59330788 Cummins PCC3 3 Technical Training

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Participant Guide

Controller

PowerCommand 3.3

Phase 1 Release

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Revision History

v1.00 (10/2008)

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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

3

Naming System

PCC 1302 PCC 2300 PCC 3300

PowerCommand 1.X PowerCommand 2.X PowerCommand 3.3

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 3.3 HMI 320 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

Phase 2 (Hydra Mech.)

PowerCommand 3.3 HMI 320

HMI 112 or HMI 114, HMI 113 AUX 101/102, AUX 104

Phase 2 (Hydra Mech.)

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

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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.

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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

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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

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PCC 3.3 & PowerCommand Control 3300 Section last page

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PowerCommand

3.3 Section 1 Introduction to the

PowerCommand Control 3300

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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.

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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).

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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

Visual 1-2 Introduction to the PowerCommand Control 3300

Participant’s Text

The PowerCommand Control 3300 is a highly integrated control providing complete genset control and protection. The Phase 1 release of this new control will

Notes:

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3

PCC 3300 Control Boards

PCC 3300 Base Board

AUX 103 Power Stage

Visual 1-3 The PCC 3300 Control Board

The PCC 3300 board uses the same large potting shell as used in the MCM3320 and PCC 2300.

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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

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4

PCC 3300 Connectors

TB7- Bus Voltage Sense

TB-15 – ModBus/RS485 J20- Genset Connections J12- Genset CT Input J26- AUX 103 Connector J22- Genset Voltage Sense Onboard BUS CTs TB-1 – Customer Connections J-25 Display Connections DSx LED Status Indicators

TB10 – Breaker Status Connections TB-9 – Analog I/O TB-3 – Customer Input/Output TB-5 – Breaker Control Connections TB-8 Customer Connections J14 – Service Tool Port

Visual 1-4 Control Board Connectors

Participant’s Guide

DSx − Status indicators: DS3 flashes to let you know the control board is operating properly.

CT1, 2, & 3 − Onboard Bus CTs

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4

PCC 3300 Connectors

TB7- Bus Voltage Sense

TB-15 – ModBus/RS485 J20- Genset Connections J12- Genset CT Input J26- AUX 103 Connector J22- Genset Voltage Sense Onboard BUS CTs TB-1 – Customer Connections J-25 Display Connections DSx LED Status Indicators

TB10 – Breaker Status Connections TB-9 – Analog I/O TB-3 – Customer Input/Output TB-5 – Breaker Control Connections TB-8 Customer Connections J14 – Service Tool Port

Visual 1-4A Control Board Connectors

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

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AUX103 AVR Power Stage

J18 – Power Input J19 – Interconnection to PCC 3300 Base Board J17 – Field Output Chassis Ground Wire

Visual 1-5 Automatic Voltage Regulator Module

The AVR Module is used with all PC 3.3 gensets.

There are 3 connectors on the board. J17 provides the excitation output.

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HMI 320 Operator Panel

Visual 1-6 Optional operator panel

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

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Operator Panel Menus

Visual 1-7 Operator Panel Menus

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.

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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.

Visual 1-8 HMI screen navigation

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.

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9

PCCNet Components

(Common @ Phase 1)

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

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

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

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

0300-6366-02 HMI 114 Horizontal lamp Bargraph (

kW & PF

)

0300-6050-01 HMI 112 Vertical lamp Bargraph (

kW & PF

)

Visual 1-9 PCCNet Components

0300-6315 HMI320 Operator Panel 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.

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PowerCommand 3.3

Quiz 1-1: Intro to PowerCommand 3300,

Operator panel, and PC 3.3 system.

Visual 1-10 Quiz for Lesson 1

Turn to Section 15 and complete Quiz 1-1. At this time I would like you to work in

groups to complete the quiz. It should take about 20 minutes.

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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.

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PowerCommand 3.3

HMI 320

Section 2: PC 3.3 HMI 320 Panel, Operation,

and Menus

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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 Guide CMT6068-EN-PG

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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.

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HMI 320 Operator Panel

Local Control Panel

0300-6315-02

Remote Control Panel

0300-6315-03

Slide 2-2

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

Notes:

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Standard HMI 320 Operator Panel

Large

Graphical

Display

Selection

Buttons

Screen

Navigation

Buttons

Breaker

Control

Buttons

Control

Function

Buttons

Function

indication

lamps

Slide 2-3 Setup Menu Access.

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

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PCC 3.3 & PowerCommand Control 3300 Service Menus 4

Display Screen

Line 1 Controller Mode Line 2 Fault Data Line 3 Screen Name

Data & Status Screen

Soft Button Options

Slide 2-4 Display Screen

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

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4

Display Screen

Line 1 Controller Mode Line 2 Fault Data Line 3 Screen Name

Soft Button Options

Data & Status Screen Page & Pages available

Slide 2-4B Display screen continued.

Soft keys are labeled across the bottom of the screen. The manual refers to them as Function Selection Buttons.

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HMI Hard Keys

Pressing these buttons simultaneously

for 3 seconds will cause the screen to

enter a DEMO mode if PCCNet is

disconnected.

The HOME button

Previous Screen Button

These hard keys enable navigation

between various menu screens

Slide 2-5 Hard Keys.

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.

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Setup Menu and Passwords

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

Slide 2-6 Genset Setup

The HMI 320 Setup Screens are accessible and viewable without a password. If you attempt to change a setting that requires a

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• 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.

Notes:

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Mode Change Password

Protection

If enabled, many of the HMI buttons will be disabled.

The operator MUST have

the password f

or them to become operational.

Slide 2-7 Mode Change Password

Look at page 5-1 of 0900-0670 service manual. MODE CHANGE PASSWORD can be confusing to many.

MODE refers to the operation mode such as – running in Manual, running in

Additional Participant’s Text

This is a feature to protect a piece of customer equipment, or to protect equipment from the customer. This feature prevents someone from

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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.

Slide 2-8 Adjust Screen

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.

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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.

Additional Participant Text & Notes

_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________

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Setup Genset Menus

The HMI has a series of 5 screens that allow for detailed setup of a multitude of operation set points.

Slide 2-9 Genset Setup

From the Home (2) screen, navigate to and highlight the “Genset Setup” menu and press Pressing the button will take you to a series of screens where you can adjust and change various genset

configuration settings.

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Paralleling Setup Menus

The HMI has a series of 6 screens that allow for detailed setup of a multitude of Paralleling operation set points.

Slide 2-10 Paralleling Setup

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

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OEM Setup Menus

The OEM Setup provides access to genset configuration settings.

Slide 2-11 OEM Setup

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.

Notes:

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Participant’s Text (OEM GENSET SETUP)

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

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Participant’s Text (OEM ENGINE SETUP)

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.

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Participant’s Text (OEM ALTERNATOR SETUP)

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

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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.

Slide 2-12 PCCNET & ModBus Setup

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.

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Setup Menus

The remaining Setup screens Display Options, Clock Setup, Configurable IO, and Calibration also contain multiple screens with many setup parameters.

Slide 2-13 Operator Setup Menus

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

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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.

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

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.

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15

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.

Slide 2-15 Activities Listing for Lesson 2

At this time I would like you to work as teams to complete these activities. These activities should be fairly easy for you,

but take your time to become comfortable

Notes:

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

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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?

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PowerCommand

3.3 Section 3 Sequence & Operation

PCC 3300 & HMI 320

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

Section 3 PowerCommand Control 3300 Sequence & Operation.

• PowerCommand Control 3300 Participant’s Guide Guide (CMT6068-EN-PG) • PC with InPower v 7.0 or later installed

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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

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2

HMI 320 Operator Panel

Local Control Panel

0300-6315-02

Remote Control Panel

0300-6315-03

Fixed buttons

Visual 3-2 Local and Optional Remote Operator Panel

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

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3

Modes of Operation

Each mode of operation has multiple choices

affecting sequence of operation.

Off Mode

Auto Mode

Manual Mode

Parallel Mode

Visual 3-3 PCC 3.3 Operation Modes

As with so many things about this control, a different style of thinking is required to understand how this control operates. Modes of Operation: Off Mode

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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

At the HMI pressing the will engage 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

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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

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4

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

Visual 3-4 PCC 3300 Starting Mode & Sequence

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.

Notes:

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Flow diagram of the normal start modes of the PCC3.3 Control system

T IM E D E L A Y T O S T A R T T IM E D E L A Y T O S T O P W A R M U P @ ID L E R A T E D S P E E D & V O L T A G E L O A D D E M A N D S T A R T E X E R C IS E L O C A L S T A R T M A N U A L L O C A L S T A R T R E M O T E S T A R T N O N -E M E R G E N C Y R E M O T E S T A R T E M E R G E N C Y R E M O T E S T A R T T IM E D E L A Y T O S T A R T W A R M U P @ ID L E W A R M U P @ ID L E R A T E D S P E E D & V O L T A G E R A T E D S P E E D & V O L T A G E R A T E D S P E E D & V O L T A G E R A T E D S P E E D & V O L T A G E T IM E D E L A Y T O S T O P T IM E D E L A Y T O S T O P T IM E D E L A Y T O ST O P in A u to M o d e & rem o te start = 1

(h ard w ired o r n etw o rk ) start m o d e = em erg

(h ard w ired o r n etw o rk )

start m o d e = n o n -em erg

(h ard w ired o r n etw o rk ) in M an u al M o d e & “m an u al” ru n is in itiated (= 1 )

T o --> A u to M o d e tran sitio n & “ex ercise” b u tto n (h ard w ired o r n etw o rk ) = 1

in A u to M o d e & rem o te start = 1 lo ad d em an d sto p = 0

(h ard w ired o r n etw o rk )

N O R M A L S T A R T /R U N /S T O P S E Q U E N C E S rem ote start = 0 rem ote start = 0 "m anual" = 0 E x ercise T im e E x p ires load dem and stop = 1 C O O L D O W N @ R A T E D C O O L D O W N @ R A T E D C O O L D O W N @ R A T E D C O O L D O W N @ R A T E D C O O L D O W N @ R A T E D load tim er expires load tim er expires load tim er expires load tim er expires tim er expires tim er expires tim er expires tim er expires tim er expires tim er expires tim er expires * * * * * O IL P R E -L U B E C ranking Is N ot D elayed (tim er expires or coolant tem p) (tim er expires or coolant tem p) (tim er expires or coolant tem p) T IM E D E L A Y T O S T A R T O IL P R E -L U B E C ranking Is N ot D elayed O IL P R E -L U B E C ranking Is D elayed till P relube C om pletes O IL P R E -L U B E C ranking Is D elayed till P relube C om pletes O IL P R E -L U B E C ranking Is D elayed till P relube C om pletes R A T E D T O ID L E D E L A Y ** R A T E D T O ID L E D E L A Y ** R A T E D T O ID L E D E L A Y ** R A T E D T O ID L E D E L A Y ** R A T E D T O ID L E D E L A Y **

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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

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6

Modes of Operation - Stopping

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 + PCC3300 Control Remot e E-STOP Contac t 1 Remote E-STOP Contact 2 Local E-STOP Contact 2 To Relay Contacts Local E-STOP Contact 1

Emergency Stop

Visual 3-6 PCC 3300 Shutdown Sequence

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

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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.

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7

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.

Visual 3-7 PCC 3.3 Prelube

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.

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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.

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8

Power Down Mode

The PC 3.3 also uses the same Bi-directional wakeup

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

Visual 3-8 PCC 3.3 Power Down

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

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9

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 0 to 4 amp – Maximum continuous operation 4 amp

– Surge ` 6 amp for 10 seconds

AUX 103 does not provide output during:

– Normal startup @ idle – Normal shutdown @ idle

– Emergency Stop (local, remote or fault shutdown)

Visual 3-9 PCC 3300 Power Stage

The AUX 103 Power Stage AVR is separate 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

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10

PWM and Self Excitation

The PCC3300 collects main alternator output power at J18 1 & 2 which is genset rated frequency.

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

Visual 3-10 PCC 3300 and Self Excitation

Self Excitation uses 2 phases of power 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.

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11

The PCC3300 collects 3 phase PMG output power at J18 which is twice genset rated frequency.

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

PWM and PMG Excitation

Visual 3-11 PCC 3300 PMG Excitation

PMG Excitation offers many advantages 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.

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12

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

Visual 3-12 Start Disconnect

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

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13

Quiz: PCC 3300 Sequence of Operation

Activities:

Visual 3-13 PCC 3300 Activities - Sequence of Operation

Work through the Quiz found in the Activity portion of Section 15.

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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.

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PCC 3.3 & PowerCommand Control 3300 Section last page

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PowerCommand

3.3 Section 4: Control Installation

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PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 Installation

Section 4 PowerCommand Control 3300 Installation

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

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

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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.

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2

Control and Option Installation

Physical Installation Requirements

Identify each of the connectors

Input and Output Connections

Visual 4-2 Control and Option Installation.

Control Installation

Most technicians will encounter the PCC3300 when it is already installed onto a 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

Notes:

Adding options in the field will most likely be a common occurrence

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3

Installation Steps for Options

Place Genset in OFF Mode & Press E-Stop

Turn Battery Charger Off

Disconnect Battery (Lock-out & Tag-out)

Static Wrist Strap (Not if AC power present

{possible 600v present}

)

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

Install Wiring Harness

Battery Connected (Remove Lock-out)

Download Proper Calibration

Turn on Battery Charger

Test Generator Set

Visual 4-3 Installation Steps for PowerCommand Control 3300 Options

Participant’s Text Installing Options

The PowerCommand Control 3300 cannot be powered down except by disconnecting the battery cable.

IMPORTANT! Press the local Emergency

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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.

Notes:

Additional Notes or Comments

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4

Baseboard Connector Location

J12- Gen CT Inputs

TB15- Service / MODBUS

J22- Gen Voltage

J25- Display Connections TB7- Bus Voltage

TB5- Circuit Breaker Control TB10- Circuit Breaker Status J26- Engine Interconnect TB3 - Customer I/O J14- Service Interface TB8- Customer I/O TB1 – Customer I/O J20- Genset input/outputs TB9- Analog I/O Bus CT Inputs

Visual 4-4 Connector Location -r PowerCommand Control 3300

Like the PC 1.X & 2.X, the PowerCommand 3.3 also uses the new common connector scheme.

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5

Bus CT Connections

CT1 CT2 CT3

Visual 4-5 Control Board CT Connections

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 pass-through.

These CTs are looking for a signal from the

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6

J12 Connections

Pin 4 Pin 1 Pin 6 Pin 3 Visual 4-6 J12 Inputs Participant’s Text

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

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7

J22 Gen Voltage Connections

Pin 1 Pin 4

Visual 4-7 J22 Gen Voltage Inputs

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.

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8

J20 Gen I/O Connections

Pin 22

Pin 1 Pin 12

Pin 11

Visual 4-8 J20 Genset I/O Connections

J20 provides connection for most genset features.

Notice J20-16 is the Oil Priming Pump Driver

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PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 Installation 9

J25 Display Connections

Pin 1 Pin 6 Pin 7 Pin 12

Visual 4-9 J25 Display Connections

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

J25 provides connection for PCCNET display connection.

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10

J26 Engine Interconnect

Pin 18 Pin 10 Pin 9 Pin 1

Visual 4-10 J26 Engine Interconnect

J26 is used for engine and AVR Power Stage connection.

Standard SAE J1939 communications can be connected at J26-1, 10, & 11. On the

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11

J14 Data / Service Interface

Pin 9

Pin 5

Pin 6

Pin 1

J14 DATA LINK (RS232)

Visual 4-11 J14 Data/Service Interface

This communication port is used 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

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12

TB1 Customer I/O Connections

Pin 16 Pin 1

Visual 4-12 TB1 Customer Connections

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

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13

TB3 Customer I/O Connections

Pin 12 Pin 1

Visual 4-13 TB3 Customer I/O connection

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

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

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14

TB5 Circuit Breaker Control

Pin 9 Pin 1

Visual 4-14 TB5 Breaker connections

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

More details about these connections will be

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15

TB8 Customer Connections

Pin 13 Pin 1

Visual 4-15 TB8 Customer Connections

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.

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16

TB10 Breaker Status Connections

Pin 17 Pin 1

Visual 4-16 TB10Breaker status connections

TB10 accepts breaker status for both utility (Mains) and genset breaker. There are also a couple paralleling performance command inputs.

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17

TB15 Data / Service Interface

Pin 5

Pin 1

Visual 4-17 TB15 Service tool connection

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.

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18

TB9 Analog I/O Connections

Pin 11

Pin 1

Visual 4-18 TB9 Analog connections

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

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19

TB7 Gen Bus/Utility Voltage Sense

Pin 4 Pin 1

Visual 4-19 TB7 Bus sense connection

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.

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20

AVR Power Stage Connectors

Pin 1

Pin 2 Pin 1

Visual 4-20 J17 - 18 Inputs and Outputs

J17 Excitation Field Power

J17-1 supplies excitation positive to X1 (F1)

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J18 Voltage Regulation Power Supply - maximum input is 240 VAC

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.

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21

AVR J19 Interconnect

Pin 14

Pin 1

Visual 4-22 Operator Panel Installation

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

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22

HMI 320 Operator Panel

Local Control Panel

0300-6315-02

Remote Control Panel

0300-6315-03

Visual 4-22 Operator Panel Installation

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

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23

HMI 320 Operator Panel

Visual 4-23 Installation HMI320

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,

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24

Common Connector Scheme 0630-3440

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.

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25

Activities

Section 4: In-Class Quiz

Visual 4-14 Quiz Listing for Section 4

Participant’s Text

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

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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.

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59330788 Cummins PCC3 3 Technical Training

Participant Guide

Controller

PowerCommand 3.3

Phase 1 Release

Revision History

Table of Contents

Preface:

Naming System

X.1 = HMI 211

X.2 = HMI 220

X.3 = HMI 320

Introduction

PowerCommand

3.3

Section 1 Introduction to the

PowerCommand Control 3300

Section 1

Introduction to the PCC 3.3, the PowerCommand

Control 3300 control board and its 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

PCC 3300 Control Boards

PCC 3300 Base Board

AUX 103 Power Stage

J Connections − Common Connectors.

TB Connections − Customer

PCC 3300 Connectors

PCC 3300 Connectors

AUX103 AVR Power Stage

HMI 320 Operator Panel

Operator Panel Menus

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.

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 (

)



0300-6050-01 HMI 112 Vertical lamp Bargraph (

)

PowerCommand 3.3



Quiz 1-1: Intro to PowerCommand 3300,

Operator panel, and PC 3.3 system.

Wrap-Up

PowerCommand 3.3

HMI 320

Section 2: PC 3.3 HMI 320 Panel, Operation,

and Menus

Section 2

PCC 3.3 HMI 320 Service Menus:

Warm Up

Objectives