Cummins Power

Command
Controls
Agenda
Program Objective: In this session participants would be able to learn,
• Cummins Controller offering
• Understanding PC1.x.
• Understanding PC3.3.
• Understanding PC3.3. Sync Application
• Understanding PC3.3. Sync with Old controllers
• Understanding PC3.3. Sync with Non Cummins DG sets

2
Cummins Rating Vs Controller

3
Cummins Rating Vs Controller

4
Cummins Rating Vs Controller

5
PowerCommand 1.x Control System

Standard standalone and featured genset control system

6
PC 1.1 Control System Architecture

HMI114 HMI113
HMI211 HMI112

or AUX101

Option
Option
Network
(4 wire)
Option

Converter
Inpower
(Service Tool)
AUX104

Modbus

PCC1302
Hydra Mechanical Version 7
PC 1. 2 Control System Architecture

HMI114 HMI113
HMI211 HMI220
AUX101

Or
Option
Option

Network
(4 wire)
Option

Converter
Inpower
(Service Tool)

J1939
Modbus

PCC1302
FAE Engine Version
8
PCC1302

The PCC1302 was developed to meet three major needs:

1. Support common connector scheme which is used on the PCC2300 and PCC3300 controls.
2. Add Native CAN support. This will provide core2 gensets a low cost genset control alternative
without the cost of the AUX101.
3. PMG support for larger gensets.

PCC1302 control has all the features of the PCC1301 plus:

1. Common Connector Support.

2. Direct 600 volt line sensing
3. Two additional configurable inputs.
4. Addition of a local emergency stop input.
5. PMG and Shunt Excitation Support.
6. Redesigned fault handler.
7. A bi-directional system wakeup scheme.
8. Software configurable Wake In Auto
9. Limited PGI CAN support.
10. Redesigned over excitation alternator protection.

9
PCC1302 - Features
 Digital Full Wave SCR AVR for Shunt or PMG Excitation with torque matching
 Digital Electronic Governing With temperature compensation and Smart Starting
 SAE J1939 Interface to Full Authority Electronic engines
 Engine Protection
Oil Pressure, Engine Temp, overspeed, DC o/u/weak Volts, and Fail to Crank & Start Sensor Failure
 AC Protection
27 (under voltage), 59 (over voltage), and 81 (Under Frequency), 51 (over current) requires CT’s & Loss of
AC Sensing
 Battle Short (Fault Bypass) Function
 Configurable Glow Plug Control
 Configurable Cycle Cranking
 Time Delay Start/Stop
 Sleep Mode (Low power in Off and/or Auto)
 Programmable I/O (2 inputs and 2 outputs)
 Low Coolant level and Low Fuel Inputs
 Self-Configuring Network
 Modbus Interface (RS485 RTU)
 InPower Compatible (PC Based Service Tool)
 Environmental Protection (NEMA 3R/IP53)
 NFPA110 Level 1 Compliant (with Remote Annunciator)
 UL508 Recognized / CSA Certified / CE Compliant

10
PowerCommand 3.3 Control

Premium, full-featured paralleling genset control system

PowerCommand 3.3

HMI 320

PCC3300

11
PC 3.3 Control System Architecture

HMI320 HMI114 HMI113

AUX101

Option
Option

Network
(4 wire)
Option

Option
AUX104
Converter
Inpower
(Service Tool)

J1939
Modbus
AUX105
PCC3300
Hydra Mechanical Version
12
PC 3.3 Control System Architecture

HMI220 or HMI320 HMI114 HMI113

AUX101

Option
Option

Network
(4 wire)

J1939

Option
AUX103
Converter
Inpower
(Service Tool)

J1939
Modbus
PCC3300
FAE Engine Version
13
PowerCommand 3.3 Control Features
 Load Dump Control
 Automatic Warm-Up and Cool-Down Functions
 Real Time Clock used in time stamping
 Configuration Change Audit Trail to tract field changes
 Exercise Clock and Time-of-Day Start and stop
 Audit Trail on control configuration changes
 Digital Frequency Synchronization and Voltage Matching with genset and utility breaker
controls
 Manual Synchronization for maximum reliability
 Droop Voltage Regulation and Droop Speed Governing
 Isochronous Load Share (island mode paralleling) – analog and future digital
 Load Govern (utility parallel)
 Droop KW and KVAR Control
 Power Transfer Control (AMF) open, momentary, and closed with load ramping modes.
 Utility Single
 Voltage and Speed Bias Inputs and Outputs for compatibility with competitive paralleling
systems

14
PWM and Self Excitation

The PCC3300 collects main alternator output power at J18 1 & 2 which is genset rated
frequency.

The PCC3300 rectifies the incoming phases for a ripple DC power signal.

The PCC 3300 regulates the DC power and then controls the amount of on time for the
signal sent back to the exciter field winding. The Pulse duration of DC signal is controlled
for the needed excitation rate. Pulse Width Modulation
15
PWM and PMG Excitation

The PCC3300 collects 3 phase PMG output power at J18 which is twice genset rated
frequency.

The PCC3300 rectifies the incoming phases for a nearly smooth DC signal.

The PCC 3300 regulates the DC power and then controls the amount of on time for the signal
sent back to the exciter field winding. The Pulse duration of DC signal is controlled for the
needed excitation rate. Pulse Width Modulation
16
Configurable Inputs
 We have added two additional configurable inputs which are defaulted to low coolant level and low fuel level inputs.
 Processing behind these hardware inputs has changed:

SW Configurable Input #N Status

Configurable Input #N Function Steps To Configure Configurable Inputs:

InActive 1. Select One of Four Function Choices
BattleShort
Configurable
Switch I. BattleShort Switch
Status,
Input Conditioning & Debounce Ci(battleshort), n II. Fault Reset Switch
Signal Level Detection Function
Sample Fault Reset
Switch
III. Fault Input
Status,
Ci(faultReset), n
If Function is Fault Input, Then
1. Select Active State
I. Active Closed
II. Active Open
2. Select Response Severity
Active Active Fault
State Select Trim I. Warning
Selection II. Shutdown
Trim Warning
Active
III. Event
Closed Discrete
Shutdown
Active
Signal
Open Status
None

sydd_dsi.vsd
17
Battery Monitoring

32VDC
 Runs a battery load test every
time the engine is required to
24VDC start.
 Continually monitors the
charging system for low and
high voltage.
10VDC  Batteries can be serviced
before experiencing a failure to
start.
NORMAL RECOVERY TIME
RECOVERY TIME WITH "WEAK BATTERY"  Improved generator set
reliability.

18
Ampsentry

AmpSentry
Operation Curve  PowerCommand Protection Based on
Alternator Thermal Damage Curve
 Single Phase Fault Regulation Protects
Alternator During Common Fault
Conditions
TIME

Three Phase
Decrement Curve  Improved Coordination
RATED AMPS

AMPS
19
Bump less Load Transfer

TOTAL PLANT LOAD

DG1
DG 2

ISO LOAD
LOAD
SHARING
Unload DG1 Signal

DG 2 Breaker
Opens (DG 1)

Breaker
Closes ( Gen 2 ) TIME
20
PowerCommand 3.3 Application

21
PC3.3 Application

Standalone
In Standalone mode operation, a single generator set is connected to a bus in order to provide power to a common load.

Sync Only
The sync only paralleling application type allows the genset synchronizer to be manually turned on through a hard wired
input. One application of this function would be for use with a closed transition transfer switch.

Isolated Bus Only

The isolated bus only paralleling application type allows the genset to operate in parallel on a common bus with multiple
gensets.

Utility Single
The utility single paralleling application type allows a single genset operate in parallel with a single utility source. Note
that Utility Single Mode Verify/Configurable Input #29 Switch must be connected to a switch input return to enable utility
single

Utility Multiple
The utility multiple application type allows the genset to operate on a common bus multiple gensets and in parallel with a
single utility source..

Power Transfer Control

The power transfer control application type allows a genset to operate with a single utility source.

22
Application Functions

23
 Standalone Mode

 Standalone is a mode that does not parallel, it does not

synchronize with any other genset or system.

 In Standalone the PCC does not control a breaker for

connection or disconnect from load, but can provide a
breaker trip signal, and it can monitor breaker position.

24
Synchronize Only

 Synchronize Only is a mode that does not parallel, however: it

does synchronize with other gensets or systems.

 In Synchronize Only, the PCC does not control a breaker for

connection or disconnect from load, but like Standalone it can
provide a breaker trip signal, and it can monitor breaker position.

 Synchronize Only is very useful for hard transfer ATS systems.

25
Isolated Bus Paralleling

 Multiple units connected to a common supply bus.

 All units are connected to the bus in a

synchronous way with matched frequency and
voltage.

 Units may be set to operate in Droop or they may

be set for Isochronous operation

26
Utility Single

 The Genset is running in parallel with utility and

there are no other gensets
 All units are connected to the bus in a
synchronous way with matched frequency and
voltage.

27
Power transfer Control

 The Power Transfer Control (PTC) function applies when the

Genset Application Type is Power Transfer Control.
 PTC primarily means that the genset controller is controlling both
the genset breaker and a utility breaker in a transfer pair
arrangement.
 PTC is only for use in a single genset / single utility arrangement.
PTC's primary job is to keep loads powered.
 PTC completely manages the system by automatically starting the
genset and transferring load when it detects utility failure, or when a
test or exercise with load is called for.

28
Utility Multiple

 In Utility Multiple Gensets are running in parallel and running in

parallel with utility.
 No additional hardware required for Forward synchronization.
 Additional Sync 1320 module required if we want Reverse Sync
with Grid.
 When in Utility Multiple mode DG sets are in Load Govern Mode

29
PC3.3 Load share scheme with old Controllers

30
PC3.3 Parallel with PCC 2100
Note : PC 3.3 has Bias control
No additional AUX 101 required
Speed Bias
0 to 5Vdc
Speed Bias
0 to 5Vdc
No
External
PC3.3
Volt Bias
Aux 101 2100 AVR
Volt Bias
+3 to -3Vdc +3 to -3Vdc

External Manual or
Auto Synchronizer
With LSM

Points to Ponder :
PC 3.3 accepts 0 -5 Vdc speed bias
& +3 - -3vdc as Voltage Bias, if the external
Sync. has a potential free pulsed 24Vdc then LOAD
To convert the 24 Vdc to 0-5Vdc use of SSP
Becomes essential.
31
PC3.3 Parallel with Non Cummins DG

32
PC 3.3 Parallel with Others
External
AVR
Speed Bias
0 to 5Vdc Raise /Lower

3.3 Volt Bias

LSM EFC EMCP
+3 to -3Vdc
Volt Bias
AVR CAT
+3 to -3Vdc
External Manual or
Auto Synchronizer

LOAD
33
PC 3.3 Parallel with Others

Analog
CAN

3.3 EasyGen

CAT
Load Share Gateway
KW and Kvar

LOAD
34
Multiple PC 3.3 Parallel with Multiple Others

Speed Bias
0 to 5Vdc Speed /Vo;t. Bias

DIEF EFC DIEF EFC

0 to 5 Volts 3.3 3.3
AVR AVR
MTU MTU
External Manual or
Auto Synchronizer
Volt Bias
+3 to -3Vdc

LOAD

35
Multiple PC 3.3 Parallel with Multiple Others

DIEF DIEF 3.3 3.3

MTU MTU

LOAD

36
PC3.3 Compatibility for MHP and MHP

37
Q+A

38
39
39