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
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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.
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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
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PowerCommand 3.3 Application
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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.
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Application Functions
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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.
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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
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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
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Q+A
38
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