6283 - Fundamentals of PowerCommand Controls - V1.1

Fundamentals of PowerCommand Controls
Lesson 1: Introduction
Objectives
• Introduce commercial generator set controllers
• Describe what makes a PowerCommand Control
• Understand how to download service literature
Lesson Length : 1 hour

Genset Controls
Genset Controller
Prime Mover
Alternator
3 12/7/2015 Cummins Confidential

Genset Control Features
 Interacts with a Customer’s on-site power system

 Starts/Stops the prime mover
 Regulates engine speed
 Regulates alternator output voltage
 Protects the genset

History of PowerCommand Controls
PCC 3100 – the first PowerCommand Control

Generator Set Control

Menu Driven

Configurable
InPower v. 10.0

Protections
Auto NOT IN AUTO

PowerCommand
SHUTDOWN
! WARNING
Fault
At: 123.2 Hrs REMOTE START
Fault Number: 1434 Auto AUTO
Local Emergency
Stop MANUAL RUN

Customer Interaction

Basic Genset Operation
 Start Type Input (Mode Selection)

 Start Input
 Start Relay/Run Relay
 Start Disconnect
 Speed Governing
 Automatic Voltage Regulation
 Protections
 Shutdown Sequence

PCC 3100

PCC 3200/3201
PCC 3200 HMI

PCC 3201 Card Cage

PCC 2100
PCC 2100 HMI

PCC 2100 Control (inside of box)

PC1.X
HMI 211
OR
PCC 1302 Control Board
HMI 220
PC2.X
HMI 220
OR
HMI 320
PC3.3
HMI 320

Using Service Literature

Lesson 2: PCC Controls Safety
Objectives
• Describe the Responsibility of the employee
• Identify the Authorization levels
• Determine Approach Boundaries
– Shock Hazard
– Arc Flash Hazard
• Determine Appropriate PPE for work on energized Power Command
Controls
• Identify specific Power Command Controls electrical hazards

Introduction
 This module is not intended to be a qualifying NFPA

70E safety course
 Every Cummins employee is responsible for his/her
own safety
– Follow safe practices and procedures
– Work only when properly trained
– De-energize, lock and tag-out
– Wear correct PPE
– Maintain training
Basic Shop Safety
 Personal Protective Equipment

– Class 0 PPE
 Local Facility Safety
– Exits
– Fire Extinguishers/Eye Wash Stations
 Additional Local Procedures

Authorization Levels
Authorized
Qualified
Unqualified
Electrical Safe Work Condition
Energized Work Permit
Electrical Shock
Shock Approach Boundaries
Limited Approach
Exposed, Restricted Approach

energized
conductor
Prohibited Approach
Approach Boundary Distances
Voltage L-L Limited Restricted Prohibited

Approach Approach Approach
Boundary Boundary Boundary
50 – 300 V 3’ – 6” Avoid Contact Avoid Contact
301 – 750 V 3’ – 6” 1’ – 0” 0’ – 1”
Arc Flash Boundary
Arc Flash
Boundary
Exposed,
energized
conductor
Labeling of Equipment
Nominal
Voltage
Hazard/Risk
Category
Approach
Boundaries
Flash
Boundary
Standard Personal Protective Equipment
Safety Glasses
Hearing Protection
8 cal/cm2 clothing
Leather Safety
Shoes
Rubber Insulating Gloves
Leather Protector
Rubber Insulating Glove
Arc Flash PPE Hazard/Risk Categories
H/R Cat 0 H/R Cat 1 H/R Cat 2
Arc Clothing Natural/Non 4 cal/cm2 8 cal/cm2

Melting
Safety Glasses Yes Yes Yes
Hearing Protection Yes Yes Yes
Leather Gloves Yes Yes Yes
Leather Shoes Yes Yes Yes
AR Face Shield No Yes Yes
Hard Hat No Yes Yes
AR Balaclava No No Yes
Table 130.7(C)
Boundaries
Typical PCC Energized Components
Bus Voltage Genset Voltage
PCC 3300 PCC 1302
AVR Power Input

CT Inputs
Lock Out Tag Out

Insulated Tools
Proper Meter Selection
Summary
 In this lesson you have learned to:

– Describe the Responsibility of the employee
– Identify the Authorization levels
– Determine Approach Boundaries
• Shock Hazard
• Arc Flash Hazard
– Determine Appropriate PPE for work
– Identify specific transfer switch hazards
Lesson 3: Controls Subsystems
Objectives
• Understand the Human Machine Interface Subsystem
• Understand Basic Generator Set Operation
• Understand AVR inputs/outputs
• Understand Governor inputs/outputs
Lesson Length : 2 hours

Human Machine Interface (HMI)

Display Connections
Display

HMI: Display
Text Only
Graphical Display
Display
Soft Pushbuttons
Menu
Structure
Hard Pushbuttons
Genset Info
Description Lines

HMI: LED Indicators
Standard PCC Configurable

LED Indicators PCC LED
Indicators

HMI: Pushbuttons
Lamp Test
Fault Reset
Genset
Operation
Menu Breaker Emergency

Navigation Control Stop
HMI: Emergency Stops
Local E-STOP Remote E-STOP
B+
To Relay Coils

HMI: Stop/Manual/Auto
Manual
Auto
Stop

HMI: Auxiliary Displays
Remote HMI
Annunciator
Bar Graph

Alternator Interface: Voltage
Alternator
L1 L2 L3 N
L1 Voltage Input
L2 Voltage Input
L3 Voltage Input
N Voltage Input
Alternator
Output

Alternator Interface: Current
Alternator
Typical CT L1 L2 L3 N
Alternator
Output

Automatic Voltage Regulation
Field Output (DC) Exciter
Alternator
L1 L2 L3 N
Voltage Sensing (AC)

AVR Input (Self Excited)
AC
Main Stator Output

(Auxiliary Windings)
Main Rotor

AVR Input (Separately Excited)
AC
Main Rotor
PMG

AVR Output Pulses
V DC
time
Time On Time Off
DC
Exciter Stator
Main Rotor

AVR Power Stage
Exciter
Alternator
L1 L2 L3 N

AVR Control
AC Voltage Sensing Varied Field DC Output
Compare to setpoint
Enter into control algorithm
• Proportional
• Integral
• Derivative
Alternator Interface: Frequency
Alternator
Voltage (frequency) input L1 L2 L3 N
Alternator
Output

Engine Interface
 ECM Connection
 Mag Pickup
 Engine Sensors
 Governor Output

Engine Interface: Speed Sensing
 Relies on magnetic
induction – pulses of
voltage as teeth go by
 PCC counts the
number of pulses per
minute, and divides by
the number of flywheel
teeth
 Pulses per min/# of
teeth = RPM

Governor Output Module
V DC Governor Actuator
Governor Output
Module

Governor Control
Engine Speed Sensing Varied Governor PWM Output
Compare to setpoint
Enter into control algorithm
• Proportional
• Integral
• Derivative
ECM Data Link
Twisted Pair
Data Link
Terminating Resistors

Power Generation Interface (PGI)
 SAE J1939 based

 Has been modified for Cummins’ proprietary use
 Two main components to the data link
– Physical (how the devices are connected together)
– Electrical (how the devices use the data link to
communicate with one another)

PGI Physical Datalink

PGI Electrical Datalink

Generator Set Interface
 Start Circuit
 Run Circuit
 Switched B+
 Battery Input
 Battery Charger Input

Protections: Thresholds
Nominal
Low Low Acceptable High High

Shutdown Warning Operating Warning Shutdown
Range

Protections: Shutdowns and Warnings
Shutdown Fault Warning Condition

Fault Numbers
Fault Type
Engine
Run Time
Fault Number
Description

Alternator Protections
 High/Low AC Voltage
 Overcurrent
 Over/Under Frequency
 Loss of Sensing
 Overexcitation
Main Rotor

Protections – AmpSentry™
 Alternator thermal
damage curve
Fails Here
– defines “how much current
10 for how long” without
damage
– log-log curve
Seconds
– does not describe how

much current can be
1
produced
OK Here
0.03
1 10 Amps ( x rated)
Protections – AmpSentry™
Typical Alternator
Thermal Damage
Curve (red)
AmpSentry™
Protection 10
(black)
1
TIME (SECONDS)
Typical Circuit
Breaker Protection
(blue)
0.1
0.05
1 3 10 100
AMPS (TIMES RATED)

Engine Protections
 Low/High Oil Pressure

 Low/High Eng. Temp
 Overspeed
 Battery Faults
 Fail to Start/Crank

Customer Connections
 Data/Network
 Ready to Load
 Configurable Outputs
 Configurable Inputs
 Remote Connections
PCC Control Board

Configurable Input
 Customer input causes event to occur in PCC

(warning/shutdown/etc)
 Active Open or Closed
TB
Cust.
Input Genset Control
COM

Configurable Outputs
 Event occurs in PCC causing configurable relay to

change state
TB
Internal Event
Customer Annunciation (Fault Code)

Lesson 4: PCC 1302 Hardware
Objectives
• Define all inputs to PCC 1302 control board
• Define all outputs from PCC 1302 control board
• Locate inputs/outputs on wiring diagram
• Locate inputs/outputs on hardware/genset

HMI 211 Front Panel
Graphical
Display LED Indicators
Menu Selection Previous & Off Mode

“Soft Buttons” “Hard Buttons”

HMI 211 Rear

PCC 1302 Connectors
DS1 – LED Status

J18 – Excitation Power
Indicator
J17 – Field Output

TB1 – Customer
Connections J22 – Genset Voltage
Sense
J25 – Display J12 – Genset CTs

Connection
TB15– RS485/Modbus
J20 – Genset J11 – Engine

Accessories Harness
TB1 Customer Connections
TB1 - Customer Connections
PIN Signal Name Connect To
TB1-1 PCCNet A Network Data A
TB1-2 PCCNet B Network Data B
TB1-3 PCCNet Shield / B+ return Pin 16
TB1-4 Ready to Load 20ma Low Side relay driver
TB1-5 B+ Output (5A)
TB1-6 Configurable Relay 1 - A
TB1-7 Configurable Relay 1 - B
TB1-8 Configurable Relay 2 - A
TB1-9 Configurable Relay 2 - B
TB1-10 Remote Start Return
TB1-11 Remote Start
Pull to TB1-13 to activate input. Remove
TB1-12 Configurable Input 1
from TB1-13 to deactivate input
TB1-13 Configurable Input - Common Common for the two fault inputs
Pull to TB1-13 to activate input. Remove
TB1-14 Configurable Input 2
from TB1-13 to deactivate input
TB1-15 Remote E-STOP Return Remote normally closed E-STOP switch
TB1-16 Remote E-STOP Remote normally closed E-STOP switch
J20 Genset Inputs and Outputs
J20 - Genset Connections
J20-1 Chassis Ground
J20-2 B+ Return
J20-3 Switched B+ Low Side Driver
J20-4 B+ Return
J20-5 Discrete Input Return Return for configurable Input 3 - J20-17
J20-6 Discrete Input Return Return for configurable Input 4 - J20-18
J20-7 B+ Return
J20-8 Discrete Input Return
J20-9 B+ Input
J20-10 B+ Input
J20-11 Starter Disconnect Input Charging Alternator
J20-12 B+ Return
J20-13 Relay Coil B+ Supply FSO, Switched B+, Starter Relay Coils
J20-14 FSO Relay Driver Low Side of FSO Relay Coil
J20-15 Starter Relay Driver Low Side of Starter Relay Coil
J20-16 NA
J20-17 Configurable Input # 3 Defaulted to Low Coolant Level Switch
J20-18 Configurable Input # 4 Defaulted to Low Fuel Level Switch
J20-19 NA
J20-20 B+ Input
J20-21 B+ Input
J20-22 Alt Flash Input
J11 Engine Inputs and Outputs
J11 - Engine Connections
J11-1 Oil Pressure Sender (Active) +5 V
Oil Pressure Sender or Switch

J11-2
Return
Oil Pressure Sender or Switch

J11-3
Signal
J11-4 Governor Drive - Governor PWM low side driver
J11-5 Governor Drive + Governor drive + (for low side driver)
J11-6 Relay Coil B+ Coil of glow plug relay
Glow plug / Ignition Control Relay

J11-7 Low side of the relay coil
Driver
J11-8 Magnetic Pickup Shield
J11-9 Magnetic Pickup Supply
J11-10 Magnetic Pickup Return
J11-11 Coolant Temperature Sender
Coolant Temperature Sender

J11-12
Return
J11-13 thru J11-16 NA
J11-17 ECM CAN shield
J11-18 B+ Return for ECM
J11-19 ECM CAN Low
J11-20 ECM CAN High
J11-21 Key-switch out Low side driver
J11-22 thru J11-24 NA

J12 Genset CT Connections
J12 - Genset CT Connections

PIN Signal Name Connect to
J12-1 CT1 CT1 – X1
J12-2 CT2 CT2 – X1
J12-3 CT3 CT3 – X1
J12-4 CT1 Common CT1 – X2 / X3
J22 Voltage Sensing Inputs
J22 -Genset Voltage Sensing Connections
J22-1 L1 600 Vmax L1 Source
J22-4 LN 600 Vmax LN Source

J17 and J18 Excitation Output and Input
J17 - Field Winding Connections
Connector
Signal Name Connect To
Pin
J17-1 Field + X+ (F1)
J17-2 Field -- XX- (F2)
J18 - Field Winding Connections

Connector
Signal Name Connect To
Pin
PMG 1 / Shunt
J18-1 240 Vmax Excitation Source
L1
PMG 2 / Shunt
J18-2 240 Vmax Excitation Source
L2
J18-3 NC
J18 J17
Note: J18 Maximum input is 240 VAC

J25 Display Connections
J25 - Display Connections
J25-1 Local Status Low side of local status lamp
J25-2 Local E-Stop Normally closed local E-Stop switch
J25-3 PCCNet A Network Data A
J25-4 PCCNet B Network Data B
J25-5 System wakeup Activates on B+ Return
J25-8 B+ Return / PCCNET Shield connection Ground / B+ Return connection to display
J25-9 B+ Return
J25-10 Manual
J25-11 Auto
J25-12 B+ B+ supply to the HMI 211

Connecting HMI 211
1 5 HMI 211
2 6 Rear
3 7
4 8
J1 or J2
J1 – HMI Display Connections
J1-1 RS485 (PCCNet) Data A Network Data A
J1-2 RS485 (PCCNet) Data B Network Data B
J1-3 B+ Network Supply
J1-4 PCCNet System Wake Up
J1-5 Return Network Supply Return
J1-6 Run Output
J1-7 Auto Output
J1-8 NA

TB15 Modbus Connection
Pin #1
Pin #5
TB15 - Tools Interface Connections

PIN Signal Name Connect to
TB15-1 Return Network Power Supply Return
TB15-2 N/A
TB15-3 RS - 485 Data A Network Data A
TB15-4 RS - 485 Data B Network Data B
TB15-5 PCCNet System wakeup
Lesson 5: Operator Menus
Objectives
• Demonstrate how to start the generator set in Automatic Mode
• Demonstrate how to start the generator set in Manual Mode
• Navigate the Operator Menus
• Acknowledge a Fault
Lesson Length : 30 minutes

Menus
Auto NOT IN AUTO

PowerCommand
SHUTDOWN
! WARNING
Battery: 27.2VDC REMOTE START

Eng. Temp:73.8°F
Auto AUTO
Eng Hrs: 123.2 MANUAL RUN
Auto Man

HMI 211 Front Panel
Graphical
Display LED Indicators
Menu Selection Previous & Off Mode

“Soft Buttons” “Hard Buttons”

Operating Modes
 Off Mode
 Manual/Run Mode
 Auto Mode
PCC 2100
HMI 211

Sleep Mode
Auto NOT IN AUTO

PowerCommand
SHUTDOWN
! WARNING
REMOTE START
Auto AUTO
MANUAL RUN

Selecting Off Mode
Auto NOT IN AUTO

PowerCommand
SHUTDOWN
! WARNING

Eng. Temp:73.8°F
Auto AUTO
Auto Man
“O”

Manual Run Mode
Manual

Auto Mode
Auto

Operator Menus
Engine Status Alternator Status Alternator L-L
Battery: 27.2VDC Power: 15.2 kVA L1-L2: 400 ͠V
Eng. Temp:73.8°F Freq.: 50.1 Hz L2-L3: 398 ͠V
Eng Hrs: 123.2 Speed: 1500 RPM L3-L1: 401 ͠V
Auto Man Auto Man Auto Man
Alternator L-N Alternator Single Phase Alternator Current

L1-N: 228 ͠
V L1-N: 220 ͠
V L1: 8 ͠A
L2-N: 230 V ͠ L2-N: 220 V ͠ L2: 9 ͠A
L3-N: 230 V ͠ L1-L2: 440 ͠V L3: 9 ͠A
Auto Man Auto Man Auto Man
Fault Handling and Acknowledgment
Auto NOT IN AUTO

PowerCommand
SHUTDOWN
! WARNING
Fault
At: 123.2 Hrs REMOTE START
Fault Number: 1434 Auto AUTO
Local Emergency
Stop MANUAL RUN

Lesson 6: PCC Service Menus
Objectives
• Navigate PCC 1302 service menus
• Configure PCC 1302 to generator set applications
• Configure PCC 1302 to customer’s specifications
Lesson Length :

Setup Mode
Auto NOT IN AUTO

PowerCommand
SHUTDOWN
! WARNING

Eng. Temp:73.8°F
Auto AUTO
Auto Man
Press Simultaneously
Two Seconds
Configuring an Adjustable Parameter
GENSET
Volts AC :400
Hertz :50
No of Phases :3
Phase : Wye
Adjust
GENSET
Volts AC :400
Hertz :50
No of Phases :3
Phase : Wye
SAVE - +

Service Menus
SERVICE MENU
1) Setup Menus
2) History/About
3) Screen Adjustment
) More Options
(1) (2) (3)
Setup Menus Password: 5-7-4

Service Menu - Setup Menu [1]
SETUP MENUS
1) Genset Service
2) Genset Setup
(1) (2)
Genset Service Menus
SETUP
1) Genset
2) Customer I/O
3) Meter Calib.
) More Options
(1) (2) (3)
SETUP
4) Annunciator
5) Modbus
) More Options
(4) (5)
Genset Service – Genset pages 1, 2
GENSET
Volts AC :400
Hertz :50
No of Phases :3
Phase :Wye
Adjust
GENSET
Charging Alt.
Enable : Yes
Adjust
Next page
FUEL SYSTEM
Fuel System:
Diesel
Glow Plug Enable:
Yes
Adjust
START/STOP DELAY
Start: 0 sec
Stop : 0 sec
Adjust
Next page
CYCLE CRANK
Attempts: 3
Crank : 15 Sec
Rest : 30 Sec
Adjust AVR SETUP
AVR Enable: Yes
Adjust
Next page
V/Hz SETUP
V/Hz Slope : 2.2
V/Hz Knee : 0.5
Adjust
REGULATOR
Gain: 100%
Int: 100%
D: 100%
Adjust
Next page
ELECT. GOVERNOR
Gov Enable: Yes
Adjust GOV. CRANK FUEL

Initial DC: 25.0%
Initial Time: 2s
Ramp Rate: 25.0
Max DC : 100.0%
Adjust
Next page
ELECT. GOVERNOR
Gain: 100%
Int: 100%
D: 100%
Adjust ELECT. GOVERNOR
Crank Exit
Fuel DC: 25.0%
Dither Factor: 15
Ramp Time: 0.25
Adjust
Next page
ELECT. GOVERNOR
Enable Speed:
1100 RPM
Min Gov. DC: 20%
Max Gov. DC: 95%
Adjust
ELECT. GOVERNOR
Preload Offset:
0%
Adjust
Next page
GENSET NUMBER
Model No:
Serial No:
Adjust DISPLAY SETUP
Connection:
Local
Access Code: No
Symbols: No
Adjust
Next page
Genset Service – Genset page 17
Adjust
VOLT AND HZ MENU
Password:
Not Required
Adjust
Genset Service – Customer I/O Submenu
FAULT INPUT 1
Function
Select :
XXXXX XXXXXXX
Adjust
Genset Service – Customer I/O pages 1-4
FAULT INPUT 1
Function
Select:
Fault Input
Adjust FAULT INPUT 2
Function
Select:
Disabled
Adjust
To Inputs 3, 4

CUSTOMER
INPUT 1 TEXT
Type: Warning
FAULT INPUT #1
Adjust
CUSTOMER INPUT 2
TEXT
Type: Shutdown
LOW COOLANT
LEVEL
Adjust
To Inputs 3, 4

FAULT INPUT 1
Active State
Select:
Active Close
Adjust
FAULT INPUT 2
Active State
Select:
Active Open
Adjust
To Inputs 3, 4

CUSTOMER
OUTPUT 1 MAP
Fault No: 1540
Adjust
CUSTOMER
OUTPUT 2 MAP
Fault No: 1541
Adjust

Genset Service - Meter Calibration
Submenu (3)
METER CALIB.
Reg Volt Adj:
100.0%
Voltage: 0.0
Adjust
Genset Service – Meter Calibration:
Voltage Measurement for Regulation
METER CALIB.
Reg Volt Adj:
100.0%
Voltage: 0.0
SAVE - +

Voltage Measurement for Display
METERING
VOLTAGE ADJUST
L1-N: 0 VAC
L2-N: 0 VAC
L3-N: 0 VAC
SAVE - +

Current Measurement for Display
METERING
CURRENT ADJUST
L1: 0 Amps
L2: 0 Amps
L3: 0 Amps
SAVE - +

Genset Service – Annunciator Submenu
(4)
ANNUNCIATOR
FAULT 1 TEXT
Type: Warning
XXXXXXXXXXXXXX
XXXXXXXXXXXXXX
Adjust
Genset Service – Modbus Submenu (5)
MODBUS ENABLE
Modbus Enable:
No
Adjust
Service Menus
SERVICE MENU
1) Setup Menus
2) History/About
3) Screen Adjustment
) More Options
(1) (2) (3)
SETUP MENUS
1) Genset Service
2) Genset Setup
(1) (2)
Genset Setup Menus Password: 1-2-0-9

Genset Setup Menus
SETUP
1) Genset
2) Volt Protect
3) Curr Protect
) More Options
(1) (2) (3)
SETUP
4) Engine Protect
) More Options
(4)

Genset Setup - Genset Submenu (1)
GENSET
CT Ratio: 50:5
MPU Enable: Yes
Fly. Teeth: 110
RPM/Hz Ratio: 30
Adjust

Genset Setup - Genset page 1, 2
GENSET
CT Ratio: 50:5
MPU Enable: Yes
Fly. Teeth: 110
RPM/Hz Ratio: 30
Adjust
GENSET
Excitation
Source: Shunt
Excitation/Line
Freq. Gain: 1
Adjust
Next page

APPLICATION
RATING SELECTION
Application
Rating: Standby
Adjust
KVA (STANDBY)
1 ph/60Hz: 25.0
3 ph/60Hz: 25.0
1 ph/50Hz: 25.0
3 ph/50Hz: 25.0
Adjust
Next page

KVA (PRIME)
1 ph/60Hz: 21.0
3 ph/60Hz: 21.0
1 ph/50Hz: 21.0
3 ph/50Hz: 21.0
Adjust
BATTERY SELECT
Nominal Battery
Voltage : 24 V
Adjust
Next page

BATT THRESHOLDS
24V
Low Batt. : 24.00V
High Batt : 32.00V
Weak Batt : 20.00V
Adjust
BATT DELAY SETUP
L. Batt TD: 60.0s
H. Batt TD: 60.0s
Wk Batt TD: 2.0s
Adjust
Next page

OIL PRESS SETUP
Sensor Type:
Switch
Adjust
OIL PRESS SETUP
Sensor Polarity:
Active High
Adjust
Next page

Genset Setup – Voltage Protection (2)
VOLT. PROTECTION
High AC Voltage
Threshold: 115 %
High AC Voltage Time
Delay: 10.0s
Adjust

Genset Setup – Volt. Protection page 1, 2
VOLT. PROTECTION
High AC Voltage
Threshold: 115%
High AC Voltage
Time Delay: 10 s
Adjust
VOLT. PROTECTION
Low AC Voltage
Threshold: 85%
Low AC Voltage
Time Delay: 10 s
Adjust
Next page

Genset Setup – Volt. Protection page 3, 4
VOLT. PROTECTION
Overfrequency
Threshold: 6.0 Hz
Overfrequency
Time Delay: -
Adjust
VOLT. PROTECTION
Underfrequency
Threshold: 6.0 Hz
Underfrequency
Time Delay: -
Adjust
Next page

Genset Setup – Current Protection (3)
CURR. PROTECTION
High Current
Shutdown Time
Delay: 10 secs
Adjust

Genset Setup – Engine Protection (4)
OVERSPEED
THRESHOLDS (60HZ)
20 : 1400 RPM
30 : 2075 RPM
60 : 4150 RPM
Adjust

Genset Setup – Eng. Protection page 1, 2
OVERSPEED
THRESHOLDS (50HZ)
20 : 1150 RPM
30 : 1725 RPM
60 : 3450 RPM
Adjust
OVERSPEED
THRESHOLDS (60HZ)
20 : 1400 RPM
30 : 2075 RPM
60 : 4150 RPM
Adjust
Next page

ENG. PROTECTION
Speed/Freq Fault
Threshold: 2.0 Hz
Speed/Freq Fault
Time Delay: 1.5 s
Adjust
LOP SETUP
LOP Warning
Threshold: 40psi
LOP Warning
Time Delay: 5 sec
Adjust
Next page

LOP SETUP
LOP Shutdown
Threshold: 35psi
LOP Shutdown
Time Delay: 8 s
Adjust
HCT SETUP
HCT Warning
Threshold: 208°F
HCT Warning
Time Delay: 2 sec
Adjust
Next page

HCT SETUP
HCT Shutdown
Threshold: 215°F
HCT Shutdown
Time Delay: 2 s
Adjust
ENG. PROTECTION
LCT Warning
Threshold: 70°F
Charger Failed H
Threshold: 0.00V
Adjust
Next page

History/About [2]
HISTORY
Starts: ###
Hours: ##.#
Control
Hours: ###.#
History/About page 1, 2
HISTORY
Starts: 592
Hours: 50.4
Control
Hours: 347.5
Adjust
ABOUT GENSET
Model Number:
Control :
Adjust
Next page

History/About page 3, 4
ABOUT GENSET
KVA (Standby)
Rating: 25.0 kVA
Adjust
ABOUT CONTROL
P/N:
S/N:
SW P/N:
SW Version:
Adjust
Next page

History/About page 5
Adjust
ABOUT DISPLAY
SW P/N: 3266811
SCRNE VER: 2.26
SCRN VER: 7.10
DISP DEVICE ID: 68
Adjust

Screen Adjust [3]
ADJUST
SCREEN
Contrast
Brightness
Units: °F, PSI
Adjust
Fault History [4]
FAULT HISTORY
At: ###.# Hrs
Fault No: ####
XXXXXXX XX XXXX
XXXXX XXXXXXXX
Status [5]
STATUS
AVR DC: ##%
GOV DC: ##.##%
Lamp Test [6]
Auto NOT IN AUTO

PowerCommand
SHUTDOWN
! WARNING
SERVICE MENU
4) Fault History REMOTE START
5) Status Auto AUTO
6) Lamp Test
) More Options MANUAL RUN
(4) (5) (6)
Network Status Menu [7]
NETWORK STATUS
AMF Modules : #
Annunciators: #
Bar Graph : #
Batt Charger: #
Clock/Exerciser [8]
TIME SETUP
Date: ##:##:##
mm:dd:yy
Time: ##:## AM
Adjust

Exerciser Example
For example, if it was desired to have a Program that ran on every

Monday at 8:12 AM for 15 Minutes, the trims should be defined like
this:
Trim Value
Scheduler Prog x Enable Enable
Scheduler Prog Start Minute 12
Scheduler Prog Start Hour 8
Scheduler Prog Start Day Monday
Scheduler Prog Start Period AM
Scheduler Prog Repeat Interval Weekly
Scheduler Prog Duration (Mins) 15

Clock/Exerciser page 1, 2
TIME SETUP
Date: ##:##:##
mm:dd:yy
Time: ##:## AM
Adjust
Daylight Saving
Adjust
Saving Time:
Enabled
Adjust: 60 mins
Adjust
Next page

Daylight Saving
Adjust Start
Mth Wk Day Hr
3 3 Sun 2AM
Adjust
Daylight Saving
Adjust End
Mth Wk Day Hr
11 3 Sun 2AM
Adjust
Next page

Exercise Schdr
Schdr Enable : Dis
Excr: Monthly
Tue 02:00 PM
Adjust
Exercise Schdr
Exercise
Duration: 30 MIN
Adjust

Volt & Hertz Adjust [9]
VOLT & HZ ADJUST

Volts AC : 240
Hertz : 60
Adjust

Lesson 7: Sequence of Operation
Objectives
• Define start types, and associate modes of operation
• Demonstrate knowledge of AVR circuitry
• Demonstrate knowledge of Electronic Governor circuitry
• Follow start/run/AVR/Elect. Governor circuits on wiring diagram
• Understand warning/shutdown protections

Dashboard
Component Interaction RPM VAC

Starter FSO Customer
Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
and/or
ECM
HMI
Dashboard
Stop/Manual/Auto Mode RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
and/or
ECM
HMI
Start Types
 Auto
– Emergency
– Non-Emergency
 Manual
– Rated
– Idle

Dashboard
Start Signal Input RPM VAC

Input Alternator
K1 K2
(Remote Start)
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU (Manual Run,
Engine LED signals)
Sensors
and/or
ECM
HMI
Dashboard
Time Delay Start/Preheat RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
and/or
ECM
HMI
Dashboard
Start Relay Output RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
and/or
ECM
HMI
Dashboard
Engine Speed Sensing RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
and/or
ECM
HMI
Dashboard
Run Signal RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
or
ECM
HMI
Cycle Cranking
RPM Crank Cycles
time
Rest Period
Crank Period

Initial Fueling
Governor Enable
Speed is Reached
Crank
Ramp Rate DC
Governor
PID Loop
Governor Duty Cycle
Exit DC
Initial
DC
Time

Pulse Width
V DC Pulses
time
Time On Time Off
Duty Cycle % = Time On/(Time On + Time Off)

Start Disconnect
 Primary Start Disconnect

 Secondary Start Disconnect

Dashboard
Start Disconnect Inputs RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
and/or
ECM

Dashboard
Governor Enable RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
ECM

Dashboard
Field Enable RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Voltage Sensing
Field AVR
PMG Amp Enable
Gov.
Actuator
Amp
MPU
Engine
Sensors
or
ECM

Dashboard
Automatic Voltage Regulation RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Voltage Sensing
Field AVR
PMG Amp Control
Gov.
Actuator
Amp
MPU
Engine
Sensors
or
ECM

Dashboard
Alternator Protection RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
or
ECM

Dashboard
Engine Protection RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
or
ECM

Dashboard
Additional Protection RPM VAC

Input Alternator
K1 K2 (Customer Faults)
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
or
ECM

Dashboard
Stop Signal Input RPM VAC

Input Alternator
K1 K2
(Remote Start
Remote E-Stop) L1 L2 L3 N
Field AVR
PMG Amp Control
Gov.
Actuator
Amp
MPU (Manual Stop,
Engine Local E-Stop)
Sensors
or
ECM
HMI
Dashboard
Time Delay Stop RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp Control
Gov.
Actuator
Amp
MPU
Engine
Sensors
or
ECM
HMI
Dashboard
Cooldown Procedures RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
or
ECM

Dashboard
Shut Down RPM VAC

Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
or
ECM

Lesson 8: Configuration - InPower
Objectives
• Connect to a PCC with InPower
• Take/send/overlay a capture file
• Perform Initial/Update calibration
• Create monitor and strip chart
• Configure and save parameters

Types of InPower
Devices Supported
Capabilities
Connections – RS232
RS232
RS232
RS232
brainbox
To PC

Connections – RS485
RS485
RS485
RS232
RS232
brainbox
To PC
Remove Existing Network
RS485
InPower Cable
Existing Network Cable

Setup Application

Setup – Units of Measurement
Setup – User Setup

Setup – Site Setup

Setup - Communications

InPower Pro V10.0 Window
Menu Bar Tool Bar
Left Window Right Window

Pane Pane
Menu Bar

Left Window Pane – Sites/Menus
Before connection After connection

Adding a Site

Tool Bar
Port Connect Refresh Exit
Faults Monitor Help
Port Disconnect Strip Chart Save Adjustments
Fault Information Systems InCal Extractor

Connect to a Device

Typical Menu Structure
 Adjustments
 Faults
 Monitor
 Test

Saving a Capture File

Capture Files
Location of Capture Files
InPower View
File Location
Connect to a Capture File

Capabilities of Capture Files
Compare Function
Compare
Filter
Print

Write Capture File to a Device

Adjustments
Icons
Editing Parameters
Strip Chart
Monitor
Reports

Update InCal
All
Download

InCal Extractor

Initial Calibration

Initial Calibration:
Select Calibration Part Number
Select Calibration History

Save and Restore Parameters

Feature List

Update Calibration

Update Calibration:
History

Lesson 9: GATRR Approach to
Troubleshooting
Objectives
• Gather information on a PCC fault
• Analyze subsystems to determine fault’s origin
• Test solution to ensure correct origin
• Repair fault
• Retest to ensure the fault has been corrected

5 Step Troubleshooting Approach
 Gather
 Analyze
 Test
 Repair
 Retest

Gather
 Gather information and speak with the operator
 Determine the symptom of the PCC Control
– Does not crank, does not start, shuts down on fault code,
etc.
 Perform a visual inspection of the overall area to
ensure that it will be safe to perform an operation
check (JSA)
 Check for the following:
– Electrical damage to components
– Loose wiring
– Indicator LED’s
– Fault/Event history
Gather cont.
 Test the genset control to replicate the problem

 Write down all symptoms outside of normal operation
 If the genset is still displaying the problem, move on
to the next step
 DOCUMENT!

Analyze
 Isolate the System
– Narrow Down the possibilities by system
– Look up fault code in the service manual
– Eliminate potential possibilities
 START WITH THE BASICS
– Genset doesn’t crank?
– Genset doesn’t start?
– Doesn’t produce voltage?
– Genset doesn’t shutdown?

Test
 Test the Likely Problem Components

– Test components in order of likeliness based on
troubleshooting trees and symptoms that are present
 Perform Manufacturers Recommended Test
 Software or Hardware
 Can the component be fixed or does it need to be

replaced?

Repair
 Perform Repair
– Software or Hardware repair
 Double check that the component to be replaced is
the problem component
 Ensure that the proper procedures are followed
based on the manufacturing guidelines
 DOCUMENT!

Retest
 Test the genset to ensure that the problem is fixed

 Perform entire sequence – genset start, voltage and
frequency, assume load, genset shutdown
 If the genset still doesn’t operate correctly, is it
displaying the same symptom(s)?
– Are there multiple faults?
 DOCUMENT!

Survey
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6283 - Fundamentals of PowerCommand Controls - V1.1

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Fundamentals of PowerCommand Controls

Lesson Length : 1 hour

3 12/7/2015 Cummins Confidential

 Interacts with a Customer’s on-site power system

4 12/7/2015 Cummins Confidential

PCC 3100 – the first PowerCommand Control

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6 12/7/2015 Cummins Confidential

7 12/7/2015 Cummins Confidential

8 12/7/2015 Cummins Confidential

Auto NOT IN AUTO

9 12/7/2015 Cummins Confidential

10 12/7/2015 Cummins Confidential

 Start Type Input (Mode Selection)

11 12/7/2015 Cummins Confidential

12 12/7/2015 Cummins Confidential

PCC 3200 HMI

13 12/7/2015 Cummins Confidential

PCC 2100 HMI

14 12/7/2015 Cummins Confidential

PCC 1302 Control Board

PCC 2300 Control Board

PCC 3300 Control Board

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18 12/7/2015 Cummins Confidential

Lesson Length : 1 hour

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 This module is not intended to be a qualifying NFPA

 Personal Protective Equipment

21 12/7/2015 Cummins Confidential

Exposed, Restricted Approach

Voltage L-L Limited Restricted Prohibited

50 – 300 V 3’ – 6” Avoid Contact Avoid Contact

H/R Cat 0 H/R Cat 1 H/R Cat 2

Arc Clothing Natural/Non 4 cal/cm2 8 cal/cm2

Safety Glasses Yes Yes Yes

Hearing Protection Yes Yes Yes

Leather Gloves Yes Yes Yes

Leather Shoes Yes Yes Yes

AR Face Shield No Yes Yes

Hard Hat No Yes Yes

PCC 3300 PCC 1302

AVR Power Input

36 12/7/2015 Cummins Confidential

 In this lesson you have learned to:

Lesson Length : 2 hours

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41 12/7/2015 Cummins Confidential

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Standard PCC Configurable

44 12/7/2015 Cummins Confidential

Menu Breaker Emergency

46 12/7/2015 Cummins Confidential

47 12/7/2015 Cummins Confidential

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49 12/7/2015 Cummins Confidential

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Field Output (DC) Exciter

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Main Stator Output

52 12/7/2015 Cummins Confidential

53 12/7/2015 Cummins Confidential