MCM3320 Application Training Switchgear Engineer Training 083006 Rev4 New Cummins Template



Features



Hardware



Operation



System Setup and Simulator (HANDS ON)



Operation (continued)



Variables



Interconnect



HMI & Simulator (HANDS ON)



InPower



Applications (GROUP)



Control and Component Mode Panels New



What are the capabilities of the MCM3320?



What are the board connections?



How does it operate?



How do I apply it?



Lotus Notes Database “Commercial ESB

Controls”



Sort by “Category”



Look for “MCM3320”



This presentation and other technical

information located there



An Application Guide is in the works to provide

a one-stop document



Documentation



PGA Controls Engineering:

1. Kevin Aufderhar

2. Paul Dahlen

G1

G2

G3

G4

Load1 Load2 Load3 Load4 Load5 Load6

MCM3320 AUX101 AUX102 HMI211 Operator Panel #2 GM UM Customer I/O Breakers or ATS AC Metering Source Failure Gensets Start/Stop Main Breaker Control Sync/Volt Match Open/Closed Transition Load Ramping Extended Paralleling kW and kVAR Control Load Demand Load Add / Shed Scheduler Modbus Diagnostics HMI112 Gensets Bargraph HMI211 Utility Bargraph HMI211 Operator Panel #1

Feature Validation



All available features have been tested



Firmware test



Bench test w/simulator



Live test at Fridley Endurance Pad test facility



Live test at Fridley with real Utility Source

(transfers, sync, base load / peak shave)

AC Metering



3 Phase metering of genset bus and utility bus

simultaneously



Phase and Total/avg metering of V, A, kW, kVAR,

kVA, PF, Hz



Phase and total metering of +kWh, kWh, +kVARh,

-kVARh, kVAh for each source



CT secondaries of 1A or 5A



PT accepts 0-480VLL directly; external PT for higher

voltages (up to 35000V)

Master Sync / Volt Match



both phase synchronization and voltage matching



20 genset limit for synchronizer



frequency offset range: +/- 1.0 Hz min; up to +/- 3.0Hz



output voltage offset range: +/- 6% min; up to +/- 10%

Master Sync / Volt Match



controls frequency and voltage via PCC kW and kVAR

load share lines



selectable phase synchronization (default) or slip

frequency synchronization



sync enable input for manual control mode



option to invert synchronizer polarity if genset and

utility swap positions in synchronizer only application

(via Modbus)

Permissive Sync Check



sync check function is independent of synchronizer



adjustable frequency window, phase window, voltage

window, and window time for permissive check



includes configurable dead bus logic



sync check output



fail to synchronize diagnostic

Breaker Control



interface for both genset main and utility main



close and open control – momentary energization until

desired position is achieved



a/b and tripped breaker position inputs



adjustable breaker recharge time delay to prevent fail

to close due to inadequate charge time

Breaker Control



utility paralleling enable output



breaker inhibit control input



breaker diagnostics with appropriate system control

reaction



adjustable fail to close and fail to open time delays



paralleling fail to disconnect diagnostic with

configurable system control reaction

Breaker Control



anti-pump avoidance logic – external breaker position

contacts not required in series with trip coil



breaker inhibit output to control individual genset

paralleling breakers in applications with no gen main,

and for backup disconnect protection capability

Power Transfer Control



open transition w/pgm transition delay, hard closed

transition (<100msec), soft load closed transition



sensors (uv, ov, freq, phase rot, loss of phase, gen

bus capacity, and breaker failure)



adjustable time delays (pgm transition, transfer,

retransfer, max parallel, gensets start delay, gensets

stop delay)



source availability determination for both utility and

genset

Power Transfer Control



gensets start/stop logic with single relay output



transfer and retransfer inhibit inputs



override input to override timers and

transfer/retransfer inhibits for immediate transfer,

retransfer or genset start

Power Transfer Control



test start input



adjustable test with or without load



option to do open transition retransfer if fail to sync

occurs

System Topologies



Transfer Pair (UM / GM)



Common Bus (UM / no GM)



Isolated Bus (GM)



Isolated Bus (no GM)

System Topologies



Transfer Pair (System Types 2,3,4,8,10,11)

G1 G2 G3 G4

UM GM

MCM 3320

System Topologies



Common Bus (System Type 9)

Load

G1 G2 G3 G4

UM

MCM 3320

System Topologies



Isolated Bus w/GM (System Type 7)

G1 G2 G3 G4

GM

MCM 3320

System Topologies



Isolated Bus Without GM (System Types 5,6)

Load

G1 G2 G3 G4

MCM 3320

System Topologies



Master Synchronizer Only (metering optional)

Source G1 G2 G3 G4 MCM 3320 Sync Check

Multiple MCM3320s



master inhibit input will inhibit the synchronizer and

power transfer control functions



use in complex systems with multiple transfer pairs and

multiple MCM3320s



external logic device is required to assert the master

inhibit as required (e.g. during a retransfer sequence of multiple pairs)



future enhancement will allow automatic priority control

through interconnected MCM3320s (similar to First Start Bus PT logic)

Extended Paralleling



MANY options available for controlling kW and kVAR in

extended paralleling mode (kVAR not applicable for

PCC3100)



kW and kVAR can be independently controlled in any

combination of base load (control the power @ gen bus)

or peak shave (control the power @ utility bus)



load control operates independently of the number of

gensets that are online



Maximum of 20 gensets



kW base load control selectable as open loop or closed

loop

Extended Paralleling



setpoints can be set from InPower, HMI, Modbus, or via analog

hardware 0-5V inputs



extended parallel start input starts/stops the mode



soft load ramping



separate diagnostic for kW and kVAR if unable to acheive

System Scheduler



12 program run schedules



run schedules configurable for start day, start

time, duration, repeat interval, and run mode



run modes: without load, with load, or extended

parallel



provides up to 6 different schedule exceptions

Real Time Clock



on-board RTC used by Scheduler function



clock keeps track of year, month, day, date, hour,

minute, and second



user must set the clock on first power-up



clock automatically accounts for leap year



configurable automatic Daylight Savings Time clock

correction



clock setting will remain valid for at least 24 hours

without B+ to the board



diagnostic fault occurs if clock needs to be set (scheduler

Load Demand



Use to match online generating capacity to load in order

to optimize fuel use and genset life



load demand for up to 4 gensets



fixed sequence OR run-hours based



adjustable shutdown and restart thresholds as well as

time delays and run hour differential



4 load demand driver outputs to connect to PCC genset

control's load demand inputs



requires genset paralleling breaker position 'a' contacts

Load Add/Shed



adds loads in steps as gensets come online



sheds loads to unload an overloaded genset bus



Requires external module: AUX101/2 PCCNet I/O

Module for feeder breaker and/or ATS control



supports up to 6 levels



supports up to 4 gensets



control up to 6 feeder breakers or ATS directly in any

combination

Modbus RTU



intended for PLC interface



published register map



read/write access



operational data, control, and setup variables



MCM3320 is Modbus slave



RS232 or RS485 connection



settable address (allowing multiple MCM3320 slaves on

RS485)

Diagnostics



individual On-Board LEDs for:

Utility Available Utility Connected Genset Available Genset Connected Not In Automatic Common Warning Heartbeat Synchronizing Synchronized Fail To Sync

Diagnostics

Genset Connected Utility Connected Genset Available Utility Available Common Alarm Not In Automatic Heartbeat (blink) Fail to Sync Blink = Sync Solid = Ok to Close LED Indicators Modbus Activity

Diagnostics



On-Board seven segment LED for indication of:

System State indication of what the control is currently doing

Fault Code Readout (hold fault reset switch active for >5sec to change to fault code readout mode)

Diagnostics

Decimal Point = Off

 System State

Seven Segment LED Indicator

Decimal Point = On

 Active Fault Code Flashout

System State LED Output Character

Not Available - (center segment) TD Start 1 TD Stop 2 TD Pgm Tran 3 TD Transfer 4 TD Retransfer 5 Synchronizing 6 Sync Check OK 7 Inhibit 8 Unassigned 9 Ramp Unload A Ramp Load b

Code Event Nam e Response

343 Har d w ar e Failu r e War n in g War n in g 353 EEPROM Wr it e Er r o r War n in g War n in g 1121 Fail To Disco n n ect War n in g War n in g 1219 Ut ilit y Main Br eaker Tr ip p ed War n in g War n in g 1222 No t In Au t o m at ic Even t Even t 1223 Ut ilit y Bu s Fr eq u en cy War n in g War n in g 1224 Gen set Bu s Over vo lt ag e War n in g War n in g 1225 Gen set Bu s Un d er vo lt ag e War n in g War n in g 1226 Gen set Bu s Fr eq u en cy War n in g War n in g 1328 Gen set Main Br eaker Tr ip p ed War n in g War n in g 1335 AC Met er in g Ou t Of Ran g e War n in g War n in g 1444 Gen set Bu s Over lo ad War n in g War n in g 1452 Gen set Main Br eaker Fail To Clo se War n in g War n in g 1453 Gen set Main Br eaker Fail To Op en War n in g War n in g 1454 Gen set Main Br eaker Po sit io n Co n t act War n in g War n in g 1455 Ut ilit y Main Br eaker Po sit io n Co n t act War n in g War n in g 1456 Syn ch r o n izer Ou t p u t Lim it War n in g War n in g 1457 Fail To Syn ch r o n ize War n in g War n in g 1458 Syn ch r o n izer Ph ase Ro t at io n Mism at ch War n in gWar n in g 1483 Co m m o n War n in g Even t Even t 1534 Lo ad Co n t r o l Ou t p u t Even t Even t 1541 Gen set Failed To Co m e On lin e War n in g War n in g 1689 Real Tim e Clo ck Po w er In t er r u p t War n in g War n in g 1912 Ut ilit y Bu s Lo ss Of Ph ase War n in g War n in g 1913 Gen set Bu s Lo ss Of Ph ase War n in g War n in g 1914 Ut ilit y Bu s Ph ase Ro t at io n War n in g War n in g 1915 Gen set Bu s Ph ase Ro t at io n War n in g War n in g 1916 Syn ch r o n ized Even t Even t 1989 kW Lo ad Co n t r o l Ou t p u t Lim it War n in g War n in g 1991 kVAR Lo ad Co n t r o l Ou t p u t Lim it War n in g War n in g 1999 Maxim u m Par allel Tim e War n in g War n in g 2328 Ut ilit y Bu s Availab le Even t Even t 2331 Ut ilit y Bu s Un d er vo lt ag e War n in g War n in g

Diagnostics



42 diagnostics (warnings and events)



each event or warning is mappable to 8 customer low side

driver outputs



active warning codes can be read out on 7segment LED on

board



some warnings alter control operation



warnings are latched until user fault reset

Diagnostics

Common Alarm Event

Genset Available Event Genset Connected Event Synchronized Event

Test / Extended Parallel Event Utility Available Event

Utility Connected Event

AC Metering Out of Range Warning Calibration Checksum Warning EEPROM Write Error Warning Fail To Disconnect Warning Fail To Synchronize Warning

Genset Main Breaker Fail To Close Warning Genset Main Breaker Fail To Open Warning Genset Main Breaker Position Contact Warning Genset Main Breaker Tripped Warning

Genset Frequency Warning Genset Loss of Phase Warning Genset Overvoltage Warning

kVAR Load Control Output Limit Warning kW Load Control Output Limit Warning Maximum Parallel Time Warning

Not In Automatic Warning

Real Time Clock Power Interrupt Synchronizer Output Limit Warning

Synchronizer Phase Rotation Mismatch Warning Utility Main Breaker Fail To Close Warning

Utility Main Breaker Fail To Open Warning Utility Main Breaker Position Contact Warning Utility Main Breaker Tripped Warning

Utility Frequency Warning Utility Loss of Phase Warning Utility Overvoltage Warning Utility Phase Rotation Warning Utility Undervoltage Warning Load Demand Setup Warning

Remote IO Communications Warning Genset Bus Overload Warning

InPower V5.5



MON RS485 interface



standard InPower folders: Adjustments, Faults,

Monitor, Test



built in Setup Tool



download new firmware

InPower V5.5 Setup Tool



special application

to assist with setup

of the MCM3320



user friendly

screens



High/Low Battery Voltage



Flexible Topology

High/Low Battery Voltage



Provide faults for high and low battery voltage

as sensed at the MCM3320

Flexible Topology



Make the MCM3320 more flexible for use in

complex system topologies



Provide Extended Parallel w/o breaker control



Provide outputs for source unloaded for utility

and generator



Eliminates need for Bitronics transducer

Feature Limits Quiz

How many gensets can be supported by the

following features ?

•AC Metering

•Synchronizing

•Load Demand

•Load Add / Shed

•Utility Paralleling

32000kW, 10000A

20

4

4

20

Annunciator Support

Utility Available Utility Connected Gen Bus Available Gen Bus connected Not In Auto Common Alarm Fail to Sync Gen 1 Running Gen 2 Running Gen 3 Running Gen 4 Running Test Extended Parallel Gen Bus Overload Load Demand Priority 1 Load On Priority 2 Load On Priority 3 Load On Priority 4 Load On Priority 5 Load On Priority 6 Load On Shed Level 1 Shed Level 2 Shed Level 3 Shed Level 4 Shed Level 5

Feature Limits Quiz

What can Load Add / Shed support ?

•Load Device Types

•Load Add Levels

•Load Shed Levels

•# of Gensets

Breaker, ATS

6

6

4

Part Numbers

Part Number Model Released? Description

0327-1520-01 MCM3320 Yes fully featured master control module

0327-1520-02 SYNC1320 Yes depopulated/defeatured synchronizer only module 0300-6090 HMI 211 Yes operator interface panel (can use one or two)

300-6050-01 HMI 112 Yes Bargraph panel (use 2 – one for genset bus, one for utility bus)

0541-1342 AUX101/2 Yes PCCNet IO Module with Expansion card for use with Load Add

Shed Feature (one only)

0338-4747 Yes 12 foot harness for connecting HMI to MCM3320; can be cut to

length

0630-3133 Yes MCM3320 Interconnect Wiring Diagram and Outline

0630-3136 Yes SYNC1320 Interconnect Wiring Diagram and Outline

0541-1199 Yes Cable and RS485/232 Converter Kit for connecting to controller

with InPower, Engineering Tool, or Setup Tool (Kit is for PCC1301 product, but will work with MCM3320 or SYNC1320)

MCM3320

Genset CT Inputs (1A or 5A) Modbus RTU (RS232) TB6 Genset PT Input (480V LL Max) Utility PT Input (480V LL Max) Utility CT Inputs (1A or 5A) TB9 Analog IO TB3 TB1 TB10 TB8 TB15 TB2 TB7 L1* L2* L3* L1* L2* L3* GEN UTILITY Switch IO / PCCNet (TB1) Switch IO / CAN (TB3)

Breaker Status Inputs (TB10) Breaker Control / Start Gensets (TB8)

InPower or Modbus RTU (RS485) Switch IO / DC Power In J14 J17

Hardwired IO

G e n O p e n G e n C l o s e G e n P o s i t i o n A

Extended Para Start Sync Enable Utility Source Failure Transfer Inhibit Retransfer Inhibit Gen CB Tripped Util CB Tripped G e n P o s i t i o n B Manual Test Start Fault Ack/Reset Gen1 Available Gen2 Available Gen3 Available Gen4 Available kVAR Load Setpoint

Master Freq Bias Master Volt Bias Master Inhibit

Load Govern Enable Load Demand Gen1 Load Demand Gen2 Load Demand Gen3 Load Demand Gen4 Start Gensets Relay

kW Master Load Control Gen CB Inhibit

Util CB Inhibit

Cfg Out1 (com warn) Cfg Out2 (fail to sync) Cfg Out3 (gen avail) Cfg Out4 (util avail) Cfg Out5 (fail to discon) Cfg Out6 (sync‟d) Cfg Out7 Cfg Out8 Relay Supply B+ Input1 Gnd RS485 PCCNet RS485/232 Mon/MB B+ Input2 Gnd CAN (Master) BIDIRECTIONAL B+ POWER DISCRETE INPUTS (active low w/ pullup) DISCRETE OUTPUTS (low side drivers)

ANALOG INPUTS (0-5V) ANALOG OUTPUTS GEN V/I BUS/UTIL V/I COMMUNICATIONS Override RELAY OUTPUTS B+ OUTPUTS BREAKER INTERFACE (discrete inputs / relay outputs) U t i l O p e n U t i l C l o s e U t i l P o s i t i o n A U t i l P o s i t i o n B Paralleling Gensets Breaker Inhibit MCM3320 Hardware I/O kW Load Setpoint

B+ Power



2 separate B+ power inputs for redundant supply of

control; station battery suggested



On-board diode-OR



Range: 9-32V



Will ride-through starter dip



Less than 1 Adc load (no external B+ loads)



On-board backup of Real Time Clock (minimum 24

hours)



No wakeup input; board is always awake



Removal of B+ will not cause loss of any historical data

PT Inputs



Nominal Range 110 – 480 V LL



External Transformer to 35 kV LL



Sensing to 125% of Nominal

CT Inputs



Primary from 5 to 10000 Amps



Secondary 1 Amp OR 5 Amp



No terminal block; CT on-board with hole



Recommend shorting block nearby



2 passes through hole for 1 Amp



1 pass for 5 Amp

HW Discrete Inputs



22 hardwire switch inputs



Inactive State: Open circuit / high impedance

(not B+)



Active State: Connect to Return



Can use local B- for return

HW Discrete Inputs

Discrete Input Active State

(to Gnd)

Inactive State (open cicuit)

Description

Fault Reset Reset Not Reset reset faults; engage fault readout

Auto/Manual Manual Auto manual or auto breaker / sync operation

Test Start Start Stop test load transfer start / stop

Extended Parallel Start Start Stop extended paralleling start / stop

Synchronizer Enable Active Inactive sync enable (applies in manual only)

Utility Source Failure Active Inactive use if external device determines failure

Transfer Inhibit Inhibit No Inhibit inhibit transfers to gens (some exceptions)

Retransfer Inhibit Inhibit No Inhibit inhibit retransfers to util (some exceptions)

Override Override No Override override timers and tran/retran inhibits

Gen Main CB Inhibit Inhibit No Inhibit open gen main / inhibit closure

Util Main CB Inhibit Inhibit No Inhibit open util main / inhibit closure

Gen Main CB Tripped Tripped Not Tripped gen main breaker tripped; source not avail

Util Main CB Tripped Tripped Not Tripped util main breaker tripped; source not avail

Gen1 CB Position Breaker Closed Breaker Open genset #1 breaker position ('a' contact)

Gen2 CB Position Breaker Closed Breaker Open genset #2 breaker position ('a' contact)

Gen3 CB Position Breaker Closed Breaker Open genset #3 breaker position ('a' contact)

Gen4 CB Position Breaker Closed Breaker Open genset #4 breaker position ('a' contact)

Util Main CB PositionA Breaker Closed Breaker Open util main breaker position ('a' contact)

Util Main CB PositionB Breaker Open Breaker Closed util main breaker position ('b' contact)

Gen Main CB PositionA Breaker Closed Breaker Open gen main breaker position ('a' contact)

Gen Main CB PositionB Breaker Open Breaker Closed gen main breaker position ('b' contact)

HW Discrete Outputs



19 hardwire discrete outputs



5 relays; 14 low-side drivers



low-side drivers can sink 200mA



breaker relays (4) can drive coils directly in

HW Discrete Outputs

Output Signal Name

(hardware) Active State (Low / Energized) Inactive State (High Impedance / Deenergized) Description

Start Gensets Relay Run Stop form C relay to start / stop gensets (via Remote Start) Util Main CB Close Relay Active Inactive N.O. relay contact for utility main close coil Util Main CB Open Relay Active Inactive N.O. relay contact for utility main open coil Gen Main CB Close Relay Active Inactive N.O. relay contact for gen main close coil Gen Main CB Open Relay Active Inactive N.O. relay contact for gen main open coil

Load Govern Enable Driver Enabled Disabled low-side driver to PCC genset's util cb position input to put PCC in load govern mode when utility paralleled Paralleling Gensets Breaker

Inhibit Driver

Inhibit All Gensets No Inhibit low-side driver to PCC genset's paralleling breaker inhibit input

Load Demand Gen1 Driver Load Demand Stop Run low-side driver to PCC genset #1 load demand input Load Demand Gen2 Driver Load Demand Stop Run low-side driver to PCC genset #2 load demand input Load Demand Gen3 Driver Load Demand Stop Run low-side driver to PCC genset #3 load demand input Load Demand Gen4 Driver Load Demand Stop Run low-side driver to PCC genset #4 load demand input Configurable Output1 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output2 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output3 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output4 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output5 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output6 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output7 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output8 Driver Driver On Driver Off activated by programmable event/warning code Relay Supply B+ Output B + Output B + output for supplying relay coil high side; low side

HW Bidirectional Discrete



Bidirectional discrete I/O for priority arbitration

(like 1

st

_{Start Bus PT)}



Used in Phase 2 for priority control among

multiple MCM3320s



Same connection as “Master Inhibit” (externally

controlled sequencing)

HW Analog Inputs



2 hardwire analog inputs



kW Load Setpoint (0-5V)



kVAR / PF Load Setpoint (0-5V)



used for base load / peak shave setpoints



alternatively set via Modbus or Trim



load setpoint profiles same as

PCC3100/3200/3201

HW Analog Outputs



2 hardwire analog outputs



kW Master Load Control (0-5V)



kVAR Master Load Control (0-5V)



Used for load control commands to PCC genset load set

inputs to control soft ramping and base load / peak shave



kVAR control only available on PCC3200/3201,

PCC3300 genset controllers



New Rev D board supports interconnection of analog

HW Bidirectional Analog



Two bidirectional analogs for synchronizer



Master Frequency Bias senses/drives kW load

share line to affect gen bus frequency



Master Voltage Bias senses/drives kVAR load

share line to affect gen bus voltage



Output range -2.5 to + 5.0 V

Communications



Controller has 2 serial ports



Port1

– Protocol Options

• PCCNet – for HMI, IO Modules (default protocol)

• Mon – for troubleshooting only (cannot download); set to

Mon mode via Modbus on Port2 or through InPower

– Physical

• RS485 on TB1

Communications



Port2:

– Protocol Options

• Modbus RTU (MCM3320 is SLAVE)

• Mon (Service Port for InPower/Setup Tools)

• Controller automatically detects protocol

– Physical

• RS232 on J14 (DB9 pins); Null Modem cable • RS485 2-wire on TB15

• RS485 is default; control switches to RS232 when RS232 RTS to CTS pins are jumpered by cable

HMI211 Operator Panel



HMI211 PCCNet interface

(4wires):

B+ / GND RS485 A / B

•

Up to two HMI211‟s can be

connected to one MCM3320

•

Use harness 0338-4747 to

connect; cut to length or extend (12ft / 3.6m)

HMI112 Bargraph



HMI112 Bargraph PCCNet

interface (4wires):

B+ / GND RS485 A / B

•

Connect two HMI211‟s to one

MCM3320 to get both source data

AUX101/2 IO Module

P11 (Inputs)

P10 (Ground for Inputs)

P2 (Relays) P3 (Relays) P4 (Relays) P14 (B+ / Gnd) P1 (PCCNet, Wakeup) P4 (Inputs) P3 (Relays - NC) P2 (Relays - Com) P1 (Relays - NO) AUX101 AUX102 Connect to Grounded Chassis

Device Number: Must Read “0” for MCM3320 Applications.

To Change Device Number, Press and hold pushbutton until decimal point is illuminated. Then push button repeatedly to cycle through numbers until it reads “0”.

Green LED: PCCNet Communcations OK Red LED: PCCNet Communcations Not

OK

Relay LEDs ON = Energized

Aux102 Board Revision Level: First letter on barcode

(read from left to right) must be “C” or higher letter.

Relay LEDs ON = Energized

Connections

•

Modules required for Load Add Shed feature

•

MCM3320 to AUX101 PCCNet interface (4 wires):

B+ / GND RS485 A / B

•

12 discrete inputs used for breaker / ATS position

monitoring



MCM3320 can completely manage simple

systems – breaker control, synchronizing, load

control, gensets start/stop, diagnostics, etc.



MCM3320 can be used as a component in more

complex systems with whichever features are

appropriate; a PLC can orchestrate the actions

of the MCM3320

 MCM3320 Major Functional Blocks – Application Configuration – System Information – IO Processing – AC Metering – Breaker Control

– Power Transfer Control

– Synchronizer & Sync Check

– Load Control – Scheduler – Load Demand – Load Add/Shed – Communications – Diagnostics / History – HMI 211

Application Configuration

Primary Settings:

System Topology

Transition Type

Extended Parallel Enable

Test With Load Enable

Settings are trims (can be saved) or can

be dynamically set via Modbus, InPower

or HMI

Application Configuration

MOST IMPORTANT SETTING (set it 1

st

₎

System Topology

Transfer Pair Common Bus

Isolated Bus with GM Isolated Bus without GM

Application Configuration

Transition Type

Open Transition (default)

Hard Closed Transition (<100msec overlap) Soft Closed Transition

Extended Parallel Enable

Disabled (default) Enabled

Test With Load Enable

Disabled (default)

Application Configuration



Must be in Manual mode to set

System

Topology



Hard Closed Transition not applicable in

Common Bus topology



Transition Type only applies to load transfers



Thus Transition Type = (Open Transition OR

Hard Closed) is compatible with Extended

Parallel Enable = Enabled

System Information



Settings

for

System Phase Rotation

,

System

Frequency

, Individual

Genset kW Ratings



Derived

Information such as

Total System

Capacity

,

Total Online Capacity, Spare Online

Capacity

, etc. for use in other control function

blocks



System State

derived variable

– Shows what system is currently doing that is most

relevant

System Information



System Lockout derived variable indicating that normal control logic has been altered due to a fault



Active / Inactive



latched until user fault reset



must be reset for normal control operation to resume



LED on HMI



Conditions which make it active:

Utility Breaker Fail to Close Fault State = Active Utility Breaker Fail to Open Fault State = Active Utility Breaker Position Contact Fault State = Active Genset Breaker Fail to Close Fault State = Active Genset Breaker Fail to Open Fault State = Active Genset Breaker Position Contact Fault State = Active

(Fail to Synchronize Fault State = Active AND Fail to Sync Lockout Enable = Enabled) Maximum Parallel Time Fault State = Active

System Information



Genset Bus Overload

is detected by kW level or

frequency or both (configurable)



Fault Code 1444



Used internally by Load Demand and Load Shed

functions



Adjustable %kW threshold: 80-140% of online

capacity



Adjustable kW delay: 0-120 sec



Adjustable Hz threshold: 0.1-10 Hz below System

IO Processing – Discrete Inputs



Most discrete inputs can be controlled from a hardwired

input OR from a communications link such as Modbus or

InPower (“<name> + Vol”)



Controller will always logically OR the two inputs



Result of OR is readable at “<name> + Sw”

HW SW

Conditioning & Level

Detection Sample

<Signal Name> Debounce_{Function <Signal Name>}

+ " Sw"



For testing and troubleshooting purposes, most discrete outputs can be directly overriden using InPower

SW _HW

HW Update _RegisterOutput (enabled)

(disabled)

<Output Signal Name> <Input Signal Name>

<Output Signal Name> + " Override Cmd"

AC Metering Setup



PT Primary Voltage

= 110-45000 VLL



PT Secondary Voltage

= 110-500 VLL



CT Primary Current

= 5-10000 A



CT Secondary Current

= 5 or 1 A



Nominal Voltage

= 110-45000 VLL

AC Metering - Voltage



Hardware inputs autoranging: 120,240,or 480

VLL = 100% at board



Input Range: 5% to 125% of above ranges



Sampled every line cycle on all 3 phases



LN, LL, LN-Avg, LL-Avg, % of nominal



3 or 4 Wire Connections



Factory calibrated to better than 1% of full scale;

field adjustable

AC Metering - Current



Hardware inputs autoranging: 5 A or 1A = 100% at board



Input Range: 0% to 125% of above ranges



Sampled every 10th line cycle



L1, L2, L3 and Average



True RMS with 14kHz Bandwidth



1A requires two pass thru on-board CT



Factory calibrated to better than 1% of full scale; field

AC Metering - Power



kW, kVAR, kVA, PF



True power readings; 14kHz bandwidth

 If harmonics present, kW2 _{+ kVAR}2 _{may not equal kVA}2



Sampled every 10th _{line cycle}



Per phase and totalized to +/- 32767k



Sign Convention is with respect to the Source

– Positive kW = real power delivered by source

– Positive kVAR = lagging vars delivered by source – Positive PF = lagging; Negative PF = leading

AC Metering - Energy



kWh  positive, negative, net



kVARh  positive, negative, net



kVAh  net



Per phase and totalized to +/- 2

31



Permanently stored

AC Metering – Time Based



Precise frequency reading 25 to 80Hz



Precise sync phase angle reading -180 to +180

degrees



Precise voltage phase angle readings

AC Metering Calibration

• MCM3320 is

factory

calibrated

• Voltage and

Current can

be adjusted in

the field if

needed

Breaker Control



Main Breaker Positions



Main Breaker Control

Main Breaker Position



„a‟ and „b‟ contact used to determine position (default)

this may change



If conflict between „a‟ and „b‟:

1. Contact fault active

2. If current on all 3 phases > threshold, then breaker

considered closed, else unknown

3. Source deemed not available if current based breaker

position is „unknown‟



Can configure for „a‟ contact only operation, this may

become the default



Breaker rack-out will cause fault and source not

Main Breaker Position



In applications without GM, a virtual GM is created by

collection of genset paralleling breakers



In this case, if any one or more genset paralleling

breaker is closed, virtual GM is closed.



IMPORTANT: If #gens <= 4, use individual genset cb

position inputs. If #gens > 4 connect cb contacts in parallel to GM position inputs.

Main Breaker Control



Separate relays for close and open



Relays energize until desired position achieved



Adjustable recharge time delay



Built-in software interlock for open transition



In applications without GM, the MCM3320 controls the

virtual gen main via the paralleling gen cb inhibit inputs on the genset controls



Breakers can be controlled manually when Auto/Manual

Main Breaker Diagnostics



Breaker Diagnostics:

Fail to Close (adjustable delay) Fail to Open (adjustable delay) Breaker Contacts

Breaker Tripped Fail to Disconnect



Diagnostics results in warning and appropriate

control reaction

Power Transfer Control



Sensors and Source Availability



Operating Mode



PTC State Machine

Sensors



Both sources have these sensors:

• Undervoltage • Overvoltage *

• Under/Over Frequency * • Phase Rotation *

• Loss of Phase *

• Main Breaker Tripped • Fail to Close

• Position Contact Failure



If any sensor is dropped-out, the source is not available

Sensor - Undervoltage



Sensor is always enabled



Configurable L-L or L-N sensing



Settings:

– Dropout Percentage – Pickup Percentage – Dropout Delay



Pickup is instantaneous



Take note how settings are converted into

actual voltages (next page)

Sensor - Undervoltage

Voltage, V UnderVoltage Sensor Status Nominal System Voltage (100%) Pickup Voltage Dropout Voltage PICKED UP (good) DROPPED OUT (bad)

Sensor - Overvoltage



Sensor is optionally enabled



Configurable L-L or L-N sensing



Settings:

– Dropout Percentage – Pickup Percentage – Dropout Delay



Pickup is instantaneous



Take note how settings are converted into

actual voltages (next page)

Sensor - Overvoltage

Voltage, V OverVoltage Sensor Status Nominal System Voltage Pickup Voltage Dropout Voltage PICKED UP (good) DROPPED OUT (bad)

Sensor - Frequency



Sensor is optionally enabled



Over and Under combined in one sensor



Settings: – Center Frequency – Dropout Bandwidth – Pickup Bandwidth – Dropout Delay



Pickup is instantaneous



Take note how settings are converted into actual

Sensor - Frequency

Frequency, Hz Frequency Sensor Status Center Frequency Upper Pickup Freq Lower Pickup Freq PICKED UP (good) DROPPED OUT (bad) Lower Dropout Freq Upper Dropout Freq

Sensor – Phase Rotation



Sensor is optionally enabled



Compares source‟s phase rotation to System Phase

Rotation setting when source is at least 60% voltage and 30Hz



Once sensor is picked up (good), sensor does not

recheck until voltage/freq drop below and then back above 60%, 30Hz



Settings:

– System Phase Rotation

– Dropout Delay

Sensor – Loss of Phase



Sensor is optionally enabled



Dropout (bad) when any phase angle between

LL phasors does not fall within 90 to 150

degrees



Settings:

– Dropout Delay



Pickup is instantaneous

Sensors - Misc



If

Main Breaker Tripped

input is active, source is

Not Available



If

Main Breaker Fail to Close

fault state is active,

source is Not Available



If

Main Breaker Position Contact

fault state is

active and current does not indicate breaker is

closed, source is Not Available

Sensors – Source Unique



Utility source additional sensor:

• Utility Source Failure switch input



Genset source additional sensor:

• Genset Online Capacity Sensor *

• sensor picks-up when online kW capacity exceeds threshold. Once gen main is closed, sensor stops checking.

Operating Mode



Evaluates utility source status, test start / stop,

and extended parallel start / stop to decides

whether or not to start or stop the gensets



Prioritizes and lets PTC core logic know which

direction a transfer should be going, if any

PTC State Machine



The core of the power transfer control



Four possible states defined by four possible

combinations of GM and UM breaker positions



In each state, logic unique to that state decides

whether to turn on synchronizer and whether to

open or close a breaker

PTC State Machine

No Command Close Utility Close Genset No Command Open Utility Close Genset No Command Close Utility Open Genset No Command Open Utility Open Genset NO SOURCE CONNECTED UTILITY CONNECTED GENSET CONNECTED PARALLELED T2B T1B _T4A T3A T4B T1A T2A T3B N1 N2 N3 N4 U1 U2 U3 U4 P1 P2 P3 P4 G1 G2 G3 G4 PTC NOT ENABLED Powerup T-INIT T99 T0

Timers



Start Timer



Stop Timer



Timer in each PTC State:

– Programmed Transition Timer (No Source Connected)

– Transfer Timer (Utility Connected)

– Retransfer Timer (Genset Connected)

Override



Override switch input (hardwired or Modbus)



Forces pending action to occur immediately



Useful in certain situations / applications



Overrides (bypasses) the following:

– Transfer Inhibit – Retransfer Inhibit – Start Delay

– Transfer Delay – Retransfer Delay



Does NOT override:

– Stop Delay

– Programmed Transition Delay – Maximum Parallel Time

– Gen Main CB Inhibit – Utility Main CB Inhibit

Synchronizer & Sync Check



Synchronizer On / Off



Synchronizer Control



Sync Check

Synchronizer On / Off



In all cases, both sources must be „available‟

for the synchronizer to run



With PTC function, Synchronizer turns on

automatically when needed if in „Auto‟ mode



In „Manual‟, Sync Enable input must be active

to turn on

Synchronizer Control



Synchronizer matches phase, frequency and voltage of

gen bus to utility bus



Freq Match Closed loop PI drives kW load share lines to

match freq/phase



Volt Match Closed loop PI drives kVAR load share lines

to match voltage



Tuning is fairly tolerant; field adjustment not expected to be required normally



Performance is very good – much improved over existing

Synchronizer Control



Two Synchronizing Options:

– Phase Sync (default) => gen bus phase is driven to match utility bus

– Slip Frequency => gen bus frequency is driven to be fixed Hz higher or lower than utility bus (e.g. 0.1Hz)



Use Slip Freq option with difficult to sync applications

such as natural gas



Nominal System Frequency

= 45-65 Hz

– Used by synchronizer – must be set to nominal operating genset frequency

Sync Check



Permissive sync check with adjustable frequency, phase,

voltage and dwell time window



Runs independently of synchronizer



PTC function uses this to decide when to close breaker



Can get sync check output by mapping sync event to a

configurable output (#6 by default)



In synchronizer only applications, can also enable sync

check individually for different dead bus scenarios (dead bus sensor is included)

Synchronizer Diagnostics



Fail to Synchronize Warning

= synchronizer has

been on for Fail to Sync time (adjustable)

without achieving sync check ok



Synchronizer Output Limit Warning

= freq bias

or volt bias drive output has been at maximum

and unable to achieve sync

Load Control



kW and kVAR are controlled during soft

transfers and extended paralleling



MCM3320 has one analog output for kW, one

for kVAR



MCM3320 drives all gensets to same %

command value



PCC Genset controllers perform ramping and

load governing

Load Control



Soft Loading



Extended Paralleling



kW Control



kVAR Control



Diagnostics



Performance / Tuning

Soft Loading



Closed transition transfer / retransfer



MCM3320 either drives load set line to +5V or 0V

depending on desired ramp direction



PCC genset controllers perform the ramp based on their

own ramp time settings



PCC genset controllers are doing the closed loop control

of kW and kVAR (load governing)



MCM3320 disconnects appropriate source when it

Extended Paralleling



Many options for how / where to control kW and

kVAR



Open loop or closed loop options



Control points at gen bus or utility bus



Setpoints from analog input, trim setting, or

Modbus



MCM3320 controls load without knowledge of

which gensets are online

kW Control Options



Gen Bus % Level (open loop)

» MCM3320 puts out fixed %kW command



Gen Bus kW (closed loop)

» MCM3320 adjusts output command to get desired kW at gen bus metering point



Gen Bus kW w/Utility Constraint (closed loop)

» MCM3320 adjusts output command to get desired kW at gen bus metering point subject to maintaining utility kW greater than a threshold



Utility Bus kW (closed loop)

» MCM3320 adjusts output command to get desired kW at utility bus metering point

kVAR Control Options



Genset Controllers

» MCM3320 does nothing

» ONLY OPTION WHICH WILL WORK ON PCC3100 GENSETS



Gen Bus % Level (open loop)

» MCM3320 puts out fixed %kVAR command



Gen Bus Power Factor (open loop)

» MCM3320 puts out %kVAR command based on power factor setting and what is currently being put out on the %kW command output



Gen Bus kVAR (closed loop)

» MCM3320 adjusts output command to get desired kVAR at gen bus metering point



Gen Bus Power Factor (closed loop)

» MCM3320 adjusts output command to get desired power factor at gen bus metering point

kVAR Control Options (cont.)



Utility Bus kVAR (closed loop)

» MCM3320 adjusts output command to get desired kVAR at utility bus metering point



Utility Bus Power Factor (closed loop)

» MCM3320 adjusts output command to get desired power factor at utility bus metering point

Load Setpoints - Source



kW, kVAR/PF setpoints can come from

hardwired analog inputs or internal setting



Internal setting can be changed from Inpower,

HMI, or Modbus

analog input (hardwired)

internal

process value

Load Setpoints – Scaling

%kW, kVAR, Power Factor vs. Input Voltage

0 10 20 30 40 50 60 70 80 90 100 110 120 0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 4.25 4.5 4.75 5 Input Voltage, Vdc %kW / %k VAR 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 Power Factor %kW/kVAR PowerFactor

Load Setpoints – Scaling



If

open loop

load control, scaling of hardwired analog

input is per graph



If

closed loop

load control, kW command level = % from

graph * Total System Capacity



If

power factor control

, scaling always follows red line



Definitions:

– Total System Capacity = sum of individual genset kW ratings – %kW = kW / Total System Capacity

Load Control Diagnostics



kW Load Control Output Limit Warning

» kW command output has been at minimum or maximum value for longer than 60 seconds » Only applicable to closed loop modes

» means that the desired kW setpoint cannot be achieved either due to inadequate capacity or operator error



kVAR Load Control Output Limit Warning

» analogous to kW diagnostic

» Means that the desired kVAR or Power Factor setpoint cannot be achieved either due to

Scheduler



Scheduler operates based on up to 12 programs

and 6 exceptions



Each program specifies a day of the week/time to

start, how long to run, how often to repeat, and what

mode to run in



Run modes are: test without load, test with load, and

extended parallel



Each exception is defined by a start date/time,

duration, and repeat interval



An exception will block a scheduled program from

Scheduler



To use Extended Paralleling with the Scheduler, the

Extended Parallel Enable must be set to Enabled



If program run mode = Extended Parallel, but Extended

Parallel Enable = Disabled, there will never be extended paralleling (nothing will happen when program becomes active)



Some applications do not allow extended paralleling, so

this provides one setting to disable all extended paralleling

Scheduler



Scheduler will follow the Program Run Mode setting

– If Program #1 Run Mode = With Load, system will run with load – If Program #1 Run Mode = Without Load, system will run without

load



The setting of Test With Load Enable variable does NOT apply to Scheduler

– E.G. If Test With Load Enable = Disabled, but Program #1 Run Mode = With Load, program will run with load



Test With Load Enable only applies to Test Start switch input (hardwired or Modbus or HMI)



This may be confusing because it is different than how the Extended Parallel Enable is used by the MCM3320

Program Overlapping



Do not overlap programs; overlapped program will be ignored

Program1

Program2

Program1 Program2

Program1 runs for its entire period Program2 does NOT run

Program1 runs and ends. Some time later Program2 runs and ends.

Exception Operation



Exceptions only block the START of a program; a program

started outside of the exception period will not be canceled by an exception

Program1

Exception1

Program1 runs for its entire period

Program1

Priorities

 Utility Failure will supersede any scheduler program

 An active program will resume when the utility source has become available again

 Two examples are shown below

Program1 (no load) Utility Failed

EXAMPLE#1:

Utility fails while gensets running no load due to Program1. System will transfer load to gensets. When utility returns, system load will remain on gensets until Program1 ends. (It does NOT retransfer until Program1 ends.)

Program1 (extended parallel) Utility Failed

EXAMPLE#2:

Utility fails while gensets running in parallel to utility due to Program1. System will open utility main breaker. When utility returns,

UM Breaker GM Breaker Closed Open Closed Open Open Closed

Operating Sequences

Normal Sequences1

Utility Fail / Return Extended Parallel

Test (with or without load)

Sequences are affected by

Transition Type Operating priority Faults2

1_{Refer to MCM3320 Operating Sequences document for listing of normal sequences}

Normal Sequence Example

Scenario:

Transfer Pair; Soft Closed Transition; Utility Fail / Return

1. Utility Failure

2. TD Start

3. Gensets Start / Close 4. Gen Bus Available 5. TD Transfer

6. Open Utility Main

7. TD Program Transition 8. Close Gen Main

9. Loads Powered by Gen Bus

10.Utility Available

11.TD Retransfer 12.Synchronizer On 13.Sync Check OK 14.Close Utility Main

15.Ramp Unload Gensets 16.Open Gen Main

17.TD Stop

18.Stop Gensets

Abnormal Condition Example

Scenario:

Transfer Pair; Soft Closed Transition; Test With Load;

UM Fails to Open

1. Test Start Initiated 2. TD Start

3. Gensets Start / Close 4. Gen Bus Available 5. TD Transfer

6. Synchronizer On 7. Sync Check OK 8. Close Gen Main

9. Ramp Load Gensets

10.Utility Unloaded 11.Open Utility Main

12.Utility Main Fails to Open

13.Open Gen Main 14.Gen Main Opens

15.Open Utility Canceled 16.Loads Powered by Utility 17.Gensets Remain Running 18.User Intervention Required

Operating Priorities



Operating priorities from highest to lowest:

1. Utility Failure

2. Extended Parallel 3. Test

Load Demand



Supports 2, 3, or 4 genset systems



4 hardwired outputs to drive gensets load demand stop



4 hardwired inputs to read genset paralleling breaker

positions



Shuts down/Restarts gensets based on genset bus total

kW load level



Adjustable shutdown / restart thresholds and time delays



Genset Sequence configurable as Fixed Sequence or

Load Demand Interconnect G1 PCC3xxx G2 PCC3xxx G3 PCC3xxx G4 PCC3xxx

Gen1 Load Demand

Gen1 Breaker Position

Gen2 Load Demand

Gen2 Breaker Position

Gen3 Load Demand

Gen3 Breaker Position

Gen4 Load Demand

Gen4 Breaker Position

MCM3320

Genset Bus Currents Genset Bus Voltages

Load Demand Operation



Genset Sequence defines shutdown order:

– GenA, GenB, GenC, GenD



GenA always runs; GenD is first to shut down, last to

restart, etc.



Sequence Determination:

– Fixed Sequence, or Run Hours Based



Fixed Sequence is set by the operator



Run Hours Based Sequence changes dynamically as run

hours accumulate on gensets – system attempts to equalize running hours on all gensets

Load Demand Operation



Fixed Sequence • GenA = Gen2 • GenB = Gen1 • GenC = Gen4 • GenD = Gen3



Sequence can be changed any time – even when load demand

is operating



Must issue “Refresh Sequence” command after defining the new

sequence in order for it to take effect (HMI211 does this for you).



On change, only the appropriate gensets will restart, then after