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
Parts No Fuses :
Control Assy. 0300-5459-02 Fuse Location, Rating Function
Base Board---10 A Protects B+
Engine Harness 0338-4232 F1 Ckt (TB1-17 & TB1-18
Base Board---5 A Protects
AC Harness 0338-4977 F2 Switched B+ Ckt (TB1-19)

Base Board---2 A Protects

Coolant/L.O. Temp. Sender 0193-0529-02 F3 Switched B+ Ckt (J7-23 &J7-9)
Base Board---5 A Protects
Lube Oil Press. Sender 0193-0444 F4 Base Board Power Supply
PTC Module (optional)---2 A
Base Board 0327-1379-01 F5 Protects PTC Module
Display Board 0300-5467
Bar Graph Board 0300-5180
Pilot Solenoid 0307-2621-02 Calibration Part No. Model
MPU 4085824 0326-6167 K-38
Low Coolant Level Switch 0193-0468 0326-5769 K-50
PCC O & M Manual 0900-0534 0326-5761 V-28
CT Ratio CT Part Number
CT's For 750KVA--2141 / 1 0302-2058-03
CT's For 1000 KVA--2839/1 0302-2058-08
CT's For 1250KVA--3867/1 0302-2058-12
CT's for 1500 KVA--4420/1 0302-2058-15

PCC Commissioning checks/pmp

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

Feature Part Numbers Description Feature Part Numbers Description

0326-5482 Lonworks Disabled 0326-5482 Lonworks Disabled
0326-5485 Application -Prime 0326-5485 Application -Prime
0326-5490 Coolant Level SD 0326-5490 Coolant Level SD
0326-5566 WYE Connection 0326-5566 WYE Connection
0326-5576 Voltage- 416 L-L 0326-5576 Voltage- 416 L-L
0326-5584 Oil Temp. Sender Enable 0326-5584 Oil Temp. Sender Enable
0326-5596 Frequency -50 Hz 0326-5596 Frequency -50 Hz
0326-5683 Excitation -PMG 0326-5683 Excitation -PMG
0326-5696 Over speed - 1800 rpm 0326-5696 Over speed - 1800 rpm
0326-5759 CT Ratio 0326-6156 Battle Short Enable
600 KW Prime/660 KW
0326-5819 standby - 3 Ph 0326-6192 CT Ratio
800 KW Prime/ 880 KW
0326-6156 Battle Short Enable 0326-6361 standby - 3 Ph
0326-6717 Gov. Gains 0326-6717 Gov. Gains

Factory Installed Feature List - 1250KVA Factory Installed Feature List - 1500KVA
Feature Part Numbers Description Feature Part Numbers Description
1200 KW Prime/ 1320 KW
0326-5482 Lonworks Disabled 0326-0411 standby - 3 Ph
0326-5485 Application -Prime 0326-5482 Lonworks Disabled
0326-5490 Coolant Lvl SD 0326-5485 Application -Prime
0326-5566 WYE Connection 0326-5490 Coolant Level SD
0326-5576 Voltage- 416 L-L 0326-5566 WYE Connection
0326-5584 Oil Temp.Sender Enable 0326-5576 Voltage- 416 L-L
0326-5596 Frequency -50 Hz 0326-5584 Oil Temp.Sender Enable
0326-5683 Excitation -PMG 0326-5596 Frequency -50 Hz
0326-5696 Overspeed - 1800 rpm 0326-5683 Excitation -PMG
1000 KW Prime/ 1100 KW
0326-5849 standby - 3 Ph 0326-5696 Overspeed - 1800 rpm
0326-6156 Battle Short Enable 0326-6156 Battle Short Enable
0326-6197 CT Ratio 0326-6199 CT Ratio
0326-6490 Gov.Gains 0326-6490 Gov.Gains

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)
P8-6 - Not Connected 4 3 2 1
P8-7 - Neutral
P8-12- V ( Y Phase Connection)
P8-13 - X ( F1 Field connection)
P8-20 - W (B-Phase Connection)
P8-21- PMG2 24 23 22 21
P8-22 - PMG3
P8-23 -PMG4 AC harness
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
1 REMOTE START 1 RS -485 +
2 REMOTE EMERGENCY STOP 2 RS -485 -
3 Remote Reset 3 B+
4 Customer Fault 1 4 GND
5 Customer Fault 2 5 Not Used
6 Customer Fault 3 6 Not Used
7 Customer Fault 4
8 Cust. Out 1 NO
9 Cust. Out 1 Common
10 Cust. Out 2 NO
11 Cust. Out 2 Common
12 Cust. Out 3 NO
13 Cust. Out 3 Common
14 Cust. Out 4 NO
15 Cust. Out 4 Common
16 SPARE
17 B+(20A FUSED)
18 B+(20A FUSED)
19 SWITCHED B+(10A FUSED)
20 GROUND
21 GROUND
22 GROUND

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 R UTILITY
Y SUPPLY
Sensing
B
20 Relay N
TB1

Remote Emergency Stop( Mandatory)

Main Panel
TB1
2 Remote Emergency
stop Switch if Ground is connected to terminal No.2
20 then engine will stop,PCC will indicate
Emergency Stop.

CUTOMER FAULTS 1,2,3 & 4 ( Earth Fault Protection Mandatory , Others Optional)
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
A34-P1-2 3 FAULT RESET Main Panel
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) Breaker Closing ( Mandatory)

TB1
14 (N/O) Breaker Closing
15 (N/O)

Sample Drawing for Breaker Closing

Aux.NC contact
TB1 of Brkr
A34-P2-4 14
Closing Coil
A34-P2-3 15 of Brkr

TB BAT-F1 17 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. Batty. Charging Alt.

Relay Activated By Switched B+

TB1 battery bank
19 Battery
Charger

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

TB1 R1 R1
M
P12-2 19
Common B-ve ( TB1-21) 230V

Engine Ground 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

Cummins Universal
Announciator
TB2 RS 485 lines P.No. 0300-5929
RS 485 + 1
RS 485 - 2
B+ 3
GND 4

Droop Operation of PCC 2100

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

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

U
T L1 G
I E
L2 N
L N
I L3 L S
T E
Y N T

AMF LOGIC Utility Breaker Aux. Contact

P5--6 24V TB1-1 PCC 2100

CUSTORMER
CONNECTION
P5--7 TB1-20 ON TB1
K1

K1
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
K-1 Relay for
11 Breaker trip

230 V from DG Set / Panel

K1
K1 NC Under voltage coil of the
K1 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 Modified V/Hz Table

Hz % Hz %
0.000 100.000 0.000 100.000
3.000 100.000 1.000 100.000
7.313 80.005 5.313 80.005
11.638 50.000 9.638 50.000
15.950 19.995 13.950 19.995
80.00 0.000 80.00 0.000

1) Calibrate Voltage and Current and PF

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

Reference : - Instruction sheet C-698

Parameters to be logged on Hourly basis
Voltage Current
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 L31 L1 L2 L3 KW PF KWh %Load %Amps

PCC Checks / PMP