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.ArchivetempA034T572 I5 ManualServico PCC3201
.ArchivetempA034T572 I5 ManualServico PCC3201
Controller
PowerCommand 3201
English
Original Instructions 5-2019 A034T572 (Issue 5)
Table of Contents
SECTION TITLE PAGE
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
HOW TO OBTAIN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CAUTION This symbol refers to a hazard or Before starting work on the generator set, discon−
unsafe practice which can result in personal in- nect battery charger from its AC source, then dis−con-
jury or product or property damage. nect starting batteries, negative (−) cable first. This will
prevent accidental starting.
FUEL AND FUMES ARE FLAMMABLE Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards in
Fire, explosion, and personal injury or death can result position over fans, drive belts, etc.
from improper practices.
Do not wear loose clothing or jewelry in the vicinity of
DO NOT fill fuel tanks while engine is running, un− moving parts, or while working on electrical equipment.
less tanks are outside the engine compartment. Fuel Loose clothing and jewerly can become caught in mov-
contact with hot engine or exhaust is a potential ing parts.
fire hazard.
If adjustment must be made while the unit is run−
DO NOT permit any flame, cigarette, pilot light, ning, use extreme caution around hot manifolds, moving
spark, arcing equipment, or other ignition source near parts, etc.
the generator set or fuel tank.
DO NOT OPERATE IN FLAMMABLE AND
Fuel lines must be adequately secured and free of EXPLOSIVE ENVIRONMENTS
leaks. Fuel connection at the engine should be made
Flammable vapor can cause an engine to overspeed and
with an approved flexible line. Do not use zinc coated or
become difficult to stop, resulting in possible fire, explo−
copper fuel lines with diesel fuel.
sion, severe personal injury and death. Do not operate a
Be sure all fuel supplies have a positive shutoff genset where a flammable vapor environment can be
valve. created by fuel spill, leak, etc., unless the genset is
equipped with an automatic safety device to block the air
Be sure battery area has been well−ventilated prior ntake and stop the engine. The owners and operators of
to servicing near it. Lead−acid batteries emit a highly explo- the genset are solely responsible for operating the gen−
sive hydrogen gas that can be ignited by arc− set safely. Contact your authorized Cummins Inc. dis-
ing, sparking, smoking, etc. tributor for more information.
Remove electric power before removing protective Make sure that rags or combustible material are not left on
shields or touching electrical equipment. Use rubber in- or near the generator set.
sulative mats placed on dry wood platforms over floors Make sure generator set is mounted in a manner to pre-
that are metal or concrete when around electrical equip- vent combustible materials from accumulating under or
ment. Do not wear damp clothing (particularly wet near the unit.
shoes) or allow skin surface to be damp when handling
electrical equipment. Do not wear jewelry. Jewelry can Remove all unnecessary grease and oil from the
short out electrical contacts and cause shock or burning. unit. Accumulated grease and oil can cause over−heat-
ing and engine damage which present a potential fire haz-
Use extreme caution when working on electrical compo- ard.
nents. High voltages can cause injury or death. DO NOT
tamper with interlocks. Keep the generator set and the surrounding area
clean and free from obstructions. Remove any debris
Follow all applicable state and local electrical codes. from the set and keep the floor clean and dry.
Have all electrical installations performed by a qualified
licensed electrician. Tag and lock open switches to Do not work on this equipment when mentally or physi-
avoid accidental closure. DO NOT CONNECT GEN- cally fatigued, or after consuming any alcohol or drug
ERATOR SET DIRECTLY TO ANY BUILDING ELEC- that makes the operation of equipment un−safe.
TRICAL SYSTEM. Hazardous voltages can flow from the Substances in exhaust gases have been identified
generator set into the utility line. This creates a potential by some state or federal agencies as causing cancer or
for electrocution or property damage. Connect only reproductive toxicity. Take care not to breath or ingest or
through an approved isolation switch or an approved come into contact with exhaust gases.
paralleling device.
Do not store any flammable liquids, such as fuel, clean-
Coolants under pressure have a higher boiling point than ers, oil, etc., near the generator set. A fire or explosion
water. DO NOT open a radiator or heat exchanger pres- could result.
sure cap while the engine is running. To prevent severe
scalding, let engine cool down before removing coolant Wear hearing protection when near an operating
pressure cap. Turn cap slowly, and do not open it fully until generator set.
the pressure has been releived.
To prevent serious burns, avoid contact with hot
Used engine oils have been identified by some state or fed- metal parts such as radiator system, turbo charger sys-
eral agencies as causing cancer or reproductive toxicity. tem and exhaust system.
When checking or changing engine oil, take care not to in-
gest, breathe the fumes, or contact used oil.
REMOTE START,
NOT IN AUTO,
SHUTDOWN,
WARNING
STATUS INDICATORS
ANALOG AC PANEL LAMP/ FAULT EMERGENCY
METERING LAMP TEST ACKNOWLEDGE STOP PUSH
PANEL BUTTON BUTTON BUTTON
GRAPHICAL 0/MANUAL/AUTO
DISPLAY SWITCH
SIGNAL CONNECTION
Emergency stop button J2−1, J2−2
AUTO J2−3 MEMBRANE PANEL J1
4
PANEL LAMP/ J1
MANUAL J2−4 LAMP TEST 3
GND
OFF J2−5
OFF/MANUAL/AUTO GND J2−6
J1
6
EXERCISE J1
J2 5
1
GND
E−Stop J2 MAN RUN/STOP J1
2 8
J1
7
5 Auto J2
3
GND
4 3 Manual
J2
4
4
J2
1 Off 5 J1
2
RESET J1
J2 1
OFF/MANUAL/AUTO SWITCH 6 GND
GND
STATE LINE
ACTION LINE
DESCRIPTION LINE
MENU DISPLAY
AREA
GRAPHICAL
DISPLAY
MENU MENU
BUTTONS BUTTONS
ENGINE MORE>>
PAGE ALTERNATOR POWER TRAN or _\_ Page
2-12 CONTROL HISTORY/ABOUT 2-9
PAGE PAGE
2-13 2-14
MENU B
Section
3
ADJUST
PARALLEL DATA PAGE
SETUP BACK<< 2-16
GRAPHICAL
Section DISPLAY MENU
3 A
MANF TEMP 75 F
MANF PRESS ABS 180 INHG Y
RAIL PRESS ABS 180 PSI
PUMP PRESS ABS 291 PSI B
FUEL INLET TEMP 172 F
COOLANT PRESSURE 59 PSI
If you press the “CONTROL” button in Menu A, the Enable Sync: Displayed in paralleling applications
Control submenu will appear (Figure 2-10). only. Intended for service personnel to turn off the
synchronizer for troubleshooting/testing purposes.
Local CONTROL Submenu Function
When the operator panel is mounted on the control
panel assembly, the Run Mode Idle/Rated button is CONTROL
active (displayed). Note in Figure 2-10 that this but- (Local)
ton is not displayed in remote applications.
The shaded area in Figure 2-10 displays the se-
lected/active mode of operation, either IDLE or
RATED.
+ RUN MODE IDLE Y
Remote CONTROL Submenu Functions B
ENABLE SYNC
When the operator panel (Figure 2-1) is mounted
remotely of the control panel assembly, the menu
buttons in the Control submenu are used to perform
the following remote operations. (To activate these
menu buttons for remote/local use, refer to page
2-8.)
BARGRAPH TEST Y
The 0/Manual/Auto switch must be in the Auto posi-
tion to activate the Remote Menu Buttons of the Con-
trol submenu.
MODEL 1750DQKB Y
VOLTAGE 416 WYE
FREQUENCY 60 B
RATING STANDBY
CONTROLLER VERSION
RTOP DN30008.DFA Y
BATS APR 23 1999
OP PANEL VERSION B
RTOP 1.09 AUG 17 1999
BATS 1.02 MAY 6 1999
If you press the “POWER TRANS” button in Menu The symbol displayed in the middle of the Pow-
A, the Power Transfer main menu will appear (Fig- er Transfer main menu indicates which breaker
ure 2-13). The Power Transfer Control (PTC) fea- (utility or genset) is closed/opened to the load. The
ture must be installed to display this menu. symbol presently shown indicates that the utility
breaker is closed and supplying power to the load.
The PTC feature enables the PCC to monitor the
utility voltage (mains) and frequency for failure and The Power Transfer main menu also indicates if the
control the opening and closing of the contacts (cir- utility and the generator set are available to accept
cuit breakers) for the utility (S1) and the genset load. When the control detects that either source is
(S2). ready to accept load, UTILITY and/or GENSET will
be displayed in inverse video.
If utility fails, the control will initiate the genset start- The Power Transfer main menu has four submenu
ing sequence, open S1 and close S2 to the load. groups. Refer to the page numbers shown in Figure
When utility returns, the load is retransferred to the 2-13 for the Power Transfer submenu descriptions.
utility (S1 closes/S2 opens) and the control initiates
the genset shutdown sequence.
MENU MENU
BUTTONS PAGE PTC STATUS LINE PAGE BUTTONS
2-19 2-22
B UTILITY GENSET B
PAGE STATUS
2-20 TRANSFER CONTROL
DEG −123 SYNCHRONIZING
PAGE MENU
2-21 A
If you press the “Status” button in the Power Trans- Retransfer inhibit is controlled by connecting a re-
fer Main menu, the Status submenus will appear mote contact between TB3-64 and TB3-65. Closing
(Figure 2-15). the contact enables the feature and opening the
contact disables it. When enabled, the event is dis-
Connected: Indicates which source(s) is con- played on the graphical display.
nected to the load.
Available: Indicates when the corresponding
sources have acceptable output voltage and fre-
quency. Both can be available simultaneously. STATUS
+ OR − BUTTON + OR − BUTTON
MENU A MENU B
MENU
ENGINE MORE>> B ADJUST
ALTERNATOR POWER TRAN or _\_ PARALLEL DATA
MENU
CONTROL HISTORY/ABOUT SETUP BACK<<
A
SETUP MENU 1
PAGE MENU
3-4 B
GOVERNING/VOLT REG Y
PAGE CUSTOMER FAULTS B NEXT
3-5 MENU
CALIBRATION
PAGE MENU
3-6 A
SETUP MENU 2
PAGE ABOVE
3-12 MENU
PAGE MENU
3-11 A
If you press the “CUSTOMER FAULTS” button in Use the button to move to each character posi-
the Setup menu, the Customer Faults submenus tion within the fault message line.
will appear (Figure 3-5).
With the desired character position selected, use +
There are a total of four customer fault inputs. or − buttons to select the appropriate character.
(Faults 3 and 4 paralleling only.) The message dis-
played at the bottom of the menu can be modified If these messages are changed, you should note
for each of these faults in addition to selecting the these changes in the Troubleshooting section of the
following operating parameters for each fault. Operator’s manual for this generator set.
Enable − On or Off
Active − Closed or Open
Response − Shutdown, Cooldown, Derate or CUSTOMER FAULTS
Warning
Shutdown: Genset will immediately shut
down. Normally used for engine faults.
Cooldown: Cooldown sequence will be initi- CUSTOMER FAULT1:
+ ENABLE ON Y
ated before shutdown. Should not be used for
− ACTIVE CLOSED B
engine faults. RESPONSE WARNING
Derate: Used to lower kW output of genset for
warnings such as pre-high coolant tempera- ***CUSTOMER FAULT1 ******************
ture, etc. Paralleling application − controller will
reduce precentage of kW load sharing on the
set. Non-paralleling application − controller will
lower percentage of kW load by operating load
shed relay contacts. CUSTOMER FAULT2:
+ Y
Warning: Display message, genset continues
− B
to operate. RESPONSE WARNING
The Enable and the Active fields apply to the Fault 1 ***CUSTOMER FAULT2 ******************
and 4 submenus only.
If you press the “ISOLATED BUS” button in the Set- PERM WIN-TIME: Adjusts the time period (in sec-
up menu, the Isolated BUS submenus will appear onds) for which the generator set must be synchro-
(Figure 3-7). nized with the system bus, before a breaker close
signal is issued by the PowerCommand control.
Use the + and − buttons to increase or decrease the Available range is 0.5 to 5 seconds. Recommended
values in the following fields. Use the arrow () but- value for PowerCommand generator sets is 0.5
ton to move the cursor within a field or to the next seconds for isolated bus applications.
field. Exit menu to safe changes.
SYNC TIME LIMIT: This parameter adjusts the time ISOLATED BUS
delay in seconds before the Fail To Synchronize
alarm will operate.
Lower reverse power set points can result in nui- CONTINUED TO NEXT PAGE
sance reverse power shutdown faults.
If you press the “UTILITY” button in the Setup KW GOVERN GAIN: This controls the rate that the
menu, the Utility submenus will appear (Figure 3-8). generator set kW load is increased after the genera-
tor set has closed to the system bus when utility
Use the + and − buttons to increase or decrease the (mains) paralleled. Decreasing this value will result
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
in slower loading of the generator set.
field. Exit menu to safe changes. KVAR GOVERN GAIN: This controls the rate that
BASE LOAD (%): This controls the maximum kW the generator set kVAR load is increased after the
load level that the generator set will operate at when generator set has closed to the system bus when
paralleled with the utility (mains). The value shown utility (mains) paralleled. Decreasing this value will
indicates the steady state load on the generator as result in slower loading of the generator set.
a percent of the generator set standby rating.
Check generator set ratings for maximum load level
UTILITY
at which the generator set should operate when
paralleled with the utility (mains). Extended opera-
tion at load levels in excess of the generator set rat-
ing can cause abnormal engine wear or premature
engine failure. UTILITY:
+ BASE LOAD 80% Y
PF LEVEL: Adjusts the power factor that the gener- PF LEVEL 1.00
− B
ator set will run at when paralleled to the utility RAMP LOAD 3
RAMP UNLD 20
(mains). Recommended setting is 1.0. MODE MULTIPLE
RAMP LOAD TIME: This is the ramp time from
present set load to level determined by the load set
analog input. This is active when the control first en-
ters the load govern mode.
UTILITY:
RAMP UNLOAD TIME: This is the ramp time from + KW GOVERN GAIN 1.00 Y
present set load to 0 kW. This ramp is active when KVAR GOVERN GAIN 1.00
−
the load set analog input is less than 0.5 volts.
MODE − MULTIPLE/SINGLE: This controls wheth-
er the set is to operate as part of a multiple set or
single set (PLTE or PLTF) system. (Refer to “LOAD
DEMAND SHUTDOWN” and “SINGLE MODE EN-
ABLE” function descriptions in wiring diagram.) FIGURE 3-8. UTILITY SUBMENUS
UTILITY SENSORS Y
PAGE GENSET SENSORS B NEXT
3-15 MENU
TIMERS
PAGE
3-17
PTC MAIN MENU 2
PAGE
TEST/EXERCISE Y
3-18
If you press the “UTILITY SENSORS” button in the U CT RATIO: Enter the CT Ratio of the Utility L2 CT.
PTC Main Menu 1, the Utility Sensors submenus This is the Ratio to 1 Amp. Range: 1−18000 (1A).
will appear (Figure 3-10).
The following field descriptions show the valid field CAUTION This CT must be rated for 1 Amp
entries and default value (shown in parenthesis) for output (e.g. NOT 5 Amp). Be sure CT secondary
each field. circuit has burden resistor or a shorting jumper
in place before putting power through the CT.
Use the + and − buttons to increase or decrease the Example: CT Ratio = 2650:1. Thus enter 2650.
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
field. Exit menu to save changes.
U SENSOR TYPE: Enter the line-to-line (L-N) for 3
phase line-neutral voltage sensing or line-to-line
U PT VOLT LL: Enter the value of the utility line-to- (L-L) for 3 phase line-line voltage sensing. This ap-
line voltage which yields 100% voltage at the termi- plies to both the utility undervoltage and overvol-
nals of the utility (bus) PT module. tage sensors. Range: L−L, L−N (L−N).
Range: 1−15000V, adjustable by standard nominal U <wye> <delta>: Enter utility connection type.
voltage values, 100V, 10V and 1V increments (1V). Range: Delta, Wye (Wye).
The 100% voltages for each of the four possible util-
ity (bus) PT modules are as follows, based on mod- U UNLOADED KW: Enter the kW on utility Line 2 at
ule dash number: which the utility is considered as unloaded. This is
−01 = 208 volts LL the L2 kW level at which a closed transition soft
−02 = 416 volts LL transfer will disconnect from the utility.
−03 = 600 volts LL
−04 = 120 volts LL UTILITY UNDERVOLTAGE: Non-adjustable field,
always enabled.
Example 1: Nominal Utility voltage is 480V. This
means that utility (bus) PT module number −02 UTILITY OVERVOLTAGE, FREQUENCY: Used to
should be used. The voltage which will yield 100% enable or disable menu function. Choose Enabled
volts at this PT module is 416 per the above table. or Disabled (Enabled).
Thus enter 416V.
Example 2: Nominal Utility voltage is 4160V. A pri- UV PICKUP: Enter a number between 85 and
mary stage transformer with a ratio of 4200/240 is 100% of the nominal voltage (90%).
used. This means that utility (bus) PT module num-
ber −01 should be used. The voltage which will yield UV DROP OUT: Enter a number between 75 and
the 100% volts (208V from above table) is calcu- 98% of the under-voltage pick-up percentage
lated as follows: (90%).
208 x (4200/240) = 3640. Thus enter 3640V.
UV DELAY: Enter a time between 0.1 and 5.0 sec-
U NOM VOLT LL: Enter the nominal utility line-to- onds (0.5 seconds).
line voltage. For example, 480, 4160, etc.. Range:
1−15000 V, adjustable by standard nominal voltage UV MIN PHASE: Displays the lowest line voltage of
values, 100V, 10V and 1V increments (1V). the three utility phases.
If you press the “GENSET SENSORS” button in the G RAMP UNLOAD: Enter the ramp time for the
PTC Main Menu 1, the Genset Sensors submenus genset ramp unload rate during a closed transtion
will appear (Figure 3-11). soft load retransfer. Ramp rate is −100%kW divided
by this time setting. Range: 0−900 seconds (20
The following field descriptions show the valid field sec).
entries and default value (shown in parenthesis) for
each field. G UNLOADED KW: Enter the %kW (based on
standby rating) that the genset is considered un-
Use the + and − buttons to increase or decrease the
loaded. This is the %kW level at which a closed tran-
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next sition soft retransfer will disconnect from the gen-
field. Exit menu to save changes. set. Range: 0−100% (5%).
G NOM VOLT LL: Non-adjustable field, displays GEN UNDERVOLTAGE: Non-adjustable field, al-
current setting of genset nominal voltage. (See Ad- ways enabled.
just submenu to adjust the output voltage 5%.) GEN OVERVOLTAGE, FREQUENCY: Used to en-
G SENSOR TYPE: Enter the line-to-line (L-N) for 3 able or disable menu function. Choose Enabled or
phase line-neutral voltage sensing or line-to-line Disabled (Enabled).
(L-L) for 3 phase line-line voltage sensing. This ap- UV PICKUP: Enter a number between 85 and
plies to both the genset undervoltage and overvol- 100% of the nominal voltage (90%).
tage sensors. Range: L−L, L−N (L−N).
UV DROP OUT: Enter a number between 75 and
G BASE LOAD: Enter the maximum load the gen- 98% of the under-voltage pick-up percentage
set will carry during a closed transition. Range: (90%).
0−100% (80%).
UV DELAY: Enter a time between 0.1 and 5.0 sec-
G RAMP LOAD: Enter the ramp time for the genset onds (4 seconds).
ramp load rate during a closed transition soft load
transfer. Ramp rate is +100%kW divided by this UV MIN PHASE: Displays the lowest line voltage of
time setting. Range: 0−900 seconds (20 sec). the three genset phases.
If you press the “TIMERS” button in the PTC Main RETRANSFER: In a Emergency to Normal transfer
Menu 1, the Timers submenu will appear (Figure this function allows the utility to stabilize before the
3-12). load is applied.
The following field descriptions show the valid field Enter a time from 0 to 1800 seconds (600 seconds).
entries and default value (shown in parenthesis) for PGM TRANSIT: Sets the time delay for Pro-
each field. grammed Transition. A setting of 0.0 disables the
program.
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow () but- Enter a time from 0 to 60 seconds (0 seconds).
ton to move the cursor within a field or to the next MAX PARALLEL: Sets the maximum time during
field. Exit menu to save changes.
closed transition that utility and genset can be paral-
leled.
START DELAY: Sets time delay for genset engine
start. Prevents nuisance genset starting during brief Enter a time from 0 to 1800 seconds (20 seconds).
power interruptions.
If you press the “TEST/EXERCISE” button in the (TEST) switch, to operate with or without load. De-
PTC Main Menu 2, the Test/Exercise submenu will fault: OFF
appear (Figure 3-13).
EXER WITH LOAD: Feature allows genset Exer-
The following field descriptions show the valid field cise sequence, which is initiated through control
entries and default value (shown in parenthesis) for panel Exercise button to operate with or without
each field. load. Default: OFF
Changes are automatically saved when you exit FREQUENCY: Used to adjust the frequency 3 Hz.
this menu.
VOLTAGE/SPEED DROOP: These two submenus
If the generator set is operating in parallel with a apply to a genset that has the paralleling option and
system bus, the voltage and frequency adjustments is configured to operate in droop mode.
MENU A
ADJUST:
MENU START DELAY 5 SEC
ENGINE MORE>> + Y
B STOP DELAY 11 SEC
ALTERNATOR _\_ − VOLTAGE 208 1.2% B
CONTROL HISTORY/ABOUT FREQ 60.0 HZ -0.0HZ
MENU B
ADJUST:
+ STANDBY Y
VOLTAGE DROOPOFF
ADJUST − BUS L1 480 B
BUS DATA POWER FACTOR 0.80
MENU VOLT 4.99 %
SETUP BACK<<
A
ADJUST:
+ STANDBY Y
SPEED DROOPOFF
− BUS FREQ 60.0 HZ
TOTAL KW 300 KW
FREQ 60.0 0.40 HZ
CONTROL
BOX DOOR
TB8
CARD
CAGE
CUSTOMER
K11, K12, K13
CONNECTIONS
NO NO NO
NC NC NC
COIL TB3-7
TB3-5
(SWITCHED B+) COM (GND)
K16
CUSTOMER
K16
CONNECTIONS
K16
K16
SHUTDOWN ALARM
NO
NC
COIL TB3-19
TB3-24
(Low Side) COM (High Side)
MAGNETIC
PICKUP
SENSOR
ENGINE
FLYWHEEL
RING GEAR