PCC Commissioning Guide Lines

Index
1. Cold Checks - Part Nos. of Various Components of PCC.

2. Wiring Checks - Engine Wiring Harness , PT/CT Harness ,
Customer Interface Harness
3. PCC Fault Codes & thresholds
4. PCC Calibration - Initial Calibration , Frequency Calibration,
Voltage Calibration,Meters Calibration
5. Settings on the PCC -Factory Settings
6. PCC Terminal Strip ( TB1-60) at a glance
7. Detailed Terminal Strip connections of Inputs / Outputs from PCC
with sample Drawings
8. Instrumentation & Cable requirements for a PCC Genset
9. Sample GA Drawing of the Control panel for a PCC Genset
10. List of Bare Minimum connections from the Terminal strip to the
main panel
11. Log sheet ( Sample parameters to be maintained in the Log book)
Commissioning report for PCC Engine

ESN:
Model:
Name of the Commissioning Engineer :

Date Of Commissioning:
Parts & their Sr.Nos. ( Kindly Confirm by actual Inspection)
Parts
Cummins Part No
ONAN Part No.
PCC
4084008
300-4615-05
Governor O/p Module
4084020
300-4625
Regulator O.P module
4084021
300-4634
PT/CT Module
4084022
300-4626-02
Bus PT Module
4084009
300-4767-02
Engine interface Board
AX1002266
300-4083
Customer Interface Board AX1004536
300-4462-01
Digital Board
AX1002262
300-4079
Analog Board
AX1002264
300-4080-02
Display Board
AX1002249
300-4286
Master first Start Sensor
CT's ( All Three)
As per Engine Model
Customer:
OEM:
Name of the OEM Engineer
Sr.No.
Parts
Water Temp.Sensor ( RB /LB)
Lube Oil Pressure Sensor
Oil Temp.Sensor
Engine Temp. Sensor
MPU
Magnetic Switch
Engine Wiring Harness
Alternator Wiring Harness
PT/CT Harness
Low Coolant Level Switch
PCC O & M Manual
Cummins Part No
4084030
4084031
4084030
ONAN Part No. Sr.No.

193-0432
193-0444
193-0432
3231404
4084033
307-2621-01
As per Engine Model
As per Engine Model
4084230
4084762
3243804
Version:
L-L Voltage
Parallel / Single
Software Version
Note : A separate table giving the Details of Version / CT Part nos w.r.t engine model is given below.
Cummins
ENGINE
KVA
KW
FILE
CT
PART
ONAN PART
MODEL
RATING Rating NAME
RATIO NOS.
NO.
KTA50G8
1500
1200
DFLF-50 4420/1 4084989
302-2058-15
Location
KTA50G3
1250
1000
DFLC-50 3867/1 4084245
302-2058-12
KTA38G5
1000
800
DFJD-50 2839/1 4084175
302-2058-08
Engine Interface
KTA2300G 750
600
DFJB-50 2141/1 4084244
302-2058-03
Engine Interface
VTA28G5
625
500
DFGC-50 1893/1 4107379
302-2058-01
VTA28G3
600
500
DFGC-50 1893/1 4107379
302-2058-01
Governor Output Module
KTA19G4
500
400
DFED-50 1419/1 4104378
302-2057-31
KTA19G3
450
360
DFEC-50 1262/1 4104388
302-2057-29
KTA1150G 380
300
DFEB-50 1070/1 4104377
302-2057-26
KT1150G
320
300
DFEB-50 946/1 4104376
302-2057-24
NTA855G2 320
250
DFCB-50 946/1 4104376
302-2057-24
NT855G6
285
227
DFBF-50 789/1 4104389
302-2057-21
TB-Bat (Engine Harness
NT855G5
250
200
DFBE-50 725/1 4104390
302-2057-19
Assembly)
NT855G4
225
180
DFBD-50 631/1 4104391
302-2057-17
PCC FUSES-- Check if in doubt
Nomenc Rating
Function
lature
A31-F1 5 Amp PCC Control B + (Ve)
A31-F3 5 Amp Aux. B+ (For panel lights, run & start
relays)
A38-F1 10 Amp Network B+ (to TB1 customer terminal
block)
A38-F2 10 Amp Switched B+ ( to TB1 customer
terminal block)
A38-F3 10 Amp Governor B+ (power for governor
output module & actuator)
F1
20 Amp Customer B+ ( to TB1 customer
terminal block
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 + ( TB Bat +Ve)
Black------------------------------S7 - ( TB Bat -Ve)
Blue------------------------------- S7-Sig (P4-7)
Plugs / Connectors ,Customer Interface Harness
P4 - Grey -- Connects on the Engine Interface Board ( Back Side of PCC) --While Fixing this plug first match the notch & push it in so that you hear a click sound.
P5 - White Connector on the Engine Interface board ( Back Side of PCC) --DO -------------------P6 - Grey ---Connects to the Governor O/P module ( On the accessory Box) -------DO
P7 -White ---Connects to the Regulator O/p Module ( on the acc. Box)
P10 - White ---Connects to the Regulator O/p Module ( on the acc. Box)
PMG wires :
PMGP2, PMG3 , PMG4---Connect this wire to the PMG wire coming out from the Main Alternator ( See that length of this adquate.
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
J-12 - Grey -- Connects to the Alternator Wiring Harness on Plug -12 ( Located in the Acc.Box)
Starter Connections
looped ( Shorted). Similarly the negative terminals of both the starters are looped (shorted & connected to Engine body)
Main Alternator Wiring Harness :

Plugs :
P1 - Black ---Match the Socket which has a similar Black colour -- On the Customer Interface board ( On the back Side of PCC)
P2 - Grey ---Match the Socket which has a similar Grey colour -- On the Customer Interface board ( On the back Side of PCC)
P3 - Blue ---Match the Socket which has a similar blue colour -- On the Customer Interface board ( On the back Side of PCC)
P8 - Grey -- Connects to the PT / CT Module
P12 - Connects to J12 of the engine harness connector
Six Wires to Bus PT Module on terminal strip - A39 - TB2-1, A39 - TB2-2, A39 - TB2-3, A39 - TB2-4, A39 - TB2-5, A39 - TB2-6,
PT/CT Harness
One end gets connected to the PT/CT Module --White Plug & the other end has ten wires.-CT Connections
1 - Neutral ( Neutral Phase Connection)
1 2 3
2 - VB ( B Phase Connection)
1
3 - VY ( Y Phase Connection)
4 - VR ( R Phase Connection)
5 - Not Used
6 - IB2 (B Phase CT Connection)
10 11 12
7 - IB1 (B Phase CT Connection)
8 - IR2 (R Phase CT Connection)
9 - IR1 (R Phase CT Connection)
PT CT harness
Connector
10- IY2 (Y Phase CT Connection)
11- IY1 (YPhase CT Connection)
12- Not Used
PCC - Fault Thresholds

Fault Code
200
Status
Warning
Description
Low Lub Oil Pressure
201
Shutdown
Low Lub Oil Pressure
211
212
214
215
223
231
230
232
301
303
313
320
321
322
330
Warning
Shutdown
Warning
Shutdown
Shutdown
Warning
Warning
Warning
Shutdown
Shutdown
Shutdown
Warning
Shutdown
Shutdown
Warning
Hi Coolant Temperature
Hi Coolant Temperature
Low Coolant Water Level
Low Coolant Water Level
Engine Overspeed
Hi DC Voltage
Low DC Voltage
Weak Battery
Hi AC Voltage
Low AC Voltage
Under Frequency
Over Current
Over Current
Short Circuit
Overload
335
337
Shutdown
Shutdown
Reverse Power
Loss Of Excitation
Thresholds
40 PSI / 276 kPa / 2.75 bar @ 1500 RPM
15 PSI / 103 kPa / 1.03 bar @ 800 RPM
35 PSI / 241 kPa / 2.41 bar @ 1500 RPM
10 PSI / 69 kPa / 0.68 bar @ 800 RPM
207 Deg F / 97 Deg C
215 Deg F / 101 Deg C
Low Level @ 800 RPM
Low Level @ 1500 RPM
115% of 1500 RPM i.e. 1725 RPM +/-1 RPM
Batt. Volt > 32 V DC
Batt. Volt< 24 V DC
Rated Volt < 60% i.e. 14.4 V DC
Rated Volt > 130% i.e. 540.8 V AC
Rated Volt < 85% i.e. 353.60 V AC, for 10 Sec.
Rated Freq. < 90% i.e.45 Hz for 10 Sec.
Rated Current > 110% for 60 Sec.
Rated Current > 110% as per PCC IDMT Curve
Rated Current > 175% Instantaneous
Rated Current > 115%, after 5 Sec. The load dump
O/P will get activated.
(-) Kw Power > 10% of Rated Kw for 3 Sec
2 seconds
Initial Calibration / Settings to be Done / Checked While Commissioning any PCC Genset
Initial Frequency Calibration
The PCC's shipped from the factory are configured to operate on 50 Hz (1500 RPM) & for isochronous operation.
1.If the DG set is running on any other speed than 50 HZ, then go to Adjust menu , go to Frequency & by using up & Down arrows se the frequency to 50 Hz.
2. Now go to set up & cal menu on the PCC. Enter the Passcode ( 574).
3. Go to the Meters Menu.Go to frequency, use up & down arrow keys to set the pointer of the analog meter to 50Hz.
4.Save these setting using the save option & then exit.
This completes the frequency setting of the PCC for the Particular set.
Initial Voltage Calibration: Single DG
1. Start the DG set on manual mode
2. Go to the Voltage screen , choose L-L voltage.
3. Using a calibrated Digital Multimeter, Measure the voltage across all the three Phases. This voltage should read 416 V.
4. If this voltage reads less or More on the multimeter --Go to the adjust menu - go to Voltage adjust
--Adjust the voltage using 'Up or Down arrows so that the Digital multimeter reads 416 volts.
5. When the voltage matches 416 volts, save this setting in the PCC.
NOTE : Do not see the voltage on the PCC Voltage screen at this moment.
7. GO to the display calibration mode ----Go to Voltage L12 --- Adjust this display to 416 using up & down arrows.
8. Similarly adjust the remaining 2 phases to 416 V. Save these setting using the save option & then exit.
This completes the Voltage setting & the display settings of the PCC for the Particular set.
Note : If you are having more than one DG.gset with PCC ----The first Disconnect the BUS PT Connector from the PCC sets & perform the same
settings as mentioned above.
Meters Calibration :
skip the steps mentioned below.
2. Go to set up & cal menu on the PCC. Enter the Passcode ( 574).
3. Go to the Meters Menu.
4.Select the phase select button & choose phase L12. Using up & down Arrows match the Voltage Meter pointer to 416 Volts.
5.Similarly adjust the remaining meter readings to 416 volts. Save these setting on the PCC menu & then exit.
This completes the Meters Calibration procedure of the said PCC.
Current Calibration
This calibration is to be done on Load.at least 50% of load is necessary.
1.Start the DG set on Run Mode & close the breaker from PCC.
2.Load the DG set to at least 50 % of the rated load. This load should be read on a calibrated Tong Tester.
4. GO to the display calibration mode ----Go to Current L1 --- Adjust this display of current in the PCC using Up & Down Arrows to the value seen on the tong tester .
5. Similarly adjust the remaining 2 line currents on the PCC using the up & down arrows to the value seen on the tong tester on their respective phases.
Save these setting using the save option & then exit.
Now go to the Power Menu & read the KW reading on the PCC. Manually calculate the 3 Ph power using Formula KW = 1.732 X V X I X Pf. &
cross check if this matches with the PCC reading.
If this doesnot match then the Initial Voltage & current calibration is incorrect.
Redo the entire exercise of Voltage & Current calibration until you get matching results.
PCC Checks/pmp
Factory Settings of PCC

Parameter
Version
Voltage/ Frequency Selection
Prime / Standby
Delta / WYE
S 5 Switch ( On Digital Board)
Start Delay
Stop Delay
Idle Speed
Gov.Regulator Menu
Gov. Gain
Gov Integral
Gov Ramp
Reg Gain
Reg Integral
Reg. VHZ
Set-Up Menu
Cycle Crank
No. Of Cycles
Crank Time - Sec
Rest Time - Sec
System Of Units
Customer Fault 1
Customer Fault 2
Customer Fault 3
Customer Fault 4
EGT - L
EGT - R
Low Coolant LVL
Language
Factory Settings
As per Eng.Model
416V / 50 HZ
Prime Always
WYE always
Awake mode
0
0
800Rpm
Range
100%
100%
1
100%
100%
11
3% to 1276%
33% to
1 to 10
ON
5
15
15
Imperial
Warning
Ground Fault - Warning
Rupture Basin- Warning
High Gen Temo - Warning
No
No
Shutdown
English
ON / OFF
3 to 6
7 to 20
7 to 20
Imperial / Metric
Warning / Shutdown
Warning / Shutdown
Warning / Shutdown
Warning / Shutdown
Yes / No
Yes / No
Warning / Shutdown
English/ Spanish
Parallel -ISO BUS

Sync Time Limit
Pwr Limit
Pwr Limit Time
Perm Win Phase
Perm Win -Time
Sync Gain
Sync Integral
KW Balance
KVAR Balance
KW Gain
KVAR Gain
1st Start Fail
Ramp UNLD Time
Ramp UNLD LEVEL
Ramp Load Time
Loss of Field Time
120
10
3
20
0.5
95
12
165 + 0
0
6
300
10
10
20
10
2
10 - 120
5 to 15
1 to 15
5 to 25
0.5 to 5 seconds
Utility
Base Load
PF Level
KW Govern Gain
KW Integral
KVAR Gain
KVAR Integral
Ramp Load Time
Ramp Unload Time
Multiple / Single
80%
1
100
4
300
200
10
10
Single
20 to 100
0.8 to 1
Deviation if Any
190V to 13.8 KV / 50/60Hz

Prime/ Standby
Delta / WYE
Sleep / Awake
0-300 seconds
0-600 seconds
700-900 Rpm
1 to 32
1 to 15
Multiple / Single
PCC Checks/PMP
PCC - Terminal Strip TB1-1 Details at a Glance

Into The PCC
O/P From PCC to the Main Panel
Into The PCC
O/P From PCC to the Main Panel
A34-P1-19
31
31
PRE-LOW OIL PRESSURE
TB BAT-F1
B+(20A FUSED)
P12-2
SWITCHED B+(10A FUSED)
A34-P1-20
32
32
LOW OIL PRESSURE
GND-ENG
GROUND
A34-P3-19
33
33
COMMON
GND-ENG
GROUND
A34-P1-18
34
34
RETURN
A34-P1-13
REMOTE START
P12-9
35
35
RUPTURE BASIN
A34-P1-7
REMOTE EMERGENCY STOP
CONT HTR1
36
36
A34-P2-10
Common Shutdown(N/O)
CONT HTR2
37
37
A34-P2-9
(COM)
A34-P2-14
38
38
A34-P2-11
(N/C)
A34-P2-13
39
39
(N/C) LOAD DUMP
10
10
Breaker Close (N/O)
A34-P2-12
40
40
COMMON
A34-P2-4
120 OR 240 VAC

(N/O) READY TO LOAD
A34-P2-3
11
11
Breaker Close (N/O)
A34-P2-8
41
41
Common Warning(N/O)
P12-5
12
12
NET POWER(+)
A34-P2-7
42
42
Common Warning (N/O)
P12-6
13
13
NET POWER(-)
A34-P2-5
43
43
Common Warning (N/C)
A34-P2-6
Common Warning (N/C)
P12-7 (RED)
14
14
NET DATA 1
P12-8 (BLACK)
15
15
NET DATA 2
44
44
45
45
P12-1/A34-P1-9
16
16
CUSTOMER FAULT 1
A34-P3-9
46
46
B+IN
A34-P1-12
17
17
A34-P1-6
18
18
CUSTOMER FAULT 2
A34-P3-1
47
47
UTILITY CB AUX
CUSTOMER FAULT 3
A34-P2-16
48
48
A34-P1-16
19
Breaker Trip(N/C)
19
CUSTOMER FAULT 4
A34-P2-2
49
49
Breaker Trip(N/C)
A34-P1-2
A34-P1-10
20
20
FAULT RESET
A34-P1-17
50
50
MASTER START SENSOR/SYNC ENABLE
21
21
ENGINE IDLE
A34-P1-3
51
51
A34-P1-5
LOAD DEMAND/UTILITY SINGLE
22
22
LOW FUEL
A34-P1-11
52
52
CB OPEN/CLOSE INHIBIT
CB POSITION
A34-P3-2
23
23
NOT ON AUTO
A34-P1-4
53
53
A34-P3-10
24
24
PRE-HIGH ENGINE TEMP
A34-P1-22(GREEN
54
54
GREEN(KVAR-)
A34-P3-11
25
25
HIGH ENGINE TEMP
A34-P1-23(RED)
55
55
RED (KVAR+)
A34-P3-12
26
26
OVERSPEED
A34-P1-8(BLACK)
56
56
BLACK (KW-)
A34-P3-16
27
27
OVERCRANK
A34-P1-15(WHITE
57
57
WHITE(KW+)
A34-P3-17
28
28
LOW ENGINE TEMP
A34-P1-1
58
58
SHEILD
A34-P3-18
29
29
LOW FUEL
A34-P2-15
59
59
EXTERNAL LOAD SET +
A34-P1-21
30
30
LOW COOLANT
A34-P2-23
60
60
EXTERNAL LOAD SET -
PCC Checks / pmp
PCC TB1-1 Connectons upto the Main Control Panel

Note : The Left Hand side connections go into the PCC. The Right hand side connections represent the OEM
side connections or the Customer side connections to be taken out on the Main panel
Sample Drawings related to each terminal of the 60 pin terminal strip are given below.
All the connections shown need not be used, the Mandatory connections are mentioned in BOLD
Positive 24 VDC
TB BAT-F1
TB1
B+(20A FUSED)
SWITCHED B+(10A FUSED) This supply 24vdc will be available only when engine
starts running and can be used to drive.
Sample drawing for running Raw water Pump
NO 1
R1
TB1
M
P12-2
2
2
P12-2
This is a permanent + 24VDC supply --can be used for looping

1
2
Common B-ve ( TB1-3
Engine Ground
GND-ENG
GND-ENG
TB1
230V
any Ground looping in the PCC Panel can be taken from here
any Ground looping in the PCC Panel can be taken from here
Remote Start ( Mandatory)

TB1
A34-P1-13
5
5
REMOTE START ( IF PCC RUN /OFF/AUTO Switch is in AUTO &
if Ground is connected to terminal No.5 then engine will remotely start

Main Panel
GND-ENG
A34-P1-13
TB1
Remote Start Switch
Sample Drawing ofr Remote start for AMF Application

3
3
GND-ENG
A34-P1-13
Main Panel
Voltage
Sensing
Relay
TB1
Remote Emergency Stop(
R
Y
B
N
SEB SUPPLY
Mandatory)
Main Panel
GND-ENG
A34-P1-7
TB1
3
6
Remote Emergency
stop Switch
if Ground is connected to terminal No.6

then engine will stop,PCC will indicate
Emergency Stop.
PCC Checks/PMP
Common Shut Down (
Mandatory)
A34-P2-10
7
8
9
A34-P2-9
A34-P2-11
7
8
9
(N/O) Common shut down

(COM) Common
(N/C)
TB1
Common shut Down ---Indication on Panel
TB1
A34-P2-10
7
7
A34-P2-9
TB BAT-F1
Main Panel
If the Engine Shuts down due to any fault

then the "NO" contact between 7 & 8
TB-1 -3
will close & indicating Lamp on the panel
24Vdc
will glow.
Note : Either Use Indicating lamp or Anounciator ( As shown ahead)
Sample Drawing of Common shut Down ---Audible Hooter

TB1
A34-P2-10
7
7
A34-P2-9
If the Engine Shuts down due to any fault

then the "NO" contact between 7 & 8
will close & Hooter on the panel
will turn ON
24Vdc
TB BAT-F1
1
24vdc or 230 vac
supply for hooter
Breaker Control
A34-P2-4
A34-P2-3
( Mandatory)
TB1
10
10
11
11
Sample Drawing for Breaker Closing

TB1
A34-P2-4
10
10
A34-P2-3
TB BAT-F1
11
11
(N/O)
Breaker Closing
(N/O)
Aux.NC contact
of Brkr
Closing Coil
of Brkr
24 vdc supply from TB1-1
The NO contact between 10 & 11 will close when:

A----( Single & NON Paralleling Sets or DEAD BUS)
1.In Run Mode, when Engine Speed & Voltage reach 90% of Rated & When the Breaker Close button on PCC is Pressed
2.In Auto Mode,When Remote start command is given & only when Speed & Voltage reach 90% of rated Automatically
OR
B ------Parallel Operated Sets
1.In Run Mode, when Engine Speed & Voltage reach 90% of Rated & only When the synchronise conditions are
met (I.e * Indication on the Synchronouscope screen of PCC) & breaker Close button on PCC is Pressed
2.In Auto Mode,When Remote start command is given & only e synchronise conditions are met , Automatically
Net Work Connections

Net Work Connections --Not to be used for Standard CIL supplied Gensts
TB1
P12-5
NET POWER(+)
12
12
P12-6
NET POWER(-)
13
13
P12-7 (RED)
NET DATA 1
14
14
P12-8 (BLACK)
NET DATA 2
15
15
PCC Checks/PMP
CUTOMER FAULTS 1,2,3 & 4 ( Earth Fault Protection Mandatory , Others Optional)
TB1
P12-1/A34-P1-9
CUSTOMER FAULT 1 ------Default Programed as Customer Fault 1 --shutdown
16
16
A34-P1-12
CUSTOMER FAULT 2 ------Default Programed as Ground Fault--Shutdown
17
17
A34-P1-6
CUSTOMER FAULT 3 ------Default Programed as Day Tank--Shutdown
18
18
A34-P1-16
CUSTOMER FAULT 1 ------Default Programed as High Gen Temp--Shutdown
19
19
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 Earth Fault
A34-P1-12
17
17
GND-ENG
Whenever there is an Earth fault,the relay will pick up & the NO contact of the relay will connect Ground to Terminal No.17
The PCC will now display Ground Fault & will trip the engine (since it it programed for Shutdown)
Example No. 2
If the Circuit Breaker trips due to an internal electrical fault 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
16
16
Aux. Contact of Breaker
GND-ENG
3
Main Panel
Fault Reset: This can be use to reset Warning Faults from Remote or Main Panel
TB1
Main Panel
A34-P1-2
FAULT RESET
20
20
When terminal No 20 is grounded ,the
A34-P1-2
20
20
warning fault from a remote location can be
Fault Reset
reset.
Switch
GND-ENG
3
3
Engine Idle
A34-P1-10
TB1
21
21
A34-P1-10
TB1
21
21
Engine Idle
Main Panel
GND-ENG
Eng. Idle
Switch
Grounding terminal No. 21 will take the

engine to Idle Speed. (700-900)
Note :By default engine speed will remain
at 1500RPM
PCC Checks/PMP
Low Fuel : Not in CIL Scope

22
22
TB1
A34-P1-5
A34-P1-10
22
22
GND-ENG
Low Fuel
Fuel Tank
Grounding terminal No. 21 will initiate

Low fuel warning on the PCC.
Float Switch Note :Float Switch is not a Standard scope
of supply
TB1
Anounciator Outputs From PCC

TB1
A34-P3-2
23
23
A34-P3-10
24
24
A34-P3-11
25
25
A34-P3-12
26
26
A34-P3-16
27
27
A34-P3-17
28
28
A34-P3-18
29
29
A34-P1-21
30
30
A34-P1-19
31
31
A34-P1-20
32
32
A34-P3-19
33
33
A34-P3-2
TB1
23
23
A34-P3-10
24
24
A34-P3-11
25
25
A34-P3-12
26
26
A34-P3-16
27
27
A34-P3-17
28
28
A34-P3-18
29
29
A34-P1-21
30
30
A34-P1-19
31
31
A34-P1-20
32
32
A34-P3-19
33
33
TB BAT-F1
NOT USED
A34-P1-18
P12-9
TB1
34
34
35
35
Mandatory Anounciations :
1.High engine Temp.
2.OverSpeed
3.Over Crank ( Only for AMF Sets)
4.Low Coolant
5.Low Oil Pressure
On any of the above fault the No contact associated
with that fault will close &24VDC will be applied to the
particular anounciator Window
NOT ON AUTO
PRE-HIGH ENGINE TEMP
HIGH ENGINE TEMP
OVERSPEED
OVERCRANK
LOW ENGINE TEMP
LOW FUEL
LOW COOLANT
PRE-LOW OIL PRESSURE
LOW OIL PRESSURE
COMMON
16 Window Anounciator
O.S
Not
in Auto
PRE
HWT
HWT
Over
Crank
L.E.T
LCL
PRE
LOP
LLOP
Rdy to
load
OVR
Load
Com.
Sht.Dn
Com.
WRN
Spare
Spare
Spare
24Vdc from terminal No.1
RETURN
RUPTURE BASIN
Control Box Heater ---Not In STD Scope of Spply

TB1
CONT HTR1
36
36
120 OR 240 VAC
CONT HTR2
37
37
PCC Checks/PMP
Ready To Load : This NO Contact is activated by PCC when the Frequency & Voltage reach 90% of Rated.
This can be used for Anounciation or can be used for Advanced Load Management system.
TB1
A34-P2-14
READY TO LOAD ( Anounciator)
38
38
A34-P2-12
TB BAT-F1
40
1
40
1
COMMON
24VDC from Terminal No 1.
Load Dump : This No Contact is activated by the PCC whenever there is an overload condition
This can be used for Anounciation or can be used for cutting off non essential loads if wired up.
TB1
A34-P2-13
LOAD DUMP (Anounciator) or to a Relay for cutting off non essential loads in an overload
39
39
condition
COMMON
40
40
24 vdc supply from terminal no.1
TB BAT-F1
1
1
Common Warning
A34-P2-8
A34-P2-7
A34-P2-5
A34-P2-6
( Mandatory Announciation)
TB1
41
42
43
44
41
42
43
44
41
41
42
42
(N/O)
(N/O)
(N/C)
(N/C)
Common Warning ( Anounciator)

TB BAT-F1
There are two set of Contacts given for Common Warning. These contacts change their state whenever there is any
warning Fault on the PCC,
The samle drawing shown above is wired up using NO contact. This contact is activated by the PCC whenever there
is any Warning Fault. Thus 24vdc gets connected to the Anounciator for Indication.
Utility Paralleling Connections (

TB1
A34-P3-9
46
46
A34-P3-1
47
47
A34-P3-9
TB BAT-F1
A34-P3-1
Mandatory For Utility Paralleling ONLY)

B+IN
UTILITY CB AUX
TB1
46
46
1
For Paralleling the PCC Genset with the Utility, give 24vdc directly to
terminal No.46
This is for the PCC to understand that it has to Parallel with Utility.
TB1
47
47
Aux. Contact of the Utility Breaker
GND-ENG
3
An Aux.NO contact of the Utility Breaker is used which connects the Ground to
terminal No.47 when the utility breaker closes
PCC Checks/PMP
Breaker Tripping ---- Use Shunt Trip Coil Only ( Coil Rating 24VDC)
TB1
A34-P2-16
(N/C)
48
48
A34-P2-2
(N/C)
49
49
Mandatory
Bkr. Aux.N/O
A34-P2-16
TB1
48
48
A34-P2-2
49
49
Shunt Trip Coil

of Brkr
TB BAT-F1
NC contacts are provided foe tripping the breaker. These contacts are activated by the PCC no sooner the engine speed
& voltage reach 90% of the rated.
Master First Start Sensor / Sync Enable

TB1
A34-P1-17
MASTER START SENSOR/SYNC ENABLE
50
50
Master First
Start Unit
A34-P1-17
50
50
This is used for Multiple Engines with PCC in island mode of operation. This unit gives pulsed o/p to the Genset to be
started first online.Not a Standard scope of supply ( Optional)
FOR SINGLE SET With UTILITY PARALLEL mode follow the drawing Below
TB1
50
50
By giving 24vdc to this terminal when single set is paralled with utility,
the Synchroinser is enabled
TB BAT-F1
1
1
Load Demand / Utility Single

TB1
A34-P1-3
51
51
FOR MULTIPLE SETS : When ground signal is given to this terminal then the Genset will slowly transfer the load to the
other sets & open its breaker, & go into the cool down cycle ( Stop Delay as set on PCC) & then shutdown with a
message on PCC " LOAD DEMAND SHUTDOWN".
When ground to this terminal is removed, then the genset will start automatically, close its breaker after synchronising &
start taking its share of load.
NOTE : This function only operates when the PCC is in AUTO Mode
A34-P1-3
GND-ENG
TB1
51
51
3
Main Panel
UTILITY SINGLE MODE : Direcly conect Ground terminal to terminal No.51.

TB1
A34-P1-3
51
51
GND-ENG
PCC Checks/PMP
Circuit Breaker Open / Close Inhibit: ( Mandatory)

This is used when it is required to work on the the Ckt breaker / Busbars for maintenance to ensure that breaker doesnot
close even if the PCC is set in AUTO mode.
To Inhibit the breaker closure apply Ground to terminal No.52
A34-P1-11
52
52
CB Open/Close Inhibit
If the Breaker is Closed & if ground is
applied to terminal No.52 this will result in
TB1
Main Panel
opening the breaker
A34-P1-11
52
52
Breaker Closure Inhibit
through Switch
GND-ENG
3
TB1
Circuit Breaker Position : (Mandatory)

Giving a ground through the Aux. NO. contact of the Breaker will ensure that the Breaker is physically
closed. If this feedback doesnot come to the PCC then the Engine will shutdown on "Fail to Close' Fault.
TB1
A34-P1-4
53
53
CB Position
A34-P1-4
Main Panel
TB1
53
53
Aux. Contact of Genset Breaker

GND-ENG
Load Share Lines(

A34-P1-22(GREEN)
A34-P1-23(RED)
A34-P1-8(BLACK)
A34-P1-15(WHITE)
A34-P1-1
Mandatory for Parallel Operation)

TB1
54
55
56
57
58
54
55
56
57
58
GREEN(KVAR-)
RED (KVAR+)
BLACK (KW-)
WHITE(KW+)
SHEILD
For Parallel Operation with Multiple PCC Sets: Interconnect these terminals form one PCC set to the other
as shown below
DG Set No 1.
DG Set No.2
DG Set No3.
A34-P1-22(GREEN)
54
54
54
54
54
A34-P1-23(RED)
55
55
55
55
55
A34-P1-8(BLACK)
56
56
56
56
56
A34-P1-15(WHITE)
57
57
57
57
57
A34-P1-1
58
58
58
58
58
TB1
Note : Use Four Core Sheilded 18 GA stranded cable only
54
55
56
57
58
For the Set to be operated on Droop Mode OR PCC set to Be Paralleled with Non PCC Set
TB1
A34-P1-22(GREEN)
54
54
5 K ohms
This is for Speed droop
A34-P1-23(RED)
55
55
A34-P1-8(BLACK)
TB1
56
56
A34-P1-15(WHITE)
57
5 K ohms
This is for Voltage Droop

57
PCC Checks/PMP
By installing the resistances in these terminals, the PCC will operate in Droop Mode.
NOTE : This Just enables the PCC for Droop operation, to set the exact % of droop please refer the Graph of % Speed
Droop Vs KW Loadshare Gain Or follow the tables given below :
Table for Speed Droop
Table for Voltage Droop
Desired % Droop KW Load Share Gain
1
2
3
4
5
% Droop
4
6
8
10
12
3
4
5
6
KVAR Load Share Gain

300
330
420
480
Procedure for Droop Paralleling Setup

1.Insert the 5 K Ohm resistor as shown above.
2. Set KW & Kvar balance = 0 ( In the PCC Parallel set , Isolated bus Menu)
3. Set the No Load Voltage & frequency to the desired value.
4. Set KW & KVAR load share gains to the desired value ( In the PCC Parallel set , Isolated bus Menu)as per the tables
given above.
NOTE : All PCC's are by Default set for Isochronous operation.
Inputs to Control Generator Load in Utility Parallel Mode ( Mandatory for Utility Paralleling)
EXTERNAL LOAD SET +
59
59
A34-P2-23
EXTERNAL LOAD SET 60
60
TB1
0-5Vdc input voltage when given to these terminals ( When Paralleled with Utility Mains), the Load on the Generator can
be either increased or decreased.
A34-P2-15
+ 5 vdc Ve
A34-P2-15
59
59
A34-P2-23
60
60
TB1
0-5vdc Source
- Ve
PCC Checks/PMP
Instrumention Required for PCC Commissioning

1
2
3
4
5
PCC Manual
Calibrated & standards Clip On meter
Phase Sequence Meter
Wrist Strap
Alternator Control Panel as built Wiring Diagram
Requirment in the Control Panel
1
2
3
4
5
6
7
8
9
10
Kwh meter
Electricaly Closing / tripping / Spring charging Circuit Breaker.
16 Channels Alarm Annunciator.
High db Hooter for Audio Alarm.
Earth Fault Protection Relay
Selector Actuator switch for Remote Start / Stop.
Selector Actuator switch for Breaker Open / Close.
Selector Actuator switch for DG Unloading
Emmergency trip P.B.
Lamp test / Acknoledge / Reset Push Button
11
12
Df / Dt protection Relay in case of Utility Paralleling.
* 0-5 V DC regulated variable power source in case of Utility Parralleling
Cable requirements for Interconnection Between PCC & Control Panel

1
2
3
2 Nos. 16 core 1.5 sq.mm F l e x i b l e cable from PCC Terminal Strip to

Control Panel.
4 core 1.5 sq.mm. F l e x i b l e cable form DG common (load) Bus to PCC
Bus PT Module.
4 core 1sq.mm. copper shielded cable from one PCC terminal strip to other
PCC terminal strip for Load Sharing Lines.
* - Kindly contact electronics Cell for this requirement.
Sample GA Drawing of the Control Panel to be supplied with PCC Genset
Busbar Chamber
H
CB ON CB OFF
Kwh
E/F
AA
ASS
DCV
DCA
PB1
PB2
PB3 VSS
P.B. SA1 SA2 SA3 SA4 S1
CB
AMF / SYN & Iso-Load Sharing Control panel with PCC

CB - EDO Type Circuit Breaker With U/V Coil, Shunt
Trip Coil, Closing Coil, & C.B. Tripped P.F. contact
E/F - Earth Fault Relay
VSR - Mains Voltage Sensing Relay
Battery Charger
Kwh - Energy Meter
A - Ammeter & Ammeter Selector Switch
V - Voltmeter & Voltmeter Selector Switch
DCV - DC Voltmeter for Battery Voltage
DCA - DC Ammeter for battery charging Current.
CTs - For Metering & E/F Protection
S1 - Battery Charging Mode Selector Switch
CB ON/OFF - Indicating Lamp
AA - 16 Windows Alarm Annunciator
PB - Emergency Stop Push Button
PB1,2,3 - Lamp Test/ Ack / Reset Push Button
SA1 - Engine Start / Stop Switch
SA2 - Ckt Bkr. Close / Open Switch
SA3 - DG Load / Unload Switch
SA4 - Rated/Idle Switch
K1 - Relay for Closing C.B.
K2 - Relay for Tripping C.B.
F1,F2,F3 - 1 Amp Fuses for giving Supply to Bus PT Module
(From Breaker O/G Supply RYBN)
H - Hooter
Mandatory Connections from the PCC to the Main panel for :

Single PCC Set Without AMF
Single PCC Set With AMF
Multiple PCC Sets for Parallel Operation
Single PCC Set with Droop Operation
Single PCC Set Paralleled with Non PCC Sets
Single PCC Set Paralleled with Utility
Multiple PCC Sets Paralleled with Utility
Bare Minimum Mandatory Connections :
Single PCC Set Without AMF
1. Remote Start Switch on Main Panel
2. Remote Emergency Stop on Main Panel
3. Common Shutdown Indication on Main Panel ( Hooter)
4. Customer Fault No.2 -Earth Fault Relay
5. Not On Auto Indication on Main Panel
6. High Engine Temp. Indication on main Panel
7. Over Speed Indication on Main Panel
8.. Low Coolant Level Indication on Main panel
9.. Low Lube Oil Pressure Indication on main Panel
10. Closing Coil connections for Breaker ( 24vdc Closing Coil)
11.Common Warning Indication on Main Panel (Hooter)
12. CB Open /Close Inhibit Switch on Main Panel
13. Shunt Trip Connections for Breaker ( 24Vdc Shunt Trip Coil)
Multiple Sets for parallel Operation

14.Load Share Line Interconnections from Set to set
Single PCC Set With AMF

1.Remote Start Connections Wired up through V. S. Relay
10.Over Crank Indication on Main Panel
11. Closing Coil for Breaker ( 24vdc Closing Coil)
14. Shunt Trip coil for Breaker ( 24Vdc Shunt Trip Coil)
Single PCC Set with Droop Operation
13. Shunt Trip coil for Breaker ( 24Vdc Shunt Trip Coil)
14. 5 K.Ohm Resistances between terminals 54,55 & 56,57
PCC Checks/pmp
Mandatory Connections from the PCC to the Main panel for :

Single PCC Set Paralleled with Non PCC Sets
14. 5 Kilo Ohm Resistances between terminals 54,55 & 56,57
15.Synchronising panel
Single PCC Set Paralleled with Utility

13. Shunt Trip for Breaker ( 24Vdc Shunt Trip Coil)
14.Ground Connection Of terminal No.51
15.24Vdc to Terminal no.50 to enable Synchroniser
16.Ext.l Load set terminal Nos.59 & 60 ( 0-5 Vdc) I/p to PCC
17.24Vdc Supply to terminal No.46.
18.Ground conn. through Utility Breaker Aux. NO Contact
Multiple PCC Sets Paralleled with Utility

14.Load Demand switch ( Terminal No.51)
15.External Load set terminal Nos.59 & 60 ( 0-5 Vdc) I/p to PCC
16.24Vdc Supply to terminal No.46.
17.Ground connection through Utility Breaker Aux. NO Contact
PCC Checks/pmp
Parameters to be logged on Hourly basis

Voltage
DG
No. Time
Cool.Te
mp.
Eng.R No. of Lube Oil Lube Right/Le Batty.
un 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

PCC Commissioning Guide Lines

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PCC Commissioning Guide Lines

Uploaded by

Copyright:

Available Formats

Index

1. Cold Checks - Part Nos. of Various Components of PCC.

Commissioning report for PCC Engine

Name of the Commissioning Engineer :

Name of the OEM Engineer

ONAN Part No. Sr.No.

PCC FUSES-- Check if in doubt

Main Alternator Wiring Harness :

PCC Commissioning checks/pmp

PCC - Fault Thresholds

Low Lub Oil Pressure

PCC Commissioning checks/pmp

Factory Settings of PCC

Parallel -ISO BUS

190V to 13.8 KV / 50/60Hz

PCC - Terminal Strip TB1-1 Details at a Glance

O/P From PCC to the Main Panel

Into The PCC

O/P From PCC to the Main Panel

PRE-LOW OIL PRESSURE

SWITCHED B+(10A FUSED)

LOW OIL PRESSURE

REMOTE EMERGENCY STOP

(N/C) LOAD DUMP

Breaker Close (N/O)

120 OR 240 VAC

Breaker Close (N/O)

Common Warning (N/O)

Common Warning (N/C)

Common Warning (N/C)

MASTER START SENSOR/SYNC ENABLE

LOAD DEMAND/UTILITY SINGLE

PRE-HIGH ENGINE TEMP

HIGH ENGINE TEMP

LOW ENGINE TEMP

EXTERNAL LOAD SET +

EXTERNAL LOAD SET -

PCC Checks / pmp

PCC TB1-1 Connectons upto the Main Control Panel

This is a permanent + 24VDC supply --can be used for looping

Common B-ve ( TB1-3

Remote Start ( Mandatory)

REMOTE START ( IF PCC RUN /OFF/AUTO Switch is in AUTO &

if Ground is connected to terminal No.5 then engine will remotely start

Remote Start Switch

Sample Drawing ofr Remote start for AMF Application

Remote Emergency Stop(

if Ground is connected to terminal No.6

Common Shut Down (

(N/O) Common shut down

If the Engine Shuts down due to any fault

Sample Drawing of Common shut Down ---Audible Hooter

If the Engine Shuts down due to any fault

Sample Drawing for Breaker Closing

The NO contact between 10 & 11 will close when:

Net Work Connections

Grounding terminal No. 21 will take the

Low Fuel : Not in CIL Scope

Grounding terminal No. 21 will initiate

Anounciator Outputs From PCC

24Vdc from terminal No.1

Control Box Heater ---Not In STD Scope of Spply

24VDC from Terminal No 1.

Common Warning ( Anounciator)