PCC2100 Participants Guide

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11/2005 CMT0686-EN-PG

Participant’s Guide

PowerCommand

)

Control 2100

with CAN Link

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Introduction PowerCommand Control 2100 w/ CAN Link

i-1 Participant’s Guide

Revision History

v5.00 (11/2005)

1. Removed last mentions of PTC Module – thanks go out to Kurt Rahkola v4.00 (09/2004)

1. Updated CAN Link section.

2. Re-ordered guide sections to put prints just before the Comment Sheet. 3. Added Performance Assessment.

v3.00 (04/21/04)

1. Added section on CAN Link to ECS on Cummins G-Drive engines. v2.0 (4/2/04)

1. Updated with changes found by guest instructor during USAF session in January 2004. Thanks Tim.

2. Updated copyright information v1.1 (8/25/02)

1. Numerous revisions found in first QTQ session. Many sections involved in this revision, subtle changes to text and diagrams.

v1.00 (7/20/02)

1. Initial draft for first QTQ session in 2002

Cummins, Onan, and PowerCommand are all registered trademarks of Cummins Inc. InPower is a trademark of Cummins Inc.

Windowst is a trademark of Microsoft Corporation.

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PowerCommand Control 2100 w/ CAN Link Introduction

PowerCommand Control 2100 with CAN Link Module

Introduction

Welcome! Welcome to the Participant’s Guide for the

PowerCommandControl 2100 with CAN Link module!

This guide was written by the Cummins Power Generation Sales and Technical Training department for your use and reference.

We suggest you read through the entire Introduction to become familiar with the guide’s structure. Then, just follow the step-by-step instructions for each lesson.

Module Purpose The purpose of the PowerCommandControl 2100 with CAN Link module is to help you, the Cummins Power

Generation distributor service technician, understand the

PowerCommand Control 2100 with CAN Link which is

going to be used on Cummins Power Generation Gensets that use standard Cummins G-Drive engine modules.. With this information, our technical force will be better prepared to meet our customers’ varying needs.

Module Audience The primary audience for this module is Cummins Power Generation distributor power generation technicians. We assume participants have previous experience with or knowledge of Integrated generator set AC and DC control operation, troubleshooting, and repair procedures.

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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.

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PowerCommand Control 2100 with CAN Link Introduction & CBT Review

1-1 Participant’s Guide

Introduction to the PowerCommand

)

Control 2100

with CAN Link and Review of PCC 2100 CBT.

Estimated Time: 4 hours

Equipment Needed

Overhead projector and screen or PC with LCD Projector and screen PowerCommand Control 2100 and simulator for each pair of participants

Materials Needed

Module overhead set or slide set One for each participant:

PowerCommand) Control 2100 Participant’s Guide Guide (CMT0686-EN–PG)

QSX15 set with PCC 2100 Operator’s Manual Manual (961-0101)

• PC with PowerCommand) Control 2100 CD-ROM CD-ROM (932-0772-CD)

Instructor’s Note: This lesson presents a review of the lessons

learned in the Computer-Based Training (CBT) program com-pleted before participants came to the hands-on class.

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Warm Up

In this lesson we are going to introduce you to the PCC 2100 with CAN Link and review the pre-class CD-ROM for the PowerCommand Control 2100.

You may want to follow along on the CD-ROM as well as in your Participant’s Guide. We will quickly review the material in the CD-ROM, and add to that information.

Objectives

After completing this lesson, the participants should be able to:

• Describe the function of the CAN Link.

• Identify the New PowerCommand Control 2100.

• Locate and identify the New PowerCommand Control 2100 panel components.

• Identify components inside the PowerCommand Control 2100.

• Identify the standard and optional component of the PowerCommand Control 2100.

• Use the Operator menus.

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Control Area Network

3 Meter Stubs

Engine Control System (ECS)

Genset Control System (GCS)

Communication Path

What is a CAN Link?

120 Ohm Resistors at each end of Bus

VIS 1-1 S&TT 09/04

Visual 1-1 What is a CAN Link?

You completed the PCC 2100 pre-read CD-ROM before coming to this course. You learned many things about the PCC 2100 and its upgrade, the PCC 2100 in that program.

The PCC 2100 sends specific governor sig-nals to the engine governor actuator. The PCC 2100 communicates over a CAN

link with the ECM on the genset G-Drive engine. The ECM sends specif-ic governor signals to the engine gov-ernor actuator.

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

Communication Path – a shielded twisted-pair cable that has specific resistance terminations at each end of the main communication cable between the ECS and the GCS, and a series of stub cables to additional devices. Termination Resistors – 120 Ohm resistors

at both ends of the main communica-tions channel. The total resistance is _____ Ohms if measured by an Ohmmeter.

ECS – Engine Control System. This is the ECM on the engine and the sensors and controls for the engine.

GCS – Generator Set Control System. This is the PCC 2100 and the rest of the generator set.

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When will the control NOT go to sleep?

3 WakeĆup signals

Engine / Alternator Control

InPower service tool software

Network Upgradable

Everything in one box

What is the PCC 2100?

VIS 1Ć2 S&TT 09/04

Smart Starting Plus

Visual 1-2 What is the PCC 2100?

The PCC 2100 controls engine and alternator functions and has preset alarm levels for engine and alternator parameters. InPower service tool software can adjust

many parameters, and download cal-ibrations.

The PCC 2100 is easily upgradeable to FT-10 PowerCommand Network compati-bility.

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The PowerCommand control 2100 WILL NOT “go to sleep” if:

• The Service tool is connected to the

control.

• The network Module is installed and

activated.

• The mode switch is in Manual or Auto • Sleep is disabled with the service tool

software.

Smart Starting Plus

• Programmable Idle Function on Start:

In this mode, generator set will start, operate at idle speed for a predefined time period or until the engine reaches operating temperature, and then ramp to rated speed and voltage.

• Cooldown at Idle: When the control

gets a signal to stop, it will ramp the engine down to idle, and then time for shut down.

Wake Up Signals

The PowerCommand control will “go to sleep” after a pre-determined time delay, set with InPower software. These signals will

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VIS 1Ć3 S&TT 09/04

Basic PCC 2100 Panel

Visual 1-3 PowerCommand Control 2100 Standard Operator Panel

Genset Control – Standard

The control panel is mounted on the genera-tor set.

There are two physical switches and nine membrane switches on the switch panel.

All writing, except the “0” position indica-tor, is on a removable panel. The leg-end panel may be removed and re-placed with another panel in a differ-ent language.

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Physical Switches

Emergency Stop Switch.

Membrane Switches

• Manual Run/Stop switch. Toggles

generator set to run/stop mode when the 0/Manual/Auto switch.

Pressing the Emergency Stop Switch will cause the generator set to immediately shutdown. If the generator set is not running, pressing the emergency stop switch will prevent it from attempting to start.

This switch has several uses in controlling the generator set.

• When placed in the “0” position while

the generator set is running, the set will shut down immediately.

• In the MANUAL position, the control

will not complete any automatic sequences.

• In the AUTO mode, the generator set

can be started by receipt of a start signal from a remote device. The control maintains an internal record of manual control activities performed on the generator set.

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• Running The genset is running

(Switched B+ indicator).

• Remote Start The control sees a

remote start signal.

There are two LEDs on the bottom part of this side of the panel:

• Shutdown There is a shutdown

condition

• Warning There is a non-shutdown

condition

There are eight LEDs on the top of the pan-el. Three are preset:

• Panel Lamp/Lamp Test Switch.

Allows the operator to switch on LED lamps to illuminate the control. Holding the switch down for two seconds allows the lamps on the panel to be illuminated, so that it can verified that they are operating properly.

Continue holding the switch down to cycle the segments on the LED Bargraph, if installed.

• If the generator set is running in the

MANUAL mode, pressing the Manual Run switch again will cause the generator set to shut down after the cooldown time delays.

• Fault Acknowledge Switch. Allows

the operator to acknowledge warnings and shutdowns from the switch panel. The 0/Run/Auto switch must be in the “0” position to acknowledge shutdown faults.

LEDs

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LEDs (continued)

• Not in Auto The 0/Run/Auto switch is

not in the AUTO position

The other five LEDs in the top half of the panel can be set for various functions and colors using InPower service tool software. The digital display panel is capable of

dis-playing up to 2 lines of data with approximately 20 characters per line. It is configurable for units of mea-surement.

The digital display panel incorporates one level of security.

• Service level (application) password

allows setup and calibration of the control.

• As with the PCC 3200, once you input

the password, the password “window” stays open for 10 minutes after the last button press.

The digital display on the Operator panel turns off after 10 minutes if no but-tons around it are pressed. This hap-pens to save the screen from burn-in. The display will wake up from the “screen saver” mode when any of the six buttons around it are pressed.

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VIS 1Ć4 S&TT 09/04

PCC 2100 Panel with LED Bargraph

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

Analog AC metering panel displays simulta-neously 3-phase AC line current, kW, power factor, frequency, and line-to-line voltage.

• Amps and kW are displayed from

0–125% of nominal value.

• Power Factor is displayed from –.6

(lagging) to +.9 (leading)

• Frequency and Voltage are displayed

from <70% to 110% of nominal value.

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VIS 1Ć5 S&TT 09/04

Inside the PCC 2100 Control

LED Board

Bargraph

Digital Display

TB1

Base Card J10 (CAN Link)

Visual 1-5 Inside the PowerCommand Control 2100

LED Board (standard) (on the door) Con-There are two circuit boards inside the stan-dard PCC, and four inside a network PCC 2100 with the Bargraph option. From the left side around they are:

Inside the PowerCommand

)

Control 2100

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EEPROM Electrically Erasable

Programmable Read-Only memory holds PCC 2100 operation data. This is really read-write software, and is updated any time you save changes in the PCC menus.

RAM Random Access Memory holds data when the PCC 2100 is running, and “forgets” what it held when the PCC 2100 is turned off.

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Network Communication Module

Network Relay Module

Network Annunciator Module

VIS 1Ć6 S&TT 09/04

Optional Modules

Universal (PCCNet) Annunciator Module

Visual 1-6 Optional modules for the PCC 2100 Control

FT-10 Network Communication Module (NCM)

• The Network Communication Module

allows the PCC 2100 to communicate with other FT-10 network modules. If the customer wants to have the gensets as part of an FT-10 network, they all need to have NCMs in them.

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FT-10 Relay Module (DIM)

• The new relay module is a redesigned

DIM with eight standard relays. There is also a plug-in module to bring the relay count up to 16. This module allows the PCC 2100 to control up to sixteen customer loads with each having a time delay before the relays are energized. FT-10 Annunciator (LSA)

• The FT-10 Annunciator provides a visual

and audible indication of the genset and ATS functions and operation.

Universal Annunciator (PCCNet)

• The PCCNet Annunciator provides a

visual and audible indication of the genset and ATS functions and operation.

• This annunciator connects to TB2 at the

bottom left in the PCC 2100.

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VIS 1Ć7 S&TT 09/04

PCCNet Universal Annunciator

Visual 1-7 PowerCommand Control 2100 System Architecture

This diagram is designed to help the techni-cian:

S understand how the PowerCommand

Control 2100 components connect, and

S help determine where a problem might

be in the PowerCommand Control 2100 System.

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There are no external standard modules with this control. All components are installed inside the control box, in-cluding the optional network module. The only components which are mounted

outside the control box are the Crank and Run relays, optional relays, the network-based relay module, and the optional Universal Annunciator.

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VIS 1Ć8 S&TT 09/04

Visual 1-8 PCC 2101 (With CAN Link) Diagram

This diagram is designed to help the techni-cian:

S understand how the PowerCommand

Control 2101 components connect, and

S help determine where a problem might

be in the PowerCommand Control 2101 System.

Participant's Text Your Notes

This diagram is like the PCC 2101 dia-gram showing the external and inter-nal modules.

It shows what each connector on the Base Card is used for, and is an aid in trou-bleshooting the PCC 2100 with CAN Link:

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There are no external standard modules with this control. All components are installed inside the control box, in-cluding the optional network module. The only components which are mounted

outside the control box are the Crank and Run relays, optional relays, the network-based relay module, and the optional Annunciators (FT-10 and PCCNet).

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VIS 1Ć9 S&TT 09/04

Customer Connections

TB2

TB1

Visual 1-9 Customer Connection Terminal Block TB1

The customer connection terminal block (TB1) is located at the bottom of the control box. All customer connec-tions are landed here.

DO NOT CONNECT the Battery Char-ger from the ATS to TB1. It has to be connected to the battery terminals. TB2 is the terminal block to the left of TB1.

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VIS 1Ć10 S&TT 09/04

PCC 2100 Main Menu A

Visual 1-10 Main Menu A

The first Main Menu allows the operator to view data on the engine operation. It also allows the operator to view data on

the operation of the alternator. It lastly allows the operator to adjust

spe-cific operating parameters of the gen-erator set, and several time delays.

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VIS 1Ć11 S&TT 09/04

PCC 2100 Main Menu B

Visual 1-11 Main Menu B

The second Main menu allows the operator to view information on the latest and previous warnings and shutdowns (Faults).

It also allows the operator to look at the status of other components on the PowerCommand Network (System).

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VIS 1Ć12 S&TT 09/04

PCC 2100 Main Menu C

Visual 1-12 Main Menu C

This third Main Menu section allows the op-erator to view information on the type of generator set the control is operat-ing (About).

It lastly allows the operator to view the cal-ibration setup by bypassing the setup password.

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Time Delay Start & Stop

No Idle warm-up

Cooldown at Idle

Manual Mode

No Time Delays

Warm-up at Idle

Cooldown at Idle

Modes of Operation

VIS 1Ć13 S&TT 09/04

Automatic Mode

Visual 1-13 PCC 2100 Modes of Operation

Manual Mode

• Move Mode switch to Manual position,

and

• Press Manual Run/Stop switch

Automatic Mode

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PowerCommand Control 2100 with CAN Link Introduction & CBT Review 1-25 Participant’s Guide VIS 1-14 S&TT 09/04

Manual Operation–Basic PCC 2100

NOTES: 1. Timer expires.

2. Coolant temperature reaches operating level. 3. Cool-down idle with software adjusted time-out.

1 or 2

EMERGENCY STOP BUTTON Engine Temperature greater than 100°F to switch from Idle to Rated

Cooldown at Idle = 10 min.

STOP CONTROL STOP BUTTON 3 COOL-DOWN @ IDLE CONTROL RUN BUTTON LOCAL START (Manual Mode) WARM-UP @ IDLE RATED SPEED & VOLTAGE

NOTE: Cooldown at Idle on B-Series sets is set to

0 minutes.

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Automatic Operation–Basic PCC 2100

TIME DELAY TO START TIME DELAY TO STOP STOP 1 1 1 EMERGENCY START EMERGENCY STOP BUTTON

Cooldown at Idle = 10 min.

COOL-DOWN @ IDLE 3 REMOTE START (Auto Mode) REMOTE START Removed RATED SPEED & VOLTAGE

NOTE: Cooldown at Idle on B-Series sets is set to

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Activity 1-1: PCC 2100 with CAN Link Quiz

Match the functions and components / switches; use the demonstrator or Participants’ Guide.

1. The CAN Link is an Echelon network. a.True

b.False

2. The CAN Link is terminated with a 120 Ohm resistor at each end of the main channel. a.True

b.False

3. The main communication on the CAN Link is a special variation of ______ Bus. a.J1208

b.J1939 c.FT–10 d.TP/XF-78

4. To check the CAN Link with InPower Service Tool you must connect to a.J7

b.J8 c.J9 d.J10

5. To check the CAN Link with InSite Service tool you must connect the InLine adapter to a.C-05

b.C-06 c.C-07 d.C-08

6. If the J1939 transceiver in the ECM fails, the ECM will use its backup protocol of a.J1208

b.J1939 c.FT–10 d.TP/XF-78

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Activity 1-2: Introduction to the PCC 2100 Quiz

Match the functions and components / switches; use the demonstrator or

Participants’ Guide.

A. Acknowledge Shutdowns here B. Red LED

C. “Switched B+” available D. Amber LED

E. Power Amp. for exciter signal F. Shows 125% Current

G. 2 lines of 20 characters each H. Feeds signal to Bargraph

I. On Base card

J. 0/Manual/Auto switch here K. TB2

L. Spanish on Front Panel M. TB1

N. Stops set NOW!

O. Standard without Bargraph 1 PCC 2100 2 Digital Display 3 Shutdown LED 4 “0” position 5 Warning LED 6 LED Board 7 Base Card 8 Bargraph Module 9 LED Legend Card 10 Customer Connections

11 Connects to PCCNet Annunciator 12 Microprocessor

13 Emergency Stop switch 14 Front Panel

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Wrap-Up

In this lesson we have reviewed the material covered in the CBT on the PCC 2100 control. First we talked about the PCC 200 Control, where it originated, and how it is different from the Detector Control.

Next we talked about the control panel and the components inside the control box.

We then discussed the options available for the PCC 2100. We will have another lesson on these options later in the course.

Next we talked about the system architecture. We noticed it’s similar to the PCC 3100 architecture, but all the components are inside the box.

Next we talked about customer connections. We reviewed the installation of a PCC 2100 genset with an ATS.

Then we reviewed the menus you learned about in the CBT. We will cover the rest of the menus later in a Service Menu lesson.

Lastly we reviewed the three Sequences of Operation of the PCC 2100 Control: Manual and Automatic Emergency.

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PowerCommand Control 2100 with CAN Link Service Menus

PowerCommand

)

Control 2100 Service Menus.

One for each participant:

PowerCommand) Control 2100 Participant’s Guide Guide (CMT0686-EN–PG)

Objectives

• Locate and identify the front panel buttons used in navigating the PowerCommand Control 2100 menus.

• Identify the menu choices accessible without using the Application password. • Use the Crank/Idle menu to monitor and change crank and idle parameters. • Use the Gov/Reg menu to change governor and AVR parameters.

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Setup Main Menu

VIS 2Ć1 S&TT 09/040

Crank/Idle Gov/Reg

Setup Main Menu

+Password – nnn About Pwr Tran Setup More>> Main Menu 3

Visual 2-1 Setup Main Menu

Once you decide to change any setup param-eters, you need the password for that specific control.

The password can be changed using InPower service tool software.

The default password is 574.

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PowerCommand Control 2100 with CAN Link Service Menus 2-3 Participant’s Guide S1 Voltage L-N 208 VAC S1 Voltage L-N

Changing Parameters

Setup Main Menu

S1 Voltage L-N Gov/Reg Setup To Save Changes Adjustment Screen Navigation Screen Navigation Screen Increase Value Decrease Value VIS 2Ć2 S&TT 09/040

Visual 2-2 Changing Parameter Values

Select the parameter you want to change us-ing the Up/Down arrows on the left of the Digital Display.

When you are at the parameter you want to change, press the lower right-hand button next to the arrow pointing to the right. This will change the display to the one having the +/– on the left. When you have made the change you need,

press the lower right-hand button again to return to the Navigation Screen.

Press the “Home” button to save the changes to EEPROM.

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Crank/Idle Setup Menus

Setup Main Menu

VIS 2Ć3 S&TT 09/040

Visual 2-3 Crank/Idle Menu

Submenu: Default Min. Max Crank cycles 3 2 7 Crank Time 15 2 20 Rest Time 15 7 40 Idle Speed 800 700 1100

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Gov/Reg Setup Menus

Setup Main Menu

VIS 2Ć4 S&TT 09/040

Visual 2-4 Gov/Reg Menu

The Gov/Reg menu allows you to change the voltage for the control, frequency, regulator and governor gain, and gov-ernor ramp time.

Submenu: Default Min. Max Voltage 3 Ph 208 1 Ph 200 3 Ph 600 Freq. 60 50 60 Reg. Gain 100 5 1000 Gov Ramp 0 0 30 sec Gov Gain 100 5 1000

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PowerCommand Control 2100 with CAN Link Service Menus Engine Alternator Adjust More_>>

Controller Configuration Menu

Main Menu 1

Press both buttons at the same time

VIS 2Ć5 S&TT 09/040

Visual 2-5 Controller Configuration Menu

The Controller configuration menu allows the technician to set the language, temperature units, and pressure units displayed by the control.

Submenu: Default Min. Max Language English English French Temp Units Deg F Deg F Deg C

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Activity 2-1: Service Menus

Using your PCC 2100 Generator Set Service Manual and the worksheet that

follows, work through the Technician-level menus on the PowerCommand Control 2100 and

simulator at your work station.

Fill in the blanks with the values you see on the PC 2100 control you are working with.

CRANK/IDLE MENU

1. Cycle Crank ______ 2. Number of crank attempts ______ 3. Crank time ______ 4. Rest time ______ 5. Idle speed ______

GOV/REG SETUP MENU

6. Voltage configuration ______

7. Alternator frequency ______ 8. Regulator Gain adjust ______ 9. Gov Ramp time ______ 10. Gov Gain adjust ______

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CONTROLLER CONFIGURATION MENU

11. Language selected ______ 12. Temperature units ______ 13. Pressure units ______

ADJUST/SETUP MENU

14. Voltage adjust ______ 15. Frequency adjust ______ 16. Start delay ______ 17. Stop delay ______ 18. Idle start ______

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Technician-Level Menu Quiz

Directions: Using the 960-0165 Operator’s Manual, complete the following worksheet. 1. Which menu pick will get the operator to the Regulator Gain adjustment?

a. Crank/Idle b. Pwr Tran c. Gov/Reg

d. None of the above

2. Which menu pick will get to the Idle Speed adjustment? a. Crank/Idle

b. Pwr Tran c. Gov/Reg

3. Which menu pick will get to the Time Delay Program Transfer adjustment? a. Crank/Idle

4. Which menu pick will get to the Isolated Bus Paralleling Menu? a. Crank/Idle

5. What is the maximum value for Governor Gain? a. 10

b. 50 c. 100 d. 1000

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6. What is the factory setting for Governor Gain? a. 10

b. 50 c. 100 d. 400

7. When you are in the Setup menus and you want to change a setting, how do you know the setting is changeable?

a. in the lower right-hand corner of the Digital Display. b.

+

– _i_{n the left-hand side of the Digital Display.}

c. in the left-hand side of the Digital Display. d. None of the above are correct.

8. What indication WILL NOT be shown when the genset is powering a Delta-connected alternator?

a. Amps b. Frequency c. Volts Line–Line d. Volts Line–Neutral

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Wrap-Up

In this lesson we have learned about the Service Menus for the PCC 2100 control. First we talked about the password 5-7-4

Next we talked about the three Setup Menus:

• Crank/Idle Cycle Crank and Idle parameters

• Gov/Reg Governor and Regulator Parameters

We then went through the choices available in these two menus. We covered the factory default settings, minimum, and maximum values available.

Then we went through the Controller Configuration menu to cover the choices available in the configuration menu.

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 Service Menus?

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PowerCommand Control 2100 with CAN Link InPower

InPower and the PowerCommand



Control 2100

One for each participant:

PowerCommand) Control 2100 Participant’s Guide Guide (CMT0686-EN–PG)

• PC with InPower v 4.0 or later installed Provided by Participant • InPower v 4.0 User’s Guide Provided by Participant

Objectives

• Connect a PC running InPower service tool software to a PowerCommand Control 2100.

• Download a capture file from the control to your PC.

• Identify the parameters used in setting up a PowerCommand Control 2100.

• Identify the parameters used in troubleshooting a PowerCommand Control 2100.

• Identify the parameters used in testing a PowerCommand Control 2100.

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Connecting to a PCC 2100

PC Running InPower Security Dongle PowerCommandR Control 2100 Service Cable DB9 to DB9 (CUMMINS P.N. 3163768) J9 Connector VIS 3Ć1 S&TT 09/04

Visual 3-1 Connecting to a PCC 2100 with InPower software

Be careful when connecting to the PCC 2100 with InPower. You can shock the Base card enough to kill it if you are not using a wrist strap.

• Connect your hardware lock (dongle) to

the parallel port of your PC and start the PC. Log in to your PC using one of the security schemes discussed in the

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InPower Service Tool Software

VIS 3Ć2 S&TT 09/04

Visual 3-2 In-Power service software connected to a PCC 2100 with CAN Link Capture file

When you connect to a PowerCommand Control 2100 with CAN Link you will see six major headings of param-eters:

• Adjustments • CAN Link

• Events and Faults • Faults

• Monitor, and • Test

You learned about the major parts of InPower in the InPower CBT or class you at-tended. We will only discuss those pa-rameters that are specific to the Power-Command Control 2100 in this lesson.

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Features / Custom Displays

VIS 3Ć3 S&TT 09/04

Visual 3-3 Custom Displays

The Custom Displays parameters allow you to set the event and/or fault which turns on the five configurable LEDs on the control panel of the PCC 2100.

You can also set the color of the individual LEDs, and whether the LED is enabled.

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Configurable Indicators Mapping

VIS 3Ć4 S&TT 09/04

Visual 3-4 Configurable Indicators mapping table

You can set the name of the event or fault in the left column.

You can set the event or fault number in the right column

• Select the cell you want to put data into, • Go to the cell by the green check mark, • Enter the data and press on the check

mark button.

• The data appears in the correct cell.

Remember to save the data before you close the window.

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Features / Customer Outputs

VIS 3Ć5 S&TT 09/04

Visual 3-5 Customer Outputs

These parameters allow you to enable or dis-able the Customer Outputs.

You can also see if the driver is on or off.

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Features / Customer Output Mapping

VIS 3Ć6 S&TT 09/04

Visual 3-6 Customer Output Mapping

This table allows you to set the event or fault which activates each of the four Cus-tomer Output relays on the Base Board.

You can set the name of the event or fault in the left column.

You can set the event or fault number in the right column

• Select the cell you want to put data into, • Go to the cell by the green check mark, • Enter the data and press on the check

mark button.

• The data appears in the correct cell.

Remember to save the data before you close the window.

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Features / Power Down Conditions

VIS 3Ć7 S&TT 09/04

Visual 3-7 Power Down Conditions

This folder allows you to enable the “sleep” mode for the PCC 2100.

The PCC 2100 will not go to sleep if the Ser-vice tool is connected, or if the NCM is installed

The time delay has to be between 1 and 600 seconds.

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PowerCommand Control 2100 with CAN Link InPower 3-9 Participant’s Guide

Features / Warmup/Cooldown

VIS 3Ć8 S&TT 09/04 Visual 3-8 Warmup/Cooldown

These parameters allow you to set the start and stop delays, and the Idle warmup and cooldown timers.

• Start Delay 0 – 300 seconds Default 0

• Stop Delay 0 – 600 seconds Default 0

• Idle Warmup 0 – 300 seconds Default 10

• Idle Cool Down 0 – 30 minutes

Default 10

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Network Parameters

VIS 3Ć9 S&TT 09/04

Visual 3-9 Network parameters in InPower

InPower allows technicians to set up several sets of network parameters for use in self-installed or more advanced FT-10 networks.

• Custom Annunciation

Custom Annunciator for LSA or DIM

• Customer Outputs

Custom Relays for DIM

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Customer Switch Setup

VIS 3Ć10 S&TT 09/04

Visual 3-10 Customer Switch Setup

This folder allows you to set the four Cus-tomer Switches:

• Enabled or Disabled • Active Closed or Open

• The Name displayed on the Digital

Display when the event is true. The default names are:

• Customer Fault 1 • Ground Fault • Low Fuel, and • High Alt Temp

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CAN ECM Inputs & Outputs

VIS 3Ć11 S&TT 09/04

Visual 3-11 CAN ECM Inputs & Outputs

These parameters display engine sender and sensor values.

The key switch override is used when pro-gramming the ECM with InSite Ser-vice Tool software.

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CAN Faults

VIS 3Ć12 S&TT 09/04

Visual 3-12 CAN Faults

These parameters are most useful when trou-bleshooting the CAN Link.

When either the ECS or GCS cannot “hear” the CAN Link, it sets a fault that it cannot communicate on the CAN Link.

If one device can communicate on the Link but the other cannot, you could have a failed device instead of a problem with the CAN Link.

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CAN Settings

VIS 3Ć13 S&TT 09/04

Visual 3-13 CAN Settings

These parameters are time delays for the CAN Link.

• Key On Time – time after turning the

ECM “ON” that the CAN Link is checked for communications.

• CAN Failure Delay – The delay from

loss of communications on the CAN Link until a shutdown Fault occurs.

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Events and Faults

VIS 3Ć14 S&TT 09/04

Visual 3-14 Events and Faults

This folder contains a list of all events and faults. It shows:

• Event or Fault Number

• A Description of the event or fault • Fault Effect (Shutdown, Warning, Event,

None)

• Notification (dialout or not) • Bypass

You can set each whether the event or fault is bypassed or not bypassed, except for three faults:

• • •

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Activity 3-1: Adjust PowerCommand Control 2100

parameters:

1. Connect to a PowerCommand Control 2100 with InPower software on your PC. 2. Make a capture file of your PCC 2100 before making any adjustments !!! 3. Set the LED parameters as as shown below:

• Configurable LED 1 Color Red

• Configurable LED 3 Color Green

4. Make sure that these LED indicators are enabled in InPower. Using the simulator and the test parameters of InPower software, verify the LEDs operate as you have programmed them.

• Using the simulator and the Test parameters of InPower software, verify the relays operate

as you have programmed them.

5. Configure customer output relays 1 and 2 as shown below:

• Relay 1 Pre-LOP

• Relay 2 Pre-HET

6. Make sure these relays are enabled in InPower. Using the simulator and the Test

parameters of InPower software, verify the relays operate as you have programmed them. Use a meter on appropriate TB1 terminals to verify relay contact closure.

7. Configure the Warmup/Cooldown parameters as shown below:

• Idle warm–up 5 seconds

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Wrap-Up

In this lesson we have reviewed using InPower software with the PCC 2100 and its options for the PowerCommand Network.

First we talked about connecting to the PCC 2100 at J9 with the null-modem cable.

Next we talked about the Adjust parameters. We changed the color of some of the LEDs on the front of the PCC 2100 and also changed the fault or event they represented.

Next we discussed the relay outputs for K1–K4 on the Base Board, their default uses and how to reset them for other events and faults. Next we talked about putting the PCC 2100 to sleep and found that if the NCM is installed, or if the S12 Mode switch is not in the “0 position, or if InPower is connected, the control will not go to sleep. Then we talked about Idle warm–up and Cooldown, and their factory settings.

Then we looked at setting up the nvoCustomAnnun table for binding to an annunciator if your customer wants something other than

NFPA110 annunciation. We also set up the nvoCustomRelays table to operate the DIM relays.

Next we looked at setting the “Bypass” setting for an event or fault and the three faults that cannot be bypassed.

Does anyone remember the three faults that cannot be bypassed? •

• •

Lastly we looked at the test parameters for the PCC 2100. You already know that you can set up oil pressure or coolant

temperature and override the sensor so the control only sees the test input.

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PowerCommand Control 2100 with CAN Link Troubleshooting

Troubleshooting the PCC 2100 and the PCC 2100 with

CAN Link.

PowerCommand) Control 2100 Participant’s Guide Guide (CMT0686-EN-TG)

QSX15 set with PCC 2100 Service Manual Manual (960-0522)

PC with InPower software provided by participants

Objectives

• Locate and use the troubleshooting information in the Service Manual.

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Troubleshooting PowerCommand Control 2100 with CAN Link

Key Troubleshooting Points

OH4Ć1 S&TT 12/01

Interpret data and LEDs

Static protection – wrist strap

Proper meter use

Use troubleshooting charts and other data

Write down your readings

Good Visual and Audible inspection

Slide 4-1 Key Troubleshooting Points

One of the most important troubleshooting points is to make a good visual inspection of the generator set – see what looks bad. Listen to the set as it starts, runs, and stops. Look at the LEDs on the Switch panel and in

the Control Box. Look at the graphical display on the Operator panel. Write down what you see before you change

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CAN Link Troubleshooting Tools

InSite Service Tool Software

InLine II or InLine IV Adapter

True RMS meter

InPower service software

Strip Chart

Fault Listing (Active/Inactive)

Test Function

Troubleshooting Tools

OH4Ć2 S&TT 2/99

Slide 4-2 Troubleshooting tools

InPower service software has several nice features which can be very useful in trou-bleshooting a PowerCommand Control 2100 generator set.

• List of Active and Inactive faults by time

and date of occurrence.

• Strip chart to look at parameters over a

period of time.

If you use the Test parameters you MUST make sure you disable the override of sensor functions before you leave the set. InPower v 4.50 will remind you to disable

tests before you close the port.

• InPower also has a test function with

which you can tell the control to ignore the reading from the sensor and use a parameter value you input.

This is not available with the 2100 with CAN Link.

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True RMS meter

CAN Link Tools

InSite Service Tool Software

InLine II or InLine IV Adapter

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Technician has to interpret data

Technician has to use a meter properly

Technician has to use diagrams

Wiring – Parts Placement

How is Troubleshooting Similar?

OH4Ć3 S&TT 10/00

Schematic – Sequence of Operation

Slide 4-3 How is troubleshooting the PCC 2100 similar to troubleshooting other controls?

The technician still has to interpret the data given by the customer, operator, and the generator set.

The technician still uses a good meter to test voltages, currents, and resistances. The technician still uses wiring diagrams to

determine if the harness is connected properly.

The technician still uses schematic diagrams to determine if the control is operating properly.

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Static Damage possible

Ground signals

Test kit for LOP & HET

Must crank engine for OC fault

How is troubleshooting different?

OH4Ć4 S&TT 10/00

Technician uses new diagnostic guide

Slide 4-4 How is troubleshooting the PCC 2100 different than troubleshooting other controls?

You can be a cause of more damage to the control than the original problem due to static electricity.

You are generally looking for ground signals. You cannot ground out the HET and LOP

senders to simulate a warning or shut-down. A software tool is needed to check the engine sensors.

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Service Manual

Digital Display

Operator Manual – Oil Pressure values

InPower software

Troubleshooting Aids

OH4Ć5 S&TT 10/00

InSite software — CAN Link controls

InLine Adapter — CAN Link controls

Slide 4-5 Troubleshooting tables in the Service Manual

The Genset Service Manual for gensets using the PCC 2100 include a troubleshooting section which lists all fault codes and troubleshooting procedures for each fault. The Digital Display panel shows the code for

that specific fault and gives a short de-scription of the nature of the fault.

The technician uses the Troubleshooting sec-tion of the manual to determine where to check for proper and improper indica-tions.

The technician uses the InPower service software tool to check signals inside the Base card.

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The InPower service tool can also be used to troubleshoot problems by replacing a real signal in the genset control with a test signal.

A table of Running and Idle Oil Pressure val-ues are shown in the Operator’s Manual for each genset family.

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InSite software

This software is used to monitor, test, and calibrate the Cummins CM570 ECM on the engine.

In the future, engines will have multiple ECMs on them to handle the complex systems on the engine.

InLine Adapter

These adapters are needed to allow InSite to communicate with the ECM.

Page 2-7 in the Service Manual shows the Main Menus and what is available from the Operator panel menu display.

Remember, just because you have a cer-tain shutdown does not mean that the engine or generator information is not available for troubleshooting. The PCC has an RMS-type metering system built in which can display many different voltages, currents, and pressures to as-sist you in its troubleshooting.

Section 9 in the Service Manual has CPG prints that might help you in trouble-shooting some problems.

You can use the Sequence of Operation prints to help troubleshoot crank and run problems also.

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CAN Status Fault

Testing with InLine Adapter

Disconnect CAN Link from J10

Monitor PCC 2100 with InPower

Troubleshooting the CAN Link

OH4Ć6 S&TT 2/99

Monitor ECM with InSite

Slide 4-6 Troubleshooting the CAN Link

The CAN Link is the communications path between the PCC 2100 and the CM570 ECM on the QSX15 G-Drive engine.

CAN Status Fault

If either the PCC 2100 or the ECM can not “hear” the CAN Link, they set a fault. These two faults have different fault

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Disconnect J10 in PCC 2100

When you disconnect the CAN Link from the PCC 2100, both the PCC 2100 and the ECM will set a CAN Communication Fault.

If you were to look inside the ECM with In-Site, you would see the CAN Commu-nication fault set there also.

Monitor PCC 2100 with InPower

When you monitor the PCC 2100 with In-Power, you can see if the CAN Link wir-ing is OK or bad. If there is no change after re-connecting the CAN Link to J10, the wiring harness may be bad. If the fault goes inactive, the wiring harness is OK.

Monitor ECM with InSite

When you monitor the ECM with InSite, you can see if the CAN Link wiring is OK or bad. If there is no change after reconnect-ing the CAN Link to J10, the wirreconnect-ing har-ness may be bad. If the fault goes inac-tive, the wiring harness is OK.

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Activity 4-1: Troubleshooting exercises

Using the Service Manual (960-0522) and the Sequence of Operation wiring diagrams provided earlier in the course, determine where you would check to solve the problems shown below. You should be able to determine what voltage or resistance would be a good value at the test point you select for each problem.

Problem #1

What is the problem on this unit?

The generator set shuts down on low oil pressure. InPower shows the same pressure as the Engine menu – 10 PSI.

Where should you check for this problem?

On what page of the Service Manual did you find a procedure for troubleshooting this problem?

What did you check to solve the problem?

What should the voltage be at the points you checked – with good oil pressure?

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Problem #2

The generator set shuts down on high coolant temperature. InPower shows 235° F, the Engine menu shows 235° F also.

What should the voltage be at the points you checked – with good coolant temperature?

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Problem #3

The generator set shows a high oil temperature warning. InPower shows 265 Deg F, as does the engine menu.

What should the voltage be at the points you checked – with good oil temperature?

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Activity 4-2: Troubleshooting PowerCommand Control

2100 systems.

Using the Service Manual provided by the instructor solve the problems on as many demonstrator units as you can. The instructor will be able to change the problems on the demonstrator units as the troubleshooting continues.

Problem #1

On what page of the Service Manual did you find an explanation of what could cause this problem?

What diagrams did you use to help determine how to troubleshoot the problem if there was no procedure in the Service Manual?

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Problem #2

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Problem #3

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Problem #4

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Problem #5

(88)

Problem #6

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Activity 4-3: CAN Link Troubleshooting Demonstration

Connect PC running InSite and InLine II or InLine IV Adapter to C-05

of QSX15-powered genset engine harness.

Connect batteries in correct polarity to QSX15-powered genset. J1939 LED on InLine Adapter should start flashing as soon as the

ECM completes its power up tests.

Verify the PCC 2100 with CAN Link does not display any CAN Faults. If there are any CAN Faults, acknowledge them to see if they clear.

When there are no CAN Faults displayed on the PCC 2100 go to the next step.

- With the InLine Adapter connected to the ECM, disconnect the CAN Link from J10 in the

PCC 2100.

The PCC 2100 should display a CAN Link fault after its time delay.

- Check in the CM570 ECM on the engine to verify it also shows a CAN Link fault. - Reconnect the CAN Link cable to J10 in the PCC 2100.

- The CAN Link fault in the PCC 2100 should go inactive after a short time delay. - Verify that the CAN Link fault in the CM570 ECM has also gone inactive. - Reset all faults.

C-05 to Adapter & PC

ECM

PCC 2100

CAN Link Cable

It helps if you think “big picture” like when you are at the first stages of troubleshooting a genset & transfer switch problem.

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Wrap-Up

In this lesson we have reviewed troubleshooting the PCC 2100 control.

First we talked about troubleshooting strategies, remembering how to troubleshoot effectively and efficiently.

What are some good troubleshooting strategies? S

S S

Next we talked about troubleshooting tools.

What type of meter do we recommend?

We then went through several troubleshooting scenarios as a group to get some quick experience on the control system and prints.

Lastly we did some actual troubleshooting of controls with troubles installed by the Instructor.

Did these problems help you to hone your troubleshooting skills?

Are there any questions we have not yet covered on troubleshooting the PCC 2100?

(91)

PowerCommand Control 2100 with CAN Link Options

PowerCommand



Control 2100 Options

Equipment Needed

Overhead projector and screen or PC with LCD Projector and screen PowerCommand Control 2100 and simulator for each pair of participants Several NCMs for installation practice.

PowerCommand) Control 2100 Participant’s Guide Guide (CMT0686-EN-TG)

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Warm Up

In this lesson we are going to learn about some of the options available for the PowerCommand Control 2100.

We will look at the modules and be able to identify them by the end of the lesson.

First, let’s look at the objectives for this lesson:

Objectives

• Identify options for the PowerCommand Control 2100.

• Install options for the PowerCommand Control 2100.

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Installing Options

VIS 5Ć1 S&TT 09/04

Static Wrist Strap

Install Wiring Harness

Install Option Card, etc.

Battery Connected

Download Proper Calibration

Test Generator Set

Battery Disconnected

Visual 5-1 Installation Steps for PowerCommand Control 2100 Options

Disable the battery charger then disconnect the battery – Negative cable first. Connect your wrist strap and remove

cov-er(s).

Install the new Base card. Install other mod-ules, etc.

Install the wiring harness for the option. Reconnect battery and enable the battery

charger.

Using InPower service software enable the feature(s) or set the required parame-ters.

Test the generator set with the new option to verify proper operation.

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FT-10 Network Options

Network Communications Module

Relay Module (DIM)

LonWorks Annunciator (LSA)

PCC 2100 Options

VIS 5-2 S&TT 04/2004

PCCNet Options

Universal Annunciator

Visual 5-2 PowerCommand Control 2100 Options

The LonWorks card is used to allow this GenSet to operate as a node on the PowerCommand Network.

The DIM allows the PCC 2100-controlled genset to control customer devices, and to receive inputs from other net-work devices.

The LSA is used with FT-10 networks to let

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Network Module

Connects to J6 on Base card

J30 Network Data wires J32 - Network Data cable

S4 Network Address

VIS 5Ć3 S&TT 09/04

Visual 5-3 Network Communication Module 327-1275 (FTT-10)

Network Communication Module (NCM)

The NCM is used to let the PCC 2100 com-municate on the FT-10 PowerCommand network.

The network card must be installed if the customer wants an annunciator or exter-nal relays to operate equipment.

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DIM Connectors

VIS 5Ć4 S&TT 12/01 J8 - NC J6 - Common J7 - NO J1 - Customer Inputs (1–4) J3 - Network J3 - NC J2 - Common J1 - NO J4 - Customer Inputs (5–8)

Base Module

(required)

Expansion Module

(optional)

Visual 5-4 Network DIM Module

DIM Base Module

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DIM Expansion Module

This part is optional, and is called the DIM Expansion Module.

It has eight relays and four customer inputs. When you have both parts of the DIM

con-nected, the customer has sixteen re-lays and eight customer inputs. All relays and customer inputs are used as

network inputs or outputs for the PCC 2100 when the DIM is config-ured as a Custom Relay Module.

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LonWorks System Annunciator

VIS 5Ć5 S&TT 09/04

Visual 5-5 LonWorks System Annunciator

The LonWorks System Annunciator (LSA) is the annunciator for FT-10 Self-Installed or LonMaker-installed net-works.

To use this annunciator, the genset control and/or transfer switch must have an FT-10 Network Communications Module (NCM).

PCC2100 Participants Guide

Participant’s Guide

PowerCommand

)

Control 2100

with CAN Link

Revision History

PowerCommand Control 2100 with CAN Link Module

Table of Contents

Introduction

Introduction to the PowerCommand

)

Control 2100

with CAN Link and Review of PCC 2100 CBT.

Objectives

Control Area Network

3 Meter Stubs

Engine Control System (ECS)

Genset Control System (GCS)

Communication Path

What is a CAN Link?

120 Ohm Resistors at each end of Bus

When will the control NOT go to sleep?

3 WakeĆup signals

Engine / Alternator Control

InPower service tool software

Network Upgradable

Everything in one box

What is the PCC 2100?

Smart Starting Plus

Basic PCC 2100 Panel

LEDs

LEDs (continued)

PCC 2100 Panel with LED Bargraph

Inside the PCC 2100 Control

Inside the PowerCommand

Control 2100

Network Communication Module

Network Relay Module

Network Annunciator Module

Optional Modules

Universal (PCCNet) Annunciator Module

Customer Connections

TB2

TB1

PCC 2100 Main Menu A

PCC 2100 Main Menu B

PCC 2100 Main Menu C

Time Delay Start & Stop

No Idle warm-up

Cooldown at Idle

Manual Mode

No Time Delays

Warm-up at Idle

Cooldown at Idle

Modes of Operation

Automatic Mode

Manual Operation–Basic PCC 2100

Automatic Operation–Basic PCC 2100

Activity 1-1: PCC 2100 with CAN Link Quiz

Activity 1-2: Introduction to the PCC 2100 Quiz

PowerCommand

)

Control 2100 Service Menus.

Objectives

Setup Main Menu

Changing Parameters

Crank/Idle Setup Menus

Gov/Reg Setup Menus

Controller Configuration Menu

Press both buttons at the same time

Activity 2-1: Service Menus

CRANK/IDLE MENU

GOV/REG SETUP MENU

CONTROLLER CONFIGURATION MENU

ADJUST/SETUP MENU

Technician-Level Menu Quiz

Wrap-Up

InPower and the PowerCommand

