Commissioning report for PCC Engine

ESN:

Model:

Name of the Commissioning Engineer :

Date Of Commissioning:

OEM

Name of the OEM Engineer

Customer:

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

Cummins Part
No
Parts
Control Assy.
0300-5459-02

Fuses :
Fuse

Engine Harness

0338-4232

F1

AC Harness

0338-4977

F2

Location, Rating Function

Base Board---10 A Protects B+
Ckt (TB1-17 & TB1-18
Base Board---5 A Protects
Switched B+ Ckt (TB1-19)

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

F3

Lube Oil Press. Sender

0193-0444

F4

Base Board
Display Board
Bar Graph Board
Pilot Solenoid
MPU
Low Coolant Level Switch
PCC O & M Manual
CT Ratio
CT's For 750KVA--2141 / 1
CT's For 1000 KVA--2839/1
CT's For 1250KVA--3867/1
CT's for 1500 KVA--4420/1

0327-1379-01
0300-5467
0300-5180
0307-2621-02
4085824
0193-0468
0900-0534
CT Part Number
0302-2058-03
0302-2058-08
0302-2058-12
0302-2058-15

F5

Base Board---2 A Protects

Switched B+ Ckt (J7-23 &J7-9)
Base Board---5 A Protects
Base Board Power Supply
PTC Module (optional)---2 A
Protects PTC Module

Calibration Part No.

0326-6167
0326-5769
0326-5761

K-38
K-50
V-28

Model

PCC Commissioning checks/pmp

Factory Installed Feature List - 750KVA

Factory Installed Feature List - 1000KVA

Feature Part Numbers

0326-5482
0326-5485
0326-5490
0326-5566
0326-5576
0326-5584
0326-5596
0326-5683
0326-5696
0326-5759

Feature Part Numbers

0326-5482
0326-5485
0326-5490
0326-5566
0326-5576
0326-5584
0326-5596
0326-5683
0326-5696
0326-6156

Description
Lonworks Disabled
Application -Prime
Coolant Level SD
WYE Connection
Voltage- 416 L-L
Oil Temp. Sender Enable
Frequency -50 Hz
Excitation -PMG
Over speed - 1800 rpm
Battle Short Enable

0326-5819

Description
Lonworks Disabled
Application -Prime
Coolant Level SD
WYE Connection
Voltage- 416 L-L
Oil Temp. Sender Enable
Frequency -50 Hz
Excitation -PMG
Over speed - 1800 rpm
CT Ratio
600 KW Prime/660 KW
standby - 3 Ph

0326-6192

0326-6156
0326-6717

Battle Short Enable

Gov. Gains

0326-6361
0326-6717

CT Ratio
800 KW Prime/ 880 KW
standby - 3 Ph
Gov. Gains

Factory Installed Feature List - 1250KVA

Feature Part Numbers
Description
0326-5482
0326-5485
0326-5490
0326-5566
0326-5576
0326-5584
0326-5596
0326-5683
0326-5696
0326-5849
0326-6156
0326-6197
0326-6490

Lonworks Disabled
Application -Prime
Coolant Lvl SD
WYE Connection
Voltage- 416 L-L
Oil Temp.Sender Enable
Frequency -50 Hz
Excitation -PMG
Overspeed - 1800 rpm
1000 KW Prime/ 1100 KW
standby - 3 Ph
Battle Short Enable
CT Ratio
Gov.Gains

Factory Installed Feature List - 1500KVA

Feature Part Numbers Description
1200 KW Prime/ 1320 KW
standby - 3 Ph
0326-0411
0326-5482
Lonworks Disabled
0326-5485
Application -Prime
0326-5490
Coolant Level SD
0326-5566
WYE Connection
0326-5576
Voltage- 416 L-L
0326-5584
Oil Temp.Sender Enable
0326-5596
Frequency -50 Hz
0326-5683
Excitation -PMG
0326-5696
0326-6156
0326-6199
0326-6490

Overspeed - 1800 rpm

Battle Short Enable
CT Ratio
Gov.Gains

PCC Commissioning checks/pmp

Visual Inspection
1. Engine Wiring Harness:
The entire wiring should be clamped appropriately, with no loose wires hanging
LCL if connected , should be wired up as follows:
LCL Wires-----------------Engine Wiring Harness
Red--------------------------------- S7 + ( J7-31 +Ve)
Black------------------------------- S7 - ( J7-35 -Ve)
Blue---------------------------------S7-Sig (J7-32)
Plugs / Connectors ,engine Harness
Connector P7 - -- Connects on the Base Board ( Inside the door of PCC 2100) --While Fixing this plug first match the notch & push it in .
CT Wires -- Connect X1 & X3 wires to individual CT's
AC Harness :
Connector No : P8 --Connects to J8 connector inside the PCC 2100 Box --PMGP2, PMG3 , PMG4---Connect this wire to the PMG wire coming out from
the Main Alternator ( See that length of this adequate.
DO NOT EXTEND THESE WIRES, IF THESE WIRES ARE SHORT IN LENGTH----If required bring these wires to a terminal strip , securely mounted
on the alternator frame inside & connect the Alternator PMG wires on the terminal strip>
X+, XX --These are field winding wires ----Connect the field winding wires from the main alternator to these wires ( F1 to X+ & F2 to XX
U,V,W & N --- These are the Main Phase voltage connections.
AC Harness Details -- P8 Connector
One side of P8 plugs inside the PCC 2100 control & the other end connections are as follows:
P8 -1,2,3,8,9,10,11,15,16,17,18,19 - Not Connected
P8-4 - U ( R Phase Connection)
P8-5 - XX ( Field -F2 Connection)
4 3 2 1
P8-6 - Not Connected
P8-7 - Neutral
P8-12- V ( Y Phase Connection)
P8-13 - X ( F1 Field connection)
P8-20 - W (B-Phase Connection)
24 23 22 21
P8-21- PMG2
P8-22 - PMG3
AC harness
P8-23 -PMG4
P8 Connector
Ensure that the wires going out of the Terminal strip towards the main panel ( OEM connections) are properly dressed & there are no loose wires
hanging. Additional spare wires to be taped & dressed separately.
Starter Connections : Only one magnetic switch drives both ( for V Engines) the starters. Physically inspect that the positive terminals of Both
the starters are looped ( Shorted). Similarly the negative terminals of both the starters are looped (shorted & connected to Engine body)

PCC Commissioning checks/pmp

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

TB-1

TB-2

REMOTE START

REMOTE EMERGENCY STOP

Remote Reset

Customer Fault 1

Customer Fault 2

Customer Fault 3

Customer Fault 4

Cust. Out 1 NO

RS -485 +
RS -485 B+
GND
Not Used
Not Used

Cust. Out 1 Common

10

Cust. Out 2 NO

11

Cust. Out 2 Common

12

Cust. Out 3 NO

13

Cust. Out 3 Common

14

Cust. Out 4 NO

15

Cust. Out 4 Common

16

SPARE

17

B+(20A FUSED)

18

B+(20A FUSED)

19

SWITCHED B+(10A FUSED)

20

GROUND

21

GROUND

22

GROUND

PCC Checks / pmp

PCC TB1 Connections

Sample Drawings related to each terminal of the TB - 1 pin terminal strip are given below.
All the connections shown need not be used, the Mandatory connections are mentioned in BOLD
Remote Start ( Mandatory For AMF applications)
TB1
1
REMOTE START ( IF PCC RUN /OFF/AUTO Switch is in AUTO &
if Ground is connected to terminal No.1 then engine will start remotely)
Main Panel
TB1
1
Remote Start Switch

20
Sample Drawing for Remote start for AMF Application
Main Panel
1
Voltage
Sensing
20
Relay
TB1

Remote Emergency Stop(

R
Y
B
N

UTILITY
SUPPLY

Mandatory)
Main Panel

TB1
2
20

Remote Emergency
stop Switch

if Ground is connected to terminal No.2

then engine will stop,PCC will indicate
Emergency Stop.

CUTOMER FAULTS 1,2,3 & 4 ( Earth Fault Protection Mandatory , Others Optional)
TB1
4
CUSTOMER Input 1 ------Default Not Programed Not Assigned
5
CUSTOMER Input 2 ------Default Programed as Ground Fault--Shutdown
6
CUSTOMER Input 3 ------Default Programed as Low Fuel level--Shutdown
7
CUSTOMER Input 4 ------Default Programed as High Alternator Temp--Shutdown
These are customer configurable inputs to the PCC, they can be either configured for Warning or Shutdown
In PCC there is no inbuilt protection for Earth Fault. An earth fault relay has to be externally used for this Purpose, the
out put of which can be brought into the PCC for shutting down the engine. For this Customer Fault No2 (Ground Fault)
has to be used.
Main Panel
TB1
Relay Activated By E/F
A34-P1-12
5
Protection Relay
GND-ENG

20

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

PCC Checks/PMP

Example No. 2
If the Circuit Breaker trips due to Breaker internal electrical Protection, then this input can be brought into the PCC & the
engine can be tripped.
Program the Customer Fault No 1 to ' Breaker Trip ' or ' Electrical Fault' ----Program it for Shutdown (Through PCC menus)
TB1
P12-1/A34-P1-9
4
Breaker Trip N/O Contact
GND-ENG
20
Main Panel

Fault Reset: This can be use to reset Warning Faults from Remote or Main Panel
TB1
Main Panel
A34-P1-2
3
FAULT RESET
When terminal No 3 is grounded ,the
A34-P1-2
20
warning fault from a remote location can be
reset.
GND-ENG
3
Fault Reset
Push Button

Customer Outputs : These are configurable outputs which close a NO contact when the desired configured event
occurs.
These Outputs can be configured for any event through Inpower.
The Default ( Factory Installed) configured outputs are : Customer Output No.1 ---- Common Warning
Customer Output No.2 ---Common Shut Down
Customer Output No.3 ---Not In Auto
Customer Output No.4 ---Ready to Load
However all these Customer outputs can be configured to any desired event through Inpower
Example No.1 : Customer out Put No.1 If Configured for Common Warning:
When there is any warning on the Genset, the PCC internal
8
contact closes & the indicating lamp will glow. This could be a
lamp, an Audible announciation or any other relay for complex
9
logic.
24 Vdc From TB1-17
17
Example No.2 : Customer Output No.4 (Default configured as Ready to Load)

TB1
14
15

(N/O)
(N/O)

Breaker Closing

( Mandatory)

Breaker Closing

Sample Drawing for Breaker Closing

A34-P2-4

TB1
14

A34-P2-3

15

TB BAT-F1

17

Aux.NC contact
of Brkr
Closing Coil
of Brkr
24 vdc supply from TB1-1

PCC Checks/PMP

The NO contact between 14 & 15 will close when:

A----( Single & NON Paralleling Sets or DEAD BUS)
1.In Run or Auto Mode, when Engine Speed & Voltage reaches 90% of Rated.

Caution : If this Genset is used for Parallel operation, then the Paralleling Breaker has to be
closed through an external Sync Check relay.

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

Switched B+ : 24 Vdc Will be available on this Terminal only when the Fly wheel Starts rotating.
Use the logic diagram given to cut off the external battery Charger if Used.
Relay Activated By Switched B+
TB1
19

Battery
Charger

Batty. Charging Alt.

battery bank

Batty. Charger Input Supply

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

Sample drawing for running Raw water Pump

R1
TB1
P12-2
19
Common B-ve ( TB1-21)

Engine Ground

R1

M
230V

TB1

GND-ENG

20

any Ground looping in the PCC Panel can be taken from here

GND-ENG

21

any Ground looping in the PCC Panel can be taken from here

22

PCC Net -- Announciator Connections

Note : Not a standard scope of supply -- Optional ( to be ordered seperately)
Cummins Proprietory Protocol - PCC Net

TB2
1
RS 485 2
B+
3
GND
4

RS 485 +

Droop Operation of PCC 2100

RS 485 lines

Cummins Universal
Announciator
P.No. 0300-5929

PCC Checks/PMP

PCC 2100 For Droop Operation :PCC 2100 can be operated on Droop. All we need to do is set the required % of Droop
( Speed or Voltage)either from the main panel or through Inpower. No external resistances are required to be connected.
What ever % of Droop is set, automatically the High idle speed to change in accordance with the droop set.
Raise / Lower Voltage & Speed (Speed/Voltage Bias is currently Not available)

PCC 2100 -- For Use with Either PCW for Monitoring Only or For BMS Integration.
If the PCC 2100 is desired for Remote Monitoring : Following Parts are required ( Not a std Scope of supply)to
be ordered seperately
NCM-- Network Communications Module -- P.No.
One Per Genset
SLTA - Serial Lon Talk Adaptor --P.No.
One per Site
CAT -5 / Cat 6 Cable --- As per Distance between sets upto the SLTA Adaptor with Power supply ( Near the Customers PC)
Genset No 1
Genset No 2

PC Serial Nul Modem Cable

Twisted pair Cat -4 / Cat 5 Cable

BMS Integration OR PLC Interface using MODLON Convertor
Third party BMS Integrator

Modlon
Convertor

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

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

PCC Checks/PMP

TS 1311 + PCC 2100

GENSET START
COMMAND P5 - 6 & P5 - 7

- +

U
T
I
L
I
T
Y

L1
N

L2
L

L3
N

AMF LOGIC
P5--6

G
E
N
S
E
T

Utility Breaker Aux. Contact

24V

TB1-1

P5--7

TB1-20
K1

K1

P5 -9 ( 24V +)
P5 - 8 ( GND)

PCC 2100
CUSTORMER
CONNECTION
ON TB1

Please note : The default setting of

Customer outputs is as below.
1 Customer o/p no. 1 - Common waring (TB1-8,9)
2 Customer o/p no. 2 - Common Shutdown (TB1-10,11)
3 Customer o/p no. 3 - Not in Auto (TB1 12,13)
4 Customer o/p no. 4 - Ready to Load (TB1-14,15)

Non AMF Mechanical Breaker with u/v trip

+ 24 V from TB BAT-F1 (17)

Common S.D.
10
11

K-1 Relay for

Breaker trip

230 V from DG Set / Panel

K1
K1 NC

K1

Under voltage coil of the

braker

Paralleling PCC 2100 in Droop Mode using Aux101

module
Connect the Aux 101 module as per instruction sheet (C698) and
change the necessary settings as listed below.

Aux 101 Enable

Device#1 Input 1 Enable Enable
Device#1 Input 2 Enable Enable
Device#1 Input 1 Sensor Type Bias Sensor
Device#1 Input 2 Sensor Type Bias Sensor
Set the Speed Bias Scale value.
Set the Voltage Bias Scale value.

It is must to adjust the V/Hz table of the PCC2100 to more closely match the V/Hz
characteristics of the Newage AVR if you are paralleling with non-PCC Genset.
Modify the V/Hz table as shown below on the PCC2100.
Original V/Hz Table
Hz
%
0.000
100.000
3.000
100.000
7.313
80.005
11.638
50.000
15.950
19.995
80.00
0.000

Modified V/Hz Table

Hz
%
0.000
100.000
1.000
100.000
5.313
80.005
9.638
50.000
13.950
19.995
80.00
0.000

1) Calibrate Voltage and Current and PF

2) Once calibrated, parallel the two Gensets without load and monitor KVARs. If
one genset is pushing KVARs onto the other, the Voltage Adjust % command
should be used to remove this offset. This parameter is on the front panel of the
PCC2100 and in InPower. Once they are calibrated, they will share load normally.
Reference : - Instruction sheet C-698

Parameters to be logged on Hourly basis

Voltage
Cool.Te
Eng.
mp.
DG
Run No. of Lube Oil Lube Right/Le Batty.
No. Time Hrs Starts Temp.
Oil Pr. ft
Volt. RPM Gov % Reg% L12

L23

Current

L31

L1

L2

L3

KW

PF

KWh

%Load %Amps

PCC Checks / PMP