2012

PC3.3 Commissioning Guidelines

Controls Team:
Vijayaraj D
Akhilesh Sorty
Nidhi Gautam
Ankit Bhagat
Cummins India Ltd DBU
2/29/2012
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INDEX

TOPICS PAGE

Cold Checks: - Part no’s 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

HT application setup 32-33

Commissioning Report 34

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Part Numbers of components used in PC 3.3

Sl Common Parts Un Common Parts

No Part No Description Part No Description
1 4053490 Adaptor "O" ring A035C915 Coolant LVL SW Harness K19
Coolant LVL SW Harness K38,
2 0327-1507 Aux 104 PCB Assy (Dynamo Gov) A035E719
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

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FEATURE CODE LIST

K50 – 1250 & 1500 KVA

KTA-50-G3 KTA-50-G8 DESCRIPTION

A040U367 A040U369 Genset Rating
A040R746 A040R749 CT Ratio
0326-7011 0326-7011 WYE connection
0326-6979 0326-6979 Genset Nominal Voltage 416V
0326-7529 0326-7529 Voltage Range 416- 480 V
0326-6984 0326-6984 AVR Enabled
0326-7518 0326-7518 Freq. Select 50Hz
A040R762 A040R762 Sync. Check window 5 Deg
A040R768 A040R768 Engine Protection
A040G806 A040G810 Engine and AVR Gains
0326-7516 0326-7516 Nominal Battery Voltage 24V
0326-7486 0326-7486 Low Coolant Level Shutdown
A040R776 A040R776 Battle Short Enable
0326-6989 0326-6989 Application Rating Selection( Prime)
A040R778 A040R778 Coolant Temperature 2 Enable
A029N140 A029N140 Genset Application Type: Utility Multiple

K 38

KTA-38-G2-I KTA-38-G3 KTA-38-G5 DESCRIPTION

750kVA 800kVA 1010kVA
0326-7870 A040R758 A040R756 Genset Rating
0326-7479 0326-7479 0326-7481 CT Ratio
0326-7011 0326-7011 0326-7011 WYE connection
0326-6979 0326-6979 0326-6979 Genset Nominal Voltage 416V
0326-7529 0326-7529 0326-7529 Voltage Range 416- 480 V
0326-6984 0326-6984 0326-6984 AVR Enabled
0326-7518 0326-7518 0326-7518 Freq. Select 50Hz
A040R762 A040R762 A040R762 Sync. Check window 5 Deg
A040R768 A040R768 A040R768 Engine Protection
A040G818 A040G818 A040G816 Engine and AVR Gains
0326-7516 0326-7516 0326-7516 Nominal Battery Voltage 24V
0326-7486 0326-7486 0326-7486 Low Coolant Level Shutdown
A040R776 A040R776 A040R776 Battle Short Enable
0326-6989 0326-6989 0326-6989 Application Rating Selection( Prime)
A040R778 A040R778 A040R778 Coolant Temperature 2 Enable
A029N140 A029N140 A029N140 Genset Application Type: Utility Multiple
0326-7525 0326-7525 0326-7525 Genset CT Secondary-1A

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V28

VTA-28-G3 600 KVA VTA-28-G5 625 KVA DESCRIPTION

0326-7742 A040U371 Genset Rating
0326-7477 0326-7477 CT Ratio
0326-7011 0326-7011 WYE connection
0326-6979 0326-6979 Genset Nominal Voltage 416V
0326-7529 0326-7529 Voltage Range 416- 480 V
0326-6984 0326-6984 AVR Enabled
0326-7518 0326-7518 Freq. Select 50Hz
A040R762 A040R762 Sync. Check window 5 Deg
A040R768 A040R768 Engine Protection
A040G828 A040G828 Engine and AVR Gains
0326-7516 0326-7516 Nominal Battery Voltage 24V
0326-7486 0326-7486 Low Coolant Level Shutdown
A040R776 A040R776 Battle Short Enable
0326-6989 0326-6989 Application Rating Selection( Prime)
A040R778 A040R778 Coolant Temperature 2 Enable
A029N140 A029N140 Genset Application Type: Utility Multiple
0326-7525 0326-7525 Genset CT Secondary-1A

K19

KTA-19-G9 500 KVA DESCRIPTION

0326-7717 Genset Rating
A040R744 CT Ratio
0326-7011 WYE connection
0326-6979 Genset Nominal Voltage 416V
0326-7529 Voltage Range 416- 480 V
0326-6984 AVR Enabled
0326-7518 Freq. Select 50Hz
A040R762 Sync. Check window 5 Deg
A040R768 Engine Protection
A040R774 Engine and AVR Gains
0326-7516 0326-7516 Nominal Battery Voltage 24V
0326-7486 Low Coolant Level Shutdown
A040R776 Battle Short Enable
0326-6989 Application Rating Selection( Prime)
A040U373 Intake Manifold Temperature Disable
A029N140 Genset Application Type: Utility Multiple

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N14

NTA-14-G3 380 KVA DESCRIPTION

A040R752 Genset Rating
A040R741 CT Ratio
0326-7011 WYE connection
0326-6979 Genset Nominal Voltage 416V
0326-7529 Voltage Range 416- 480 V
0326-6984 AVR Enabled
0326-7518 Freq. Select 50Hz
A040R762 Sync. Check window 5 Deg
A040R764 Engine Protection
A040R772 Engine and AVR Gains
0326-7516 Nominal Battery Voltage 24V
0326-7486 Low Coolant Level Shutdown
A040R776 Battle Short Enable
0326-6989 Application Rating Selection( Prime)
A040R373 Intake Manifold Temperature Disable
A029N140 Genset Application Type: Utility Multiple

POWER LIMITS

Signal Name Power Limit

Fused B+ (TB1, J25) Internally fused at 3 A
Key switch B+ (J11) Internally fused at 1.85A, shared with Relay Supply
Relay Supply (J20) Internally fused at 1.85A, shared with Key switch B+
Relay Supply (J25) Internally fused at 1.85A, shared with Key switch B+
Battery Charger Alternator Flash (J20) Internally Fused at 1.5A
Return pins 5A/pin using 18 AWG wire

Internal Fusing:

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

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

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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 First Occurrence – Last Occurrence of Daylight Savings End Day in
in Month Occurrence 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 First Occurrence – Last Occurrence of Daylight Savings End Day in
Occurrence in Month Occurrence which DST Starts

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PC3.3 FAULT THRESHOLDS

FAULT STATUS DESCRIPTION THRESHOLDS

CODE
135 Warning Engine Oil Rifle Pressure 1 Sensor Circuit - Voltage 40 PSI / 276 kPa / 2.75 bar @ 1500 RPM
Above Normal, or Shorted to High Source

141 Warning Engine Oil Rifle Pressure 1 Sensor Circuit - Voltage 15 PSI / 103 kPa / 1.03 bar @ 800 RPM
Below Normal, or Shorted to Low Source

415 Shutdown Engine Oil Rifle Pressure - Data Valid but Below 35 PSI / 241 kPa / 2.41 bar @ 1500 RPM
Normal Operational Range - Most Severe Level 10 PSI / 69 kPa / 0.68 bar @ 800 RPM
144 Warning Engine Coolant Temperature 1 Sensor Circuit - 207 Deg F / 97 Deg C
Voltage Above Normal, or Shorted to High Source

151 Shutdown Engine Coolant Temperature - Data Valid but Above 215 Deg F / 101 Deg C
Normal Operational Range - Most Severe Level

197 Warning Coolant Level - Data Valid but Below Normal Low Level @ 800 RPM
Operational Range - Moderately Severe Level

235 Shutdown Coolant Level - Data Valid but Below Normal Low Level @ 1500 RPM
Operational Range - Most Severe Level

Shutdown Engine Over speed 115% of 1500 RPM i.e. 1725 RPM +/-1
RPM
442 Warning High DC Voltage Batt. Volt > 32 V DC
441 Warning Low DC Voltage Batt. Volt< 24 V DC
1442 Warning Weak Battery Rated Volt < 60% i.e. 14.4 V DC
1446 Shutdown High AC Voltage Rated Volt > 130% i.e. 540.8 V AC

1447 Shutdown Low AC Voltage Rated Volt < 85% i.e. 353.60 V AC, for 10
Sec
1448 Shutdown Under Frequency Rated Freq. < 90% i.e.45 Hz for 10 Sec

1472 Shutdown High Current Shutdown Rated Current > 110% as per PCC IDMT
Curve
1471 Warning High Current Warning Rated Current > 110% for 60 Sec.
1445 Shutdown Short Circuit Rated Current > 175% Instantaneous
1444 Warning Overload Rated Current > 115%, after 5 Sec. The
load dump O/P will get activated.

1459 Shutdown Reverse Power (-) Kw Power > 10% of Rated Kw for 3 Sec

1461 Shutdown Loss of Excitation 2 seconds

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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 Minimum Resistance (Megaohm)

Generator Voltage Setting Main Stator Main Rotor Excitor Stator/Rotor

600 VAC or less 500 5.0-1.0 5.0-1.0 5.0-1.0

601 thru 5000 VAC 2500 400-50

1000 5.0-1.0 5.0-1.0

5001 thru 15000VAC 5000 1000-200

1000 5.0-1.0 5.0-1.0

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.

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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: -

PCC3100 PCC3200 PCC3201 PC3.3

TB-1 TB-5 TB-3 TB-9
KVAR - 54 12 54 11
KVAR+ 55 13 53 10
KW- 56 14 52 7
KW+ 57 15 51 8
Shield 58 16 55 9

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

HT Breaker Panel

1) Check that Panel is grounded correctly.

2) Ensure HT Breaker is Earthed at both ends.
3) Check there should not be any loose item inside the panel which may fall down during breaker operation.
4) Ensure the cable connection for proper phase sequence.
5) Make sure that the panel is not live and get it is cleaned thoroughly.
6) Ensure HT Cable terminations are tighten with proper torque.
7) Locate the Handle, Rack out and rack in the breaker and ensure racking is smooth and proper.
8) 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.

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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) Check that panel is grounded correctly.

2) Panel Aux supply AC/DC is connected correctly and polarity is as per drawing.
3) Check the continuity of control cables as per drawing and cable schedule.
4) Check Cable grounding / termination / tightness / ferruling are perfect.
5) Clean the panel with cotton and by blowing dry air thoroughly.
6) By secondary Current / Voltage injection ensure the tripping of Protection relay is perfect.
7) Charge the panel with Aux AC/DC supply and check the proper indications on Panel.
8) Connect the laptop using InPower. The communication cable part no. is 0338-4590.
9) Take a capture file and save it positively.
10) Check the settings to be done
11) Start the engine at no load for 5-10 minutes and increase the load gradually, Check the performance.
12) 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 K11

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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

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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 Range Deviation If any

Version As per engine model
Prime / Standby/Base Prime Prime/ Standby/Base
Delta / WYE WYE always Delta / WYE
Genset Idle enable Enabled Disabled/Enabled
Remote Fault Reset Enabled Disabled Disabled/Enabled
Battery Short Enable Disabled Disabled/Enabled
Fail to shutdown delay 5 seconds 0-30 seconds
Delayed Shutdown Enable Disabled Disabled/Enabled
Delay shutdown time delay Disabled Disabled/Enabled
Reset Fuel Consumption Inactive Inactive/Active
Genset Reset all energy meters Do nothing Do nothing/Clear counters
Start Time Delay 0 seconds 0-300 seconds
Time Delay to stop 0 seconds 0-600 seconds
Commit to transfer timeout 120 seconds 0-3200seconds
Transition Type Open Transition Open Transition/Softly Closed
Transition/hardly Closed Transition
Test with Load Enable Disabled Enabled/Disabled
System Phase rotation L1-L2-L3 L1-L2-L3/L1-L3-L2
Extended parallel Enable Disabled Enabled/Disabled
Commit to transfer Method Utility Disconnect Utility Disconnect/no
commit/Genset Start
Genset Application Type Isolated Bus / Utility Standalone/Synchronize
Multiple only/Isolated Bus/Utility
Single/Utility Multiple/Power
Transfer Control
First Start Backup Time 10Seconds 3-120 Seconds
Nominal Voltage 416Vac 110-45000Vac
Frequency 50Hz 50Hz/60Hz
Breaker Position Contacts Dual Contacts Single Contact/Dual Contacts
Genset CB Fail to Close Time 026 seconds 0.1-1 second
Delay

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Parameter Factory Settings Range Deviation If any

Genset CB Fail to Open Time Delay 1 second 0.25-5 Seconds
Permissive Voltage Window 5% 0.5-10%
Permissive Phase Window 5 deg 15 deg
Permissive Window Time 0.5 seconds 0.5-5 seconds
Permissive Frequency Window 1Hz 0.001-1Hz
Synchronizer Voltage Control Voltage Match Voltage Match/ External
Method
Voltage Match Kp 400 10-800
Voltage Match Ki 50 0-255
Utility Current Metering 3Ph 3 Sensed 3Ph 3 sensed/ 3 Ph 1 Sensed
Configuration
Synchronizer Speed Control Phase Match Phase Match/Slip
Method Frequency/External
Slip Frequency 0.1Hz -3-3Hz
Frequency Match Kp 30 1-300
Frequency Match Ki 20 0-250
Phase Match Kp 150 10-1500
Fail to Synchronize Time 120Seconds 10-900 Seconds
Isolated Bus Speed Control Constant Constant/Droop
Method
Speed Droop percentage 5% 0-15%
Speed Droop Enable Inactive Active/Inactive
Switch(PCCNet)
Speed Bias OOR Check Enable Disabled Enable/Disabled
Speed Bias OOR High Limit 5Vdc -5-5Vdc
Speed Bias OOR Low Limit -5Vdc -5-5Vdc
Speed Bias OOR Time 1 second 0-10 Seconds
Isolated Voltage Control Method Constant Constant/Droop
Voltage droop Percentage 4% 0-15%
Voltage Adjust 0% -5-5%
Voltage Droop enable Inactive Inactive/Active
Switch(PCCNet)
Genset KW Set point Percent 0% 0-100%
Genset Power factor set point 1PF 0.78-1PF
Load Govern KW Kp 60 0-1000
Load Govern KW Ki 60 0-250
Load Govern KVAR Kp 120 0-1000
Load Govern KVAR Ki 50 0-250
Load Govern KVAR ramp Load 20 Seconds 0-900 Seconds
time
Load Govern KVAR ramp Unload 20 Seconds 0-900 Seconds
Time

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Parameter Factory Settings Range Deviation If any

Load Govern KW maximum 80% 0-100%
Load Govern KW Maximum 80% 0-100%
Delayed
Utility Parallel Voltage Control Load govern Load Govern/Droop/Load Govern
method with Deep Feed Forward
Voltage Droop Percentage 4% 0-15%
Utility Parallel Speed Control Load Govern Load Govern/ Droop
Speed Droop Percentage 5% 0-15%
ECM CAN Enable Disabled Disabled/Enabled
ECM Data save Time Delay 30 seconds 0-60 seconds
Prelube Function Enable Disabled Disabled/Enabled
Idle Speed 800 rpm 700-1100 rpm
Starter Disconnect Speed 450 rpm 100-600 rpm
Nominal Battery Voltage 24V 12V, 24V
High Battery Voltage Set time 60 seconds 2-60 seconds
Low Battery Voltage Set time 60 seconds 2-60 seconds
Weak Battery Voltage Set Time 2 seconds 1-5seconds
Adjustable freq/Speed Gain 30rpm/Hz 0-240Rpm/Hz
Starting to Rated Ramp Time 1 sec 0-30 Seconds
Governor Ramp Time 0.25 seconds 0-30Seconds
Glow Plug Enable Disable Enable/Disabled
Governor Enable Engine Speed 1100 rpm 601-1400 rpm
Governor Preload Offset 0% 0-400%
Maximum Duty Cycle 95% 0-100%
Minimum Duty Cycle 25% 0-100%
Dither Factor 15% 0-30%
Excitation Source PMG Shunt, PMG
Excitation Disable Override Excitation On Excitation Off, Excitation ON
AVR Enable Enable 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

J22-Genset Voltage Sense
Voltage Sense Connections
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 TB3-Customer Input/output

TB1-Customer Connections
TB8-Customer Connections

TB10- Breaker Status Connection

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TB1 CUSTOMER CONNECTIONS

TO PCC TO OEM
CONNECTIONS

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 Ready to Load 250mA Low side relay driver
TB1-05 Customer Fused B+ (3A)
TB1-06 Common Warning O/P (N/O) Relay contacts of rating 3.5A @30VDC
TB1-07 Common Relay contacts of rating 3.5A @30VDC
TB1-08 Common Shutdown O/P (N/O) Relay contacts of rating 3.5A @30VDC
TB1-09 Common Relay contacts of rating 3.5A @30VDC
TB1-10 Remote Start Return Works with (TB1-11)
TB1-11 Remote Start Works with (TB1-10)
TB1-12 Customer Input # 1 Works with (TB1-13)
TB1-13 Return Works with (TB1-12)
TB1-14 Customer Input # 2 Works with (TB1-13)
TB1-15 Remote ESTOP Return Common Return for (TB-14) & (TB-16)
TB1-16 Remote Emergency Stop (N/C) Remote ESTOP switch

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REMOTE PANEL TB1-11 REMOTE E-Stop TB1-16

(NO contact) Switch

TB1-10 (NC Contact) TB1-15

TB3 CUSTOMER I/O CONNECTIONS

TO OEM CONNECTIONS TO PCC

TB3-xx Customer Input & Output CONNECTS TO

TB3-01 Return Use as Signal Return for Switch Inputs. Works with TB3-9 & TB3-10
Configurable Output # 20
TB3-05 Intended to drive Relay Coil
Status
Configurable Output # 21
TB3-06 Intended to drive Relay Coil
Status
TB3-07 NA
Configurable Output # 22
TB3-08 Intended to drive Relay Coil
Status
**Transfer Inhibit/ Config.
TB3-09 Normally inhibits Transfer to Genset, under some conditions it is ignored;
Input # 20 Switch
**Retransfer Inhibit /
TB3-10 Normally inhibits retransfer to Utility, under some conditions it is ignored;
Config. Input # 21 Switch
TB3-11 First Start Arbitration 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 Return
TB3-12)

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TB5 BREAKER CONTROL CONNECTIONS TO PCC

TO OEM
CONNECTIONS

TB5-xx Circuit Breaker Control CONNECTS TO

TB5-01 Circuit Breaker Close Control (NO) Contact for closing Genset Breaker, rating 5A @ 30VDC
TB5-02 COM
TB5-03 NA
TB5-04 Circuit Breaker Open Control (NC) Contact for opening Genset Breaker, rating 5A @ 30VDC
TB5-05 COM
TB5-06 Utility Breaker Close Control (NO) Contact for closing Utility Breaker, rating 5A @ 30VDC
TB5-07 COM
TB5-08 Utility Breaker Open Control (NC) 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

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TB7 GEN BUS/UTILITY VOLTAGE SENSE

TO OEM CONNECTIONS TO PCC

TB7-xx Genset Bus/Utility Voltage Sensing CONNECTS TO

TB7-01 Genset Bus L1 Voltage OR Utility L1 Voltage Up to 600VAC Line to Line direct connect
TB7-02 Genset Bus L2 Voltage OR Utility L2 Voltage Up to 600VAC Line to Line direct connect
TB7-03 Genset Bus L3 Voltage OR Utility L3 Voltage Up to 600VAC Line to Line direct connect
TB7-04 Neutral Sensing If delta voltage connection leave unconnected

TB8 CUSTOMER CONNECTIONS

TO PCC
TO OEM
CONNECTIONS

TB8-xx Customer Input & Output CONNECTS TO

TB8-01 Discrete Return Works with TB8-5
TB8-02 Discrete Return 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 Customer Input & Output CONNECTS TO

TB8-06 Start Type Emergency / Non Emergency Start Type
TB8-07 Customer Configurable Input # 13 Works with TB8-12
TB8-08 Customer Configurable Input # 14 Works with TB8-13
TB8-09 Customer Configurable Output # 4 250mA Low side relay driver
TB8-10 Customer Configurable Output # 3 250mA Low side relay driver
TB8-11 Load Dump 250mA Low side relay driver, works with TB1-5
TB8-12 Discrete Return Works with TB8-7
TB8-13 Discrete Return Works with TB8-8
TB9 ANALOG I/O CONNECTIONS

TO OEM CONNECTIONS TO PCC

TB9-xx Analog Input & Output CONNECTS TO

Kw Load Set point/Config.
TB9-01 Also can be set as "External Speed Bias input"
Analog Input # 1
TB9-02 Return Analog Input Return
Kvar Load Set point/Config.
TB9-03 Also can be set as "External Voltage Bias Input"
Analog Input #2
Connect Genset to Genset when paralleling to enable genset to share Kw
TB9-07 KW Load Share - 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
TB9-08 KW Load Share + Load. In addition can be used as input from master synchronizer for
freq./phase matching.
TB9-09 SHIELD Load share shield connection point
Connect Genset to Genset when paralleling to enable genset to share Kvar
TB9-10 KVAR Load Share + 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
TB9-11 KVAR Load Share - Load. In addition can be used as input from master synchronizer for voltage
matching.

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TB10 BREAKER STATUS CONNECTIONS

TO PCC TO OEM CONNECTIONS

TB10-xx Circuit Breaker Status CONNECTS TO

Use as Signal return for switch inputs. Works with TB10-3, TB10-4,
TB10-01 Return
TB10-5
TB10-03 Utility CB Position A Switch Utility Main Breaker Aux A contact to determine breaker position
TB10-04 Utility CB Position B Switch Utility Main Breaker Aux B contact to determine breaker position
TB10-05 Utility CB Tripped Switch Utility Main Breaker 86 Relay Aux A contact
TB10-06 UTILITY CB Inhibit Opens Utility main Breaker if closed; Inhibit closure if Breaker is open.
TB10-02 Return Use as Signal return for switch inputs. Works with TB10-7, TB10-8,
TB10-07 Genset CB Position A Switch Genset Breaker Aux A contact to determine breaker position
TB10-08 Genset CB Position B Switch Genset Main Breaker Aux B contact to determine breaker position
TB10-09 Return Use as Signal return for switch inputs. Works with TB10-10, TB10-11,
TB10-10 Genset CB Tripped Switch 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 PCC TO OEM CONNECTIONS

TB15-xx PC Tool Interface CONNECTS TO

TB15-01 RS 485 Shield Network Shield
TB15-02 NA
TB15-03 RS485 (+) Network Data A
TB15-04 RS485 (-) Network Data B

J12 CONNECTOR ( GEN CT INPUTS)

PIN DESCRIPTION CONNECTS TO

J12-1 CT1 CT1-X1
J12-2 CT2 CT2-X1
J12-3 CT2 CT3-X1
J12-4 CT1 COMMON CT1-X2/X3
J12-5 CT2 COMMON CT2-X2/X3
J12-6 CT3 COMMON CT3-X2/X3

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J22 ( GEN VOLTAGE CONNECTOR )

PIN DESCRIPTION CONNECTS TO

J22-1 L1 ALTERNATOR TERMINAL U ( R )
J22-2 L2 ALTERNATOR TERMINAL V ( Y )
J22-3 L3 ALTERNATOR TERMINAL W ( B )
J22-4 N ALTERNATOR TERMINAL NEUTRAL

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J20 ( GEN I/O CONNECTOR )

PIN DESCRIPTION CONNECTS TO

J20-1 CHASSIS GROUND
J20-2 B+ RETURN BATTERY NEGATIVE
J20-3 Switched B+ LOW SIDE DRIVER
J20-4 B+ RETURN BATTERY NEGATIVE
J20-5 DISCRETE INPUT RETURN RETURN FOR CONFIGURABLE O/P #5 J20-17
J20-6 DISCRETE INPUT RETURN RETURN FOR CONFIGURABLE O/P #6 J20-18
J20-7 B+ RETURN BATTERY NEGATIVE
J20-8 DISCRETE INPUT RETURN RETURN FOR CONFIGURABLE O/P #12 J20-19
J20-9 B+ INPUT (FUSED B+) BATTERY POSITIVE
J20-10 B+ INPUT (FUSED B+) BATTERY POSITIVE
J20-11 STARTER DISCONNECT INPUT CHARGING ALTERNATOR
J20-12 B+ RETURN BATTERY NEGATIVE
J20-13 RELAY COIL B+ SUPPLY SWITCHED B+
J20-14 FSO RELAY DRIVER LOW SIDE OF FUEL SHUT OFF RELAY COIL
J20-15 STARTER RELAY DRIVER LOW SIDE OF STARTTER RELAY COIL
J20-16 OIL PRIMING PUMP DRIVER LOW SIDE OF OIL PRIMING PUMP RELAY COIL
J20-17 CONFIGURABLE I/P #5 DEFAULTS TO LOW COOLANT SWITCH LEVEL
J20-18 CONFIGURABLE I/P #6 DEFAULTS TO LOW FUEL LEVEL SWITCH
J20-19 CONFIGURABLE I/P # 12 DEFAULTS TO RUPTURE BASIN SWITCH
J20-20 B+ INPUT (FUSED B+) BATTERY POSITIVE
J20-21 B+ INPUT (FUSED B+) BATTERY POSITIVE
J20-22 ALT FLASH INPUT CHARGING ALTERNATOR

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J25 DISPLAY CONNECTOR

PIN DESCRIPTION CONNECTS TO

J25-1 LOCAL STATUS 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

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J26 ENGINE INTERCONNECT

PIN DESCRIPTION CONNECTS TO

J26-1 J1939 (SHIELD) CAN DATALINK
J26-2 BACKUP START DISCONNECT AUX 103 AVR POWERSTAGE
J26-3 AVR PWM- AUX 103 AVR POWERSTAGE
J26-4 NA
J26-5 B POSITIVE RETURN POWER FOR AUX 103 AVR POWERSTAGE
J26-6 NA
J26-7 FIELD - ALTERNATOR FIELD XX - (F2)
J26-8 NA
J26-9 AVR FUSED B+ POWER FOR AUX 103 AVR POWERSTAGE
J26-10 J1939(-) CAN DATALINK
J26-11 J1939(+) CAN DATALINK
J26-12 NA

CUSTOMER CONNECTIONS FROM TB1 TO MAIN PANEL

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

Ready to load connections

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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 con

connected and configured as an input.

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

Remote Emergency stop

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MANDATORY CONNECTORS FOR PARALLELING

Connections mandatory for multiple sets in parallel operation

Step – 1 Loop the connections

ons 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.

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SINGLE SET
1. In Run Mode, when Engine Speed & Voltage reach 90% of Rated & When the Breake
Breakerr Close button
on HMI can be pressed.
2. In Auto Mode, When Remote start command is given & 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 synchroni
synchronizing
zing
conditions are met, the circuit breaker can be closed from HMI.
2. In Auto Mode, when Remote start command is given with Speed & Voltage 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
mplete 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.

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SPEED & VOLTAGE BIAS SIGNALS

If PC 3.3 is being paralleled with a Non--PCC

PCC set, one can provide external input signals for Speed bias and Voltage bias.
a. Change the Genset application type to “Utility Multiple”
b. Change KW load setpoint/Config.
int/Config. Analog Input 1 trim from “Default” to “External Speed Bias Input”.
c. Change 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:

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How to setup the PCC3300 for HT application

Important Note :-

PCC3300 software version 3.070 onwards will support the Toyo Denki HT alternators with PT of 110 secondary.
Earlier versions will trigger the FC# 2817 “Genset PT ratio too large” warning. This will not affect the genset
performance, but the warning will stay active. Only remedy to reset the fault is use a PT with secondary ratio
greater than 134 volts L-L.

Following parameters need to be changed either by HMI or from Inpower Tool

1. 3 ph high conn Genset nom voltage lo limit – Set it to 25500 Volts

2. 3 ph high conn Genset nom voltage hi limit – Set it to 45000 Volts
3. 3 ph low conn Genset nom voltage lo limit – Set it to 1 Volts
4. 3 ph low conn Genset nom voltage hi limit – Set it to 22499 Volts
5. Single phase Genset nom voltage lo limit – Set it to 1 Volts
6. Single phase Genset nom voltage hi limit – Set it to 45000 Volts
7. Genset Nominal Voltage – Set it to required value (11000 , 6600 or 3300 volts)
8. Genset PT Primary Voltage – Set it same as the Genset Nominal Voltage
9. Genset PT Secondary Voltage – Set it as per the Genset PT secondary rating
10. Genset CT Primary Current – Set it as per the Genset CT Primary Current
11. Genset CT Secondary Current – Set it as per the Genset CT Secondary Current. Normally it will be 1

Save all the parameters.

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Refer the below Genset OEM Setup Wizard snap shot for reference. All yellow highlighted parameters are
listed above.

In addition to this following parameters need to be set if the Genset Application type is “Utility Multiple”

Utility PT Primary Voltage – Set it same as the Genset Nominal Voltage

Utility PT Secondary Voltage - Set it as per the Utility PT secondary value.

Genset Bus PT Primary Voltage – Set it same as the Genset Nominal Voltage

Genset But PT Secondary Voltage – Set it as per the Genset Bus PT secondary Voltage

These are the only parameters need to be set for converting a 416 V L-L genset to HT Application.

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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 don’t 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

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