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2012

PC3.3 Commissioning Guidelines


Team:
Vijayaraj D
Akhilesh Sorty
Nidhi Gautam
Ankit Bhagat
Cummins India Ltd DBU
2/9/2012

PC 3.3 Commissioning Guidelines


th

Released 09 Feb 2012

Revision 1.1

INDEX

TOPICS

PAGE

 Cold Checks: - Part nos of various components of PC3.3----------------------------------- 3


 Feature Code List-------------------------------------------------------------------------------- 4-6
 PC3.3 Real Time Clock ------------------------------------------------------------------------- 7
 Fault Codes & Thresholds ------------------------------------------------------------------------ 8
 Settings to be done while commissioning ------------------------------------------------------ 9-11
 Controller Calibration.----------------------------------------------------------------------------- 12-13
 PC3.3 Factory Settings ---------------------------------------------------------------------------- 13-15
 PC3.3 Terminal Strip At a Glance.--------------------------------------------------------------- 16
 Terminal Strip Connection------------------------------------------------------------------------- 17-27
 Mandatory Connections---------------------------------------------------------------------------- 28-31
 Commissioning Report----------------------------------------------------------------------------- 32

CSS - Genset Controls Team

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PC 3.3 Commissioning Guidelines


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Revision 1.1

Part Numbers of components used in PC 3.3


Sl
No

Common Parts
Part No

Description

Un Common Parts
Part No

Description

1 4053490

Adaptor "O" ring

A035C915

Coolant LVL SW Harness K19

2 0327-1507

Aux 104 PCB Assy (Dynamo Gov)

A035E719

Coolant LVL SW Harness K38,


K50

3 A028T766

AUX 105

A035E715

Coolant LVL SW Harness N14

4 0327-1536

AUX101

A035E717

Coolant LVL SW Harness V28

5 0327-1265

AUX102

A034Y731

Harness Engine K19

6 0327-1593

AUX103 AVR Power Stage

A034Y728

Harness Engine K38

7 S-985-C

Bushing, Reducing Pipe

A034X430

Harness Engine K50

8 A034X426

Harness AC (Common)

A034Y733

Harness Engine N14

9 0300-6366-02

HMI 114 ( Bar graph )

A034Y726

Harness Engine V28

10 0300-6315-02

HMI 320 (Operator Panel)

4913140

Pump Fuel K50

11 0098-7902-01

Label Logo

2879740

Fuel Pump K38 G2 & G5

12 0098-8104-03

Label Warning (Var Voltages)

2879732

Fuel Pump K19

13 4085824

Magnetic Pickup

4971761

Pump Fuel N14

14 A028T799

Manual Operator

2865870

Fuel Pump V28

15 A029R841

Manual Service

0302-2058-12

CT (3867/1) K50G3 1250 KVA

16 A034Z167

Panel, Control Box

0302-2058-15

CT (4420/1) K50G5 1500KVA

17 0327-1601-01

PCC3300 Controller

0302-2058-08

CT (2839/1) K38G5 1010 KVA

18 3017993

Rapid Start Fuel Shutoff valve

0302-2058-03

CT (2141/1) K38G2 750 KVA

19 0193-0468

Sender - Low Coolant Level

0302-2057-24

CT (946/1) KT1150 320 KVA

20 A028X493

Sender - Pressure

0302-2057-26

CT (1070/1) KT11550 380 KVA

21 0193-0529-02

Sender - Temperature

0302-2057-29

CT (1262/1) K19 G3 450 KVA

22 3054609

Solenoid (Magnetic Switch)

0302-2057-31

CT (1419/1) K19 G4 500 KVA

CSS - Genset Controls Team

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PC 3.3 Commissioning Guidelines


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Revision 1.1

FEATURE CODE LIST


K50 1250 & 1500 KVA
KTA-50-G3
A040U367
A040R746
0326-7011
0326-6979
0326-7529
0326-6984
0326-7518
A040R762
A040R768
A040G806
0326-7516
0326-7486
A040R776
0326-6989
A040R778
A029N140

KTA-50-G8
A040U369
A040R749
0326-7011
0326-6979
0326-7529
0326-6984
0326-7518
A040R762
A040R768
A040G810
0326-7516
0326-7486
A040R776
0326-6989
A040R778
A029N140

DESCRIPTION
Genset Rating
CT Ratio
WYE connection
Genset Nominal Voltage 416V
Voltage Range 416- 480 V
AVR Enabled
Freq. Select 50Hz
Sync. Check window 5 Deg
Engine Protection
Engine and AVR Gains
Nominal Battery Voltage 24V
Low Coolant Level Shutdown
Battle Short Enable
Application Rating Selection( Prime)
Coolant Temperature 2 Enable
Genset Application Type: Utility Multiple

K 38
KTA-38-G2-I
750kVA
0326-7870
0326-7479
0326-7011
0326-6979
0326-7529
0326-6984
0326-7518
A040R762
A040R768
A040G818
0326-7516
0326-7486
A040R776
0326-6989
A040R778
A029N140
0326-7525

KTA-38-G3
800kVA
A040R758
0326-7479
0326-7011
0326-6979
0326-7529
0326-6984
0326-7518
A040R762
A040R768
A040G818
0326-7516
0326-7486
A040R776
0326-6989
A040R778
A029N140
0326-7525

CSS - Genset Controls Team

KTA-38-G5
1010kVA
A040R756
0326-7481
0326-7011
0326-6979
0326-7529
0326-6984
0326-7518
A040R762
A040R768
A040G816
0326-7516
0326-7486
A040R776
0326-6989
A040R778
A029N140
0326-7525

DESCRIPTION
Genset Rating
CT Ratio
WYE connection
Genset Nominal Voltage 416V
Voltage Range 416- 480 V
AVR Enabled
Freq. Select 50Hz
Sync. Check window 5 Deg
Engine Protection
Engine and AVR Gains
Nominal Battery Voltage 24V
Low Coolant Level Shutdown
Battle Short Enable
Application Rating Selection( Prime)
Coolant Temperature 2 Enable
Genset Application Type: Utility Multiple
Genset CT Secondary-1A

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PC 3.3 Commissioning Guidelines


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V28
VTA-28-G3 600 KVA
0326-7742
0326-7477
0326-7011
0326-6979
0326-7529
0326-6984
0326-7518
A040R762
A040R768
A040G828
0326-7516
0326-7486
A040R776
0326-6989
A040R778
A029N140
0326-7525

VTA-28-G5 625 KVA


A040U371
0326-7477
0326-7011
0326-6979
0326-7529
0326-6984
0326-7518
A040R762
A040R768
A040G828
0326-7516
0326-7486
A040R776
0326-6989
A040R778
A029N140
0326-7525

DESCRIPTION
Genset Rating
CT Ratio
WYE connection
Genset Nominal Voltage 416V
Voltage Range 416- 480 V
AVR Enabled
Freq. Select 50Hz
Sync. Check window 5 Deg
Engine Protection
Engine and AVR Gains
Nominal Battery Voltage 24V
Low Coolant Level Shutdown
Battle Short Enable
Application Rating Selection( Prime)
Coolant Temperature 2 Enable
Genset Application Type: Utility Multiple
Genset CT Secondary-1A

K19
KTA-19-G9 500 KVA
0326-7717
A040R744
0326-7011
0326-6979
0326-7529
0326-6984
0326-7518
A040R762
A040R768
A040R774
0326-7516
0326-7486
A040R776
0326-6989
A040U373
A029N140

CSS - Genset Controls Team

DESCRIPTION
Genset Rating
CT Ratio
WYE connection
Genset Nominal Voltage 416V
Voltage Range 416- 480 V
AVR Enabled
Freq. Select 50Hz
Sync. Check window 5 Deg
Engine Protection
Engine and AVR Gains
0326-7516 Nominal Battery Voltage 24V
Low Coolant Level Shutdown
Battle Short Enable
Application Rating Selection( Prime)
Intake Manifold Temperature Disable
Genset Application Type: Utility Multiple

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PC 3.3 Commissioning Guidelines


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N14
NTA-14-G3 380 KVA
A040R752
A040R741
0326-7011
0326-6979
0326-7529
0326-6984
0326-7518
A040R762
A040R764
A040R772
0326-7516
0326-7486
A040R776
0326-6989
A040R373
A029N140

DESCRIPTION
Genset Rating
CT Ratio
WYE connection
Genset Nominal Voltage 416V
Voltage Range 416- 480 V
AVR Enabled
Freq. Select 50Hz
Sync. Check window 5 Deg
Engine Protection
Engine and AVR Gains
Nominal Battery Voltage 24V
Low Coolant Level Shutdown
Battle Short Enable
Application Rating Selection( Prime)
Intake Manifold Temperature Disable
Genset Application Type: Utility Multiple

POWER LIMITS
Signal Name

Power Limit

Fused B+ (TB1, J25)

Internally fused at 3 A

Key switch B+ (J11)

Battery Charger Alternator Flash (J20)

Internally fused at 1.85A, shared


with Relay Supply
Internally fused at 1.85A, shared
with Key switch B+
Internally fused at 1.85A, shared
with Key switch B+
Internally Fused at 1.5A

Return pins

5A/pin using 18 AWG wire

Relay Supply (J20)


Relay Supply (J25)

Internal Fusing:

The PCC3300s internal fusing protection is temperature dependant. It will allow 2X rated current at 20C (about
room temp), and allow rated current at 85C.

The internal fusing is a current limiting device that self resets once the short circuit is removed and its cooled down.

CSS - Genset Controls Team

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PC 3.3 Commissioning Guidelines


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Revision 1.1

PC3.3 REAL TIME CLOCK


The PCC3300 control system includes a real time clock function. The Real Time Clock (RTC) is used for calculating controller
on time, recording fault occurrence times, supporting factory test, and for the automatic scheduler feature. Once
programmed, the real time clock accurately* calculates seconds, minutes, hours, date of the month, month, day of the week,
and year with leap year compensation valid up to 2100. The clock operates in 24 hour format and automatically adjusts the
end of the month for months fewer than 31 days.
When battery power is removed from the PCC3300, the RTC remains powered via internal circuitry on the PCC3300. The
internal circuitry will provide power to the RTC for about one hour, after which the RTC will become reset to 0 Seconds, 0
Hour, 0 Minutes, 0 Month, 0 Date, 0 Year. Under this condition, the RTC Power Interrupt Fault (1689) will become active
indicating that the clock needs to be reset.
The RTC also has supports Daylights Savings Time, which is a convention used to advance the time by one hour so afternoons
have more daylight then mornings. The DST logic adds the DST Adjustment time to the current time when the current time is
equal to the DST Start Time. The DST logic subtracts the DST Adjustment time from the current time when the current time is
equal to the DST End Time. To Enable DST, the trim Daylight Savings Enabled needs to be set to Enabled. To setup DST,
specify the values for the following trims.

Trim

Value

Meaning

Daylight Savings End Day

Monday - Sunday

Calendar Day in which DST Ends

Daylight Savings End Hour

02 19 hours

Hour (24 Hr) in which DST Ends

Daylight Savings End Month

1 12 months

Month in which DST Ends

Daylight Savings End Week Occurrence


in Month

First Occurrence Last


Occurrence

Occurrence of Daylight Savings End Day in


which DST Ends

Daylight Savings Start Day

Monday - Sunday

Calendar Day in which DST Starts

Daylight Savings Start Hour

02 19 hours

Hour (24 Hr) in which DST Starts

Daylight Savings Start Month

1 12 months

Month in which DST Starts

Daylight Savings Start Week


Occurrence in Month

First Occurrence Last


Occurrence

Occurrence of Daylight Savings End Day in


which DST Starts

CSS - Genset Controls Team

Page 7 of 31

PC 3.3 Commissioning Guidelines


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Released 09 Feb 2012

Revision 1.1

PC3.3 FAULT THRESHOLDS


FAULT STATUS
CODE

DESCRIPTION

THRESHOLDS

135

Warning

Engine Oil Rifle Pressure 1 Sensor Circuit - Voltage


Above Normal, or Shorted to High Source

40 PSI / 276 kPa / 2.75 bar @ 1500 RPM

141

Warning

Engine Oil Rifle Pressure 1 Sensor Circuit - Voltage


Below Normal, or Shorted to Low Source

15 PSI / 103 kPa / 1.03 bar @ 800 RPM

415

Shutdown

Engine Oil Rifle Pressure - Data Valid but Below


Normal Operational Range - Most Severe Level

35 PSI / 241 kPa / 2.41 bar @ 1500 RPM


10 PSI / 69 kPa / 0.68 bar @ 800 RPM

144

Warning

Engine Coolant Temperature 1 Sensor Circuit Voltage Above Normal, or Shorted to High Source

207 Deg F / 97 Deg C

151

Shutdown

Engine Coolant Temperature - Data Valid but Above


Normal Operational Range - Most Severe Level

215 Deg F / 101 Deg C

197

Warning

Coolant Level - Data Valid but Below Normal


Operational Range - Moderately Severe Level

Low Level @ 800 RPM

235

Shutdown

Coolant Level - Data Valid but Below Normal


Operational Range - Most Severe Level

Low Level @ 1500 RPM

Shutdown

Engine Over speed

442

Warning

High DC Voltage

115% of 1500 RPM i.e. 1725 RPM +/-1


RPM
Batt. Volt > 32 V DC

441
1442
1446

Warning
Warning
Shutdown

Low DC Voltage
Weak Battery
High AC Voltage

Batt. Volt< 24 V DC
Rated Volt < 60% i.e. 14.4 V DC
Rated Volt > 130% i.e. 540.8 V AC

1447

Shutdown

Low AC Voltage

1448

Shutdown

Under Frequency

Rated Volt < 85% i.e. 353.60 V AC, for 10


Sec
Rated Freq. < 90% i.e.45 Hz for 10 Sec

1472

Shutdown

High Current Shutdown

1471
1445
1444

Warning
Shutdown
Warning

High Current Warning


Short Circuit
Overload

1459

Shutdown

Reverse Power

(-) Kw Power > 10% of Rated Kw for 3 Sec

1461

Shutdown

Loss of Excitation

2 seconds

CSS - Genset Controls Team

Rated Current > 110% as per PCC IDMT


Curve
Rated Current > 110% for 60 Sec.
Rated Current > 175% Instantaneous
Rated Current > 115%, after 5 Sec. The
load dump O/P will get activated.

Page 8 of 31

PC 3.3 Commissioning Guidelines


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Revision 1.1

Settings to be done while commissioning


Alternator
1) Check there no any damage / short supply / for the Alternator.
2) Ensure Alternator mounting bolts are high tension bolts and lock nuts are provided for mounting bolts and ensure
proper torque applied for foundation bolts used between generator and frame.
3) Check for ingress of moisture or solid object.
4) Check the alignment of Alternator and Engine.
5) Ensure double Earthing of Alternator.
6) Ensure Power cable and control cable gland Earthing.
7) Ensure the Megger Value between ph-ph and ph-Gnd of alternator winding terminals are within limit as per bellow
table.

Megger VDC
Generator Voltage

Minimum Resistance (Megaohm)

Setting

Main Stator

600 VAC or less

500

5.0-1.0

601 thru 5000 VAC

2500

400-50

1000
5001 thru 15000VAC

5000

Main Rotor

Excitor Stator/Rotor

5.0-1.0

5.0-1.0

5.0-1.0

5.0-1.0

5.0-1.0

5.0-1.0

1000-200

1000

8) If the Megger value not found within limit, use anti-condensation heater inside Alternator or blow warm air through
the generator with a fan. The winding should be dried out and Megger test should be repeated.
9) Ensure the Megger Value between ph-ph, ph-N, ph-Gland of Power Cable is within limit.
10) Carry out HV Test of Power cable putting both ends of cable disconnected.
11) Remove loose items from terminal box and clean the Alternator by blowing dry Air.
12) Check that Power cable connections are properly routed inside Alternator terminal box.
13) Check that Power cable termination box is properly supported no stresses on terminals.
14) Check that Power cables are tightens with Plane and spring washers.
15) Ensure RTD, BTD, and space heaters are provided and check their connections.
16) Check the ratio of CT/PT mounted inside the Alternator box.
17) Check the control cable connections of Field winding, PMG, AVR, Isolation Transformer are proper and tight and
secured.
18) Ensure other end connections of Power cable are tightly connected to the breaker incoming Bus bar.
19) Write down No load and full load excitation volt and current from Alternator Name plate.
20) Run the Engine at low idle speed and ensure there is no any abnormal sound.
21) Run the Genset at High idle speed observe the rated Voltage of Alternator and adjust if required.

CSS - Genset Controls Team

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PC 3.3 Commissioning Guidelines


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Genset Controller
1) Check that Panel is grounded correctly. There is a small yellow colored wire that comes from the baseboard. This is the
chassis ground which needs to be grounded.
2) Ensure Engine Battery (Ve) is Earthed.
3) Ensure control cable gland earthing.
4) Check and ensure that control cable connections at Genset TB strip are as per drawing.
5) Ensure connections of Genset Remote Start/Stop, Breaker ON/OFF, Load Demand Stop and Emergency Stop
buttons/switches are correct. In standalone condition and with no input signals to controller, the controller should not
show any FC or any active remote signal.
6) Change the operation mode in PCC3300 to Utility Multiple or Standalone Or as per the customer requirement.
7) Ensure CT/PT sensing wiring Harness connections at both ends is correct.
8) Ensure PMG and field wiring Harness connections at both ends are correct. All three lugs viz. PMG2, PMG3 & PMG4
should be tightly connected.
9) Ensure sharing lines TB9-7, TB9-8, TB-9, TB10, TB11 connections with other Genset (For ex PCC3100) TB-54, 55, 56, 57,
58 are correct.
For ex: -

KVAR KVAR+
KWKW+
Shield

10)
11)
12)
13)
14)
15)

PCC3100 PCC3200 PCC3201


TB-1
TB-5
TB-3
54
12
54
55
13
53
56
14
52
57
15
51
58
16
55

PC3.3
TB-9
11
10
7
8
9

Check the Oil level, Fuel, Cooling water in the system.


Start the Priming Pump and check Engine Oil pressure.
Run the Genset at Rated Speed (1500rpm) and ensure all Engine parameters are Normal, rated Voltage is built up.
Close the Genset Breaker from controller and ensure Controller is displaying Bus Voltage.
Adjust the Voltage at required level if required. (Nominal Voltage to be selected 416V).
Load the Genset with available load and Ensure KVA, Amp, Kw, Kvar, PF, HZ, readings on Controller.

HT Breaker Panel
1)
2)
3)
4)
5)
6)
7)
8)

Check that Panel is grounded correctly.


Ensure HT Breaker is Earthed at both ends.
Check there should not be any loose item inside the panel which may fall down during breaker operation.
Ensure the cable connection for proper phase sequence.
Make sure that the panel is not live and get it is cleaned thoroughly.
Ensure HT Cable terminations are tighten with proper torque.
Locate the Handle, Rack out and rack in the breaker and ensure racking is smooth and proper.
Ensure the aux supply voltage for breaker accessories U/V Coil, Shunt Trip coil, closing coil, spring charging motor are
as per drawing.
9) Ensure insulating mat is laid in front of the HT breaker Panel.
10) Switch ON the aux supplies of breaker Panel and check the operation of breaker in Test mode.

CSS - Genset Controls Team

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11) Putting the breaker in Service mode ensure Breaker incomer and outgoing is dead and check various condition as
spring charge/ Ready to close / Breaker close / breaker Open.
12) Ensure Remote breaker Closing / Opening and Tripping is OK.
13) Check that the breaker auxiliary contact connections are operating properly.
14) Open the CT shorting links provided in the panel, Charge incoming of the breaker ensuring Breaker O/G is dead, switch
ON the breaker.
15) Check the phase sequence of supply at PT secondary output.
16) Charge the Transformer and check the Phase sequence at the output of the transformer is as per required.
Control Panel Commissioning
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)

Check that panel is grounded correctly.


Panel Aux supply AC/DC is connected correctly and polarity is as per drawing.
Check the continuity of control cables as per drawing and cable schedule.
Check Cable grounding / termination / tightness / ferruling are perfect.
Clean the panel with cotton and by blowing dry air thoroughly.
By secondary Current / Voltage injection ensure the tripping of Protection relay is perfect.
Charge the panel with Aux AC/DC supply and check the proper indications on Panel.
Connect the laptop using InPower. The communication cable part no. is 0338-4590.
Take a capture file and save it positively.
Check the settings to be done
Start the engine at no load for 5-10 minutes and increase the load gradually, Check the performance.
If any fault occurs, refer the Trouble shooting guidelines and reset the fault. And perform the Engine Starting
function again at no load for 10 minutes and then increase load gradually.
13) Open the CT shorting links if provided.
14) Do the Protection relays settings as per the KVA/Voltage/Current rating of the Genset and as per CT/ PT ratio.
15) Check the relay connections. While commissioning, these relay connections are open. Please refer the below picture
and do the connections.

RELAY CONNECTIONS
K8-FSO CONTROL

K7- STARTER CONTROL

CSS - Genset Controls Team

K11

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PC 3.3 Commissioning Guidelines


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Revision 1.1

Controller Calibration
There are Three Different parameters which need to be calibrated. These are voltage measurement for display, voltage
measurement for regulation, and current measurement for display.
The internal circuits must be calibrated in the following order.
Voltage Measurement for Regulation
With a PC Based Service Tool:
1) Connect to the control with your PC based service tool.
2) Verify the Nominal Voltage Trim is set to the desired value.
3) Adjust the trim Voltage Regulation Calibration 50Hz or Voltage Regulation Calibration 60Hz for your desired application.
Adjust the trim so regulated voltage matches the desired nominal voltage measured with a known calibrated voltage meter.
4) Save the adjustments by doing a Save Trims with your PC based service tool
With the Operator Panel:
1) Go to Setup and press OK
2) Select Adjust Droop and press OK
3) Select Adjust Voltage and press OK
4) Voltage can be adjusted to + / - 5 % using HMI Up / Down keys with scaling of 0.1 %
5) Press OK to save the parameter

Voltage Measurement for Display


With a PC Based Service Tool:
1) Connect to the control with your PC based service tool.
2) Verify the Nominal Voltage Trim is set to the desired value.
3) Adjust the trim Alternator LX-N 50Hz Voltage Display Adjust or Alternator LX-N 60Hz Voltage Display Adjust trim for your
application. Each line will need to be adjusted independently. The goal is to have the value read by the PC based service tool
correspond to the actual voltage being produced.
4) Save the adjustments by doing a Save Trims with your PC based service tool.
With the Operator Panel:
1) Go to Setup and press OK
2) Go to Calibration Setup and press OK
3) Select L2 voltage and press OK. The password screen will ask to enter Level 1 password which 574. Enter the password
using HMI Up / down keys and press OK
4) After entering correct password, again Press OK selecting L12 voltage.
5) adjust the HMI voltage display with calibrated meter reading by decreasing or increasing the voltage adjust %.
6) The procedure is required for all the 3 phases. (Once correct password is entered, for other two parameters password is
not required)

Current for Measurement for Display

CSS - Genset Controls Team

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PC 3.3 Commissioning Guidelines


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Revision 1.1

With a PC Based Service Tool:


1) Apply a load to the genset and monitor the current with a calibrated current meter.
2) Connect to the control with your PC based service tool.
3) Verify the ct ratio settings and power ratings are correct for your application.
4) adjust the LX 50Hz Current adjust or LX 60Hz Current Adjust trim for your current application
5) Adjust the HMI current display with calibrated meter reading by decreasing or increasing the L1 %.
6) The procedure is required for all 3 phases. (Once correct password is entered, for other two parameters password is not
required.

Settings on the PCC- Factory Settings


Parameter

Factory Settings

Version
Prime / Standby/Base
Delta / WYE
Genset Idle enable
Remote Fault Reset Enabled
Battery Short Enable
Fail to shutdown delay
Delayed Shutdown Enable
Delay shutdown time delay
Reset Fuel Consumption
Genset Reset all energy meters
Start Time Delay
Time Delay to stop
Commit to transfer timeout
Transition Type

As per engine model


Prime
WYE always
Enabled
Disabled
Disabled
5 seconds
Disabled
Disabled
Inactive
Do nothing
0 seconds
0 seconds
120 seconds
Open Transition

Test with Load Enable


System Phase rotation
Extended parallel Enable
Commit to transfer Method

Disabled
L1-L2-L3
Disabled
Utility Disconnect

Genset Application Type

Isolated Bus / Utility


Multiple

First Start Backup Time


Nominal Voltage
Frequency
Breaker Position Contacts
Genset CB Fail to Close Time
Delay

10Seconds
416Vac
50Hz
Dual Contacts
026 seconds

CSS - Genset Controls Team

Range

Deviation If any

Prime/ Standby/Base
Delta / WYE
Disabled/Enabled
Disabled/Enabled
Disabled/Enabled
0-30 seconds
Disabled/Enabled
Disabled/Enabled
Inactive/Active
Do nothing/Clear counters
0-300 seconds
0-600 seconds
0-3200seconds
Open Transition/Softly Closed
Transition/hardly Closed Transition
Enabled/Disabled
L1-L2-L3/L1-L3-L2
Enabled/Disabled
Utility Disconnect/no
commit/Genset Start
Standalone/Synchronize
only/Isolated Bus/Utility
Single/Utility Multiple/Power
Transfer Control
3-120 Seconds
110-45000Vac
50Hz/60Hz
Single Contact/Dual Contacts
0.1-1 second

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PC 3.3 Commissioning Guidelines


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Parameter

Factory Settings

Revision 1.1

Range

Genset CB Fail to Open Time Delay


Permissive Voltage Window
Permissive Phase Window
Permissive Window Time
Permissive Frequency Window
Synchronizer Voltage Control
Method

1 second
5%
5 deg
0.5 seconds
1Hz
Voltage Match

0.25-5 Seconds
0.5-10%
15 deg
0.5-5 seconds
0.001-1Hz
Voltage Match/ External

Voltage Match Kp
Voltage Match Ki
Utility Current Metering
Configuration

400
50
3Ph 3 Sensed

10-800
0-255
3Ph 3 sensed/ 3 Ph 1 Sensed

Synchronizer Speed Control


Method
Slip Frequency
Frequency Match Kp
Frequency Match Ki
Phase Match Kp
Fail to Synchronize Time
Isolated Bus Speed Control
Method
Speed Droop percentage
Speed Droop Enable
Switch(PCCNet)
Speed Bias OOR Check Enable
Speed Bias OOR High Limit
Speed Bias OOR Low Limit
Speed Bias OOR Time
Isolated Voltage Control Method
Voltage droop Percentage
Voltage Adjust
Voltage Droop enable
Switch(PCCNet)

Phase Match
0.1Hz
30
20
150
120Seconds
Constant

Phase Match/Slip
Frequency/External
-3-3Hz
1-300
0-250
10-1500
10-900 Seconds
Constant/Droop

5%
Inactive

0-15%
Active/Inactive

Disabled
5Vdc
-5Vdc
1 second
Constant
4%
0%
Inactive

Enable/Disabled
-5-5Vdc
-5-5Vdc
0-10 Seconds
Constant/Droop
0-15%
-5-5%
Inactive/Active

0%
1PF
60
60
120
50
20 Seconds

0-100%
0.78-1PF
0-1000
0-250
0-1000
0-250
0-900 Seconds

20 Seconds

0-900 Seconds

Genset KW Set point Percent


Genset Power factor set point
Load Govern KW Kp
Load Govern KW Ki
Load Govern KVAR Kp
Load Govern KVAR Ki
Load Govern KVAR ramp Load
time
Load Govern KVAR ramp Unload
Time

CSS - Genset Controls Team

Deviation If any

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Parameter

Factory Settings

Revision 1.1

Range

Deviation If any

Load Govern KW maximum


Load Govern KW Maximum
Delayed
Utility Parallel Voltage Control
method

80%
80%

0-100%
0-100%

Load govern

Load Govern/Droop/Load Govern


with Deep Feed Forward

Voltage Droop Percentage


Utility Parallel Speed Control
Speed Droop Percentage
ECM CAN Enable
ECM Data save Time Delay
Prelube Function Enable
Idle Speed
Starter Disconnect Speed
Nominal Battery Voltage
High Battery Voltage Set time
Low Battery Voltage Set time
Weak Battery Voltage Set Time
Adjustable freq/Speed Gain
Starting to Rated Ramp Time
Governor Ramp Time
Glow Plug Enable
Governor Enable Engine Speed
Governor Preload Offset
Maximum Duty Cycle
Minimum Duty Cycle
Dither Factor
Excitation Source
Excitation Disable Override
AVR Enable

4%
Load Govern
5%
Disabled
30 seconds
Disabled
800 rpm
450 rpm
24V
60 seconds
60 seconds
2 seconds
30rpm/Hz
1 sec
0.25 seconds
Disable
1100 rpm
0%
95%
25%
15%
PMG
Excitation On
Enable

0-15%
Load Govern/ Droop
0-15%
Disabled/Enabled
0-60 seconds
Disabled/Enabled
700-1100 rpm
100-600 rpm
12V, 24V
2-60 seconds
2-60 seconds
1-5seconds
0-240Rpm/Hz
0-30 Seconds
0-30Seconds
Enable/Disabled
601-1400 rpm
0-400%
0-100%
0-100%
0-30%
Shunt, PMG
Excitation Off, Excitation ON
Enable, Disable

Note:- Clearly mention in your FSR if there is any deviation in these settings

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PCC Terminal Strip at a Glance


TB7-Utility / Genset Bus
Voltage Sense Connections

J22-Genset Voltage Sense


J12-CT Connections

CT1

CT2

CT3

TB9-Analog
Signals
J20-Genset
Connections
J25-Display
Connections

TB15 - Service
Tool / MODBUS
J26- J1939 Interface
to Engine Control
J14- service Tool
TB5-Breaker Control
Connections
TB8-Customer Connections

TB3-Customer Input/output
TB1-Customer Connections

TB10- Breaker Status Connection

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TB1 CUSTOMER CONNECTIONS


TO OEM
CONNECTIONS

TO PCC

TB1-xx

Customer Input & Output

CONNECTS TO

TB1-01

PCC NET A (+)

Network Data A

TB1-02

PCC NET B (-)

Network Data B

TB1-03

PCC Net Shield/B+ Return

TB1-04
TB1-05
TB1-06
TB1-07
TB1-08
TB1-09
TB1-10
TB1-11
TB1-12
TB1-13
TB1-14
TB1-15
TB1-16

Ready to Load
Customer Fused B+ (3A)
Common Warning O/P (N/O)
Common
Common Shutdown O/P (N/O)
Common
Remote Start Return
Remote Start
Customer Input # 1
Return
Customer Input # 2
Remote ESTOP Return
Remote Emergency Stop (N/C)

CSS - Genset Controls Team

250mA Low side relay driver


Relay contacts of rating 3.5A @30VDC
Relay contacts of rating 3.5A @30VDC
Relay contacts of rating 3.5A @30VDC
Relay contacts of rating 3.5A @30VDC
Works with (TB1-11)
Works with (TB1-10)
Works with (TB1-13)
Works with (TB1-12)
Works with (TB1-13)
Common Return for (TB-14) & (TB-16)
Remote ESTOP switch

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TB1-11

REMOTE PANEL
(NO contact)

Revision 1.1

TB1-16

REMOTE E-Stop
Switch

TB1-10

TB1-15

(NC Contact)

TB3 CUSTOMER I/O CONNECTIONS


TO OEM CONNECTIONS

TB3-xx
TB3-01

Customer Input & Output

TB3-11

Return
Configurable Output # 20
Status
Configurable Output # 21
Status
NA
Configurable Output # 22
Status
**Transfer Inhibit/ Config.
Input # 20 Switch
**Retransfer Inhibit /
Config. Input # 21 Switch
First Start Arbitration

TB3-12

Return

TB3-05
TB3-06
TB3-07
TB3-08
TB3-09
TB3-10

TO PCC

CONNECTS TO
Use as Signal Return for Switch Inputs. Works with TB3-9 & TB3-10
Intended to drive Relay Coil
Intended to drive Relay Coil

Intended to drive Relay Coil


Normally inhibits Transfer to Genset, under some conditions it is ignored;
Normally inhibits retransfer to Utility, under some conditions it is ignored;
For Paralleling connect supply to supply (TB3-11 to TB3-11)
Return for MFS TB3-11. For Paralleling connect return to return (TB3-12 to
TB3-12)

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TB5 BREAKER CONTROL CONNECTIONS


TO OEM
CONNECTIONS

TB5-xx
TB5-01

Circuit Breaker Control


Circuit Breaker Close Control (NO)

TB5-02

COM

TB5-03
TB5-04
TB5-05
TB5-06
TB5-07
TB5-08

NA
Circuit Breaker Open Control (NC)
COM
Utility Breaker Close Control (NO)
COM
Utility Breaker Open Control (NC)

Revision 1.1

TO PCC

CONNECTS TO
Contact for closing Genset Breaker, rating 5A @ 30VDC

Contact for opening Genset Breaker, rating 5A @ 30VDC


Contact for closing Utility Breaker, rating 5A @ 30VDC
Contact for opening Utility Breaker, rating 5A @ 30VDC

TB5
TB10

PCC 3300
BASE BOARD

Note:- TB5-1 & TB5-2 are the NO contacts which closes when the breaker is closed from HMI or the contacts automatically
close in AUTO once engine reaches 90% of rated voltage and speed. The functionality is vice versa for TB5-4 and TB 5-5

CSS - Genset Controls Team

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TB7 GEN BUS/UTILITY VOLTAGE SENSE


TO OEM CONNECTIONS

TB7-xx
TB7-01
TB7-02
TB7-03
TB7-04

TO PCC

Genset Bus/Utility Voltage Sensing


Genset Bus L1 Voltage OR Utility L1 Voltage
Genset Bus L2 Voltage OR Utility L2 Voltage
Genset Bus L3 Voltage OR Utility L3 Voltage
Neutral Sensing

CONNECTS TO
Up to 600VAC Line to Line direct connect
Up to 600VAC Line to Line direct connect
Up to 600VAC Line to Line direct connect
If delta voltage connection leave unconnected

TB8 CUSTOMER CONNECTIONS


TO PCC
TO OEM
CONNECTIONS

TB8-xx

Customer Input & Output

CONNECTS TO

TB8-01
TB8-02

Discrete Return
Discrete Return

Works with TB8-5


Works with TB8-6

TB8-03

Delayed Off

Low side Driver (Can be used for starting cooling / vent. System)

TB8-04

SW_B+ relay ctrl 2

Low side Driver (Can be used as Genset Run Signal)

TB8-05

Remote Fault Reset

Works with TB8-1

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TB8-xx
TB8-06
TB8-07
TB8-08
TB8-09
TB8-10
TB8-11
TB8-12
TB8-13

Customer Input & Output


Start Type
Customer Configurable Input # 13
Customer Configurable Input # 14
Customer Configurable Output # 4
Customer Configurable Output # 3
Load Dump
Discrete Return
Discrete Return

Revision 1.1

CONNECTS TO
Emergency / Non Emergency Start Type
Works with TB8-12
Works with TB8-13
250mA Low side relay driver
250mA Low side relay driver
250mA Low side relay driver, works with TB1-5
Works with TB8-7
Works with TB8-8

TB9 ANALOG I/O CONNECTIONS


TO OEM CONNECTIONS

TB9-xx
TB9-01
TB9-02
TB9-03

Analog Input & Output


Kw Load Set point/Config.
Analog Input # 1
Return
Kvar Load Set point/Config.
Analog Input #2

TB9-07

KW Load Share -

TB9-08

KW Load Share +

TB9-09

SHIELD

TB9-10

KVAR Load Share +

TB9-11

KVAR Load Share -

TO PCC

CONNECTS TO
Also can be set as "External Speed Bias input"
Analog Input Return
Also can be set as "External Voltage Bias Input"
Connect Genset to Genset when paralleling to enable genset to share Kw
Load. In addition can be used as input from master synchronizer for
freq./phase matching.
Connect Genset to Genset when paralleling to enable genset to share Kw
Load. In addition can be used as input from master synchronizer for
freq./phase matching.
Load share shield connection point
Connect Genset to Genset when paralleling to enable genset to share Kvar
Load. In addition can be used as input from master synchronizer for voltage
matching.
Connect Genset to Genset when paralleling to enable genset to share Kvar
Load. In addition can be used as input from master synchronizer for voltage
matching.

CSS - Genset Controls Team

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TB10 BREAKER STATUS CONNECTIONS

TO PCC

TB10-xx

TO OEM CONNECTIONS

Circuit Breaker Status

CONNECTS TO

TB10-01

Return

TB10-03
TB10-04
TB10-05
TB10-06
TB10-02
TB10-07
TB10-08
TB10-09
TB10-10

Utility CB Position A Switch


Utility CB Position B Switch
Utility CB Tripped Switch
UTILITY CB Inhibit
Return
Genset CB Position A Switch
Genset CB Position B Switch
Return
Genset CB Tripped Switch

Use as Signal return for switch inputs. Works with TB10-3, TB10-4,
TB10-5
Utility Main Breaker Aux A contact to determine breaker position
Utility Main Breaker Aux B contact to determine breaker position
Utility Main Breaker 86 Relay Aux A contact
Opens Utility main Breaker if closed; Inhibit closure if Breaker is open.
Use as Signal return for switch inputs. Works with TB10-7, TB10-8,
Genset Breaker Aux A contact to determine breaker position
Genset Main Breaker Aux B contact to determine breaker position
Use as Signal return for switch inputs. Works with TB10-10, TB10-11,
Genset Main Breaker 86 Relay Aux A contact

TB10-11

Genset CB Inhibit

Opens Genset Breaker if closed; Inhibit closure if Breaker is open.

TB10-12

Single Mode Verify

Can used when Single Genset used for Utility Paralleling.

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TB15 DATA SERVICE INTERFACE


TO OEM CONNECTIONS

TO PCC

TB15-xx
TB15-01
TB15-02
TB15-03
TB15-04

PC Tool Interface
RS 485 Shield
NA
RS485 (+)
RS485 (-)

CONNECTS TO
Network Shield
Network Data A
Network Data B

J12 CONNECTOR ( GEN CT INPUTS)

PIN
J12-1
J12-2
J12-3
J12-4
J12-5
J12-6

DESCRIPTION
CT1
CT2
CT2
CT1 COMMON
CT2 COMMON
CT3 COMMON

CSS - Genset Controls Team

CONNECTS TO
CT1-X1
CT2-X1
CT3-X1
CT1-X2/X3
CT2-X2/X3
CT3-X2/X3

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J22 ( GEN VOLTAGE CONNECTOR )

PIN
J22-1
J22-2
J22-3
J22-4

DESCRIPTION
L1
L2
L3
N

CSS - Genset Controls Team

CONNECTS TO
ALTERNATOR TERMINAL U ( R )
ALTERNATOR TERMINAL V ( Y )
ALTERNATOR TERMINAL W ( B )
ALTERNATOR TERMINAL NEUTRAL

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J20 ( GEN I/O CONNECTOR )

PIN
J20-1
J20-2
J20-3
J20-4
J20-5
J20-6
J20-7
J20-8
J20-9
J20-10
J20-11
J20-12
J20-13
J20-14
J20-15
J20-16
J20-17
J20-18
J20-19
J20-20
J20-21
J20-22

DESCRIPTION
CHASSIS GROUND
B+ RETURN
Switched B+ LOW SIDE DRIVER
B+ RETURN
DISCRETE INPUT RETURN
DISCRETE INPUT RETURN
B+ RETURN
DISCRETE INPUT RETURN
B+ INPUT (FUSED B+)
B+ INPUT (FUSED B+)
STARTER DISCONNECT INPUT
B+ RETURN
RELAY COIL B+ SUPPLY
FSO RELAY DRIVER
STARTER RELAY DRIVER
OIL PRIMING PUMP DRIVER
CONFIGURABLE I/P #5
CONFIGURABLE I/P #6
CONFIGURABLE I/P # 12
B+ INPUT (FUSED B+)
B+ INPUT (FUSED B+)
ALT FLASH INPUT

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CONNECTS TO
BATTERY NEGATIVE
BATTERY NEGATIVE
RETURN FOR CONFIGURABLE O/P #5 J20-17
RETURN FOR CONFIGURABLE O/P #6 J20-18
BATTERY NEGATIVE
RETURN FOR CONFIGURABLE O/P #12 J20-19
BATTERY POSITIVE
BATTERY POSITIVE
CHARGING ALTERNATOR
BATTERY NEGATIVE
SWITCHED B+
LOW SIDE OF FUEL SHUT OFF RELAY COIL
LOW SIDE OF STARTTER RELAY COIL
LOW SIDE OF OIL PRIMING PUMP RELAY COIL
DEFAULTS TO LOW COOLANT SWITCH LEVEL
DEFAULTS TO LOW FUEL LEVEL SWITCH
DEFAULTS TO RUPTURE BASIN SWITCH
BATTERY POSITIVE
BATTERY POSITIVE
CHARGING ALTERNATOR

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J25 DISPLAY CONNECTOR

PIN
J25-1

DESCRIPTION
LOCAL STATUS

CONNECTS TO
FOR FUTURE

J25-2

LOCAL E-STOP

LOCAL E-STOP SWITCH

J25-3

PCC NET B

NETWORK DATA B

J25-4

PCC NET A

NETWORK DATA A

J25-5

SYSTEM WAKEUP

J25-6

DISCRETE INPUT RETURN

J25-7

DISCRETE INPUT RETURN

J25-8

B + RETURN

BATTERY -

J25-9

B + RETURN/ PCC NET SHIELD

PCC NET HARNESS SHIELD

J25-10

MANUAL

MANUAL RUN COMMAND

J25-11

AUTO

AUTO COMMAND

J25-12

N/A

CSS - Genset Controls Team

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Revision 1.1

J26 ENGINE INTERCONNECT

PIN
J26-1
J26-2
J26-3
J26-4
J26-5
J26-6
J26-7
J26-8
J26-9
J26-10
J26-11
J26-12

DESCRIPTION
J1939 (SHIELD)
BACKUP START DISCONNECT
AVR PWMNA
B POSITIVE RETURN
NA
FIELD NA
AVR FUSED B+
J1939(-)
J1939(+)
NA

CONNECTS TO
CAN DATALINK
AUX 103 AVR POWERSTAGE
AUX 103 AVR POWERSTAGE
POWER FOR AUX 103 AVR POWERSTAGE
ALTERNATOR FIELD XX - (F2)
POWER FOR AUX 103 AVR POWERSTAGE
CAN DATALINK
CAN DATALINK

CUSTOMER CONNECTIONS FROM TB1 TO MAIN PANEL


NOTE: For relay specification details, please refer document part no. 0630-3440

Ready to load connections

CSS - Genset Controls Team

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Revision 1.1

Configurable Output signals (Output1)

Note: Connection logic for Output 2 is same as described for Output 1

Remote start Signal


The engine starts provided the controller is put in auto mode. Remote start indication can be seen on HMI 320.

Customer Input 1
Faults like Earth Fault relay or Level switch can be connected and configured as an input.

Note: Connection logic for Input 2 is same as described for Input 1.

Remote Emergency stop

CSS - Genset Controls Team

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Revision 1.1

MANDATORY CONNECTORS FOR PARALLELING


Connections mandatory for multiple sets in parallel operation
Step 1 Loop the connections between the TB9 terminals of all the sets for sharing KW and KVAR load.

Step -2 When PCC is being paralleled with other PCC sets (3100/3200/3201), loop the load sharing lines with respect to the
proper signals. Below figure gives a clear idea for the same.
NOTE: TB13 terminals mentioned in the below connection drawing is the TB strip on BUS PT.

Step - 3 Complete the breaker open & close control connections.

CSS - Genset Controls Team

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Revision 1.1

SINGLE SET
1. In Run Mode, when Engine Speed & Voltage reach 90% of Rated & When the Breaker Close button
on HMI can be pressed.
2. In Auto Mode, When Remote start command is ggiven
iven & only when Speed & Voltage reach 90% of
rated automatically.

PARALLEL SET
1. In Run Mode, when Engine Speed & Voltage reach 90% of Rated & when the synchronizing
conditions are met, the circuit breaker can be closed from HMI.
2. In Auto Mode, when Remote start command is given with Speed & V
Voltage
oltage reach 90% of rated and
synchronizing conditions are met, the circuit breaker closes automatically. Indication for the same can
be seen from HMI.

Step - 4 Complete the genset breaker connections. The feedback for breaker closed/open can be given for either single
position or dual position breaker feedback. Default setting in PC 3.3 is for single position contact. Tripped status is an
OPTIONAL connection.

Step - 5 Provide the bus voltage signal to PCC control. This can be done by providing AC voltage to TB 7 connector. This is the
most important step because if these signals are not provided, the controller will sense dead bus and will give the closing
command without synchronizing.

CSS - Genset Controls Team

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Revision 1.1

SPEED & VOLTAGE BIAS SIGNALS


PCC set, one can provide external input signals for Speed bias and Voltage bias.
If PC 3.3 is being paralleled with a Non--PCC
a.

Change the Genset application type to Utility Multiple

b.

Change KW load setpoint/Config. Analog Input 1 trim from Default to External Speed Bias Input.

c.

Change
ge KVAR load setpoint/Config. Analog Input 2 trim from Default to External Voltage Bias Input.

d.

Connect 0-55 V DC pot as shown in the figure below:

CSS - Genset Controls Team

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Revision 1.1

Commissioning Report
Dealer promotion ID
Service Engineer
Dealer Name
Engine Model
Alternator
Serial No
Controller Serial No
GSN
Engine Running Hours
Commissioning Hours
Control Run Time
KW Hours -1) Genset
2) Utility
RPM
Lube Oil Pressure
Coolant Temperature
O/P Voltage
Current
KW
RTC
Actual Date & Time
Controller Sleep Mode( Yes/No)
Controller Sleep Mode in Auto( Yes/No)

In case of Doubts dont hesitate to contact the nearest Head Zonal Electronics.
Zone

Name

Mobile

North

Rakesh Tripathi

9891799305

East

Nilesh Kale

9826952104

West

Saranraj P

9594002685

South

Konnur Bs

9448496780

CSS - Genset Controls Team

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