Genset Controls: HHP Natural Gas Engine & Generator Controls

HHP Natural Gas Engine & Generator Controls
MODULE 4
Genset Controls
Refresh: Genset Layout
GIB
GIB (v.2) Contents:

• A/C MCB’s & Contactors
• VDC Interfaces & Controls
• Engine Control (CM700)
• Genset Control (PCC 3.3)
• VDC Primary Supply
• Customer Connections
• HMI (HMI320 & HMI114)
• Customer I/O Modules
(AUX101’s #3 & #4)
• Alternator Mains Decoupling
Relay (Optional)
CUMMINS, INC TRAINING - Gas Engine Controls / Genset Controls / KDL / 10 - 2009 / REV 1.1 2
GIB Components
External
HMI320
HMI114
VDC
Isolator
E-Stop
VAC
Isolator Harness
Connections
GIB Components
Internal (Doors Removed) Service
VDC Termination Rail Rail
VAC Termination Rail
PCC3300
Rail for
Optional Customer
Mains Termination
Decoupling Rail
Relay
VAC Aux Termination Rail

CM700
AUX101 AUX101 (ECM)
(3) (4)
GIB Components
VAC Supply from VAC Isolator
37
38
39
42
43
44
31
32
33
34
35
36
40
41
45
46
47
48
49
50
7 8
Battery
1 2 3 4 5 6 PSU Check
Module KM’s
VDC Source
MCB’s Management &
Isolator
GIB Components
VAC Termination Rail – MCB’s
COMPONENT MODULE RATING
Contactor 12A @ 440VAC

MCB1
- MCB5 Class 10 for 3Ph Motors
Circuit Breaker
Bus Bar input from VAC Isolator Set Range: 3 to 12A
Contactor 32A @ 440VAC

MCB6 Class 10 for 1Ph Motors
Circuit Breaker
Set Range: 4.5 - 18A
MCB7 Circuit Breaker 3 Pole, 2A
MCB8 Circuit Breaker 6A
1 2 3 4 5 6 7 8
GIB Components
Contactor + CB Assemblies (MCB’s 1 Æ 6)
GIB Components
- Continued -
CB Trip Position
CB Off Position CB On Position
CB Reset Position
CB Trip Test
Thermal / Magnetic
Trip Settings
GIB Components
- Continued -
L3
Source L2
L1
DC
A/C
N.O. Auxiliary
N.C. Contacts
Contactor
Source +
Controls Controlled
Ground -
L1
Output L2
L3
GIB Components
Refresh: VAC Termination Rail
VAC Supply from VAC Isolator
37
38
39
42
43
44
31
32
33
34
35
36
40
41
45
46
47
48
49
50
7 8
Battery
1 2 3 4 5 6 PSU Check
Module KM’s
VDC Source
MCB’s Management &
Isolator
GIB Components
VAC Termination Rail – VDC Source
Genset & Engine Control Systems
VAC Isolator Input Battery

380Æ500VAC 3Ph Check
50/60 Hz Module
Diagnostics
PSU:
Output: 20A
24VDC 480W
VDC + Æ VDC Iso.
VDC +
VDC Back-up
Batteries
CAUTION: This system is not
intended to be the VDC source (2 x 12VDC in Series)
to the Genset electronic starter
motors.
MCB7
VAC Supply
L1 L2 L3
GIB Components Battery
VAC Termination Rail – VDC Source Check
Genset & Engine Control Systems Module
Batt. In Out
+ + +
PSU
DC
- - -
A/C + + - -
To Diagnostic
Relay Contact
(Not Used)
VDC Source
(Not Backed Up)
(Not Used)
SDC Iso. Switch
VDC Source
(Backed Up)
+ - + - + - + -
Backup Backup
Battery #1 Battery #2
GIB Components
VDC Source Backup Battery Location
• Cover
• Battery Pack (x2)
• Genset Skid
VDC Source Backup w/ Cover On

DO NOT use as a step!
VDC Source Backup w/ Cover On

Side Profile
GIB Components
VAC Termination Rail – VDC Source (Backup Batteries)
Genset & Engine Control Systems
GIB Components
VAC Termination Rail – KM’s
COMPONENT RATING
Input (max): 24VDC±20% 6.6mA 160mW

VDC Response / Drop: 15.4V / 6.5V
KM31 - KM36,
IDC Pickup / Drop: 4mA / 1.2mA
KM39 - KM41,
KM45 - KM50
Switch (max): 250VAC, 6A Input from
Switch (min): 12V, 100mA VAC Isolator
Input (max): 24VDC±10% 16mA 400mW
VDC Response / Drop: 16.8V / 2.4V
KM37 - KM38,
KM42 - KM44
Switch (max): 250VAC, 10A
Switch (min): 10V, 100mA
GIB Components
KM’s 31 – 36, 39 – 41, 45 - 50
Green LED
On = Coil Energized
Relay
(Pluggable)
Relay
Base
GIB Components
KM’s 37, 38, 42 - 44
Relay
(Pluggable)
Relay
Base
GIB Components
VDC Termination Rail
GIB Components
100’s
4 Wire Connections
COMPONENT RATING per Terminal
Surge Voltage (Max): (excluding Jumper Bar)
- IEC: 8kV
Nominal Voltage (Max):
- IEC = 800V
100's
- UL / CSA = 600V
(all)
Nominal Current (Max):
- IEC / CSA = 27A
- UL = 25A
CSA / UL: AWG 30 - AWG 12
Insert Jumper
Bar Here
Jumper Bar Jumper Bar

N1 N2
GIB Components
Fuses (F)
COMPONENT RATING
Surge Voltage (Max):
- IEC: 6kV
- IEC = 400V
Fuse Block's
- UL / CSA = 300V
(all)
- IEC / UL = 30A
VDC+ Red LED - CSA = 25A
Jumper Bar CSA / UL: AWG 22 - AWG 10
VDC Isolator On = Open Fuse
F2 – F15
Spade Type
Fuses
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
VDC+ out
Control Circuit
GIB Components
S’s
S3
S5
S7
S11
S13
S19
S21
S23
S4
S6
S8
S10
S12
S20
S24
S1
S2
S9
S14
S15
S16
S17
S18
S22
GIB Components
CM’s
Resistor
COMPONENT RATING
Resistor 120Ω, 0.33W
GIB Components
KM’s
KM15
KM22
KM16
KM12
KM14
KM17
KM18
KM19
KM11
KM20
KM21
KM13
GIB Components
KM11 & KM13
COMPONENT RATING
Coil: 24VDC, 69mA, 350Ω
Contact (pf = 1): 110VAC 10A, 24VDC 10A
- Carry Current: 10A
- Switching Voltage (Max): 250VAC, 125VDC
Relay - Switching Current (Max): 10A
KM11 - Switching Power (Max): 1100VA, 240W
KM13 Contact (pf = 0.4): 110VAC 7.5A, 24VDC 5A
- Carry Current: 10A
- Switching Voltage (Max): 250VAC, 125VDC
- Switching Current (Max): 10A
- Switching Power (Max): 825VA, 120W
GIB Components
VAC AUX Termination Rail
V4 – V3
V8 – V7
V12 – V11
T4 – T3
T6 – T5
V2 – V1
V6 – V5
V10 – V9
T2 – T1
AC1 through AC25
VAC
Isolator
GIB Components
AC1 through AC25
COMPONENT RATING
Surge Voltage (kV) (Max):
- IEC: 8
Nominal Voltage (V) (Max):
- IEC / UL / CSA = 800 / 600 / 600
Terminal Block Nominal Current (A) (Max):
- IEC / UL / CSA = 24 / 25 / 27
Wire Size (AWG) (Min - Max) :
- CSA: 22 - 10
- UL: 30 - 12
GIB Components
T1 through T6, V1 through V12
Odd #
Connections
Even #
Connections
COMPONENT RATING
Surge Voltage (kV) (Max):
- IEC: 6
- IEC / UL / CSA = 500 / 300 / 300
Terminal Block Nominal Current (A) (Max):
- IEC / UL / CSA = 20 / 10 / 10
- CSA: 26 - 12
- UL: 30 - 12
GIB Components
VAC Isolator
VAC Supply
To GIB
COMPONENT RATING
- IEC = 440
VAC Nominal Current (A) (Max):
Isolator Isolation Switch - IEC / UL & CSA = 100 / 100
Motor Load Rating (HP) (Max):
- UL & CSA (240V): 25
- UL & CSA (480V): 40
VAC Supply
From Customer
380 – 440VAC
50 Hz 3Ph
GIB Components
Customer Terminal Rail
Genset
Connections
M1 through M4
(paired)
C93 through C100
C301 through C304

110 / 240 VAC
Euro / US Socket
Customer
Connections
GIB Components
C1 through C76
Odd #
Connections
Even #
Jumper Bar Connections
N3
Jumper Bar
Connection
C1 through C76
(paired)
GIB Components
C77 through C92
Jumper Bar
Jumper Bar
Connection
COMPONENT RATING
Surge Voltage (Max):
- IEC: 8kV
- IEC = 800V
- UL / CSA = 600V
Terminal Block
- IEC = 24A
- CSA = 27A
- UL = 25A
UL: AWG 30 - AWG 12
GIB Components
C93 through C100
Odd #
Connections
Jumper Bar
Even #
Connections
Jumper Bar
Connection
GIB Components
R1 through R18, M1 through M4
Jumper Bar
Connection
Resistor
R1 through R18 COMPONENT RATING

Resistor 120Ω, 0.33W
GIB Components
Euro / US Socket
COMPONENT RATING
Socket 250 / 125 VAC - 2P+E 10 / 15A
Euro / US Socket
110 / 240 VAC
GIB Components
C301 through C304
Odd #
Connections
Jumper Bar
Even #
Connections
Jumper Bar
Connection
GIB Components
C322 through C327 (CT Shorting)
Slider
(Engage in jumper to
connect with locked block)
Jumper
Lock
(Retains the engaged
position for one
disconnect terminal)
C322
through
C327
COMPONENT RATING
- IEC / UL / CSA = 500 / 300 / 300
Nominal Current (A) (Max):
Disconnect Terminal - IEC / UL / CSA = 57 / 45 / 45
- CSA: 20 - 8
- UL: 20 - 8
GIB Components
C101 through C150
Odd #
Connections
Even #
Connections
Jumper Bar
Connection
GIB Components
Service Rail
Engine Aux Oil Pump Stay-In-Boot J1939 R232

Push-Button Switch (CM850) (Cense)
On = Button Depressed On = 1 Service Tool Connection
INSITE™
ECM Keyswitch
Switch
On = 1
GIB Components
Service Rail
STCC & STCD
STCC STCD
J1587 / J1939 INSITE Service Tool Connector Socket RS-232 CENSE Software Download
Connector Plug - Shown w/ Mounting
Screws for Connector Pattern Identification
A
24VDC (–)
100
D
J1939 (–)
BLACK 303
C RS232 TX –
J1939 (+)
CLEAR 309
E
J1939
RED 302 RS232 RX –
SCREEN 304 B
24VDC (+)
RED 308
156
F
J1587 (+)
RED 318
I
NOT USED
RS232 GND –
G
J1587 (–)
BLACK 310
BLACK 319
H
NOT USED
GIB Components
Internal (Doors Removed)
Service
VDC Termination Rail Rail
PCC3300
Rail for
Optional
Customer
Mains
Termination
Decoupling
Rail
Relay
VAC Aux Termination Rail

CM700
AUX101 AUX101 (ECM)
(3) (4)
GIB Components
PCC3300 – Refresh
TB15
TB10 J14 TB9
Genset Control
TB7 • Isochronous or droop governing
TB8 • Remote start / stop / e-stop
• Temperature variable in governing algorithm
• Local e-stop
CT1
• Sleep mode
CT2
Engine Control
TB5 • SAE J1939 CAN communications & control
• Cycle cranking limits
CT3
• Time delay (start & stop) for cool down
J12
Alternator Control
TB3 • Digital output voltage regulation: 3Ph L-L via shunt or PMG
• Droop voltage regulation
TB1 • Torque matched V / Hz overload control
J22 • Fault current regulation
J26 J25 J20 CUMMINS, INC TRAINING - Gas Engine Controls / Genset Controls / KDL / 10 - 2009 / REV 1.1 41
GIB Components
PCC3300 – Refresh – Cont’d
Paralleling Control
TB15 • First Start Sensor™
TB10 J14 TB9
• Digital synchronization of:
• frequency
• slip frequency
• phase
• voltage
• kVAR & kW load sharing
TB7 • Load govern mode
B8 • Sync check for breaker closure
• Genset & utility AC bus metering
• Power transfer control (PTC)
CT1 • over / under voltage / frequency protection
• Phase loss / rotation protection
CT2 • Genset breaker trip sensing
• Start / stop / transfer / re-transfer / programmed transition
delay & maximum parallel time control
B5 • Utility & genset CB control & diagnostics
CT3 • Extended paralleling mode
• Exercise clock
J12
Applications
B3
• Standalone
• Synchronizer Only
B1 • Isolated Bus
J22 • Utility Single / Multiple
• Protective Functions
• Battle short mode
• Derate
• Customer configurable alarms & state inputs
J26 J25 J20 CUMMINS, INC TRAINING - Gas Engine Controls / Genset Controls / KDL / 10 - 2009 / REV 1.1 42
GIB Components
PCC3300 – CT’s
Standard Function Connection LBNG Function
1 Genset Bus or Utility L1 Current C311 & C312 Utility CT1 (L1) Output Current Sense
2 Genset Bus L2 or Neutral or Utility L2 Current C313 & C314 Utility CT2 (L2) Output Current Sense
3 Genset Bus or Utility L3 Current C315 & C316 Utility CT3 (L3) Output Current Sense
GIB Components
PCC3300 – TB1 Basic
1 PCCNet A (+) RS485 R5 PCCNet A (+) RS485
2 PCCNet B (-) RS485 R4 PCCNet B (-) RS485
3 PCCNet Sheild R3 PCCNet Sheild

Low Side Driver: Ready to
4 Load O/P KM45-A2 Return: KM45 Relay Coil (Ready to Load)
5 Supply: Fused 3A B+ - Supply: Fused 3A B+
6 Config O/P #1 - Relay NO KM31-A2 Return: KM31 Relay Coil (Common Warning)
7 Config O/P #1 - Relay COM TB1-9 Return: TB1-6
8 Config O/P #2 - Relay NO KM32-A2 Return: KM32 Relay Coil (Common Shutdown)
TB1-7 & TB1-
9 Config O/P #2 - Relay COM 13 Return: TB1-8
Return: Fused 3A B+ /
10 Remote Start (Wake Up) - Return: Fused 3A B+
11 I/P: Remote Start (Wake Up) R7 & C27 Supply: Remote Start
12 Config I/P #1 C7 Config I/P #1
13 Config I/P (Common) TB1-7 Return: Config I/P #1 & #2
14 Config I/P #2 C9 Config I/P #2
15 Local E-Stop Return KM18-1 (11) Return: KM18-1 Contact (Remote E-Stop)
16 Local E-Stop (Wake Up) KM18-1 (14) Supply: KM18-1 Contact (Remote E-Stop)
GIB Components
PCC3300 – TB3 Customer I/O
1 Return - Return
2 Master CAN Shield C79 Master CAN Shield
3 Master CAN L C78 Master CAN L
4 Master CAN H C77 Master CAN H
5 Config O/P #20 State KM47-A2 Return: KM47 Relay Coil (Start Inhibit Event)
6 Config O/P #21 State - Config O/P #21 State
7 - - -
Return: KM41 Relay Coil (Engine @ Idle
8 Config O/P #22 State KM41-A2 Speed)
9 Config I/P #20 - Transfer Inhibit C57 Transfer Inhibit (PTC)
10 Config I/P #21 - Retransfer Inhibit C59 Retransfer Inhibit (PTC)
11 Master First Start O/P State C29 First Start Arbitration
12 Return - Return
GIB Components
PCC3300 – TB5 Circuit Breaker Control
TB7 Genset Bus Voltage
1 Genset Bus or Utility L1 Voltage C301 Utility L1
4 Genset Bus or Utility Neutral Voltage C304 Utility Neutral
1 Genset CB Close KM38-A1 Supply: KM38 Relay Coil (Genset CB Close)
2 Genset CB Close Return TB5-4 Return: TB5-1
3 - - -
4 Genset CB Open State KM37-A1 Supply: KM37 Relay Coil (Genset CB Open)
5 Genset CB Open State Return TB5-7 Return: TB5-4
6 Utility CB Close State KM43-A1 Supply: KM43 Relay Coil (Utility CB Close)
7 Utility CB Close State Return TB5-9 Return: TB5-6
8 Utility CB Open State KM44-A1 Supply: KM44 Relay Coil (Utility CB Open)
9 Utility CB Open State Return S22 Return: TB5-8
GIB Components
PCC3300 – TB8 Premium

Return: Fault Reset
1 (Wake Up) - Return
2 Return: Start Type - Return

Low Side Driver: Delayed
3 Off O/P - Return: Delayed Off
Low Side Driver: Switched
4 B+ (Run) O/P KM39-A2 Return: KM39 Relay Coil (Run)
Supply: Fault Reset
5 (Wake Up) C25 & R8 Supply: Fault Reset
6 Supply: Start Type C33 Supply: Start Type
7 Supply: Config I/P #3 C11 Supply: Config I/P #3
8 Supply: Config I/P #4 C13 Supply: Config I/P #4

Low Side Driver: Config Return: KM48 Relay Coil (Common
9 O/P #4 KM48-A2 Fault)
Low Side Driver: Config Return: KM33 Relay Coil (Common
10 O/P #3 KM33-A2 Controlled Shutdown)
Low Side Driver: Load Return: KM46 Relay Coil (Load
11 Dump O/P KM46-A2 Dump)
12 Discrete I/P Return - Return
13 Discrete I/P Return - Return
GIB Components
PCC3300 – TB9 Analog I/O
1 Config Analog I/P #1 - kW Load Set Point C81 Sense: kW Load Set Point
2 Analog Return C82 & C83 Return: kW & kVAR Load Set Point
Config Analog I/P #2 - kVAR Load Set
3 Point C84 Sense: kVAR Load Set Point
4 Config Analog O/P #2 - Voltage Bias C85 Speed Bias
5 Config Analog O/P #1 - Speed Bias C88 Voltage Bias
6 Analog Return C86 & C87 Return: Speed & Voltage Bias
7 kW Load Share Level C89 Return: kW Load Share
8 - C90 kW Load Share
9 Load Share Shield C80 Return: TB9 Wire Shields
10 kVAR Load Share Level C91 Return: kVAR Load Share
11 - C92 kVAR Load Share
GIB Components
PCC3300 – TB10 CB Status
1 Return - Return
2 Return - Return
3 Utility CB Position (A) C37 Utility CB Position (A)
4 Config I/P #23 - Utility CB Position (B) - Utility CB Position (B)
5 Utility CB Tripped C39 Utility CB Tripped
6 Config I/P #25 - Utility CB Inhibit C41 Utility CB Inhibit
7 Genset CB Position (A) C43 Genset CB Position (A)
8 Config IP #26 - Genset CB Position (B) - Genset CB Position (B)
9 Return - Return
10 Genset CB Tripped C45 Genset CB Tripped
11 Config I/P #28 - Genset CB Inhibit C47 Genset CB Inhibit
12 Config I/P #29 - Utility Single Mode Verify C49 Utility Single Verify
13 Config I/P #30 - Sync Enable C51 Sync Enable
14 Config I/P #31 - Load Demand Stop C53 Load Demand
15 Congif I/P #32 - Extended Parallel C55 Ramp Load / Unload
16 Return - Return
17 Return - Return
GIB Components
PCC3300 – TB15 Modbus (RS485) / PC Tool
& J12 Genset Current
1 RS485 Shield - RS485 Shield
2 - - -
3 RS485 Data A - RS485 Data A
4 RS485 Data B - RS485 Data B
5 System Wakeup R6 System Wakeup
1 Genset L1 CT1-X1 See AVR WD's Genset L1 CT1-X1
4 Genset L1 CT1-X2/X3 (Common) See AVR WD's Genset L1 CT1-X2/X3 (Common)
GIB Components
PCC3300 – J14 Modbus / PC Tool
J22 Genset Voltage
1 - - -
2 RS232 (R) - RS232 (R)
3 RS232 (T) - RS232 (T)
4 - - -
5 RS232 (G) - RS232 (G)
6 - - -
7 - - -
8 - - -
9 - - -
1 Alternator Terminal U (R) See AVR WD's Alternator Terminal U (R)

PT’s employed where
L-L Voltage > 600VAC 2 Alternator Terminal V (Y) See AVR WD's Alternator Terminal V (Y)
3 Alternator Terminal W (B) See AVR WD's Alternator Terminal W (B)
4 Alternator Terminal Neutral See AVR WD's Alternator Terminal Neutral
GIB Components
1 Chassis Ground GND Chassis Ground
2
PCC3300 - J20 Genset
Return: B+ S18 Return: B+
3 Relay Driver: Switched B+ (Run) Control - Switched B+ Low Side Driver
4 Return: B+ S18 Return: B+
5 Return: Config Digital I/P #3 (Low Coolant Level Switch / Wake Up) KM21-2 (21) Return: Fire Shutdown
6 Return: Config Digital I/P #4 (Fuel Level Switch / Wake Up) - Return: Earth Fault
8 Supply: Config Digital I/P #12 (Rupture Basin Switch / Wake Up) S17 Return: Differential Fault Shutdown
9 Fused B+ - Control Fused B+ Supply
10 Fused B+ S17 Control Fused B+ Supply
11 Starter Disconnect I/P - Starter Disconnect I/P
13 Relay Driver: B+ Oil Priming Pump Control - Relay Coil B+ Supply
14 Relay Driver - FSO Control S19 Relay Driver - FSO
15 Relay Driver - Starter Control - Relay Driver - Starter
16 Relay Driver - Oil Priming Pump Control - Relay Driver - Oil Priming Pump
17 Supply: Config Digital I/P #3 (Low Coolant Level Switch / Wake Up) KM21-2 (24) Supply: Fire Shutdown
18 Supply: Config Digital I/P #4 (Fuel Level Switch / Wake Up) C61 Supply: Earth Fault
19 Supply: Config Digital I/P #12 (Rupture Basin Switch / Wake Up) C63 Supply: Differential Fault Shutdown
22 Alternator Flash I/P - -

GIB Components
PCC3300 – J25 Display
1 - - -
2 I/P (Wake Up on Open) KM17-1 (14) Supply: KM17 Contact 1 (Local E-Stop)
HMI320 J29-2
3 PCCNet B (-)
HMI114 J1-4
PCCNet B (-)
HMI320 J29-1
4 PCCNet A (+)
HMI114 J1-3
PCCNet A (+)
HMI320 J29-3
5 System Wake Up
HMI114 J1-5
System Wake Up
6 Return: I/P (Wake Up on Open) KM17-1 (11) Return: KM17 Contact 1 (Local E-Stop)
7 Return: Discrete I/P - -
HMI320 J6-2
8 Return: B+
HMI114 J28-3
Return: HMI320 & HMI114 B+
9 PCCNet Shield - PCCNet Shield
10 Run (Wake Up) HMI320 J29-6 Run (Wake Up)
11 Auto (Config Wake Up) HMI320 J29-4 Auto
HMI320 J28-1
12 HMI Fuse B+
HMI114 J6-1
Supply: HMI Fuse B+
GIB Components
PCC3300 – J26 Interconnect (AVR & Engine)
1 J1939 Shield ? J1939 Shield
2 Backup Start Disconnect AUX103 J19-3 Backup Start Disconnect
3 AVR PWM - AUX103 J19-9 AVR PWM -
4 - - -
5 Return: AVR Fused B+ AUX103 J19-8 Return: AVR Fused B+
6 - - -
7 Field Current (-) AUX103 J19-10 Field Current (-)
8 - - -
9 Supply: AVR Fused B+ AUX103 J19-1 Supply: AVR Fused B+
10 J1939 (-) ? J1939 (-)
11 J1939 (+) ? J1939 (+)
12 - - -
13 - - -
14 Field Current (+) AUX103 J19-4 Field Current (+)
15 ECM Keyswitch KM22-A2 Return: KM22 Relay Coil (ECM Keyswitch)
16 AVR PWM + AUX103 J19-2 AVR PWM +
17 - - -
18 - - -
GIB Components
AUX101-3 & 4
# Rating
Relay O/P’s
1
2
3
30VDC
4 250VAC
5 NO: 5A
6
NC: 3A
Analog I/P’s
7
# Rating
8
1
Sense I/P: + / - 5V
2
3
4 Sense I/P: 0 - 5V
Current O/P: 5VDC,
5
20A Max
6
7
Sense I/P: 0 - 38V
8
GIB Components
AUX101-3 & 4
J1 J2 J3 J4
1 Relay 1 O/P NO Relay 5 O/P NO Relay 7 O/P NO
2 Relay 1 O/P Common Relay 5 O/P Common Relay 7 O/P Common
3 PCCNet A (+) Relay 1 O/P NC Relay 5 O/P NC Relay 7 O/P NC
4 PCCNet B (-) Relay 2 O/P NO Relay 6 O/P NO Relay 8 O/P NO
5 System Wake-Up Relay 2 O/P Common Relay 6 O/P Common Relay 8 O/P Common
6 Relay 2 O/P NC Relay 6 O/P NC Relay 8 O/P NC
7 Relay 3 O/P NO
8 Relay 3 O/P Common
9 Relay 3 O/P NC
10 Relay 4 O/P NO
11 Relay 4 O/P Common
12 Relay 4 O/P NC
GIB Components
AUX101-3 & 4
J10 J11 J14

1 J1939 H Analog I/P #1: Sense Supply (B+): AUX101
2 J1939 L Analog I/P #1: Sense Return Return (B-): AUX101
3 Analog I/P #3: Current Return Analog I/P #2: Sense
4 Analog I/P #4: Current Return Analog I/P #2: Sense Return
5 Analog I/P #5: Current Return Analog I/P #3: Sense
6 Analog I/P #6: Current Return Analog I/P #3: Sense Return
7 5VDC Supply #1 (20A Max) Analog I/P #4: Sense
8 5VDC Supply #2 (20A Max) Analog I/P #4: Sense Return
9 Analog I/P #3: Current Supply Analog I/P #5: Sense
10 Analog I/P #4: Current Supply Analog I/P #5: Sense Return
J14
11 Analog I/P #5: Current Supply Analog I/P #6: Sense
12 Analog I/P #6: Current Supply Analog I/P #6: Sense Return
13 Analog I/P #7: Sense
14 Analog I/P #7: Sense Return
15 Analog I/P #8: Sense
16 Analog I/P #8: Sense Return
GIB Components
AUX101-3 & 4
AUX101-3 AUX101-4
1 Derate Authorization C35 GIB Isolator Open VAC Isolator
2 Start System Trip C31 Alternator Heater On KM6 (14)
3 Vent Fan Trip C3 Alternator DE Bearing Temperature See AVR WD's
Analog 4 Louvres Closed C1 Gearbox Oil Pressure 1-B

I/P 5 Radiator Fan Trip C5 Gearbox Oil Temperature 1-D
6 Start Inhibit N1 C17 Engine DC PSU Unavailable VDC Reg Alarm 4
7 Start Inhibit N2 C19 Alternator Heater Trip MCB6-SD (95)
8 Start Inhibit N3 C21 - -
1 - - Alternator Heater Control (NO) MCB6-A2
2 - - Emergency Stop P/B (NO) KM18-2 (24)
3 Vent Fan Control (NO) KM35-A1 - -
Relay 4 Louvres Control (NO) KM36-A1 - -

O/P 5 Radiator Fan Control (NO) KM34-A1 - -
6 - - - -
7 - - - -
8 - - - -
GIB Components
AUX101-3, 4 & 5 – Default Functions
Warning
Key: Digital Input (H=active high, L=active low) Key:
Analogue Input Shutdown
I/O Type Digital Output
Shutdown Type Controlled Shutdown
GIB Components
Internal (Doors Removed)
PCC3300
Rail for
Optional
Mains
Decoupling
Relay
CM700
AUX101 AUX101 (ECM)
(3) (4)
GIB Components
Mains Decoupling Relay (Optional)
Purpose:
Protect the Genset’s alternator from the utility
Protect the utility from the Genset’s alternator
Meet utility protection requirements (VDEW, G59) for utility paralleling applications
Space allotted to fit one mains decoupling relay:

Manufacturer: Woodward SEG
Model: XRN2-1
GIB Components
Mains Decoupling Relay
(Optional)
XRN2-1 Protection Features:

Over / under voltage
TIME (SECONDS)
Over/ under frequency

Vector Surge
GIB Components
(Optional)
FAULT INDICATORS FAULT INDICATORS SELECTION OF TEST TRIPPING

(Parameter) (Phase & Function) FUNCTION & & SOFTWARE
RESETTING OF VERSION
LED illuminates when the respective LED illuminates when the respective
DEVICE ENQUIRY
adjustment value has been selected measuring value has been selected
(GREEN when setting / RED after (GREEN normal / RED tripped ).
activation value reached ).
ON
ALHA NUMERIC KEYS FOR KEY FOR STORING DIP SWITCHES - OFF
LED INDICATOR CHANGING SET ‘SET’ VALUES
VALUES
Woodward XRN 2 – 1 Fascia
GIB Components
(Optional)
XRN2-2 Terminal Connections
Voltage Analogue I/P

(A1& A2) Not used?
Blocking
Input
U/V U/F ∆Ө Self

TRIP ALARM ALARM ALARM Supervision
External
Reset
External Tripping - All Indication of over Indication Indication Indication self Network
reset & 11, 12, 14 and & under voltage of over & of df/dt- supervision Connection
blocking I/P 21, 22, 24 alarm. under alarm (internal fault To PCC
Not used ? 31, 32, 34 and 41, frequency 61, 62, of the unit) Net or not
42, 44 (N/O) alarm. 64 (N/O) 71, 72, 74 used ???
Set o/p to AUX config I/P and configure 51, 52, 54 (N/C)
(N/O)
GIB Components
(Optional)
XRN2 - 1Adjustments and Setting.

Four DIP Switches are located on the front panel. Their function is shown in the table
below. Switch 4 has no function assigned.
Manual RESET of alarm RELAY is Manually carried out by pushing the “SELECT/RESET”
button on the relay fascia for approximately 3 seconds.
Factory default Password is “++++” and should not be changed. Enter this code to make
changes to parameter settings for up to 5 minutes (auto time out).
After password press “ENTER” to call up the Parameter Menu. Press “SELECT/RESET” to
reach parameter to be set. Press “+”/”-” to change setting then “ENTER” to save new
setting.
After entering the password the “TRIP” button may be used to test the output Alarm relay
circuits (both tripping & signaling contacts operate).
CPG DIP
Default
1- OFF
2 - ON
3 - OFF
N/A
Refresh: Genset Layout
Alternator Control Box (Rear of Genset)
Shown on Frame 8 Alternator – Cover Removed
Alternator
AVR AUX101
(AUX105) (5) Termination
Rails
Protocol and Interface Standards
Modbus is the Industry standard microprocessor communications package protocol.
Modbus communication is used to communicate between PCC3300, B&R HMI, I-watch (RMS) and any
customer interface that may be required .
Modbus can operate on RS422 or RS485 Interface connections. We run Modbus on RS485 interface.
150Ώ Line terminating resistors required – polarity sensitive.
RS 232
INTERFACE
RX RX RS232 Interface Standard connection
TX TX
Error checking by multi transmit (parity check),
if not received shuts down.
GND GND Maximum communicating distance 5 mtrs.
9 PIN ‘D’ Baud rate for a RS232 / 422 9 PIN ‘D’ RS422 Interface Standard connection
Connectors
Connectors interface is 2,400 to 19,600 baud.
RS 422 Error checking by collision detection and
INTERFACE RX1 parity check, both lines work in parallel
RX1
allowing higher power transmission.
TX1 TX1
RX2 RX2 Maximum communicating distance 15 mtrs.

TX2 TX2
RS485 Interface Standard connection

Baud rate for RS485
9 PIN ‘D’ 9 PIN ‘D’
Connectors interface is 250K baud. Connectors
RS485 uses the new RS222 connection (2
RS 485
wire as RS232) which is then electrically
INTERFACE enhanced to give RS422 type operation.
RX RX
TX TX
MODBUS PCC3300
(1900 baud)
Network Data Links Slave

Master \ Slave
Cummins (Point to Point)
Peer to Peer J1939 Proprietary Peer to Peer Data Link
(Multi-tasking) CAN 2.0B (Multi-tasking)
Data Link (250K baud) Genset Control (500K baud) Data Link
System
(PCC3300/AUX101) Master
CENSE on H/E
SERVICE TOOL QSK 60G
CONNECTOR
CM700 Customer
Options
CM700 (PLC/HMI)
J1
93
CM558
CM558
9
Sy
C
A
st
N
em
CM558
N
(+) CM558
et
B
(-)
w
us
or
N
(SHIELD)
k
et
B
w
ac
or
Networks constructed
kb
k
CENSE on
on
B
with twisted two core standard

ac
e
shielded cable.
kb
QSK 60G
on
External terminating
e
resistors fitted where

indicated CONNECTION CHECKS
120 Ohm - J1939 / CAN 2.0B Polarity - Terminating Resistors - Shield Connections
150 Ohm - MODBUS CUMMINS, INC TRAINING - Gas Engine Controls / Genset Controls / KDL / 10 - 2009 / REV 1.1 68
PCC Net Overview
Protocol
PCC Net is a communication system that uses a standardized
proprietary protocol unique to Cummins Power generation.
Interface
2-wire, RS-485 Data Connection TB1-1 & TB1-2 Shielded
2-wire Power Connection. twisted pair
Data terminals are polarity sensitive TB1-5 (B+) & TB1-3 (B-)
PCC Net Must use a “daisy chain” topology for data connections
Up to 4,000 feet network data length
No Termination Required
Total of 20 PCCNet devices on one network
Control System Network Line Diagram
J1939 +
PGI BUS J1939 Network
120Ω 120Ω
(250K baud)
J1939 –
Note: When CM850’s

System CENSE fitted in place of
PCC3300 Inputs / CM700 CM558-A CM558-B OR CENSE they connect
to the CAN network
Outputs CM850 as shown.
150Ω
CAN 2.0B +
120Ω CAN 2.0 B Network
120Ω
(500 K baud)
CAN 2.0B –
OPTIONAL Cummins Customer

DEVICES I-watch (RMS) PLC
MODBUS +
MODBUS link
150Ω
PCC Net (19,200 baud)
(19,200 baud) MODBUS –
Signal
- 24v dc
+ 24v dc
Note A; Network devices are designed to be
‘Daisy Chain” connected as shown.
AUX HMI114 HMI320 OPTIONAL DEVICES
( PHII Release )
101/2 Bargraph Display
Note B; PHII release J1939 “System Bus network”
to other PCC3300 controllers not shown.
Auxiliary Control
AUXILIARY DATA DESCRIPTION DATA SOURCE DATA OUPUT

PCC3300 CM700 HMI320 MODBUS
Alternator Heaters Off 9 z z
Alternator Heaters Requested 9 z z
Coolant Circulating Pump Off 9 z z

This table shows
the controlling
Coolant Circulating Pump Requested 9 z z
device and the
Coolant Heaters Off 9 z z available output
GIB Isolator Open 9 z z data sources for
GIB Isolator Closed 9 z z
each system
Lube Oil Low 9 z z
Lube Oil Priming Pump Off 9 z z
Lube Oil Priming Pump Requested 9 z z
Oil Heater Off 9 z z
Oil Heater Requested 9 z z
Generic PCC Net Devices
REMOTE HMI 320 HMI 114
HMI 320
HMI 112
AUX 101/102 – for PCC Net

Aux boards to be added in
the next software release
which will enable HMI113
customers to add remote Future development
I/O that can be configured for LBNG
for any system alarm with
ease
* The device list is subject to change as more devices are added or removed
Operator Interface & Data Displays
HMI320
Overview
HMI 320 – Main Operator Interface
Manual / Start / Stop / Auto / Reset
selection, circuit breaker command, system
display and menu navigation.
Protocol / Interface connection – RS485 /
PCC NET HMI 114
HMI 114 – Bar Graph

Graphic Digital Display of A,V,PF and Hz.
Protocol / Interface connection – RS485 /
PCC NET
These components will be covered in detail in Module 6.
AUX103 AVR Driver Module
Features:
12 and 24vdc Operation
InPower Compatible (PC Based Service J17
Field Output
Tool)
The AVR receives digital signals from
the PCC3300 base board to switch /
control the level of power supplied for
Alternator excitation.
Power for Alternator excitation comes J18
Power Input
from the Permanent Magnet Generator
(PMG).
The AUX103 also provides starter
disconnect using the output frequency J19
Connection to PCC33000
from the Alternator. Ground / Earth base board (J26).
Wire
The AUX103 is located in the
Alternator box.
Alternator Box Layout
The Alternator box houses

the Aux 101-5 Alt I/O module
and the AUX103 AVR Driver
Module.
The alternator box also
provides access to the
interconnection terminals. No
additional fusing or protection
is provided for these
components.
A flexible harness connects
the Alternator box to the GIB.
AVR Driver AUX Board Interconnection Flexible
Module (101-5) Alt Terminal Block Harness
(AUX103) (TB x – xx)
Understanding Control Configuration & Set Up
• ISLAND MODE PARALLELING

- ISOCHRONOUS LOAD SHARING FOR
MULTIPLE GENERATORS.
- DROOP LOAD SHARING FOR MULTIPLE
GENERATORS. ( WHEN PARALLELING WITH
NON CUMMINS SUPPLIED GENERATORS).
• UTILITY PARALLELING MODES

- GENERATORS SUPPLY A PERCENTAGE OF
THEIR RATED POWER BASED ON THE ZERO
TO 5 vdc. LOAD SET INPUT SIGNAL APPLIED
(KW/Kvar). CUMMINS, INC TRAINING - Gas Engine Controls / Genset Controls / KDL / 10 - 2009 / REV 1.1 76
UTILITY PARALLELING MODES:
- BASE LOAD MODE.

Generators provide base load power up to their total rating.
Power above this rating is supplied by the utility.
- PEAK SHAVE MODE.

Utility provides base load power. Generators provide
additional power above a pre-set level.
- IMPORT / EXPORT MODE.

Generators provide their rated power. Utility is used as a
buffer to supply additional power as required (Import) or as
a load (Export) for excess power generated.
PCC 3300 Utility Parallel -
Modes of Operation
The PCC3300 is configurable via HMI 320 panel or the InPower service tool
to operate in either Island Mode or one of two different modes of utility
paralleling: Multiple Mode and Single Mode.
Selection of the Multiple Mode allows the Genset to operate in both isolated
bus load sharing mode and utility paralleling mode.
The Single Mode is a special mode of software designed for single Genset to
single utility supply/breaker. Selecting Single Mode will disable load sharing
capability.
Utility Single Mode
PCC3300 Control
Single Mode - ONLY used in the configuration 3300
shown. i.e.. Single set with bus sensing on

live (Utility side) of the Utility breaker. Generator
Sensing
Utility
Sensing
Selection of Single Mode enables the G2
PCC3300 synchronizer to run when the genet

breaker is closed. The genset can therefore
re-synchronize with the utility on mains From Utility
Source
restoration.
The single set power transfer mode is the U1
ONLY configuration where the PC3.3 will 52-G2
directly Control the Utility breaker on mains

restoration. All other configurations will utilize
a PC3320 DMC board to control the utility
breaker when required. 52-UM
NOTE: To ensure Single Mode is not selected

advertantly Single Mode verify terminals must
be linked for single mode operation (CXX &
CXX) in HHP Gas GIB Panels. To
Loads
L1,L2 & L3 Sensing Voltages
Overview of PCC3300 modes
of operation with associated
active control features
PH 2 ONLY
GENSET APPLICATION
(Mode)
F
E - M/F
A
T
U
R
E
S
Understanding Genset application type is of primary importance for configuring and adjusting
paralleling features and general for system troubleshooting.
PCC3300 Isochronous Load
Sharing for Island Mode
2.5v @ f/load
LOAD SHARE LINE
PCC3 PCC3 INTERCONNECTIONS
300 300
#N #1
PCC3.3 Terminal Block 9
Terminal Block 9
TB9 - 7 = KW ( - )
PCC3 PCC TB9 - 8 = KW (+ )
300 3300 TB9 – 10 = KVAR ( - )
#3 #2 TB9 – 11 = KVAR ( + )
TB9 – 9 = RETURN
PCS #1
sensed kW Example of kW error
(VkW1) circuit, a similar circuit is
used to derive VAR error.
Error signals are used to

Ve = Vpwr - VkW1
adjusts voltage regulation
Ve kW Error kW Error Ve for VAR match and fueling
to PCS #1 to PCS #NINC TRAINING - Gas Engine
CUMMINS, for kW
Controls match.
/ Genset Controls / KDL / 10 - 2009 / REV 1.1 81
PCC3300 - Integrated
Synchronizer & Sync Check
The Synchronizer is Enabled when all of the following conditions are
met:
- Bus Voltage % (L1L2, L2L3 and L3L1) is 60-110% of Genset Nominal

Voltage
- Bus Frequency is 60-110% of Alternate Frequency Switch
- If Genset CB Fail to Close Standalone Mode Enable is set to Enable,
Warning fault 1452 (Genset Breaker Fail to Close) is Inactive
- The PCC is not raising the engine speed to idle speed or rated speed, or
lowering the engine speed to idle speed
- Event 1465 (Ready to Load) is Active
- If the PCC is in Manual Mode, Sync Disable is Inactive
- If Fail to Sync Lockout is Enabled, event 1457 (Fail to Synchronize) is
Inactive
- Synchronizer Speed Control Method is not External, Synchronizer Voltage
Control Method is not External, or both are not External
Paralleling Frequency Reference Offset:

The PCC adjusts the speed reference (bias) to make the Genset frequency match the Bus
frequency. The PCC may also try to make the Genset phase match the Bus phase. This
adjustment is the Paralleling Frequency Reference Offset.
The PCC uses one of two methods to calculate the Paralleling Frequency Reference Offset:
Slip Frequency synchronizing control logic: Selected when:-
- It is important that the power flows in the desired direction when the Gensets are
first connected in parallel.
- The Genset cannot be controlled well enough to make the Genset phase match
the Bus phase (for example, with Gas Gensets).
Phase Matching synchronizing control logic: Selected when:-
- A phase difference exists between the Genset and the Bus (for example, if there is
a delta/wye transformer in the system).
The PCC3300 default setting for synchronizing control is Slip Frequency control logic
Slip Frequency Synchronizing Control Logic: The PCC attempts to drive a fixed frequency
between the two sources.
The following conditions must all occur before the permissive function will
allow automatic or manual closure of the Genset breaker:
0
– a) The difference between the Genset frequency and the Bus frequency is
-10° +10° equal to or less than 10 degrees.
– b) Voltage difference between Genset and Bus is less than 5% (voltage
matching is standard on PCC)
– d) Phase rotation between Genset and Bus is correct after other sync
conditions are met
– e) All of the above conditions are met for greater than 100 milliseconds
– f) Phase angle must be moving towards zero (in either direction) and less
than 1 degree
If a breaker “close” signal is given and the phase difference moves out of
the permissive window, then the breaker close signal is removed until the
conditions are re-established.
Phase Matching Synchronizing Control Logic: The PCC attempts to drive the Phase
Error to zero.
The following conditions must all occur before the permissive function will
allow automatic or manual closure of the Genset breaker:
– a) Phase difference (Error) between the Genset and the Bus must be less
0 than 5 degrees (adjustable from front keypad between 5 and 20 degrees)
-5° +5° – b) Voltage difference between Genset and Bus is less than 5% (voltage
matching is standard on PCS)
– d) Phase rotation between Genset and Bus is correct after other sync
conditions are met
– e) All of the above conditions are met for greater than 0.5 seconds
(adjustable from 0.5 to 5 seconds)
– f) Phase angle must be moving towards zero (in either direction) and less
than 1 degree
If a breaker “close” signal is given and the phase difference moves out of
the permissive window, then the breaker close signal is removed until the
conditions are re-established.
IMPORTANT NOTE: If changing from ‘Slip Sync’ to ‘Phase Matching’ synchronizing control logic, the
Permissive Phase Angle MUST be changed from the default setting of 10° to the preferred setting of 5°.
This can be changed via the PCC3300 front panel or via InPower.
Speed/Load Bias to CM700
Speed bias can influence base engine
NOTE: PCC3300 TB9 – 4 / TB9 - 5 is a customer
speed between – 10% to + 10% of
Speed Bias signal output only (+10/-10Vdc).
nominal.
The speed bias is a digital signal
transmitted from the PCC3.3 to the CM700
over the J1939 System Bus.
When no speed bias is required, the PC3.3 Customer GIB Alt
digital output is Zero, commanding NO Inteface
AUX101
Intefa
AUX101
ce
box
AUX101
Intefac
PCC3300
speed change from the CM700 governed MODBUS / I/O I/O e
I/O
nominal speed (i.e. no speed correction InPower
(MON)
J1939
from it’s current base speed set-point). Tool Con.
(on board)
System Bus (250KBPS)
J1587
The PC3.3 synchronises the Genset by PWM
(250KBPS)
CM700
varying the digital output (positive and AUX103
negative) , thereby biasing (changing) the AVR
CM558L
J1587 Service
Tool Connector
base governed speed of the engine to CAN
2.0B
match the Genset and bus voltage CM558R
waveforms.
CENSE or J1939 Service
The PC3.3 controls multiple Gensets for 2 x CM850 Tool ConnectorCM850
core 2 module ONLY
set-to-set load sharing and kW load
against the utility in the same way.
Failure of the J1939 System Bus causes
an Immediate critical shutdown.
PCC 3.3 Utility Parallel –
Import/Export Operation
This figure shows the utility load set analog
5.0 voltage input versus kW load govern reference
4.185 produced by that voltage.
The kVAR load reference is determined by the
Volts kW reference and the PF level set in the
control.
Load Track
Voltages between 0.5 and 1.0 represent a
0%kW reference. A voltage of 4.185 or greater
1.5 (up to 24 VDC) represents 100% output.
1.0 The kW Reference % for voltages between 1.0
Zero kW
0.5 and 4.185 are represented by the equation:
0% 50% 100% kW% = 31.4 x (Load Set Volts -1)
kW Output % e.g. Load set = 2.0v
Load set voltage signal : The load set voltage kW output = 31.4 x ( 2 - 1 )
must be “Conditioned” so that change is “ramped” = 31.4%
rather than stepped. The load set voltage must be
OR, 3v = 62.8%, etc.
applied BEFORE the UTILITY PARALLEL
contact is closed and the set signaled to run. PCC3300 TB9 – 1/ 3, TB9- 2 RETURN
Utility Parallel Mode is Activated by linking the Utility Parallel Enable Terminals in the GIB. This is
often achieved using an Auxiliary contact on the Utility Breaker. Utility Parallel enable contact selects
CM700 utility governor gain table and signals PCC to load control via the 0-5v load set (demand)
signal up to max load and Power Factor set on the HMI 320 Operator Panel.
Master First Start Control
for Multi-Set Applications
Master First Start Connection Feature.

The master first start feature is designed to prevent two or more
generator circuit breakers closing onto a “dead bus” at the same
time.
When a Genset reaches 90% Speed and Volts it is considered
ready to close its output breaker to the bus. At this time each
PCC3300 boards sends a series of random bursts (1- 8 ms each)
for 800 ms. If another genset receives these signals when up to
speed and volts it holds off for closing for another 2.5 seconds.
A set that sees no MFS pulses closes its breaker onto a dead bus
after 800 ms and at the same time supplies a first start connection TB3
to prevent any other gensets from receiving permission to close. If
two or more reach 90% speed and volts at the same time this MFS Connection :
process is called arbitration and all other units are locked out until PCC3300 TB3 – 12
synchronous conditions have been met. Terminals must be “daisy
Chain” connected between
First Start Backup Timer – Used to give PCC authority to close generators in order for the MFS
function to operate.
it’s circuit breaker should the MFS feature fail for any reason.
Ensure First Start Backup time is set differently on each
generator PCC3300 board.
Circuit Breaker Control
The level of control the PCC has over the Genset circuit breaker depends on the Genset application type or
mode.
Standalone and Synchronizer Only

If Genset CB Shunt Trip Enable is set to Enable, the PCC may be connected to the Genset circuit breaker to
trip the circuit breaker when there is a shutdown fault or a shutdown with cool down fault.
Isolated Bus Only, Utility Single and Utility Multiple

The PCC is connected to the Genset circuit breaker to open and close the circuit breaker. The PCC sends an
open signal and a close signal to the Genset circuit breaker. The logic is arranged so that one of the signals is
on at almost all times and so that the open signal has higher priority than the close signal.
Power Transfer Control ( 2nd release only)

The PCC controls the Genset circuit breaker and the utility circuit breaker. Transition type controls the way the
PCC transfers load from one source to the other. Typically used on Diesel Genset systems only.
Genset CB Inhibit Signal

This signal may come from any of these sources.
• PCC Genset CB Inhibit Switch connection
• PCCNet devices
• Modbus network
The level of control the PCC has over the Genset circuit breaker depends on the Genset
application type. Note: This section applies only if Genset Application Type is set to
Utility Single, Utility Multiple, or Power Transfer Control.
Genset CB Close Request
A Genset CB close request comes from one of these sources:
• Dead Bus process

• First Start process
- Dead Bus Gen CB Close Request indicates that the Dead Bus process or First
Start process is generating a Genset CB Close Request.
• Synchronize
- Sync Gen CB Close Request indicates that the synchronizer is generating a
Genset CB Close Request.
The PCC will display “ Breaker Failed To Close” if :-

- The output breaker fails to close when PCC commands it to.
The level of control the PCC has over the Genset circuit breaker depends on the Genset
application type. Note: This section applies only if Genset Application Type is set to
Utility Single, Utility Multiple, or Power Transfer Control.
Genset CB Open Request

There is a Genset CB open request when at least one of these conditions are met:
• The PCC is in Manual mode, Excitation Disable Override is set to Excitation Off, or the CB
Open button is pressed on the Operator Panel.
• If the PCC is not in Manual mode, the Genset CB inhibit signal is active.
• The Genset is not running at rated speed and voltage.
• The engine is running at rated speed in one of the following stop sequences; the PCC is
running the load govern kW ramp unload process; and Load Govern kW Reference is zero.
• There is an idle request from engine or Genset control.
• There is an active Shutdown fault.
• If Genset CB Fail To Close Standalone Mode Enable is set to Enable, Warning fault 1452
(Genset Breaker Fail To Close) is Inactive, or the PCC has stopped the Genset for any
reason other than a Shutdown fault since Warning fault 1452 became Active.
• It has been less than Genset CB Recharge Delay since the close signal became active.
The PCS will display “ Breaker Failed To Close” if :-
- The output breaker opens when the PCS did not tell it to.
Additional circuit breaker control can be instigated through a circuit breaker inhibit
command.
Genset CB Inhibit Signal
This signal may come from any of these sources.
• PCC Genset CB Inhibit Switch connection
• PCC Net devices
• Modbus network
GIB – Harness & Service Connector Layout
PLAN VIEW OF BASE OF GIB – INSIDE PANEL

(Photograph required + add connector circuit numbers)
Gear Box Harness J1939 Service J1587 Service tool connector.

LB & RB Genset
when fitted. tool connector TO CM700 ONLY.
Harness connectors
(Protections)
(Multi-Pin Harting)
Twin Solenoid Gas Valve

Harness Connector
PCC3300 / AUX103 AVR / CM700 Control & Sensing Logic
Woodward
ProAct
CM558R MCM700
CAN/Proprietary Datalink
Connector A
A 12V 3kHz signal is used to ‘trigger’ the Woodward 4 13 3 16 6
AVR, allowing transformed PMG power to CM558L
ProAct
the exciter windings. This is ‘% Regulator’
viewed on the PCC HMI. 304 Jumper Bar – S16 Speed
Field Current (-)
● ● 4 3 Sensor
Field Current (+) 303 Jumper Bar – S15
AVR PWM (-)
● ●
302 Jumper Bar – S14
AVR PWM (+) ● ● Flywheel
J1939 Shield
Return Speed Bias Signal (Sync, load share or
J1939 (+)
J1939 (-)
parallel with grid) communicated via
AVR Fused (+)
J1939 Comms
Backup Start Disconnect
14 3 10 4 9 2 8 1 2 7 14 3 16 5 9 1 10 11 15 Utility Current Sensing

J19 J19 J26 PCC3300
AUX103 AVR
J18 J17 J12 J22 TB7 CT3 CT2 CT1
494
493
490
495
491
492
3 2 1 2 1 2 5 1 4 3 6 U V W N L3 L2 L1 N
C316 C315 C314 C313 C312 C311

P2 P3 P4 13 14 ACB Terminal Rail 42 43 40 41 44 45 U V W N C303 C302 C301 C304 Customer Terminal Rail
12 – 50 VDC C326 C325 C324 C323 C322 C321

0.55A
0.55A
0.55A
(12V = No Load,
0.55A
0.55A
0.55A
50 V = Overload) Breaker
● W ●
CTA CT1
PMG Exciter Alternator ● V ●
CTA CT2
PMG Output:
1200RPM/60Hz 170VAC
● U ●
1500RPM/50Hz 195VAC Rotating CTA CT3
1800RPM/60Hz 220VAC
Diode Pack
● N ●
There are 6 diodes (3 +ve, 3 –ve), 2 per phase. At Full Load, the Exciter outputs approximately 42 amps through each diode. Each diode has a capacity of 72
amps. If the PCS is not correctly calibrated (L-L, L-N imbalances), or the set is crash synchronised, then circulating currents can be present in the main
alternator stator winding, which try to back-feed through CUMMINS,
the diodes.INCThese
TRAINING - Gas Engine
circulating Controls
currents can/ Genset Controls
be as high as /300
KDL amps.
/ 10 - 2009 / REV 1.1 94
Module 4 - Genset Control Systems
Team Tasks…
Group Practical Exercises
Cummins, Inc Training
Team Tasks… Group Practical Exercises
Split into groups of 2 or 3 people and carry out the following tasks.
Using the appropriate wiring diagrams, determine the Control Logic for
Relays, Fuses, Power Supply, etc. for the following systems -
• Oil Pre-Lube Pump
• Coolant Circulation Pump
• Engine Coolant Pre-Heaters
• Alternator Bearing Temperature
HHP Natural Gas Engine & Generator Controls
(M700 & PCC3300)
Module 4 - Genset Control Systems
End
Cummins, Inc Corporate Training

Genset Controls: HHP Natural Gas Engine & Generator Controls

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Genset Controls: HHP Natural Gas Engine & Generator Controls

Uploaded by

Copyright:

Available Formats

HHP Natural Gas Engine & Generator Controls

GIB (v.2) Contents:

VAC Aux Termination Rail

VAC Supply from VAC Isolator

COMPONENT MODULE RATING

Contactor 12A @ 440VAC

Contactor 32A @ 440VAC

MCB7 Circuit Breaker 3 Pole, 2A

MCB8 Circuit Breaker 6A

CB Off Position CB On Position

VAC Supply from VAC Isolator

VAC Isolator Input Battery

VDC + Æ VDC Iso.

• Battery Pack (x2)

VDC Source Backup w/ Cover On

VDC Source Backup w/ Cover On

Input (max): 24VDC±20% 6.6mA 160mW

Jumper Bar Jumper Bar

C301 through C304

R1 through R18 COMPONENT RATING

Engine Aux Oil Pump Stay-In-Boot J1939 R232

VAC Aux Termination Rail

Standard Function Connection LBNG Function

Standard Function Connection LBNG Function

1 PCCNet A (+) RS485 R5 PCCNet A (+) RS485

2 PCCNet B (-) RS485 R4 PCCNet B (-) RS485

3 PCCNet Sheild R3 PCCNet Sheild

5 Supply: Fused 3A B+ - Supply: Fused 3A B+

7 Config O/P #1 - Relay COM TB1-9 Return: TB1-6

12 Config I/P #1 C7 Config I/P #1

13 Config I/P (Common) TB1-7 Return: Config I/P #1 & #2

14 Config I/P #2 C9 Config I/P #2

Standard Function Connection LBNG Function

2 Master CAN Shield C79 Master CAN Shield

3 Master CAN L C78 Master CAN L

4 Master CAN H C77 Master CAN H

6 Config O/P #21 State - Config O/P #21 State

9 Config I/P #20 - Transfer Inhibit C57 Transfer Inhibit (PTC)

10 Config I/P #21 - Retransfer Inhibit C59 Retransfer Inhibit (PTC)

11 Master First Start O/P State C29 First Start Arbitration

Standard Function Connection LBNG Function

1 Genset Bus or Utility L1 Voltage C301 Utility L1

2 Genset Bus or Utility L2 Voltage C302 Utility L2

3 Genset Bus or Utility L3 Voltage C303 Utility L3

4 Genset Bus or Utility Neutral Voltage C304 Utility Neutral

Standard Function Connection LBNG Function

1 Genset CB Close KM38-A1 Supply: KM38 Relay Coil (Genset CB Close)

2 Genset CB Close Return TB5-4 Return: TB5-1

5 Genset CB Open State Return TB5-7 Return: TB5-4

7 Utility CB Close State Return TB5-9 Return: TB5-6

9 Utility CB Open State Return S22 Return: TB5-8

Standard Function Connection LBNG Function

2 Return: Start Type - Return

6 Supply: Start Type C33 Supply: Start Type

7 Supply: Config I/P #3 C11 Supply: Config I/P #3

8 Supply: Config I/P #4 C13 Supply: Config I/P #4

12 Discrete I/P Return - Return

13 Discrete I/P Return - Return

Standard Function Connection LBNG Function

4 Config Analog O/P #2 - Voltage Bias C85 Speed Bias

5 Config Analog O/P #1 - Speed Bias C88 Voltage Bias

7 kW Load Share Level C89 Return: kW Load Share

8 - C90 kW Load Share