PCC 2100 Commissioning Guide Lines_Rev2.6

Commissioning report for PCC Engine

Name of the Commissioning Engineer : Date Of Commissioning:

Customer: Parts & their Sr.Nos. ( Kindly Confirm by actual Inspection)

Parts

Cummins Part

No Fuses :

Control Assy. 0300-5459-02 Fuse Location, Rating Function

Engine Harness 0338-4232 F1

Base Board---10 A Protects B+ Ckt (TB1-17 & TB1-18

AC Harness 0338-4977 F2

Base Board---5 A Protects Switched B+ Ckt (TB1-19)

Coolant/L.O. Temp. Sender 0193-0529-02 F3

Base Board---2 A Protects Switched B+ Ckt (J7-23 &J7-9)

Lube Oil Press. Sender 0193-0444 F4

Base Board---5 A Protects Base Board Power Supply

Base Board 0327-1379-01 F5

PTC Module (optional)---2 A Protects PTC Module

Display Board 0300-5467

Bar Graph Board 0300-5180

Pilot Solenoid 0307-2621-02 Calibration Part No. Model

MPU 4085824 0326-6167 K-38

Low Coolant Level Switch 0193-0468 0326-5769 K-50

PCC O & M Manual 0900-0534 0326-5761 V-28

CT Ratio CT Part Number

CT's For 750KVA--2141 / 1 0302-2058-03 CT's For 1000 KVA--2839/1 0302-2058-08 CT's For 1250KVA--3867/1 0302-2058-12 CT's for 1500 KVA--4420/1 0302-2058-15 Name of the OEM Engineer

Model:

OEM

Factory Installed Feature List - 750KVA Factory Installed Feature List - 1000KVA

Feature Part Numbers Description Feature Part Numbers Description

0326-5482 Lonworks Disabled 0326-5482 Lonworks Disabled

0326-5485 Application -Prime 0326-5485 Application -Prime

0326-5490 Coolant Level SD 0326-5490 Coolant Level SD

0326-5566 WYE Connection 0326-5566 WYE Connection

0326-5576 Voltage- 416 L-L 0326-5576 Voltage- 416 L-L

0326-5584 Oil Temp. Sender Enable 0326-5584 Oil Temp. Sender Enable

0326-5596 Frequency -50 Hz 0326-5596 Frequency -50 Hz

0326-5683 Excitation -PMG 0326-5683 Excitation -PMG

0326-5696 Over speed - 1800 rpm 0326-5696 Over speed - 1800 rpm

0326-5759 CT Ratio 0326-6156 Battle Short Enable

0326-5819

600 KW Prime/660 KW

standby - 3 Ph 0326-6192 CT Ratio

0326-6156 Battle Short Enable 0326-6361

800 KW Prime/ 880 KW standby - 3 Ph

0326-6717 Gov. Gains 0326-6717 Gov. Gains

Factory Installed Feature List - 1250KVA Factory Installed Feature List - 1500KVA

Feature Part Numbers Description Feature Part Numbers Description

0326-5482 Lonworks Disabled 0326-0411

1200 KW Prime/ 1320 KW standby - 3 Ph

0326-5485 Application -Prime 0326-5482 Lonworks Disabled

0326-5490 Coolant Lvl SD 0326-5485 Application -Prime

0326-5566 WYE Connection 0326-5490 Coolant Level SD

0326-5576 Voltage- 416 L-L 0326-5566 WYE Connection

0326-5584 Oil Temp.Sender Enable 0326-5576 Voltage- 416 L-L

0326-5596 Frequency -50 Hz 0326-5584 Oil Temp.Sender Enable

0326-5683 Excitation -PMG 0326-5596 Frequency -50 Hz

0326-5696 Overspeed - 1800 rpm 0326-5683 Excitation -PMG

0326-5849

1000 KW Prime/ 1100 KW

standby - 3 Ph 0326-5696 Overspeed - 1800 rpm

0326-6156 Battle Short Enable 0326-6156 Battle Short Enable

0326-6197 CT Ratio 0326-6199 CT Ratio

0326-6490 Gov.Gains 0326-6490 Gov.Gains

Visual Inspection

The entire wiring should be clamped appropriately, with no loose wires hanging LCL if connected , should be wired up as follows:

LCL Wires---Engine Wiring Harness Red--- S7 + ( J7-31 +Ve) Black--- S7 - ( J7-35 -Ve) Blue---S7-Sig (J7-32) Plugs / Connectors ,engine Harness

Connector P7 - -- Connects on the Base Board ( Inside the door of PCC 2100) --While Fixing this plug first match the notch & push it in . CT Wires -- Connect X1 & X3 wires to individual CT's

AC Harness :

Connector No : P8 --Connects to J8 connector inside the PCC 2100 Box --PMGP2, PMG3 , PMG4---Connect this wire to the PMG wire coming out from the Main Alternator ( See that length of this adequate.

DO NOT EXTEND THESE WIRES, IF THESE WIRES ARE SHORT IN LENGTH----If required bring these wires to a terminal strip , securely mounted on the alternator frame inside & connect the Alternator PMG wires on the terminal strip>

X+, XX --These are field winding wires ----Connect the field winding wires from the main alternator to these wires ( F1 to X+ & F2 to XX U,V,W & N --- These are the Main Phase voltage connections.

AC Harness Details -- P8 Connector

One side of P8 plugs inside the PCC 2100 control & the other end connections are as follows: P8 -1,2,3,8,9,10,11,15,16,17,18,19 - Not Connected P8-4 - U ( R Phase Connection) P8-5 - XX ( Field -F2 Connection) P8-6 - Not Connected P8-7 - Neutral P8-12- V ( Y Phase Connection) P8-13 - X ( F1 Field connection) P8-20 - W (B-Phase Connection) P8-21- PMG2 P8-22 - PMG3 P8-23 -PMG4

Ensure that the wires going out of the Terminal strip towards the main panel ( OEM connections) are properly dressed & there are no loose wires hanging. Additional spare wires to be taped & dressed separately.

Starter Connections : Only one magnetic switch drives both ( for V Engines) the starters. Physically inspect that the positive terminals of Both the starters are looped ( Shorted). Similarly the negative terminals of both the starters are looped (shorted & connected to Engine body)

4 3 2 1

24 23 22 21

AC harness P8 Connector

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

TB-2

1 REMOTE START 1 RS -485 +

2 REMOTE EMERGENCY STOP 2 RS 485

-3 Remote Reset 3 B+

4 Customer Fault 1 4 GND

5 Customer Fault 2 5 Not Used

6 Customer Fault 3 6 Not Used

7 Customer Fault 4

8 Cust. Out 1 NO

9 Cust. Out 1 Common

10 Cust. Out 2 NO

11 Cust. Out 2 Common

12 Cust. Out 3 NO

13 Cust. Out 3 Common

14 Cust. Out 4 NO

15 Cust. Out 4 Common

16 SPARE

17 B+(20A FUSED)

18 B+(20A FUSED)

19 SWITCHED B+(10A FUSED)

20 GROUND

21 GROUND

22 GROUND

TB-1

PCC TB1 Connections

Sample Drawings related to each terminal of the TB - 1 pin terminal strip are given below. All the connections shown need not be used, the Mandatory connections are mentioned in BOLD Remote Start (

Mandatory For AMF applications)

1 REMOTE START ( IF PCC RUN /OFF/AUTO Switch is in AUTO &

if Ground is connected to terminal No.1 then engine will start remotely)

1 20

Sample Drawing for Remote start for AMF Application Main Panel 1

20

Remote Emergency Stop

( Mandatory)

Main Panel 2

if Ground is connected to terminal No.2 20 then engine will stop,PCC will indicate

Emergency Stop.

CUTOMER FAULTS 1,2,3 & 4 ( Earth Fault Protection Mandatory , Others Optional) 4 CUSTOMER Input 1 ---Default Not Programed Not Assigned

5 CUSTOMER Input 2 ---Default Programed as Ground Fault--Shutdown

6 CUSTOMER Input 3 ---Default Programed as Low Fuel level--Shutdown

7 CUSTOMER Input 4 ---Default Programed as High Alternator Temp--Shutdown

These are customer configurable inputs to the PCC, they can be either configured for Warning or Shutdown

In PCC there is no inbuilt protection for Earth Fault. An earth fault relay has to be externally used for this Purpose, the out put of which can be brought into the PCC for shutting down the engine. For this Customer Fault No2 (Ground Fault) has to be used.

A34-P1-12 5

GND-ENG 20

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

Main Panel Voltage Sensing Relay UTILITY SUPPLY

Relay Activated ByE/F Protection Relay Main Panel

Remote Start Switch

R Y B N Remote Emergency stop Switch TB1 TB1 TB1 TB1 TB1 TB1 PCC Checks/PMP

Example No. 2

If the Circuit Breaker trips due to Breaker internal electrical Protection, then this input can be brought into the PCC & the engine can be tripped.

Program the Customer Fault No 1 to ' Breaker Trip ' or ' Electrical Fault' ----Program it for Shutdown (Through PCC menus)

P12-1/A34-P1-9 4

GND-ENG 20

Fault Reset: This can be use to reset Warning Faults from Remote or Main Panel

A34-P1-2 3 FAULT RESET

When terminal No 3 is grounded ,the

A34-P1-2 20 warning fault from a remote location can be

reset.

GND-ENG 3

Customer Outputs : These are configurable outputs which close a NO contact when the desired configured event occurs.

These Outputs can be configured for any event through Inpower.

The Default ( Factory Installed) configured outputs are : Customer Output No.1 ---- Common Warning Customer Output No.2 ---Common Shut Down Customer Output No.3 ---Not In Auto

Customer Output No.4 ---Ready to Load However all these Customer outputs can be configured to any desired event through Inpower Example No.1 : Customer out Put No.1 If Configured for Common Warning:

8 9 17

Example No.2 : Customer Output No.4 (Default configured as Ready to Load) Breaker Closing

( Mandatory)

14 (N/O)

15 (N/O)

Sample Drawing for Breaker Closing

A34-P2-4 14

A34-P2-3 15

TB BAT-F1 17 24 vdc supply from TB1-1

BreakerTrip N/O Contact

Main Panel Main Panel TB1 TB1 Fault Reset Push Button 24 Vdc From TB1-17

When there is any warning on the Genset, the PCC internal contact closes & the indicating lamp will glow. This could be a lamp, an Audible announciation or any other relay for complex logic. Breaker Closing Closing Coil of Brkr Aux.NC contact of Brkr TB1 TB1 PCC Checks/PMP

The NO contact between 14 & 15 will close when: A----( Single & NON Paralleling Sets or DEAD BUS)

1.In Run or Auto Mode, when Engine Speed & Voltage reaches 90% of Rated.

Caution : If this Genset is used for Parallel operation, then the Paralleling Breaker has to be

closed through an external Sync Check relay.

Mandatory Connection to Cut out the External Battery charger if used :

Switched B+ : 24 Vdc Will be available on this Terminal only when the Fly wheel Starts rotating. Use the logic diagram given to cut off the external battery Charger if Used.

19

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

Sample drawing for running Raw water Pump

P12-2 19

Engine Ground

GND-ENG 20 any Ground looping in the PCC Panel can be taken from here GND-ENG 21 any Ground looping in the PCC Panel can be taken from here

22

PCC Net -- Announciator Connections

Note : Not a standard scope of supply -- Optional ( to be ordered seperately)

RS 485 + 1 RS 485 - 2 B+ 3 GND 4 Droop Operation of PCC 2100 R1 230V M Common B-ve ( TB1-21) TB2 TB1 TB1

Relay Activated By Switched B+ TB1

Battery Charger

battery bank Batty. Charging Alt.

RS 485 lines

Cummins Universal Announciator P.No. 0300-5929

Cummins Proprietory Protocol - PCC Net

Batty. Charger Input Supply

R1

PCC 2100 For Droop Operation :PCC 2100 can be operated on Droop. All we need to do is set the required % of Droop ( Speed or Voltage)either from the main panel or through Inpower. No external resistances are required to be connected. What ever % of Droop is set, automatically the High idle speed to change in accordance with the droop set.

Raise / Lower Voltage & Speed (Speed/Voltage Bias is currently Not available)

PCC 2100 -- For Use with Either PCW for Monitoring Only or For BMS Integration.

If the PCC 2100 is desired for Remote Monitoring : Following Parts are required ( Not a std Scope of supply)to be ordered seperately

NCM-- Network Communications Module -- P.No. One Per Genset SLTA - Serial Lon Talk Adaptor --P.No. One per Site

CAT -5 / Cat 6 Cable --- As per Distance between sets upto the SLTA Adaptor with Power supply ( Near the Customers PC) Genset No 1 Genset No 2

BMS Integration OR PLC Interface using MODLON Convertor

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

Twisted pair Cat -4 / Cat 5 Cable

PC Serial Nul Modem Cable

Modlon Convertor

Third party BMS Integrator

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

TS 1311 + PCC 2100

-

AMF LOGIC _{Utility Breaker Aux. Contact} N L N L3 L2 L1 U T I L I T Y G E N S E T GENSET START COMMAND P5 - 6 & P5 - 7 P5--6 P5--7 24V K1 TB1-1 TB1-20 K1 PCC 2100 CUSTORMER CONNECTION ON TB1

Please note : The default setting of Customer outputs is as below.

1 Customer o/p no. 1 - Common waring (TB1-8,9) 2 Customer o/p no. 2 - Common Shutdown (TB1-10,11) 3 Customer o/p no. 3 - Not in Auto (TB1 12,13)

4 Customer o/p no. 4 - Ready to Load (TB1-14,15)

Non AMF Mechanical Breaker with u/v trip

Common S.D. 10 11 K1 K1 NC K1 K-1 Relay for Breaker trip + 24 V from TB BAT-F1 (17)

Under voltage coil of the braker

Paralleling PCC 2100 in Droop Mode using Aux101

module

Connect the Aux 101 module as per instruction sheet (C698) and

change the necessary settings as listed below.

• Aux 101 – Enable

• Device#1 Input 1 Enable – Enable

• Device#1 Input 2 Enable – Enable

• Device#1 Input 1 Sensor Type – Bias Sensor

• Device#1 Input 2 Sensor Type – Bias Sensor

• Set the Speed Bias Scale value.

It is must to adjust the V/Hz table of the PCC2100 to more closely match the V/Hz

characteristics of the Newage AVR if you are paralleling with non-PCC Genset.

Modify the V/Hz table as shown below on the PCC2100.

Original V/Hz Table

Modified V/Hz Table

Hz % Hz %

0.000 100.000

0.000 100.000

3.000 100.000

1.000 100.000

7.313 80.005

5.313 80.005

11.638 50.000

9.638 50.000

15.950 19.995

13.950 19.995

80.00 0.000

80.00 0.000

1) Calibrate Voltage and Current and PF

2) Once calibrated, parallel the two Gensets without load and monitor KVARs. If

one genset is pushing KVARs onto the other, the Voltage Adjust % command

should be used to remove this offset. This parameter is on the front panel of the

PCC2100 and in InPower. Once they are calibrated, they will share load normally.

Reference : - Instruction sheet C-698

Parameters to be logged on Hourly basis

Volt. RPM Gov % Reg% L12 L23 L31 L1 L2 L3 KW PF KWh %Load %Amps

Current Voltage