PCC2100 Participants Guide

Technical Training Participant’s Guide PowerCommand) Control 2100 with CAN Link

CMT0686-EN-PG 11/2005

PowerCommand Control 2100 w/ CAN Link

Introduction

Revision History v5.00 (11/2005) 1. Removed last mentions of PTC Module – thanks go out to Kurt Rahkola v4.00 (09/2004) 1. Updated CAN Link section. 2. Re-ordered guide sections to put prints just before the Comment Sheet. 3. Added Performance Assessment. v3.00 (04/21/04) 1. Added section on CAN Link to ECS on Cummins G-Drive engines. v2.0 (4/2/04) 1. Updated with changes found by guest instructor during USAF session in January 2004. Thanks Tim. 2. Updated copyright information v1.1 (8/25/02) 1. Numerous revisions found in first QTQ session. Many sections involved in this revision, subtle changes to text and diagrams. v1.00 (7/20/02) 1. Initial draft for first QTQ session in 2002

Cummins, Onan, and PowerCommand are all registered trademarks of Cummins Inc. InPower is a trademark of Cummins Inc. Windowst is a trademark of Microsoft Corporation. Copyright E 2001-2005 by Cummins Power Generation

Participant’s Guide

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Introduction

PowerCommand Control 2100 w/ CAN Link

PowerCommand Control 2100 with CAN Link Module Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1 The introduction describes the audience, the purpose, and the structure of the training module. Review of the PowerCommand Control 2100 CBT . . . . . . . . . . . . . . . . . . . . 1-1 This lesson presents an overview of the PowerCommand Control 2100. The participant will learn to identify the main features of the PowerCommand Control 2100. PowerCommand Control 2100 Service Menus . . . . . . . . . . . . . . . . . . . . . . . . 2-1 This lesson presents the Setup and Calibration menu system used in the PowerCommand Control 2100. InPowert software and the PowerCommand Control 2100 . . . . . . . . . . . 3-1 This lesson presents the steps required to setup the optional modules for a PowerCommand Control 2100 with InPower v 4.0 or later. Troubleshooting the PCC 2100 with CAN Link . . . . . . . . . . . . . . . . . . . . . . . . 4-1 This lesson presents the troubleshooting steps and job aids for the PowerCommand Control 2100. PowerCommand Control 2100 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 This lesson presents the steps required to properly install and setup the optional modules for a PowerCommand Control 2100. PCCNet and the Universal Annunciator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 This lesson presents information on the Universal Annunciator that connects to the PCCNet connector (TB2) in the PCC 2100. Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 This section lists the most common terms used throughout this training module pertaining to the PowerCommand family of Controls. Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 This section has copies of all prints used in the course. i-2

Participant’s Guide

PowerCommand Control 2100 w/ CAN Link

Introduction

Module Comment Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 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.

Participant’s Guide

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PowerCommand Control 2100 w/ CAN Link

Introduction

Introduction Welcome!

Welcome to the Participant’s Guide for the PowerCommand Control 2100 with CAN Link module! This guide was written by the Cummins Power Generation Sales and 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 PowerCommand Control 2100 with CAN Link module is to help you, the Cummins Power Generation distributor service technician, understand the PowerCommand Control 2100 with CAN Link which is going to be used on Cummins Power Generation Gensets that use standard Cummins G-Drive engine modules.. 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.

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

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Participant’s Guide

PowerCommand Control 2100 w/ CAN Link

Introduction

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.

Participant’s Guide

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Introduction

PowerCommand Control 2100 w/ CAN Link

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Participant’s Guide

PowerCommand Control 2100 with CAN Link

Introduction & CBT Review

Introduction to the PowerCommand) Control 2100 with CAN Link and Review of PCC 2100 CBT. Estimated Time: 4 hours Equipment Needed Overhead projector and screen or PC with LCD Projector and screen PowerCommand Control 2100 and simulator for each pair of participants Materials Needed Module overhead set or slide set One for each participant: PowerCommand ) Control 2100 Participant’s Guide

Guide (CMT0686-EN–PG)

QSX15 set with PCC 2100 Operator’s Manual

Manual (961-0101)

• PC with PowerCommand ) Control 2100 CD-ROM

CD-ROM (932-0772-CD)

Instructor’s Note: This lesson presents a review of the lessons learned in the Computer-Based Training (CBT) program completed before participants came to the hands-on class.

Participant’s Guide

1-1

Introduction & CBT Review

PowerCommand Control 2100 with CAN Link

Warm Up In this lesson we are going to introduce you to the PCC 2100 with CAN Link and review the pre-class CD-ROM for the PowerCommand Control 2100. You may want to follow along on the CD-ROM as well as in your Participant’s Guide. We will quickly review the material in the CD-ROM, and add to that information.

Objectives After completing this lesson, the participants should be able to: • Describe the function of the CAN Link. • Identify the New PowerCommand Control 2100. • Locate and identify the New PowerCommand Control 2100 panel components. • Identify components inside the PowerCommand Control 2100. • Identify the standard and optional component of the PowerCommand Control 2100. • Use the Operator menus. • Describe the sequence of operation for the PowerCommand Control 2100.

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Participant’s Guide

PowerCommand Control 2100 with CAN Link

Introduction & CBT Review

What is a CAN Link? Control Area Network Engine Control System (ECS) Genset Control System (GCS) Communication Path 120 Ohm Resistors at each end of Bus 3 Meter Stubs

VIS 1-1

S&TT 09/04

Visual 1-1 What is a CAN Link?

Participant's Text

Your Notes

You completed the PCC 2100 pre-read CDROM before coming to this course. You learned many things about the PCC 2100 and its upgrade, the PCC 2100 in that program. The PCC 2100 sends specific governor signals to the engine governor actuator. The PCC 2100 communicates over a CAN link with the ECM on the genset GDrive engine. The ECM sends specific governor signals to the engine governor actuator.

Participant’s Guide

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Introduction & CBT Review

Participant's Text

PowerCommand Control 2100 with CAN Link

Your Notes

CAN Link – a Control Area Network used to allow an engine-mounted control system to monitor the engine and communicate with a generator set control system.

ECS – Engine Control System. This is the ECM on the engine and the sensors and controls for the engine. GCS – Generator Set Control System. This is the PCC 2100 and the rest of the generator set.

Communication Path – a shielded twistedpair cable that has specific resistance terminations at each end of the main communication cable between the ECS and the GCS, and a series of stub cables to additional devices. Termination Resistors – 120 Ohm resistors at both ends of the main communications channel. The total resistance is _____ Ohms if measured by an Ohmmeter. Stubs – Short pieces of communication cable connecting other devices into the CAN Link. These cannot be longer than 3 meters (10 feet).

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Participant’s Guide

PowerCommand Control 2100 with CAN Link

Introduction & CBT Review

What is the PCC 2100? Engine / Alternator Control InPower service tool software Network Upgradable Everything in one box Smart Starting Plus When will the control NOT go to sleep? 3 WakeĆup signals VIS 1Ć2

S&TT 09/04

Visual 1-2 What is the PCC 2100?

Participant's Text

Your Notes

The PCC 2100 controls engine and alternator functions and has preset alarm levels for engine and alternator parameters. InPower service tool software can adjust many parameters, and download calibrations. The PCC 2100 is easily upgradeable to FT-10 PowerCommand Network compatibility.

Participant’s Guide

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Introduction & CBT Review

Participant's Text

PowerCommand Control 2100 with CAN Link

Your Notes

Smart Starting Plus • Programmable Idle Function on Start: In this mode, generator set will start, operate at idle speed for a predefined time period or until the engine reaches operating temperature, and then ramp to rated speed and voltage. • Cooldown at Idle: When the control gets a signal to stop, it will ramp the engine down to idle, and then time for shut down. The PowerCommand control 2100 WILL NOT “go to sleep” if: • The Service tool is connected to the control. • The network Module is installed and activated. • The mode switch is in Manual or Auto • Sleep is disabled with the service tool software.

Wake Up Signals The PowerCommand control will “go to sleep” after a pre-determined time delay, set with InPower software. These signals will wake up the control: • Remote Start signal input to TB1-1. • Panel Lamp/ Lamp Test switch pressed for one second. • Move mode switch to Manual or Auto from 0 position.

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Participant’s Guide

PowerCommand Control 2100 with CAN Link

Introduction & CBT Review

Basic PCC 2100 Panel

VIS 1Ć3

S&TT 09/04

Visual 1-3 PowerCommand Control 2100 Standard Operator Panel

Participant's Text Genset Control – Standard

Your Notes

The control panel is mounted on the generator set. There are two physical switches and nine membrane switches on the switch panel. All writing, except the “0” position indicator, is on a removable panel. The legend panel may be removed and replaced with another panel in a different language.

Participant’s Guide

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Introduction & CBT Review

Participant's Text

PowerCommand Control 2100 with CAN Link

Your Notes

Physical Switches Emergency Stop Switch. Pressing the Emergency Stop Switch will cause the generator set to immediately shutdown. If the generator set is not running, pressing the emergency stop switch will prevent it from attempting to start. 0/Manual/Auto switch. This switch has several uses in controlling the generator set. • When placed in the “0” position while the generator set is running, the set will shut down immediately. • In the MANUAL position, the control will not complete any automatic sequences. • In the AUTO mode, the generator set can be started by receipt of a start signal from a remote device. The control maintains an internal record of manual control activities performed on the generator set.

Membrane Switches • Manual Run/Stop switch. Toggles generator set to run/stop mode when the 0/Run/Auto switch is in the RUN position.

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Participant’s Guide

PowerCommand Control 2100 with CAN Link

Participant's Text

Introduction & CBT Review

Your Notes

• If the generator set is running in the MANUAL mode, pressing the Manual Run switch again will cause the generator set to shut down after the cooldown time delays. • Fault Acknowledge Switch. Allows the operator to acknowledge warnings and shutdowns from the switch panel. The 0/Run/Auto switch must be in the “0” position to acknowledge shutdown faults. • Panel Lamp/Lamp Test Switch. Allows the operator to switch on LED lamps to illuminate the control. Holding the switch down for two seconds allows the lamps on the panel to be illuminated, so that it can verified that they are operating properly. Continue holding the switch down to cycle the segments on the LED Bargraph, if installed.

LEDs There are two LEDs on the bottom part of this side of the panel: • Shutdown There is a shutdown condition • Warning There is a non-shutdown condition There are eight LEDs on the top of the panel. Three are preset: • Running The genset is running (Switched B+ indicator). • Remote Start The control sees a remote start signal.

Participant’s Guide

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Introduction & CBT Review

Participant's Text

PowerCommand Control 2100 with CAN Link

Your Notes

LEDs (continued) • Not in Auto The 0/Run/Auto switch is not in the AUTO position The other five LEDs in the top half of the panel can be set for various functions and colors using InPower service tool software. The digital display panel is capable of displaying up to 2 lines of data with approximately 20 characters per line. It is configurable for units of measurement. The digital display on the Operator panel turns off after 10 minutes if no buttons around it are pressed. This happens to save the screen from burn-in. The display will wake up from the “screen saver” mode when any of the six buttons around it are pressed. The digital display panel incorporates one level of security. • Service level (application) password allows setup and calibration of the control. • As with the PCC 3200, once you input the password, the password “window” stays open for 10 minutes after the last button press. Trainer's Personal Comments

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Participant’s Guide

PowerCommand Control 2100 with CAN Link

Introduction & CBT Review

PCC 2100 Panel with LED Bargraph

VIS 1Ć4

S&TT 09/04

Visual 1-4 PowerCommand Control 2100 with LED Bargraph option

Participant's Text Analog AC metering panel displays simultaneously 3-phase AC line current, kW, power factor, frequency, and line-toline voltage.

Your Notes

• Amps and kW are displayed from 0–125% of nominal value. • Power Factor is displayed from –.6 (lagging) to +.9 (leading) • Frequency and Voltage are displayed from