Instruction Sheet 044X528 (Issue 1) 41-2013 Upgrade Instructions from PCC3300 to PCC3300 with MLD 1 General Information This Instruction Sheet describes the upgrade of generator set control from PCC3300 to PCC3300 with Masterless Load Demand (MLD) and installing an s-CAN network. NOTICE PCC3300 MLD functionality requires that the PCC3300 MLD control is installed and the |s-CAN network connection made on all paralled generator sets. 2 Safety 241 General Safety Precautions Coolants under pressure can cause severe scalding. Do not open a radiator or heat exchanger pressure cap while the engine is running. Let the engine cool down before [removing the coolant pressure cap. Turn the cap slowly and do not open it fully until the pressure has been relieved. ‘Moving parts can cause severe personal injury or death and hot exhaust parts can ‘cause severe burns. Make sure all protective guards are properly in place before Starting the generator set. Used engine oils have been identified by some state and federal agencies to cause cancer or reproductive toxicity. Do not ingest, breathe the fumes, or contact used oil when checking or changing engine oil. ‘Operation of equipment is unsafe when mentally or physically fatigued. Do not operate ‘equipment in this condition, or after consuming any alcohol or drug. ‘Substances in exhaust gases have been identified by some state and federal agencies to cause cancer or reproductive toxicity. Do not breath in or come into contact with exhaust gases. English 044X526 (Issue 1) * Original Instructions Page 1 of 10 (©2013 Cummins Power Generation, Inc.All rights reserved.‘Flammable liquids can cause fire or explosion. Do not store fuel, cleaners, oil, etc. near the generator set. Wear hearing protection when going near an operating generator set . Hot metal parts can cause severe burns. Avoid contact with the radiator, turbo charger, and exhaust system. Maintaining or installing a generator set can cause severe personal injury. Wear [personal protective equipment such as safety glasses, protective gloves, hard hats, Steel-toed boots, and protective clothing when working on equipment. Ethylene glycol, used as engine coolant, is toxic fo humans and animals. Clean up coolant spills and dispose of used antifreeze in accordance with local environmental regulations. ‘Starting fluids, such as ether, can cause explosion and generator set engine damage. Do not use. ‘Stepping on the generator set can cause parts to bend or break, leading to electrical shorts, or to fuel, coolant, or exhaust leaks. Do not step on the generator set when entering or leaving the generator room. To prevent accidental or remote starting while working on the generator set, disconnect the negative (-) battery cable at the battery using an insulated wrench. Make sure that rags are not left on or near the engine. ‘Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit. ‘Accumulated grease and oil can cause overheating and engine damage presenting a [potential fire hazard. Keep the generator set clean and repair any oil leaks promptly. 044X528 (Issue 1) Page 2 of 102.2 2.3 Before performing maintenance and service procedures on enclosed generator sets, make sure the service access doors are secured open. ‘Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry. NOTICE Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels and gaseous fuels. Class C fires involve live electrical equipment. (Refer to NFPA No. 10 in applicable region.) Generator Set Safety Code Before operating the generator set, read the manuals and become familiar with them and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. Improper operation and maintenance can lead to severe personal injury, or loss of life and property, by fire, electrocution, mechanical breakdown, or exhaust gas asphyxiation. Read and follow all Safety Precautions, Warnings, and Cautions throughout this manual and the documentation supplied with your generator set. Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death ‘Any work with exposed energized circuits with potentials of 50 Volts AC or 75 Volts DC ‘or higher poses a significant risk of electrical shock and electrical arc flash. These silent hazards can cause severe injuries or death. Refer to standard NFPA 70E or equivalent safety standards in corresponding regions for details of the dangers involved and for the safety requirements. Guidelines to follow when working on de-energized electrical systems: + Use proper PPE. Do not wear jewelry and make sure that any conductive items are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards. + De-energize and lockouvtagout electrical systems prior to working on them Lockout/Tagout is intended to prevent injury due to unexpected start-up of equipment or the release of stored energy. Please refer to the lockouttagout section for more information ‘044X528 (Issue 1) Page 3 of 103.1 3.2 + De-energize and lockoutitagout all circuits and devices before removing any protective shields or making any measurements on electrical equipment. * Follow all applicable regional electrical and safety codes. Guidelines to follow when working on energized electrical systems: Itis the policy of Cummins Inc. to perform all electrical work in a de-energized state. However, employees or suppliers may be permitted to occasionally perform work on jenergized electrical equipment only when qualified and authorized to do so and when troubleshooting, or if de-energizing the equipment would create a greater risk or make {the task impossible and all other alternatives have been exhausted. NOTICE Exposed energized electrical work is only allowed as per the relevant procedures and must be undertaken by a Cummins authorized person with any appropriate energized work permit for the work to be performed while using proper PPE, tools and equipment. In summary: + Do not tamper with or bypass interlocks unless you are authorized to do so. + Understand and assess the risks, use proper PPE. Do not wear jewelry and make sure that any conductive items are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards. + Make sure that an accompanying person who can undertake a rescue is nearby. Upgrade Instruc’ Hardware Needed + PCC3300 with MLD functionality (A041W736) + s-CAN communications cable, see Section 3.5.2 for cable specifications. Required Equipment and Tools InPower is required to transfer the settings from the existing controller to the new controller. The following are required * Laptop + RS-232 Port or USB-to-RS-232 adapter + InPower Pro + Latest calibrations and SRV files ‘Make sure to download ALL of the latest commercial generator set calibration files from the InCal website and run the InPower InCal extractor utility. ‘A044x528 (Issue 1) Page 4 of 10+ Service Tool Harness Kit (0541-1199) Reference Documents available on QuickServe Online + PowerCommand 3.3 Controller Service Manual (0900-0670) + Paralleling with PC3xxx Controller Genset (CPGF-S-00000045-1) + Fail Code Manual (F1115C) 3.3 Required Control Calibration Please make sure that all controls have been upgraded to the minimum firmware version listed in the table below to make sure compatibility with the upgrade kit. Any control calibrated with a later firmware version should be sufficient. TABLE 1. CALIBRATION OF CONTROLS Name Part Number Firmware PCC3300 ‘A0OSFA56 ¥3.130 HMI320 (Local) ‘A0O0AS78 v3.0 NOTICE Itis required that the control be updated with the latest firmware, the latest calibration file is available on the InCal website. For assistance, refer to the Web-InCal User Guide in the program menu, under User Guides next to InPower or refer to Instruction Sheet G755 which details the process on how to register for the service, find the latest firmware, and help with troubleshooting. 3.4 Control Panel Safety Precautions ‘Accidental starting of the generator set while working on it can cause severe personal injury or death. Prevent accidental starting by disconnecting the starting battery cables (negative (-) first). Arcing can ignite explosive hydrogen gas given off by batteries, causing severe personal injury. Arcing can occur when cable is removed or reconnected, or when negative (-) battery cable is connected and a tool used to connect or disconnect positive (+) battery cable touches frame or other grounded metal part of the set. Always Fomove negative () cable first, and reconnect it last, Make certain hydrogen from battery, engine fuel, and other explosive fumes are fully dissipated. This is especially important if battery’ has been connected to battery charger. Make certain the battery area has been well-ventilated before servicing battery. ‘AC power presents a shock hazard that can cause severe personal injury or death. Before servicing the generator set, disconnect all power when multiple disconnection sources are used. ‘A044X528 (Issue 1) Page 5 of 10Electrostatic discharge will damage circuit boards. To prevent this damage, always wear a grounding wrist strap when handling circuit boards or socket-mounted Integrated Circuits (ICs). Always disconnect a battery charger from its AC source before disconnecting the battery cables. Otherwise, disconnecting the battery cables can result in voltage spikes high enough to damage the DC control circuits of the set. 3.5 Replacement of a PCC3300 Control Board This section provides instructions on how to remove the PCC3300 control (327-1601-01) and replace it with the PCC3300MLD control (A041W736). Incorrect service of replaceznent of parts car result in severe personal injury, dest, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and mechanical service. Read the Safety Precautions, and carefully ‘observe all of the instructions and precautions in this instruction. 1. Create a capture file to save the current settings of the existing PCC3300 board in the generator set. ‘To ensure all setting are properly transferred, make sure to download ALL of the latest commercial generator set calibration files from the InCal website and run the InPower InCal extractor utility prior to creating a capture fil ‘Tum off or remove AC power from the battery charger. Press the Emergency Stop button, and wait 30 seconds, Remove the negative (-) battery cable from the generator set starting battery. Interrupt bus voltage sensing circuit by opening the fuses in the lines that go to TB-7 if the bus is being sensed. gReN 6. Follow all appropriate lockout/tagout procedures. 7. After making sure all power has been removed from the board, attach the grounding wrist strap clip to an unpainted surface that is connected to the same ground to which the control board is connected, and place the strap around technician's wrist. 8. Disconnect all cables and terminal blocks that are connected to the contro! board. 9. Remove the control board. 10. Install control board A041W736, all mounting points will be the same. 11. Reconnect the cables and terminal blocks to the MLD board. Connection points are the same. 044X528 (Issue 1) Page 6 of 1012. Connect the s-CAN communication cable at TB3 between all MLD capable generator sets. for important installation details. 13. Install s-CAN network termination. S1 s-CAN network (bus) must be terminated by 120 ‘ohm resistors on both ends of the s-CAN network. This can be done by installing a resistor at TB3 in the hamess or using the on-board terminating resistor (S1). See SAE J1939-11 for full list of network physical requirements. See Section 3.5.1 14. Connect the negative (-) battery cable to the generator set starting battery 15. Turn on or connect AC power to the battery charger. 16. Calibrate the PCC3300 with the latest software available on the InCal website 17. Restore the capture file from the original 3300 board on that generator set 18. Calibrate the HMI320 with the latest software available on the InCal website. 3.5.1 $1.s-CAN Terminating Resistor Switch st Note: STS shown in (ON position FIGURE 1. $1 TERMINATING RESISTOR SWITCH LOCATION TABLE 2. S1 SWITCH Name Description Function / Connects to. ist s-CAN Terminating Resistor Switch ‘The network must be terminated, to use on-board terminating resistors move switch $1 to the ON position PCC 3300 with MLD ONLY 3.5.2 TB3 Connections 12 1 FIGURE 2. TB3 PINS ‘044X526 (Issue 1) Page 7 of 10TABLE 3. TB3 PIN ASSIGNMENTS: CUSTOMER INPUTIOUTPUT CONNECTIONS Description. Function / Connects to Ground 's-CAN shield connection point or use as a signal return for switch inputs ras - 3 SCAN Isolated Ground ‘S-CAN network ground only, Do nat connect to chassis/Battery Ground Connect to TB3-2 of other PCC3300 PCC 3300 with MLD ONLY S-CAN CAN L ‘SCAN data line for control-to-control ‘communications Connect to TB3-3 of other PCC3300 PCC 3300 with MLD ONLY i183 - 4 'S-CAN CAN H. '-CAN data line for control-to-control ‘communications Connect to TB3-4 of other PCC3300 PCC 3300 with MLD ONLY ‘TB3-2, TB3-3, and TB3-4 s-CAN Network Connections (PCC 3300 with MLD ONLY) s-CAN NETWORK SEN! | GEN2 DIAGRAM T Po . tmMAX 200m MAX. ~-—Honfjes (ax 18) i FIGURE 3. S-CAN NETWORK DIAGRAM s-CAN cable requirements: Twisted pair (shielded) cable meets SAE J1939-11 standards, 200m maximum network length. NOTICE Recommended cable type: Belden 3106A or equivalent. cable/segment. To prevent ground loops shield/drain wire are to be connected to TB3-1 at only one end of a s- CAN network (bus) cable/segment. Shield continuity must be maintained over entire length of Drees Recommended shield connection method Figure 4 ‘044X528 (Issue 1) Page 8 of 10PCC3300 MLD PCC3300 MLD PCC3300 MLD Shield drain wire connected to TB3-1 at only —— Miste0 par one end of the s-CAN network cable segment SHIELD 3.6 FIGURE 4, SHIELD CONNECTIONS ON MLD S-CAN NETWORK Setup Instructions for a PCC3300MLD Control on the s-CAN Network This process describes how to setup and enable a generator set control to the s-CAN network See PC3.3 control service manual 0900-0670 Issue 11 or newer for additional details on where to find MLD settings on the HMI320 and how to complete the s-CAN Network setup. 1. From the HMI320 or using the InPower service tool, set the Genset ID (Genset ID) to a Unique value 2. Verify all generator sets on the s-CAN Network are communicating, System Network Datalink Status (Datalink Stat) is active and Load Demand Genset Status Table is not equal to Genset Lost (Lost). 3. Update System Settings one the generator set, by setting Synchronize System Settings (Sync System Settings) to Yes from any OTHER generator set on the network with known correct settings. 4. Verify the System Settings Status (System Settings Status) are updated to the s-CAN Network on the affected generator set. System Settings Status (System Settings Status) will indicatd in Sync on the affected generator set. 5. Set any other applicable Local MLD settings if required. 6. Set Load Demand Genset Enable (LD Gen Enable) to Enable. The generator set is now operating in MLD mode. Load Demand Genset Status will change from OK to Disconnect (OK To Disc) to Ineligible. 7. Set the generator set to Auto and apply the Remote Start input. The generator set will start and connect to the AC Bus, 8 Set Load Demand System Enable (LD Sys Enable) to Enable and Syncronize System Settings (Sync System Settings) to Yes. 9. The system is now operating in MLD mode. Generator sets will start and stop based MLD settings, generator set priority, and load on the system. ‘044X528 (Issue 1) Page 9 of 103.7 PCC3300MLD s-CAN Network Wiring Diagram POWER COMMAND 93 CUSTOMER CONMECTIN GENSET SPRLCATION TYPE CMA = ISOLATED BUS QHLY [SENSET TO GENSET NIEEACE. PoC 3200 BASEBOARD ISOLATED BUS OMY FIGURE 5. 0630-3440 REVISION M (SHEET 13 OF 20) 044X528 (Issue 1) Page 10 of 103.7 PCC3300MLD s-CAN Network Wiring Diagram POWER COMMAND 3:3 CUSTOMER CONNECTIONS CGENSET APPLICATION TYPE (TRM) = ISOLATED BUS ONLY (GENSET TO GENET NIECE 139 oc 3300 BASEBOARD ISLATED OUS ONLY FIGURE 5. 0630-3440 REVISION M (SHEET 13 OF 20) ‘044X528 (Issue 1) Page 10 of 10