PCC 2100 Commissioning Guide Lines_Rev2.6

Commissioning report for PCC Engine ESN:

Model:

Name of the Commissioning Engineer : Date Of Commissioning:

OEM

Name of the OEM Engineer

Customer:

Parts & their Sr.Nos. ( Kindly Confirm by actual Inspection) Cummins Part No Parts Control Assy. 0300-5459-02

Fuses : Fuse

Engine Harness

0338-4232

F1

AC Harness

0338-4977

F2

Location, Rating Function Base Board---10 A Protects B+ Ckt (TB1-17 & TB1-18 Base Board---5 A Protects Switched B+ Ckt (TB1-19)

Coolant/L.O. Temp. Sender 0193-0529-02

F3

Lube Oil Press. Sender

0193-0444

F4

Base Board Display Board Bar Graph Board Pilot Solenoid MPU Low Coolant Level Switch PCC O & M Manual CT Ratio CT's For 750KVA--2141 / 1 CT's For 1000 KVA--2839/1 CT's For 1250KVA--3867/1 CT's for 1500 KVA--4420/1

0327-1379-01 0300-5467 0300-5180 0307-2621-02 4085824 0193-0468 0900-0534 CT Part Number 0302-2058-03 0302-2058-08 0302-2058-12 0302-2058-15

F5

Base Board---2 A Protects Switched B+ Ckt (J7-23 &J7-9) Base Board---5 A Protects Base Board Power Supply PTC Module (optional)---2 A Protects PTC Module

Calibration Part No. 0326-6167 0326-5769 0326-5761

K-38 K-50 V-28

Model

PCC Commissioning checks/pmp

Factory Installed Feature List - 750KVA

Factory Installed Feature List - 1000KVA

Feature Part Numbers 0326-5482 0326-5485 0326-5490 0326-5566 0326-5576 0326-5584 0326-5596 0326-5683 0326-5696 0326-5759

Feature Part Numbers 0326-5482 0326-5485 0326-5490 0326-5566 0326-5576 0326-5584 0326-5596 0326-5683 0326-5696 0326-6156

Description Lonworks Disabled Application -Prime Coolant Level SD WYE Connection Voltage- 416 L-L Oil Temp. Sender Enable Frequency -50 Hz Excitation -PMG Over speed - 1800 rpm Battle Short Enable

0326-5819

Description Lonworks Disabled Application -Prime Coolant Level SD WYE Connection Voltage- 416 L-L Oil Temp. Sender Enable Frequency -50 Hz Excitation -PMG Over speed - 1800 rpm CT Ratio 600 KW Prime/660 KW standby - 3 Ph

0326-6192

0326-6156 0326-6717

Battle Short Enable Gov. Gains

0326-6361 0326-6717

CT Ratio 800 KW Prime/ 880 KW standby - 3 Ph Gov. Gains

Factory Installed Feature List - 1250KVA Feature Part Numbers Description 0326-5482 0326-5485 0326-5490 0326-5566 0326-5576 0326-5584 0326-5596 0326-5683 0326-5696 0326-5849 0326-6156 0326-6197 0326-6490

Lonworks Disabled Application -Prime Coolant Lvl SD WYE Connection Voltage- 416 L-L Oil Temp.Sender Enable Frequency -50 Hz Excitation -PMG Overspeed - 1800 rpm 1000 KW Prime/ 1100 KW standby - 3 Ph Battle Short Enable CT Ratio Gov.Gains

Factory Installed Feature List - 1500KVA Feature Part Numbers Description 1200 KW Prime/ 1320 KW standby - 3 Ph 0326-0411 0326-5482 Lonworks Disabled 0326-5485 Application -Prime 0326-5490 Coolant Level SD 0326-5566 WYE Connection 0326-5576 Voltage- 416 L-L 0326-5584 Oil Temp.Sender Enable 0326-5596 Frequency -50 Hz 0326-5683 Excitation -PMG 0326-5696 0326-6156 0326-6199 0326-6490

Overspeed - 1800 rpm Battle Short Enable CT Ratio Gov.Gains

PCC Commissioning checks/pmp

Visual Inspection 1. Engine Wiring Harness: The entire wiring should be clamped appropriately, with no loose wires hanging LCL if connected , should be wired up as follows: LCL Wires-----------------Engine Wiring Harness Red--------------------------------- S7 + ( J7-31 +Ve) Black------------------------------- S7 - ( J7-35 -Ve) Blue---------------------------------S7-Sig (J7-32) Plugs / Connectors ,engine Harness Connector P7 - -- Connects on the Base Board ( Inside the door of PCC 2100) --While Fixing this plug first match the notch & push it in . CT Wires -- Connect X1 & X3 wires to individual CT's AC Harness : Connector No : P8 --Connects to J8 connector inside the PCC 2100 Box --PMGP2, PMG3 , PMG4---Connect this wire to the PMG wire coming out from the Main Alternator ( See that length of this adequate. DO NOT EXTEND THESE WIRES, IF THESE WIRES ARE SHORT IN LENGTH----If required bring these wires to a terminal strip , securely mounted on the alternator frame inside & connect the Alternator PMG wires on the terminal strip> X+, XX --These are field winding wires ----Connect the field winding wires from the main alternator to these wires ( F1 to X+ & F2 to XX U,V,W & N --- These are the Main Phase voltage connections. AC Harness Details -- P8 Connector One side of P8 plugs inside the PCC 2100 control & the other end connections are as follows: P8 -1,2,3,8,9,10,11,15,16,17,18,19 - Not Connected P8-4 - U ( R Phase Connection) P8-5 - XX ( Field -F2 Connection) 4 3 2 1 P8-6 - Not Connected P8-7 - Neutral P8-12- V ( Y Phase Connection) P8-13 - X ( F1 Field connection) P8-20 - W (B-Phase Connection) 24 23 22 21 P8-21- PMG2 P8-22 - PMG3 AC harness P8-23 -PMG4 P8 Connector Ensure that the wires going out of the Terminal strip towards the main panel ( OEM connections) are properly dressed & there are no loose wires hanging. Additional spare wires to be taped & dressed separately. Starter Connections : Only one magnetic switch drives both ( for V Engines) the starters. Physically inspect that the positive terminals of Both the starters are looped ( Shorted). Similarly the negative terminals of both the starters are looped (shorted & connected to Engine body)

PCC Commissioning checks/pmp

PCC 2100 - Terminal Strip TB1 & TB2 Details at a Glance TB-1

TB-2

1

REMOTE START

1

2

REMOTE EMERGENCY STOP

2

3

Remote Reset

3

4

Customer Fault 1

4

5

Customer Fault 2

5

6

Customer Fault 3

6

7

Customer Fault 4

8

Cust. Out 1 NO

9

RS -485 + RS -485 B+ GND Not Used Not Used

Cust. Out 1 Common

10

Cust. Out 2 NO

11

Cust. Out 2 Common

12

Cust. Out 3 NO

13

Cust. Out 3 Common

14

Cust. Out 4 NO

15

Cust. Out 4 Common

16

SPARE

17

B+(20A FUSED)

18

B+(20A FUSED)

19

SWITCHED B+(10A FUSED)

20

GROUND

21

GROUND

22

GROUND

PCC Checks / pmp

PCC TB1 Connections Sample Drawings related to each terminal of the TB - 1 pin terminal strip are given below. All the connections shown need not be used, the Mandatory connections are mentioned in BOLD Remote Start ( Mandatory For AMF applications) TB1 1 REMOTE START ( IF PCC RUN /OFF/AUTO Switch is in AUTO & if Ground is connected to terminal No.1 then engine will start remotely) Main Panel TB1 1 Remote Start Switch

20 Sample Drawing for Remote start for AMF Application Main Panel 1 Voltage Sensing 20 Relay TB1

Remote Emergency Stop(

R Y B N

UTILITY SUPPLY

Mandatory) Main Panel

TB1 2 20

Remote Emergency stop Switch

if Ground is connected to terminal No.2 then engine will stop,PCC will indicate Emergency Stop.

CUTOMER FAULTS 1,2,3 & 4 ( Earth Fault Protection Mandatory , Others Optional) TB1 4 CUSTOMER Input 1 ------Default Not Programed Not Assigned 5 CUSTOMER Input 2 ------Default Programed as Ground Fault--Shutdown 6 CUSTOMER Input 3 ------Default Programed as Low Fuel level--Shutdown 7 CUSTOMER Input 4 ------Default Programed as High Alternator Temp--Shutdown These are customer configurable inputs to the PCC, they can be either configured for Warning or Shutdown In PCC there is no inbuilt protection for Earth Fault. An earth fault relay has to be externally used for this Purpose, the out put of which can be brought into the PCC for shutting down the engine. For this Customer Fault No2 (Ground Fault) has to be used. Main Panel TB1 Relay Activated By E/F A34-P1-12 5 Protection Relay GND-ENG

20

Whenever there is an Earth fault,the relay will pick up & the NO contact of the relay will connect Ground to Terminal No.5 The PCC will now display Ground Fault & will trip the engine (since it it programed for Shutdown)

PCC Checks/PMP

Example No. 2 If the Circuit Breaker trips due to Breaker internal electrical Protection, then this input can be brought into the PCC & the engine can be tripped. Program the Customer Fault No 1 to ' Breaker Trip ' or ' Electrical Fault' ----Program it for Shutdown (Through PCC menus) TB1 P12-1/A34-P1-9 4 Breaker Trip N/O Contact GND-ENG 20 Main Panel

Fault Reset: This can be use to reset Warning Faults from Remote or Main Panel TB1 Main Panel A34-P1-2 3 FAULT RESET When terminal No 3 is grounded ,the A34-P1-2 20 warning fault from a remote location can be reset. GND-ENG 3 Fault Reset Push Button

Customer Outputs : These are configurable outputs which close a NO contact when the desired configured event occurs. These Outputs can be configured for any event through Inpower. The Default ( Factory Installed) configured outputs are : Customer Output No.1 ---- Common Warning Customer Output No.2 ---Common Shut Down Customer Output No.3 ---Not In Auto Customer Output No.4 ---Ready to Load However all these Customer outputs can be configured to any desired event through Inpower Example No.1 : Customer out Put No.1 If Configured for Common Warning: When there is any warning on the Genset, the PCC internal 8 contact closes & the indicating lamp will glow. This could be a lamp, an Audible announciation or any other relay for complex 9 logic. 24 Vdc From TB1-17 17 Example No.2 : Customer Output No.4 (Default configured as Ready to Load)

TB1 14 15

(N/O) (N/O)

Breaker Closing

( Mandatory)

Breaker Closing

Sample Drawing for Breaker Closing

A34-P2-4

TB1 14

A34-P2-3

15

TB BAT-F1

17

Aux.NC contact of Brkr Closing Coil of Brkr 24 vdc supply from TB1-1

PCC Checks/PMP

The NO contact between 14 & 15 will close when: A----( Single & NON Paralleling Sets or DEAD BUS) 1.In Run or Auto Mode, when Engine Speed & Voltage reaches 90% of Rated.

Caution : If this Genset is used for Parallel operation, then the Paralleling Breaker has to be closed through an external Sync Check relay.

Mandatory Connection to Cut out the External Battery charger if used : Switched B+ : 24 Vdc Will be available on this Terminal only when the Fly wheel Starts rotating. Use the logic diagram given to cut off the external battery Charger if Used. Relay Activated By Switched B+ TB1 19

Battery Charger

Batty. Charging Alt.

battery bank

Batty. Charger Input Supply Example No 2 : Use of switched B+ for starting Raw Water Pump for HE cooled engines.

Sample drawing for running Raw water Pump R1 TB1 P12-2 19 Common B-ve ( TB1-21)

Engine Ground

R1

M 230V

TB1

GND-ENG

20

any Ground looping in the PCC Panel can be taken from here

GND-ENG

21

any Ground looping in the PCC Panel can be taken from here

22

PCC Net -- Announciator Connections Note : Not a standard scope of supply -- Optional ( to be ordered seperately) Cummins Proprietory Protocol - PCC Net

TB2 1 RS 485 2 B+ 3 GND 4

RS 485 +

Droop Operation of PCC 2100

RS 485 lines

Cummins Universal Announciator P.No. 0300-5929

PCC Checks/PMP

PCC 2100 For Droop Operation :PCC 2100 can be operated on Droop. All we need to do is set the required % of Droop ( Speed or Voltage)either from the main panel or through Inpower. No external resistances are required to be connected. What ever % of Droop is set, automatically the High idle speed to change in accordance with the droop set. Raise / Lower Voltage & Speed (Speed/Voltage Bias is currently Not available)

PCC 2100 -- For Use with Either PCW for Monitoring Only or For BMS Integration. If the PCC 2100 is desired for Remote Monitoring : Following Parts are required ( Not a std Scope of supply)to be ordered seperately NCM-- Network Communications Module -- P.No. One Per Genset SLTA - Serial Lon Talk Adaptor --P.No. One per Site CAT -5 / Cat 6 Cable --- As per Distance between sets upto the SLTA Adaptor with Power supply ( Near the Customers PC) Genset No 1 Genset No 2

PC Serial Nul Modem Cable

Twisted pair Cat -4 / Cat 5 Cable BMS Integration OR PLC Interface using MODLON Convertor Third party BMS Integrator

Modlon Convertor

RS 232 Serial (2,3,5 Straight through Cable)

In this configuration All our Genset data can be given to a third party Integrator through the Modlon convertor which converts Lon data given by our Gensets to Modbus RTU. This BMS integrator brings in data from various other devices & then the Integrator uses his own software to monitor all the devices connected to the integrator on a PC.

PCC Checks/PMP

TS 1311 + PCC 2100 GENSET START COMMAND P5 - 6 & P5 - 7

- +

U T I L I T Y

L1 N

L2 L

L3 N

AMF LOGIC P5--6

G E N S E T

Utility Breaker Aux. Contact

24V

TB1-1

P5--7

TB1-20 K1

K1

P5 -9 ( 24V +) P5 - 8 ( GND)

PCC 2100 CUSTORMER CONNECTION ON TB1

Please note : The default setting of Customer outputs is as below. 1 Customer o/p no. 1 - Common waring (TB1-8,9) 2 Customer o/p no. 2 - Common Shutdown (TB1-10,11) 3 Customer o/p no. 3 - Not in Auto (TB1 12,13) 4 Customer o/p no. 4 - Ready to Load (TB1-14,15)

Non AMF Mechanical Breaker with u/v trip

+ 24 V from TB BAT-F1 (17)

Common S.D. 10 11

K-1 Relay for Breaker trip

230 V from DG Set / Panel

K1 K1 NC

K1

Under voltage coil of the braker

Paralleling PCC 2100 in Droop Mode using Aux101 module Connect the Aux 101 module as per instruction sheet (C698) and change the necessary settings as listed below. • • • • • • •

Aux 101 – Enable Device#1 Input 1 Enable – Enable Device#1 Input 2 Enable – Enable Device#1 Input 1 Sensor Type – Bias Sensor Device#1 Input 2 Sensor Type – Bias Sensor Set the Speed Bias Scale value. Set the Voltage Bias Scale value.

It is must to adjust the V/Hz table of the PCC2100 to more closely match the V/Hz characteristics of the Newage AVR if you are paralleling with non-PCC Genset. Modify the V/Hz table as shown below on the PCC2100. Original V/Hz Table Hz % 0.000 100.000 3.000 100.000 7.313 80.005 11.638 50.000 15.950 19.995 80.00 0.000

Modified V/Hz Table Hz % 0.000 100.000 1.000 100.000 5.313 80.005 9.638 50.000 13.950 19.995 80.00 0.000

1) Calibrate Voltage and Current and PF 2) Once calibrated, parallel the two Gensets without load and monitor KVARs. If one genset is pushing KVARs onto the other, the Voltage Adjust % command should be used to remove this offset. This parameter is on the front panel of the PCC2100 and in InPower. Once they are calibrated, they will share load normally. Reference : - Instruction sheet C-698

Parameters to be logged on Hourly basis Voltage Cool.Te Eng. mp. DG Run No. of Lube Oil Lube Right/Le Batty. No. Time Hrs Starts Temp. Oil Pr. ft Volt. RPM Gov % Reg% L12

L23

Current

L31

L1

L2

L3

KW

PF

KWh

%Load %Amps

PCC Checks / PMP