dokumen.tips_mcm3320-application-training-switchgear-engineer-training-083006-rev4-new-cummins

MCM3320
QTQ Training
Rev 1.5 prd

June 13, 2006
Presentation Outline
 Introduction
 Features
 Hardware
 Operation
 System Setup and Simulator (HANDS ON)
 Operation (continued)
 Variables
 Interconnect
 HMI & Simulator (HANDS ON)
 InPower
 Applications (GROUP)
 Control and Component Mode Panels New
 Discussion/Questions/Comments
Rev 1.5 prd

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June 13, 2006
Presentation Goals
 What are the capabilities of the MCM3320?

 What are the board connections?
 How does it operate?
 How do I apply it?
 How do I set it up?
Rev 1.5 prd

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June 13, 2006
MCM3320 Information
 Lotus Notes Database “Commercial ESB

Controls”
 Sort by “Category”
 Look for “MCM3320”
 This presentation and other technical
information located there
 An Application Guide is in the works to provide
a one-stop document
Rev 1.5 prd

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June 13, 2006
MCM3320 Technical Support
 Documentation
 PGA Controls Engineering:
1. Kevin Aufderhar
2. Paul Dahlen
3. Rich Scroggins
Rev 1.5 prd

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June 13, 2006
FEATURES
One-Line Feature Summary (Q2 2006)

MCM3320
AC Metering HMI211 HMI112
Source Failure Operator Gensets
Gensets Start/Stop Panel #1 Bargraph
Main Breaker Control
Customer I/O Sync/Volt Match
Open/Closed Transition
Load Ramping HMI211 HMI211
Extended Paralleling Operator Utility
kW and kVAR Control Panel #2 Bargraph
Load Demand
Load Add / Shed
Scheduler
Modbus
Diagnostics
G1
GM UM
G2
G3
AUX101
G4 AUX102
Breakers
or
ATS
Load1 Load2 Load3 Load4 Load5 Load6
Rev 1.5 prd

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June 13, 2006
FEATURES
Feature Validation
 All available features have been tested

 Firmware test
 Bench test w/simulator
 Live test at Fridley Endurance Pad test facility
 Live test at Fridley with real Utility Source
(transfers, sync, base load / peak shave)
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June 13, 2006
FEATURES
AC Metering
 3 Phase metering of genset bus and utility bus
simultaneously
 Phase and Total/avg metering of V, A, kW, kVAR,
kVA, PF, Hz
 Phase and total metering of +kWh, -kWh, +kVARh, -
kVARh, kVAh for each source
 CT secondaries of 1A or 5A
 PT accepts 0-480VLL directly; external PT for higher
voltages (up to 35000V)
 PT and CT inputs pre-calibrated
Rev 1.5 prd

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June 13, 2006
FEATURES
Master Sync / Volt Match

 both phase synchronization and voltage matching
 20 genset limit for synchronizer
 frequency offset range: +/- 1.0 Hz min; up to +/- 3.0Hz
 output voltage offset range: +/- 6% min; up to +/- 10%
 offset range generally independent of gen bus load
Rev 1.5 prd

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June 13, 2006
FEATURES
Master Sync / Volt Match

 controls frequency and voltage via PCC kW and kVAR
load share lines
 selectable phase synchronization (default) or slip
frequency synchronization
 sync enable input for manual control mode
 option to invert synchronizer polarity if genset and
utility swap positions in synchronizer only application
(via Modbus)
Rev 1.5 prd

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June 13, 2006
FEATURES
Permissive Sync Check

 sync check function is independent of synchronizer
 adjustable frequency window, phase window, voltage
window, and window time for permissive check
 includes configurable dead bus logic
 sync check output
 fail to synchronize diagnostic
 phase rotation mismatch diagnostic
Rev 1.5 prd

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June 13, 2006
FEATURES
Breaker Control
 interface for both genset main and utility main
 close and open control – momentary energization until
desired position is achieved
 a/b and tripped breaker position inputs
 adjustable breaker recharge time delay to prevent fail
to close due to inadequate charge time
Rev 1.5 prd

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June 13, 2006
FEATURES
Breaker Control
 utility paralleling enable output
 breaker inhibit control input
 breaker diagnostics with appropriate system control
reaction
 adjustable fail to close and fail to open time delays
 paralleling fail to disconnect diagnostic with
configurable system control reaction
Rev 1.5 prd

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June 13, 2006
FEATURES
Breaker Control
 anti-pump avoidance logic – external breaker position
contacts not required in series with trip coil
 breaker inhibit output to control individual genset
paralleling breakers in applications with no gen main,
and for backup disconnect protection capability
Rev 1.5 prd

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June 13, 2006
FEATURES
Power Transfer Control

 open transition w/pgm transition delay, hard closed
transition (<100msec), soft load closed transition
 sensors (uv, ov, freq, phase rot, loss of phase, gen
bus capacity, and breaker failure)
 adjustable time delays (pgm transition, transfer,
retransfer, max parallel, gensets start delay, gensets
stop delay)
 source availability determination for both utility and
genset
 source connected determination for both utility and
genset
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June 13, 2006
FEATURES

 gensets start/stop logic with single relay output
 transfer and retransfer inhibit inputs
 override input to override timers and
transfer/retransfer inhibits for immediate transfer,
retransfer or genset start
 auto/manual mode input
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June 13, 2006
FEATURES

 test start input
 adjustable test with or without load
 option to do open transition retransfer if fail to sync
occurs
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June 13, 2006
FEATURES
System Topologies
 Transfer Pair (UM / GM)
 Common Bus (UM / no GM)
 Isolated Bus (GM)
 Isolated Bus (no GM)
 Master Synchronizer Only
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June 13, 2006
FEATURES
System Topologies
 Transfer Pair (System Types 2,3,4,8,10,11)
G1 G2 G3 G4
MCM
3320
UM GM
Load
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June 13, 2006
FEATURES
System Topologies
 Common Bus (System Type 9)
G1 G2 G3 G4
MCM
3320
UM
Load
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June 13, 2006
FEATURES
System Topologies
 Isolated Bus w/GM (System Type 7)
G1 G2 G3 G4
MCM
3320
GM
Load
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June 13, 2006
FEATURES
System Topologies
 Isolated Bus Without GM (System Types 5,6)
G1 G2 G3 G4
MCM
3320
Load
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June 13, 2006
FEATURES
System Topologies
 Master Synchronizer Only (metering optional)
G1 G2 G3 G4
MCM
3320
Sync
Source Check
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June 13, 2006
FEATURES
Multiple MCM3320s
(External)
 master inhibit input will inhibit the synchronizer and
power transfer control functions
 use in complex systems with multiple transfer pairs and
multiple MCM3320s
 external logic device is required to assert the master
inhibit as required (e.g. during a retransfer sequence of
multiple pairs)
 future enhancement will allow automatic priority control
through interconnected MCM3320s (similar to First Start
Bus PT logic)
Rev 1.5 prd

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June 13, 2006
FEATURES
Extended Paralleling
 MANY options available for controlling kW and kVAR in
extended paralleling mode (kVAR not applicable for
PCC3100)
 kW and kVAR can be independently controlled in any
combination of base load (control the power @ gen bus)
or peak shave (control the power @ utility bus)
 load control operates independently of the number of
gensets that are online
 Maximum of 20 gensets
 kW base load control selectable as open loop or closed
loop
 kW peak shave control is closed loop only
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June 13, 2006
FEATURES
 setpoints can be set from InPower, HMI, Modbus, or via analog
hardware 0-5V inputs
 extended parallel start input starts/stops the mode
 soft load ramping
 separate diagnostic for kW and kVAR if unable to acheive
setpoint within 60 seconds
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June 13, 2006
FEATURES
System Scheduler
 12 program run schedules

 run schedules configurable for start day, start
time, duration, repeat interval, and run mode
 run modes: without load, with load, or extended
parallel
 provides up to 6 different schedule exceptions
 uses on-board Real Time Clock
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June 13, 2006
FEATURES
Real Time Clock
 on-board RTC used by Scheduler function

 clock keeps track of year, month, day, date, hour,
minute, and second
 user must set the clock on first power-up
 clock automatically accounts for leap year
 configurable automatic Daylight Savings Time clock
correction
 clock setting will remain valid for at least 24 hours
without B+ to the board
 diagnostic fault occurs if clock needs to be set (scheduler
won’t run)
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June 13, 2006
FEATURES
Load Demand
 Use to match online generating capacity to load in order

to optimize fuel use and genset life
 load demand for up to 4 gensets
 fixed sequence OR run-hours based
 adjustable shutdown and restart thresholds as well as
time delays and run hour differential
 4 load demand driver outputs to connect to PCC genset
control's load demand inputs
 requires genset paralleling breaker position 'a' contacts
connected to 3320
Rev 1.5 prd

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June 13, 2006
FEATURES
Load Add/Shed
 adds loads in steps as gensets come online

 sheds loads to unload an overloaded genset bus
 Requires external module: AUX101/2 PCCNet I/O
Module for feeder breaker and/or ATS control
 supports up to 6 levels
 supports up to 4 gensets
 control up to 6 feeder breakers or ATS directly in any
combination
 monitoring of breaker / ATS position provided
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June 13, 2006
FEATURES
Modbus RTU
 intended for PLC interface
 published register map
 read/write access
 operational data, control, and setup variables
 MCM3320 is Modbus slave
 RS232 or RS485 connection
 settable address (allowing multiple MCM3320 slaves on RS485)
 communications setup and diagnostics
Rev 1.5 prd

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June 13, 2006
FEATURES
Diagnostics
 individual On-Board LEDs for:
Utility Available
Utility Connected
Genset Available
Genset Connected
Not In Automatic
Common Warning
Heartbeat
Synchronizing
Synchronized
Fail To Sync
Modbus Communication Activity
Rev 1.5 prd

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June 13, 2006
FEATURES
Diagnostics
LED Indicators
Utility Genset
Connected Connected
Utility Genset Modbus

Available Available Activity
Fail to Sync
Not In Common Heartbeat
Blink = Sync Automatic Alarm (blink)
Solid = Ok
to Close
Rev 1.5 prd

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June 13, 2006
FEATURES
Diagnostics
 On-Board seven segment LED for indication of:
System State indication of what the control is currently doing
Fault Code Readout (hold fault reset switch active for >5sec to change to
fault code readout mode)
Rev 1.5 prd

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June 13, 2006
FEATURES
Diagnostics Seven Segment LED Indicator

Decimal Point = On
 Active Fault Code Flashout
Co d e Ev e n t Na m e Re s p o ns e
343 Ha r d w a r e Fa ilu r e Wa r n in g Wa r n in g
353 EEP ROM Wr it e Er r o r Wa r n in g Wa r n in g
1121 Fa il To Dis c o n n e c t Wa r n in g Wa r n in g
1219 Ut ilit y Ma in Br e a ke r Tr ip p e d Wa r n in g Wa r n in g
1222 No t In Au t o m a t ic Eve n t Eve n t
1223 Ut ilit y Bu s Fr e q u e n c y Wa r n in g Wa r n in g
1224 Ge n s e t Bu s Ove r vo lt a g e Wa r n in g Wa r n in g
1225 Ge n s e t Bu s Un d e r vo lt a g e Wa r n in g Wa r n in g
1226 Ge n s e t Bu s Fr e q u e n c y Wa r n in g Wa r n in g
1328 Ge n s e t Ma in Br e a ke r Tr ip p e d Wa r n in g Wa r n in g
1335 AC Me t e r in g Ou t Of Ra n g e Wa r n in g Wa r n in g Decimal Point = Off
1444
1452
Ge n s e t Bu s Ove r lo a d Wa r n in g
Ge n s e t Ma in Br e a ke r Fa il To Clo s e Wa r n in g
Wa r n in g
Wa r n in g
 System State
1453 Ge n s e t Ma in Br e a ke r Fa il To Op e n Wa r n in g Wa r n in g
1454 Ge n s e t Ma in Br e a ke r P o sit io n Co n t a c t Wa r n in g Wa r n in g System State LED Output
1455 Ut ilit y Ma in Br e a ke r P o s it io n Co n t a c t Wa r n in g Wa r n in g Character
1456 Syn c h r o n iz e r Ou t p u t Lim it Wa r n in g Wa r n in g
1457 Fa il To Syn c h r o n iz e Wa r n in g Wa r n in g
Not Available - (center segment)
1458 Syn c h r o n iz e r P h a s e Ro t a t io n Mis m a t c h Wa r n in gWa r n in g TD Start 1
1483 Co m m o n Wa r n in g Eve n t Eve n t TD Stop 2
1534 Lo a d Co n t r o l Ou t p u t Eve n t Eve n t
1541 Ge n s e t Fa ile d To Co m e On lin e Wa r n in g Wa r n in g
TD Pgm Tran 3
1689 Re a l Tim e Clo c k Po w e r In t e r r u p t Wa r n in g Wa r n in g TD Transfer 4
1912 Ut ilit y Bu s Lo s s Of P h a se Wa r n in g Wa r n in g TD Retransfer 5
1913 Ge n s e t Bu s Lo s s Of P h a s e Wa r n in g Wa r n in g
1914 Ut ilit y Bu s Ph a s e Ro t a t io n Wa r n in g Wa r n in g Synchronizing 6
1915 Ge n s e t Bu s P h a se Ro t a t io n Wa r n in g Wa r n in g Sync Check OK 7
1916 Syn c h r o n iz e d Eve n t Eve n t Inhibit 8
1989 kW Lo a d Co n t r o l Ou t p u t Lim it Wa r n in g Wa r n in g
1991 kVAR Lo a d Co n t r o l Ou t p u t Lim it Wa r n in g Wa r n in g Unassigned 9
1999 Ma xim u m P a r a lle l Tim e Wa r n in g Wa r n in g Ramp Unload A
2328 Ut ilit y Bu s Ava ila b le Eve n t Eve n t Ramp Load b
2331 Ut ilit y Bu s Un d e r vo lt a g e Wa r n in g Wa r n in g
2332 Ut ilit y Bu s Co n n e c t e d Eve n t Eve n t Manual C
2333 Ge n s e t Bu s Co n n e c t e d Eve n t Eve n t Utility Failure d
2358 Ut ilit y Bu s Ove r vo lt a g e Wa r n in g Wa r n in g
Test E
2396 Ut ilit y Ma in Br e a ke r Fa il To Clo s e Wa r n in g Wa r n in g
2397 Ut ilit y Ma in Br e a ke r Fa il To Op e n Wa r n in g Wa r n in g Standby J
2416 Ca lib r a t io n Ch e c ks u m Wa r n in g Wa r n in g Extended Parallel H
2647 Lo a d De m a n d Se t u p Wa r n in g Wa r n in g
2648 Re m o t e IO Co m m u n ic a t io n Fa ilu r e Wa r n in g Wa r n in g
2965 Ge n s e t Bu s Ava ila b le Eve n t Eve n t
2971 Te st / Ext e n d e d P a r a lle l Eve n t Eve n t
Rev 1.5 prd
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June 13, 2006
FEATURES
Diagnostics
 42 diagnostics (warnings and events)
 each event or warning is mappable to 8 customer low side
driver outputs
 active warning codes can be read out on 7segment LED on
board
 some warnings alter control operation
 warnings are latched until user fault reset
 events are not latched
Rev 1.5 prd

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June 13, 2006
FEATURES
Diagnostics kVAR Load Control Output Limit Warning

Common Alarm Event kW Load Control Output Limit Warning
Genset Available Event Maximum Parallel Time Warning
Genset Connected Event Not In Automatic Warning
Synchronized Event Real Time Clock Power Interrupt
Test / Extended Parallel Event Synchronizer Output Limit Warning
Utility Available Event Synchronizer Phase Rotation Mismatch
Utility Connected Event Warning
AC Metering Out of Range Warning Utility Main Breaker Fail To Close Warning
Calibration Checksum Warning Utility Main Breaker Fail To Open Warning
EEPROM Write Error Warning Utility Main Breaker Position Contact Warning
Fail To Disconnect Warning Utility Main Breaker Tripped Warning
Fail To Synchronize Warning Utility Frequency Warning
Genset Main Breaker Fail To Close Warning Utility Loss of Phase Warning
Genset Main Breaker Fail To Open Warning Utility Overvoltage Warning
Genset Main Breaker Position Contact Warning Utility Phase Rotation Warning
Genset Main Breaker Tripped Warning Utility Undervoltage Warning
Genset Frequency Warning Load Demand Setup Warning
Genset Loss of Phase Warning Remote IO Communications Warning
Genset Overvoltage Warning Genset Bus Overload Warning
Genset Phase Rotation Warning Genset Failed To Come Online Warning
Genset Undervoltage Warning Utility Source Unloaded Event – Coming Soon
Hardware Failure Warning Generator Source Unloaded Event – Coming
Soon
Rev 1.5 prd

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June 13, 2006
FEATURES
InPower V5.5
 MON RS485 interface

 standard InPower folders: Adjustments, Faults,
Monitor, Test
 built in Setup Tool
 download new firmware
 capture files
Rev 1.5 prd

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June 13, 2006
FEATURES
InPower V5.5 Setup Tool

 special application
to assist with setup
of the MCM3320
 user friendly
screens
 help file
Rev 1.5 prd

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June 13, 2006
MCM3320 FEATURES
In Development
 High/Low Battery Voltage
 Flexible Topology
 Annunciator Support
Rev 1.5 prd

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June 13, 2006
FEATURES
High/Low Battery Voltage
 Provide faults for high and low battery voltage

as sensed at the MCM3320
 Details to be determined
Rev 1.5 prd

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June 13, 2006
FEATURES
Flexible Topology
 Make the MCM3320 more flexible for use in

complex system topologies
 Provide Extended Parallel w/o breaker control
 Provide outputs for source unloaded for utility
and generator
 Eliminates need for Bitronics transducer
 Allows PLC to control breakers
Rev 1.5 prd

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June 13, 2006
FEATURES
Feature Limits Quiz
How many gensets can be supported by the

following features ?
•AC Metering 32000kW, 10000A
•Synchronizing 20
•Load Demand 4
•Load Add / Shed 4
•Utility Paralleling 20
Rev 1.5 prd

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June 13, 2006
FEATURES
Annunciator Support
Annunciator 1 Layout Annunciator 2 Layout
Utility Available Priority 1 Load On

Utility Connected Priority 2 Load On
Gen Bus Available Priority 3 Load On
Gen Bus connected Priority 4 Load On
Not In Auto Priority 5 Load On
Common Alarm Priority 6 Load On
Fail to Sync Shed Level 1
Gen 1 Running Shed Level 2
Test
Extended Parallel
Gen Bus Overload
Load Demand
Rev 1.5 prd

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June 13, 2006
FEATURES
Feature Limits Quiz
What can Load Add / Shed support ?

•Load Device Types Breaker, ATS
•Load Add Levels 6
•Load Shed Levels 6
•# of Gensets 4
Rev 1.5 prd

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June 13, 2006
HARDWARE
MCM3320 HMI211 AUX101/2
InPower Cable HMI Harness HMI112
Rev 1.5 prd

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June 13, 2006
HARDWARE
Part Numbers
Part Number Model Released? Description

0327-1520-01 MCM3320 Yes fully featured master control module
0327-1520-02 SYNC1320 Yes depopulated/defeatured synchronizer only module
0300-6090 HMI 211 Yes operator interface panel (can use one or two)
300-6050-01 HMI 112 Yes Bargraph panel (use 2 – one for genset bus, one for utility bus)
0541-1342 AUX101/2 Yes PCCNet IO Module with Expansion card for use with Load Add
Shed Feature (one only)
0338-4747 Yes 12 foot harness for connecting HMI to MCM3320; can be cut to
length
0630-3133 Yes MCM3320 Interconnect Wiring Diagram and Outline
0630-3136 Yes SYNC1320 Interconnect Wiring Diagram and Outline
0541-1199 Yes Cable and RS485/232 Converter Kit for connecting to controller
with InPower, Engineering Tool, or Setup Tool (Kit is for
PCC1301 product, but will work with MCM3320 or SYNC1320)
Rev 1.5 prd

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June 13, 2006
HARDWARE (MCM3320)
MCM3320
Genset CT Inputs Utility CT Inputs Utility PT Input
(1A or 5A) (1A or 5A) (480V LL Max)
TB7
L1* L2* L3* L1* L2* L3*

GEN UTILITY
Genset PT Input
TB6
(480V LL Max)
TB2
Switch IO /
DC Power In
Analog IO TB9
J14
Modbus RTU TB8 InPower or
TB15 Modbus RTU
(RS232) TB1 J17
(RS485)
TB3 TB10
Switch IO / PCCNet (TB1)

Breaker Control / Start Gensets (TB8)
Switch IO / CAN (TB3) Factory Test Connector (J17)
Breaker Status Inputs (TB10)
Rev 1.5 prd

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June 13, 2006
HARDWARE (MCM3320)
Hardwired IO
B+ Input1 Master Freq Bias
B+ Input2 Master Volt Bias
B+ POWER BIDIRECTIONAL
Gnd Master Inhibit
Gnd
RELAY OUTPUTS Start Gensets Relay
CAN (Master)
RS485 PCCNet COMMUNICATIONS
RS485/232 Mon/MB
Load Govern Enable
Load Demand Gen1
Extended Para Start Load Demand Gen2
Sync Enable DISCRETE Load Demand Gen3
OUTPUTS Load Demand Gen4
Utility Source Failure (low side drivers)
DISCRETE Cfg Out1 (com warn)
INPUTS
Transfer Inhibit (active low w/ Cfg Out2 (fail to sync)
Retransfer Inhibit pullup) Cfg Out3 (gen avail)
Gen CB Tripped Cfg Out4 (util avail)
Util CB Tripped Cfg Out5 (fail to discon)
Gen CB Inhibit Cfg Out6 (sync’d)
Util CB Inhibit MCM3320 Hardware I/O Cfg Out7
Manual Cfg Out8
Paralleling Gensets
Test Start Breaker Inhibit
Fault Ack/Reset
Gen1 Available
Gen2 Available Relay Supply
B+ OUTPUTS
Gen3 Available
Gen4 Available
Override
ANALOG
OUTPUTS
kW Load Setpoint BREAKER kW Master Load Control
ANALOG
kVAR Load Setpoint INPUTS INTERFACE
(discrete inputs / kVAR Master Load Control
(0-5V)
relay outputs)
GEN BUS/UTIL
V/I V/I
Gen Position B
Gen PositionA
Util Position B
Util PositionA
Gen Close
Gen Open
Util Close
Util Open
Gen Utility
P. Dahlen
9/8/05 Load
Rev 1.5 prd

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June 13, 2006
HARDWARE (MCM3320)
B+ Power
 2 separate B+ power inputs for redundant supply of

control; station battery suggested
 On-board diode-OR
 Range: 9-32V
 Will ride-through starter dip
 Less than 1 Adc load (no external B+ loads)
 On-board backup of Real Time Clock (minimum 24
hours)
 No wakeup input; board is always awake
 Removal of B+ will not cause loss of any historical data
(controller on-time, kWh, etc.)
Rev 1.5 prd

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June 13, 2006
HARDWARE (MCM3320)
PT Inputs
 Nominal Range 110 – 480 V LL

 External Transformer to 35 kV LL
 Sensing to 125% of Nominal
 3 Wire or 4 Wire
Rev 1.5 prd

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June 13, 2006
HARDWARE (MCM3320)
CT Inputs
 Primary from 5 to 10000 Amps

 Secondary 1 Amp OR 5 Amp
 No terminal block; CT on-board with hole
 Recommend shorting block nearby
 2 passes through hole for 1 Amp
 1 pass for 5 Amp
 Sensing to 125%
Rev 1.5 prd

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June 13, 2006
HARDWARE (MCM3320)
HW Discrete Inputs
 22 hardwire switch inputs

 Inactive State: Open circuit / high impedance
(not B+)
 Active State: Connect to Return
 Can use local B- for return
 Inputs are activated by current (opto coupled)
Rev 1.5 prd

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June 13, 2006
HARDWARE (MCM3320)
HW Discrete Inputs
Discrete Input Active State Inactive State Description

(to Gnd) (open cicuit)
Fault Reset Reset Not Reset reset faults; engage fault readout
Auto/Manual Manual Auto manual or auto breaker / sync operation
Test Start Start Stop test load transfer start / stop
Extended Parallel Start Start Stop extended paralleling start / stop
Synchronizer Enable Active Inactive sync enable (applies in manual only)
Utility Source Failure Active Inactive use if external device determines failure
Transfer Inhibit Inhibit No Inhibit inhibit transfers to gens (some exceptions)
Retransfer Inhibit Inhibit No Inhibit inhibit retransfers to util (some exceptions)
Override Override No Override override timers and tran/retran inhibits
Gen Main CB Inhibit Inhibit No Inhibit open gen main / inhibit closure
Util Main CB Inhibit Inhibit No Inhibit open util main / inhibit closure
Gen Main CB Tripped Tripped Not Tripped gen main breaker tripped; source not avail
Util Main CB Tripped Tripped Not Tripped util main breaker tripped; source not avail
Gen1 CB Position Breaker Closed Breaker Open genset #1 breaker position ('a' contact)
Util Main CB PositionA Breaker Closed Breaker Open util main breaker position ('a' contact)
Util Main CB PositionB Breaker Open Breaker Closed util main breaker position ('b' contact)
Gen Main CB PositionA Breaker Closed Breaker Open gen main breaker position ('a' contact)
Gen Main CB PositionB Breaker Open Breaker Closed gen main breaker position ('b' contact)
Master Inhibit Inhibit No Inhibit master inhibit for multiple pair operation
Rev 1.5 prd

54
June 13, 2006
HARDWARE (MCM3320)
HW Discrete Outputs
 19 hardwire discrete outputs

 5 relays; 14 low-side drivers
 low-side drivers can sink 200mA
 breaker relays (4) can drive coils directly in
some limited cases; else use interposing relays
Rev 1.5 prd

55
June 13, 2006
HARDWARE (MCM3320)
HW Discrete Outputs
Output Signal Name Active State Inactive State Description

(hardware) (Low / Energized) (High
Impedance /
Deenergized)
Start Gensets Relay Run Stop form C relay to start / stop gensets (via Remote Start)
Util Main CB Close Relay Active Inactive N.O. relay contact for utility main close coil
Util Main CB Open Relay Active Inactive N.O. relay contact for utility main open coil
Gen Main CB Close Relay Active Inactive N.O. relay contact for gen main close coil
Gen Main CB Open Relay Active Inactive N.O. relay contact for gen main open coil
Load Govern Enable Driver Enabled Disabled low-side driver to PCC genset's util cb position input to
put PCC in load govern mode when utility paralleled
Paralleling Gensets Breaker Inhibit All Gensets No Inhibit low-side driver to PCC genset's paralleling breaker
Inhibit Driver inhibit input
Load Demand Gen1 Driver Load Demand Stop Run low-side driver to PCC genset #1 load demand input
Configurable Output1 Driver Driver On Driver Off activated by programmable event/warning code
Relay Supply B+ Output B + Output B + output for supplying relay coil high side; low side
connected to a low-side driver output
Rev 1.5 prd

56
June 13, 2006
HARDWARE (MCM3320)
HW Bidirectional Discrete
 Bidirectional discrete I/O for priority arbitration

(like 1st Start Bus PT)
 Used in Phase 2 for priority control among
multiple MCM3320s
 Same connection as “Master Inhibit” (externally
controlled sequencing)
Rev 1.5 prd

57
June 13, 2006
HARDWARE (MCM3320)
HW Analog Inputs
 2 hardwire analog inputs

 kW Load Setpoint (0-5V)
 kVAR / PF Load Setpoint (0-5V)
 used for base load / peak shave setpoints
 alternatively set via Modbus or Trim
 load setpoint profiles same as
PCC3100/3200/3201
Rev 1.5 prd

58
June 13, 2006
HARDWARE (MCM3320)
HW Analog Outputs
 2 hardwire analog outputs

 kW Master Load Control (0-5V)
 kVAR Master Load Control (0-5V)
 Used for load control commands to PCC genset load set
inputs to control soft ramping and base load / peak
shave
 kVAR control only available on PCC3200/3201,
PCC3300 genset controllers
 New Rev D board supports interconnection of analog
outputs amongst multiple 3320s
Rev 1.5 prd

59
June 13, 2006
HARDWARE (MCM3320)
HW Bidirectional Analog
 Two bidirectional analogs for synchronizer

 Master Frequency Bias senses/drives kW load
share line to affect gen bus frequency
 Master Voltage Bias senses/drives kVAR load
share line to affect gen bus voltage
 Output range -2.5 to + 5.0 V
 drives up to 20 gensets simultaneously
Rev 1.5 prd

60
June 13, 2006
HARDWARE (MCM3320)
Communications
 Controller has 2 serial ports

 Port1
– Protocol Options
• PCCNet – for HMI, IO Modules (default protocol)
• Mon – for troubleshooting only (cannot download); set to
Mon mode via Modbus on Port2 or through InPower
– Physical
• RS485 on TB1
• Multidrop for PCCNet
Rev 1.5 prd

61
June 13, 2006
HARDWARE (MCM3320)
Communications
 Port2:
– Protocol Options
• Modbus RTU (MCM3320 is SLAVE)
• Mon (Service Port for InPower/Setup Tools)
• Controller automatically detects protocol
– Physical
• RS232 on J14 (DB9 pins); Null Modem cable
• RS485 2-wire on TB15
• RS485 is default; control switches to RS232 when
RS232 RTS to CTS pins are jumpered by cable
Rev 1.5 prd

62
June 13, 2006
HARDWARE (HMI211)
HMI211 Operator Panel
 HMI211 PCCNet interface

(4wires):
 B+ / GND
 RS485 A / B
• Up to two HMI211’s can be
connected to one
MCM3320
• Use harness 0338-4747 to
connect; cut to length or
extend (12ft / 3.6m)
Rev 1.5 prd

63
June 13, 2006
HARDWARE (HMI112)
HMI112 Bargraph
 HMI112 Bargraph PCCNet

interface (4wires):
 B+ / GND
 RS485 A / B
• Connect two HMI211’s to one
MCM3320 to get both source
data
Rev 1.5 prd

64
June 13, 2006
HARDWARE (AUX101/2)
AUX101/2 IO Module
Connect to Grounded
Chassis
Device Number: Must Read “0” for

AUX101 MCM3320 Applications.
To Change Device Number, Press and
hold pushbutton until decimal point is
P11 (Inputs)
illuminated. Then push button
repeatedly to cycle through numbers
until it reads “0”.
P10 (Ground for Inputs) AUX102
P14 (B+ / Gnd) P4 (Inputs)
Relay LEDs
ON = Energized Relay LEDs
ON = Energized
P1 (PCCNet, Wakeup)
P3 (Relays - NC) Aux102 Board Revision
Level: First letter on barcode
Green LED: PCCNet
(read from left to right) must
Communcations OK
P2 (Relays - Com) be “C” or higher letter.
Red LED: PCCNet P3 P4
Communcations Not (Relays) (Relays)
OK P2 (Relays) P1 (Relays - NO)
AUX101 connects to Load AUX102 connects to

Devices #1,2,3,4 Load Devices #5,6
Rev 1.5 prd

65
June 13, 2006
HARDWARE (AUX101/2)
Connections
• Modules required for Load Add Shed feature

• MCM3320 to AUX101 PCCNet interface (4 wires):
 B+ / GND
 RS485 A / B
• 12 discrete inputs used for breaker / ATS position
monitoring
• 12 form C relays used for breaker / ATS control
Rev 1.5 prd

66
June 13, 2006
MCM3320 OPERATION
 MCM3320 can completely manage simple

systems – breaker control, synchronizing, load
control, gensets start/stop, diagnostics, etc.
 MCM3320 can be used as a component in more
complex systems with whichever features are
appropriate; a PLC can orchestrate the actions
of the MCM3320
Rev 1.5 prd

67
June 13, 2006
MCM3320 FUNCTIONS
 MCM3320 Major Functional Blocks

– Application Configuration
– System Information
– IO Processing
– AC Metering
– Breaker Control
– Power Transfer Control
– Synchronizer & Sync Check
– Load Control
– Scheduler
– Load Demand
– Load Add/Shed
– Communications
– Diagnostics / History
– HMI 211
Rev 1.5 prd

68
June 13, 2006
FUNCTIONS
Application Configuration
Primary Settings:
System Topology
Transition Type
Extended Parallel Enable
Test With Load Enable
Settings are trims (can be saved) or can
be dynamically set via Modbus, InPower
or HMI
Rev 1.5 prd

69
June 13, 2006
FUNCTIONS
MOST IMPORTANT SETTING (set it 1st)

System Topology
Transfer Pair
Common Bus
Isolated Bus with GM
Isolated Bus without GM
Master Synchronize Only (default)
Rev 1.5 prd

70
June 13, 2006
FUNCTIONS
Transition Type
Open Transition (default)
Hard Closed Transition (<100msec overlap)
Soft Closed Transition
Extended Parallel Enable
Disabled (default)
Enabled
Test With Load Enable
Disabled (default)
Enabled
Rev 1.5 prd

71
June 13, 2006
FUNCTIONS
 Must be in Manual mode to set System

Topology
 Hard Closed Transition not applicable in
Common Bus topology
 Transition Type only applies to load transfers
 Thus Transition Type = (Open Transition OR
Hard Closed) is compatible with Extended
Parallel Enable = Enabled
Rev 1.5 prd

72
June 13, 2006
FUNCTIONS
System Information
 Settings for System Phase Rotation, System

Frequency, Individual Genset kW Ratings
 Derived Information such as Total System
Capacity, Total Online Capacity, Spare Online
Capacity, etc. for use in other control function
blocks
 System State derived variable
– Shows what system is currently doing that is most
relevant
– Use for information only, not for control decisions
Rev 1.5 prd

73
June 13, 2006
FUNCTIONS
System Information
 System Lockout derived variable indicating that normal

control logic has been altered due to a fault
 Active / Inactive
 latched until user fault reset
 must be reset for normal control operation to resume
 LED on HMI
 Conditions which make it active:
Utility Breaker Fail to Close Fault State = Active
Utility Breaker Fail to Open Fault State = Active
Utility Breaker Position Contact Fault State = Active
Genset Breaker Fail to Close Fault State = Active
Genset Breaker Fail to Open Fault State = Active
Genset Breaker Position Contact Fault State = Active
(Fail to Synchronize Fault State = Active AND Fail to Sync Lockout Enable = Enabled)
Maximum Parallel Time Fault State = Active
Genset Bus Overload Fault State = Active AND (Load Demand = Enabled OR Load Add Shed = Enabled)
Rev 1.5 prd

74
June 13, 2006
FUNCTIONS
System Information
 Genset Bus Overload is detected by kW level or

frequency or both (configurable)
 Fault Code 1444
 Used internally by Load Demand and Load Shed
functions
 Adjustable %kW threshold: 80-140% of online
capacity
 Adjustable kW delay: 0-120 sec
 Adjustable Hz threshold: 0.1-10 Hz below System
Frequency setting
 Adjustable Hz delay: 0-20 sec
Rev 1.5 prd

75
June 13, 2006
FUNCTIONS
System Setup1
Rev 1.5 prd

76
June 13, 2006
FUNCTIONS
System Setup2
Rev 1.5 prd

77
June 13, 2006
FUNCTIONS
IO Processing – Discrete Inputs

 Most discrete inputs can be controlled from a hardwired
input OR from a communications link such as Modbus or
InPower (“<name> + Vol”)
 Controller will always logically OR the two inputs
 Result of OR is readable at “<name> + Sw”
HW SW
Conditioning & Debounce

<Signal Name> Level Function <Signal Name>
Detection Sample + " Sw"
< Signal Name > + " Vol"
Rev 1.5 prd

78
June 13, 2006
FUNCTIONS
IO Processing – Discrete Outputs
 For testing and troubleshooting purposes, most

discrete outputs can be directly overriden using
InPower
SW HW
(enabled)
<Output Signal Name> + " Override Cmd"
Output
HW Update Register <Output Signal Name>
<Input Signal Name>
(disabled)
<Output Signal Name> + " Override Enable"
<Output Signal Name> + " Status"
Rev 1.5 prd

79
June 13, 2006
FUNCTIONS
AC Metering Setup
 PT Primary Voltage = 110-45000 VLL

 PT Secondary Voltage = 110-500 VLL
 CT Primary Current = 5-10000 A
 CT Secondary Current = 5 or 1 A
 Nominal Voltage = 110-45000 VLL
– Used for %volt scaling
Rev 1.5 prd

80
June 13, 2006
FUNCTIONS
AC Metering - Voltage
 Hardware inputs autoranging: 120,240,or 480

VLL = 100% at board
 Input Range: 5% to 125% of above ranges
 Sampled every line cycle on all 3 phases
 LN, LL, LN-Avg, LL-Avg, % of nominal
 3 or 4 Wire Connections
 Factory calibrated to better than 1% of full scale;
field adjustable
Rev 1.5 prd

81
June 13, 2006
FUNCTIONS
AC Metering - Current
 Hardware inputs autoranging: 5 A or 1A = 100% at board

 Input Range: 0% to 125% of above ranges
 Sampled every 10th line cycle
 L1, L2, L3 and Average
 True RMS with 14kHz Bandwidth
 1A requires two pass thru on-board CT
 Factory calibrated to better than 1% of full scale; field
adjustable
Rev 1.5 prd

82
June 13, 2006
FUNCTIONS
AC Metering - Power
 kW, kVAR, kVA, PF

 True power readings; 14kHz bandwidth
 If harmonics present, kW2 + kVAR2 may not equal kVA2
 Sampled every 10th line cycle
 Per phase and totalized to +/- 32767k
 Sign Convention is with respect to the Source
– Positive kW = real power delivered by source
– Positive kVAR = lagging vars delivered by source
– Positive PF = lagging; Negative PF = leading
Rev 1.5 prd

83
June 13, 2006
FUNCTIONS
AC Metering - Energy
 kWh  positive, negative, net

 kVARh  positive, negative, net
 kVAh  net
 Per phase and totalized to +/- 231
 Permanently stored
 Resettable/Settable
Rev 1.5 prd

84
June 13, 2006
FUNCTIONS
AC Metering – Time Based
 Precise frequency reading 25 to 80Hz

 Precise sync phase angle reading -180 to +180
degrees
 Precise voltage phase angle readings
– Used by loss of phase sensor
Rev 1.5 prd

85
June 13, 2006
FUNCTIONS
AC Metering Setup
Rev 1.5 prd

86
June 13, 2006
FUNCTIONS
AC Metering Calibration
• MCM3320 is
factory
calibrated
• Voltage and
Current can
be adjusted in
the field if
needed
Rev 1.5 prd

87
June 13, 2006
FUNCTIONS
Breaker Control
 Main Breaker Positions

 Main Breaker Control
 Main Breaker Diagnostics
Rev 1.5 prd

88
June 13, 2006
FUNCTIONS
Main Breaker Position
 ‘a’ and ‘b’ contact used to determine position (default)

this may change
 If conflict between ‘a’ and ‘b’:
1. Contact fault active
2. If current on all 3 phases > threshold, then breaker
considered closed, else unknown
3. Source deemed not available if current based breaker
position is ‘unknown’
 Can configure for ‘a’ contact only operation, this may
become the default
 Breaker rack-out will cause fault and source not
available
Rev 1.5 prd

89
June 13, 2006
FUNCTIONS
Main Breaker Position
 In applications without GM, a virtual GM is created by

collection of genset paralleling breakers
 In this case, if any one or more genset paralleling
breaker is closed, virtual GM is closed.
 IMPORTANT: If #gens <= 4, use individual genset cb
position inputs. If #gens > 4 connect cb contacts in
parallel to GM position inputs.
 Refer to 0630-3133 dwg
Rev 1.5 prd

90
June 13, 2006
FUNCTIONS
Main Breaker Control
 Separate relays for close and open

 Relays energize until desired position achieved
 Adjustable recharge time delay
 Built-in software interlock for open transition
 In applications without GM, the MCM3320 controls the
virtual gen main via the paralleling gen cb inhibit inputs
on the genset controls
 Breakers can be controlled manually when Auto/Manual
switch input = Manual
Rev 1.5 prd

91
June 13, 2006
FUNCTIONS
Main Breaker Diagnostics
 Breaker Diagnostics:
Fail to Close (adjustable delay)
Fail to Open (adjustable delay)
Breaker Contacts
Breaker Tripped
Fail to Disconnect
 Diagnostics results in warning and appropriate
control reaction
Rev 1.5 prd

92
June 13, 2006
FUNCTIONS
Breaker Setup
Rev 1.5 prd

93
June 13, 2006
FUNCTIONS
 Sensors and Source Availability

 Operating Mode
 PTC State Machine
 Timers
Rev 1.5 prd

94
June 13, 2006
FUNCTIONS
Sensors
 Both sources have these sensors:

• Undervoltage
• Overvoltage *
• Under/Over Frequency *
• Phase Rotation * (* = optionally enabled)
• Loss of Phase *
• Main Breaker Tripped
• Fail to Close
• Position Contact Failure
 If any sensor is dropped-out, the source is not available
Rev 1.5 prd

95
June 13, 2006
FUNCTIONS
Sensor - Undervoltage
 Sensor is always enabled

 Configurable L-L or L-N sensing
 Settings:
– Dropout Percentage
– Pickup Percentage
– Dropout Delay
 Pickup is instantaneous
 Take note how settings are converted into
actual voltages (next page)
Rev 1.5 prd

96
June 13, 2006
FUNCTIONS
SensorUnderVoltage
- Undervoltage
Sensor
Status
PICKED UP
(good)
DROPPED OUT
(bad)
Voltage, V
Dropout Pickup Nominal
Voltage Voltage System
Voltage
(100%)
Pickup Voltage = Pickup Percentage * Nominal Voltage

Dropout Voltage = Dropout Percentage * Pickup Percentage * Nominal Voltage
Rev 1.5 prd

97
June 13, 2006
FUNCTIONS
Sensor - Overvoltage
 Sensor is optionally enabled

 Configurable L-L or L-N sensing
 Settings:
– Dropout Percentage
– Pickup Percentage
– Dropout Delay
 Take note how settings are converted into
actual voltages (next page)
Rev 1.5 prd

98
June 13, 2006
FUNCTIONS
Sensor - Overvoltage
OverVoltage
Sensor
Status
PICKED UP
(good)
DROPPED OUT
(bad)
Voltage, V
Nominal Pickup Dropout

System Voltage Voltage
Voltage
(100%)
Pickup Voltage = Pickup Percentage * Dropout Percentage * Nominal Voltage

Dropout Voltage = Dropout Percentage * Nominal Voltage
Rev 1.5 prd
99
June 13, 2006
FUNCTIONS
Sensor - Frequency

 Over and Under combined in one sensor
 Settings:
– Center Frequency
– Dropout Bandwidth
– Pickup Bandwidth
– Dropout Delay
 Take note how settings are converted into actual
voltages (next page)
Rev 1.5 prd

100
June 13, 2006
FUNCTIONS
Sensor - Frequency
Frequency
Sensor
Status
PICKED UP
(good)
DROPPED OUT
(bad)
Frequency, Hz
Lower Lower Center Upper Upper

Dropout Pickup Frequency Pickup Dropout
Freq Freq Freq Freq
Lower Pickup Freq = (1 - Pickup Bandwidth) * Center Frequency

Upper Pickup Freq = (1 + Pickup Bandwidth) * Center Frequency
Lower Dropout Freq = (1 - Pickup Bandwidth - Dropout Bandwidth) * Center Frequency
Upper Dropout Freq = (1 + Pickup Bandwidth + Dropout Bandwidth) * Center Frequency
Rev 1.5 prd

101
June 13, 2006
FUNCTIONS
Sensor – Phase Rotation

 Compares source’s phase rotation to System Phase
Rotation setting when source is at least 60% voltage and
30Hz
 Once sensor is picked up (good), sensor does not
recheck until voltage/freq drop below and then back
above 60%, 30Hz
 Settings:
– System Phase Rotation
– Dropout Delay
Rev 1.5 prd

102
June 13, 2006
FUNCTIONS
Sensor – Loss of Phase

 Dropout (bad) when any phase angle between
LL phasors does not fall within 90 to 150
degrees
 Settings:
– Dropout Delay
 Not same as negative sequence voltage
Rev 1.5 prd

103
June 13, 2006
FUNCTIONS
Sensors - Misc
 If Main Breaker Tripped input is active, source is

Not Available
 If Main Breaker Fail to Close fault state is active,
source is Not Available
 If Main Breaker Position Contact fault state is
active and current does not indicate breaker is
closed, source is Not Available
Rev 1.5 prd

104
June 13, 2006
FUNCTIONS
Sensors – Source Unique
 Utility source additional sensor:

• Utility Source Failure switch input
 Genset source additional sensor:
• Genset Online Capacity Sensor *
• sensor picks-up when online kW capacity exceeds
threshold. Once gen main is closed, sensor stops
checking.
Rev 1.5 prd

105
June 13, 2006
FUNCTIONS
Sensors Setup (utility)
Rev 1.5 prd

106
June 13, 2006
FUNCTIONS
Sensors Setup (genset)
Rev 1.5 prd

107
June 13, 2006
FUNCTIONS
Operating Mode
 Evaluates utility source status, test start / stop,

and extended parallel start / stop to decides
whether or not to start or stop the gensets
 Prioritizes and lets PTC core logic know which
direction a transfer should be going, if any
Rev 1.5 prd

108
June 13, 2006
FUNCTIONS
PTC State Machine
 The core of the power transfer control

 Four possible states defined by four possible
combinations of GM and UM breaker positions
 In each state, logic unique to that state decides
whether to turn on synchronizer and whether to
open or close a breaker
Rev 1.5 prd

109
June 13, 2006
FUNCTIONS
PTC State Machine

T-INIT
Powerup
PTC
NOT
ENABLED
T99
T0
UTILITY
CONNECTED
Open Close
Utility U1 U3 Genset
U2 U4
No
T1A Command T2A
Close
Utility Open
T3A Genset
N2 T2B P4
N1
NO P3
SOURCE No
No
CONNECTED Command PARALLELED
Command
N3 P1
Close N4
T1B T4A P2 Open
Genset
Utility
T4B No T3B
Command
G4 G2
Open G3 G1 Close
Genset Utility
GENSET
CONNECTED
Rev 1.5 prd

110
June 13, 2006
FUNCTIONS
Timers
 Start Timer
 Stop Timer
 Timer in each PTC State:
– Programmed Transition Timer (No Source Connected)
– Transfer Timer (Utility Connected)
– Retransfer Timer (Genset Connected)
– Maximum Parallel Timer (Paralleled)
Rev 1.5 prd

111
June 13, 2006
FUNCTIONS
Override
 Override switch input (hardwired or Modbus)

 Forces pending action to occur immediately
 Useful in certain situations / applications
 Overrides (bypasses) the following:
– Transfer Inhibit
– Retransfer Inhibit
– Start Delay
– Transfer Delay
– Retransfer Delay
 Does NOT override:
– Stop Delay
– Programmed Transition Delay
– Maximum Parallel Time
– Gen Main CB Inhibit
– Utility Main CB Inhibit
Rev 1.5 prd

112
June 13, 2006
FUNCTIONS
Synchronizer & Sync Check
 Synchronizer On / Off
 Synchronizer Control
 Sync Check
 Synchronizer Diagnostics
Rev 1.5 prd

113
June 13, 2006
FUNCTIONS
Synchronizer On / Off
 In all cases, both sources must be ‘available’

for the synchronizer to run
 With PTC function, Synchronizer turns on
automatically when needed if in ‘Auto’ mode
 In ‘Manual’, Sync Enable input must be active
to turn on
Rev 1.5 prd

114
June 13, 2006
FUNCTIONS
Synchronizer Control
 Synchronizer matches phase, frequency and voltage of

gen bus to utility bus
 Freq Match Closed loop PI drives kW load share lines to
match freq/phase
 Volt Match Closed loop PI drives kVAR load share lines
to match voltage
 Tuning is fairly tolerant; field adjustment not expected to
be required normally
 Performance is very good – much improved over existing
analog master synchronizer
Rev 1.5 prd

115
June 13, 2006
FUNCTIONS
Synchronizer Control
 Two Synchronizing Options:

– Phase Sync (default) => gen bus phase is driven to match utility
bus
– Slip Frequency => gen bus frequency is driven to be fixed Hz
higher or lower than utility bus (e.g. 0.1Hz)
 Use Slip Freq option with difficult to sync applications

such as natural gas
 Nominal System Frequency = 45-65 Hz
– Used by synchronizer – must be set to nominal operating
genset frequency
Rev 1.5 prd

116
June 13, 2006
FUNCTIONS
Sync Check
 Permissive sync check with adjustable frequency, phase,

voltage and dwell time window
 Runs independently of synchronizer
 PTC function uses this to decide when to close breaker
 Can get sync check output by mapping sync event to a
configurable output (#6 by default)
 In synchronizer only applications, can also enable sync
check individually for different dead bus scenarios (dead
bus sensor is included)
Rev 1.5 prd

117
June 13, 2006
FUNCTIONS
Synchronizer Diagnostics
 Fail to Synchronize Warning = synchronizer has

been on for Fail to Sync time (adjustable)
without achieving sync check ok
 Synchronizer Output Limit Warning = freq bias
or volt bias drive output has been at maximum
and unable to achieve sync
Rev 1.5 prd

118
June 13, 2006
FUNCTIONS
Sync Setup
Rev 1.5 prd

119
June 13, 2006
FUNCTIONS
Load Control
 kW and kVAR are controlled during soft

transfers and extended paralleling
 MCM3320 has one analog output for kW, one
for kVAR
 MCM3320 drives all gensets to same %
command value
 PCC Genset controllers perform ramping and
load governing
Rev 1.5 prd

120
June 13, 2006
FUNCTIONS
Load Control
 Soft Loading
 Extended Paralleling
 kW Control
 kVAR Control
 Diagnostics
 Performance / Tuning
Rev 1.5 prd

121
June 13, 2006
FUNCTIONS
Soft Loading
 Closed transition transfer / retransfer

 MCM3320 either drives load set line to +5V or 0V
depending on desired ramp direction
 PCC genset controllers perform the ramp based on their
own ramp time settings
 PCC genset controllers are doing the closed loop control
of kW and kVAR (load governing)
 MCM3320 disconnects appropriate source when it
senses kW below threshold
Rev 1.5 prd

122
June 13, 2006
FUNCTIONS
 Many options for how / where to control kW and

kVAR
 Open loop or closed loop options
 Control points at gen bus or utility bus
 Setpoints from analog input, trim setting, or
Modbus
 MCM3320 controls load without knowledge of
which gensets are online
Rev 1.5 prd

123
June 13, 2006
FUNCTIONS
kW Control Options
 Gen Bus % Level (open loop)

» MCM3320 puts out fixed %kW command
 Gen Bus kW (closed loop)
» MCM3320 adjusts output command to get desired kW at
gen bus metering point
 Gen Bus kW w/Utility Constraint (closed loop)
gen bus metering point subject to maintaining utility kW
greater than a threshold
 Utility Bus kW (closed loop)
utility bus metering point
Rev 1.5 prd

124
June 13, 2006
FUNCTIONS
kVAR Control Options
 Genset Controllers
» MCM3320 does nothing
» ONLY OPTION WHICH WILL WORK ON PCC3100 GENSETS
 Gen Bus % Level (open loop)
» MCM3320 puts out fixed %kVAR command
 Gen Bus Power Factor (open loop)
» MCM3320 puts out %kVAR command based on power factor
setting and what is currently being put out on the %kW command
output
 Gen Bus kVAR (closed loop)
» MCM3320 adjusts output command to get desired kVAR at gen
bus metering point
 Gen Bus Power Factor (closed loop)
» MCM3320 adjusts output command to get desired power factor at
gen bus metering point
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FUNCTIONS
kVAR Control Options (cont.)
 Utility Bus kVAR (closed loop)

» MCM3320 adjusts output command to get desired
kVAR at utility bus metering point
 Utility Bus Power Factor (closed loop)

» MCM3320 adjusts output command to get desired
power factor at utility bus metering point
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June 13, 2006
FUNCTIONS
Load Setpoints - Source
 kW, kVAR/PF setpoints can come from

hardwired analog inputs or internal setting
 Internal setting can be changed from Inpower,
HMI, or Modbus
analog input (hardwired)

process value
internal
setpoint source
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June 13, 2006
FUNCTIONS
Load Setpoints – Scaling
%kW, kVAR, Power Factor vs. Input Voltage
120 1.2
110 1.1
%kW/kVAR
100 1
PowerFactor
90 0.9
80 0.8
%kW / %kVAR
Power Factor
70 0.7
60 0.6
50 0.5
40 0.4
30 0.3
20 0.2
10 0.1
0 0
0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 4.25 4.5 4.75 5
Input Voltage, Vdc
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June 13, 2006
FUNCTIONS
Load Setpoints – Scaling

 If open loop load control, scaling of hardwired analog
input is per graph
 If closed loop load control, kW command level = % from
graph * Total System Capacity
 If power factor control, scaling always follows red line
 Definitions:
– Total System Capacity = sum of individual genset kW ratings
– %kW = kW / Total System Capacity
– %kVAR = kVAR / (Total System Capacity / 0.8)
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FUNCTIONS
Load Control Diagnostics
 kW Load Control Output Limit Warning

» kW command output has been at minimum or
maximum value for longer than 60 seconds
» Only applicable to closed loop modes
» means that the desired kW setpoint cannot be
achieved either due to inadequate capacity or
operator error
 kVAR Load Control Output Limit Warning

» analogous to kW diagnostic
» Means that the desired kVAR or Power Factor
setpoint cannot be achieved either due to
inadequate capacity or operator error
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June 13, 2006
FUNCTIONS
Load Control Setup (kW)
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131
June 13, 2006
FUNCTIONS
Load Control Setup (kVAR)
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132
June 13, 2006
FUNCTIONS
Scheduler
 Scheduler operates based on up to 12 programs

and 6 exceptions
 Each program specifies a day of the week/time to
start, how long to run, how often to repeat, and what
mode to run in
 Run modes are: test without load, test with load, and
extended parallel
 Each exception is defined by a start date/time,
duration, and repeat interval
 An exception will block a scheduled program from
starting during the exception period
 Scheduler will not run if real time clock has not been
set
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June 13, 2006
FUNCTIONS
Scheduler
Extended Paralleling Clarification
 To use Extended Paralleling with the Scheduler, the
Extended Parallel Enable must be set to Enabled
 If program run mode = Extended Parallel, but Extended
Parallel Enable = Disabled, there will never be extended
paralleling (nothing will happen when program becomes
active)
 Some applications do not allow extended paralleling, so
this provides one setting to disable all extended
paralleling
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June 13, 2006
FUNCTIONS
Scheduler
Test With / Without Load Clarification
 Scheduler will follow the Program Run Mode setting
– If Program #1 Run Mode = With Load, system will run with load
– If Program #1 Run Mode = Without Load, system will run without
load
 The setting of Test With Load Enable variable does NOT apply
to Scheduler
– E.G. If Test With Load Enable = Disabled, but Program #1 Run
Mode = With Load, program will run with load
 Test With Load Enable only applies to Test Start switch input
(hardwired or Modbus or HMI)
 This may be confusing because it is different than how the
Extended Parallel Enable is used by the MCM3320
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FUNCTIONS
Scheduler Setup
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June 13, 2006
FUNCTIONS
Program Overlapping
 Do not overlap programs; overlapped program will be ignored
Program1
Program1 runs for its entire period
Program2
Program2 does NOT run
Program1 Program2 Program1 runs and ends. Some time

later Program2 runs and ends.
Program1 Program2 Program1 runs and ends. Program2 starts

at same minute Program1 ends.
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FUNCTIONS
Exception Operation
 Exceptions only block the START of a program; a program
started outside of the exception period will not be canceled by
an exception
Program1
Exception1
Program1 does NOT run
Program1
Program1 runs for its entire period
Exception1
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FUNCTIONS
Priorities
 Utility Failure will supersede any scheduler program
 An active program will resume when the utility source has become
available again
 Two examples are shown below
Program1 (no load)
EXAMPLE#1:
Utility fails while gensets running no load
Utility Failed
due to Program1. System will transfer load
to gensets. When utility returns, system load
UM Closed Closed
will remain on gensets until Program1 ends.
Breaker Open (It does NOT retransfer until Program1 ends.)
Closed
GM Open Open
Breaker
Program1 (extended parallel) EXAMPLE#2:

Utility fails while gensets running in parallel
Utility Failed to utility due to Program1. System will open
utility main breaker. When utility returns,
UM Closed Closed system will sync across utility main, close
Breaker Open utility main and continue in parallel until
Program1 ends.
Closed
GM Open Open
Breaker
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June 13, 2006
FUNCTIONS
Clock & DST Setup
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June 13, 2006
FUNCTIONS
Operating Sequences
Normal Sequences1
Utility Fail / Return
Extended Parallel
Test (with or without load)
Sequences are affected by
Transition Type
Operating priority
Faults2
1
Refer to MCM3320 Operating Sequences document for listing of normal sequences
2
Refer to MCM3320 Abnormal Conditions Operation document for description of control reaction for
fault conditions.
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FUNCTIONS
Normal Sequence Example

Scenario:
Transfer Pair; Soft Closed Transition; Utility Fail / Return
1. Utility Failure 10.Utility Available

2. TD Start 11.TD Retransfer
3. Gensets Start / Close 12.Synchronizer On
4. Gen Bus Available 13.Sync Check OK
5. TD Transfer 14.Close Utility Main
6. Open Utility Main 15.Ramp Unload Gensets
7. TD Program Transition 16.Open Gen Main
8. Close Gen Main 17.TD Stop
9. Loads Powered by Gen Bus 18.Stop Gensets
19. Loads Powered by Utility
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FUNCTIONS
Abnormal Condition Example

Scenario:
Transfer Pair; Soft Closed Transition; Test With Load;
UM Fails to Open
1. Test Start Initiated 10.Utility Unloaded

2. TD Start 11.Open Utility Main
3. Gensets Start / Close 12.Utility Main Fails to Open
4. Gen Bus Available 13.Open Gen Main
5. TD Transfer 14.Gen Main Opens
6. Synchronizer On 15.Open Utility Canceled
7. Sync Check OK 16.Loads Powered by Utility
8. Close Gen Main 17.Gensets Remain Running
9. Ramp Load Gensets 18.User Intervention Required
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June 13, 2006
FUNCTIONS
Operating Priorities
 Operating priorities from highest to lowest:

1. Utility Failure
2. Extended Parallel
3. Test
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June 13, 2006
FUNCTIONS
Load Demand
 Supports 2, 3, or 4 genset systems

 4 hardwired outputs to drive gensets load demand stop
 4 hardwired inputs to read genset paralleling breaker
positions
 Shuts down/Restarts gensets based on genset bus total
kW load level
 Adjustable shutdown / restart thresholds and time delays
 Genset Sequence configurable as Fixed Sequence or
Run Hours Based
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June 13, 2006
FUNCTIONS
Load Demand Interconnect

Remote Start
Gen1 Load Demand PCC3xxx G1
Gen1 Breaker Position

MCM3320
Gen4 Load Demand PCC3xxx

G4
Genset Bus Currents

Genset Bus Voltages
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June 13, 2006
FUNCTIONS
Load Demand Operation
 Genset Sequence defines shutdown order:

– GenA, GenB, GenC, GenD
 GenA always runs; GenD is first to shut down, last to
restart, etc.
 Sequence Determination:
– Fixed Sequence, or Run Hours Based
 Fixed Sequence is set by the operator
 Run Hours Based Sequence changes dynamically as run
hours accumulate on gensets – system attempts to
equalize running hours on all gensets
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June 13, 2006
FUNCTIONS
 Fixed Sequence
• GenA = Gen2
• GenB = Gen1
• GenC = Gen4
• GenD = Gen3
 Sequence can be changed any time – even when load demand
is operating
 Must issue “Refresh Sequence” command after defining the new
sequence in order for it to take effect (HMI211 does this for
you).
 On change, only the appropriate gensets will restart, then after
time delay, unnecessary gensets stop in sequence
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June 13, 2006
FUNCTIONS

 Run Hours Based Sequence
• Gen1 Online Time = 100 Hr  GenA (lowest hr)
• Gen2 Online Time = 250 Hr  GenC
• Gen3 Online Time = 150 Hr  GenB
• Gen4 Online Time = 400 Hr  GenD (highest hr)
 Sequence is sorted by Online Time when:
• Load Demand Enable changed to Enable
• Load Demand Type changed to Run Hours Based
• Refresh Sequence command changed to “Refresh”
 Run Hours Differential setting will determine how
frequently gensets are restarted due to hours
accumulation – typically set to 50hr
 Online Time is accumulated by the MCM3320 based on
amount of time that GenX paralleling breaker is closed
 MCM3320 does not get running hours from genset
control…but operator can enter hours into MCM3320 as
starting point
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June 13, 2006
FUNCTIONS
 Normal Operation Steps

1. Gensets start and come online
2. Gen Main Breaker Closes (if present)
3. Load Demand times “Initial Delay”
4. Load Demand monitors Load vs. Gensets
5. Load Demand times “Shutdown Delay” if load allows
shutting down a genset
6. Load Demand tells lowest priority genset to shutdown
7. Load Demand continues to monitor load
8. Load Demand stops additional gensets as load allows
9. Load Demand restarts gensets as load requires
10. Load Demand restarts appropriate gensets if sequence
changes due to operator or run hours (as configured)
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June 13, 2006
FUNCTIONS
 Shutdown Decision
 [Genset Bus Load < Shutdown Percent * (Total Online
Capacity – kW Rating of Next Genset to Shutdown)] = true
continously for Shutdown Delay
 Restart Decision
 Genset Bus Load > Restart Percent * (Total Online
Capacity)
 Sequence has changed due to operator or run hours
 Genset Bus is overloaded
 Genset(s) have failed
 Load Demand Enable changed to Disabled
 MCM3320 has detected a problem with AC metering
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June 13, 2006
FUNCTIONS

Online Capacity vs. Total Load
4500
4000
Gen4 Stop
3500
Gen4 Restart
ity
Online Capacity, kW
3000 ac
Cap
Gen3 Stop
oad=
2500
Gen3 Restart L
2000
4 Gensets each rated at 1000kW
Gen2 Stop Shutdown Percent = 60%
1500 Gen2 Restart
Restart Percent = 80%
GenA = Gen1
1000
GenB = Gen2
GenC = Gen3
500 GenD = Gen4
0
0 500 1000 1500 2000 2500 3000 3500 4000
Total Load, kW
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June 13, 2006
FUNCTIONS
 Overload Operation
 If Genset Bus Overload fault occurs, ALL load demand stopped
gensets will restart
 Condition is latched until overload no longer exists and operator
resets the fault
 Individual Genset Failure Operation
 If a single genset fails, that genset is removed from the load
demand logic; fault occurs
 If available, a stopped genset will restart to replace the failed
genset
 When the failed genset comes back online, it will be readded to
load demand logic and normal operation will resume
 Genset Bus Failure Operation
 If the genset bus fails (goes “Not Available”), ALL load demand
stopped gensets will restart
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June 13, 2006
FUNCTIONS
 Minimum Online Capacity

 Optional function allows operator to keep more than one
genset running at all times
 Minimizes exposure to a single genset failure if load
demand has shut down all except one genset
 Example: 4 gensets rated at 1000kW each; Set Load
Demand Minimum Online Capacity = 2000kW  2 gensets
will always remain running
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June 13, 2006
FUNCTIONS
Load Demand Notes
 PCC3100, PCC3200/1 only support load

demand in isolated bus mode
 PCC3300 will support load demand in utility
parallel and isolated bus mode
 MCM3320 Load Demand function operates both
in isolated and utility parallel modes
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155
June 13, 2006
FUNCTIONS
Load Demand Setup
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156
June 13, 2006
FUNCTIONS
Load Add Shed

 Supports up to 4 gensets, 6 levels of Add, 6 levels of
Shed, and status for up to 6 breakers or ATS
 Each Breaker or ATS can be assigned to any Add
level and any Shed level
 Requires AUX101 and AUX102 module
 Adds levels in sequence as gensets (up to 4) come
online; remaining add levels are timed
 Sheds levels in timed sequence when Genset Bus
Overload condition detected; shed stops when
overload is corrected
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June 13, 2006
FUNCTIONS
Load Add Shed Interconnect

BREAKER ATS
'tripped' normal emergency
'a' contact contact source source
position position
AUX101 Input1 Input2 Input1 Input2 Input1 Input2 Input1 Input2

B+ Load 1 Load 2 Load 3 Load 4
GND Add Add Shed
Add Shed Shed Add Shed
RS485-A
RS485-B
Cable
Ribbon
MCM3320 AUX102 Input1 Input2 Input1 Input2
Load 5 Load 6
Add Shed Add Shed
PCCNet
Port
Relays are shown in de-energized state.

Add relays energize to add load. Two second pulse for Breaker; Continuous for ATS
Shed relays energize to shed load. Continuous for both Breaker and ATS.
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June 13, 2006
FUNCTIONS
Load Device = Breaker

 FEEDER BREAKER CONTROL
Add and Shed Relays have FormC contacts
Add Relay energizes for 2 seconds to add the load; typically
used to drive breaker close coil
Shed Relay energizes continuously to shed the load; typically
used to drive breaker open coil
Use of breaker pilot relays is recommended
AUX101 Relays: 30Vdc/250Vac,
N.O.=5A N.C.=3A
AUX102 Relays: 30Vdc/250Vac, 2A
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June 13, 2006
FUNCTIONS
Load Device = Breaker
 FEEDER BREAKER MONITOR

Two inputs available to monitor breaker
Input 1 for breaker position from ‘a’ contact
Input 2 for breaker tripped status from overcurrent trip contact
Breaker monitoring is provided for operator benefit only;
connections are OPTIONAL; Load Add Shed function does
not use this information
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June 13, 2006
FUNCTIONS
Load Device = ATS
 ATS CONTROL
Add and Shed Relays have FormC contacts
Add Relay energizes continuously to add the load; typically
used to tell ATS that it can transfer to genset
Shed Relay energizes continously to shed the load; typically
used to tell ATS to shed load (go to neutral position)
Use of pilot relays may not be required
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June 13, 2006
FUNCTIONS
Load Device = ATS
 ATS MONITOR
Two inputs available to monitor ATS
Input 1 for Source 1 switch position
Input 2 for Source 2 switch position
ATS Position monitor = No Source Connected, Source 1
Connected, Source 2 Connected
ATS monitoring is provided for operator benefit only;
connections are OPTIONAL; Load Add Shed function does
not use this information
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June 13, 2006
FUNCTIONS
Load  Level Assignment
 6 Add Levels available: 1,2,3,4,5,6

 6 Shed Levels available: 0,1,2,3,4,5
 Loads can be assigned to any Add Level and any
Shed Level
 Add assignment not required to match Shed
assignment
 Add Levels add in sequence 1,2,3,4,5,6
 Shed Levels shed in sequence 1,2,3,4,5
 Loads assigned to Shed Level 0 are never shed
 Load Devices can be any combination of Feeder
Breaker or Automatic Transfer Switch (ATS)
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163
June 13, 2006
FUNCTIONS
Load  Level Assignment
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164
June 13, 2006
FUNCTIONS
Load Add Shed Operation
 Load Add Shed Modes

Automatic Genset Load Add
Automatic Genset Load Shed
Manual Load Add / Shed / Restore
Automatic Utility Load Add
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June 13, 2006
FUNCTIONS
Automatic Genset Load Add

 Automatic Genset Load Add Example:
3 gensets; 6 add levels
Timed Add
After Last Genset
Is Online
Gen2 Gen1 Gen3
Online Online Online
TIME
Level 1 Level 2 Level 3 Level 4 Level 5 Level 6

Added Added Added Added Added Added
Genset Bus Genset Bus Genset Bus

Load Add Load Add Load Add
Delay Delay Delay
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June 13, 2006
FUNCTIONS
Automatic Genset Load Add
 NOTE: If all gensets do not come online, the Load

Add sequence will stop and remaining add levels will
not be added automatically
Option1: Operator gets all gensets running – load add
sequence completes automatically
Option2: Operator manually adds any remaining levels
desired
Option3: Configure “Required Online Capacity” to force an
automatic timed add of the remaining levels when online
capacity is greater than or equal to this setting (assumes
total load < this setting)
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June 13, 2006
FUNCTIONS
Automatic Genset Load Shed

 Automatic Genset Load Shed Example
Genset Genset
Bus Bus
Overload Overload
Condition = Condition =
ACTIVE INACTIVE
TIME
Shed Shed
Level 1 Level 2
ON ON
Load Load
Shed Shed
Delay Delay
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June 13, 2006
FUNCTIONS
Automatic Genset Load Shed
 Shed Levels which are ON can only be restored by:

 Option1: Manual restore by operator
 Option2: Retransfer to Utility or Genset Main Breaker (or all
genset paralleling breakers) opened and reclosed
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June 13, 2006
FUNCTIONS
Manual Load Add / Shed / Restore
 When Load Bus is fed by Genset Bus, Load Add Shed

feature can be put into “Manual” mode through HMI,
Setup Tool, or Modbus
 This is NOT the same setting as the Auto/Manual
switch for the Main Breakers
 Manual mode allows operator to:
Turn ON specific Add Levels which have not added
Restore specific Shed Levels which are ON
Turn ON Shed Levels which are OFF
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June 13, 2006
FUNCTIONS
Manual Load Add / Shed / Restore
 Restoring a Shed Level does two things:

Turns off the shed relays assigned to that Shed Level
Turns on the Add relays assigned to that SHED LEVEL (2
sec pulse for Breaker; continous for ATS)
 Manual mode is automatically exited if certain events
occur: overload, retransfer to utility, etc…
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June 13, 2006
FUNCTIONS
Automatic Utility Load Add
 Upon reconnection to utility source:

 all Shed Levels will be turned off
 all Add Levels will be added in sequence
 Utility add delay adjustable from 0 to 60 seconds
Utility
Main
Breaker
Closes
TIME
All Shed Add Add Add Add Add Add

Levels Level 1 Level 2 Level 3 Level 4 Level 5 Level 6
OFF ON ON ON ON ON ON
Utility Bus Utility Bus Utility Bus Utility Bus Utility Bus
1/4 sec Load Add Load Add
Load Add Load Add Load Add
Delay Delay Delay Delay Delay
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172
June 13, 2006
FUNCTIONS
Load Add Shed Setup
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173
June 13, 2006
FUNCTIONS
Modbus RTU
 RS485 OR RS232
 MCM3320 is Slave
 Configurable Address, Baud, Parity
 Register Map Published
 Setup, Control, and Monitor of MCM3320s
 Steve Prater has developed some Quantum /
Momentum PLC code
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June 13, 2006
FUNCTIONS
Modbus Register Map
 40xxx -- Genset control registers

 41xxx -- Transfer switch control registers
 42xxx -- Master control registers (MCM3320)
 4x0xx -- General data registers for genset bus
 4x1xx -- General data registers for utility bus
 4x2xx -- Configuration and status registers
 4x3xx -- Settings – Block 1
 4x4xx -- Settings – Block 2
 4x5xx -- Bitmaps
 4x6xx -- Switch IO
 4x7xx -- Status registers continued
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June 13, 2006
FUNCTIONS
Modbus Register Map
Modbus Modbus
Address
System Name Access
Specifications Description
0: Master Synchronize Only
1: Isolated Bus w/out GM Sets the system topology. THIS
2: Isolated Bus w/GM
42300 System Topology Read/Write
3: Common Bus RESETS OTHER APP CONFIG
4: Transfer Pair SETTINGS!
Default: Master Synchronize Only
0: Open Transition
1: Hard Closed Transition sets the type of transition that will be
42301 Transition Type Read/Write
2: Soft Closed Transition used
Default: Open Transition
0: Disabled
use to enable extended paralleling
42302 Extended Parallel Enable Read/Write 1: Enabled
operation
Default: Disabled
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June 13, 2006
FUNCTIONS
Modbus RTU
 Diagnostic Tools:
• Message Counters
• Exception Counter
• CRC Counter
 Available through InPower or by Modbus
Diagnostic Function (code 08)
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June 13, 2006
FUNCTIONS
Faults & Events

 There are faults (warnings) and events
» Fault Example: UM Fail to Close
» Event Example: Utility Bus Available
 Each has a code number (see previous slide for list)
 Three 32 bit Bitmaps of fault/event states available on
Modbus
 Code numbers can be used for mapping to any of 8
configurable low-side driver outputs
 NOTE: When Fault 343 (Hardware Failure) is mapped to a
low-side output, it is inverted. Output is ON when hardware is
OK.
 Fault states are latched until fault reset and condition is
inactive
 Events are not latched
 Common Warning is an event which is active if any fault
states are active
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June 13, 2006
FUNCTIONS
Faults & Events
 Fault (Warning) Logic -- Ladder Diagram
Fault Condition Fault State
Reset Fault State
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June 13, 2006
FUNCTIONS
Faults & Events

 Variables Available
» Three 32bit Bitmaps of fault / event states
» Current Fault Code
» Active Fault Code List
» Active Event Code List
» Historical Information Tables – see ahead
 Fault Troubleshooting Document
Code Name Type Meaning Hints

1444 Genset Bus Warning Total Kw delivered by Genset Bus is  Make sure gensets`s Kw power is greater than the one
Overload greater than or equal to Genset Bus demanded by connected load . Check for faulted gensets. Use
kW Overload Threshold continuously different meters from the built-in ones furnished in
for Genset Bus kW Overload Delay MCM3320.
AND/OR Underfrequency Delta (  Make sure meter calibration is OK.
System frequency - Current Genbus  Check PT`s and CT`s ratios are well set in MCM3320. Make
frequency ) is greater than or equal to sure PTs and CTs are operating properly.
Genset Bus Underfrequency Overload  Verify that PT`s and CT`s rated values match the ones set in
Threshold continuously for Genset MCM3320 and your system actual rated values.
Bus Underfrequency Overload Delay.  Make sure there is no low-frequency conditions on GenBus
due to poor quality fuel.
 Check your fuel supply for inappropriate conditions at
components – dirty filters, pipe size,etc.
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June 13, 2006
FUNCTIONS
Historical Data
 Non-volatile historical data

– Controller On-Time
– Fault/Event history
– System state history
– Energy accumulators
 Removal of B+ does not result in any loss of
data
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June 13, 2006
FUNCTIONS
System State History
 System State History

» Records 20 most recent system states with COT
stamp
» Can use to track past sequence of events
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June 13, 2006
FUNCTIONS
Energy Accumulators
 Per phase quantities recorded for both sources:

» +kWh
» -kWh
» +kVARh
» -kVARh
» kVAh
 Positive = energy delivered by the source
 Negative = energy absorbed by the source
 Accumulators can be reset
 Totalized values also available (calculated by MCM3320)
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June 13, 2006
FUNCTIONS
HMI 211
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June 13, 2006
FUNCTIONS
HMI 211 - LEDs
 Utility Parallel = both breakers closed

 Lockout = System Lockout is active
 Warning = any warning fault state active
 Remote Start = 3320 start output active

 Auto = auto/manual switch input = auto
 Manual = auto/manual switch input = manual
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June 13, 2006
FUNCTIONS
HMI 211 – Home Screen
 MENU softkey: enter main navigation tree

 RESET softkey: reset/ack faults
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186
June 13, 2006
FUNCTIONS
HMI 211 – Fault PopUp
 Faults pop up on screen when they occur

 Acknowledge with ▼ softkey (does not reset)
 Reset with RESET softkey
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187
June 13, 2006
FUNCTIONS
HMI 211 – System Op/Control
 CONTROL menu tree includes user friendly

screens for starting / stopping system and
making operating point adjustments
 Password for making Adjustments is “574”
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188
June 13, 2006
FUNCTIONS
HMI112 Bargraph
 Bargraph Hardware Device

ID Setup:
1. Press/hold button on back of
bargraph until lower right
LED(s) illuminate (~5sec).
2. Press again to cycle through
1, 2, 3, 4 LEDs. Genset Bus =
1 LED on, Utility Bus = 2 LEDs
on.
3. Number of LEDs illuminated =
device ID.
4. Wait 5 sec for control to
resume operation.
• Configure Utility Scaling with
InPower
• Update rate up to 10Hz; 1Hz
minimum
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June 13, 2006
FUNCTIONS
HMI112 Setup
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190
June 13, 2006
SYSTEM SETUP
 InPower V5.5 Setup Tool

 PCC3xxx Genset Controller Setup
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June 13, 2006
SETUP
InPower V5.5 Setup Tool
 Screen by Screen Review

 User Participation (Demo Mode or Live with
Controller)
 Note that Scheduler and Real Time Clock
screens will be available as a patch
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192
June 13, 2006
SETUP
PCC3xxx Genset Controller Setup
 Configure for Utility Multiple even if only one genset

 Bus PT module connected on load side of genset
paralleling breaker
 Set TD Start, TD Stop = 0 if want MCM3320 to control
time delays (else time delays are additive)
 Set Load Govern Ramp Times to be compatible with
Maximum Parallel Time setting in MCM3320
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193
June 13, 2006
SETUP
PCC3100 Genset Controller Setup
 When using MCM3320 with PCC3100s, use InPower to

search on PCC3100 for parameter called "Reactive
power scale". Change it from 695 to 820. Save it.
 If PCC3100 is in system with PCC3200/1, set PCC3100
kVAR Balance = 29 (InPower or front panel Setup)
 If these changes are not done, may experience reverse
kVAR (loss of field) shutdowns or inability to synchronize
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194
June 13, 2006
MCM3320 Simulator
 Simulator Overview
 Simulate Operating Scenarios
– Utility Fail / Return Soft CT
– Synchronizer Performance Plotting
– Test With / Without Load
– Extended Paralleling
– Faults
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June 13, 2006
SIMULATOR
MCM3320 Simulator Overview
MCM3320
switch
inputs
Breaker fault
simulation
MCM3320
switch inputs
Gen is available
when genset
breaker closes
Utility bus
control
Rev 1.5 prd

196
June 13, 2006
SIMULATOR
MCM3320 Simulator Overview

MCM3320 simulator Genset simulator
Bus
voltage
Alternator
Load
Load
Engine
MCM3320 control PCC3100/3200
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June 13, 2006
InPower
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198
June 13, 2006
INPOWER
InPower DOWNLOAD
 “Initial Calibration”
» All trim values will revert to default settings
» Any custom settings will be lost
» Historical data will be lost
» Factory calibration data will NOT be lost
» Field calibration of voltage / current will be lost
 “Update Calibration” (recommended)

» Use to update controller firmware without altering
your settings or losing historical data
» Field calibration of voltage / current will remain
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199
June 13, 2006
INPOWER
VARIABLES
 Trims (screwdriver symbol)

» Variables which can be permanently saved in EE
» Nearly all settings are trims
» Writing to a trim variable changes its RAM value
only
» Controller always uses RAM value to operate from
» Save command required to get RAM value saved in
non-volatile memory
» On power-up, RAM value is loaded from EE
 Volatiles (light switch symbol)
» Variables which are writeable, but only exist in RAM
» On power-up, RAM value is loaded with hard-coded
default
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June 13, 2006
INPOWER
VARIABLES
 Monitor Points (magnifying glass symbol)

» Read only variables in RAM
» E.G.: Utility L1-L2 Voltage
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June 13, 2006
Applications
 Application Flexibility
 Participant Application Examples
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202
June 13, 2006
APPLICATIONS
Application Flexibility
 MCM3320 is not a PLC

 MCM3320 is designed to be flexible and work for
most applications
 Alternatives for special requirements:
1. Use PLC
2. Be clever with 3320 capabilities
3. Ask for changes to 3320
 Changes to 3320 will only be implemented if change
is universally useful and resources can be assigned to
implement the change
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203
June 13, 2006
APPLICATIONS
 Example1: What if the MCM3320 fails ?

 Map Fault Code 343 (Hardware Failure) to one of
the Configurable Low-Side Outputs (Default =
Output 8)
 Connect a relay to this output
 For this particular fault, logic is inverted: output is
energized when fault is Inactive
 If MCM3320 experiences an internal failure or loses
B+ power, the relay will de-energize
 Use relay contacts to perform desired action
 For example, if using Load Demand, use relay to
open circuit all load demand drives so that all
gensets will run
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204
June 13, 2006
APPLICATIONS
 Example2: What if I don’t want a Transfer to

Gensets to occur if I get an AC Metering Failure
(1335) ?
 Map Fault Code 1335 to one of the Configurable
Low-Side Outputs
 Connect this output to the Transfer Inhibit input
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205
June 13, 2006
APPLICATIONS
 Example3: What if I don’t want the Transfer or

Retransfer Time Delays to occur for an
Extended Parallel run ?
 Turn on the Override switch input (hardwired or
Modbus) at the same time as turning on the
Extended Parallel switch input (hardwired or
Modbus)
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June 13, 2006
APPLICATIONS
Application Examples
 Participant Examples ?
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June 13, 2006
Project Examples
Does this system require a PLC?
Utility
Source 1
YES
G1 G2 GN
52-UM1
52-G1 52-G2 ... 52-GN
52-GM1
52-F1 ... 52-FN
 System Type 10 low voltage

 4 diesel gensets
 6 feeder breakers with 6 level capacity based load add/shed control
 Extended Parallel Control
 Normal Standby Operation
 Load demand based on engine run hours
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June 13, 2006
Project Examples
Utility
Source 1
G1 G2 GN
YES
52-UM1
52-G1 52-G2 .. . 52-GN
52-F1 ... 52-FN
 System Type 9 medium voltage

 6 feeder breakers with simple load add/shed control
 Load demand based on customer set fixed sequence
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209
June 13, 2006
Project Examples
Utility
Source 1
NO
G1 G2 GN
52-UM1
52-G1 52-G2 ... 52-GN
52-GM1
52-F1 ... 52-FN

 24 feeder breakers with 6 level simple load add/shed control
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210
June 13, 2006
Project Examples
Utility
Source 1
YES
G1 G2 GN
52-UM1
52-G1 52-G2 ... 52-GN
52-GM1
52-F1 ... 52-FN

 4 gas gensets
 No Standby Operation CHP application
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211
June 13, 2006
Project Examples
Utility
Source 1
G1 G2 GN
MAYBE
52-UM1
52-G1 52-G2 .. . 52-GN
52-F1 ... 52-FN
 System Type 9 medium voltage

 6 feeder breakers with 6 level simple load add/shed control
 Load demand based on customer set fixed sequence
 Utility breaker provided by others
– If we control the breaker NO, if not then YES
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June 13, 2006
Project Examples
G1 G2 GN
52-G1 52-G2 ...

NO
52-GN
52-GM1
52-F1 .. . 52-FN

Rev 1.5 prd

213
June 13, 2006
Standard Swgr Project
Overview
Genset Interface Board

MCM3320 (Connection to 4 gensests and MCM3320
Genset Interface Board
(Connection to 4 gensests and
interconnect to additional panels) interconnect to additional panels)
CT Shorting Block CT Shorting Block
CT Shorting Block
Expansion
SID Board
(Load Add Shed Control and Status) (Load Add Shed
Control and Status)
Component Mode Panel

CT Shorting Block
Control Relay Board

(24 control relays to include: 12 w/single form C contact and 12 w/4 form C contacts
capable of operation all cirtcuit breaker open/close coils, need to look at manual
option could all relay that switches from MCM inputs to manual switch inputs)
Control Mode Panel

Rev 1.5 prd
214
June 13, 2006
MCM3320
Questions / Discussion / Comments
Rev 1.5 prd

215
June 13, 2006

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MCM3320

Rev 1.5 prd

Rev 1.5 prd

 What are the capabilities of the MCM3320?

Rev 1.5 prd

 Lotus Notes Database “Commercial ESB

Rev 1.5 prd

Rev 1.5 prd

One-Line Feature Summary (Q2 2006)

Load1 Load2 Load3 Load4 Load5 Load6

Rev 1.5 prd

 All available features have been tested

Rev 1.5 prd

Rev 1.5 prd

Master Sync / Volt Match

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Master Sync / Volt Match

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Permissive Sync Check

Rev 1.5 prd

Rev 1.5 prd

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Power Transfer Control

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Power Transfer Control

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Power Transfer Control

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 Common Bus (System Type 9)

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 Isolated Bus w/GM (System Type 7)

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 Isolated Bus Without GM (System Types 5,6)

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 Master Synchronizer Only (metering optional)

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 12 program run schedules

Rev 1.5 prd

Real Time Clock

 on-board RTC used by Scheduler function

Rev 1.5 prd

 Use to match online generating capacity to load in order

Rev 1.5 prd

 adds loads in steps as gensets come online

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Utility Genset Modbus

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Diagnostics Seven Segment LED Indicator

Rev 1.5 prd

Diagnostics kVAR Load Control Output Limit Warning

Rev 1.5 prd

 MON RS485 interface

Rev 1.5 prd

InPower V5.5 Setup Tool

Rev 1.5 prd