximum network length with no terminations needed.
PCCNet data connections MUST use a daisy chain topology
Maximum is 20 devices. This count includes the HMI display and bar graph.
Participants’ Guide
Section6 Page5
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
PCCNET Communication Operation PCCNet is a Token Passing Network The authority (Token) to speak (broadcast) passes from device 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 this exceeds 10 seconds, ALL other devices arbitrate again. 4
Visual 6-4 PCCNet Operation
Participant’s Text
Notes:
Broadcast Messages are output messages from a device that has a hard-wired input. Broadcast messages are sent out: • every time the input changes, or • every five seconds. Gensets broadcast NFPA-110 data to the network. Annunciators listen for these messages. Annunciators will also broadcast updates of their hard-wired inputs. The token is passed from device to device in sequence and each device reports its status within the 5 seconds it takes to pass the token throughout the group. If a device is unplugged or if it fails, the rest of the network will notice the absence and will re-negotiate the communication sequence.
Participants’ Guide
Section6 Page6
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
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 5
Visual 6-5 PCCNet Devices
Participant’s Text
Notes:
These are the most common devices that you can expect to encounter on a PCC 3300 application. HMI 320 – Previously called a display, touch screen, or customer interface. HMI 220 – For special product applications only. Special programming of the HMI is needed for it to communicate to the PCC 3300 AUX 101 & 102 – Remote relay device with expansion module. The PCC 3300 will not communicate to the AUX 101 until the release of Phase 2. HMI 112 –Bar graph display. PCC 3300 calculates power factor, so only the 9 column display P/N 0300-6050-01 will be found with PCC 3300 controls.
Participants’ Guide
Section6 Page7
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
Participant’s Text
Notes:
HMI 113 – Universal Annunciator. This item was the original PCCNet device and it was first used with the PCC 2100 control. It is primarily used in the North American market, but it is sometimes found in some global projects.
PC 3.3 PCCNet Architecture HMI114
HMI113
HMI320 Option
Option
PCC3300
PCCNet Network (4 wire) AVR Power Stage Not a PCCNet device
Remote HMI320 Option
AUX101&102 (Future)
AUX 103
6
Visual 6-6 PCCNet Architecture
Participants’ Guide
Section6 Page8
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
Configuring with InPower
This value is determined during initial arbitrations. 7
Visual 6-7 PCCNet setup with InPower
Participant’s Text
Notes:
There is one folder devoted for configuring PCCNet devices in InPower. Phase 1 of the PC 3.3 control will not communicated to the AUX 101/102 so InPower will only show setup for the HMI 113 and the other supported PCCNet devices. The Annunciator configuration process is exactly the same between PC 2.X and PC 3.X There is a ModBus annunciator for use in Paralleling Master Control systems. Some details about that annunciator will be covered in the ModBus lesson.
Participants’ Guide
Section6 Page9
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
PowerCommand Control 3300 PCCNET
Notes:
InPower allows you to configure some of the PCCNet device to launch a fault that will tell you if a device is no longer able to communicate on the network. You have the option to configure a device to ignore a device that is no longer communicating by leaving at the default Non-Critical Device Response, or you can set it to a Critical Device Response. If you have multiple HMI 320s in the system and only 1 fails its communications, the other HMI 320s will display a PCCNet failure alarm. The “PCCNet Device Failure Time Delay” is adjustable from 0 seconds to a maximum of 250 seconds. If the PCCNet system cannot re-establish communication to the device set to Critical Device Response by the end of this set time, a fault will be generated.
Participants’ Guide
Section6 Page10
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
HMI 113 Universal Annunciator
8
Visual 6-8 Universal Annunciator
Participant’s Text
Notes:
The PCCNet Annunciator has Network and Physical inputs.
REMEMBER! The annunciator only works with PCCNet or hard-wired installations, and cannot be used in a LonWorks based network.
This annunciator supports both Network wiring and discrete wiring terminals There can be up to four annunciators in a network. If their configuration modes are different, they will display different information. There is a Universal Annunciator Operator’s Manual available (900-0301) that covers installation and service topics, and there is a quick reference card (900-0304) that provides configuration notes.
Participants’ Guide
Section6 Page11
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
PCCNet HMI 113 Switch Settings Setup Mode Must be ENABLED to write changes to the PCCNet setup. Inputs at the Annunciator can be configured as faults to be displayed on the HMI 320 screen. Output relays at the Annunciator can be set up to actuate for any fault code originating from the PC 3.3 9
Visual 6-9 Annunciator Switch Settings
Participant’s Text
Notes:
InPower is used for changing PCCNet Annunciator Switch Settings and can only be changed when the device is communicating with the PCC Genset control Faults 1, 2, & 3 are fault inputs FROM the annunciator TO the PCC 3300 and displayed on the HMI 320.The text inserted into the Value box will be displayed when the input is active. The PC 3.3 can control four (4) output relays located on the Annunciator. Insert the genset fault/event code number you desire into the value area and when it becomes active at the control, the control will send a relay close command to the Annunciator.
Participants’ Guide
Section6 Page12
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
HMI 112 Bargraph
10
Visual 6-10 Vertical display Bargraph
Participant’s Text
Notes:
The HMI 112 is optional and in rare occasions, it may be encountered on a PC 3.3 system. It has previously been referred to as the Bar Graph display. The PCC 3300 is able to and does calculate Power Factor, therefore only the optional P/N 0300-6050-01 HMI112 version that has 9 bars is used. There are no setup parameters for this device in InPower or in the HMI 320 setup screens. The device is truly and completely Plug & Play
Participants’ Guide
Section6 Page13
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
HMI 114 Bargraph J6 2 1
J1
J1 5 4 3 2 1
J3 8 1
J6
J3
0300-6366-02 10
Visual 6-11 Configuring the Universal Annunciator
Participant’s Text
Notes:
The HMI 114 is a new bargraph and is an optional device. There are no setup parameters for this device as it is truly a plug & play device. The J3 connection on the back of the HMI 114 is the same as J29 connection of the HMI 320. If this jumper is in place between J3-4 & 5, it will keep the system awake at all times and will not allow it to go into power-down mode (Sleep).
Participants’ Guide
Section6 Page14
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
PCCNET Troubleshooting The HMI fault response type feature provides a way to deduce PCCNet communication problems. HMI display capabilities also allow checking of the network integrity.
12
Visual 6-12 Troubleshooting PCCNet systems.
Participant’s Text
Notes:
Troubleshooting PCCNet networks can be easy ---- if you want it to be! As mentioned previously, PCCNet is based on an EIA communication standard referred to as RS485. This standardized industrial protocol has been in use since the 1960s and is well understood in the electronics industry. There are many commercially available testing tools such as protocol analyzers, signal strength & interference testing equipment and media test equipment. If you are experienced with and/or have access to such tools, use them. If you are unfamiliar with such items, there is no need to invest in additional equipment beyond your usual PowerCommand troubleshooting equipment.
Participants’ Guide
Section6 Page15
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
PowerCommand Control 3300 PCCNET
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 is used on the PCC 3300 is actually a PCCNet system so if you are able to connect to the HMI or to TB15, then you know PCCNet is operational on those items. The most common and best tool available is your own ingenuity. Here are some suggestions that my help you reason and figure out the cause for a network problem:
Shut down power to the entire PCCNet Network. When power is restored, each of the devices will try to reestablish communication and “arbitrate”. If one or more of the devices was confused, it may begin working properly after cycling power.
Wire problems are the most common failure. Check continuity of each of the comm.. wires and check if B+ and B- is available at each of the modules.
If the wires check out ok, try disconnecting the device at the far end of the network. Keep doing this as you work your way back to the PCC 3300, or until the Network begins to work again.
Retrieve all the devices in the Network and bring them all close to the 3300 and connect them with very short sections of good wire and see if the system works. Start connecting each device 1 at a time to see if one causes the Network to fail. This technique also helps identify if there are problems with an environment that causes communication problems. This helps identify if the wire is incompatible with the installation, or if EMI noise is present.
Participants’ Guide
Section6 Page16
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
Check the wire installation throughout the facility. The communication wire should cross power lines/conduits or any AC power in a perpendicular fashion and should never be run parallel to a line carrying AC power.
Pay attention to the facility! Look around you.
PowerCommand Control 3300 PCCNET
Notes:
During troubleshooting, it is common for someone to assume the device they know the least about is the problem component. Resist this temptation. Check the things you know the most about and reach a conclusion about a failed component after a process of elimination trial. Sometimes a device will fail, but most importantly, do not ASSUME that the device failed – try to prove it! Look for a reason for it to fail too.
Participants’ Guide
Section6 Page17
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 PCCNET
Activities 6-1 6-2 6-3 6-4
Universal Annunciator Connections Configure Annunciator for Fault Inputs Configure Annunciator for Relay Outputs Quiz
13
Visual 6-13 Activities
Participant’s Text
Notes:
The Activity Guide for Section 6 PCCNet exercises is found in Section 15. At this time, please work as teams to complete these activities.
Participants’ Guide
Section6 Page18
PCC 3.3 & PowerCommand Control 3300 PCCNET
PowerCommand Control 3300
Wrap-Up In this lesson we have learned about the PCCNet network and devices used with the PCC 3300. This lesson gave us the opportunity to learn about the about installation of the PCC 3300 PCCNet communication system. We covered the connections that must be made from the genset 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?
Participants’ Guide
Section6 Page19
PCC 3.3 & PowerCommand Control 3300
Section last page
THIS PAGE IS INTENTIONALLY LEFT BLANK
Participants’ Guide
Section Last Page
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
PowerCommand 3.3 Section 7:PCC 3300 ModBus Communication
Visual 7-1 ModBus Communications
Participant’s Guide
Section 7 Page1
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
Section 7: ModBus and the PCC 3300. Estimated Time: 4 hours Equipment Needed
Materials Needed PowerCommand Control 3300 Participant’s Guide PC 3.3 SERIES MODBUS REGISTER MAP Appendix B – Using ModScan Software
(CMT6068-EN-PG) MANUAL 900-0670 (APPENDIX D) (CMT6068-EN-PG)
Computer: must meet system requirement to effectively operated InPower 7.0 or higher. InPower Connection Cable
Participant’s Guide
(P/N: 0541-1199)
Section 7 Page2
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
Warm Up In this lesson, we are going to look at the on board ModBus system that communicates information from the PowerCommand Control 3300. First, let us look at the objectives for this lesson: Objectives After completing this lesson, the participants should be able to:
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.
Participant’s Guide
Section 7 Page3
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
ModBus Overview ModBus is a industrial communication protocol system that is not controlled by or influenced by Cummins Power Generation. It is considered a “Open Protocol”
ModBus is not related to PowerCommand Networks or PCCNet.
ModBus operates using industry standards and in the case of Cummins Power Generation genset controls, it is usually used as a communication protocol that enables others to gain communication access to the generator set control. 2
Visual 7-2 ModBus overview
Participant’s Text
Notes:
ModBus is an open communication system available onboard the PCC 3300 ModBus was developed in the 1970’s as an industrial protocol to work with Modicon PLCs (Programmable Logic Control) Unlike PCCNet, ModBus does provide functional communication for monitoring or building management systems. The ModBus feature is well suited to support this. All of the content of the ModBus communication messages are predetermined and cannot be changed in the field. (The term message has a very specific meaning in ModBus, so from now on we will call these packets of info Registers.)
Participant’s Guide
Section 7 Page4
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
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 multiple
slave nodes. The PC1.X, 2.X & 3.3 controls are a Slave Node. A bus can accommodate 32 devices without repeaters, but up to a maximum of 247 slave nodes can exist on a large ModBus network bus. ModBus can communicate using many different physical media. The PCC 1302 uses EIA-485 (RS485) two-wire (2 wire) interface. ModBus can use two different serial transmission modes: RTU mode or ASCII mode. All ModBus transmissions are verified for CRC errors.
3
Visual 7-3 ModBus overview
Participant’s Text
Notes:
The PCC 3300 ModBus port is a serial port. It follows EIA standards and is configured for rs485: ModBus is comprised of multiple different transmission modes. The most common modes encountered on CPG systems are: RTU. (modern & most common) ASCII (considered old & rare and is not 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 slave device. The slave address can be assigned in the field.
Participant’s Guide
Section 7 Page5
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
PowerCommand Control 3300 ModBus
Notes:
In a master – slave system, the master device requests data from a particular slave device. This is called a poll. The register sent back from the slave device is called a response. The slave device does not send any data unless it is polled by the master. If the master device sends a command such as a engine start command the slave device will still send back a response acknowledging that it received the command 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 message is corrupted or damaged during its transmission. Sometimes this check is called a Check Sum. CRC errors do NOT indicate that a device is having trouble or is faulty; it indicates that the register created by the device is good at origination, but it is corrupt at the destination. Serial communication systems are very susceptible to electro-magnetic interference and other electronic noise, so it is not considered the best choice for installation into a power generation environment. Therefore the CRC error checking feature built into ModBus is very important. The PCC 3300 is not able to warn you of CRC errors, but the master device in the system will. Since the master device is usually the responsibility of a 3rd party, you will need to work with them to identify and resolve the problem.
Participant’s Guide
Section 7 Page6
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
TB15 Data / Service Interface Pin 5
Pin 1
4
Visual 7-4 ModBus Connection
Participant’s Text
Notes:
TB15 serves a dual function: •
When connected to InPower, it serves as a service port connection.
•
When connected to a ModBus master device and enabled, it will serve as a communication port connection.
TB15 can also transmit PCCNet, but the port has to be configured for one or the other, it CAN NOT serve both communication systems simultaneously. For wire connection details, refer to wiring diagram 0630-3440.
Participant’s Guide
Section 7 Page7
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
ModBus wire and PCC 3300 The ModBus network wire type and length is specified by ModBus 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 the integrator who is attaching to the control.
If installing the iWatch product to communicate with the PC 3.3, refer to the iWatch installation guide for information about the proper wire. 5
Visual 7-5 ModBus Cable
Participant’s Text
Notes:
Remember the previous statement about serial communications being susceptible to EMI and other noise. The type of communication cable used can affect communication reliability too. Designers of Building Management Systems (BMS) usually have a specification for the cable used in their system. It is rare that CPG installing technicians will be requested to supply the ModBus communication cable. If installing an iWatch to monitor a PCC 3300, try to keep the ModBus cable as short as possible or practical. Details of the installation will be found in the iWatch installation guide. A 120 Ω, ¼ watt terminator resistor is commonly installed in long bus applications to suppress signal reflections. Participant’s Guide
Section 7 Page8
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
ModBus Setup with InPower
6
Visual 7-6 InPower Configuration of the ModBus port
Participant’s Text
Notes:
There is a ModBus Setup folder located under the Setup folder of InPower. There are 8 adjustments found in the ModBus Setup folder along with 11 monitor functions, and 10 switch functions: Connect InPower using the normal 541-1199 tool connected to TB15. The Setup Mode Enable must be set to “Enable” for adjustments to take effect.
Participant’s Guide
Section 7 Page9
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
InPower – Setup - ModBus
Setup Mode must be ENABLED J14 and TB15 provide ModBus communications Setup functions specific to the J14 connection are labeled 7
Visual 7-7 InPower Configuration of the ModBus port
Participant’s Text
Notes:
Refer to section 5-57, “ModBus Setup” of the Service Manual #900-0670. On page 5-58, all the ModBus submenus are presented. There are setting for the TB15 connector and there are adjustments for the J14 connector. Many of the adjustment parameters have a drop box in the value field; a few allow direct entry of a value.
Participant’s Guide
Section 7 Page10
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
PowerCommand Control 3300 ModBus
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 a different address than the TB15 address. Recall that a ModBus network may contain up to 247 nodes. The node address identifies 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 must be set at to communicate in the Network. The ModBus Parity setting changes the register structure per the requirements of the network design. The default is Even. The Parity adjustment for TB15 can be set differently than the Parity adjustment for J14. ModBus Failure Time Delay can trigger fault 2939 – ModBus Failure if the Master response time exceeds the set amount of time. The ModBus Communications Lost Response Method can be set to reset in case there is a 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 CPG installer.
Participant’s Guide
Section 7 Page11
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
InPower - Monitor - ModBus Monitor Points
Monitor Points
8
Visual 7-8 ModBus Monitor
Participant’s Text
Trainers Text
Refer to section 5-57, “ModBus Setup” of the Service Manual #900-0670. On page 5-58, all the ModBus submenus are presented. The visual shows the monitor points. The appropriate setup values will be determined by the system integrator, or they will be called out by the appropriate installation guide provided with the CPG communication kit.
Participant’s Guide
Section 7 Page12
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
PowerCommand Control 3300 ModBus
Trainers Text
InPower Of course, it is not possible to monitor a communicating ModBus network with InPower since the TB-15 port is used for ModBus communication and for connection to InPower. The data displayed in the Monitor screens is recorded data.
Bus Message Count – this is the number of times that the PCC 3300 has been polled by the Master. Slave Message Count – this is the number of times the PCC 3300 has responded to polls. No Response Count – this is the number of times the PCC 3300 HAS NOT been able to respond. CRC Error Count – this is the number of times the network has seen a faulty register. Exception Count – this is the number of times the system has seen a corrected version of a faulty register.
CRC errors are encountered when a register is sent correctly, but the receiving device views it and finds errors in it. The receiving device will automatically request that the register be sent again. This error count is very valuable to you if you are troubleshooting ModBus communications. It indicates that the devices are trying to send or receive messages, but someplace along the transmission stream, the register is being damaged. Start inspecting the wiring and connections. The problem could be caused by poor quality or inadequate wire, poor connections, or environmental issues such as electromagnetic interference.
Participant’s Guide
Section 7 Page13
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
ModBus Settings The ModBus adjustments and settings are also accessible through the HMI 320.
9
Visual 7-9 HMI
Participant’s Text
Trainers Text
Refer to section 5-57, “ModBus Setup” of the Service Manual #900-0670. On page 5-58, all the ModBus submenus are presented. The visual shows the HMI screen layout.
Participant’s Guide
Section 7 Page14
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
ModBus Testing & Troubleshooting ModBus Register Map – Provided by CPG ModScan – Available as freeware InPower – Has some minor test capability.
10
Visual 7-10 Testing ModBus systems.
Participant’s Text
Notes:
The ModBus register map is available from CPG. A copy is attached to the Service Manual, and is found in Appendix D. ModScan is 3rd party software that can be used to prove to customers that the ModBus port is operational. InPower can be used to assist with troubleshooting a ModBus installation that may not be communicating reliably.
Participant’s Guide
Section 7 Page15
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
ModBus Register Map NFPA110 bitmap (Register 40016) NFPA 110 Description Common Alarm Genset Supplying Load Genset Running Not in Auto High Battery Voltage Low Battery Voltage Charger AC Failure Fail to Start Low Coolant Temperature Pre–High Engine Temperature High Engine Temperature Pre–Low Oil Pressure Low Oil Pressure Overspeed Low Coolant Level Low Fuel Level
11
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Bit (MSB)
(LSB)
MSB = Most Significant Bit LSG = Least Significant Bit
Visual 7-11 ModBus Register Map
Participant’s Text
Notes:
Register maps are specific to the product. The register map for a PCC 3300 control is the same as the map for the PCC 2300 control. Other generator sets and systems may use different maps, be sure you are referencing the proper map. The map provides details about the different types of individual registers. It can tell you the many details about how to poll it, calibration details about a specific register, or the combinations of information contained within a particular register.
Participant’s Guide
Section 7 Page16
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
ModScan testing Register Type
Slave address
ModScan requests to communicate Device responses to ModScan requests
Register address to begin polling
Number of registers to be polled ModBus register and the data communicated from the device 12
Visual 7-12 ModScan Software
Participant’s Text
Notes:
ModScan is not a Cummins product. It is available as freeware from WinTech via Web download or through several other free sources. The free version limits connection time to an active ModBus network to 3 minutes, and then it stops polling. A code to enable unlimited connection time is available for purchase from WinTech. CPG encourages the use of ModScan as a testing tool to prove to customers and integrators that the ModBus port is communicating properly. There are other software products that can be used too, but ModScan is considered a simple to use.
Participant’s Guide
Section 7 Page17
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
PowerCommand Control 3300 ModBus
Notes:
ModScan Software. Once connected, ModScan will poll registers and will allow write registers. Write registers will send a command to the generator set. A common command is to START the genset. The genset must be in Auto for the command to take effect. It is a simple process to configure ModScan to communicate with PCC 3300, but if you need assistance with proper setup and operation, refer to the details found in Appendix B The standard InPower communication cable from the computer com port to the PCC 3300 TB-15 port can be used. The RS232/RS485 converter must be used too. Refer to the ModBus register map to help you identify the register that you may wish to poll. The 2 most common register types to check are: 1. Coil Status – this is an on/off statue indication. 1=ON & 0=OFF 2. Holding Register – this indicates a message indicating up to 16 bits of information. Example in visual 7-9 shows register #40016. It will appear {0000000000000000} A common test is to “Write” bit “1” to register 40300, the genset should start if the control is in automatic mode. (Remote) Register 40302 can activate the Emergency Stop. If this is activated via ModBus, you cannot reset the shutdown at the genset control until the ModBus command is set to 0.
Participant’s Guide
Section 7 Page18
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
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 the device but it is not getting proper responses. 13
Visual 7-13 ModScan software
Participant’s Text
Notes:
Refer to the Appendix about operating ModScan.
.
Notice the message line in Visual 11 and in Visual 12. The line in Visual 11 indicates that ModScan is not able to communicate to anything, but the line in Visual 12 indicates that ModScan is talking to a device but the information is not understandable. Try to keep the length requests as short as possible, and do not attempt to poll across empty registers.
Participant’s Guide
Section 7 Page19
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
Quiz & Activities 7-1 7-2 7-3 7-4
Quiz (found in section 15) Connect InPower and Configure Configure at the HMI Connect with ModScan (optional)
14
Visual 7-14 Activities
Participant’s Text
Notes:
Find the Section 7 activities in the Section 15. Work with partners to complete each activity.
Participant’s Guide
Section 7 Page20
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
Wrap-Up In this lesson we have learned about the ModBus communication system and the ModBus feature built into the PCC 3300. First we talked about the basics of ModBus communications and some of the specific information about how the system works. Next we talked about ModBus connection requirement on the PCC 3300, its connectors and wire information. 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 that required 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 this communication feature on the PCC 3300. This section is a basic introduction to ModBus communications with PCC control and communication systems. We will continue delving deeper into ModBus communications with more advanced controls. This section serves as a prerequisite for 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?
Participant’s Guide
Section 7 Page21
PCC 3.3 & PowerCommand Control 3300
PowerCommand Control 3300 ModBus
THIS PAGE IS INTENTIONALLY LEFT BLANK
Participant’s Guide
Section 7 Page22
PCC 3.3 & PowerCommand Control 3300
PGI
PowerCommand 3.3 Section 8: PGI CAN Communication
Visual 8-1 PGI CAN Communications
Participants’ Guide
Section 8 Page 1
PCC 3.3 & PowerCommand Control 3300
PGI
Section 8 PowerCommand Control 3300 & PGI Estimated Time: 4 hours Materials Needed
•
PowerCommand Control 3300Participant’s Guide
•
PC with InPower v7.0 or higher installed
•
Registered Dongle
•
InPower Connection Cable
•
INSITE v7.1 or higher installed
•
Peak System Adapter and associated software/drivers installed
•
Inline Adapter Kit w/Software and Drivers Installed
Participants’ Guide
Guide (CMT6068-EN-PG)
Kit #541-1199
Section 8 Page 2
PCC 3.3 & PowerCommand Control 3300
PGI
Warm Up In this lesson we are going to learn about the Power Generation Interface (PGI) for the PowerCommandControl 3300. First, let’s look at the objectives for this lesson: 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.
Participants’ Guide
Section 8 Page 3
PCC 3.3 & PowerCommand Control 3300
PGI
What Is PGI? 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 new interface is referred to as the Power Generation Interface (PGI)
2
Visual 8-2 What is PGI?
Participant’s Text
Notes:
The Power Generation Interface (PGI) Specification is intended to drive commonality in the On-Engine Controls (diesel and gas) across the entire CPG product line. Two of the main areas that make up PGI are: • •
Physical Datalink Electrical Datalink
Datalinks are a way to communicate information between systems. CPG uses Multiplexing Datalinks to send or receive multiple messages among electronic modules using a serial bus.
Participants’ Guide
Section 8 Page 4
PCC 3.3 & PowerCommand Control 3300
PGI
Past Control Product PCC3200 (1 Box) PCC3201 (1 Box & 2Box) PCC2100 (1 Box & 2 Box) PCC1301 (1Box)
AVR
GCS
With PGI
FAE / Mech. Engine
Alternator CMYYY
Alternator
W/o PGI
OEM Control
OEM Control w/ CAN
GCS
OEM Control
CMxxx
FAE / Mech. Engine G-Drive OEM
FAE / Mech. Engine No GCS !!!
3
Visual 8-3 PGI Architecture
Participant’s Text
Notes:
In Visual 8-3 you see a graphic representation of how the past product lines operate (PCC 2100, 3200, 3201, and 1301). They operate by direct engine control or with the use of a Genset Controller (GCS). PCC 3300 can communicate directly with a Cummins Engine Controller Module (ECM) using PGI or to other engine manufacturers ECM using CAN standards. This training covers PGI basics and communication to Cummins engines.
Participants’ Guide
AVR
CMxxx
FAE / Mech. Engine CMxxx
PCC3300 w/ CAN PCC2300 w/ CAN PCC1302 w/ CAN
Section 8 Page 5
Interface CAN/J1939
CMxxx CMYYY
Corporate Genset
PCC 1.x, 2.x and 3.x Product
PCC 3.3 & PowerCommand Control 3300
PGI
Required Hardware/Software Inline 4/5 Datalink Adapter (note: Inline 2 will work with CPG products and you do not need to install drivers with this product) - 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
4
Visual 8-4 Hardware/Software
Participant’s Text
Trainer’s Guide
In order to view/change parameters and perform certain tests, technicians will need InPower, INSITE, and Inline software/hardware/drivers in order to connect to the engine ECM and PCC 3300 control. An easy and cost effective way to view signals and perform simple troubleshooting tasks is to use the Peak System Adapter. While the Peak Sys Adapter does not allow you to perform calibrations, it is an easy tool to operate and see if the system ECM and PCC are communicating properly.
Participants’ Guide
Section 8 Page 6
PCC 3.3 & PowerCommand Control 3300
PGI
INSITETM - Monitor & adjust parameters and features
5
Visual 8-5 INSITE
Participant’s Text
Notes:
INSITE is an engine tool that allows technicians to perform a variety of engine diagnostic checks as well as calibrations and adjustments. With the introduction of the PGI, PowerGen technicians are needed to understand this tool for troubleshooting as well as setup of the engine. With the increased usage of ECM operated engines for emissions standards, technicians should attend a course on INSITE to gain more familiarity than this course will offer. You can get INSITE information from: insite.cummins.com
Participants’ Guide
Section 8 Page 7
PCC 3.3 & PowerCommand Control 3300
PGI
INPOWERTM – Adjustments
6
Visual 8-6 InPower
Participant’s Text
Notes:
With InPower you are able to click on the CORE II ECS icon and perform a variety of different tests on the system. You cannot perform these tests while connected to the controller and you must be connected to the engine harness 9-pin Deutsch plug. Most notably you are able to perform the Witness Testing Procedures as seen in the Installation Section of this guide.
Participants’ Guide
Section 8 Page 8
PCC 3.3 & PowerCommand Control 3300
PGI
Peak System Adapter
7
Visual 8-7 Peak System Adapter
Participant’s Text
Notes:
The Peak System Adapter allows technicians to view CAN messages broadcasted on the 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)
Participants’ Guide
Section 8 Page 9
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
PGI
Notes:
You can purchase the Peak Adapter from the Cummins Hardware Shelf or from www.gridconnect.com/usbcanin.html Not only will you need to order the adapter itself, but you will need to buy an inline CAN terminator. You will also need a CAN cable that allows you to connect from the 9-pin plug on your Peak System Adapter to the 3-pin Deutsch connector on the genset. After you have all of the required hardware, you will need to download the software and associated drivers. Drivers to operate the Peak System Adapter can be ordered from the Cummins Software Shelf. You will need to order these software tools: •
Peak All In One Driver
•
PCAN Explorer (optional)
Once you have the hardware and software installed, you can connect to a device and read the messages. The software will have a default baud rate of 500Kbit/sec. This needs to be changed to 250Kbit/sec in order to communicate with the PGI system. You do not need the engine running to see messages transmitted on the system. Once you have the Peak System Adapter setup properly you will be able to connect and read the messages sent. This tool provides an easy way to help determine whether the ECM (s), PCC, or backbone is faulty.
Participants’ Guide
Section 8 Page 10
PCC 3.3 & PowerCommand Control 3300
PGI
Physical Datalink J1939 Datalink Connector 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 J1939 support (no battery voltage supply)
Pin
Signal
A
J1939 Datalink (+)
B
J1939 Datalink (-)
C
J1939 Datalink (Shield)
8
Visual 8-8 J1939 Connector
Participant’s Text
Notes:
The first portion of PGI we will cover is the PHYSICAL datalink. There are three main parts of the physical datalink: Backbone, Plugs, and Stubs. The Backbone consists of a three-wire system that has a high, low and a shield wire. In visual 8-5 above you can see the pinout of this system. There are two different types of Plugs that are used on this system. The first is the plug that has orange keys inserted into the Deutsch connector. The second is a termination plug. This is verified by a blue key and is capped with a 120ohm resistor receptacle.
Participants’ Guide
Section 8 Page 11
PCC 3.3 & PowerCommand Control 3300
PGI
Basic J1939 Backbone and Stub Configuration
9
Visual 8-9 J1939 Backbone
Participant’s Text
Notes:
The total length of the backbone is not to exceed 40m (approx 131 ft) in length. This is a J1939 SAE standard requirement. The Stubs are depicted in Visual 8-6. These stubs need to be kept to 1m (approx 3 ft) in length. There are a maximum of 30 different devices that can be installed on the backbone at once. To minimize message reflections (echo) on the data link, a 120ohm terminating resistor is needed at each end of the backbone.
Participants’ Guide
Section 8 Page 12
PCC 3.3 & PowerCommand Control 3300
PGI
Extending length of J1939 backbone
10
Visual 8-10 Extending J1939
Participant’s Text
Notes:
If you need to extend the length of the backbone, you can do so by removing the terminating resistor on the end you wish to extend, add the required length of backbone (remember this extension plus the original backbone can not exceed 40 meters in length) and reinstall the terminating resistor at the end of the extended piece. As an example, you may want to extend the backbone if you are removing the controller pedestal from the genset and mount it elsewhere.
Participants’ Guide
Section 8 Page 13
PCC 3.3 & PowerCommand Control 3300
PGI
J1939 Topology Coolant Level Switch
Fuel/Water Separator
11
Visual 8-11 J1939 Typology
Participant’s Text Visual 8-8 shows a typical J1939 topology. You can see that some of the stubs are going to such devices as the Fuel/Water Separator and Coolant Level Switch.
You must also connect shield at each device. Notes:
All stubs that are unused must have receptacles installed on them. Ensure you ground the shield at one point only.
Participants’ Guide
Section 8 Page 14
PCC 3.3 & PowerCommand Control 3300
PGI
Harness Block Diagram Engine Harness Coolant level 4-pin connector (Plug)
Genset Harness
3-pin J1939 connector with 120 Ohm resistor 16-pin power connector (Receptacle)
60-pin engine 50-pin OEM connector connector
16-pin power connector (Plug)
Controller harness ‘Y-pin’ connector
PCC Harness Engine harness connector
PCC Board
ECM power
ECM 9-pin service connector
J1939 3-pin connector (Plug)
Pedestal
J1939 3-pin connector (Receptacle)
3-pin J1939 connector with 120 Ohm resistor
Starter relay
Extension Harness
Alternator
HMI Battery
‘X-pin’ Connector to mate with extension harness
12
Visual 8-12 Harness Block Diagram
Participant’s Text
Notes:
Visual 8-9 show the different components and connections made on a genset. It is broken down into the Engine Harness, Genset Harness and PCC Harness.
Participants’ Guide
Section 8 Page 15
PCC 3.3 & PowerCommand Control 3300
PGI
9-Pin Deutsch Pin
ID
A
Datalink Return
B
Datalink Power
C
J1939 Datalink (+)
D
J1939 Datalink (-)
E
Datalink Shield
F
Unconnected
G
Unconnected
Service connector
H
Unconnected
9-pin Receptacle Cummins P/N: 3163295
J
Unconnected
Deutsch HD10-9-1939P Location: Engine Harness
13
Visual 8-13 9-Pin Deutsch
Participant’s Text
Notes:
The 9-pin Deutsch connector is where you will connect with your Inline adapter kit. It is also a location where you can perform some testing of the system. Pins A and B should have battery voltage present. Battery voltage present at this connector is needed to power-up your Inline adapter.
Participants’ Guide
Section 8 Page 16
PCC 3.3 & PowerCommand Control 3300
PGI
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 communicating 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.
14
Visual 8-14 Troubleshooting Datalinks
Participant’s Text
Notes:
This is a simple chart to follow in order to check the physical datalink. If you are having communication errors these are good points to start with the troubleshooting process.
Keyswitch should be cycled every time there is an engine shutdown in order to save important ECM data (Ex: fault codes, ECM run time etc.). Wait 30 secs or more before engine restart.
There are NO Fault Acknowledge inputs to the ECM to reset active faults. The ECM will broadcast an active fault as long as the condition is true.
Participants’ Guide
Section 8 Page 17
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
You can remove one terminating resistor and you should be able to see the other resistor of 120 ohms. You can replace that terminating resistor and remove the other one to check for 120 ohms on that resistor.
While both terminating resistors are installed, remove J11 from base board. Check resistance between J11-19 and J1120. Resistance should be approximately 60 ohms if the backbone is ok. If you have less than 55 or more than 65 ohms there is a potential problem with an open or ground on the datalink.
PGI
Notes:
Here are some rules to apply for an open or shorted CAN circuit. CAN_H is Shorted to VBat - Data communication is not possible if VBat is greater than the maximum allowed common mode bus voltage. CAN_L is Shorted to GND - Data communication is possible, because the bus voltages are within the allowed common mode voltage range. Signal-tonoise ratio is reduced and radiation is increased. The electromagnetic immunity is decreased. CAN_H is Shorted to GND - Data communication is not possible. CAN_L is Shorted to VBat - Data communication is not possible. CAN_H is Shorted to CAN_L - Data communication is not possible. Loss of Termination Resistor - Data communication via the bus may be possible, but with reduced signal-to-noise ratio.
Participants’ Guide
Section 8 Page 18
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
PGI
Notes:
Loss of Termination Resistor - Data communication via the bus may be possible, but with reduced signal-to-noise ratio. Topology Parameter Violations (i.e., Bus Length, Cable Stub Length, Node Distribution) - Data communication via the bus may be possible, but with reduced signal-to-noise ratio
Participants’ Guide
Section 8 Page 19
PCC 3.3 & PowerCommand Control 3300
PGI
CM850 – QSB5/7, QSL9, J3 QSK19/38/50/60 J1 J2 J1
15
Connector Function
Connector Type
Connector Name
Engine
60 Pin
J1
OEM
50 Pin P/N 3163071
J2
Battery Power
4 Pin P/N 3165121
J3
* Please Refer to the appropriate Harness Wiring Diagram for Pinouts of J1, J2, and J3
J2
J3 Note: J3 only required for QSB 5/7 and QSL 9
Visual 8-15 CM850 ECM
Participant’s Text
Notes:
The CM850 is one of the basic ECM’s that you will see on our gensets. The ECM will: •
Perform all Engine Protection with the exception of Low Coolant Level & Low Coolant 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 Idle from rated speed
Participants’ Guide
Section 8 Page 20
PCC 3.3 & PowerCommand Control 3300
PGI
CM876 – QSM11 T3
Connector Function
Connector Type
Connector Name
Engine
60 Pin
J1
OEM
50 Pin P/N 3163071
J2
Battery Power
4 Pin P/N 3165121
J3
16
Visual 8-16 CM876 ECM
Participant’s Text
Notes:
The CM876 is another one of the basic ECM’s that you will see on our gensets. It consists of three connectors. It is very similar to the CM850, with the exception of the keyways on the connectors. You will see the CM210 and CM2250 in the future. These ECM’s will have similar physical characteristics.
Participants’ Guide
Section 8 Page 21
PCC 3.3 & PowerCommand Control 3300
PGI
Electrical Datalink 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.
Shield
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.
17
Visual 8-17 J1939 Messages
Participant’s Text
Notes:
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 with some advanced troubleshooting, but it is being mentioned here to illustrate that common electronics tools can be used to help identify problems. This is not a recommended check.
Participants’ Guide
Section 8 Page 22
PCC 3.3 & PowerCommand Control 3300
PGI
Signals Nominal Values 0
1
J1939 high
2.5 v
3.5v
J1939 low
2.5 v
1.5v
V differential
0v
2v
Since the messages are sent by a voltage differential, it is
essential 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 voltage differential to another. Hence messages get corrupted and communication is lost.
18
Visual 8-18 J1939 Voltages
Participant’s Text
Notes:
The properties of the J1939 datalink message are broken down into bits. A “bit” takes, at most, 0.0000002secs to travel down a 40m datalink. And an entire message (110bits) takes 0.00044secs to be transmitted. That’s a possible 2000 messages per second. If two devices attempt to broadcast at the same time, the message with the highest priority wins and the other device “waits”.
Participants’ Guide
Section 8 Page 23
PCC 3.3 & PowerCommand Control 3300
PGI
Activities 8-1 PGI Written Quiz
19
Visual 8-19 Activities
Participant’s Guide
Trainer’s Guide
Find the Section 8 Quiz in Section 15. Work with partners to complete each activity.
Participants’ Guide
Section 8 Page 24
PCC 3.3 & PowerCommand Control 3300
PGI
Wrap-Up In this lesson we introduced the Power Generation Interface (PGI) usage with the PCC 3300 for FAE engines. We covered the basics of what constitutes a PGI system, associated hardware and software, 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.
Participants’ Guide
Section 8 Page 25
PCC 3.3 & PowerCommand Control 3300
PGI
THIS PAGE IS INTENTIONALLY LEFT BLANK
Participants’ Guide
Section 8 Page 26
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
PowerCommand 3.3 Section 9: Paralleling Introduction
Visual 9-1
Participants’ Guide
Section 9 Page1
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
Section 9 PPC 3.3 Paralleling Introduction Estimated Time: 1.5 hours
Materials Needed
Wiring Diagram 0630-3440 (A007M115 D)
PowerCommand Control 3300 Participant’s Guide
PC 3.3 Controller Service Manual
Participants’ Guide
Sheets 1 to 18 or diagrams in 900-0670 Guide (CMT6068-EN-PG) #900-0670
Section 9 Page2
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
Warm Up In this lesson we will introduce connections and operation options that can be used with the PC 3.3 in a paralleling environment. This lesson will not delve into the operation and setup for each of the paralleling modes, but it will introduce the paralleling abilities of this control. Objectives After completing this lesson, the participants should be able to: •
Understand the different paralleling setups and modes available in the PowerCommand Control 3300.
•
Find and understand the paralleling configuration information in the service manual, InPower and the HMI320.
Participants’ Guide
Section 9 Page3
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
What is Paralleling? Paralleling is the synchronous operation of two or more generator sets connected to a common bus in order to provide power to a common load
kW Demanded by Load kVar Demanded by Load
Engines Produce kW Alternators Make kVAR 2
Visual 9-2 What is paralleling.
Participant’s Text
Notes:
The Power Command 3.3 control provides paralleling functionality for several modes of parallel operation. Parallel operation is not a new or unique feature. It has been offered with many of the predecessors to the PCC3300, however: this control provides any desired mode of paralleling operation as standard. The control is fully configurable in the field AT WILL. You no longer have to contact the factory and purchase new codes or added features. They are all here.
Participants’ Guide
Section 9 Page4
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
PC 3.3 Paralleling Modes
Standalone Synchronization Droop Load Share Load Govern Power Transfer Control
3
Visual 9-3 Paralleling Modes
Participant’s Text
Notes:
Standalone: Standalone mode is more like a non paralleling control configuration. There are a couple of added features that make this configuration more desirable than just using a PC2.X control. Synchronization: This is a mode designed to allow the genset to match frequency and voltage with another source. In some modes of this operation the PCC does not control connection to the source and in some modes the PCC is in full control of all connection functions.
Participants’ Guide
Section 9 Page5
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
Paralleling Introduction
Notes:
Sync. Cont: Synchronization is utilized in all the different paralleling modes beyond the Standalone mode. Droop: Droop is an adjustable feature that can be turned on as the application requires. The unit is able to operate in speed droop, and/or voltage droop. Load Share: In Load Share, the PCC is in parallel with other gensets while isolated from the utility. The PCC adjusts the speed reference and the voltage set point so that the genset takes its fair share of the load. The genset should run at the same percentage of its rated load at which other gensets run. Load Govern: In Load Govern, the PCC is in parallel with the utility. Since the utility frequency and voltage are fixed, the PCC regulates the genset kW output and genset kVAR output, instead of the genset frequency and genset voltage. Power Transfer Control: Power Transfer Control (PTC) is a feature that will be available during the Phase 2 launch. This feature allows the PCC to act as the transferswitch control in addition to acting as the genset control.
Participants’ Guide
Section 9 Page6
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
PC 3.3 Modes of Paralleling
4
Visual 9-4 Modes of PowerCommand Control 3300 Paralleling
Participant’s Text
Notes:
Modes are a set of operating configurations that 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, and operation become progressively more complex. The following training guide sections will discuss each mode in detail.
Participants’ Guide
Section 9 Page7
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
Paralleling Connector Location Bus CT Inputs
TB7- Bus Voltage
TB3 - Customer I/O
TB9- Analog I/O
TB10- Circuit Breaker Status
TB1 – Customer I/O
TB8- Customer I/O
TB5- Circuit Breaker Control
5
Visual 9-5 Control Board Connections
Participant’s Text
Notes:
The previous sections only introduced the function of each of these connectors. All of these connectors are reserved for customer or site connections. You may encounter some factory connections on a couple of these connectors, but they are only for options or accessories ordered with the generator set. Each connector listed on this visual will be discussed in the section which uses a connection on it.
Participants’ Guide
Section 9 Page8
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
Wire diagram Connections
6
Visual 9-6 Common Connection for paralleling
Participant’s Text
Notes:
The common connector scheme wire diagram provides connection information for each of the paralleling modes. Beginning on page 12 the Common Connector Diagram changes focus from showing genset connection to showing the paralleling connections. Page 18 is devoted to showing a table of optional inputs, outputs and configuration available on connectors TB3, TB9, and TB10. Dotted lines on these diagrams represent optional connections for the mode of operation
Participants’ Guide
Section 9 Page9
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
InPower Configuration Status screens Monitor the functions (OEM Setup - Paralleling Not available in Phase 1)
Setup screens provide complete configuration and adjustment for all paralleling functions.
7
Visual 9-7 InPower
Participant’s Text
Notes:
In previous sections we have covered setup functions for the genset only. InPower also has configuration abilities for all the paralleling functions. InPower has a large section for monitoring the 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 setup functions in later releases.
Participants’ Guide
Section 9 Page10
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
HMI Paralleling Setup Menus
Any Paralleling operation setup function available in InPower is also available through the HMI. Most HMI operation setup function require the Level Password.
8
Visual 9-8 HMI Setup
Participant’s Text
Notes:
The HMI will allow complete configuration of the paralleling setups. Just like with InPower, the first phase release will not support OEM Setup of the paralleling functions. There are 6 setup screens available in the Paralleling Basic Setup menu.
Participants’ Guide
Section 9 Page11
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
Parallel Intro Activities Section 9: In-Class Quiz
7
Visual 9-9 Quiz for Section 9
Participant’s Text
Notes:
At this time I would like you to work alone to complete the quiz.
Participants’ Guide
Section 9 Page12
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
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?
Participants’ Guide
Section 9 Page13
PCC 3.3 & PowerCommand Control 3300
Paralleling Introduction
THIS PAGE IS INTENTIONALLY LEFT BLANK
Participants’ Guide
Section 9 Page14
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
PowerCommand 3.3 Section 10: Standalone Mode
Visual 10-1
Participants’ Guide
Section 10 Page1
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
Section 10 PPC 3.3 Standalone Mode Estimated Time: 1.5 hours
Materials Needed
Wiring Diagram 0630-3440 (A007M115 D)
PowerCommand Control 3300 Participant’s Guide
PC 3.3 Controller Service Manual
Participants’ Guide
Sheets 1 to 18 or diagrams in 900-0670 Guide (CMT6068-EN-PG) #900-0670
Section 10 Page2
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
Warm Up In this lesson we will cover the Standalone mode operation. We will experience the setup process and configuration of the control in addition to the physical connections that can be used with the PC 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. After completing this lesson, the participants should be able to: •
Understand the reason for operating the PC 3.3 in Standalone mode.
•
Find and understand the configuration information in the service manual, InPower and the HMI320.
Participants’ Guide
Section 10 Page3
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
Is Standalone Paralleling? Standalone is a mode that does not parallel, it does not synchronize with any other genset or system.
In Standalone the PCC does not control a breaker for connection or disconnect from load, but can provide a breaker trip signal, and it can monitor breaker position. kW Demanded by Load kVar Demanded by Load
In Standalone mode operation, a single generator set is connected to a bus in order to provide power to a common load. 2
Visual 10-2 What is Standalone paralleling.
Participant’s Text
Notes:
Standalone is a mode of operation that allows the generator set to be used in a single power supply situation and still provide some added feature for monitoring and protecting the genset AND the installation. In Standalone mode the power capacity of the power system is regulated by the capacity of the single generator set and it alone is responsible for maintaining voltage and frequency. In paralleling systems, all of the units in the system contribute and share this function.
Participants’ Guide
Section 10 Page4
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
Wire diagram Connections
3
Visual 10-3 Common Connector diagram
Participant’s Text
Notes:
Standalone: There are few connections to the PCC 3300 in the Standalone mode. The dotted lines designate the connection is optional. IMPORTANT! The information bullets found on the diagram provides valuable information. Read them!
Participants’ Guide
Section 10 Page5
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
Notes:
Participant’s Text The above bullet describes operating features that are affected by the connection of the breaker information and control.
The genset is not able to read 3 phase bus current when configured for Standalone mode. It is able to monitor the Neutral current but not for any protective purpose such as the noted Ground Fault.
. Greater detail about the bullet references can be found in Service Manual 900-0670 Section 4 and Section 2.
Participants’ Guide
Section 10 Page6
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
InPower Modes of Paralleling
Genset Application Type Setup – Modes of Operation 4
Visual 10-4 InPower
Participant’s Text
Notes:
InPower has a specific folder (Paralleling Setup) devoted to the setup and configuration of the paralleling features. No more hunting and searching for different folders for individual setup features. . This visual highlights the specific adjustment for placing the control into any one of the various modes of paralleling. Unlike previous controls were customers were charged for different levels of paralleling capability, this control provides all the levels for one basic price.
Participants’ Guide
Section 10 Page7
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
HMI320 Paralleling Setup
The HMI paralleling setup functions are the same with InPower. This screen shows the Genset Application Type is set to Isolated Bus. Use the proper password code to change the type. 5
Visual 10-5 HMI Setup
Participant’s Text
Notes:
InPower is an easy tool for configuring the control, but the HMI has all the setup features built in too. There will be many situations when it will be more convenient to make adjustments and changes from the HMI then to try and connect 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 HMI Basic Setup screen. To change the Gen App Type, use the Level 1 or Level 2password.
Participants’ Guide
Section 10 Page8
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
Paralleling Connector Use in Standalone Mode Bus CT #2
TB10- Circuit Breaker Status
TB5- Circuit Breaker Control 6
Visual 10-6 Connector
Participant’s Text
Notes:
There are 3 connections used in Standalone Mode for providing input/output and monitoring functions. Important!: Only CT #2 is used for Standalone mode. It is polarity sensitive and limited to a maximum of 5 amp passthrough.
Participants’ Guide
Section 10 Page9
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
Bus CT Connections
CT2
Optional: Only Provides Metering of Neutral Current
7
Visual 10-7 Bus Connection
Participant’s Text
Notes:
Only CT #2 is used in Standalone mode and it can only be used to monitor bus Neutral Current. Remember, this control can be used in a single phase application and Delta configuration too. Even in these applications, neutral current is all this CT should be employed to monitor. Input is limited to a standard 0 to 5 amp CT output. The tables in section 2 of service manual provide information about setting and calibrating this input. Shorting blocks or some sort of shorting system must be used to protect the CT.
Participants’ Guide
Section 10 Page10
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
TB5 Circuit Breaker Control
M
B+
B+ Return
8
Visual 10-8 Breaker connection
Participant’s Text
Notes:
TB5 provides the hookup points to control breakers. Standalone mode supports only 1 contact point on this connector. Pins 1 and 2 provide limited output to drive a breaker open or shunt trip command. It is very important to know the inrush coil specifications of the breaker shunt trip or motor. If you suspect the 5A, 30VDC inductive loading will exceed 7 milliseconds, use a pilot relay.
DO NOT overload this driver, overloading may lead to and require board replacement.
Participants’ Guide
Section 10 Page11
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
TB10 Breaker Status Connections In Standalone Mode, Breaker tripped connections are optional. Pin 10
Pin 2
CB Tripped Status: TB10 - 10
Return: TB10 - 2
9
Visual 10-9 Breaker status Participant’s Text
Notes:
This is Customer Input #27 so an excellent time to learn about the FUNCTION POINTER setup in InPower. In the SETUP folder – Configurable I/O you find dozens of configurable settings If you scroll down the list, at approximately the 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 the conditions that can be used to close this contact. This will trip fault code 1454.
Participants’ Guide
Section 10 Page12
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
Standalone Mode Activities Section 10: In-Class Quiz
10
Visual 10-10 Quiz for Section 10
Participant’s Text
Notes:
At this time I would like you to complete the quiz. The Quiz is found in Section 15.
Participants’ Guide
Section 10 Page13
PCC 3.3 & PowerCommand Control 3300
Standalone Mode
Wrap-Up In this lesson, we have learned about installation of the PCC 3300 genset control and important 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 each individual connector and the connections available from the control to the genset components and why each is important. Q. Are there any questions we have not yet covered about installation of the PCC 3300?
Participants’ Guide
Section 10 Page14
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
PowerCommand 3.3 Section 11: Synchronizer Only Mode
Visual 11-1
Participants’ Guide
Section 11 Page1
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
Section 11 PPC 3.3 Synchronize Only Mode Estimated Time: 1.5 hours Equipment Needed
Materials Needed
Wiring Diagram 0630-3440 (A007M115 D)
PowerCommand Control 3300 Participant’s Guide
PC 3.3 Controller Service Manual
Participants’ Guide
Sheets 1 to 18 or diagrams in 900-0670 Guide (CMT6068-EN-PG) #900-0670
Section 11 Page2
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
Warm Up Differences and similarities between Standalone mode operation and Synchronize Only will be covered in this lesson. We will experience the setup process and configuration of the control in addition 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. After completing this lesson, the participants should be able to: •
Understand the reason for operating the PC 3.3 in Synchronize Only mode.
•
Find and understand the configuration information in the service manual, InPower and the HMI320.
•
Execute a control setup and configuration for a genset or simulator to operate in this mode.
Participants’ Guide
Section 11 Page3
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
Synchronize Only Synchronize Only is a mode that does not parallel, however: it does synchronize with other gensets or systems.
In Synchronize Only, the PCC does not control a breaker for connection or disconnect from load, but like Standalone it can provide a breaker trip signal, and it can monitor breaker position.
Synchronize Only is very useful for hard transfer ATS systems.
2
Visual 11-2 Synchronize only
Participant’s Text
Notes:
The operating features of Synchronize Only are the same as those used in more advanced paralleling modes. The control will not command breaker closure in this mode but it will monitor the position of the Gen breaker and it can also provide a generator breaker open or shunt trip command. This feature is well suited to work with the PLTH product and it will work with hard and bump-less transferswitch systems.
Participants’ Guide
Section 11 Page4
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
Synchronizer Only Mode
Notes:
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 / wye transformer for example. The second method of synchronizing is Slip Frequency which will attempt to drive a fixed frequency difference between the two sources. In some cases this is used to insure that power will flow in the desired direction at the initial time the sources are paralleled, or with a genset whose governing cannot be accurately enough controlled to phase match (such as gas gensets). The control provides one method of automatic voltage synchronizing which is voltage match. This method will attempt to drive the voltage error to zero. In most cases synchronizing is automatically initiated by the control when necessary. This is done by connecting sync enable/configurable input #30 on TB10 to a return.
Participants’ Guide
Section 11 Page5
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
Wire diagram Connections
3
Visual 11-3 Common Connector diagram
Participant’s Text
Notes:
Notice the same dotted lines on this diagram as you found on the Standalone diagram. Again, the dotted lines designate the connection is optional. IMPORTANT! The information bullets found on the diagram provides valuable information. Read them! Bus voltage input is needed for synchronizing, but bus CT input is not needed for this function.
Participants’ Guide
Section 11 Page6
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
InPower Modes of Paralleling The setup process encountered in InPower is the same as that used with Standalone Mode. Genset Application Type Setup Modes of Operation Choose Synchronize 4
Visual 11-4 InPower
Participant’s Text
Notes:
InPower has a specific folder (Paralleling Setup) devoted to the setup and configuration of the paralleling features. No more hunting and searching for different folders for individual setup features. . This visual repeats the same information that was covered in the Standalone section. It is repeated to reinforce the point that this control is easily configured. One place – you choose the setup – no more hunting through many InPower folders to find the proper adjustments.
Participants’ Guide
Section 11 Page7
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
HMI320 Paralleling Setup
The HMI paralleling setup functions are the same with InPower. This screen shows the Genset Application Type is set to Isolated Bus. Use the proper password code to change the type. 5
Visual 10-5 HMI Setup
Participant’s Text
Notes:
Are you catching on yet? Hopefully you are noticing a repeating pattern about how you can configure this control. YOU have a choice for your preferred method of setup of a control, you can use InPower or you can use the HMI. As you saw in the previous visual, the first adjustment under Basic Setup is Genset Application Type. It is also in the HMI Basic Setup screen. To change the Gen App Type, use the Level 1 or Level 2password.
Participants’ Guide
Section 11 Page8
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
Paralleling Connector Used in Synchronize Mode TB7- Bus Voltage
Bus CT Inputs
TB10- Circuit Breaker Status
TB8- Customer I/O
TB5- Circuit Breaker Control
6
Visual 11-6 Connector
Participant’s Text
Notes:
Now there are 5 connections (potentially 7 if you use all CTs) used in Standalone Mode for providing input/output and monitoring functions. Important!: Only CT #2 is used to monitor neutral current . The connection diagram does not show installation of shorting blocks for the CT connections, but it is strongly recommended. TB7 Voltage inputs are rated to accept up to 600 volts
Participants’ Guide
Section 11 Page9
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
Bus CT Connections OR
CT1
CT2
CT3
Optional: Only Provides Metering of Neutral Current CT2
7
Visual 11-7 Bus CT Connection
Participant’s Text
Notes:
Remember, this control can be used in a single phase application and Delta configuration too. Even in these applications, neutral current is all that this CT should be employed to monitor. Input is limited to a standard 0 to 5 amp CT output. The tables in section 2 of service manual provide information about setting and calibrating this input. Shorting blocks or some sort of shorting system must be used to protect the CT.
Participants’ Guide
Section 11 Page10
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
TB5 Circuit Breaker Control
M
B+
B+ Return
8
Visual 10-8 Breaker connection
Participant’s Text
Notes:
TB5 hookup is optional. Synchronize Only mode and Standalone mode support only 1 contact point on this connector. Pins 1 and 2 provide limited output to drive a breaker open or shunt trip command. It is very important to know the inrush coil specifications of the breaker shunt trip or motor. If you suspect the 5A, 30VDC inductive loading will exceed 7 milliseconds, use a pilot relay.
Participants’ Guide
Section 11 Page11
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
Synchronizer Only Mode
Notes:
This is an excellent time to learn about the FUNCTION POINTER setup in InPower. In the SETUP folder – Configurable I/O you find dozens of configurable settings If you scroll down the list, at approximately the 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 the conditions that can be used to close this contact. Chose the appropriate one that will open the breaker as your application would require.
The trim Function Pointer is used to set what conditions the configurable output becomes active. Associated with the Input #27 Function Pointer is the Active State Selection choice. This can be set for “Active Closed”, or “Active Open”.
Participants’ Guide
Section 11 Page12
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
TB10 Breaker Status Connections
17
10
13
8&7
2
#2 Return 10
optional
8 13
7
#17 Return 9
Visual 10-9 Breaker status
Participant’s Text
Notes:
TB10 provides breaker status information and it provides the Sync Enable input. The Sync Enable input is required for Synchronize Only Mode. It is the command the causes the genset to synchronize to Source 1. The breaker status inputs are optional. There is no breaker control function with this mode, so this would be used for reporting the status of the breaker over ModBus or generally for reporting the position.
Participants’ Guide
Section 11 Page13
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
Activities Activity 11-1: In-Class Quiz
10
Visual 10-10 Quiz for Section 10
Participant’s Text
Notes:
At this time I would like you to complete the quiz and the activity. The quiz is located in Section 15
Participants’ Guide
Section 11 Page14
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
Wrap-Up This lesson is not only supposed teach you about the synchronizing feature of this control, 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 setup of 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?
Participants’ Guide
Section 11 Page15
PCC 3.3 & PowerCommand Control 3300
Synchronizer Only Mode
THIS PAGE IS INTENTIONALLY LEFT BLANK
Participants’ Guide
Section 11 Page16
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
PowerCommand 3.3 Section 12: Isolated Bus Paralleling
Visual 12-1
Participants’ Guide
Section 12 Page1
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
Section 12 PPC 3.3 Isolated Bus Mode Estimated Time: 2.5 hours
Materials Needed
Wiring Diagram 0630-3440 (A007M115 D)
PowerCommand Control 3300 Participant’s Guide
PC 3.3 Controller Service Manual
Participants’ Guide
Sheets 1 to 18 or diagrams in 900-0670 Guide (CMT6068-EN-PG) #900-0670
Section 12 Page2
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
Warm Up What you have learned about Standalone mode operation and Synchronize Only will be applied in this lesson. We will experience the setup process and configuration of the control in addition to the physical 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. After completing this lesson, the participants should be able to: •
Understand the configuration of various Isolated Bus systems, and the reason for operating the PC 3.3 in droop or isochronous mode.
•
Find and understand the configuration information in the service manual, InPower and the HMI320.
•
Execute a control setup and configuration for a genset or simulator to operate in this mode.
Participants’ Guide
Section 12 Page3
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
Isolated Bus Paralleling Multiple units connected to a common supply bus. All units are connected to the bus in a synchronous way with matched frequency and voltage.
Units may be set to operate in Droop or they may be set for Isochronous operation
2
Visual 12-2 Isolated bus
Participant’s Text
Notes:
All units operate at the same frequency (speed) and voltage. Generally speaking, the units can operate in various modes which will determine how individual units will react to load conditions, but all units will work together 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 cable connections between gensets and breakers.
Participants’ Guide
Section 12 Page4
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
Isolated Bus Paralleling Dead Bus Close First Start Arbitration Synchronizing Load sharing between units
3
Visual 12-3 Isolated bus
Participant’s Text 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. The genset controls arbitrate with each other through an interconnected first start signal. Once a genset has reached the ready to load state and the bus is sensed as being dead, it can join in the arbitration. When the arbitration completes, one genset has "won" permission to close and will be allowed to command its breaker to close. At the same time this genset puts the interconnected 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 the other 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 that permission 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 a situation where no genset closes to the bus due to a failed first start system.
Participants’ Guide
Section 12 Page5
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
WARNING! --- This does present a risk of multiple gensets closing to the dead bus, but this risk is reduced 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 assumption is that all gensets were started at the same time.
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 / wye transformer for example. The second method of synchronizing is Slip Frequency which will attempt to drive a fixed frequency difference between the two sources. In some cases this is used to insure that power will flow in the desired direction at the initial time the sources are paralleled, or with a genset whose governing cannot be accurately enough controlled to phase match (such as gas gensets). The control provides one method of automatic voltage synchronizing which is voltage match. This method will attempt to drive the voltage error to zero. In most cases synchronizing is automatically initiated by the control when necessary. This is done by 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 determine how much of the total bus load to take. The desired result is for each genset to take its equal share of the load relative to its own rating while maintaining the bus frequency and voltage at the 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). Isochronous In 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 voltage droop.) This is accomplished via the “load share lines”. There is a pair for kW and a pair for kVAR. 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 to insure comparable load sharing performance. These adjustments are NOT necessary if the controls 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.
Participants’ Guide
Section 12 Page6
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
4. Even after balancing the kVAR sharing at one kVAR load condition, the kVAR sharing may 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 or overload condition). 6. Reverse kW or Reverse kVAR shutdowns may occur during Master Synchronizing with MCM3320 Droop Droop 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) is reduced, 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 other gensets to pick up more lagging kVAR thus resulting in a balance. Droop can be used on an isolated 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. The other sets operating in droop will be forced to go to the isochronous speed and thus they will be effectively base-loaded. The lead unit then takes up all the changes in load that occur while maintaining a fixed frequency bus. As an example, if the genset set to operate in isochronous mode at a frequency of 57Hz were run in parallel with a genset operating in droop set as shown in 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% kW output 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% kW ouput the genset will be operating at 90% of nominal frequency. In other words for a nominal frequency 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 case the 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 a nominal voltage of 480VAC the genset will be running at 456VAC at full load.
Participants’ Guide
Section 12 Page7
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
Load Share - Droop kW 101 100 99
% Nominal Frequency
98 97 96 95 94 93 92 91 90 89 88 87 0
20
40
60
80
100
120
140
100
120
140
% kW Output
Figure 1 Load Share DROOP kW
Load Share - Droop kVAR 101 100
% Nominal Voltage
99 98 97 96 95 94 93 0
20
40
60
80
% kVAR Output
Figure 1 Load Share DROOP kVAR
Participants’ Guide
Section 12 Page8
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
Isolated Bus Paralleling Sequence
4
Visual 12-4 Sequence diagram
Participant’s Text
Notes:
The PCC control is acting on many inputs and actions that must take place in a particular sequence for the PCC to parallel with other generator sets. This diagram provides a basic sequence of operation and graphically shows each event that must happen. A large fold out sheet is available in Appendix B: Sequence Diagrams of the Service Manual.
Participants’ Guide
Section 12 Page9
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
Wire Diagram Connections
5
Visual 12-5 Common Connector diagram
Participant’s Text
Notes:
This is the first diagram when full connection and control of the genset breaker is encountered. This is the first diagram when connections to the TB9 analog connection are encountered. The connections are polarity sensitive and must be connected between each generator so each unit will share load correctly.
Participants’ Guide
Section 12 Page10
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
Isolated Bus Mode
Notes:
There will be a 52G for each generator set. (52G is the standard ANSI designation for a motor actuated breaker for a generator set.)
A Contact = B Contact =
C Contact =
MEDIUM VOLTAGE & HIGH VOLTAGE – Potential of 600voltAC is generally considered the threshold to Medium voltage. Systems operating at potential above 600voltAC must use PTs (Potential Transformers) {VT =Voltage Transformer---- a common term in many of the global regions} to lower the voltage. Additional Notes or Comments _______________________________________________________________________________
Participants’ Guide
Section 12 Page11
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
Isolated Bus Paralleling Connectors TB7- Bus Voltage
Bus CT Inputs
TB9- Analog I/O
TB3 - Customer I/O
TB10- Circuit Breaker Status
TB5- Circuit Breaker Control 6
Visual 12-6 Connectors
Participant’s Text
Notes:
Customer connections must be made at each of these connection points. The next few pages will highlight the connections required at each of the terminal blocks. In addition to the connections that were made on the Synchronize Only Mode, connections must also land at TB3 Customer I/O, TB9 Analog I/O, and the TB7 Bus Voltage.
Participants’ Guide
Section 12 Page12
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
Bus CT Connections
CT1
CT2
CT3
7
Visual 12- 7 Bus CTs
Participant’s Text
Notes:
Bus CT connections are polarity sensitive and the sense wire must be routed through the CT in the proper direction. If the CTs wires are installed backwards, the control will sense a phase shift and the control may not parallel correctly or there will be erroneous readings of load or PF. Most Switchgear manufacturers build their gear with CT shorting blocks in place. It is the responsibility of the installation designer to make certain there are shorting blocks in the system. Question the maker if you do not find any.
Participants’ Guide
Section 12 Page13
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
TB3 Customer I/O Connections Pin 12
First Start Arbitration Return
First Start Arbitration Supply
Gen 1
Pin 12 Gen 2
8
Visual 12-8 Connection TB3
Participant’s Text
Notes:
In this paralleling mode, the only connection to TB3 is the optional First Start Status signal. The connections are considered polarity sensitive with output from the first genset connected to the next genset.
TB3-11 to TB3-11 on all gensets
TB3-12 to TB3-12 on all gensets
Participants’ Guide
Section 12 Page14
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
TB5 Circuit Breaker Control
M
B+ Return
M
B+
B+ Return
B+
9
Visual 12-9 Breaker connection
Participant’s Text
Notes:
TB5 provides the hookup points to control breaker open and another for breaker close control. Breaker motors can consume a large amount of energy during actuation. The power consumption is so great that damage to PCC control can take place if you attempt to drive the breaker directly from this connector. Use a pilot relay of sufficient size to run the breaker, but be aware that relay motors can sometimes consume a large amount of energy. Make sure the relay motor does not exceed the specification listed on this visual.
Participants’ Guide
Section 12 Page15
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
TB10 Breaker Status Connections
17
14
10
7
2
#2 Return
15 #16 Return
11
10
#9 Return
8
14
7
#17 Return 10
Visual 12-10 Breaker status
Participant’s Text
Notes:
TB10 provides information to the control about breaker position, and it also provides control input from a Master Control. There are 3 discrete input points. These are optional, but they are available to be used as Customer Inputs #28, #31, & #32.
#28 is Genset CB Inhibit. It uses TB10-9 and TB10-11.
#31 is Load Demand Stop. It uses TB1014 and TB10-17.
#32 is Ramp Load/Unload. It uses TB1015 and TB10-16.
Participants’ Guide
Section 12 Page16
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
Isolated Bus Mode
Notes:
There are 3 breaker status indications
Terminal #7 input indicates Genset CB Position It uses “A” contact input fromTB10-2 and TB10-7.
Terminal #8 input indicates Genset CB Position It uses “B” contact input fromTB10-2 and TB10-8.
Terminal #10 input indicates Genset CB tripped It uses “A” contact input fromTB10-2 and TB10-10.
Participants’ Guide
Section 12 Page17
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
TB9 Analog I/O Connections kW Load Share - Neg kW Load share + Pos
kVAR Load Share - Neg kVAR Load share + Pos
Pin 1
Pin 1
- Neg Shield
Pin 11
+ Pos + Pos
Pin 11
- Neg
The shield must shield all load share wires between gensets, but it can be connected to Pin 9 on ONLY one genset.
11
Visual 12-11 Connection TB9
Participant’s Text
Notes:
The Analog input connections on TB9 provide the load share information. The connections are considered polarity sensitive with output from the first genset TB3-11 connected to the input connection TB3-12 of the next genset. Also the first genset TB3-12 terminal must be connected to the connection TB3-11 of the next genset.
Participants’ Guide
Section 12 Page18
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
TB7 Gen Bus Voltage Sense
1 Phase
WYE Pin 1
Pin 1
Pin 4
Neutral
V W
U
V
Pin 1
Pin 4
U
W
V Neutral
U
Pin 4
W
Delta
Unconnected
12
Visual 12-12 Connection TB7
Participant’s Text
Notes:
TB7 can monitor voltage of 600 voltAC or less.
Fuses listed are optional and provided by others. The fuse rating should be appropriate to protect the wire system. =
Participants’ Guide
Unconnected
Section 12 Page19
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
InPower Trim Adjustments
Genset Application Type Setup – First step 13
Visual 12-13 InPower
Participant’s Text
Notes:
It has been pointed out in previous lessons that all paralleling setup functions and adjustments are found under the Paralleling Setup – Basic section of InPower. The first and most important adjustment to check when configuring a paralleling setup is Genset Application Type.
Participants’ Guide
Section 12 Page20
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
InPower Trim Adjustments
InPower Adjustment Screen
Service Manual Menu Description
14
Visual 12-14 Trims
Participant’s Text
Notes:
Within the InPower Setup ---- Paralleling Setup ----- Basic folder you will see the dozens of adjustments for paralleling functions. All adjustments for all the modes of paralleling are intermingled in this Basic folder. This is represented on the left of this visual. The right side of this visual shows an extraction from Section 5 SETUP & CALIBRATION of the 0900-0670 Service Manual. You will notice the sequence of the InPower list matches the Service Manual list. This will help you find descriptions and adjustments.
Participants’ Guide
Section 12 Page21
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
InPower Trim Adjustments
OOR = Out Of Range
15
Visual 12-15 InPower
Participant’s Text
Notes:
These highlighted adjustments affect Utility/mains connections and performance. They are listed in the basic setup section and may cause some confusion. OOR is a common acronym that can be encountered in many control systems, but it may be a new term for those in the Power Generation service field.
Participants’ Guide
Section 12 Page22
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
Quiz & Activities Activity 12-1: In-Class Quiz
16
Visual 12-16 Quiz
Participant’s Text
Notes:
At this time I would like you to complete the quiz and the activity
Participants’ Guide
Section 12 Page23
PCC 3.3 & PowerCommand Control 3300
Isolated Bus Mode
Wrap-Up In this lesson, we have learned about Isolated Bus Paralleling configuration of the PCC 3300 genset control and important connection locations. Q. Are there any questions we have not yet covered about Isolated Bus installation of the PCC 3300?
Participants’ Guide
Section 12 Page24
PCC 3.3 & PowerCommand Control 3300
Troubleshooting & Service Manual.
PowerCommand 3.3 Section 13: Troubleshooting & Service Manual
Visual 13-1
Participants’ Guide
Section 13 Page1
PCC 3.3 & PowerCommand Control 3300
Troubleshooting & Service Manual.
Section 13 PC 3.3 Troubleshooting Estimated Time: 1.0 hours
Materials Needed Guide (CMT6068-EN-PG)
PowerCommand Control 3300 Participant’s Guide
PC 3.3 Controller Service Manual
Wiring Diagram 0630-3440 (A007M115 D) Sheets 1 to 18 or use diagrams in 900-0670
Participants’ Guide
#900-0670
Section 13 Page2
PCC 3.3 & PowerCommand Control 3300
Troubleshooting & Service Manual.
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. After completing this lesson, the participants should be able to: •
Use the Troubleshooting guide in the Service Manual.
•
Find fault codes and sequence of operation information in the Service Manual.
Participants’ Guide
Section 13 Page3
PCC 3.3 & PowerCommand Control 3300
Troubleshooting & Service Manual.
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 2
Visual 13-2 Troubleshooting Tools.
Participant’s Text
Notes:
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 only a small fraction of information about this control. We have provided you with guidance and an overview about how major features operate. Not only have you been learning how to properly configure the control, you have been learning how it is supposed to work. Now that you have this knowledge, please use it.
Participants’ Guide
Section 13 Page4
PCC 3.3 & PowerCommand Control 3300
Troubleshooting & Service Manual.
Service Manual #0900-0670 Concise Table of Contents Seven Section • • • • • • •
System Overview Hardware Control Operation Paralleling Operation Setup and Calibration Parameters Troubleshooting
Appendix • • • •
Schematics Sequence Diagrams Parts List ModBus Register Mapping
3
Visual 13-3 Service Manual.
Participant’s Text
Notes:
The Service Manual table of contents is 12 pages long and it provides detailed and explicit directions about where to find any particular piece of information. The manual is separated into the listed 7 sections of information and is set up in such a way that you will find information according to the type of activity you are engaged in as opposed to which part of the machine you are working with. The Appendix is also divided into sections labeled A, B, C, & D. Each section provides reference information such as the ModBus Register Map or a parts list.
Participants’ Guide
Section 13 Page5
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
Troubleshooting & Service Manual.
Notes:
Section 7 of the Service Manual provides a comprehensive troubleshooting guide. Before opening to Section 7, please look at the Table of Content information about Section 7 Troubleshooting beginning on page vii of the Service Manual. Notice the fault codes are listed in sequence with a description of the fault and a reference 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 help you understand the conditions of the fault.
Diagnosis and Repair will guide you to possible or probable solutions.
Read and understand the Diagnosis and Repair suggestions. SRT (Standard Rate Tables) are based on these troubleshooting suggestions.
Participants’ Guide
Section 13 Page6
PCC 3.3 & PowerCommand Control 3300
Troubleshooting & Service Manual.
Quality VOM
$4.95 @ Amazon
4
Visual 13-4 Troubleshooting Tools.
Participant’s Text
Notes:
There are many makers of quality meters. CPG does not endorse any one maker, but we do encourage use of tools that are safe to use and provide accurate and reliable readings. 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.
Participants’ Guide
Section 13 Page7
PCC 3.3 & PowerCommand Control 3300
Troubleshooting & Service Manual.
Wire diagram Connections Test locations are clearly noted on each diagram.
5
Visual 13-5 Connector diagram
Participant’s Text
Notes:
Now that you have a good VOM to work with, where do you connect it? The Common Connector Diagram tells us The information bullets IMPORTANT! found on the diagram provides valuable information. Troubleshooting data can be found on many of them!
Particpants’ Guide
Section 13 Page8
PCC 3.3 & PowerCommand Control 3300
Participant’s Text
Troubleshooting & Service Manual.
Notes:
The bullet below identifies a reason why the Oil 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 specification information that can help with troubleshooting. Using your VOM you could check your exciter field. In earlier sections we learned this AVR output is a PWM signal so with a quality meter you could check duty cycle OR you could check the current draw.
Particpants’ Guide
Section 13 Page9
PCC 3.3 & PowerCommand Control 3300
Troubleshooting & Service Manual.
InPower Troubleshooting Tips InPower continues to have the Snapshot feature. The Phase 1 PCC3300 does not record Snapshots,
InPower is able to record Monitor information and it can create a viewable Stripchart of performance.
InPower has a quick navigation to the Fault List. 6
Visual 13-6 InPower
Participant’s Text
Notes:
InPower has been a valuable troubleshooting tool for many years. It is most likely the most important troubleshooting tool available for servicing a PC 3.3 control. Most of the features shown on this visual have been around a long time. Some of them may have been forgotten about. Such as the quick link to view the fault list.. Phase 2 of the PCC3300 control board is planned support fault Snapshots. The Phase 1 release (this training session) does not support the Snapshot function.
Particpants’ Guide
Section 13 Page10
PCC 3.3 & PowerCommand Control 3300
Troubleshooting & Service Manual.
ModScan Troubleshooting Tips ModScan is not a configuration tool, it is a troubleshooting and testing tool. Holding Registers display data. Registers 43517 is the Prelube State parameter.
This middle digit reports Prelube ON state. 7
Visual 13-7 Troubleshooting Tools.
Participant’s Text
Notes:
ModScan was covered in detail in Section 7 of this Training guide. Consider using ModScan as a troubleshooting tool to test some of the operating functions. 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 state changes to 00100, but the Prelube relay does not pick up, this could help you understand that the internal fuse may have failed.
Particpants’ Guide
Section 13 Page11
PCC 3.3 & PowerCommand Control 3300
Troubleshooting & Service Manual.
InSite
8
Visual 13-8 InSite
Participant’s Text
Notes:
InSite is a valuable service tool for troubleshooting engine related problems. CPG does not train or certify technicians to use this tool, but if a PowerGen technician is trained to use this tool and has it available, by all means – use it! InSite connects to the CAN communication system through the InLine tool. InLine IV and InLine V tools are the current connection tools available at the Phase 1 launce of the PC 3.3 control.
Particpants’ Guide
Section 13 Page12
PCC 3.3 & PowerCommand Control 3300
Troubleshooting & Service Manual.
Troubleshooting Activities Activity 13-1: In-Class Quiz
9
Visual 13-9 Quiz & Activity
Participant’s Text
Notes:
At this time I would like you to complete the quiz and the activity
Particpants’ Guide
Section 13 Page13
PCC 3.3 & PowerCommand Control 3300 Manual.
Troubleshooting & Service
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?
Particpants’ Guide
Section 13 Page14
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
SECTION 14 -- Glossary AC
Alternating Current (AC) is electric current that alternates between a positive maximum value and a negative maximum value at a characteristic frequency, usually 50 or 60 cycles per second (Hertz).
Alarm
Used 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 its properties of absorbing or deadening sound.
Active Power Active power is the real power (kW) supplied by the generator set to the electrical load. Active power 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 Breaker An air circuit breaker automatically interrupts the current flowing through it when the current exceeds the trip rating of the breaker. Air is the medium of electrical insulation between electrically live parts and grounded (earthed) metal parts.
Alternator Alternator is another term for AC generator.
Alternator Rating Effect
Some 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 an alternator’s capability in these areas is not available, the PowerCommand Control will default to basing the limits on the on the GenSet rating — as the previous version of the PowerCommand Control did. (GenSet rating is either engine limited or alternator limited — normally engine limited.)
Training Guide
Section 14 Page1
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Amortisseur Windings
The amortisseur windings of a synchronous AC generator are the conductors embedded in the pole faces 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 by code.
Ampere
The 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 equipment monitored is not located in a portion of the facility that is normally attended. The NFPA has specific 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).
Armature The 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 Jurisdiction
The authority having jurisdiction is the individual with the legal responsibility for inspecting a facility 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 started and paralleled while coming up to rated frequency and voltage. Because the generator excitation system is not turned on until the generator set is started (thus the term "dead field"), the generator sets automatically synchronize as they come to rated speed and voltage.
B+ Return Similar to battery negative (B-). This may be an isolated battery negative circuit and may not be directly connected to chassis ground or the battery negative. In some circumstances it may float at a different potential than chassis ground.
Training Guide
Section 14 Page2
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Backup Protection
Backup protection consists of protective devices, which are intended to operate only after other protective devices have failed to operate or detect a fault.
Bandwidth The amount of data that can be transmitted in a fixed amount of time. For digital devices, it is expressed as bits per second, or bytes per second. For analog devices, it is usually expressed as cycles per second, or Hertz.
Bar Graph A metering panel which is optional a PowerCommand Control. This optional panel is referred to as the HMI112 and it allows the operator to view a display of Amperes, KVA, Frequency, and Voltage provided by the generator set. There is also a version that will display KVA and Power Factor in addition to the other listed functions.
Base Card The main processor board of the PowerCommand Control. This board contains the main power supply for the control, microprocessor, flash memory for updates to the operating system (calibration download), interface to the optional HMIs, PCCNET and Modbus connections, and inputs for engine sensor data.
Base Load Base load is that portion of a building load demand which is constant. It is the "base" of the building demand curve.
Baud Rate
The 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.
Binding
The process of making the logical connections to the network (also called connecting). This involves connecting network variable outputs to network variable inputs using LonWorks software.
Bit Binary Digit.
Black Start
Black Start refers to the starting of a power system with its own power sources, without the assistance 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.)
Training Guide
Section 14 Page3
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Bound
A network communication technique whereby a node automatically receives a network variable from a sender node whenever the sender node sends it out. Whenever this condition exists, the node is said to be "bound".
Bumpless Transition
Bumpless 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.
Bus Bus can refer to the current-carrying copper bars that connect the AC generators and loads in a paralleling system, to the paralleled output of the AC generators in a system or to a feeder in an electrical distribution system.
Bus Bars
Bus Bars are rectangular copper or aluminum bars that connect the output of the generator set circuit breakers to the transfer switches, circuit breakers, or fusible switches that transfer power to the load. The bus bars are sized and assembled in multiples according to the current they must carry under load. A typical sizing criteria for copper bus bars rated from 500-5,000 amps is to maintain a current density of 1,000 amps per square inch of cross-sectional area. This results in a bus temperature rise at full load that is within acceptable limits.
Bus Capacity Bus 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, control circuits and protective relaying. They usually have 5 ampere secondaries.
Calibration
Non-volatile adjustment made on the factory floor. A data set downloaded to a G-Drive or GenSet control to update the operation of the control.
Cellular Refers to a communication system that divides geographic regions into sections called cells. The purpose 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 have only one channel (UTP cable and 78 KBPS transmission speed). In a large network, there may be
Training Guide
Section 14 Page4
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
multiple channels and each channel may or may not be of the same media type. Typically, channels are linked together using routers.
Channel Terminator
This 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 Currents
Circulating Harmonic Currents are currents that flow because of differences in voltage waveforms between 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 with quotes. PowerCommand for windows uses the CSV record format.
Connecting Devices Connecting 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 or more (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 higher internal voltage supplies reactive power (kVAR) to the other genset(s). The amount of cross current that 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.
Training Guide
Section 14 Page5
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Cross Current Compensation
Cross current compensation is a method of controlling the reactive power supplied by AC generators 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 the control system was designed for.
Current Current 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-limiting range, 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 positive maximum to zero again and then from zero to a negative maximum to zero again. The number of cycles per second is the frequency.
CRC Error This is a digital communication test. It is a acronym for Cyclical Redundancy Check. An error indicates that a digital message did not arrive at its destination with all of the original data intact.
Dead Bus
Dead Bus refers to the de-energized state of the power connections between outputs of paralleled generator sets. The term bus in this usage can either be rigid solid bus bars or insulated flexible cables.
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 to the end of the next phase, forming the triangle-shaped Greek letter Delta. The load lines are connected 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 is a low load level on the system.
Training Guide
Section 14 Page6
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Deviation Factor
The deviation factor is the maximum instantaneous deviation, in percent, of the generator voltage from a true sine wave of the same RMS value and frequency.
Dielectric Strength Dielectric 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 different series 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. These devices 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 on Cummins 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 some distance. 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 form a distributed control system. Typically, they communicate on a peer-to-peer level. This is different from a type of system where all control and interaction between components is dictated by one central 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 loads connected to a main distribution device.
Distribution Switchgear
Distribution switchgear may include automatic transfer switches, drawout air frame circuit breakers, fusible switches, or molded case breakers.
Training Guide
Section 14 Page7
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Domain
A domain is a network concept that allows independently functioning networks to share resources such as transmission media. A domain designation provides an ID number to identify the devices that 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 carriage and contact structures that permit the breaker to be removed from the enclosure without manually disconnecting power cables and control wires.
Droop Load Sharing
Droop load sharing is a method of making two or more parallel generator sets share a system kW load. This is accomplished by having each governor control adjusted so that the sets have the same droop (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. This bar is connected to the earth or ground connection when the system is installed. The grounding or earthing 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 on Cummins FAE engines, but it is also used when referring to PCC series controls that are used to control engine speed and engine protection.
EEPROM
Electrically Erasable Programmable Read Only Memory. This memory holds data after the power has been removed, but can be changed by writing new data on top of old data. This is where the PowerCommand Control stores its calibration data. InPower, the service software, can write a new calibration into the control flash memory.
Efficiency (EFF)
Efficiency is the ratio of energy output to energy input, such as the ratio between the electrical energy 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 permit remote control of a circuit breaker.
Training Guide
Section 14 Page8
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Emergency Bus
An emergency bus is the silver-plated copper bus bars or flexible cable used to connect the paralleling breakers to the emergency system feeder breakers, and ultimately to automatic transfer switches or other distribution devices.
Emergency System
An emergency system is independent power generation equipment that is legally required to feed equipment or systems whose failure may present a life safety hazard to persons or property.
Energy Energy is manifest in forms such as electricity, heat, light and the capacity to do work. It is convertible from one form to another, such as in a generator set, which converts rotating mechanical energy into electrical energy. Typical units of energy are kW/h, Btu (British thermal unit), Hp/h, ft/lbf, joule and calorie.
EPS Engine Position Sensor. Serves the similar function as an MPU (Magnetic Pick Up) however it uses Hall 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). See Field.
Exciter Paralleling Control
An exciter paralleling control initiates the start of generator excitation in generator sets used in automatic paralleling systems.
FAE Acronym for Full Authority Engine. These engines typically employ high tech electronic fuel injection and control systems.
Fault
A condition occurred which caused a warning or shutdown alarm.
Feeder Circuit Breaker See Distribution Circuit Breaker.
Fiber Optic Cable
A technology using glass or plastic threads (fibers) to transmit data. A fiber optic cable is a bundle of 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
Training Guide
Section 14 Page9
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
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 increasingly more common for use with Local-Area Networks (LANs).
Field The generator field (rotor) consists of a multi-pole electromagnet which induces output voltage in the armature coils (stator) of the generator when it is rotated by the engine. The field is energized by DC supplied by the exciter.
Field Breaker with Auxiliary Switch
This is the circuit breaker (usually mounted in the generator control panel) that monitors the alternating current input to the automatic voltage regulator. If a malfunction occurs in the excitation system, the circuit breaker trips on overcurrent-closing the auxiliary switch, shutting down the generator set, and energizing the alarm circuit.
First Start Sensor
A first start sensor is an electronic device within some paralleling equipment that senses generator set and bus voltage and frequency, and determines whether or not a generator set is the first unit ready to close to the bus following a call to start under "black start" conditions.
Form - C Relay
Refers to a type of relay that has a normally closed contact and a normally closed contact. The relay coil 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 medium having the quality of transmitting sound equally in all directions) which is free of boundaries. In practice, it is a field in which the effects of the boundaries are negligible in the region of interest. In the free field, the sound pressure level decreases 6 dB for each doubling of the distance from a point source.
Frequency
Frequency 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 per second).
Frequency Adjust Potentiometer
A frequency adjust potentiometer is used to manually bring the frequency (speed) of the incoming set 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.
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Frequency Regulation
Frequency regulation is a measure that states the difference between no-load and full-load frequency as a percentage of full-load frequency.
FT-10 Network FT-10, sometimes described as FTT-10, is the large network transceiver system used with Cummins Power Generation systems employing the LonWorks protocol. FTT-10 stands for “Free Topology Type - 10Mbaud.” The Free Topology protocol allows multiple topologies to be used in one network. The maximum network cable length in a free topology network is 500 meters. If the network is designed and installed using a multi-drop bus topology the maximum distance is 4,000 feet.
Fusible Switch
A fusible switch is an isolating switch and overcurrent protective device used for feeder or transfer switch 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 Network Gateway Module (NGM) provides a communication protocol that a PC can understand. Other gateway devices may be used to interface between our Lontalk protocol and other systems such as a SCADA 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, yet they 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 under various load conditions. The governor must have provision for adjusting speed (generator frequency) and speed droop (no load to full load).
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Grid
The utility-owned power distribution system.
Ground A ground is a connection, either intentional or accidental, between an electrical circuit and the earth or some conducting body serving in place of the earth.
Ground Fault Protection
This function trips (opens) a circuit breaker or sounds an alarm in the event that there is an electrical fault between one or more of the phase conductors and ground (earth). This ground fault protection function may be incorporated into a circuit breaker.
Ground Return
Ground return is a method of ground fault detection that employs a single sensor (CT) encircling the 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 all feeders 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-wire generator, 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, and current sensing applications.
Harmonic Distortion (Total Harmonic Distortion)
Total harmonic distortion is an expression of the total harmonic content of a voltage waveform. The harmonic 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 the fundamental voltage amplitude).
Harmonics
Harmonics are voltage or current components which operate at integral multiples of the fundamental 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 describe frequency.
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HMI
Human Machine Interface: Commonly referred to as touch panel, or control display, and now includes reference to the annunciator and bargraph .
Hub A common connection point for devices or nodes in a network or sub-network. Hubs are commonly used to connect segments of a LAN and contain multiple ports.
Hunting
Hunting is a phenomenon that can occur upon load changes in which the frequency or the voltage continues to rise above and fall below the desired value without reaching a steady-state value. It is caused by insufficient damping.
Incoming Set
This is the generator set that is about to be connected to (paralleled with) the energized bus.
Initial Calibration Downloading a data set to a PowerCommand Control to set up the operation of the control. In this type of calibration the technician has to manually enter the dataplate information for the genset into InPower software. If a capture file is not downloaded into the control after this type of calibration is performed, 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.
Insulation
Insulation 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 a maximum continuous-duty temperature.
Internal Voltage
The internal voltage is the voltage a generator would develop at no load if it were not connected in a parallel operation. Excitation of the generator field controls internal voltage.
Interoperability Design to allow one product to work with another product without modification.
Interruptible
This refers to the practice of operating on-site power systems, at the request of a utility, to reduce electrical demand on the utility grid during periods of high consumption. Interruptible facilities may 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.
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Interrupting Capacity
Interrupting capacity is the magnitude of electrical current that a device can safely interrupt (open against), without failure of the component.
kW Load Sensor The kW load sensor is an electronic device provided to sense kW level at various points in a system, 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 in amperes multiplied by its rated operating voltage. In the case of three-phase generator sets, kVA is the kW ouput rating divided by 0.8, the rated power factor. kVA is the vector sum of the active power (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 is associated with the reactive power which flows between paralleled generator windings and between generators 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 generator set's engine but does limit the generator thermally.
kW This is an abbreviation for kilowatt, an alternate term for rating electrical devices. Generator sets in the United States are usually rated in kW. Sometimes called active power, kW loads the generator set 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 Factor
Lagging 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 Power Factor.
Lead Unit In a paralleling system that has a load demand feature, the lead unit is the last unit to be shut down in the event that load demand mode is in operation.
Leading Power Factor
Leading power factor in AC circuits (0.0 to -1.0) is caused by capacitive loads or overexcited synchronous motors which cause the current to lead the voltage. See Power Factor.
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Leg
A leg is a phase winding of a generator, or a phase conductor of a distribution system.
Line-To-Line Voltage Line-to-line voltage is the voltage between any two phases of an AC generator.
Line-To-Neutral Voltage
In a 3-phase, 4-wire, Y-connected generator, line-to-neutral voltage is the voltage between a phase and the common neutral where the three phases are tied together.
Load Demand Load Demand is a paralleling system operating mode in which the system monitors the total kW output of the generator sets, and controls the number of operating sets as a function of the total load on the system. The purpose of load demand controls is to reduce fuel consumption and limit problems caused by light load operation of reciprocating diesel generator sets.
Load Dump Signal output from a genset which is activated by the genset when it enters an overload and/or underfrequency condition. In today’s systems, this tells the master control that it needs to shed some load.
Load Factor The 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 Shedding Load shedding is the process by which the total load on a paralleling system is reduced, on overload of the system bus, so that the most critical loads continue to be provided with reliable electrical 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 the network. This involves two wires, one that goes to the node and another that returns to the main network bus. The total local loop distance must be added to the total network length. This becomes important 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 building or group of buildings.
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Locations
Locations are subdivisions of a network that can be selected for easier organization. Locations may designate physical places, but are not required to do so. For example, network devices in one location may communicate with network devices in another location when requested to do so.
Low Side Driver
DC loads have a positive side and a negative side. On the PCC 1302, the Low Side Driver is the switched negative side of a load when the circuit operates because of a internal power supply. It may 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 single disconnect point for all power in a switchboard or device.
Mains
Mains 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.
Media The main network bus defined by two characteristics: 1) The electrical signal level and 2) the characteristics of the wiring they will travel over. Typically, our standard PowerCommand Network uses 22 AWG Unshielded Twisted-Pair (UTP) wire operating at 78 KBPS.
Medium Voltage
AC system operating voltages from 601 to 15000 VAC.
MODBUS An industrial networking system that uses RS-232 serial master-slave communications at data transfer rate of up to 19.2 KBPS and is a messaging structure developed by Modicon in 1979, used to establish master-slave/client-server communication between intelligent industrial devices. There are multiple variations of the protocol.
MODBUS® Protocol
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Modbus II
An industrial networking system that uses token-passing peer-to-peer communications at data transfer 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 data transfer rates of one megabit per second (MBPS). The network media is shielded twisted-pair cable.
Modules
Modules are also called nodes or devices. These are devices such as Genset Communication Modules (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 the medium of electrical insulation for enclosing the mechanisms, and for separating conducting surfaces from one another and from grounded (earthed) metal parts. Molded case circuit breakers usually contain thermal-magnetic trip units, although larger sizes can be equipped with solid state trip sensors.
Motoring In 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, drawing power 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 load can motor the generator set if insufficient additional load is present.
Multi-drop Bus Topology The 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. The maximum stub length (See Definition of Local Loop) must not exceed 10ft. and must be included in 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.
NEMA
National Electrical Manufacturers Association
NEMA 1 Enclosure This enclosure designation is for indoor use only-where dirt, dust, and water are not a consideration. Personnel protection is the primary purpose of this type of enclosure.
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NFPA
National Fire Protection Association
NFPA 110 National Fire Protection Agency Section 110 (NFPA 110) deals with the regulations concerning Emergency 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 PowerCommand Network device. For example, we can provide NFPA 110-alarm annunciation for gensets with the use of a NAM.
Network Bus The 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 also refer 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 the transferswitch 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 PCC 2100 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 Manchester Encoding that makes the signal insensitive to polarity. The signal is transformer-coupled to the network data wire at a rate of 78 KBPS.
Network Data Wire Unshielded-Twisted Pair (UTP) cable that carries the network data over the main network bus. The maximum 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 takes the UTP wire and then provides an RS-232 port for connection to either a modem or PC.
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Neutral
Neutral refers to the common point of a Y-connected AC generator, a conductor connected to that point or to the mid-winding point of a single-phase AC generator.
Neutral Current Neutral current is the current that flows in the neutral leg of a paralleling system. Often, this term is used in reference to circulating currents or cross currents.
Node
A module that can communicate over the network data to other modules. A module contains a Neuron Chip. Certain devices are nodes such as Genset Communication Modules (GCMs) and Control Communication Modules (CCMs). Other devices are not nodes, as they cannot communicate 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. The nominal value is 60.0 Hz.
Nonlinear Load
A nonlinear load is a load for which the relationship between voltage and current is not a linear function. Some common nonlinear loads are fluorescent lighting, SCR motor starters and UPS systems. 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 is ready to provide power to the load in the event of utility failure.
Octave Band In sound pressure measurements (using an octave band analyzer), octave bands are the eight divisions of the measured sound frequency spectrum, where the highest frequency of each band is twice 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).
Ohm The ohm is a unit of electrical resistance. One volt will cause a current of one ampere to flow through a resistance of one ohm.
On-Set Paralleling
On-set paralleling is a manual paralleling system that is built onto the generator set, no additional switchboards are required.
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One-Line Diagram
A one-line diagram is a schematic diagram of a three-phase power distribution system which uses one line to show all three phases. It is understood when using this easy to read drawing that one line represents three.
Operating Source
An operating source is a source of electrical power that is delivering power to a load. The operating source can be either a generator set or a commercial (utility bus) power line.
Out-Of-Phase Out-Of-Phase refers to alternating currents or voltages of the same frequency which are not passing through their zero points at the same time.
Overcrank
Overcrank is an alarm function provided with most generator sets that indicate that the generator set has failed to start.
Overload Rating
The overload rating of a device is the load in excess of the nominal rating the device can carry for a specified length of time without being damaged.
Overshoot Overshoot refers to the amount by which voltage or frequency exceeds the nominal value as the voltage regulator or governor responds to changes in load.
Parallel Operation
Parallel Operation is the operation of two or more sources of AC electrical power whose output leads are connected to a common load. Connection of the power sources is made so that the sources electrically 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 control of a single generator set.
Paralleling Suppressers
Paralleling suppressors are semiconductor devices that protect the silicon diodes on a brushless excitation system from damaging overvoltages. Overvoltages, usually of short duration, occur when a generator is paralleled out of phase with the energized bus.
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Parameter
Monitored values or settings in the PCC or the Operator Panel that can be looked at and, in some cases, adjusted. Some parameters are protected by passwords.
Parity In error detecting schemes, a Bit (even or odd) that represents the binary sum of the data transmitted. Primarily used when transmitting data over a long distance. For example, when transmitting information using modems.
Pass Thru Refers to a junction box connection where the network bus comes to a connector and then continues 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 on setup or restart.
Per Unit (PU) Definition #1: A unitless quantity that is the ratio of the current operating value to the rated/nominal value. For example, a standby rated genset of 250 kW, 0.8 power factor with a load of +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 Load
Peak load is the highest point in the kilowatt demand curve of a facility. This is used as the basis for the utility company's demand charge.
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Peer-To-Peer
A network operating system where any device on the main network bus can initiate communication.
Phase Phase 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 or reach their maximums are 120 degrees apart, where one complete cycle is considered 360 degrees. A single-phase generator has only one winding.
Phase Angle
Phase angle refers to the relation between two sine waves which do not pass through zero at the same time. Considering one full cycle to be 360 degrees, the phase angle expresses how far apart the two waves are in relation to each other in degrees.
Phase Rotation Phase rotation (or phase sequence) describes the order (A-B-C, R-S-T, or U-V-W) of the phase voltages at the output terminals of a three-phase generator. The generator phase rotation must match the facility phase rotation. This must be checked prior to operation of the electrical loads in a facility 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 connected directly to high power DC loads such as fuel shut off solenoids or starter solenoids.
Pitch
Pitch 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 generator designer may use the pitch of a machine to optimize the generator cost versus the quality of the voltage waveform generated.
Pole
Pole is used in reference to magnets, which are bipolar. The poles of a magnet are designated North and South. Because magnets are bipolar, all generators have an even number of poles. The number of 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 a frequency of 60 Hz (1500 rpm for 50 Hz). Pole can also refer to the electrodes of a battery or to the number of phases served by a switch or breaker.
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Port
The external connector on a device at which the network cable or medium is attached.
Power Power refers to the rate of performing work or of expending energy. Typically, mechanical power is expressed in terms of horsepower and electrical power in terms of kilowatts. One kW equals 1.34 hp.
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 interrupting ratings. A power circuit breaker can be an insulated case or power air circuit breaker.
PowerCommand Control 1302
The 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 sets commonly have non-Cummins engines. The PCC 1302 control operates on 12 Volt or 24 Volt battery systems. It can be used without extra componentry on gaseous fuel gensets. When used on some Diesel gensets, an external governor signal amplifier is needed. The PCC 1302 is intended to be 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 power generation modules. The PowerCommand Network will utilize Echelon LonWorks for system module interconnection.
Power Factor
Power factor is the cosine of the angle between the active power (kW) and apparent power (kVA) in a circuit.
Prime Power
Prime Power describes an application where the generator set(s) must supply power on a continuous basis and for long periods of time between shutdowns. No utility service is present in typical prime power applications.
Priority Control
Priority control is the process by which the total loads on the bus is limited to the most critical loads 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.
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Pulse Alarms
Pulse alarms are alarm logic systems that allow all alarms to be annunciated, even if a previous alarm has been silenced but is still present in the system.
RAM Random-Access Memory. This is the memory that the PowerCommand Control uses to actually operate 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 Interference
Radio interference refers to the interference with radio reception caused by a generator set.
Radio Interference Suppression
Radio interference suppression refers to the methods employed to minimize radio interference.
Random Access Paralleling
Random access paralleling is a paralleling operation where any generator may be the first unit to close to the bus on startup of the system. Random access systems use active synchronizing to force the second and all subsequent generator sets to close to the bus as fast as possible.
Rated Current To be calculated based on rated power (kW) and nominal voltage.
Rated kW
Definition #1: This is set by the end application — standby, limited time prime, unlimited time prime, or continuous. Definition #2: Determined by the rated current and voltage programmed into the Base card by the Manufacturing Tool or calibration downloaded by InPower software. This is the maximum kilowatt load 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 the output. An example situation would be when a synchronizing control loop is attempting to drive the genset frequency to match the bus frequency. Perhaps the genset nominal frequency is 60.0 Hz, the genset 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 to match the bus. At this time, the reference value is 59.0 Hz.
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Register
A ModBus communication packet of information. Cummins Power Generation uses 40000 level designations 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.
RPM
Revolutions Per Minute.
Reactance
Reactance is the opposition to the flow of current in AC circuits caused by inductances and capacitances. It is expressed in terms of ohms and its symbol is X.
Reactive Differential Compensation Reactive 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 equally share the total reactive load on the bus, without inducing significant voltage droop in the system.
Reactive Droop Compensation
Reactive droop compensation is one method used in paralleled generator sets to enable them to share 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 voltage of a set is reduced by 4% from that at no load when reactive droop compensation is used.
Reactive Power
Reactive power is power that flows back and forth between the inductive windings of the generator and the inductive windings of motors, transformers, etc., which are part of the electrical load. This power does no useful work in the electrical load nor does it present load to the engine. It does apply load 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 Power Real power is the product of current, voltage and power factor (the cosine of the angle by which current leads or lags voltage) and is expressed as W (watts).
Resistance
Resistance is the opposition to the flow of current in DC and AC circuits. It is expressed in ohms and its symbol is R.
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Reverse Power Relay
A reverse power relay is a relay with a wattmeter movement that senses the direction of power flow. In paralleled sets, a flow of reverse power (i.e., power flow into set) will actuate the reverse power relay and disconnect the set from the system. If one set stops and reverse power protection is not 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.
Risers
Risers are rectangular copper or aluminum bars that connect circuit breakers, fusible switches, and transfer switches with the main system bus. As with bus bars, they are sized and assembled in multiples 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 network router is programmed as a "repeater" to create another channel on the main network bus. Each channel can have a 4,600 ft. network bus and is capable of having 44 nodes. The PowerCommand Network can have up to twenty (20) channels.
Save and Restore Calibration Downloading 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.
SCR
Silicon Controlled Rectifier -- a three-electrode solid-state device which permits current to flow in one direction only, and does this only when a suitable potential is applied to the third electrode, called the gate.
Selective Coordination
Selective coordination is the selective application of overcurrent devices such that short circuit faults 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 regulation circuit. 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 the normal electrical service.
Training Guide
Section 14 Page26
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Sequential Paralleling
Sequential paralleling is a type of automatic paralleling system where the generators in a system close to the bus in a prescribed order, typically by use of a single synchronizer.
Service Entrance The service entrance is the point where the utility service enters the facility. In low voltage systems the 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 operator adjusted 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 Trip Shunt 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 y axis) 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 data transmission. They respond to commands or requests initiated by a master device. In digital communication systems such as ModBus, this would be a device that is not capable of originating or initiating communications. It can only respond when asked for information.
Soft Loading Soft loading refers to the ramping of load onto or off of a generator in a gradual fashion for the purpose of minimizing voltage and frequency transients on the system.
Training Guide
Section 14 Page27
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Sound
Sound is considered both in terms of the sound pressure waves travelling in air (pressures superimposed 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 at points 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 meters indicate 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 propagates through the air. Because of the wide range of pressures to which the ear responds, a logarithmic scale 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 in decibels (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 Connection See Wye Connection.
Star Topology
A topology where all the devices must connect to a central hub. Star topologies are relatively easy to install and manage, but can have bottlenecks occur as all the information must pass through the hub.
Starting Current
The initial value of current drawn by a motor when it is started from standstill.
Stator
The 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 Rating Steady state rating is the maximum load that a generator set or paralleling system can carry, on a continuous basis, for the duration of a utility power outage.
Training Guide
Section 14 Page28
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Surge
Surge is the sudden rise in voltage in a system, usually caused by load disconnect.
Surge Rating Surge rating is the rating of a machine, usually in excess of its normal operating level, for which it can provide power for a very short time.
Surge Suppressor
Surge suppressors are devices capable of conducting high transient voltages. They are used for protecting other devices that could be destroyed by the transient voltages.
Switching Hub
Short for port-switching hub, a special type of hub that actually forwards information to the appropriate port based on the IP address assigned. Conventional hubs simply rebroadcast information 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 voltage sources and provides a signal when the voltage sources are within specific preset parameters.
Synchronization
In 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 voltage sources and provides a connection signal to an engine governor, to force the generator set to synchronize to the system bus.
Synchronizing Lights
Synchronizing 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 sources coincide and paralleling can be completed.
Synchronous Generator A synchronous generator is an AC generator having a DC exciter. Synchronous generators are used as stand-alone generators for emergency power and can also be paralleled with other synchronous generators and the utility system.
Training Guide
Section 14 Page29
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Synchroscope
A synchroscope is a meter that indicates the relative phase angle between an incoming set voltage and the bus voltage. The synchroscope pointer indicates whether the set is faster or slower than the bus and allows the operator to adjust the frequency (speed) accordingly before manually paralleling to the bus.
Telephone Influence Factor (TIF)
The higher harmonics in the voltage wave shape of a generator can cause undesirable effects on telephone communications when power lines parallel telephone lines. The telephone influence factor is calculated by squaring the weighted RMS values of the fundamental and the non-triple series 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 the Residual Component RIF.
Termination Both ends of the main network bus must be terminated to avoid transmission reflections. The effective network data bus may be made up of several different physical buses. The Terminator is a RC 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 the data path.
Token
In digital data transmission communications, this is a “permission to speak” bit that passes from network 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. Ring topologies are relatively expensive to install, but they offer high bandwidth and can span larger distances.
Topology The 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. An automatic transfer switch monitors the condition of the sources and connects the load to the alternate source if the preferred source fails.
Training Guide
Section 14 Page30
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Trim
Non-volatile adjustment made in the field by an operator, user, or service technician. It is a subset of 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 “TwistedPair, Transformer-Coupled, 78 kbaud speed network.” The TP/XF-78 network has been replaced by PCCNet network in small systems and by the FT-10 network in larger systems.
Utility The 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.”
Undershoot
Undershoot 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.
Volt
The volt is a unit of electrical potential. A potential of one volt will cause a current of one ampere to flow through a resistance of one ohm.
Voltage Control The voltage control is a rheostat that sets the operating point of the voltage regulator and therefore controls the output voltage of the generator set, within its design limits.
Voltage Dip
Voltage dip is the dip in voltage that results when a load is added, occurring before the regulator can correct it, or resulting from the functioning of the voltage regulator to unload an overloaded engine-generator.
Voltage Regulation
Voltage regulation is a measure that states the difference between maximum and minimum steadystate 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 user or operator of an out of normal condition which could eventually adversely affect operation of the Genset (i.e. could shut it down or prevent it from starting or operating properly).
Training Guide
Section 14 Page31
PCC 3.3 and PowerCommand Control 3300
PowerCommand Control 3300 Glossary
Watt
The watt is a unit of electric power. In direct current (DC) circuits, wattage equals voltage times amperage. In alternating current (AC) circuits, wattage equals effective (RMS) voltage times effective (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 indication of 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 recording increment is in kW-hours.
Wattmeter
A wattmeter records power being delivered from a source to the load. Wattmeters for paralleling systems 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 a three-phase system to form a configuration resembling the letter Y. A fourth (neutral) wire can be connected at the center point.
Zero Sequence Zero sequence is a method of ground fault detection that utilizes a sensor (CT) that encircles all the phase conductors as well as the neutral conductors. The sensor will produce an output proportional to the imbalance of ground fault current in the circuit. This output is then measured by a relay to initiate circuit breaker tripping or ground fault alarm.
Zones of Protection
Zones of protection are defined areas within a distribution system that are protected by specific groups.
Training Guide
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PCC 3.3 & PowerCommand Control 3300
Participants’ Activity Section 15 I
_____________________________________________________________________
Section 15: 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 2 - 2 Menu Activities
15-7
Section 2 - 3 Menu Activities
15-13
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
Participants’ Guide
Section 15 - 1
PCC 3.3 & PowerCommand Control 3300
Participants’ Activity Section 15 I
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Section 15 - 2
PCC 3.3 & PowerCommand Control 3300
Participants’ Activity Section 15 I
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Activity 1-1: 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
_____ 12) DSx LED Status Indicators
_____ 2) J19 Control Board Interconnection
_____ 13) Onboard CT’s
_____ 3) TB-7 Bus Voltage Sense
_____ 14) J26 AUX105 Connections
_____ 4) AUX 105 Power Stage
_____ 15) J22 Genset Voltage Sense
_____ 5) J14 Service Tool Port
_____ 16) TB-9 Analog I/O
_____ 6) J12 Genset CT Input
_____ 17) TB-10 Breaker Status Connections
_____ 7) TB-8 Customer Connections
_____ 18) J18 – Power Input
_____ 8) J20 Genset Connections
_____ 19) Chassis Ground Wire
_____ 9) TB-1 Customer Connections
_____ 20) TB-3 Customer Input/Output
_____ 10) J17 – Field Output
_____ 21) J25 Display Connections
_____ 11) TB-15 ModBus/RS485 Service Port
_____ 22) PCC 3300
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Participants’ Activity Section 15
Activity 2-1: 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
Participants’ Guide
Section 15 - 5
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
4. Fault History Fault Index 1
Fault Index 2
__________ Fault Number
__________ Fault Number
__________ Fault History at # Hours
__________ Fault History at # Hours
_____________________Fault Name
______________________ Fault Name
Fault Index 3
Fault Index 4
__________ Fault Number
__________ Fault Number
__________ Fault History at # Hours
__________ Fault History at # Hours
____________________ Fault Name
______________________ 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?
Participants’ Guide
Section 15 - 6
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 2-2: 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
Participants’ Guide
Section 15 - 7
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
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 Participants’ Guide
Section 15 - 8
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
____________________ 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
Participants’ Guide
Section 15 - 9
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
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 Participants’ Guide
Section 15 - 10
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
___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: ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________
Participants’ Guide
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PCC 3.3 and PowerCommand Control 3300
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Section 15 - 12
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 2-3: Soft Key Menu Navigation 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 Participants’ Guide
Section 15 - 13
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
____________________ 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: Participants’ Guide
Section 15 - 14
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
____________________ Exhaust Port Temp #2 ____________________ Exhaust Port Temp #20 ____________________ Governor Ramp State ____________________ Battery Charger Voltage
Participants’ Guide
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PCC 3.3 and PowerCommand Control 3300
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Section 15 - 16
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 3-1: 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 HMI 320? _______________________________________________________________________ 3. If the genset is running and then enters Manual operation, how long do you have to push 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 the PowerCommand 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 to close? _______________________________________________________________________
Participants’ Guide
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PCC 3.3 and PowerCommand Control 3300
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Section 15 - 18
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 4-1: PC3.3 Installation Quiz Answer the following questions about functions and components; use the demonstrator, Participants’ Guide or Operator Manual 900-0670. 1. When powering down the PCC 3300, it is important to press the local Emergency Stop button and wait approximately 30 seconds before removing battery power. Why? A. To ensure that the ECM has time to cool down before power down B. 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. B. C. D.
J17-1 and J17-2 J20-11 and J20-22 J26-7 and J26-14 None of the above
3. Which of the following is a true statement? A. B. C. D.
Low side is the same as battery ground B+ return is the same as battery negative B+ return is the same as ground None of the above
Match each of the following components in column A to its corresponding function in column B Column A (Component) 4. _______CT1, CT2, CT3 5. _______J26 6. _______TB5 7. _______HMI320 8. _______TB9
Participants’ Guide
Column B (Function) A. Provides analog paralleling load management input and output B. Monitor the Bus current C. Monitor the genset current D. Connection to the engine and AVR Power Stage E. Connection to the circuit breaker controls F. Interface to the generator and controller functions Section 15 - 19
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PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 5-1: PC3.3 Setup and InPower Quiz Answer the following questions about functions and components; use the demonstrator, Participants’ Guide or Operator Manual 900-0670. 1. Kit 0541-1199 allows the technician to connect InPower to both the Operator Panel and the Base Board at the same time. A. B.
True False
2. Which of the following is true with regard to connecting InPower to the HMI? A. B. C. D.
The HMI needs to powered by a DC source via connector 15 Communication takes place through J28 on the HMI The HMI can be powered through the control board via connector 15 None of the above
Match each of the following feature folders in column A to its corresponding function in column B Column A (Component) 3. _______Advanced Status
Column B (Function) A. Allows the user to view fault information and set fault 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, genset and 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 the adjustments folder. F. Allows the user to monitor alternator performance data only
Participants’ Guide
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PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
8. The snapshot feature allows the user to select a particular fault and then view data for the preceding few seconds before that fault becomes active. A. B.
True 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 setup screens must be highlighted in order to be able to make any adjustments/changes. A. B.
True False
Participants’ Guide
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PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 5-2: 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 at 10:00AM 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 year 2008. 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.
Participants’ Guide
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Participants’ Activity Section 15
Activity 6-1: PC3.3 PCCNet Quiz Answer the following questions about functions and components; use the demonstrator, Participants’ Guide or Operator Manual 900-0670. 1. The recommended data cable for the data and power wires used with PCCNET is Beldin #9729. A. True B. False 2. The maximum number of devices in the network is 20 and should not span more than 4000ft of data wire. A. True B. 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 systems D. It is a token passing network 4. List 4 devices that the PCC 3300 communicates with
Participants’ Guide
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PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
5. Which of the following is true about the Universal Annunciator? A. PCCNET allows for up to four annunciator’s in a network B. The Annunciator supports both network and discrete wiring terminals C. PCCNet Annunciator Switch Settings can only be changed when the device is connecting with the PCC Genset D. Both A and B E. All of the above
Activity 6-2: 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. More PCCNet devices will be available at that time. The skills and experience of setup and installation of the PHASE 2 devices will be more valuable at that time.
Participants’ Guide
Section 15 - 26
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 7-1: PC3.3 ModBus Quiz Answer the following questions about functions and components; use the demonstrator, Participants’ Guide or Operator Manual 900-0670. 1. Since the PowerCommand 3.3 follows the master-slave protocol, would the PowerCommand 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 Genset LL Average Voltage? ________________________________________________________________________ 8. What software can be used to help troubleshoot the PowerCommand 3.3 ModBus communication? ________________________________________________________________________
Participants’ Guide
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PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 8-1: PC3.3 PGI CAN Communication Quiz Answer the following questions about functions and components; use the demonstrator, Participants’ Guide or Operator Manual 900-0670. 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 2300 base board with InPower? _______________________________________________________________________ 4. If you were connected with a Peak System Adapter and did not see DC as part of any source 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? _______________________________________________________________________
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PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 9-1: PC3.3 Parallel Intro Quiz Answer the following questions about functions and components; use the demonstrator, Participants’ Guide or Operator Manual 900-0670. 1. The PC3.3 comes fully configurable and there is no requirement to purchase new codes or additional features. _____True _____False 2. In what mode would you use Load Govern? A. Standby B. Isolated Bus C. Utility Single D. Utility Multiple E. C & D 3. Load Share is a feature that allows? A. The amount of KVAR sharing B. 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. TB10 B. TB1 C. TB5 D. TB3 5. There are many adjustments and few monitor screens in the paralleling setup folder. _____True _____False
Participants’ Guide
Section 15 - 31
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
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Section 15 - 32
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 10-1: PC3.3 Standalone Paralleling Quiz Answer the following questions about functions and components; use the demonstrator, Participants’ Guide or Operator Manual 900-0670. 1. The password used for changing the Genset Application Type from the HMI is? A. 121 B. No password is required C. 574 D. 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. 1213 B. 1454 C. 1456 D. 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 relay D. breaker trip relay.
Participants’ Guide
Section 15 - 33
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
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Section 15 - 34
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 11-1: PC3.3 Synchronize Only Quiz Answer the following questions about functions and components; use the demonstrator, Participants’ Guide or Operator Manual 900-0670. 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 only mode? A. 40954 B. 43954 C. 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 &17 B. 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 command B. InPower C. Configurable Input #30. D. after the control fails to Phase Match synchronizes for 10 consecutive seconds.
Participants’ Guide
Section 15 - 35
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
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Section 15 - 36
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 12-1: PC3.3 Isolated Bus Paralleling Quiz Answer the following questions about functions and components; use the demonstrator, Participants’ Guide or Operator Manual 900-0670. 1. The genset circuit breaker close control output is provided at terminals? A. TB10 – 8 & TB10 - 2 B. TB5 – 1 & TB5 - 2 C. TB10 – 9 & TB10 - 11. D. None of the above 2. Which connector is used for circuit breaker control? A. TB3 B. TB7 C. TB5 D. None of the above 3. Which connector inputs are used for First Start Arbitration? A. TB3-9 & TB3-1 B. TB10 - 13 & TB10 - 17 C. 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 the PCC3300 control board? A. TB9- pins 7, 8, 10, & 11 B. TB7 – pins 1, 2, 3, and 4 C. TB7 – pins 5, 6, 7, and 8. D. TB7 – pins 1, 2, and 3
Participants’ Guide
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PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
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Section 15 - 38
PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
Activity 13-1: PC3.3 Troubleshooting Quiz Answer the following questions about functions and components; use the demonstrator, 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. manual?
is found on which page in the service
A. A-5 B. A-7 C. A-5, 6, 7, and 8. D. A-12
Participants’ Guide
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PCC 3.3 and PowerCommand Control 3300
Participants’ Activity Section 15
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Section 15 - 40
PCC 3.3 and PowerCommand Control 3300
Appendix Section 16
Section 16: 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
Participants’ Guide
Section 16 Appendix
PCC 3.3 and PowerCommand Control 3300
Appendix Section 16
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Participants’ Guide
Section 16 Appendix
PC 3.3 REAL TIME CLOCK & EXERCISE
Appendix A
PC 3.3 Real Time Clock 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
First Occurrence – Last
Occurrence of Daylight Savings End
Occurrence in Month
Occurrence
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
First Occurrence – Last
Occurrence of Daylight Savings End
Occurrence in Month
Occurrence
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 3.3 Training Guide
Appendix A Page1
PC 3.3 REAL TIME CLOCK & EXERCISE
Appendix A
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
First Occurrence
Occurrence in Month Daylight Savings Start Day
Thursday
Daylight Savings Start Hour
15
Daylight Savings Start Month
9
Daylight Savings Start Week
Second Occurrence
Occurrence in Month Daylight Savings Time Adjustment
60
*The real time clock is accurate with 30 minutes over the course of 1 calendar year.
PC 3.3 Exercise Scheduler 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 3.3 Training Guide
Appendix A Page2
PC 3.3 REAL TIME CLOCK & EXERCISE
Appendix A
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
Once, Twice…
Specifies the repeating behavior of
Interval
Program X
Scheduler Program x Duration
0 – 23
Specifies how many hours Program X
Hours
will run.
Scheduler Program X Duration
1 – 59
Specifies how many minutes Program
Minutes
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
Every Week
Interval Scheduler Program x Duration
1
Hours Scheduler Program X Duration
30
Minutes
PC 3.3 Training Guide
Appendix A Page3
PC 3.3 REAL TIME CLOCK & EXERCISE
Appendix A
The following table is the Exercise Scheduler table which contains the information for Programs 1 thru 12. Scheduler
Scheduler
Schedule Repeat
Program
Program
Program
Interval
Start Day
Duration
Run Mode
Scheduler
Scheduler
Program Enable
Start Time
Hr
Min
Hr
Week
Min
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
PC 3.3 Training Guide
0 – 23
Specifies how many hours Exception X will be valid for.
Appendix A Page4
PC 3.3 REAL TIME CLOCK & EXERCISE
Scheduler Exception X Duration
Appendix A
1 – 59
Specifies how many minutes
Minutes
Exception X will be valid for.
Scheduler Exception X Duration
0 – 44
Specifies how many days Exception X
Days
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 Jan 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
23
Hours Scheduler Exception X Duration
1
Minutes Scheduler Exception X Duration
7
Days
The following is the Exercise Scheduler which contains all the exceptions 1 - 6.
Scheduler
Scheduler
Scheduler
Scheduler
Exception
Exception Time
Duration
Exception
Schedul er
Exception
Exceptio
Enable
n Repeat Month
(Interval)
Date Hour
Minute
Days
Hours
Minute s
Exception 1 Exception 2 Exception 3 Exception 4 Exception 5 Exception 6
PC 3.3 Training Guide
Appendix A Page5
PC 3.3 REAL TIME CLOCK & EXERCISE
Appendix A
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 started again 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.
PC 3.3 Training Guide
Appendix A Page6
Appendix B
PC 3.3 ModBus
USING MODSCAN SOFTWARE ModScan is a software tool that can help you verify ModBus communications from the PowerCommand control. It is not a Cummins Power Generation product, it is a product designed by 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 a neutral third party software. The following directions and examples apply to using ModScan with PCC 1301 and 1302 genset controls. 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 standard PCC 1300 series service cable must be installed between the PC serial port and the TB-15 connector on the PCC 1302 control board. PC serial ports communicate using RS232 so a RS485 converter must be used. Figure 1 show the initial screen displayed upon launching the program.
Page 1
Appendix B
PC 3.3 ModBus
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 designate the 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 2
Appendix B
PC 3.3 ModBus
FIGURE 3. FT–10 NETWORK CONNECTION DETAILS DIALOG BOX
3. Click on the “Protocol Selections” button and change the Transmission Mode to “RTU” (see Figure 4). Do not be concerned with settings in the other boxes. Click “OK” button.
FIGURE 4. MODBUS PROTOCOL SELECTION DIALOG BOX
Page 3
Appendix B
PC 3.3 ModBus
4.Click “OK” on the two open dialog boxes. You should notice in the upper right of the dialog box, the “Number of Polls” counter incrementing. Notice the message at the top of the register list captured by **____**. In Figure 4-2 the message **MODBUS Exception Response from Slave Device ** is indicating the device has responded, 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 find anything 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. ModScan is not satisfied if it polls a group of registers and finds one in the sequence that is not programmed, it will display a “Exception Response” as in Figure 4-2. Minimize the number of registers polled to a sequential length as listed in the register map. WARNING
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 the preceding 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 register addresses 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) Page 4
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 in step 5. 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 Auto mode, the genset WILL start. WARNING
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 Register dialog 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 on register 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 5
Appendix B
PC 3.3 ModBus
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. There are other features used on some of the other PowerCommand ModBus systems, but the processes and examples so far listed will enable a technician prove to a customer or system integrator that the PCC 1301 or 1302 will communicated properly.
Page 6
Appendix B
PC 3.3 ModBus
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 set to “0,” the genset stops.
Fault Reset - This should be a momentary signal of about 2 seconds duration. Entering a “1” in the fault reset register resets any non–active warning and, If there is not a remote start on the genset, 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 PowerCommand control. It cannot be reset remotely.
Miscellaneous
Fault State - As part of Gen Status State, digital value 4 (Fault State 1) = shutdown with an active run command (cannot be remotely reset) and digital value 5 (Fault State 2) = shutdown with no active run command (can be remotely reset).
Fault Code - This register contains the fault code number of the currently active fault. See service manual for list of supported fault codes. Fault Type - This register contains the fault type of currently active fault 0=Normal 1=Warning 2=Derate (this is a feature NOT currently supported by the PCC 1300 series) 3=Shutdown with Cool down 4=Shutdown
Fault bypass (battle short) feature enable – Activation of battle short via ModBus is just as serious as any other activation of battle short.
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Appendix B
PC 3.3 ModBus
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PCC 3.3 and PowerCommand Control 3300
Diagrams Section 17
Section 17: 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
Participants’ Guide
Section 17 Sequence Diagrams
PCC 3.3 & PowerCommand Control 3300
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PARALLELING SEQUENCES LEGEND
B-3
SYNCHRONIZE ONLY
B-4
ISOLATED BUS ONLY
B-5
PCC 3.3 & PowerCommand Control 3300
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Section Last Page
PowerCommand 3.3 & PowerCommand Control 3300 Section 18 ________________________________________________________________
Section 18: PC 3.3 & PCC 3300 Module Comment Sheet Participants are requested to turn in the Comment Sheet at the end of the course to help update the course materials as needed.
Participants’ Guide
Section 18
PowerCommand 3.3 & PowerCommand Control 3300 Section 18 ________________________________________________________________
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Participants’ Guide
Section 18
PowerCommand 3.3 & PowerCommand Control 3300 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
Your Skill level
Before the program
After the program
High Skill
No skill
No skill
High Skill
Understanding the CPG model and component naming system.
0
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Selection of proper Section topics and Section content.
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Use of Installation guides, Instruction 0 Sheets, Guides, and Appendix Material.
1
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Operating the HMI, and navigating the control system.
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Operation of the HMI for configuration processes and setup.
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Operation and connection of InPower for configuration processes and setup.
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Understanding Common Connector Scheme and new schematics.
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Understanding connector locations and functions.
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Understanding features and commonality of options.
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Setup various PCCNet components and install them.
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Setup the ModBus feature, test it and understand its basic operation.
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Identify PGI CAN system components and understand their operation.
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Troubleshoot CAN genset control systems.
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Converse about genset communication ability with Building Management System installers.
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Participants’ Guide
Section 18
PowerCommand 3.3 & PowerCommand Control 3300 Section 18 ________________________________________________________________
We are interested in your opinion about the effectiveness and usefulness of this training module. We will use the results of your response to help improve and modify training modules and the effectiveness of their delivery. Please fill out the form by placing a mark on the scale next to each statement.
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Section 18
PowerCommand 3.3 & PowerCommand Control 3300 Section 18 ________________________________________________________________
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