Cummins Pcc3 3 Powercommand Controltechnical Training

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Participant Guide

Controller
PowerCommand 3.3
Phase 1 Release

CMT6068-EN-PG
Created 10/2008

This is the cut pages sample. Download all 394 page(s) at: ManualPlace.com
 Revision History
v1.00 (10/2008)
1. Initial draft for product launch QTQ 2008

Cummins, Onan, and PowerCommand are all registered trademarks of Cummins Inc. InPower is a trademark of
Cummins Inc. Windows� is a trademark of Microsoft Corporation.

Copyright � 2006−2007 by Cummins Power Generation

 PowerCommand Control 3300 & HMI 320
Table of Contents

Preface: I
This generation of Genset controls will use a new naming system. The preface
will identify the various controls and combinations that make up the new control
family.

Introduction: II
The introduction describes the audience, the purpose, and the structure of the
training module.

Introduction to the PowerCommand Control 3.3, the PowerCommand

Control 3300 control board and its standard options: 1
This lesson presents an overview of the PowerCommand Control 3300. The
participant will learn to identify the main features and components of the
PowerCommand Control 3300, its standard features and options.

PowerCommand 3.3 & HMI 320 Operation and Service Menus: 2

This lesson presents the Setup and Calibration menu system used in the PCC3.3
and HMI 320

PowerCommand Control 3.3 Sequence of Operation: 3

This lesson presents sequence of operation and feature operation and
performance information about the PowerCommand Control 3300.

PowerCommand Control 3300 Installation: 4

This section provides installation information, procedures, and requirements for
the PowerCommand Control 3300.

PowerCommand Control 3300 Control Setup and InPower: 5

This lesson covers the basic adjustments and configuration details using InPower
as the setup tool. This section addresses the non-paralleling functions.

PCCNet Network for the PC3.3: 6

This lesson presents an overview of the PCCNet network and an introduction to
the unique PCCNet network and components used with the PCC 3300,
PowerCommand Control 3300 ModBus: 7
This lesson presents the ModBus communications feature on the PCC 3300, and
introduces some of the advanced ModBus abilities offered in this control.

PowerCommand Control 3300 PGICAN: 8

This section provides familiarization with the J1939 CAN communications
available on the PCC 3300, for use with Full Authority Engine controls.

PowerCommand Control 3300 Paralleling Introduction: 9

This lesson introduces the various paralleling features and abilities offered in
this control.

PowerCommand Control 3300 Paralleling - Standalone: 10

This lesson covers setup, operation and configuration of PCC 3300, and HMI
320 when applied in a single unit non paralleled configuration.

PowerCommand Control 3300 Paralleling - Synchronizer: 11

This lesson covers the synchronizer operation and configuration of PCC 3300,
and HMI 320 when applied in a paralleled and non paralleled configuration.

PowerCommand Control 3300 Paralleling – Isolated Bus: 12

This lesson covers setup, operation and configuration of PCC 3300, and HMI
320 when applied in a multiple unit paralleled configuration that is completely
separated from any utility (Mains) connection.

PowerCommand Control 3300 Paralleling Troubleshooting: 13

This lesson presents tools, problem scenarios, and solutions that are commonly
encountered when encountering operation problems with the PC 3.3.

Glossary: 14
This section lists the most common terms used throughout this training module
pertaining to the PowerCommand family of Controls.

Activities: 15
Copies of Participant In-class and Homework Activities, and each Section Quiz
are found in this section.

Appendix: 16
This section contains several useful guides and lists, including the ModBus
register list.
Diagrams: 17
This section has copies of all prints used in the course.

Module Comment Sheet: 18

Participants are requested to turn in the Comment Sheet at the end of the course
to help update the course materials as needed.

Participants have a copy of this sheet as the last page in their Participant Guide,
but if you need a master we provide one here.
Preface:
The new generation of PowerCommand Controls will use a new easier to understand naming
system. The new controls are modular and therefore it can be confusing to know what feature are
being used it the genset control system is only referred to by the control board model. There are
several combinations of control boards and HMIs

Naming System
PowerCommand 1.X PowerCommand 2.X PowerCommand 3.3

PCC 1302 PCC 2300 PCC 3300

PowerCommand 1.1 PowerCommand 2.2 PowerCommand 3.3

HMI 211 HMI 220 HMI 320
PowerCommand 1.2 HMI 112(w/PF) or HMI 114, HMI 113 Phase 1 (FAE)
HMI 220 Phase 1 (FAE)

PowerCommand 2.2 PowerCommand 3.3

HMI 220 HMI 320
PowerCommand 2.3 HMI 112 or HMI 114, HMI 113
AUX 101/102, AUX 104
HMI 320
HMI 112 or HMI 114, HMI 113 Phase 2 (Hydra Mech.)
AUX 101/102, AUX 104
Phase 2 (Hydra Mech.)

Naming Chart - PCC 1.X, 2.X, 3.X Naming System

The above naming chart shows the naming system for the new series of controls, PowerCommand
Control 1.X, 2.X, and 3.X. The X represents the HMI Operator Panel you have with the series of
control board.

Here is a list showing how they are structured:

1.X = PCC 1302 control board

2.X = PCC 2300 control board
3.X = PCC 3300 control board

Participants’ Guide Title & Introduction Page6

 X.1 = HMI 211
X.2 = HMI 220
X.3 = HMI 320

The PCC 2.X and 3.3 will be released in a couple of different phases. These phases will support
certain devices as depicted in the visual above and in more detail throughout this training course.

The 2.X, & 3.X series designation will identify the high level of control ability however, there will
be several subcategories of different control board features. The first category of 2.X, & 3.3
controls will only work on FAE controlled engines. The next category will be used with hydra
mechanical engine applications. As new features and categories develop, additional training
courses will also develop.

Series 2.X with FAE control training and 3.3 with FAE control training will be the most
comprehensive training programs about the PCC 2300 and PCC 3300 controls. The training
programs that follow will concentrate on the specific feature enhancements, HMI, or accessory
developments relative to the specific Series. The Series 2.X & 3.3 FAE training will be a
prerequisite to any future training program

It has been planned that the PCC 3300 & HMI320 combination will be the only combination
available for the high level paralleling gensets. The plan is to only have a PC 3.3 control and never
a PC 3.2 or PC 3.4.

Participants’ Guide Title & Introduction Page7

Introduction

Welcome!

Welcome to the Particpants Guide for the PC 3.3 & PowerCommand Control 3300 module! This
guide was written by the Cummins Power Generation Technical Training department for your use
and reference.

We suggest you read through the entire Introduction to become familiar with the guide’s
structure. Then, just follow the step-by-step instructions for each lesson.

Module Purpose

The purpose of the PC 3.3 & PowerCommand Control 3300 module is to help you, the Cummins
Power Generation distributor service technician, understand the PC 3.3 & PowerCommand Control
3300 which is going to replace the specialized gen set control modules. It is also expected that the
PowerCommand Control 3300 will be used on many of the Cummins−powered gensets with Full
Authority Engines (FAE) and the hydro−mechanical fuel systems.

With this information, our technical force will be better prepared to meet our customers’
varying needs.

Module Audience

The primary audience for this module is Cummins Power Generation distributor power
generation technicians. We assume participants have previous experience with or knowledge of
integrated generator set AC and DC control operation, troubleshooting, and repair procedures. It
is a prerequisite to attend a PC 2.X course prior to attending this course.

Module Structure

This module contains lessons on related topics. Each lesson follows a carefully designed training
format, including a warm up, presentation, and activity (or exercise).

Lesson Format

Warm ups help participants focus and begin thinking about the lesson topic. The presentation
portion of the lesson is where participants receive new information. The activity & Quiz follows
the presentation; it gives participants the chance to practice new skills or work with new ideas.

Participants’ Guide Title & Introduction Page8

Module Assessment

After completing all the lessons in the module, participants will complete a module assessment.
The module assessment lets us evaluate the level of knowledge participants have on the topic after
completing the module.

Module Comment Form

Participants will also complete a module comment form. This form gives participants the chance to
comment on the usefulness and effectiveness of the training module and make suggestions for
improvements.

We will use the results from the module assessments and module comment forms to help us
determine if there is a need to modify the module.

Please mail the module assessments and comment forms to Cummins Power Generation’s Sales
and Technical Training department as soon as possible after the training session. The address is:
Cummins Power Generation
Technical Training OUJ3
1400 73rd Avenue NE
Minneapolis, MN 55432

Preview the lessons−−Review the lesson objectives and read through the trainer’s instructions. Use
the Notes column to write any comments or additional information you want to include.

Participants’ Guide Title & Introduction Page9

PCC 3.3 & PowerCommand Control 3300 Section last page

THIS PAGE IS INTENTIONALLY LEFT BLANK

Participants’ Guide Section Last Page

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

PowerCommand
3.3
Section 1 Introduction to the
PowerCommand Control 3300

Visual 1-1 PowerCommand Control

Participants’ Guide Section 1 Page1

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

Section 1

Introduction to the PCC 3.3, the PowerCommand

Control 3300 control board and its options.
Estimated Time: 2.5 hours

Participants’ Guide Section 1 Page2

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

Warm Up

In this lesson we are going to learn about the PowerCommand Control 3300 and its
components

We will see the standard and optional components, and learn their functions.

Objectives

After completing this lesson, the participants should be able to:

• Identify the PCC 3.3 standard components.

• Identify the PCC 3.3 & PowerCommand Control 3300 optional components.
• Describe the main functions of the PowerCommand Control 3300 and its features.
• Describe the standard operator interface (switch and LED).
• Use the Operator menus on the optional control panel.

Participants’ Guide Section 1 Page3

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

PowerCommand Control 3300

ƒ Premium Paralleling Genset Control

ƒ Integrated J1939 CAN Link for FAE sets

ƒ Optional governor amp. for non-FAE sets (Phase 2)

ƒ Separate module for AVR (Voltage Regulation)

ƒ Common wiring harness with “3-series” controls

Visual 1-2 Introduction to the PowerCommand Control 3300

Participant’s Text Notes:

The PowerCommand Control 3300 is a

highly integrated control providing
complete genset control and protection.

The Phase 1 release of this new control will

support Lean Burn Natural Gas (LBNG)
gensets and Diesel FAE engine-driven
sets

The phase 2 release will support a governor

drive module which is needed for diesel
sets equipped with electric actuator.

Participants’ Guide Section 1 Page4

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

PCC 3300 Control Boards

AUX 103 Power Stage

PCC 3300 Base Board

Visual 1-3 The PCC 3300 Control Board

Participant’s Text Notes:

The PCC 3300 board uses the same large

potting shell as used in the MCM3320
and PCC 2300.

The control board provides many connectors

for input and output information.
• Many of the connectors are common
among all “3-series” controls.
This is the primary board of the control
system and is call the Base board.

Participants’ Guide Section 1 Page5

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

Participant’s Text Notes:

There are14 connection points on the PCC

3300:

• J Connections − Common Connectors.

• TB Connections − Customer
Connections and Feature inputs.
3 CT connection on the PCC 3300:

3 connection points on the AUX 103 Power

Stage:

• J17 − Excitation Output (X1, X2)

• J18 − AVR Power (PMG)
• J19 − AVR Control Communications

Participants’ Guide Section 1 Page6

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

PCC 3300 Connectors

TB7- Bus Voltage Sense Onboard BUS CTs
DSx LED Status Indicators J12- Genset CT Input

TB-9 – Analog I/O J22- Genset

Voltage Sense

TB-15 – ModBus/RS485

J20- Genset
Connections
J14 – Service Tool Port
J26- AUX 103
Connector
TB10 – Breaker Status
Connections J-25 Display
Connections

TB-8 Customer TB-5 – Breaker Control TB-3 – Customer TB-1 – Customer

Connections Connections Input/Output Connections

Visual 1-4 Control Board Connectors

Participant’s Guide Notes:

DSx − Status indicators: DS3 flashes to let

you know the control board is operating
properly.
CT1, 2, & 3 − Onboard Bus CTs
J12 − Generator CT inputs
J14 − Connection port for InPower.
J20 − Genset Accessories connection
J22 − Genset voltage sense
J25 − Operator Panel (HMI) connection
J26 − AUX 103 & Interconnect

Participants’ Guide Section 1 Page7

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

PCC 3300 Connectors

TB7- Bus Voltage Sense Onboard BUS CTs
DSx LED Status Indicators J12- Genset CT Input

TB-9 – Analog I/O J22- Genset

Voltage Sense

TB-15 – ModBus/RS485

J20- Genset
Connections
J14 – Service Tool Port
J26- AUX 103
Connector
TB10 – Breaker Status
Connections J-25 Display
Connections

TB-8 Customer TB-5 – Breaker Control TB-3 – Customer TB-1 – Customer

Connections Connections Input/Output Connections

Visual 1-4A Control Board Connectors

Participant’s Guide Notes:

TB1 − Customer I/O connections

TB3 − Customer I/O connections
TB5 − Circuit breaker control connection
TB7 − Bus/utility voltage sense
TB8 − Customer I/O connections
TB9 − Analog control I/O connections
TB10 − Circuit breaker control connection
TB15 − RS485 / ModBus Communication
connection

Participants’ Guide Section 1 Page8

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

AUX103 AVR Power Stage

J19 – Interconnection
to PCC 3300
Base Board
J17 – Field Output

J18 – Power Input

Chassis Ground
Wire
5

Visual 1-5 Automatic Voltage Regulator Module

Participant’s Text Notes:

The AVR Module is used with all PC 3.3

gensets.
There are 3 connectors on the board.
ƒ J17 provides the excitation output.
ƒ J18 provides the power input
ƒ J19 connects to J26 on the 3300 Control
Board.

Participants’ Guide Section 1 Page9

Cummins Pcc3 3 Powercommand Controltechnical Training
Full download: http://manualplace.com/download/cummins-pcc3-3-powercommand-controltechnical-training/
PCC 3.3 & PowerCommand Control 3300 Introduction and Options

HMI 320 Operator Panel

Visual 1-6 Optional operator panel

Participant’s Text Notes:

HMI 320 Operator Panel is also highly

populated with display and control
features.
ƒ Multiple LEDs for status and operator
information
ƒ Large graphical display for menus and
information display.
ƒ Multiple buttons for operation and
control.
Same physical size and layout as the HMI
220 but has a much larger display.

Participants’ Guide Section 1 Page10

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