PC3.3 Cummins

Participant Guide
Controller
PowerCommand 3.3
Phase 1 Release
CMT6068-EN-PG
Created 10/2008

Revision History
v1.00 (10/2008)
1. Initial draft for product launch QTQ 2008
Cummins, Onan, and PowerCommand are all registered trademarks of Cummins Inc. InPower is a trademark of
Cummins Inc. Windows� is a trademark of Microsoft Corporation.
Copyright � 2006−2007 by Cummins Power Generation

PowerCommand Control 3300 & HMI 320

Table of Contents
Preface: I
This generation of Genset controls will use a new naming system. The preface
will identify the various controls and combinations that make up the new control
family.
Introduction: II
The introduction describes the audience, the purpose, and the structure of the
training module.
Introduction to the PowerCommand Control 3.3, the PowerCommand

Control 3300 control board and its standard options: 1
This lesson presents an overview of the PowerCommand Control 3300. The
participant will learn to identify the main features and components of the
PowerCommand Control 3300, its standard features and options.
PowerCommand 3.3 & HMI 320 Operation and Service Menus: 2

This lesson presents the Setup and Calibration menu system used in the PCC3.3
and HMI 320
PowerCommand Control 3.3 Sequence of Operation: 3

This lesson presents sequence of operation and feature operation and
performance information about the PowerCommand Control 3300.
PowerCommand Control 3300 Installation: 4

This section provides installation information, procedures, and requirements for
the PowerCommand Control 3300.
PowerCommand Control 3300 Control Setup and InPower: 5

This lesson covers the basic adjustments and configuration details using InPower
as the setup tool. This section addresses the non-paralleling functions.
PCCNet Network for the PC3.3: 6

This lesson presents an overview of the PCCNet network and an introduction to
the unique PCCNet network and components used with the PCC 3300,

PowerCommand Control 3300 ModBus: 7

This lesson presents the ModBus communications feature on the PCC 3300, and
introduces some of the advanced ModBus abilities offered in this control.
PowerCommand Control 3300 PGICAN: 8

This section provides familiarization with the J1939 CAN communications
available on the PCC 3300, for use with Full Authority Engine controls.
PowerCommand Control 3300 Paralleling Introduction: 9

This lesson introduces the various paralleling features and abilities offered in
this control.
PowerCommand Control 3300 Paralleling - Standalone: 10

This lesson covers setup, operation and configuration of PCC 3300, and HMI
320 when applied in a single unit non paralleled configuration.
PowerCommand Control 3300 Paralleling - Synchronizer: 11

This lesson covers the synchronizer operation and configuration of PCC 3300,
and HMI 320 when applied in a paralleled and non paralleled configuration.
PowerCommand Control 3300 Paralleling – Isolated Bus: 12

This lesson covers setup, operation and configuration of PCC 3300, and HMI
320 when applied in a multiple unit paralleled configuration that is completely
separated from any utility (Mains) connection.
PowerCommand Control 3300 Paralleling Troubleshooting: 13

This lesson presents tools, problem scenarios, and solutions that are commonly
encountered when encountering operation problems with the PC 3.3.
Glossary: 14
This section lists the most common terms used throughout this training module
pertaining to the PowerCommand family of Controls.
Activities: 15
Copies of Participant In-class and Homework Activities, and each Section Quiz
are found in this section.
Appendix: 16
This section contains several useful guides and lists, including the ModBus
register list.

Diagrams: 17
This section has copies of all prints used in the course.
Module Comment Sheet: 18

Participants are requested to turn in the Comment Sheet at the end of the course
to help update the course materials as needed.
Participants have a copy of this sheet as the last page in their Participant Guide,
but if you need a master we provide one here.

Preface:
The new generation of PowerCommand Controls will use a new easier to understand naming
system. The new controls are modular and therefore it can be confusing to know what feature are
being used it the genset control system is only referred to by the control board model. There are
several combinations of control boards and HMIs
N a m in g S y s te m
PowerCommand 1.X PowerCommand 2.X Pow erCommand 3.3
PCC 1302 PCC 2300 PCC 3300
PowerCommand 1.1 PowerCommand 2.2 PowerCommand 3.3

HMI 211 HMI 220 HMI 320
PowerCommand 1.2 HMI 112(w/PF) or HMI 114, HMI 113 Phase 1 (FAE)
HMI 220 Phase 1 (FAE)
PowerCommand 2.2 PowerCommand 3.3

HMI 220 HMI 320
PowerCommand 2.3 HMI 112 or HMI 114, HMI 113
AUX 101/102, AUX 104
HMI 320
HMI 112 or HMI 114, HMI 113 Phase 2 (Hydra Mech.)
AUX 101/102, AUX 104
Phase 2 (Hydra Mech.)

Naming Chart - PCC 1.X, 2.X, 3.X Naming System
The above naming chart shows the naming system for the new series of controls, PowerCommand
Control 1.X, 2.X, and 3.X. The X represents the HMI Operator Panel you have with the series of
control board.
Here is a list showing how they are structured:
1.X = PCC 1302 control board

Participants’ Guide Title & Introduction Page6

X.1 = HMI 211

X.2 = HMI 220
X.3 = HMI 320
The PCC 2.X and 3.3 will be released in a couple of different phases. These phases will support
certain devices as depicted in the visual above and in more detail throughout this training course.
The 2.X, & 3.X series designation will identify the high level of control ability however, there will
be several subcategories of different control board features. The first category of 2.X, & 3.3
controls will only work on FAE controlled engines. The next category will be used with hydra
mechanical engine applications. As new features and categories develop, additional training
courses will also develop.
Series 2.X with FAE control training and 3.3 with FAE control training will be the most
comprehensive training programs about the PCC 2300 and PCC 3300 controls. The training
programs that follow will concentrate on the specific feature enhancements, HMI, or accessory
developments relative to the specific Series. The Series 2.X & 3.3 FAE training will be a
prerequisite to any future training program
It has been planned that the PCC 3300 & HMI320 combination will be the only combination
available for the high level paralleling gensets. The plan is to only have a PC 3.3 control and never
a PC 3.2 or PC 3.4.

Introduction
Welcome!
Welcome to the Particpants Guide for the PC 3.3 & PowerCommand Control 3300 module! This
guide was written by the Cummins Power Generation Technical Training department for your use
and reference.
We suggest you read through the entire Introduction to become familiar with the guide’s
structure. Then, just follow the step-by-step instructions for each lesson.
Module Purpose
The purpose of the PC 3.3 & PowerCommand Control 3300 module is to help you, the Cummins
Power Generation distributor service technician, understand the PC 3.3 & PowerCommand Control
3300 which is going to replace the specialized gen set control modules. It is also expected that the
PowerCommand Control 3300 will be used on many of the Cummins −powered gensets with Full
Authority Engines (FAE) and the hydro −mechanical fuel systems.
With this information, our technical force will be better prepared to meet our customers’
varying needs.
Module Audience
The primary audience for this module is Cummins Power Generation distributor power
generation technicians. We assume participants have previous experience with or knowledge of
integrated generator set AC and DC control operation, troubleshooting, and repair procedures. It
is a prerequisite to attend a PC 2.X course prior to attending this course.
Module Structure
This module contains lessons on related topics. Each lesson follows a carefully designed training
format, including a warm up, presentation, and activity (or exercise).
Lesson Format
Warm ups help participants focus and begin thinking about the lesson topic. The presentation
portion of the lesson is where participants receive new information. The activity & Quiz follows
the presentation; it gives participants the chance to practice new skills or work with new ideas.

Module Assessment
After completing all the lessons in the module, participants will complete a module assessment .
The module assessment lets us evaluate the level of knowledge participants have on the topic after
completing the module.
Module Comment Form
Participants will also complete a module comment form. This form gives participants the chance to
comment on the usefulness and effectiveness of the training module and make suggestions for
improvements.
We will use the results from the module assessments and module comment forms to help us
determine if there is a need to modify the module.
Please mail the module assessments and comment forms to Cummins Power Generation’s Sales
and Technical Training department as soon as possible after the training session. The address is:
Cummins Power Generation

Technical Training OUJ3
1400 73rd Avenue NE
Minneapolis, MN 55432
Preview the lessons−−Review the lesson objectives and read through the trainer’s instructions. Use
the Notes column to write any comments or additional information you want to include.

PCC 3.3 & PowerCommand Control 3300 Section last page
THIS PAGE IS INTENTIONALLY LEFT BLANK
Participants’ Guide Section Last Page

PCC 3.3 & PowerCommand Control 3300 Introduction and Options
PowerCommand
3 .3
Section 1 Introduction to the

PowerCommand Control 3300

Visual 1-1 PowerCommand Control
Participants’ Guide Section 1 Page1

Section 1
Introduction to the PCC 3.3, the PowerCommand

Control 3300 control board and its options.
Estimated Time: 2.5 hours

Warm Up
In this lesson we are going to learn about the PowerCommand Control 3300 and its
components
We will see the standard and optional components, and learn their functions.

Objectives
After completing this lesson, the participants should be able to:
• Identify the PCC 3.3 standard components.

• Identify the PCC 3.3 & PowerCommand Control 3300 optional components.
• Describe the main functions of the PowerCommand Control 3300 and its features.
• Describe the standard operator interface (switch and LED).
• Use the Operator menus on the optional control panel.

PowerComm and Control 3300
 Premium Paralleling Genset Control
 Integrated J 1939 CAN Link for FAE sets
 Optional governor amp. for non-FAE sets (Phase 2)
 Separate module for AVR (Voltage Regulation)
 Common wiring harness with “3-series”controls
Visual 1-2 Introduction to the PowerCommand Control 3300
Participant’s Text Notes:
The PowerCommand Control 3300 is a

highly integrated control providing
complete genset control and protection.
The Phase 1 release of this new control will

support Lean Burn Natural Gas (LBNG)
gensets and Diesel FAE engine-driven
sets
The phase 2 release will support a governor

drive module which is needed for diesel
sets equipped with electric actuator.

PCC 3300 Control Boards
AUX 103 Power Stage
PCC 3300 Base Board
Visual 1-3 The PCC 3300 Control Board
The PCC 3300 board uses the same large

potting shell as used in the MCM3320
and PCC 2300.
The control board provides many connectors

for input and output information.
• Many of the connectors are common
among all “3-series” controls.
This is the primary board of the control
system and is call the Base board.

There are14 connection points on the PCC

3300:
• J Connections − Common Connectors.

• TB Connections − Customer
Connections and Feature inputs.
3 CT connection on the PCC 3300:
3 connection points on the AUX 103 Power

Stage:
• J17 − Excitation Output (X1, X2)

• J18 − AVR Power (PMG)
• J19 − AVR Control Communications

PCC 3300 C onnectors

TB7- Bus Voltage Sense Onboard BUS CTs
DSx LED S tatus Indicators J 12- Genset CT Input
TB-9 – Analog I/O J 22- Genset

Voltage Sense
TB-15 – ModBus/RS485
J 20- Genset
Connections
J 14 – Service Tool Port
J 26- AUX 103
Connector
TB10 – Breaker Status
Connections J -25 Display
Connections
TB-8 Customer TB-5 – Breaker Control TB-3 – Customer TB-1 – Customer

Connections Connections Input/Output Connections
Visual 1-4 Control Board Connectors
Participant’s Guide Notes:
DSx − Status indicators: DS3 flashes to let

you know the control board is operating
properly.
CT1, 2, & 3 − Onboard Bus CTs
J12 − Generator CT inputs
J14 − Connection port for InPower.
J20 − Genset Accessories connection
J22 − Genset voltage sense
J25 − Operator Panel (HMI) connection
J26 − AUX 103 & Interconnect

PCC 3300 C onnectors

TB7- Bus Voltage Sense Onboard BUS CTs
DSx LED S tatus Indicators J 12- Genset CT Input
TB-9 – Analog I/O J 22- Genset

Voltage Sense
TB-15 – ModBus/RS485
J 20- Genset
Connections
J 14 – Service Tool Port
J 26- AUX 103
Connector
TB10 – Breaker Status
Connections J -25 Display
Connections
TB-8 Customer TB-5 – Breaker Control TB-3 – Customer TB-1 – Customer

Connections Connections Input/Output Connections
Visual 1-4A Control Board Connectors
TB1 − Customer I/O connections

TB5 − Circuit breaker control connection
TB7 − Bus/utility voltage sense
TB9 − Analog control I/O connections
TB10 − Circuit breaker control connection
TB15 − RS485 / ModBus Communication
connection

AUX103 AVR Power Stage

J 19 – Interconnection
to PCC 3300
Base Board
J 17 – Field Output
J 18 – Power Input
Chassis Ground
Wire
5
Visual 1-5 Automatic Voltage Regulator Module
The AVR Module is used with all PC 3.3

gensets.
There are 3 connectors on the board.
 J17 provides the excitation output.
 J18 provides the power input
 J19 connects to J26 on the 3300 Control
Board.

HM I 320 Operator Panel
Visual 1-6 Optional operator panel
HMI 320 Operator Panel is also highly

populated with display and control
features.
 Multiple LEDs for status and operator
information
 Large graphical display for menus and
information display.
 Multiple buttons for operation and
control.
Same physical size and layout as the HMI
220 but has a much larger display.

Operator Panel Menus
Visual 1-7 Operator Panel Menus
The panel allows easy navigation through

multitudes of monitoring screens. There
are also a great many screens available for
setup of the control and the accessory
features.
There is a HOME screen that provides
guidance and access to many screens.
The number of screens available will depend
on features activated and the type of
applications chosen.
Instead of menu screens, we now have menu
choices. The menu choice will provide
access to a single or multiple pages of
information or setup functions.

HM I Display N avigation
 Multiple Combinations of button

pushing will allow navigation to
various messages, data, and
adjustment screens.
 Participant Guide Visual 1-7 shows an

example of some of the navigation
choices.
Visual 1-8 HMI screen navigation
Navigating the many different screens

requires practice. There is a DEMO mode
on the screen that enables an operator to
learn many of the button sequences
required for screen navigation.
Some screens allow you to view data in either

a graph mode or in a table of data.
There are a series of soft keys, and hard keys.

The soft keys change function depending
on the screen being viewed. This will be
discussed more in the next section.
All of the keys provide tactile feed back.

PCCNet Components
(Common @ P hase 1)
 0300-6315-02 HMI 320 Operator Panel (Local)
 0300-6315-03 HMI 320 Operator Panel (Remote)
 0300-5929-01 HMI 113 Annunciator (No Box)
 0300-5929-02 HMI 113 Annunciator (With Box)
 0300-6366-02 HMI 114 Horizontal lamp Bargraph (kW & PF)
 0300-6050-01 HMI 112 Vertical lamp Bargraph (kW & PF)
Visual 1-9 PCCNet Components
0300-6315 HMI320 Operator Panel This

is the Operator Panel for the PCC 3300.
There is one for local control and an
optional one, 0300-63115-03 for remote
mounting.
0300-5929-01 or -02 Annunciator This is
the same Universal Annunciator that is
used with many other CPG products. The
-01 kit contains the Annunciator only, -02
kits contain a mounting box too.
0300-6366-02 & 0300-6050 Bargraph
Module These modules allow the
customer to have a graphical readout of
alternator information.

PowerCommand 3.3
 Quiz 1-1: Intro to PowerCommand 3300,

Operator panel, and PC 3.3 system.
10

Visual 1-10 Quiz for Lesson 1
Turn to Section 15 and complete Quiz 1-1.
At this time I would like you to work in

groups to complete the quiz. It should
take about 20 minutes.

Wrap-Up
In this lesson we have learned about the PCC 3300 control boards.
First we talked about the PCC 3300 Control, where it is used, and where it may be used
in the future.
Next we talked about the control board and a little bit about the connectors that join the harness to
the board:
Next we talked about the HMI 320 operator interface to the PCC 3.3 control.
After introduction of the operator panel we talked about the Operator Panel Menus and took a little
peek at the vast array of menu choices.
Then we looked at a drawing of the Optional Governor Drive stage for Diesel gensets .
Finally, we introduced the optional PCCNet components
Are there any questions that you have about the PCC 3.3 controls we have not yet covered? The
following sections will delve deeper into all of the items introduced here.


PCC 3.3 & PowerCommand Control 3300 Service Menus
P o w e rC o m m a n d 3 .3
HM I 320
Section 2: PC 3.3 HMI 320 Panel, Operation,

and Menus
Visual 2-1

Section 2
PCC 3.3 HMI 320 Service Menus:
Estimated Time: 2 hours
Materials Needed
PowerCommand Control 3300 Participant’s Guide Guide CMT6068-EN-PG
Operator Installation Manual – 3300 Series Genset Control 0900-0670

Warm Up
In this lesson we are going to learn about the Service and Setup Menus for thePCC3.3
You will have a chance to go through the menus as an in-class activity after we complete the lesson
material. Please don’t get lost in the menus as we are trying to go through the Participant’s Guide
material.
First, let’s look at the objectives for this lesson:
Objectives
• Locate and identify the front panel buttons used in navigating the PCC 3.3 HMI 320 menus.
• Identify the menu choices accessible without using the Application password.
• Access and use the Setup menu − Genset Service to view and/adjust Service menus.
• Use the Setup menu − Genset Setup to view and/adjust Setup menus.

HMI 320 Operator Panel

Remote Control Panel
0300-6315-03
Local Control Panel

0300-6315-02
Slide 2-2
We were introduced to the HMI 320 Operator .

Panel in lesson 1.
This view is of a local version HMI which is
standard, and the optional remote HMI.
 Local HMI 320 = 0300-6315-02
 Remote HMI 320 = 0300-6315-03
The remote version will not allow changes to
the mode of operation.
The Participant’s Guide contains some of the
basic familiarization with the HMI 320, but
we will reference the 900-0670 Service
Manual for most of the lesson.

Standard HM I 320 Operator Panel
Large Function
Graphical indication
Display lamps
Menu
Control
Selection
Function
Buttons
Buttons
Screen
Navigation
Buttons Breaker
Control
Buttons
3
Slide 2-3 Setup Menu Access.
The HMI 320 layout is very similar to the

HMI 220 with several added features..
Function indicator lamps and control function
buttons are located in the same locations as
the HMI 220 and they operate the same.
Breaker control buttons are available to
provide breaker control during manual
paralleling operation.
Screen navigation buttons (Hard Keys)
provide control of screen viewing functions.
They are laid out and operate vary similar to
cell phone navigation buttons.

Display Sc reen
Line 1 Line 2
Controller Mode Fault Data
Line 3
Screen Name
Data & Status

Screen
Data & Status
Screen
Soft Button Options

4
Slide 2-4 Display Screen
Top three lines of display are reserved for:

 Line 1 will always display the Controller
Mode or Status information.
 Line 2 will always display the genset
fault popup message.
 Line 3 will always display the screen
name or menu description of what is
viewable in the Data & Status screen.
The Data & Status Screen section can show a

vast amount of data or menu choices.
There are 9 lines of display in 2 columns for a

total of 18 viewable parameters.

Display Sc reen
Line 1 Line 2
Controller Mode Fault Data
Line 3
Screen Name
Page &
Pages available
Data & Status

Data & Status
Screen
Screen
Soft Button Options

4
Slide 2-4B Display screen continued.
Soft keys are labeled across the bottom of the

screen. The manual refers to them as
Function Selection Buttons.
Some of the soft keys are used for Previous
and Next screen selection.
The up arrow indicates navigation to a

previous screen.
The down arrow indicates navigation

to a next screen.
Other soft buttons are used to directly
navigate to other data screens

HMI Hard Keys
The HOME
button
These hard keys enable navigation

between various menu screens
Pressing these buttons simultaneously

for 3 seconds will cause the screen to
enter a DEMO mode if PCCNet is
Previous Screen
Button
disconnected.
5
Slide 2-5 Hard Keys.
The seven buttons at the bottom of the PCC

3300 Operator Panel lead to menus and
provide control of menu navigation.
• – pressing it will return you to the

Home screen menu from any other screen.
• - will return you to the previous

menu or to the Home screen
• OK – will engage the highlighted menu

choice and advance to that screen.
• The 4 -will advance, back up one

screen, or highlight menu choice

Setup Menu and Passwords
There are 4 levels of passwords available for adjustments,

setup and control.
Slide 2-6 Genset Setup
The HMI 320 Setup Screens are accessible

and viewable without a password. If you
attempt to change a setting that requires a
password, you will be prompted to supply
a password. The passwords must be
entered for the appropriate level as the
screen requests.
There are various levels of authority for
making changes or adjustments.
• Level 0 = minor adjustments only -
anyone can access.
• Level 1 = minor adjustments and some
calibrations

• Level 2 = high level adjustments,

calibrations, and configurations.
• Level 3 = very high level configuration
and reserved for engineering or factory
access.
As an example:
• If you access the setup screen for PCCNet
Setup, you will not be asked for a
password. This is an example of a Level 0
password setup parameter.
• If you attempt to access the Adjust
Voltage screen, you will be prompted for
a Level 1 (574) or higher password.
• If you attempt to access the OEM setup
parameters, you will be prompted for a
Level 2 (1209) or higher password.
• The Level 3 password is reserved for
engineering and factory configuration and
is not shared for field access or setup.
If a password is entered, it will remain active
until a higher level password is entered or
the HMI is I NACTIVE for 5 minutes.

Mode Change Password
Mode Change Password

Protection
If enabled, many of the HMI buttons will be
disabled. The operator MUST have
the password f or them to become
operational.
7
Slide 2-7 Mode Change Password
Participant’s Text Additional Participant’s Text
Look at page 5-1 of 0900-0670 service This is a feature to protect a piece of
manual. MODE CHANGE PASSWORD customer equipment, or to protect
can be confusing to many. equipment from the customer. This
 MODE refers to the operation mode such feature prevents someone from
as – running in Manual, running in accidentally or unknowingly changing the
Automatic, Manual parallel, etc... I control from Automatic Mode to Manual
Mode or from sending a breaker close
 If Mode Change Password Protection is command when they shouldn’t. It is to
enabled, the buttons are disabled so an prevent an unauthorized person from
unauthorized operator cannot switch making unauthorized changes.
from one mode to another.
If Enabled, any button push on the HMI will Field technicians may want to use this feature
prompt a password request screen to for protection from inadvertent button
appear. actuations during service work.
The Password is 121

Adjust Menus
The HMI has a Adjustment screen
for minor adjustment of operation set
points.
Setting of the Keyswitch

overide to Activ e will allow
for service connection to
the engine ECM.
8
Slide 2-8 Adjust Screen

Turn to page 5-30 in the 900-0670 Service

Manual
Table 5-22 provides a slight description of

each ADJUST function.
IMPORTANT: Keyswitch Status. The engine

must be stopped to activate the Keyswitch
Override.
The Keyswitch Override is provided to

support control service. This setting exists
to allow ECM to power down and it will
not trigger a “CAN Link Degrade” fault.

Participant’s Text Additional Participant Text & Notes
What is the purpose of having a Keyswitch _________________________________

override? When servicing an ECM on an _________________________________
automotive application, the ignition key is _________________________________
turned to the on position which provides _________________________________
the input to the ECM to turn on and _________________________________
operate its program. This is the mode you _________________________________
want the ECM to be in during service. On _________________________________
a generator set, we use the E-Stop button _________________________________
as the Keyswitch. _________________________________
The Keyswitch Override will return to
_________________________________
INACTIVE if the E-Stop button is _________________________________
pushed, and/or you will not be able to _________________________________
switch the override to INACTIVE if the _________________________________
local or remote E-Stop is activated. _________________________________
_________________________________
The control must be in the Manual mode to _________________________________
change the override from INACTIVE to
ACTIVE.
Switching the control from Manual to

Automatic while the override is in the
ACTIVE state will cause a Data Link
Error fault to be generated.

Setup Genset Menus

The HMI has a series of 5 screens
that allow for detailed setup of a
multitude of operation set points.
Slide 2-9 Genset Setup
From the Home (2) screen, navigate to and

highlight the “Genset Setup” menu and
press Pressing the button will take
you to a series of screens where you can
adjust and change various genset
configuration settings.
If you attempt to make any change, you will

be prompted for a Password.
Some parameter can be changed if you use

the 574 password; however, using the
level 2 password will allow you to adjust
any of the parameters.

Paralleling Setup M enus

The HMI has a series of 6 screens
that allow for detailed setup of a
multitude of P aralleling operation set
points.
10
Slide 2-10 Paralleling Setup

From the Home (2) screen, navigate to and

highlight the “Paralleling Basic Setup”
menu and press Pressing the
button will take you to a series of 6 setup
screens where you can adjust and change
various genset configuration settings.
PTC (Power Transfer Control) is a feature
that will become available at the Phase 2
release.
Pressing the “Status” soft key will jump you
out of setup and take you to monitoring of
the Paralleling mode.
Future chapters will cover the Paralleling
functions.

OEM Setup Menus

The OEM Setup provides access
to genset configuration settings.
11
Slide 2-11 OEM Setup
OEM (Original Equipment Maker [or

Manufacture]) setup menu provide access
to a multitude of settings.
These settings are mostly genset
configuration settings; a Level 2 password
is required for almost all adjustments.
OEM Setup Menus duplicate the setup
functions found in InPower. InPower will
be covered in later lessons.

Participant’s Text (OEM GENSET Notes:

SETUP)
It is possible to completely configure a new

generator control from the HMI, however
it is not recommended or you probably do
not want to expend the effort. The task of
inputting a 10 character genset serial
number can take as many as 970 button
pushes. The HMI buttons are rated for
hundreds of thousands of button pushes,
but your finger most likely is not.
If you try to input Serial Numbers or Model
Numbers, you will find 96 characters
available to scroll through, including the
entire alphabet in upper case and again in
lower case, numerals 0 through 9, 33
symbols and even a blank character.
In the OEM GENSET SETUP, you will find

reference to “ Input Factory Lock ”
functions. You will notice there are more
than 3 dozen inputs affected by this setup.
When the factory configures a genset with all
its option, some inputs are consumed and
are “Locked”.
Factory Lock prevents causal operator
changes to the genset setup. Password
1209 is required to change any input from
Lock to Unlock or Unlock to Lock. Once
unlocked, the input configuration can be
changed.

Participant’s Text (OEM ENGINE Notes:

SETUP)
There are 2 pages to Engine Setup. This

training course will only address some of
the FAE application points. Other PC 3.3
control courses will address other engine
setup functions.
ECM CAN ENABLE turns on the SAE J1939
CAN communications to the engine
ECM. Changing the setup to Disable will
lead to communication and Operation
problems. There may be times when you
want to Disable this such as
troubleshooting the ECM, but it must be
Enabled for genset operation.
Fault 1117 Enable is a ECM warning that can
be Enabled or Disabled, the setup criteria
for this setting will be discussed in more
detail several lessons ahead.
Prelube Enable is a newer feature option that
is available with some engines. There are
control provisions to allow for either a
rolling Prelube or Prelube pump
engagement. Setting this up correctly is
dependent on engine and genset
configuration.
Page 2 offers several setup parameters that
should be familiar to technicians.

Participant’s Text (OEM Notes:

ALTERNATOR SETUP)
There are 3 pages to Alternator Setup. Like in

other OEM SETUP screens, there is a
combination of Level 1 and Level 2
password authorized settings.
OEM ALTERNATOR SETUP is different
from OEM GENSET SETUP. Alternator
setup concentrates on voltage regulation
performance and on alternator protection
setting. Most settings require a Level 2
password.
On page 1 you will notice an option for
choosing the Excitation Source. You are
able to choose between PMG (Permanent
Magnet Generator) or SHUNT. Shunt is a
term unique to Cummins Power
Generation excitation systems and it is
synonymous with the industry common
term Self Excitation.
Scroll through the Alternator Setup pages and
you will notice some of the protection
settings are very high level protections
and these settings if improperly set can
contribute to serious damage of the
alternator or system. Be VERY
CAUTIOUS about sharing the level 2
password with others.

PCCNet & M odBus Setup Menus

The PCCNet and ModBus Setup
screens will be covered in
greater detail in upcoming
lessons.
The PCCNet and ModBus Setup screens use Level 1 passwords.
12
Slide 2-12 PCCNET & ModBus Setup
PCCNet and ModBus setup menus will be

covered in detail in upcoming lessons.
All of the navigation choices and functions

found in these menus have been
experienced. Using your simulator,
navigate to, and open the PCCNet and
ModBus menu screens.
Later Lessons will cover the detailed setup of

both these features.

Setup Menus
The remaining Setup screens

Display Options, Clock Setup,
Configurable IO, and Calibration
also contain multiple screens
with many setup parameters.
13
Slide 2-13 Operator Setup Menus
The remaining setup menus on this screen

utilize the same navigation buttons and
sequences covered previously.
The Configurable IO menu contains many

configuration settings and labels. As
mentioned in previous screens, when
inputting lots of character data, it can take
a long time to input descriptions. If you
are only changing a couple of descriptions
it is ok to attempt it from the HMI menus,
but some people may prefer to us InPower
for this configuration. InPower setup
menus will be covered in upcoming
lessons.

DEMO MOD E Operation

The HMI has a DEMO MODE of
operation that allows for practice at
navigation through the various
screens. There is a series of 5
screens that allow for detailed setup
of a multitude of operation set points.
The DEMO MODE is accessed by

pressing these buttons simultaneously
for a few seconds will cause the screen
to enter a DEMO mode if PCCNet is
14
disconnected.
Slide 2-14 Demo Mode Menus
Demo mode is very useful for training

customers and site operators on
navigation skills.
You must remove the PCCNet

communication connector before you
attempt to enter Demo Mode.

Activities
2-1 Menu Hands On Activity

Section 2 Activities are found in Section 15 of the

Training Guide.
15
Slide 2-15 Activities Listing for Lesson 2
At this time I would like you to work as When everyone is done with the activities, we
teams to complete these activities. will discuss the correct answers.
These activities should be fairly easy for you,

but take your time to become comfortable
with the button pushing sequences.

Wrap-Up
In this lesson we have learned about the Service Menus for the PCC 3.3 and PCC3300/HMI 320
control.
We talked about the Service Menu password: 5 − 7 − 4
We talked about the Service Setup Menu Password: 1 − 2 − 0 − 9
We also talked about the Setup Menus:
Genset Service Menus

• Genset
• Customer I/O
• Meter Calibration
• Annunciator
Genset Setup Menus
• Genset
• Voltage Protection
• Current Protection
• Engine Protection
View Setup Menus
• No Adjustments
We then went through the choices available in these menus. We covered the some factory default
settings, minimum, and maximum values available.
Lastly we worked through the menus and recorded the settings in the controls you have at your
workstations, and took a quiz on the Service Menus.
Are there any questions we have not yet covered on the Operator Panel Menus?
In the next lesson we will cover the use of InPower software with the PCC 3300 control.

PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 Sequence of Operation
PowerCommand
3.3
Section 3 Sequence & Operation

PCC 3300 & HMI 320

Visual 3-1

Section 3
PowerCommand Control 3300 Sequence & Operation.

Materials Needed
• PowerCommand Control 3300 Participant’s Guide Guide(CMT6068-EN-PG)
• PC with InPower v 7.0 or later installed
• PowerCommand 3.3 Service Manual #900-0670

Warm Up
In this lesson we are going to learn the operating features and sequence for the PowerCommand
Control 3300.
What we learn in this lesson will be applied in the troubleshooting lesson and in both the written
and performance examinations.
Objectives
• Create an understanding of the operation and functions of modes, sequences, and connections
used during the sequence of operation from start command to shutdown.
• Describe how to isolate a failure in the operation of the PCC 3.3 and find the failed part.
• Use the PC 3.3 Service Manual #900-0670 to understand the function of various modes of
operation.


Local Control Panel Remote Control Panel
0300-6315-02 0300-6315-03
Fixed buttons
Visual 3-2 Local and Optional Remote Operator Panel
There are 2 Operator Panels. The Local

version is considered standard and the
Remote version is optional.
The HMI 320 Local allows greater control of
the control and setup functions. It offers
operator interface to the digital voltage
regulation, engine speed governing, and
remote start/stop control, and protective
functions.
The obvious difference between each HMI is
noticeable when to look at the fixed
buttons.

Mo des of Operation
Each mode of operation has multiple choices
affecting sequence of operation.
 Off Mode
 Auto Mode
 Manual Mode
 Parallel Mode
Visual 3-3 PCC 3.3 Operation Modes
As with so many things about this control, a

different style of thinking is required to
understand how this control operates.
Modes of Operation: Off Mode
On most controls we think of OFF as a
condition when no power is being used for
any purpose. That is not what this control is
doing.
In OFF MODE, this control is actively
monitoring communications, engine
condition, and generator conditions, but it
does NOT allowing the engine to run. The
control is not operating in Manual nor is it
operating in Automatic. The Control is very
hard at work making the genset do nothing.

Modes of Operation: Auto Mode

Auto Mode operates the same as previous
controls. The unit is in a state of readiness
awaiting a remote start signal via digital
commutations or a remote discrete contact start
command.
Auto Mode also supports start commands initiated
by Exercise and the exercise signal.
In Auto Mode when auto start commands are
removed, the PCC will enter a shutdown with
cooldown sequence.
The Exercise Signal can originate from any of
these sources.
 ModBus signal command.
 Operator panel exercise command
 Exerciser Schedule. (The control has a built in
exercise scheduler much like transferswitch
controls)
 InPower exercise command.
 Exercise switch PCCNet input
Modes of Operation: Manual Mode
At the HMI pressing the will engage the

Manual mode if the HMI is configured to allow
this.
If the engine is already running when this button is
pushed, it will continue to run if the START
button is pressed again within 250ms -- yes that
is ¼ of a second. If you are not fast enough, the
unit will go into a Shutdown WITHOUT
cooldown
If the unit is not running and the button is

pushed, the unit will be available for Manual
start & stop commands.
If you engage the Manual mode, you must push
the manual button again within 10 seconds or
the control will enter the OFF MODE.

Modes of Operation: Manual Mode
If the HMI button has been engaged with

the engine off, normal start functions will be
available and take place with a idle warm up
if needed. Once the engine ramps to rated,
the control can operate in Parallel Mode if
the control is configured to allow this. If the
control is configured for a Parallel Mode
and you are operating in Manual Mode the
buttons will allow control of the

paralleling circuit breakers.
Modes of Operation: Paralleling Mode

There are 7 states of paralleling operation of
which 5 are associated with application
performance modes.
 Dead Bus Close
 First Start Arbitration
 Droop
 Synchronization
 Load Share
 Load Govern
 Power Transfer Control
Dead bus close and 1 st start arbitration are
sequence modes that are incorporated into
some of the other paralleling modes, but
they merit recognition at this point.
The operation of the various modes involved
with Paralleling will be covered in detail in
later lessons.

Modes of Operation - Starting

Multiple START sequences available.
 Emergency Start
 Non-emergency Start
Non-emergency Start With Idle Warm up

Non-emergency Start Without Idle Warm up


 Manual Start
Manual Start With Idle Warm up

Manual Start Without Idle Warm up


 Load Demand Start

4
Visual 3-4 PCC 3300 Starting Mode & Sequence
Starting Modes of operation

The control operates the generator differently
depending on the operation mode and the
desired start type.
Refer to Section 3-12 of 900-0670 Control
Service Manual for more information.

Manual Start:
The PCC3.3 Control System can be place in Manual Run by

pressing the Manual button and then the Start button on the
HMI320. When the control system is transferring into Manual
Run mode the Green LED above the manual button will flash, once the control system has
successfully transferred into Manual Run Mode the Green LED will be lit solid.
If the Manual button is pressed, but the Start button is not, the control system will not start and the
control system will revert back to ‘Off’ after 10 seconds.
After the Start button is pressed on the HMI320, the PCC3.3 Control system enters Manual Run
mode which begins with the start sequence. The start sequence begins with the engine Pre-Lube
Cycle Prelube Cycle Enable if Enabled.
After the Pre-Lube cycle is complete, the PCC3.3 control system commands the genset to start
cranking by turning on the starter Low-Side Relay driver on Pin J20 -15. At this point, the
control system verifies the engine is rotating by monitoring the Average Engine Speed
parameter coming from the ECM.
If the engine speed is zero after two seconds from engaging the starter the control system turns off
the starter, waits two seconds and then re-engages the starter. At this point, if engine speed is
still zero the control issues a Fail To Crank (1438) shutdown fault.
Once the engine speed is greater then the Start Disconnect speed, the starter is disengaged. For
Start Mode = Emergency engine will accelerate to rated speed and voltage and bypass all the
idle warm-up delays. At this point, an engine is allowed will warm-up at idle speed until the
Idle Warmup Time delay has expired or the engine coolant temperature is greater then the Idle
Warmup Coolant Temperature. Upon completing the warm-up sequence, the engine will be
commanded to accelerate to rated speed and the genset to rated voltage. Upon reaching rated
speed and voltage the ‘Ready To Load’ command will become active.
Once the PCC3.3 receives a stop command by placing the control system in Off mode, it will go
into cool-down at rated speed if the genset was running with load that is greater than 10% of
genset rating. The genset will run in cool-down at rated mode for the Rated Cooldown Time
trim setting. The purpose of the cool-down at rated is to cool-down and preserve the engine.
After the cool-down at rated is completed the genset will cool-down at Idle speed. After the cool
down at Idle speed time expires, the genset is shut down via a normal stop.

Modes of Operation - Stopping

Multiple STOP sequences  Emergency Stop
available.
 Controlled Shutdown
With Idle Cool Down

Without Idle Cool Down


Emergency Stop With


Idle Cool Down

Remot
e E- PCC3300
Local E- STOP Control
STOP Contac
 Automatic Shutdown B
Contact 2
Local E-
STOP
t1
Remote
With Idle Cool Down + To Relay

Contact 1
E- Contacts
STOP
Contact
Without Idle Cool Down
 2
Visual 3-6 PCC 3300 Shutdown Sequence
For operation of the genset, a short between

TB1-15 and TB1-16 must be present. The
control enters an emergency stop mode
when the short is removed. Before the
genset can be restarted, the control must
be manually reset by re-applying the short
and acknowledging the fault.
Local Emergency Stop:
For operation of the genset, a short between

J25-2 and J25- 6 must be present. The
control enters an emergency stop mode
when the short is removed.

Before the genset can be restarted, the control

must bemanually reset by re-applying the
short and acknowledging the fault.
It is also required to have physical

interruption of the Keyswitch, FSO and
Starter relays when emergency stop
(either local or remote) is active. In order
to achieve this, a second NC switch
contact should be added to the Estop
switch such that when a Estop button is
pressed, this second NC contact is
opened. The second NC contact should be
wired in series with B+ and the
Keyswitch, FSO, and Starter relay coils.
Thusly, when the Estop button is pressed,
power is removed from the Keyswitch,
FSO, and Starter relay coils which in
turns de-energizes the relays and prevents
further genset operation.

Prelube Cycle
The PCC 3300 is able to initiate a Prelube cycle period
allowing the engine to circulate engine oil pressure.
Prelube Cycle is adjustable. Adjustments are available for:


 Prelube Cycle Enable.

 Prelube Cycle Time.
 Prelube Oil Pressure Threshold
 Prelube Timeout Period
Prelube Mode

Emergency start: Crank relay and Oil Priming Pump relay is energized
during start.
Visual 3-7 PCC 3.3 Prelube
Prelube pumps can be controlled by the PCC

3300 control and they can be cycled as
desired to maintain an oil coating on the
bearing surfaces during times of
inactivity.
The Prelube relay is optional per genset
design requirements. The Prelube pump is
optional and types may vary.
The relay will engage when the engine is not
running, so be aware of unanticipated
pump engagement.
Prelube will usually be found with larger
engines since long & heavy crankshafts
and heavy flywheels need to be supported
by a sufficient film of oil on bearings.

InPower supports the setup functions

associated with Prelube.
 Prelube Cycle Enable – turns the Prelube
function on or off.
 Prelube Cycle Time – Sets the amount of
time between Prelube cycles. Default 168
hours (7 days)
 Prelube Oil Pressure Threshold – this as
an adjustable setting so that when the
predetermined oil pressure is achieved
during Prelube Cycle pumping, the cycle
will disengage.
 Prelube Timeout Period – this is an
adjustable setting determining how long
the Prelube pump should run.
Charging the engine lube system with Prelube
keeps internal engine components coated
with oil and keeps the oil galleries
charged with oil supply. With Cycle
Prelube you can set a schedule when the
pump will recharge the lube system with
pressurized oil.
Prelube will also engage at the beginning of
an Emergency start command to help
charge the lube oils system and bring the
system up to safe oil pressure levels as
soon as possible.
The Prelube cycle is disabled and does not
operate while the engine is running.

Power Down Mode

 The PC 3.3 also uses the same Bi-directional wakeup
scheme found in the PC 1.X and PC 2.X control
systems.
 PCC Current Draw (base board) {HMI}

– Normal Operation ---- (750 mA) {150 mA}
– Power Down (Sleep) --- (5 mA) {1 mA}
 If one PCCNet device awakens, it will wake up the

other PCCNet devices by driving the Bi-directional
system wakeup pin.
 When all devices are satisfied, the PCCNet will go to

sleep as one system.
Visual 3-8 PCC 3.3 Power Down
The PCC 3300 power consumption changes

depending which of mode of sleep or
wake it is in.
The current draw of the HMI changes during
power down mode. Look at Table 3-11 in
Section 3 (page 11) of the 900-0670
Service Manual.
The system Power Down Mode Time Delay
timer is adjustable under the GenSet
Setup of InPower or the HMI setup
screens.

PCC 3300 A VR Op eration

 The PC 3.3 AUX103 Power Stage (AVR) provides
a PWM signal to the generator Exciter
 AUX 103 Current Output

– Normal Operation 0 to 4 amp
– Maximum continuous operation 4 amp
– Surge ` 6 amp for 10 seconds
 AUX 103 does not provide output during:

– Normal startup @ idle
– Normal shutdown @ idle
– Emergency Stop (local, remote or fault shutdown)
Visual 3-9 PCC 3300 Power Stage
The AUX 103 Power Stage AVR is separate from

PCC 3300 main control board to help
dissipate the heat being rejected from the
AVR circuits.
The AUX 103 MUST be mounted with the
heat sink fins vertical so convective airflow
can help carry heat up and away from the
board.
Processors on board this module communicate to
the rest of the control to optimize Volt/Hz
performance and to shut down the AVR
output during idle.
The AUX 103 also communicates Backup Start
Disconnect information.

PWM and Self Excitation
The PCC3300 collects main alternator output power at J 18 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
10
Visual 3-10 PCC 3300 and Self Excitation
Self Excitation uses 2 phases of power coming

off the main output leads of the generator for
powering the voltage regulation process. and
the voltage could be as low as 100 volts to as
high as 240 volts RMS.
PWM provides very high performance for
voltage regulation response. One of the main
shortcomings of a self excited system is the
lack of supply power to the excitation system
when very heavy loads are applied to the
main windings. Motor start performance is
not as good with self excitation as you get
with PMG power supply.

PWM and PMG Excitation
The PCC3300 collects 3 phase PMG output power at J 18 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
11
Visual 3-11 PCC 3300 PMG Excitation
PMG Excitation offers many advantages over

Self Excitation.
PMGs are not affected by harmonics or
loading on the main windings and can
provide a clean source of the needed
power to the voltage regulation system as
needed when needed.
As can be noticed in the above image of the
PWM signal, the on time (red) and the off
time will vary. If the on time increases,
the voltage will increase. The variation of
this relationship is called the “% Duty
Cycle” on previous controls. Now it is
termed AVR PWM Software
Command.

PCC 3300 Start Disconnect

 The PC 3.3 can use multiple signal or inputs for
starter disconnect.
 Primary Start Disconnect:
– ECM speed reference
– Battery Charging Alternator output
 Alternator Frequency
 AUX 103 Provides Backup Start Disconnect:

– If PMG – PMG voltage (105 volt AC)
– If Self Excited – Alternator frequency
12
Visual 3-12 Start Disconnect
The PCC 3300 provides for multiple forms

and options for starter disconnect.
The PCC control provides control of the
starter control relay, but in FAE
applications the ECM is the one who
decides when the primary starter
disconnect should take place. On FAE
applications the EPS (Speed Reference) is
determined by the ECM and the
information is communicated through
CAN to the genset PCC control.
If PMG is used, the AUX 103 determines
backup start disconnect when PMG
voltage achieves 105 volts.

Activities:
 Quiz: PCC 3300 Sequence of Operation
13
Visual 3-13 PCC 3300 Activities - Sequence of Operation

Work through the Quiz found in the Activity

portion of Section 15.

Wrap-Up
In this lesson we have learned about the operation information about the PCC 3300 control board.
First we talked about the PCC 3300 Control board connections and the HMI 320 Operator Panel as
a quick review.
Next we talked about the control operation sequence during a engine start through shutdown.
Next we talked about the start modes available on the PCC 3.3 control.
Next we looked at the excitation operation possibilities.
Finally, we mentioned the start disconnect.
Are there any questions that you have about the operation of PC 3.3 controls we have not yet
covered? The following section will look at installation, and connections details.


PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 Installation
PowerCommand
3 .3
Section 4: Control Installation

Visual 4-1

Section 4
PowerCommand Control 3300 Installation
Materials Needed
 Wiring Diagram 0630-3440 (A007M115 D) Sheets 1 to 18 or diagrams in 900-0670
 PowerCommand Control 3300 Participant’s Guide Guide (CMT6068-EN-PG)
 PC 3.3 Controller Service Manual #900-0670

Warm Up
In this lesson we are going to look at the installation and connections that can be used with the
PowerCommand Control 3300.
We will also give you a chance to work with some optional devices and controls at your
workstations.
Objectives
• Understand options for the PowerCommand Control 3300.
• Identify the correct connection points on options and the PCC 3300 control module.
• Connect and install options for the PowerCommand Control 3300.

Co ntrol and Option Installation
 Physical Installation Requirements
 Identify each of the connectors
 Input and Output Connections
Visual 4-2 Control and Option Installation.
Control Installation
Most technicians will encounter the PCC3300 Adding options in the field will most likely
when it is already installed onto a factory be a common occurrence
built generator set. However, there will be
situations when technicians will need to
know about proper installation of the PCC
3300, such as instances when an
old/obsolete control needs to be replaced
or when troubleshooting, or if adding
more features or options.
Attaching to and utilizing the I/O features

will be the most common reason to
become familiar with the connectors on
this control.

Installation Steps for Op tions
 Place Genset in OFF Mode & Press E-Stop

 Turn Battery Charger Off
 Disconnect Battery (Lock-out & Tag-out)
 Static Wrist Strap (Not if AC power present {possible
600v present})
 Install Option, (Bargraph, Sensor, Harness, etc.)
 Install Wiring Harness
 Battery Connected (Remove Lock-out)
 Download Proper Calibration
 Turn on Battery Charger
 Test Generator Set
Visual 4-3 Installation Steps for PowerCommand Control 3300 Options
Installing Options
The PowerCommand Control 3300 cannot be
powered down except by disconnecting the
battery cable.
IMPORTANT! Press the local Emergency
Stop button and wait approximately 30
seconds before removing battery power.
The ECM needs to save data in
memory before power down.
Pressing the E-Stop (Keyswitch)
initiates the save process. If the
ECM experiences an
unanticipated power down, ECM
files may be corrupted.

Disable the battery charger FIRST! then

disconnect the battery − Negative cable
first. Remember to remove the chassis
end of the negative battery cable to
prevent sparking and possible battery
explosions. In class we will power down
the simulator to remove power from the
control. Remove control-housing cover(s)
and connect your wrist strap.
Static wrist straps are recommended to
prevent static discharge damage to the
control boards, but this control may
have up to 600vac bus power
connected. For safety reasons, it is best
NOT to use a wrist strap, but antistatic
handling measures must be employed.
Install the new option or card or other
modules, etc.
Install the wiring harness for the option.
Reconnect battery and enable the battery
charger. Remove Lock-out Tag-out.
If necessary, use InPower service software to
enable the feature(s) or set the required
parameters.
Test the generator set with the new option to
verify proper operation.
Additional Notes or Comments

_______________________________________________________________________________

Baseb oard Connector Location

Bus CT Inputs J12- Gen CT Inputs
TB7- Bus Voltage
J22- Gen Voltage
J20- Genset input/output s

TB9- Analog I/O
J25- Display Connections

TB15- Service / MODBUS
J26- Engine Interconnect

J14- Service Interface
TB3 - Customer I/O
TB10- Circuit
Breaker Status TB1 – Customer I/O
TB8- Customer I/O TB5- Circuit Breaker Control

Visual 4-4 Connector Location -r PowerCommand Control 3300
Like the PC 1.X & 2.X, the PowerCommand

3.3 also uses the new common connector
scheme.
All connectors use a tension or mechanical

latch to hold the harness jack in place.
All connectors are keyed so the harness jack

will not be inserted incorrectly.

Bus CT Connections
CT1 CT2 CT3
Visual 4-5 Control Board CT Connections
There are 3 donut style CTs mounted to the

board and they are used for monitor of
Bus current, not Genset current.
These CTs are polarity sensitive and are
limited to a maximum of 5 amp pass-
through.
These CTs are looking for a signal from the
bus primary CT mounted in the
switchgear bus. Passing the output loop
from the bus CT through the center of
each CT will induce a signal for the PCC
to measure.
Make sure each CT is monitoring the proper
phase as the voltage sense!

J12 Connections
Pin 4 Pin 6
Pin 1 Pin 3
Visual 4-6 J12 Inputs
J12 provides input from the genset mounted

CT and monitor genset output current.
Input is limited to a standard 0 to 5 amp. CT.
The plug is keyed so incorrect insertion will
be minimized.
The genset harness will be prewired and it is
unlikely that the plug can be inserted
wrong. However, the wires at the other
end of this plug are susceptible to
miswire.
Do Not unplug this connector while
the genset is operating! Shorting
blocks or some sort of shorting system
must be used to protect the Gen CTs from
open circuit when unplugged.

J22 Gen Voltage Connections
Pin 1 Pin 4
Visual 4-7 J22 Gen Voltage Inputs
J22 provides voltage sensing inputs to the

control. The control uses this information
for voltage regulation and other protection
functions.
There are 4 pins on this connection. 1 pin for

each phase plus neutral.
J22 is rated to accept up to 600 volt AC. For

voltages greater than 600, a Potential
Transformer (PT) must be used to lower
the voltage down to an acceptable level.
Refer to Service Manual 900-0670 Section 2

for proper PT Sizing Rules.

J20 Ge n I/O Co nnections
Pin 22
Pin 11
Pin 12 Pin 1
Visual 4-8 J20 Genset I/O Connections
J20 provides connection for most genset

features.
Notice J20-16 is the Oil Priming Pump Driver

which was discussed previously in lesson
3.
J20-9 & 10 are Fused B+ inputs and need to

be fused for a maximum of 20 amp.
Low Side IS NOT THE SAME AS
BATTERY GROUND!
B+ RETURN = Battery Negative
B+ RETURN IS NOT EQUAL TO
GROUND

J25 D isplay Conne ctions
Pin 1 Pin 7
Pin 6 Pin 12
Visual 4-9 J25 Display Connections
J25 uses the exact same connection points at

used on PC 1.X and 2.X controls.
J25 provides connection for PCCNET display
connection.

J26 Eng ine Interconnect

Pin 18 Pin 9
Pin 10 Pin 1
10
Visual 4-10 J26 Engine Interconnect
J26 is used for engine and AVR Power Stage

connection.
Standard SAE J1939 communications can be

connected at J26-1, 10, & 11. On the
chart, this may seem spread out
haphazardly, but if you look at the
connector you will notice they are
consolidated neatly.
J26 – 7 & 14 provide F1 & F2 information

from the AVR Power Stage to the PCC
3300 processor to so it can properly
monitor and protect the excitation system.

J14 Data / Service Interface

Pin 9 Pin 6
Pin 5 Pin 1
J14 DATA LINK (RS232)
11
Visual 4-11 J14 Data/Service Interface
This communication port is used to

communicate with a computer running a
PC based service tool. This port can also
be used to communicate with the external
devices via the MODBUS protocol.
InPower service cable #0338-3277 can be

used to communicate direct into the board
using RS232 communication from your
computer port.

TB1 Customer I/O Connections

Pin 16 Pin 1
12
Visual 4-12 TB1 Customer Connections
PCCNet connections on TB1-1, 2, & 3

duplicate the PCCNet functions and
connections of J25.
Ready to Load on TB1-4 becomes active
when the genset achieves 90% voltage
and/or frequency during startup.
Look at page 9 of print 0630-3440. At the top
of the page next to TB1 – Basic you will
see , this is the

part number for the connector terminal
block that is missing on the above visual.
Remote Start is between TB1-10 & 11.


Pin 12 Pin 1
13
Visual 4-13 TB3 Customer I/O connection
TB3 has many inputs that will be utilized

with the PTC functions to be released in
Phase 2.
TB3-11 & 12 are utilized in many paralleling
applications for First Start arbitration.

TB5 Circuit Breaker Control

Pin 9 Pin 1
14
Visual 4-14 TB5 Breaker connections
TB5 is reserved for connections devoted to

controlling Genset breakers and Utility
(Mains) breakers.
More details about these connections will be

covered in later lessons.
Refer to print 630-3440 page 13 through 17

or Appendix A page A-7, through A-11 of
the 900-0670 Service Manual.

TB8 Customer Connections

Pin 13 Pin 1
15
Visual 4-15 TB8 Customer Connections
TB8 is used in paralleling applications for

several control functions. Most
connections will be shown in CPG
paralleling interconnect drawings.
The inputs are used for paralleling

performance commands.
More details about these connections will be

covered in later lessons.
Refer to print 630-3440 page 13 through 17

or Appendix A page A-7, through A-11 of
the 900-0670 Service Manual.
In the PC 2.X course, this connector was

referred to as the Premium Connector .

TB1 0 Breaker Status Connec tions
Pin 17 Pin 1
16
Visual 4-16 TB10Breaker status connections
TB10 accepts breaker status for both utility

(Mains) and genset breaker. There are
also a couple paralleling performance
command inputs.
print 630-3440 page 12 through 17 or

Appendix A page A-6, through A-11
of the 900-0670 Service Manual.

TB1 5 Da ta / Service Interface

Pin 5
Pin 1
17
Visual 4-17 TB15 Service tool connection
TB15 is the standard service tool connection

port.
This port can be used for InPower connection
or it can be used for ModBus
communications, but it cannot be used for
both simultaneously.

TB9 Analog I/O Co nnections
Pin 11
Pin 1
18
Visual 4-18 TB9 Analog connections
TB9 provides analog paralleling load

management input and output.
Look at Section 2 page 15 through 18 of the
Service Manual 900-670 for details about
the connection made to this terminal
block.
The analog voltage is 0 to 5 volt. TB9 does

not have any 4 to 20 milliamp signal
terminals.
The details about connection to this TB will

be covered in later paralleling lessons.

TB 7 Gen Bus/Utility Voltage Sense

Pin 1 Pin 4
19
Visual 4-19 TB7 Bus sense connection
TB7 provides the bus voltage sense input to

the control.
This connection will sense up to 600 vac. If
the bus voltage exceeds 600 vac, a PT/VT
(Potential Transformer/Voltage
Transformer) must be used to lower the
bus voltage to a value less than 600 volts.
More details about this connection and
InPower setup will be covered in later
lessons.

AVR P ower Stage Connectors
Pin 1
Pin 1
Pin 2
20
Visual 4-20 J17 - 18 Inputs and Outputs
J17 Excitation Field Power
J17-1 supplies excitation positive to X1 (F1)
J17-2 supplies excitation negative to X1 (F1)

J18 Voltage Regulation Power Supply - maximum input is 240 VAC
The PCC 3300 will operate in either a self

excited (Shunt excitation) mode or in
PMG excitation mode.
J18 can receive input from either the

alternator output, or from phase 1 & 2 of a
PMG.
J18 has 3 connector pins; however, only 2 of

them are used in Self Excited
applications.
The J18-1 & 2 inputs are limited to a

maximum input of 240 VAC.
CGT (Cummins Generator Technologies

supplies 600 VAC alternators with a
special winding tap that supplies the
proper voltage for voltage regulator input.
If these taps are not available, proper
transformers must supply 240 VAC or
less to the J18 inputs.

AVR J19 Interconnect
Pin 14
Pin 1
21
Visual 4-22 Operator Panel Installation
The AVR J19 connector is expected to be

used on all applications.
There is a short connection harness from the

AUX 103 J19 terminal that plugs into the
J26 interconnect harness.
J19 – 4 & 10 are reserved for future plans to

monitor field current. This is not
supported during the Phase 1 program.


Local Control Panel Remote Control Panel
0300-6315-02 0300-6315-03
22
Visual 4-22 Operator Panel Installation
The HMI320 Local Control is required and is

expected to be used on all applications.
The HMI320 Remote is optional and is not

used on all applications.
Optional languages can be loaded

(programmed) into the HMI
Environmental installation requirements are

listed on this visual.

23
Visual 4-23 Installation HMI320
Refer to Service Manual #900-0670 Section

2-24 for proper connection information.
LED11 blinks at a 1 second rate to indicate a

Heartbeat. If it is not blinking it is dead,
or the control is in a Power Down Mode.
TB15 is a connection for InPower and is used

for calibration updates.
Inserting a jumper across J36 will prevent the

HMI from entering Power Down Mode,
thereby engaging the Bi-directional
Wakeup mode for the entire PCCNet
control system.

24
Common Connector Scheme 0630-3440
The PC 1, 2, & 3 generation of

PowerCommand Controls will use a new
Common Connector Scheme.
Genset connections are displayed on print
0630-3440, pages 1 through 11.Pages 12
through 18 concentrate on paralleling
connections.
The same basic “J” connectors are used on all
3 series and phases of controls allowing
for simplified control upgrades without
changing engine harnesses.
There are many new features imbedded in the
print. Look at each Legend, and you will
notice valuable information.

Activities
Section 4: In-Class Quiz
25
Visual 4-14 Quiz Listing for Section 4
At this time I would like you to work alone to

complete the quiz.

PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300

Installation
Wrap-Up
In this lesson, we have learned about installation of the PCC 3300 genset control and
important connection locations.
We talked about each individual connector and the connections available from the control
to the genset components and why each is important.
We also encountered the Common Connector Scheme diagrams.
Q. Are there any questions we have not yet covered about installation of the PCC 3300?

PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 Setup and InPower
PowerCommand
3.3
Section 5: Control Setup and InPower

Visual 5-1 Control Setup & InPower

Section 5
PowerCommand Control 3300 Control Setup and

InPower
Materials Needed
 PowerCommand Control 3300 Participant’s Guide (CMT6068-EN-TG)
 PC with InPower v 7.0 or later installed
 Registered Dongle or authorization code.
 InPower Connection Cable Kit #0541-1199

Warm Up
In this lesson we are going to learn about the InPower parameters for the PowerCommandControl
3300.
You will have a chance to use InPower with the training controls as an in-class activity after we
complete the lesson material.
Objectives
After completing this lesson, participants should be able to:
• Connect a PC running InPower service tool software to a PowerCommand Control 3300.
• Download a capture file from the control to your PC.
• Identify the parameters used in setting up a PowerCommand Control 3300.
• Identify the parameters used in troubleshooting a PowerCommand Control 3300.
• Identify the parameters used in testing a PowerCommand Control 3300.

Connecting to a PCC 3300
Visual 5-2 Connecting to a PCC 3300 with InPower software
Connect your hardware lock (dongle) to the

USB port of your PC and start the PC.
Log in to your PC using one of the
security schemes discussed in the
InPower class or on the Power Generation
University training program.
The converter and cable of Communication
Kit #0541-1199 is also used when
connecting InPower to a PC 3.3 control
system.


InPow er Service Tool Software
Visual 5-3 In-Power service software connected to a PCC 3300 control
The screen structure is different for the

PCC3300 than some other controls. There
are several new features.
• Advanced Status allows you to monitor a
vast amount of engine, alternator, genset
and fuel system performance and data.
• Alternator Data contains monitoring
points for alternator performance data
only.
• Engine Data contains monitoring points
for engine performance data only.

• Setup is a folder containing functions that

used to be found in the Adjustments
folder
• Faults contains information and fault
configurations
• Test provides access to a great many test
features such as Witness Test Folder
Additional Notes:

This choice will take you to a

setup screen
A simple right mouse

button click on the
SETUP folder will
bring up the dialog
box with the
Genset OEM Setup
choice
Visual 5-4 InPower Setup
The PCC 2300 and 3300 both have a special

Genset OEM Setup function choice. This
feature facilitates easy setup of all of the
same OEM setup functions we looked at
in Lesson 2 about the HMI screens.
Just like on the HMI, there are setup screens
for:
• OEM Alternator Setup (2 screens)
• OEM Engine Setup (6 screens)
• OEM Genset Setup (4 screens)

InPower: Genset OEM S etup

Screen 1
Radio buttons
accept a
simple click to
activate or
deactivate
Text boxes
accept upper
and lower
case
alphabet,
Adjustable numerals,
rating with and special
listing of characters.
possible range
Visual 5-5 Genset OEM Setup
The first default screen is page 1 of the OEM

Genset Setup. This screen offers the exact
same setup functions as found on this
page in the HMI OEM Genset Setup
screen.
Notice the “Setup Mode Disabled” button in
the lower left corner. If it is highlighted,
you are prevented from implementing
changes. Click on the “Enable Setup
Mode” to activate all of the adjustment
choices.
InPower must be connected to the control to
enter the Enable Setup Mode. You cannot
make changes to a capture file.

Setup Screen: Genset Screen 2
Check boxes
accept a
simple click to
activate or
deactivate
Visual 5-6 Battle Short
Battle Short setup procedures are more

complex than placing a simple check in
this screens checkbox. Refer to the
Service Manual 0900-0670 Section 7 for
details on the proper mode configuration
process. There are approximately 6 pages
devoted to the procedures involved with
activating the mode.
Removing the check in a Factory Lock check
box will allow the input or output to be
used for a different purpose.

Radio buttons
accept a simple
click to change Text boxes
response to: only use
None, upper case
Warning, or alphabet,
Shutdown numerals,
and special
characters.
Response must
be set to:
Warning, or
Shutdown
to enter text into
the Fault Text
box.
Visual 5-7 Configurable Switch Settings
Screen 3 allows you to set these Configurable

Inputs:
• Input #1, #2, #13 & #14
• Response of None, Warning, or
ShutdownEvent
• Names for display at the HMI display
screen (s), or transmission via a ModBus
register (16 characters of text maximum)

Visual 5-8 Genset Settings
These settings allow for easy configuration of

premium genset options available from
the factory. The genset wire harness has
preconfigured inputs for factory genset
options such as a sub base fuel tank or an
optional coolant level sensor.
These items would be Factory Lock functions

if enabled at the factory. They are pre
mapped for communications to
annunciator lamps and for fault display.

Setup Sc reen: Engine Screen 1
Visual 5-9 Engine Setup Screen 1
The PCC 3300 phase 1 release supports Full

Authority Electronic Engines, and phase 2
will support mechanical control engines.
Oil Priming Pump enabling requires other
adjustments to be made on other screens
for Time & Pressure requirements.
Fuel System settings support Diesel & several
spark ignited engines.
Glow Plug options will be available on some
engines. Time & Temperature settings
will be made on other screens.
Starter Owner designates if the ECM or the
genset control sends the start engagement
command to the starter.

10
Visual 5-10 Engine Setup Screen
These parameters are almost all related to

Hydra mechanical applications.
Watt Sentry is a function for Gas fuel systems.
It is described in Section 3 (3 – 19) of
Service Manual 0900-0670. It is supposed
to help protect large turbocharged gas
genset engine.
Mag Pickup and Flywheel Teeth, function
together, Flywheel ring tooth count is used
to calculate RPM.

11
Visual 5-11 Engine OEM Setup Screen.
All parameters on Screen 4 support Hydra

mechanical application. These functions
will be covered in Phase 2 training.

12
Visual 5-12 Engine Setup Screen 5
The settings in Screen 5 are intended to

support Hydra Mechanical applications,
just like the adjustments we saw in Screen
4.
Screens 2 and 6 will also support Hydra

mechanical functions. The content of
screens 2 and 6 will be available when
Phase 2 is complete.

Setup S creen: Alternator Screen 1
Pay attention to
this Note:
Voltages less than
600 volts can be
sensed directly
without a PT.
There is no There are useful

SHUNT involved Notes found on
with the excitation this page. Follow
system, it is just a the directions to
term loosely used properly set up
by CPG to describe the CTs.
a self excited
regulation system.
13
Visual 5-13 Alternator Setup
Do not confuse the notes on this screen as

implying that a PT/CT module is used
with this control. Remember – this control
can handle direct 600 volt AC into the J22
connection. Refer to page 2-8 of the 0900-
0670 Service Manual for PT info.
For CT setup and calibration refer to page 2-5
of the 0900-0670 Service Manual. Do not
confuse these CT settings with Bus CT
settings. This Screen supports the Genset
CTs only.

Setup S creen: Alternator Screen 2
This control is
able to
monitor total
KWH output. This control
You can also will support
reset the single and 3
KWH meter. phase
generator
output. .
14
Visual 5-14 Alternator Setup.
The K factors adjust the tuning for regulation

performance. Refer to page 5-51 and 5-52
for an explanation of the K1, 2, 3, & 4
settings.
• K1 – is similar to GAIN adjustments.
• K2 – is similar to Integral settings for
overshoot & undershoot.
• K3 – is similar to a stability setting for
response.
• K4 - is a calculation value dependent on
the alternator hysterisis characteristics and
usually should not be changed.
• Shunt Gain Multiplier should remain at
1.5


A standard left
mouse button click on
the SETUP folder will
provide a standard
drop down list of
more adjustment
folder.
Choosing the OEM

GENSET SETUP
folder will give you
setup choices in a
different format from
the previous visuals –
It is your choice how
you prefer to view the
screens.
15
Visual 5-15 Setup Folders
If you prefer not to use the OEM Setup

Screens that we just covered, you can
execute the same functions using
conventional InPower screens for setting
up the PCC 3300 control. There are
folders for:
• OEM Alternator Setup
• OEM Engine Setup
• OEM Genset Setup

InPower Service Tool Software
SETUP contains
a folder for setup
of the real time
clock. This clock
is referenced for
time stamps on
faults and is
used for
exercise
programs.
16
Visual 5-16 Setup Clock
This folder contains a clock setup for

adjusting the real time clock. The clock is
used for time stamps on faults and for the
exerciser scheduler.
If the battery is disconnected, the clock will
continue running for about 4 hour.
Look in Section 5 of the 0900-0670 Service
Manual for details about setting the clock.
Also look at Appendix B of this guide for
detailed info about setting the clock and
exerciser.
Clock Year shows 2 digits for the year,
however it does not show a 0 before the
year, so 8 is all that will be shown for
2008.

InPower Service Tool - FAULTS
17
Visual 5-17 Fault Screens
The FAULTS folder conveniently

consolidates all fault information in one
location. There are 3 main folders for:
• Active Faults
• Events and Faults
• Fault History
In the Events and Faults folder, under the
Snapshot column it is possible to select a
fault that will record data for the
preceding few seconds before a fault
becomes active. The memory of the PCC
3300 holds a limited amount of snapshot
data, so only turn on snapshots of
important points.

InPow er: History & About
 The History/About
folder contains
several adjustment
trims that allow
keyboard insertion
of Serial and Model
numbers
18

Visual 5-18 History & About
In an earlier section you discovered that serial

and model numbers could be inserted via
the HMI setup using many consecutive
button pushes. InPower allows you to use
the computer keyboard to type the
character.

Activities
 5-1 PC 3.3 Setup and InPower Quiz

 5-2 Real Tim e Clock Setup
19
Visual 5-15Activities Listing for Lesson 1
You will find Section 5 Activities in Section

15 of your guide.
Please find the Activities and at this time and

work as teams to complete these
activities.

Wrap-Up
In this lesson we have reviewed using InPower version 7.0 or later with the PCC 3300. First we
talked about connecting to the PCC 3300 control at TB15 with the RS-485 to RS-232 adapter and
the Cummins cable.
We then discussed the main InPower folders and parameters available when connected.
Q. Are there any questions we have not yet covered that you may have?
In thenext lesson wewill learn about the PCC 3300 PCCNet Communications.

PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 PCCNET
PowerCommand
3.3
Section 6: PC 3.3 & PCCNet
Visual 6-1 PCCNet
Participants’ Guide Section6 Page1

Section 6
PCCNet Network for the PCC 3300
Materials Needed
PowerCommand Control 3300 Participant’s Guide (CMT6068-EN-PG)
Universal Annunciator Operator’s Manual (optional) (900-0301)
Universal Annunciator Quick Reference Card (optional) (900-0304)
Instructor’s Note: This lesson presents information on the PCCNet modules used with the
PowerCommand Control 3300: Universal Annunciator, and HMI Control Panel. The Phase 1
release of the PC 3.3 supports only a few PCCNet devices, Phase 2 will support more.
Warm Up
In this lesson, we are going to look at the optional devices that communicate with the
PowerCommand Control 3300.
We will also give you a chance to work with the optional devices with the controls at your
workstations.
First, let us look at the objectives for this lesson:

Objectives
 Understand the basic operation of PCCNet communications

 Identify the PCCNet devices common to PCC 3300 installations.
 Connect the Universal Annunciator and/or HMI114 to the PCC 3300 genset control and
simulator.
 Configure the Universal Annunciator and/or HMI114 used with PCCNet and the simulator.
 Test the Universal Annunciator and/or HMI114 with the PCC 3300 genset control and
simulator.
 Participants will use InPower and gain more experience with the setup process and screens
found in InPower.

PCCNET Overview
 PCCNE T is a flexible communication system that
uses a standardized proprietary protocol unique to
Cummins P ower Generation
 PCCNE T provides device to device connectivity and

is supported by many of the P owerCommand
genset controls. It is a dynamic system that supports
two way communications between many devices.
 The list of available devices is subject to change

from time to time with the addition or subtraction of
devices, or device availability differences from
region to region or application to application.
Visual 6-2
PCCNet is a proprietary communication

system used on PCC 3300 and several
other PowerCommand controls and
devices.
PCCNet is a low cost communication system

developed as a solution for simple
networking. A simple network is limited
to only 1 generator set control.
PCCNet provides functional communication
from device to device and it is not for
monitoring or building management
systems. The ModBus feature is better
suited to support this.

PowerCommand PCCNET Overview

 2-Wire RS-485 Data Connection
 2-Wire Power Connection
 Recommended wire: Beldin #9729
 Up to 4,000 feet network data wire length
 No Termination Required
 Total of 20 PCCNET devices on one network.
Visual 6-3
PCCNet Basics on the PCC 3300:

 Two Data Wires and Two Power wires
needed. Beldin #9729 shielded data cable
is recommended.
 DATA TERMINALS ARE
POLARITY SENSITIVE!
A = + = 1 & B = - = 2

 Power Terminals are TB1-5 (+) and TB1-

3 (B+ Return)
 Up to 4,000 feet maximum network
length with no terminations needed.
 PCCNet data connections MUST use a
daisy chain topology
 Maximum is 20 devices. This count
includes the HMI display and bar graph.

PCCNET Communication Operation

PCCNet is a Token Passing Network
 The authority (Token) to speak (broadcast) passes from

device to device on schedule.
 Sequence of this schedule is determined during arbitration

(Initializing Communication) at power up.
 Each device knows who is next in line.
 The Token holder is the only device allowed to speak.
 If there are no communications from a device, and this

exceeds 10 seconds, ALL other devices arbitrate again.
4
Visual 6-4 PCCNet Operation
Broadcast Messages are output messages from a

device that has a hard-wired input. Broadcast
messages are sent out:
• every time the input changes, or
• every five seconds.
Gensets broadcast NFPA-110 data to the
network. Annunciators listen for these
messages. Annunciators will also broadcast
updates of their hard-wired inputs.
The token is passed from device to device in
sequence and each device reports its status
within the 5 seconds it takes to pass the
token throughout the group.
If a device is unplugged or if it fails, the rest of
the network will notice the absence and will
re-negotiate the communication sequence.

PCCNET Devices – PCC 3300

PCC 3300 communicates with these devic es
 HMI 320 plus Remote HMI 320
 HMI 220 (Specific applications only)
 AUX101 & 102 Module (Max. 2 set) (Available @ Phase 2)
 HMI 112 (Bar Graph) (9 Bar Display only)
 HMI 114 (Horizontal Bar Graph)
 HMI 113 (Universal Annunciator)
 MCM 3320 (Someday)
 This list may change with the addition of new or special devices
Visual 6-5 PCCNet Devices
These are the most common devices that you

can expect to encounter on a PCC 3300
application.
 HMI 320 – Previously called a display,
touch screen, or customer interface.
 HMI 220 – For special product
applications only. Special programming
of the HMI is needed for it to
communicate to the PCC 3300
 AUX 101 & 102 – Remote relay device
with expansion module. The PCC 3300
will not communicate to the AUX 101
until the release of Phase 2.
 HMI 112 –Bar graph display. PCC 3300
calculates power factor, so only the 9
column display P/N 0300-6050-01 will be
found with PCC 3300 controls.

 HMI 113 – Universal Annunciator. This

item was the original PCCNet device and
it was first used with the PCC 2100
control. It is primarily used in the North
American market, but it is sometimes
found in some global projects.

PC 3.3 PCCNet Architecture

HMI114 HMI113
HMI320
Option Option
PCC3300
PCCNet
Network
(4 wire)
AVR Pow er Stag e
Not a
PCCNet
device
Remote HMI320
Option
AUX101&102 (Fut ur e)
AUX 1 03
6

Visual 6-6 PCCNet Architecture

Configuring w ith InPow er
This value is determined during initial arbitrations.

7
Visual 6-7 PCCNet setup with InPower
There is one folder devoted for configuring

PCCNet devices in InPower.
Phase 1 of the PC 3.3 control will not
communicated to the AUX 101/102 so
InPower will only show setup for the
HMI 113 and the other supported PCCNet
devices.
The Annunciator configuration process is
exactly the same between PC 2.X and PC
3.X
There is a ModBus annunciator for use in
Paralleling Master Control systems. Some
details about that annunciator will be
covered in the ModBus lesson.

InPower allows you to configure some of the

PCCNet device to launch a fault that will
tell you if a device is no longer able to
communicate on the network.
You have the option to configure a device to
ignore a device that is no longer
communicating by leaving at the default
Non-Critical Device Response, or you can
set it to a Critical Device Response.
If you have multiple HMI 320s in the system
and only 1 fails its communications, the
other HMI 320s will display a PCCNet
failure alarm.
The “PCCNet Device Failure Time Delay”
is adjustable from 0 seconds to a
maximum of 250 seconds. If the PCCNet
system cannot re-establish
communication to the device set to
Critical Device Response by the end of
this set time, a fault will be generated.

HM I 113 Universal Annunc iator
Visual 6-8 Universal Annunciator
The PCCNet Annunciator has Network and REMEMBER! The annunciator only works
Physical inputs. with PCCNet or hard-wired installations,
This annunciator supports both Network and cannot be used in a LonWorks based
wiring and discrete wiring terminals network.
There can be up to four annunciators in a

network. If their configuration modes are
different, they will display different
information.
There is a Universal Annunciator Operator’s
Manual available (900-0301) that covers
installation and service topics, and there is
a quick reference card (900-0304) that
provides configuration notes.

PCCN et HMI 113 S witch Settings

Setup Mode
Must be
ENABLED to
write changes
to the PCCNet
setup.
Inputs at the
Annunciator can
be configured
as faults to be
displayed on
the HMI 320
screen.
Output relays at
the Annunciator
can be set up to
actuate for any
fault code
originating from
the PC 3.3
Visual 6-9 Annunciator Switch Settings
InPower is used for changing PCCNet

Annunciator Switch Settings and can only
be changed when the device is
communicating with the PCC Genset
control
Faults 1, 2, & 3 are fault inputs FROM the
annunciator TO the PCC 3300 and
displayed on the HMI 320.The text
inserted into the Value box will be
displayed when the input is active.
The PC 3.3 can control four (4) output relays
located on the Annunciator. Insert the
genset fault/event code number you desire
into the value area and when it becomes
active at the control, the control will send a
relay close command to the Annunciator.

HM I 112 Bargraph
10
Visual 6-10 Vertical display Bargraph
The HMI 112 is optional and in rare

occasions, it may be encountered on a PC
3.3 system. It has previously been referred
to as the Bar Graph display .
The PCC 3300 is able to and does calculate
Power Factor, therefore only the optional
P/N 0300-6050-01 HMI112 version that
has 9 bars is used.
There are no setup parameters for this device
in InPower or in the HMI 320 setup
screens.
The device is truly and completely Plug &
Play

HMI 114 Bargraph

J 6 J1
2 1 5 4 3 2 1
J 1 J 3
8
J 6
J 3
0300-6366-02
10

Visual 6-11 Configuring the Universal Annunciator
The HMI 114 is a new bargraph and is an

optional device.
There are no setup parameters for this device
as it is truly a plug & play device.
The J3 connection on the back of the HMI
114 is the same as J29 connection of the
HMI 320. If this jumper is in place
between J3-4 & 5, it will keep the system
awake at all times and will not allow it to
go into power-down mode (Sleep).

PCCNET Troubleshooting
 The HMI fault response type feature provides a way to

deduce PCCNet communication problems.
 HMI display capabilities also allow checking of the

network integrity.
12
Visual 6-12 Troubleshooting PCCNet systems.
Troubleshooting PCCNet networks can be

easy ---- if you want it to be!
As mentioned previously, PCCNet is based
on an EIA communication standard
referred to as RS485. This standardized
industrial protocol has been in use since
the 1960s and is well understood in the
electronics industry. There are many
commercially available testing tools such
as protocol analyzers, signal strength &
interference testing equipment and media
test equipment. If you are experienced
with and/or have access to such tools, use
them. If you are unfamiliar with such
items, there is no need to invest in
additional equipment beyond your usual
PowerCommand troubleshooting
equipment.

InPower is an excellent troubleshooting tool

when working with PCCNet networks.
Use it to check if a device is enabled. The
InPower communication system that is
used on the PCC 3300 is actually a
PCCNet system so if you are able to
connect to the HMI or to TB15, then you
know PCCNet is operational on those
items.
The most common and best tool available is
your own ingenuity. Here are some
suggestions that my help you reason and
figure out the cause for a network
problem:
 Shut down power to the entire PCCNet
Network. When power is restored, each of
the devices will try to reestablish
communication and “arbitrate”. If one or
more of the devices was confused, it may
begin working properly after cycling
power.
 Wire problems are the most common
failure. Check continuity of each of the
comm.. wires and check if B+ and B- is
available at each of the modules.
 If the wires check out ok, try
disconnecting the device at the far end of
the network. Keep doing this as you work
your way back to the PCC 3300, or until
the Network begins to work again.
 Retrieve all the devices in the Network
and bring them all close to the 3300 and
connect them with very short sections of
good wire and see if the system works.
Start connecting each device 1 at a time to
see if one causes the Network to fail. This
technique also helps identify if there are
problems with an environment that causes
communication problems. This helps
identify if the wire is incompatible with
the installation, or if EMI noise is present.

 Check the wire installation throughout the

facility. The communication wire should
cross power lines/conduits or any AC
power in a perpendicular fashion and
should never be run parallel to a line
carrying AC power.
 Pay attention to the facility! Look around
you.
During troubleshooting, it is common for
someone to assume the device they know
the least about is the problem component.
Resist this temptation. Check the things
you know the most about and reach a
conclusion about a failed component after
a process of elimination trial.
Sometimes a device will fail, but most
importantly, do not ASSUME that the
device failed – try to prove it! Look for a
reason for it to fail too.

Activities
6-1 Universal Annunciator Connections

6-2 Configure Annunciator for Fault Inputs
6-3 Configure Annunciator for Relay Outputs
6-4 Quiz
13

Visual 6-13 Activities
The Activity Guide for Section 6 PCCNet

exercises is found in Section 15.
At this time, please work as teams to
complete these activities.

PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300

PCCNET
Wrap-Up
In this lesson we have learned about the PCCNet network and devices used with the PCC
3300.
This lesson gave us the opportunity to learn about the about installation of the PCC 3300
PCCNet communication system. We covered the connections that must be made from the
genset control to the various components/devices and why each is important.
Q. Are there any questions we have not yet covered on PCCNet for the PCC 3300?


PCC 3.3 & PowerCommand Control 3300 PowerCommand Control 3300 ModBus
PowerCommand
3.3
Section 7:PCC 3300 ModBus Communication

Visual 7-1 ModBus Communications
Participant’s Guide Section 7 Page1

Section 7:
ModBus and the PCC 3300.
Equipment Needed
Materials Needed
PowerCommand Control 3300 Participant’s Guide (CMT6068-EN-PG)
PC 3.3 SERIES MODBUS REGISTER MAP MANUAL 900-0670 (APPENDIX D)
Appendix B – Using ModScan Software (CMT6068-EN-PG)
Computer: must meet system requirement to effectively operated InPower 7.0 or higher.
InPower Connection Cable (P/N: 0541-1199)

Warm Up
In this lesson, we are going to look at the on board ModBus system that communicates information
from the PowerCommand Control 3300.
First, let us look at the objectives for this lesson:
Objectives
 Understand the basic operation of ModBus communications

 Identify the ModBus port on the PCC 3300 control.
 Connect to the ModBus port on the PCC 3300 control.
 Configure and setup the ModBus port on the PCC 3300 control using InPower or the HMI320.
 Test the ModBus communications.

ModBus Overview
 ModBus is a industrial communication protocol
system that is not controlled by or influenced by
Cummins P ower Generation. It is considered a
“Open Protocol”
 ModBus is not related to PowerCommand Networks

or PCCNet.
 ModBus operates using industry standards and in

the case of Cummins P ower Generation genset
controls, it is usually used as a communication
protocol that enables others to gain communication
access to the generator set control.

Visual 7-2 ModBus overview
ModBus is an open communication system

available onboard the PCC 3300
ModBus was developed in the 1970’s as an

industrial protocol to work with Modicon
PLCs (Programmable Logic Control)
Unlike PCCNet, ModBus does provide
functional communication for monitoring
or building management systems. The
ModBus feature is well suited to support
this.
All of the content of the ModBus
communication messages are
predetermined and cannot be changed in
the field.
(The term message has a very specific
meaning in ModBus, so from now on we will
call these packets of info Registers .)

ModBus Overview
 CP G uses ModBus over Serial Line Protocol.
 ModBus S erial Line protocol is a Master - Slave protocol.
 A Master-slave type system can have only one master node and multiple
slave nodes.
 The PC1.X, 2.X & 3.3 controls are a Slave Node.
 A bus can accommodate 32 devices without repeaters, but up to a
maximum of 247 slave nodes can exist on a large ModBus network bus.
 ModBus can communicate using many different physical media. The P CC
1302 uses EIA-485 (RS485) two-wire (2 wire) interface.
 ModBus can use two different serial transmission modes: RTU mode or
ASCII mode.
 All ModBus transmissions are verified for CRC errors.
Visual 7-3 ModBus overview
The PCC 3300 ModBus port is a serial port.

It follows EIA standards and is
configured for rs485:
ModBus is comprised of multiple different
transmission modes. The most common
modes encountered on CPG systems are:
 RTU. (modern & most common)
 ASCII (considered old & rare and is
not used on the PCC 3300)
ModBus is a Master – Slave communication
system
 There can only be 1 master.
 There can be up to 247 slave devices.
 The PCC 3300 can ONLY be a slave
device.
 The slave address can be assigned in
the field.

In a master – slave system, the master device

requests data from a particular slave
device. This is called a poll. The register
sent back from the slave device is called a
response.
The slave device does not send any data
unless it is polled by the master. If the
master device sends a command such as a
engine start command the slave device
will still send back a response
acknowledging that it received the
command register (poll)
Many communication systems use a CRC
error checking scheme. ModBus does too,
and it is highly effective.
CRC stands for Cyclical Redundancy Check,
which is a way of checking if a message
is corrupted or damaged during its
transmission. Sometimes this check is
called a Check Sum.
CRC errors do NOT indicate that a device is
having trouble or is faulty; it indicates
that the register created by the device is
good at origination, but it is corrupt at the
destination.
Serial communication systems are very
susceptible to electro-magnetic
interference and other electronic noise, so
it is not considered the best choice for
installation into a power generation
environment. Therefore the CRC error
checking feature built into ModBus is
very important.
The PCC 3300 is not able to warn you of
CRC errors, but the master device in the
system will. Since the master device is
usually the responsibility of a 3 rd party,
you will need to work with them to
identify and resolve the problem.

TB15 Data / Service Interface

Pin 5
Pin 1

Visual 7-4 ModBus Connection
TB15 serves a dual function:

• When connected to InPower, it serves as a
service port connection.
• When connected to a ModBus master
device and enabled, it will serve as a
communication port connection.
TB15 can also transmit PCCNet, but the port

has to be configured for one or the other, it
CAN NOT serve both communication
systems simultaneously.
For wire connection details, refer to wiring
diagram 0630-3440.

ModBus w ire and PCC 3300

 The ModBus network wire type and length is specified by
ModBus standards, not by Cummins Power Generation.
 Use stranded wire to endure the vibration present on gensets.
 Refer to www.modbus.org for details and wire specification.
 The responsibility for meeting these standards belong to the

integrator who is attaching to the control.
 If installing the iWatch product to communicate with the PC

3.3, refer to the iWatch installation guide for information about
the proper wire.
5
Visual 7-5 ModBus Cable
Remember the previous statement about

serial communications being susceptible
to EMI and other noise. The type of
communication cable used can affect
communication reliability too.
Designers of Building Management Systems
(BMS) usually have a specification for the
cable used in their system. It is rare that
CPG installing technicians will be
requested to supply the ModBus
communication cable.
If installing an iWatch to monitor a PCC
3300, try to keep the ModBus cable as
short as possible or practical. Details of
the installation will be found in the
iWatch installation guide.
A 120 Ω, ¼ watt terminator resistor is
commonly installed in long bus applications
to suppress signal reflections.

ModB us Setup with InPower

Visual 7-6 InPower Configuration of the ModBus port
There is a ModBus Setup folder located

under the Setup folder of InPower.
There are 8 adjustments found in the ModBus
Setup folder along with 11 monitor
functions, and 10 switch functions:
Connect InPower using the normal 541-1199
tool connected to TB15. The Setup Mode
Enable must be set to “ Enable” for
adjustments to take effect.

In Po we r – S etu p - M od Bu s
Setup Mode must be ENABLED

J 14 and TB15 provide ModBus communications
Setup functions specific to the J 14 connection are labeled

7
Visual 7-7 InPower Configuration of the ModBus port
Refer to section 5-57, “ModBus Setup” of the

Service Manual #900-0670.
On page 5-58, all the ModBus submenus are
presented.
There are setting for the TB15 connector and
there are adjustments for the J14
connector.
Many of the adjustment parameters have a
drop box in the value field; a few allow
direct entry of a value.

The ModBus Node Address is default as 1;

however it may need to change.
The J14 ModBus Node Address is default as
1 also; however it can be changed to a
different address than the TB15 address.
Recall that a ModBus network may contain
up to 247 nodes. The node address
identifies to the ModBus Master which of
those 247 devices is the PCC 3300.
The ModBus Baud Rate adjusts the speed of
communication that the PCC 3300 must
be set at to communicate in the Network.
The ModBus Parity setting changes the
register structure per the requirements of
the network design. The default is Even.
The Parity adjustment for TB15 can be set
differently than the Parity adjustment for
J14.
ModBus Failure Time Delay can trigger fault
2939 – ModBus Failure if the Master
response time exceeds the set amount of
time.
The ModBus Communications Lost Response
Method can be set to reset in case there is
a loss of communication.
The ModBus settings are usually requested
by the network installer. The Failure
Time Delay and Lost Response Method
settings are usually chosen by the CPG
installer.

In Po w er - M o nito r - M o dB us
Monitor Points
Monitor Points
Visual 7-8 ModBus Monitor
Participant’s Text Trainers Text

presented.
The visual shows the monitor points.
The appropriate setup values will be
determined by the system integrator, or
they will be called out by the appropriate
installation guide provided with the CPG
communication kit.

InPower
Of course, it is not possible to monitor a
communicating ModBus network with
InPower since the TB-15 port is used for
ModBus communication and for
connection to InPower.
The data displayed in the Monitor screens is
recorded data.
 Bus Message Count – this is the number
of times that the PCC 3300 has been
polled by the Master.
 Slave Message Count – this is the number
of times the PCC 3300 has responded to
polls.
 No Response Count – this is the number
of times the PCC 3300 HAS NOT been
able to respond.
 CRC Error Count – this is the number of
times the network has seen a faulty
register.
 Exception Count – this is the number of
times the system has seen a corrected
version of a faulty register.
CRC errors are encountered when a register is
sent correctly, but the receiving device
views it and finds errors in it. The
receiving device will automatically
request that the register be sent again.
This error count is very valuable to you if
you are troubleshooting ModBus
communications. It indicates that the
devices are trying to send or receive
messages, but someplace along the
transmission stream, the register is being
damaged. Start inspecting the wiring and
connections. The problem could be
caused by poor quality or inadequate
wire, poor connections, or environmental
issues such as electromagnetic
interference.

ModB us S ettings
 The ModBus adjustments and settings are also
accessible through the HMI 320.
Visual 7-9 HMI

presented.
The visual shows the HMI screen layout.

Mod Bus Te sting & Troub leshooting
 ModBus Register Map – Provided by CPG
 ModScan – Available as freeware
 InPower – Has some minor test capability.
10

Visual 7-10 Testing ModBus systems.
The ModBus register map is available from

CPG. A copy is attached to the Service
Manual, and is found in Appendix D.
ModScan is 3rd party software that can be
used to prove to customers that the
ModBus port is operational.
InPower can be used to assist with
troubleshooting a ModBus installation
that may not be communicating reliably.

ModB us Register Map

NFPA110 bitmap (Register 40016)
NFPA 110
Description Bit
Common Alarm 0 (MSB)
Genset Supplying Load 1
Genset Running 2
Not in Auto 3
High Battery Voltage 4
Low Battery Voltage 5
Charger AC Failure 6
Fail to Start 7
Low Coolant Temperature 8
Pre–High Engine Temperature 9
High Engine Temperature 10
Pre–Low Oil Pressure 11
Low Oil Pressure 12
Overspeed 13
Low Coolant Level 14
Low Fuel Level 15 (LSB)
MSB = Most Significant Bit

LSG = Least Significant Bit
11
Visual 7-11 ModBus Register Map
Register maps are specific to the product. The

register map for a PCC 3300 control is the
same as the map for the PCC 2300
control. Other generator sets and systems
may use different maps, be sure you are
referencing the proper map.
The map provides details about the different
types of individual registers. It can tell
you the many details about how to poll it,
calibration details about a specific
register, or the combinations of
information contained within a particular
register.

Mod Scan testing ModScan

requests to
Register Type communicate
Slave address
Device
responses
to
Register ModScan
address to requests
begin polling
Number of
registers
to be
polled
ModBus register and the data
communicated from the device
12
Visual 7-12 ModScan Software
ModScan is not a Cummins product. It is

available as freeware from WinTech via
Web download or through several other
free sources. The free version limits
connection time to an active ModBus
network to 3 minutes, and then it stops
polling. A code to enable unlimited
connection time is available for purchase
from WinTech.
CPG encourages the use of ModScan as a
testing tool to prove to customers and
integrators that the ModBus port is
communicating properly. There are other
software products that can be used too, but
ModScan is considered a simple to use.

ModScan Software.
Once connected, ModScan will poll registers
and will allow write registers. Write
registers will send a command to the
generator set. A common command is to
START the genset. The genset must be in
Auto for the command to take effect.
It is a simple process to configure ModScan
to communicate with PCC 3300, but if
you need assistance with proper setup and
operation, refer to the details found in
Appendix B
The standard InPower communication cable
from the computer com port to the PCC
3300 TB-15 port can be used. The
RS232/RS485 converter must be used
too.
Refer to the ModBus register map to help you
identify the register that you may wish to
poll.
The 2 most common register types to check
are:
1. Coil Status – this is an on/off
statue indication. 1=ON & 0=OFF
2. Holding Register – this
indicates a message indicating up to 16
bits of information. Example in visual
7-9 shows register #40016. It will
appear {0000000000000000}
A common test is to “Write” bit “1” to
register 40300, the genset should start if
the control is in automatic mode.
(Remote)
Register 40302 can activate the Emergency
Stop. If this is activated via ModBus, you
cannot reset the shutdown at the genset
control until the ModBus command is set
to 0.

ModScan Troubleshooting
 This message indicates the device sent a response,

but the message string had problems.
 This shows that ModScan is trying to talk to the

device but it is not getting proper responses.
13

Visual 7-13 ModScan software
Refer to the Appendix about operating

ModScan. .
Notice the message line in Visual 11 and in
Visual 12. The line in Visual 11 indicates
that ModScan is not able to communicate
to anything, but the line in Visual 12
indicates that ModScan is talking to a
device but the information is not
understandable.
Try to keep the length requests as short as
possible, and do not attempt to poll across
empty registers.


Quiz & Activities
7-1 Quiz (found in section 15)

7-2 Connect InPower and Configure
7-3 Configure at the HMI
7-4 Connect with ModScan (optional)
14

Find the Section 7 activities in the Section 15.

Work with partners to complete each
activity.

Wrap-Up
In this lesson we have learned about the ModBus communication system and the ModBus feature
built into the PCC 3300.
First we talked about the basics of ModBus communications and some of the specific information
about how the system works.
Next we talked about ModBus connection requirement on the PCC 3300, its connectors and wire
information.
Next we talked about the setup and configuration using InPower and the HMI320 setup.
Then we talked about the testing and troubleshooting. This was separated into 3 separate areas that
required additional information.
Lastly we went through each of the testing and troubleshooting tools and information available to
technicians.
This lesson gave us the opportunity to learn some basics of ModBus and a little about this
communication feature on the PCC 3300. This section is a basic introduction to ModBus
communications with PCC control and communication systems. We will continue delving deeper
into ModBus communications with more advanced controls. This section serves as a prerequisite
for training on some of the more advanced PCC controls
Q. Are there any questions we have not yet covered on ModBus for the PCC 3300?


PCC 3.3 & PowerCommand Control 3300 PGI
PowerCommand
3 .3
Section 8: PGI CAN

Communication

Visual 8-1 PGI CAN Communications

Section 8
PowerCommand Control 3300 & PGI

Materials Needed
• PowerCommand Control 3300Participant’s Guide Guide (CMT6068-EN-PG)
• PC with InPower v7.0 or higher installed
• Registered Dongle
• InPower Connection Cable Kit #541-1199
• INSITE v7.1 or higher installed
• Peak System Adapter and associated software/drivers installed
• Inline Adapter Kit w/Software and Drivers Installed

Warm Up
In this lesson we are going to learn about the Power Generation Interface (PGI) for the
PowerCommandControl 3300.
Objectives
After completing this lesson, participants should be able to:
• Identify the system architecture of a PGI system.
• Locate components of the PGI system.
• Determine how a PGI system is working with the PowerCommand Control 3300.
• Develop general troubleshooting skills.
• Identify test equipment for troubleshooting PGI system.
• Set-up software and drivers for test equipment usage.
• Working knowledge and usage of test equipment to hook up to a PGI system.

What Is PGI?
 Cummins Power Generation is moving away from the Full

Authority Engine & Genset controller as found on the PCC
3200 and PCC 3201 (governing, engine protection, features,
etc) and towards communicating with the EBU controllers
like the Motorola CM850, CM876 etc.
 New Cummins Power Generation software and hardware

interface has been developed for this purpose. This new
interface is referred to as the Power Generation Interface
(PGI)
Visual 8-2 What is PGI?
The Power Generation Interface (PGI)

Specification is intended to drive
commonality in the On-Engine Controls
(diesel and gas) across the entire CPG
product line.
Two of the main areas that make up PGI are:
• Physical Datalink
• Electrical Datalink
Datalinks are a way to communicate

information between systems.
CPG uses Multiplexing Datalinks to send or

receive multiple messages among
electronic modules using a serial bus.

Past Control Product PCC 1.x, 2.x and 3.x

Product
PCC3200 (1 Box ) Corporate
PCC3201 (1 Box & 2Box) AVR Genset PCC3300 w/ CAN
PCC2100 (1 Box & 2 Box) PCC2300 w/ CAN AVR
PCC1301 (1Box ) PCC1302 w/ CAN
CMxxx CMYYY GCS CMxxx

9
FAE / Mech. 3
FAE / Mech. Engine Alternator Alternator 9
Engine 1
J
/
CMxxx With PGI CMYYY W/o PGI N
A
C
e
c
a
f
OEM Control OEM Control OEM r
e
t
w/ CAN Control
n
I
GCS
CMxxx
FAE / Mech. FAE / Mech.
Engine Engine
G-Drive
OEM No GCS !!!
3

Visual 8-3 PGI Architecture
In Visual 8-3 you see a graphic representation

of how the past product lines operate
(PCC 2100, 3200, 3201, and 1301). They
operate by direct engine control or with
the use of a Genset Controller (GCS).
PCC 3300 can communicate directly with a

Cummins Engine Controller Module
(ECM) using PGI or to other engine
manufacturers ECM using CAN
standards. This training covers PGI basics
and communication to Cummins engines.

Required Hardware/Software
 Inline 4/5 Datalink Adapter (note: Inline 2 will work with
CPG products and you do not need to install drivers with this
product)
- INLINE 4 Kit P/N - 4918190
- INLINE 5 USB Kit P/N – 4918416
 INSITE V6.5.1
– INCAL Calibration Download
 InPower V6.0
– CM850/CM876 Products
– All Except QSX15, QSL9-IND
 Peak System Adapter

– USB CAN adapter
– PCAN Explorer, PCAN View
Visual 8-4 Hardware/Software
Participant’s Text Trainer’s Guide
In order to view/change parameters and

perform certain tests, technicians will
need InPower, INSITE, and Inline
software/hardware/drivers in order to
connect to the engine ECM and PCC
3300 control.
An easy and cost effective way to view

signals and perform simple
troubleshooting tasks is to use the Peak
System Adapter. While the Peak Sys
Adapter does not allow you to perform
calibrations, it is an easy tool to operate
and see if the system ECM and PCC are
communicating properly.

INSITETM - Monito r & adjus t parameters and featur es


Visual 8-5 INSITE
INSITE is an engine tool that allows

technicians to perform a variety of engine
diagnostic checks as well as calibrations
and adjustments.
With the introduction of the PGI, PowerGen

technicians are needed to understand this
tool for troubleshooting as well as setup
of the engine. With the increased usage
of ECM operated engines for emissions
standards, technicians should attend a
course on INSITE to gain more
familiarity than this course will offer.
You can get INSITE information from:

insite.cummins.com

INPOWER TM – Adjustments
Visual 8-6 InPower
With InPower you are able to click on the

CORE II ECS icon and perform a variety
of different tests on the system. You
cannot perform these tests while
connected to the controller and you must
be connected to the engine harness 9-pin
Deutsch plug.
Most notably you are able to perform the

Witness Testing Procedures as seen in the
Installation Section of this guide.

Peak System Adapter
Visual 8-7 Peak System Adapter
The Peak System Adapter allows technicians

to view CAN messages broadcasted on
the system. Here is an example:
Message Interpretation: 18FE7C00h
 18 – Priority of the Message
 FE7C – PGN (Parameter Group Number)
 00 – Source Address ( ECM- Parent –
Source Address 00, Child 1 – Source
Address 01, Child 2 – Source Address 90;
PCC Source Address is DC)

You can purchase the Peak Adapter from the

Cummins Hardware Shelf or from
www.gridconnect.com/usbcanin.html
Not only will you need to order the adapter

itself, but you will need to buy an inline
CAN terminator. You will also need a
CAN cable that allows you to connect
from the 9-pin plug on your Peak System
Adapter to the 3-pin Deutsch connector
on the genset.
After you have all of the required hardware,

you will need to download the software
and associated drivers.
Drivers to operate the Peak System Adapter

can be ordered from the Cummins
Software Shelf. You will need to order
these software tools:
• Peak All In One Driver

• PCAN Explorer (optional)
Once you have the hardware and software
installed, you can connect to a device and
read the messages. The software will
have a default baud rate of 500Kbit/sec.
This needs to be changed to 250Kbit/sec
in order to communicate with the PGI
system.
You do not need the engine running to see

messages transmitted on the system.
Once you have the Peak System Adapter
setup properly you will be able to connect
and read the messages sent. This tool
provides an easy way to help determine
whether the ECM (s), PCC, or backbone
is faulty.

Physical Datalink
J 1939 Datalink Connector
Location: Engine Harness:
 3-Pin Plug Cummins P/N – 3164635 (detail 1), Deutsch DT06-3S-E008
 3-Pin Receptacle with 120Ω resistor Cummins P/N – 3163051, Deutsch DT04-3P-P006
Location: Genset Harness:
 3-Pin Receptacle Cummins P/N – 3163918 (detail 2) Deutsch DT04-3P-E008
The 3-Pin connectors ONLY supply the SAE J 1939 support (no battery voltage supply)
Pin Signal
A J1939 Datalink (+)
B J1939 Datalink (-)
C J1939 Datalink (Shield)
Visual 8-8 J1939 Connector
The first portion of PGI we will cover is the

PHYSICAL datalink. There are three
main parts of the physical datalink:
Backbone, Plugs, and Stubs.
The Backbone consists of a three-wire system
that has a high, low and a shield wire. In
visual 8-5 above you can see the pinout of
this system.
There are two different types of Plugs that are
used on this system. The first is the plug
that has orange keys inserted into the
Deutsch connector. The second is a
termination plug. This is verified by a
blue key and is capped with a 120ohm
resistor receptacle.

Basic J1939 Backbone and Stub Configuration
Visual 8-9 J1939 Backbone
The total length of the backbone is not to

exceed 40m (approx 131 ft) in length.
This is a J1939 SAE standard
requirement.
The Stubs are depicted in Visual 8-6. These
stubs need to be kept to 1m (approx 3 ft)
in length.
There are a maximum of 30 different devices
that can be installed on the backbone at
once.
To minimize message reflections (echo) on
the data link, a 120ohm terminating
resistor is needed at each end of the
backbone.

Extending length of J1939 backbone
10
Visual 8-10 Extending J1939
If you need to extend the length of the

backbone, you can do so by removing the
terminating resistor on the end you wish
to extend, add the required length of
backbone (remember this extension plus
the original backbone can not exceed 40
meters in length) and reinstall the
terminating resistor at the end of the
extended piece.
As an example, you may want to extend the
backbone if you are removing the
controller pedestal from the genset and
mount it elsewhere.

J1939 Topology
Coolant Level
Switch
Fuel/Water
Separator
11
Visual 8-11 J1939 Typology
Participant’s Text Y ou must also connect shield at each device.

Notes:
Visual 8-8 shows a typical J1939 topology.
You can see that some of the stubs are
going to such devices as the Fuel/Water
Separator and Coolant Level Switch.
All stubs that are unused must have
receptacles installed on them.
Ensure you ground the shield at onepoint
only.

Harness Block Diagram
Engine Harness Genset Harness PCC Harness

Coolant level 4-pin 3-pin J1939
connector (Plug) connector Controller
with 120 Ohm harness Engine harness
resistor ‘Y -pin’ connector
16-pin power connector
connector 16-pin power
50-pin OEM (Receptacle) connector (Plug)
60-pin engine
connector PCC
connector
Board
ECM
power
ECM
9-pin service Pedestal
connector J1939 3-pin J1939 3-pin
connector connector
(Plug) 3-pin J 1939
(Receptacle) connector
with 120 Ohm
resistor
Starter relay
Extension HMI
Alternator Battery ‘X-pin’ Connector to mate
Harness
with extension harness
12
Visual 8-12 Harness Block Diagram
Visual 8-9 show the different components and

connections made on a genset. It is broken
down into the Engine Harness, Genset
Harness and PCC Harness.

9-Pin Deutsc h
Pin ID
A Datalink Return
B Datalink Power
C J1939 Datalink (+)
D J1939 Datalink (-)
E Datalink Shield
F Unconnected
G Unconnected
Service connector H Unconnected
9-pin Receptacle Cummins P/N: 3163295 J Unconnected
Deutsch HD10-9-1939P
Location: EngineHarness
13

Visual 8-13 9-Pin Deutsch
The 9-pin Deutsch connector is where you

will connect with your Inline adapter kit.
It is also a location where you can
perform some testing of the system. Pins
A and B should have battery voltage
present. Battery voltage present at this
connector is needed to power-up your
Inline adapter.

Troub leshootin g Datalinks

Check Topology
Check Back Bone is not longer than 40m
Check there is 120 Ohm resistor at each end of the back bone. 55 - 65 Ohm
Check each Stub is not longer than 1m
Check that stubs are located appropriately on the datalink (not opposite each other)
Check Continuity
Check that the J1939 high and J1939 low are not open ciruit < 10 ohms
Chec k t hat the J1939 hi gh and J1939 l ow are not short ed t o ground > 100k ohm s
Check that the ground wire is not open circuit < 10 ohms
Check that sheiding wire is not open ciruit < 10 ohms
Check that all grounds are the same
Check all ECM are commu nicating
If you have a Inline II, connect it and look at J1939 light on the adaptor. If the J1939 light
is flashing, connect one ECM at a time to determine which ones are communicating.
14
Visual 8-14 Troubleshooting Datalinks
This is a simple chart to follow in order to

check the physical datalink.
If you are having communication errors these

are good points to start with the
troubleshooting process.
 Keyswitch should be cycled every time

there is an engine shutdown in order to
save important ECM data (Ex: fault codes,
ECM run time etc.). Wait 30 secs or more
before engine restart.
 There are NO Fault Acknowledge inputs to
the ECM to reset active faults. The ECM
will broadcast an active fault as long as the
condition is true.

 You can remove one terminating resistor

and you should be able to see the other
resistor of 120 ohms. You can replace that
terminating resistor and remove the other
one to check for 120 ohms on that resistor.
 While both terminating resistors are

installed, remove J11 from base board.
Check resistance between J11-19 and J11-
20. Resistance should be approximately 60
ohms if the backbone is ok. If you have
less than 55 or more than 65 ohms there is
a potential problem with an open or ground
on the datalink.
Here are some rules to apply for an open or

shorted CAN circuit.
CAN_H is Shorted to VBat - Data

communication is not possible if VBat is
greater than the maximum allowed
common mode bus voltage.
CAN_L is Shorted to GND - Data

communication is possible, because the
bus voltages are within the allowed
common mode voltage range. Signal-to-
noise ratio is reduced and radiation is
increased. The electromagnetic immunity
is decreased.
CAN_H is Shorted to GND - Data

communication is not possible.
CAN_L is Shorted to VBat - Data

CAN_H is Shorted to CAN_L - Data

Loss of Termination Resistor - Data

communication via the bus may be
possible, but with reduced signal-to-noise
ratio.

Loss of Termination Resistor - Data

communication via the bus may be
possible, but with reduced signal-to-noise
ratio.
Topology Parameter Violations (i.e., Bus

Length, Cable Stub Length, Node
Distribution) - Data communication via the
bus may be possible, but with reduced
signal-to-noise ratio

CM850 – QSB5/7, QSL9,

J3 QSK19/38/50/60
J1
J2
J1
Connector Connector Connector

J2
Function Type Name
Engine 60 Pin J1
OEM 50 Pin J2
P/N 3163071
Battery 4 Pin J3 J3
Power P/N 3165121
Note: J3 only required for QSB 5/7 and
* Please Refer to the appropriate Harness Wiring
QSL 9
15 Diagram for Pinouts of J1, J2, and J3
Visual 8-15 CM850 ECM
The CM850 is one of the basic ECM’s that

you will see on our gensets. The ECM
will:
• Perform all Engine Protection with the

exception of Low Coolant Level & Low
Coolant Temperature
• All metering of engine pressures,

temperatures, speed, flow, etc.
• All fueling and emissions control

• Engine Speed Governing
• Control of Idle speed and ramping to Idle
from rated speed

CM876 – QSM11 T3
Connector Connector Connector

Function Type Name
Engine 60 Pin J1
OEM 50 Pin J2
P/N 3163071
Battery 4 Pin J3
Power P/N 3165121
16
Visual 8-16 CM876 ECM
The CM876 is another one of the basic

ECM’s that you will see on our gensets.
It consists of three connectors. It is very
similar to the CM850, with the exception
of the keyways on the connectors.
You will see the CM210 and CM2250 in the

future. These ECM’s will have similar
physical characteristics.

Electrical Datalink
 The J1939 datalink carries a series of 1’s and 0’s in each
message.
 A 1 is a HIGH voltage differential between the J1939 high and the J1939 low.
 A 0 is a LOW voltage differential between the J1939 high and the J1939 low.
Shield
At a Baud Rate of 250k it is possible for the voltages on the J1939 high and
low wires to change from 0 to 1 250 thousand times per second. Hence a
high resolution oscilloscope is required to be able to view these voltages.
17
Visual 8-17 J1939 Messages
The second portion of the CAN system is the

ELECTRICAL datalink.
Cummins communication is at a speed of

250Kbit/sec.
Connecting an oscilloscope can help you with

some advanced troubleshooting, but it is
being mentioned here to illustrate that
common electronics tools can be used to
help identify problems. This is not a
recommended check.

Signals
Nominal Values
0 1
J1939 hig h 2.5 v 3.5v
J1939 low 2.5 v 1.5v
V 0v 2v
differential
 Since the messages are sent by a voltage differential, it is

essential that all devices are on the same ground plain.
– If the grounds of two ECM’s are different, then a low voltage
differential of one ECM may appear to be a high voltage
differential to another. Hence messages get corrupted and
communication is lost.
18
Visual 8-18 J1939 Voltages
The properties of the J1939 datalink message

are broken down into bits. A “bit” takes,
at most, 0.0000002secs to travel down a
40m datalink.
And an entire message (110bits) takes

0.00044secs to be transmitted. That’s a
possible 2000 messages per second.
If two devices attempt to broadcast at the

same time, the message with the highest
priority wins and the other device “waits”.

Activities
 8-1 PGI Wri tt en Quiz
19
Participant’s Guide Trainer’s Guide
Find the Section 8 Quiz in Section 15. Work

with partners to complete each activity.

Wrap-Up
In this lesson we introduced the Power Generation Interface (PGI) usage with the PCC 3300 for
FAE engines. We covered the basics of what constitutes a PGI system, associated hardware and
software, troubleshooting tools, and some adjustments that can be made on the ECM.
Q. Are there any questions we have not yet covered that you wrote down as you went through
the CBT?
In the next lesson we will learn about the PCC 3300 support materials.


PCC 3.3 & PowerCommand Control 3300 Paralleling Introduction
PowerCommand
3 .3
Section 9: Paralleling Introduction

Visual 9-1

Section 9
PPC 3.3 Paralleling Introduction
Materials Needed

Warm Up
In this lesson we will introduce connections and operation options that can be used with the PC 3.3
in a paralleling environment.
This lesson will not delve into the operation and setup for each of the paralleling modes, but it will
introduce the paralleling abilities of this control.
Objectives
• Understand the different paralleling setups and modes available in the PowerCommand Control
3300.
• Find and understand the paralleling configuration information in the service manual, InPower
and the HMI320.

W hat is Paralleling?
 Paralleling is the synchronous operation of
two or more generator sets connected to a
common bus in order to provide power to a
common load
kW Demanded by Load
kVar Demanded by Load
 Engines Produce kW
 Alternators Make kVAR
2
Visual 9-2 What is paralleling.
The Power Command 3.3 control provides

paralleling functionality for several modes
of parallel operation.
Parallel operation is not a new or unique

feature. It has been offered with many of
the predecessors to the PCC3300,
however: this control provides any
desired mode of paralleling operation as
standard. The control is fully configurable
in the field AT WILL. You no longer have
to contact the factory and purchase new
codes or added features. They are all here.

PC 3.3 Paralleling M odes
 Standalone
 Synchronization
 Droop
 Load Share
 Load Govern
 Power Transfer Control
Visual 9-3 Paralleling Modes
Standalone:
Standalone mode is more like a non paralleling
control configuration. There are a couple
of added features that make this
configuration more desirable than just
using a PC2.X control.
Synchronization:
This is a mode designed to allow the genset to
match frequency and voltage with another
source. In some modes of this operation
the PCC does not control connection to the
source and in some modes the PCC is in
full control of all connection functions.

Sync. Cont: Synchronization is utilized in all

the different paralleling modes beyond the
Standalone mode.
Droop:
Droop is an adjustable feature that can be
turned on as the application requires. The
unit is able to operate in speed droop,
and/or voltage droop.
Load Share:
In Load Share, the PCC is in parallel with
other gensets while isolated from the
utility. The PCC adjusts the speed
reference and the voltage set point so that
the genset takes its fair share of the load.
The genset should run at the same
percentage of its rated load at which other
gensets run.
Load Govern:
In Load Govern, the PCC is in parallel with
the utility. Since the utility frequency and
voltage are fixed, the PCC regulates the
genset kW output and genset kVAR
output, instead of the genset frequency
and genset voltage.
Power Transfer Control:

Power Transfer Control (PTC) is a feature
that will be available during the Phase 2
launch. This feature allows the PCC to act
as the transferswitch control in addition to
acting as the genset control.

PC 3.3 Mode s of Pa ralleling
Visual 9-4 Modes of PowerCommand Control 3300 Paralleling
Modes are a set of operating configurations

that are determined by a setup choice.
This chart is mostly self explanatory.
As you look at the modes from left to right,

the hookup, setup, calibration, and
operation become progressively more
complex.
The following training guide sections will

discuss each mode in detail.

Paralleling Connec tor Location

TB7- Bus Voltage Bus CT Inputs
TB9- Analog I/O TB3 - Customer I/O
TB10- Circuit
Breaker Status TB1 – Customer I/O
Visual 9-5 Control Board Connections
The previous sections only introduced the

function of each of these connectors.
All of these connectors are reserved for

customer or site connections. You may
encounter some factory connections on a
couple of these connectors, but they are
only for options or accessories ordered
with the generator set.
Each connector listed on this visual will be

discussed in the section which uses a
connection on it.

W ire diagram C onnections
Visual 9-6 Common Connection for paralleling
The common connector scheme wire diagram

provides connection information for each
of the paralleling modes.
Beginning on page 12 the Common

Connector Diagram changes focus from
showing genset connection to showing the
paralleling connections.
Page 18 is devoted to showing a table of
optional inputs, outputs and configuration
available on connectors TB3, TB9, and
TB10.
Dotted lines on these diagrams represent
optional connections for the mode of
operation

InPow er Con figuration
Status screens
Monitor the
functions
(OEM Setup - Paralleling

Not available in Phase 1)
Setup screens
provide complete
configuration and
adjustment for all
paralleling functions.
Visual 9-7 InPower
In previous sections we have covered setup

functions for the genset only. InPower
also has configuration abilities for all the
InPower has a large section for monitoring

the paralleling functions. Under the
Paralleling Status folder you will not
find any adjustments.
There are many adjustments and only a few

monitor screens in the Paralleling Setup
folder.
OEM Setup will contain paralleling setup

functions in later releases.

HM I Paralleling Setup Menu s
Any Paralleling operation setup

function available in InPower is also
available through the HMI.
Most HMI operation setup function

require the Level Password.
Visual 9-8 HMI Setup
The HMI will allow complete configuration

of the paralleling setups.
Just like with InPower, the first phase release

will not support OEM Setup of the
There are 6 setup screens available in the

Paralleling Basic Setup menu.

Pa rallel Intro Activities
Visual 9-9 Quiz for Section 9
At this time I would like you to work alone to

complete the quiz.

Wrap-Up
This is an introduction section. This section should encourage discussion.
There are several different state features that were discussed. They were Standalone,
synchronization, Droop, Load Share, Load Govern and Power Transfer Control.
Q. Are there any questions we have not yet covered about this lesson?


PCC 3.3 & PowerCommand Control 3300 Standalone Mode
PowerCommand
3.3
Section 10: Standalone Mode

Visual 10-1

Section 10
PPC 3.3 Standalone Mode
Materials Needed

Warm Up
In this lesson we will cover the Standalone mode operation. We will experience the setup process
and configuration of the control in addition to the physical connections that can be used with the
PC 3.3.
Objectives
This is the first lesson in the series introducing participants to the paralleling features or options.
These lessons will not teach the theory and science of paralleling. It will cover the basics about
connecting, configuring and adjusting the features of this control to optimize unit performance.
Understanding the operation of these features provides a solid base for troubleshooting if
performance problems should ever occur.
Standalone operation will be covered first because it is the most basic. Later lessons will provide
the details about more complex configurations.
• Understand the reason for operating the PC 3.3 in Standalone mode.
• Find and understand the configuration information in the service manual, InPower and the
HMI320.

Is Standa lone Paralleling?

 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.
kW Demanded by Load
kVar Demanded by Load

 In Standalone mode operation, a single generator set is
connected to a bus in order to provide power to a common
load.
2
Visual 10-2 What is Standalone paralleling.
Standalone is a mode of operation that allows

the generator set to be used in a single
power supply situation and still provide
some added feature for monitoring and
protecting the genset AND the
installation.
In Standalone mode the power capacity of the

power system is regulated by the capacity
of the single generator set and it alone is
responsible for maintaining voltage and
frequency. In paralleling systems, all of
the units in the system contribute and
share this function.

Wire diagram Connec tions
Visual 10-3 Common Connector diagram
Standalone:
There are few connections to the PCC 3300 in
the Standalone mode. The dotted lines
designate the connection is optional.
IMPORTANT! The information bullets
found on the diagram provides valuable
information. Read them!

The above bullet describes operating features

that are affected by the connection of the
breaker information and control.
The genset is not able to read 3 phase bus

current when configured for Standalone
mode. It is able to monitor the Neutral
current but not for any protective purpose
such as the noted Ground Fault.
.
Greater detail about the bullet references can
be found in Service Manual 900-0670
Section 4 and Section 2.

InPowe r Mod es of P aralleling
Genset Application Type Setup – Modes of Operation
Visual 10-4 InPower
InPower has a specific folder ( Paralleling

Setup) devoted to the setup and
configuration of the paralleling features.
No more hunting and searching for
different folders for individual setup
features. .
This visual highlights the specific adjustment

for placing the control into any one of the
various modes of paralleling.
Unlike previous controls were customers

were charged for different levels of
paralleling capability, this control
provides all the levels for one basic price.

HM I320 Pa ralleling Setup
 The HMI paralleling setup

functions are the same with
InPower. This screen
shows the Genset
Application Type is set to
Isolated Bus. Use the
proper password code to
change the type.
5
InPower is an easy tool for configuring the

control, but the HMI has all the setup
features built in too. There will be many
situations when it will be more
convenient to make adjustments and
changes from the HMI then to try and
connect with InPower.
There are 6 screens of adjustment.
As you saw in the previous visual, the first

adjustment under Basic Setup is Genset
Application Type. It is also in the HMI
Basic Setup screen.
To change the Gen App Type, use the Level 1

or Level 2password .

Paralleling Co nnec tor Use in

Standalone Mode
Bus CT #2
TB10- Circuit
Breaker Status
TB5- Circuit Breaker Control

6
Visual 10-6 Connector
There are 3 connections used in Standalone

Mode for providing input/output and
monitoring functions.
Important!: Only CT #2 is used for
Standalone mode. It is polarity sensitive
and limited to a maximum of 5 amp pass-
through.

Bus CT Connec tions
CT2
Optional: Only Provides Metering of

Neutral Current
Visual 10-7 Bus Connection
Only CT #2 is used in Standalone mode and it

can only be used to monitor bus Neutral
Current.
Remember, this control can be used in a
single phase application and Delta
configuration too. Even in these
applications, neutral current is all this CT
should be employed to monitor.
Input is limited to a standard 0 to 5 amp CT
output.
The tables in section 2 of service manual
provide information about setting and
calibrating this input.
Shorting blocks or some sort of shorting
system must be used to protect the CT.

B+
M
B+Return
Visual 10-8 Breaker connection
TB5 provides the hookup points to control

breakers. Standalone mode supports only
1 contact point on this connector.
Pins 1 and 2 provide limited output to drive a

breaker open or shunt trip command. It is
very important to know the inrush coil
specifications of the breaker shunt trip or
motor. If you suspect the 5A, 30VDC
inductive loading will exceed 7
milliseconds, use a pilot relay.
DO NOT overload this driver, overloading

may lead to and require board
replacement.

In Standalone Mode, Breaker

tripped connections are optional.
Pin 10 Pin 2
CB Tripped Status: TB10 - 10
Return: TB10 - 2
Visual 10-9 Breaker status

This is Customer Input #27 so an excellent

time to learn about the FUNCTION
POINTER setup in InPower.
In the SETUP folder – Configurable I/O you

find dozens of configurable settings
If you scroll down the list, at approximately

the 105th trims down the list you will
notice several settings for Genset CB.
Open the Genset CB Tripped/Configurable

Input #27 Function Pointer Value. You
will see a dropdown list of all the
conditions that can be used to close this
contact. This will trip fault code 1454.

Standalone M ode A ctivities
10
At this time I would like you to complete the

quiz.
The Quiz is found in Section 15.

Wrap-Up
In this lesson, we have learned about installation of the PCC 3300 genset control and
important connection locations.
First, we talked about the procedure for installing options to the control on a genset.
Then, we used the Common Connector Scheme diagrams and visuals to view each
individual connector and the connections available from the control to the genset
components and why each is important.
Q. Are there any questions we have not yet covered about installation of the PCC 3300?

PCC 3.3 & PowerCommand Control 3300 Synchronizer Only Mode
PowerCommand
3.3
Section 11: Synchronizer Only Mode

Visual 11-1

Section 11
PPC 3.3 Synchronize Only Mode
Equipment Needed
Materials Needed

Warm Up
Differences and similarities between Standalone mode operation and Synchronize Only will be
covered in this lesson. We will experience the setup process and configuration of the control in
addition to the physical connections that can be used with the PC 3.3.
Objectives
These early lesson in the paralleling lesson series introduce participants to the paralleling features
or options. These lessons will not teach the theory and science of paralleling. It will cover the
basics about connecting, configuring and adjusting the features of this control to optimize unit
performance. Understanding the operation of these features provides a solid base for
troubleshooting if performance problems should ever occur.
Synchronize is a very basic introduction to paralleling functions and it prepares everyone for
encounters with more complex modes of paralleling operation.
• Understand the reason for operating the PC 3.3 in Synchronize Only mode.
HMI320.
• Execute a control setup and configuration for a genset or simulator to operate in this mode.

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.
Visual 11-2 Synchronize only
The operating features of Synchronize Only

are the same as those used in more
advanced paralleling modes.
The control will not command breaker

closure in this mode but it will monitor
the position of the Gen breaker and it can
also provide a generator breaker open or
shunt trip command.
This feature is well suited to work with the

PLTH product and it will work with hard
and bump-less transferswitch systems.

The frequency/phase matching control

provides for two methods of automatic
frequency synchronizing. The first is
Phase Match which will attempt to drive
the phase error to zero. A phase offset
adjustment is included for cases where a
phase shift exists due to a delta / wye
transformer for example. The second
method of synchronizing is Slip
Frequency which will attempt to drive a
fixed frequency difference between the
two sources. In some cases this is used to
insure that power will flow in the desired
direction at the initial time the sources are
paralleled, or with a genset whose
governing cannot be accurately enough
controlled to phase match (such as gas
gensets).
The control provides one method of

automatic voltage synchronizing which is
voltage match. This method will attempt
to drive the voltage error to zero.
In most cases synchronizing is automatically

initiated by the control when necessary.
This is done by connecting sync
enable/configurable input #30 on TB10 to
a return.

Notice the same dotted lines on this diagram as

you found on the Standalone diagram.
Again, the dotted lines designate the
connection is optional.
information. Read them!
Bus voltage input is needed for synchronizing,
but bus CT input is not needed for this
function.

InPowe r Mod es of P aralleling
The setup
process
encountered in
InPower is the
same as that
used with
Standalone
Mode.
Genset Application Type Setup

Modes of Operation
Choose Synchronize
4
Visual 11-4 InPower
InPower has a specific folder ( Paralleling

Setup) devoted to the setup and
configuration of the paralleling features.
No more hunting and searching for
different folders for individual setup
features. .
This visual repeats the same information that

was covered in the Standalone section. It
is repeated to reinforce the point that this
control is easily configured. One place –
you choose the setup – no more hunting
through many InPower folders to find the
proper adjustments.

HM I320 Pa ralleling Setup
 The HMI paralleling setup

functions are the same with
InPower. This screen
shows the Genset
Application Type is set to
Isolated Bus. Use the
proper password code to
change the type.
5
Are you catching on yet? Hopefully you are

noticing a repeating pattern about how
you can configure this control. YOU have
a choice for your preferred method of
setup of a control, you can use InPower or
you can use the HMI.
As you saw in the previous visual, the first

adjustment under Basic Setup is Genset
Application Type. It is also in the HMI
Basic Setup screen.
To change the Gen App Type, use the Level 1

or Level 2password .

Paralleling Connecto r Used in

Synchronize M ode
TB10- Circuit
Breaker Status

6
Visual 11-6 Connector
Now there are 5 connections (potentially 7 if

you use all CTs) used in Standalone Mode
for providing input/output and monitoring
functions.
Important!: Only CT #2 is used to monitor
neutral current .
The connection diagram does not show
installation of shorting blocks for the CT
connections, but it is strongly
recommended.
TB7 Voltage inputs are rated to accept up to
600 volts

Bus CT Connec tions
OR
CT1 CT2 CT3
Optional: Only Provides

Metering of Neutral Current
CT2
Visual 11-7 Bus CT Connection
Remember, this control can be used in a

single phase application and Delta
configuration too. Even in these
applications, neutral current is all that this
CT should be employed to monitor.
Input is limited to a standard 0 to 5 amp CT
output.
The tables in section 2 of service manual
provide information about setting and
calibrating this input.
Shorting blocks or some sort of shorting
system must be used to protect the CT.

B+
M
B+Return
TB5 hookup is optional. Synchronize Only

mode and Standalone mode support only
1 contact point on this connector.
Pins 1 and 2 provide limited output to drive a

breaker open or shunt trip command. It is
very important to know the inrush coil
specifications of the breaker shunt trip or
motor. If you suspect the 5A, 30VDC
inductive loading will exceed 7
milliseconds, use a pilot relay.

This is an excellent time to learn about the

FUNCTION POINTER setup in InPower.
In the SETUP folder – Configurable I/O you

find dozens of configurable settings
If you scroll down the list, at approximately

the 105th trims down the list you will
notice several settings for Genset CB.
Open the Genset CB Tripped/Configurable

Input #27 Function Pointer Value. You
will see a dropdown list of all the
conditions that can be used to close this
contact. Chose the appropriate one that
will open the breaker as your application
would require.
The trim Function Pointer is used to set what

conditions the configurable output
becomes active.
Associated with the Input #27 Function

Pointer is the Active State Selection
choice. This can be set for “ Active
Closed”, or “ Active Open”.

TB10 Breaker Status Connections
17 10 8&7 2
13
#2 Return
10 optional
8
13
7
#17 Return
9
TB10 provides breaker status information and

it provides the Sync Enable input.
The Sync Enable input is required for

Synchronize Only Mode. It is the
command the causes the genset to
synchronize to Source 1.
The breaker status inputs are optional. There

is no breaker control function with this
mode, so this would be used for reporting
the status of the breaker over ModBus or
generally for reporting the position.

Activities
Activity 11-1: In-Class Quiz
10

quiz and the activity. The quiz is located
in Section 15

Wrap-Up
This lesson is not only supposed teach you about the synchronizing feature of this
control, but it is also supposed to prepare you for lesson 12: Isolated Bus Paralleling.
In this lesson, we have learned about synchronizing, installation connections, and setup
of the PCC 3300 genset control for operating in Synchronize Only mode.
Q. Are there any questions we have not yet covered about Synchronize Only Mode of the
PCC 3300?


PCC 3.3 & PowerCommand Control 3300 Isolated Bus Mode
PowerCommand
3.3
Section 12:
Isolated Bus Paralleling

Visual 12-1

Section 12
PPC 3.3 Isolated Bus Mode
Materials Needed

Warm Up
What you have learned about Standalone mode operation and Synchronize Only will be applied in
this lesson. We will experience the setup process and configuration of the control in addition to the
physical connections that can be used with the PC 3.3.
Objectives
This lesson will provide a very basic introduction to Isolated bus paralleling functions and it will
prepare everyone for encounters with more complex utility/mains paralleling operation.
• Understand the configuration of various Isolated Bus systems, and the reason for operating the
PC 3.3 in droop or isochronous mode.
HMI320.
• Execute a control setup and configuration for a genset or simulator to operate in this mode.

Isolated Bu s Pa ralleling
 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
Visual 12-2 Isolated bus
All units operate at the same frequency

(speed) and voltage.
Generally speaking, the units can operate in

various modes which will determine how
individual units will react to load
conditions, but all units will work
together on line to share the load.
Droop and Isochronous modes are available. ,
The bus system may consist of switchgear

with bus work or it may consist of cable
connections between gensets and
breakers.

Isolated Bu s Paralleling
 Dead Bus Close
 First Start Arbitration
 Synchronizing
 Load sharing between units
Visual 12-3 Isolated bus
Participant’s Text
Dead Bus Close & First Start Arbitration:

First start arbitration is used in a multi-genset system to control which genset gets to close to a dead
bus. Only one genset is allowed to close to a dead bus. All others must synchronize. The
genset controls arbitrate with each other through an interconnected first start signal. Once a
genset has reached the ready to load state and the bus is sensed as being dead, it can join in the
arbitration. When the arbitration completes, one genset has "won" permission to close and will
be allowed to command its breaker to close. At the same time this genset puts the
interconnected arbitration signal into an inhibit state which tells all other gensets that they do
not have permission to close. Once the permitted genset has closed to the dead bus, then the
other gensets will see the genset bus go live and begin synchronizing to it.
If a genset has been waiting to win permission to close to a dead bus and it has not received that
permission within a set amount of time, it will assume that the first start system has failed and
will close its breaker to the dead bus. This is the First Start Backup function. This prevents a
situation where no genset closes to the bus due to a failed first start system.

WARNING! --- This does present a risk of mu ltiple gensets closing to the dead bus, but this ris k is
reduced by setting the first start backup time delays to be signific antly different on each genset.
E.G. 10 sec, 20sec, 30 sec, etc. Then the assumpt ion is that all gensets w ere started at the same
time.
Synchronizing:
The frequency/phase matching control provides for two methods of automatic frequency
synchronizing. The first is Phase Match which will attempt to drive the phase error to zero. A
phase offset adjustment is included for cases where a phase shift exists due to a delta / wye
transformer for example. The second method of synchronizing is Slip Frequency which will
attempt to drive a fixed frequency difference between the two sources. In some cases this is
used to insure that power will flow in the desired direction at the initial time the sources are
paralleled, or with a genset whose governing cannot be accurately enough controlled to phase
match (such as gas gensets). The control provides one method of automatic voltage
synchronizing which is voltage match. This method will attempt to drive the voltage error to
zero.
In most cases synchronizing is automatically initiated by the control when necessary. This is done
by connecting sync enable/configurable input #30 to a return.
Load Share:
The load share function manages the genset’s kW and kVAR production when it is connected to a
common bus with other gensets while isolated from the utility bus. Each genset must determine
how much of the total bus load to take. The desired result is for each genset to take its equal
share of the load relative to its own rating while maintaining the bus frequency and voltage at
the nominal values. (i.e. Each would end up taking the same % load.) The sharing of kW is
controlled by fuel (speed). The sharing of kVAR is controlled by excitation (voltage).
Isochronous
In order to share load while maintaining fixed frequency and voltage, some form of communication
between the gensets must occur. (The other option with no communication is speed and voltage
droop.) This is accomplished via the “load share lines”. There is a pair for kW and a pair for
kVAR.
Controller compatibility for Paralleling must b considered. When a paralleling system consists of
different models of PCC3XXX genset controls, some adjustments are necessary in order to
insure comparable load sharing performance. These adjustments are NOT necessary if the
controls are all identical control models.
What are the symptoms or issues if these adjustments are not made or are made improperly?
1. Reverse kVAR (Loss of Field) shutdowns may occur.

2. Bus Voltage may shift from nominal. (I.E. It may look like voltage droop.)
3. With the control default kVAR balance settings, the kVAR sharing will not be balanced.

4. Even after balancing the kVAR sharing at one kVAR load condition, the kVAR sharing
may not be balanced at a different kVAR load.
5. kVAR sharing will not be equal when V/Hz is acting (e.g. during a large kW transient or
overload condition).
6. Reverse kW or Reverse kVAR shutdowns may occur during Master Synchronizing with
MCM3320
Droop
Droop is a passive means of having paralleled gensets share kW (via speed droop) and kVAR (via
voltage droop). In the case of speed droop, as kW load increases, speed (i.e. fueling) is
reduced, forcing other gensets to pick up more kW thus resulting in a balance. In the case of
voltage droop, as lagging kVAR increases, voltage (i.e. excitation) is reduced, forcing other
gensets to pick up more lagging kVAR thus resulting in a balance. Droop can be used on an
isolated bus for passive sharing among gensets.
All gensets may be operated in droop, but this leads to a frequency which changes with load.
Another alternative is to operate one of the sets as a “lead” unit in the isochronous mode. The
other sets operating in droop will be forced to go to the isochronous speed and thus they will be
effectively base-loaded. The lead unit then takes up all the changes in load that occur while
maintaining a fixed frequency bus. As an example, if the genset set to operate in isochronous
mode at a frequency of 57Hz were run in parallel with a genset operating in droop set as shown
in Figure 1 with a nominal frequency of 60Hz the genset in droop would be loaded at 50% kW.
If it were desired to run both gensets at 60Hz and still load the genset operating in droop to 50%
set the Frequency Adjust trim on the genset operating in droop to 3 to increase the 0% kW
output frequency to 63Hz.
Figure 1 Load Share – Droop kW is a graphical representation of speed droop. In this case the
Speed Droop Percentage trim has been set to 10%. As can be seen from the graph at 100% kW
ouput the genset will be operating at 90% of nominal frequency. In other words for a nominal
frequency of 60Hz the genset will be running at 54Hz at full load.
Figure 2 Load Share – Droop kVAR is a graphical representation of voltage droop. In this case
the Voltage Droop Percentage trim has been set to 5%. As can be seen from the graph at 100%
kVAR ouput the genset will be operating at 95% of nominal voltage. In other words, for a
nominal voltage of 480VAC the genset will be running at 456VAC at full load.

Load Share - Droop k W
101
100
99
98
y 97
c
n 96
e
u
q 95
e
r
F
l 94
a
n
i 93
m
o 92
N

% 91
90
89
88
87
0 20 40 60 80 100 120 140
% kW Outp ut

Figure 1 Load Share DROOP kW
Load Share - Droop kVAR
101
100
99
e
g
a
t
l 98
o
V
l
a 97
n
i
m
o
N 96

%
95
94
93
0 20 40 60 80 100 120 140
% kVAR Output

Figure 1 Load Share DROOP kVAR

Isolated B us P aralleling Sequenc e
Visual 12-4 Sequence diagram
The PCC control is acting on many inputs

and actions that must take place in a
particular sequence for the PCC to
parallel with other generator sets.
This diagram provides a basic sequence of

operation and graphically shows each
event that must happen. A large fold out
sheet is available in Appendix B:
Sequence Diagrams of the Service
Manual.

W ire Diagram Connections
This is the first diagram when full connection

and control of the genset breaker is
encountered.
This is the first diagram when connections to

the TB9 analog connection are
encountered. The connections are polarity
sensitive and must be connected between
each generator so each unit will share load
correctly.

There will be a 52G for each generator set.

(52G is the standard ANSI designation for
a motor actuated breaker for a generator
set.)
A Contact =
B Contact =
C Contact =
MEDIUM VOLTAGE & HIGH VOLTAGE

– Potential of 600voltAC is generally
considered the threshold to Medium
voltage. Systems operating at potential
above 600voltAC must use PTs (Potential
Transformers) {VT =Voltage
Transformer---- a common term in many
of the global regions} to lower the
voltage.
Additional Notes or Comments

_______________________________________________________________________________

Isolated B us P aralleling Connec tors

TB9- Analog I/O
TB10- Circuit Breaker TB3 - Customer I/O

Status
TB5- Circuit Breaker Control
Visual 12-6 Connectors
Customer connections must be made at each

of these connection points.
The next few pages will highlight the

connections required at each of the
terminal blocks.
In addition to the connections that were made

on the Synchronize Only Mode,
connections must also land at TB3
Customer I/O, TB9 Analog I/O, and the
TB7 Bus Voltage.

Bus CT Connections
CT1 CT2 CT3
Visual 12- 7 Bus CTs
Bus CT connections are polarity sensitive and

the sense wire must be routed through the
CT in the proper direction.
If the CTs wires are installed backwards, the

control will sense a phase shift and the
control may not parallel correctly or there
will be erroneous readings of load or PF.
Most Switchgear manufacturers build their

gear with CT shorting blocks in place. It
is the responsibility of the installation
designer to make certain there are
shorting blocks in the system. Question
the maker if you do not find any.


Pin 12
First Start First Start

Arbitration Arbitration
Return Supply
Gen 1
Pin 12
Gen 2
Visual 12-8 Connection TB3
In this paralleling mode, the only connection

to TB3 is the optional First Start Status
signal.
The connections are considered polarity
sensitive with output from the first genset
connected to the next genset.
 TB3-11 to TB3-11 on all gensets
 TB3-12 to TB3-12 on all gensets

B+
B+Return M
M B+Return
B+
TB5 provides the hookup points to control

breaker open and another for breaker
close control.
Breaker motors can consume a large amount
of energy during actuation. The power
consumption is so great that damage to
PCC control can take place if you attempt
to drive the breaker directly from this
connector.
Use a pilot relay of sufficient size to run the
breaker, but be aware that relay motors
can sometimes consume a large amount of
energy. Make sure the relay motor does
not exceed the specification listed on this
visual.

17 10 7 2
14
#2 Return
11 10
15 #9 Return 8
#16 Return 14
7
#17 Return
10
TB10 provides information to the control

about breaker position, and it also
provides control input from a Master
Control.
There are 3 discrete input points. These are

optional, but they are available to be used
as Customer Inputs #28, #31, & #32.
 #28 is Genset CB Inhibit. It uses TB10-9
and TB10-11.
 #31 is Load Demand Stop. It uses TB10-
14 and TB10-17.
 #32 is Ramp Load/Unload. It uses TB10-

15 and TB10-16.

There are 3 breaker status indications

 Terminal #7 input indicates Genset CB
Position It uses “A” contact input
fromTB10-2 and TB10-7.
Position It uses “B” contact input

tripped It uses “A” contact input

TB9 Analog I/O Co nnections
kW Load Share - Neg

kW Load share +P os
kVAR Load Share - Neg

kVAR Load share +Pos
The shield must shield

Pin 1 Pin 1 all load share wires
between gensets, but
- Neg it can be connected to
Shield
+Pos Pin 9 on ONLY one
+Pos
Pin 11
genset.
- Neg Pin 11
11
The Analog input connections on TB9

provide the load share information.
The connections are considered polarity
sensitive with output from the first genset
TB3-11 connected to the input connection
TB3-12 of the next genset.
Also the first genset TB3-12 terminal must be
connected to the connection TB3-11 of
the next genset.

TB7 Gen Bus Voltage Sense
WYE 1 Phase
Pin Pin
Pin Pin
Pin Pin 1 4
1 4
1 4
U V
Neutral U V W
U V W
l
a
r
t
u
e
N
Unconnected
Delta
12
TB7 can monitor voltage of 600 voltAC or

less.
Fuses listed are optional and provided by

others. The fuse rating should be
appropriate to protect the wire system.
Unconnected
=

InPower Trim A djustments
Genset Application Type Setup – First step
13
Visual 12-13 InPower
It has been pointed out in previous lessons

that all paralleling setup functions and
adjustments are found under the
Paralleling Setup – Basic section of
InPower.
The first and most important adjustment to
check when configuring a paralleling
setup is Genset Application Type .

InPower T rim Adjustments
InPower Adjustment Screen Service Manual Menu Description
14
Visual 12-14 Trims
Within the InPower Setup ---- Paralleling

Setup ----- Basic folder you will see the
dozens of adjustments for paralleling
functions. All adjustments for all the
modes of paralleling are intermingled in
this Basic folder. This is represented on
the left of this visual.
The right side of this visual shows an
extraction from Section 5 SETUP &
CALIBRATION of the 0900-0670
Service Manual.
You will notice the sequence of the InPower
list matches the Service Manual list. This
will help you find descriptions and
adjustments.

InPower T rim Adjustments
OOR =Out Of Range
15
Visual 12-15 InPower
These highlighted adjustments affect

Utility/mains connections and
performance. They are listed in the basic
setup section and may cause some
confusion.
OOR is a common acronym that can be
encountered in many control systems, but
it may be a new term for those in the
Power Generation service field.

Qu iz & Activities
16
Visual 12-16 Quiz

quiz and the activity

Wrap-Up
In this lesson, we have learned about Isolated Bus Paralleling configuration of the PCC
3300 genset control and important connection locations.
Q. Are there any questions we have not yet covered about Isolated Bus installation of the
PCC 3300?

PCC 3.3 & PowerCommand Control 3300 Troubleshooting & Service Manual.
PowerCommand
3.3
Section 13: Troubleshooting &

Service Manual

Visual 13-1

Section 13
PC 3.3 Troubleshooting
Materials Needed
 Wiring Diagram 0630-3440 (A007M115 D) Sheets 1 to 18 or use diagrams in 900-0670

Warm Up
This is the last lesson and if everyone is not warmed up by now, they never will be.
Objectives
Troubleshooting is a skill that comes from experience and training can only enhance the
proficiency of the individual practicing the skill. This section will provide guidance on finding
resources to support troubleshooting efforts.
• Use the Troubleshooting guide in the Service Manual.
• Find fault codes and sequence of operation information in the Service Manual.

Troubleshooting Too ls & Resources

 #1 = Brains
 Service Manual 0900-0670
 Quality VOM
 Common Connector Scheme Diagram
 InPower
 ModScan
 InSite
 InLine IV or V Adapter or PEAK Adapter
Visual 13-2 Troubleshooting Tools.
Brain:
Don’t leave your brains at home. If you

remembered to bring it to the jobsite, Use
It!
This course has been pouring lots and lots of

information into your heads but it is only
a small fraction of information about this
control. We have provided you with
guidance and an overview about how
major features operate. Not only have you
been learning how to properly configure
the control, you have been learning how it
is supposed to work. Now that you have
this knowledge, please use it.

Service Man ual #0900-0670

Concise Table of Contents

Seven Section

• System Overview
• Hardware
• Control Operation
• Paralleling Operation
• Setup and Calib ration
• Parameters
• Troubleshooting
 Appendix
• Schematics
• Sequence Diagrams
• Parts List
• ModBus Register Mapping
Visual 13-3 Service Manual.
The Service Manual table of contents is 12

pages long and it provides detailed and
explicit directions about where to find any
particular piece of information.
The manual is separated into the listed 7

sections of information and is set up in
such a way that you will find information
according to the type of activity you are
engaged in as opposed to which part of
the machine you are working with.
The Appendix is also divided into sections

labeled A, B, C, & D. Each section
provides reference information such as
the ModBus Register Map or a parts list.

Section 7 of the Service Manual provides a

comprehensive troubleshooting guide.
Before opening to Section 7, please look at
the Table of Content information about
Section 7 Troubleshooting beginning on
page vii of the Service Manual.
Notice the fault codes are listed in sequence
with a description of the fault and a
reference to a page in section 7.
Assume that the HMI displays fault #1438.
 Open the Table of Contents to page viii.
 Code 1438 - Fail to Crank……….. 7-39
 Open to Section 7. Troubleshooting
 Open to page 39 of the section.
 You should see the heading for this code.
 There are Logic, Possible Cause and
Diagnosis and Repair headings.
 The Logic & Possible Cause will help
you understand the conditions of the fault.
 Diagnosis and Repair will guide you to
possible or probable solutions.
Read and understand the Diagnosis and

Repair suggestions. SRT (Standard Rate
Tables) are based on these
troubleshooting suggestions.

Quality VO M
$4.95 @ Amazon
There are many makers of quality meters.

CPG does not endorse any one maker, but
we do encourage use of tools that are safe
to use and provide accurate and reliable
readings.
Look for these features & Accuracy:

 Measure 1000 V ac & dc
 True RMS ac voltage & current
 Frequency to 200kHz and % Duty cycle
 Min/Max Averaging
 Peak Capture
 Diode Test
 +/- .1% ac Volt
 +/- .4% Ω
 +/- .2% per kHz - DutyCycle.

Test
locations
are clearly
noted on
each
diagram.
Visual 13-5 Connector diagram
Now that you have a good VOM to work with,

where do you connect it? The Common
Connector Diagram tells us

information. Troubleshooting data can be
found on many of them!
Particpants’ Guide Section 13 Page8

The bullet below identifies a reason why the

Oil Priming Pump does not start. If
someone put too large of a relay motor on
the genset, could this fuse burn out?
Many of the bullets provide specification

information that can help with
troubleshooting. Using your VOM you
could check your exciter field. In earlier
sections we learned this AVR output is a
PWM signal so with a quality meter you
could check duty cycle OR you could
check the current draw.

InPower T roubleshooting Tips

InP ower continues to have
the Snapshot feature. The
Phase 1 PCC3300 does not
record Snapshots,
InPower is able to record

Monitor information and it
can create a viewable
Stripchart of performance.
InPower has a quick

navigation to the Fault List.
Visual 13-6 InPower
InPower has been a valuable troubleshooting

tool for many years. It is most likely the
most important troubleshooting tool
available for servicing a PC 3.3 control.
Most of the features shown on this visual

have been around a long time. Some of
them may have been forgotten about.
Such as the quick link to view the fault
list..
Phase 2 of the PCC3300 control board is

planned support fault Snapshots. The
Phase 1 release (this training session)
does not support the Snapshot function.

Mod Scan Troubleshooting Tips
ModScan is not a
configuration tool, it
is a troubleshooting
and testing tool.
Holding Registers
display data.
Registers 43517
is the Prelube
State parameter.
This middle digit reports

Prelube ON state.
7
ModScan was covered in detail in Section 7

of this Training guide.
Consider using ModScan as a troubleshooting

tool to test some of the operating
functions. The ModBus register map in
the Appendix Dof the Service Manual
lists many different control functions.
If you command the genset to enter Prelube

Mode On and this Prelube ON state
changes to 00100, but the Prelube relay
does not pick up, this could help you
understand that the internal fuse may have
failed.

InSite
Visual 13-8 InSite
InSite is a valuable service tool for

troubleshooting engine related problems.
CPG does not train or certify technicians to

use this tool, but if a PowerGen
technician is trained to use this tool and
has it available, by all means – use it!
InSite connects to the CAN communication

system through the InLine tool. InLine IV
and InLine V tools are the current
connection tools available at the Phase 1
launce of the PC 3.3 control.

Troubleshooting Activities
Visual 13-9 Quiz & Activity

quiz and the activity

PCC 3.3 & PowerCommand Control 3300 Troubleshooting & Service

Manual.
Wrap-Up
In this lesson, we covered tools and multiple ways to troubleshoot the PC 3.3 control.
Q. This is the last training Section before the final test. Are there any questions we have
not yet covered about the PC 3.3?

PCC 3.3 and PowerCommand Control 3300 PowerCommand Control 3300 Glossary
SECTION 14 -- Glossary
AC
Alternating Current (AC) is electric current that alternates between a positive maximum value and a
negative maximum value at a characteristic frequency, usually 50 or 60 cycles per second (Hertz).
Alarm
Used generically to indicate either a warning or a shutdown fault.
ANSI
American National Standards Institute.
Acoustic Material
Acoustic material is any material considered in terms of its acoustic properties, especially its
properties of absorbing or deadening sound.
Active Power
Active power is thereal power (kW) supplied by the generator set to the electrical load. Active
power creates a load on the generator set's engine and is limited by the horsepower of the engine.
Active power does thework of heating, turning motor shafts, etc.
Air Circuit Breaker

An air circuit breaker automatically interrupts thecurrent flowing through it when the current
exceeds the trip rating of the breaker. Air is themediumof electrical insulation between electrically
live parts and grounded (earthed) metal parts.
Alternator
Alternator is another term for AC generator.
Alternator Rating Effect

Some of the alternator protections are inherently related to the alternator capabilities rather than
GenSet power rating. For example, Reverse VARs (Loss of Field), is inherently a function of
alternator capability. Overcurrent is inherently a function of alternator capability. If data to an
alternator’s capability in these areas is not available, the PowerCommand Control will default to
basing the limits on the on the GenSet rating — as the previous version of the PowerCommand
Control did. (GenSet rating is either engine limited or alternator limited — normally engine
limited.)
Training Guide Section 14 Page1

Amortisseur Windings
The amortisseur windings of a synchronous AC generator are the conductors embedded in the pole
faces of the rotor. They are connected together at both ends of the poles by end rings or end plates.
Their function is to dampen waveform distortion during load changes.
Ampacity
Ampacity is the safe current-carrying capacity of an electrical conductor in amperes as defined by
code.
Ampere
The ampere is a unit of electric current flow. One ampere of current will flow when a potential of
one volt is applied across a resistance of one ohm.
Annunciator
An annunciator is an accessory device used to give remote indication of the status of an operating
component in a system. Annunciators are typically used in applications where the equipment
monitored is not located in a portion of the facility that is normally attended. The NFPA has
specific requirements for remote annunciators used in some applications, such as hospitals.
Apparent Power
Apparent power is the product of current and voltage, expressed as kVA. It is real power (kW)
divided by the power factor (PF).
Armature
The armature of an AC generator is the assembly of windings and metal core laminations in which
the output voltage is induced. It is the stationary part (stator) in a revolving-field generator.
Authority Having Jurisdiction

The authority having jurisdiction is the individual with the legal responsibility for inspecting a
facility and approving the equipment in the facility as meeting applicable codes and standards.
Automatic (Exciter) Paralleling

Automatic (Exciter) Paralleling describes a system where two or more generator sets can be started
and paralleled while coming up to rated frequency and voltage. Because the generator excitation
system is not turned on until the generator set is started (thus the term "dead field"), the generator
sets automatically synchronize as they come to rated speed and voltage.
B+ Return
Similar to battery negative (B-). This may be an isolated battery negative circuit and may not be
directly connected to chassis ground or the battery negative. In some circumstances it may float at a
different potential than chassis ground.

Backup Protection
Backup protection consists of protective devices, which are intended to operate only after other
protective devices have failed to operate or detect a fault.
Bandwidth
The amount of data that can be transmitted in a fixed amount of time. For digital devices, it is
expressed as bits per second, or bytes per second. For analog devices, it is usually expressed as
cycles per second, or Hertz.
Bar Graph
A metering panel which is optional a PowerCommand Control. This optional panel is referred to as
the HMI112 and it allows the operator to view a display of Amperes, KVA, Frequency, and
Voltage provided by the generator set. There is also a version that will display KVA and Power
Factor in addition to the other listed functions.
Base Card
The main processor board of the PowerCommand Control. This board contains the main power
supply for the control, microprocessor, flash memory for updates to the operating system
(calibration download), interface to the optional HMIs, PCCNET and Modbus connections, and
inputs for engine sensor data.
Base Load
Base load is that portion of a building load demand which is constant. It is the "base" of the
building demand curve.
Baud Rate
The speed of data transmission in serial data communications approximately equal to the number of
code elements (bits) per second (BPS). Bits per second are also termed BPS, with the prefix (k)
denoting thousands.
Binding
The process of making the logical connections to the network (also called connecting). This
involves connecting network variable outputs to network variable inputs using LonWorks software.
Bit
Binary Digit.
Black Start
Black Start refers to the starting of a power system with its own power sources, without the
assistance from external power supplies.
Boolean
A logical system used to express one of two states, such as on or off (yes or no, 1 or 0, etc.)

Bound
A network communication technique whereby a node automatically receives a network variable
from a sender node whenever the sender node sends it out. Whenever this condition exists, the node
is said to be "bound".
Bumpless Transition
Bumpless transition is make-before-break transfer of an electrical load from one source to another
where voltage and frequency transients are kept to a minimum.
Bus
Bus can refer to the current-carrying copper bars that connect the AC generators and loads in a
paralleling system, to the paralleled output of the AC generators in a system or to a feeder in an
electrical distribution system.
Bus Bars
Bus Bars are rectangular copper or aluminum bars that connect the output of the generator set
circuit breakers to the transfer switches, circuit breakers, or fusible switches that transfer power to
the load. The bus bars are sized and assembled in multiples according to the current they must carry
under load. A typical sizing criteria for copper bus bars rated from 500-5,000 amps is to maintain a
current density of 1,000 amps per square inch of cross-sectional area. This results in a bus
temperature rise at full load that is within acceptable limits.
Bus Capacity
Bus capacity is the maximum load that can be carried on a system without causing degradation of
the generator frequency to less than a prescribed level (usually 59 Hz in a 60 Hz system).
CT (Current Transformer)
Current transformers are instrument transformers used in conjunction with ammeters, control
circuits and protective relaying. They usually have 5 ampere secondaries.
Calibration
Non-volatile adjustment made on the factory floor. A data set downloaded to a G-Drive or GenSet
control to update the operation of the control.
Cellular
Refers to a communication system that divides geographic regions into sections called cells. The
purpose of this division is to make the most use of the limited number of transmission frequencies.
Channel
A Channel is the physical communications media that connects the devices and the properties of
these media (such as transmission speed). Most PowerCommand network installations will have
only one channel (UTP cable and 78 KBPS transmission speed). In a large network, there may be

multiple channels and each channel may or may not be of the same media type. Typically, channels
are linked together using routers.
Channel Terminator
This is used to terminate networks on devices that do not have terminate switches. These are
devices such as Gateways, RCI's, Routers, etc. that do not terminate circuits built into their design.
Circuit
A circuit is a path for an electric current across a potential (voltage).
Circuit Breaker
A circuit breaker is a protective device that automatically interrupts the current flowing through it
when that current exceeds a certain value for a specified period of time. See Air Circuit Breaker,
Main Breaker, Molded Case Circuit Breaker and Power Circuit Breaker.
Circulating Harmonic Currents

Circulating Harmonic Currents are currents that flow because of differences in voltage waveforms
between paralleled power sources, or induced by operation of non-linear loads.
Comma Separated Value (CSV)

A record layout that separates data fields with a comma and usually surrounds character data with
quotes. PowerCommand for windows uses the CSV record format.
Connecting Devices
Connecting to refers to the process of assigning connections--linking an output variable of one
device to an input variable of another device. This process is also called "binding".
Contactor
A contactor is a device for opening and closing an electric power circuit.
Continuous Load
A continuous load is a load where the maximum current is expected to continue for three hours or
more (as defined by the NEC for design calculations).
Cross Current
Cross currents are currents that circulate between paralleled generator sets when the internal
(excitation) voltage of one genset is different from the other genset(s). The genset with the higher
internal voltage supplies reactive power (kVAR) to the other genset(s). The amount of cross current
that flows is a measure of this reactive power. Cross currents are 90 degrees out of phase (lagging)
compared to the current that the generator would supply at 1.0 (unity) power factor.

Cross Current Compensation

Cross current compensation is a method of controlling the reactive power supplied by AC
generators in a paralleling system so that they share equally the total reactive load on the bus
without significant voltage droop.
Cross Current Transformer (CCT)

Cross Current Transformers are used to step down the higher line current to a lower current that the
control system was designed for.
Current
Current is the flow of electric charge. Its unit of measure is the ampere.
Current Limiting Fuse

A current limiting fuse is a fast-acting device that, when interrupting currents in its current-limiting
range, will substantially reduce the magnitude of current, typically within one-half cycle, that
would otherwise flow.
Cycle
A cycle is one complete reversal of an alternating current or voltage from zero to a positive
maximum to zero again and then from zero to a negative maximum to zero again. The number of
cycles per second is the frequency.
CRC Error
This is a digital communication test. It is a acronym for Cyclical Redundancy Check. An error
indicates that a digital message did not arrive at its destination with all of the original data intact.
Dead Bus
Dead Bus refers to the de-energized state of the power connections between outputs of paralleled
generator sets. The term bus in this usage can either be rigid solid bus bars or insulated flexible
cables.
Dead Field Paralleling

Automatic (Exciter) Paralleling
Delta Connection
Delta connection refers to a three phase connection in which the start of each phase is connected to
the end of the next phase, forming the triangle-shaped Greek letter Delta. The load lines are
connected to the corners of the triangle.
Demand Mode Standby Unit(s) (DMSU)

Demand Mode Standby Units are generator sets that can be shut down by the system when there is
a low load level on the system.

Deviation Factor
The deviation factor is the maximum instantaneous deviation, in percent, of the generator voltage
from a true sine wave of the same RMS value and frequency.
Dielectric Strength
Dielectric strength is the ability of insulation to withstand voltage without breaking down.
Differential Relay
A differential relay is a protective device that is fed by current transformers located at two different
series points in the electrical system. The differential relay compares the currents and picks up
when there is a difference in the two, which signifies a fault in the zone of protection. These
devices are typically used to protect windings in generators or transformers.
Digital Display
A small display board that communicates with the Base Board. This item is now sysnonomis with
the HMI. This display module shows menus, adjustment information, alarms, and statistics of
events. This module is optional on some products.
Digital Master Control (DMC)

This device is designed to control the power systems in a facility. It is offered as an option on
Cummins switchgear.
Direct Current (DC)

Direct current is current with no reversals in polarity.
Distributed Control System

A collection of nodes that interact to control a system whose components are spread out over some
distance. Each node has intelligence for operating its own particular component of the system.
Different parts of the system communicate status and control information with one another to form
a distributed control system. Typically, they communicate on a peer-to-peer level. This is different
from a type of system where all control and interaction between components is dictated by one
central control. This is a common master/slave arrangement.
Distribution Circuit Breaker

A distribution circuit breaker is a device used for overload and short current protection of loads
connected to a main distribution device.
Distribution Switchgear
Distribution switchgear may include automatic transfer switches, drawout air frame circuit
breakers, fusible switches, or molded case breakers.

Domain
A domain is a network concept that allows independently functioning networks to share resources
such as transmission media. A domain designation provides an ID number to identify the devices
that can communicate within that domain. A network must have at least one domain.
PowerCommand Network installations will usually have only one specified domain.
Draw Out Unit

A draw out unit is a structure that holds a circuit breaker in an enclosure. It has a movable carriage
and contact structures that permit the breaker to be removed from the enclosure without manually
disconnecting power cables and control wires.
Droop Load Sharing

Droop load sharing is a method of making two or more parallel generator sets share a system kW
load. This is accomplished by having each governor control adjusted so that the sets have the same
droop (reduction of speed). Typical droop is two cycles in frequency from no load to full load.
Earth Fault Protection

A grounding bar is a copper bar that electrically joins all the metal sections of the switchgear. This
bar is connected to the earth or ground connection when the system is installed. The grounding or
earthing protects personnel from stray currents that could leak to the metallic enclosures.
ECM
Acronym for Engine Control Module. This term usually refers to the control that is supplied on
Cummins FAE engines, but it is also used when referring to PCC series controls that are used to
control engine speed and engine protection.
EEPROM
Electrically Erasable Programmable Read Only Memory. This memory holds data after the power
has been removed, but can be changed by writing new data on top of old data. This is where the
PowerCommand Control stores its calibration data. InPower, the service software, can write a new
calibration into the control flash memory.
Efficiency (EFF)
Efficiency is the ratio of energy output to energy input, such as the ratio between the electrical
energy input to a motor and the mechanical energy output at the shaft of the motor.
Electrical Operator
An electrical operator is the electric motor driven closing and tripping (opening) devices that permit
remote control of a circuit breaker.

Emergency Bus
An emergency bus is the silver-plated copper bus bars or flexible cable used to connect the
paralleling breakers to the emergency system feeder breakers, and ultimately to automatic transfer
switches or other distribution devices.
Emergency System
An emergency system is independent power generation equipment that is legally required to feed
equipment or systems whose failure may present a life safety hazard to persons or property.
Energy
Energy is manifest in forms such as electricity, heat, light and the capacity to do work. It is
convertible from one form to another, such as in a generator set, which converts rotating
mechanical energy into electrical energy. Typical units of energy are kW/h, Btu (British thermal
unit), Hp/h, ft/lbf, joule and calorie.
EPS
Engine Position Sensor. Serves the similar function as an MPU (Magnetic Pick Up) however it uses
Hall Effect sensing and provides input to the ECM (Engine Control Module)
Exciter
An exciter is a device that supplies direct current (DC) to the field coils of a synchronous generator,
producing the magnetic flux required for inducing output voltage in the armature coils (stator). See
Field.
Exciter Paralleling Control

An exciter paralleling control initiates the start of generator excitation in generator sets used in
automatic paralleling systems.
FAE
Acronym for Full Authority Engine. These engines typically employ high tech electronic fuel
injection and control systems.
Fault
A condition occurred which caused a warning or shutdown alarm.
Feeder Circuit Breaker

See Distribution Circuit Breaker.
Fiber Optic Cable

A technology using glass or plastic threads (fibers) to transmit data. A fiber optic cable is a bundle
of either glass or plastic threads capable of transmitting messages modulated into light waves.
Typically, fiber optic cable has greater bandwidth allowing them to carry more data than metal
wires. Fiber optic cable is lighter and less susceptible to interference than metal wires. Also, data

can be transmitted digitally rather being transformed into analog data for transmission as is the case
with metal wires when used for computer data transmission. Fiber optics are becoming increasingly
more common for use with Local-Area Networks (LANs).
Field
The generator field (rotor) consists of a multi-pole electromagnet which induces output voltage in
the armature coils (stator) of the generator when it is rotated by the engine. The field is energized
by DC supplied by the exciter.
Field Breaker with Auxiliary Switch

This is the circuit breaker (usually mounted in the generator control panel) that monitors the
alternating current input to the automatic voltage regulator. If a malfunction occurs in the excitation
system, the circuit breaker trips on overcurrent-closing the auxiliary switch, shutting down the
generator set, and energizing the alarm circuit.
First Start Sensor

A first start sensor is an electronic device within some paralleling equipment that senses generator
set and bus voltage and frequency, and determines whether or not a generator set is the first unit
ready to close to the bus following a call to start under "black start" conditions.
Form - C Relay
Refers to a type of relay that has a normally closed contact and a normally closed contact. The relay
coil must be energized for the contacts to switch position.
Free Field (Noise Measurements)

In noise measurements, a free field is a field in a homogeneous, isotropic medium (a medium
having the quality of transmitting sound equally in all directions) which is free of boundaries. In
practice, it is a field in which the effects of the boundaries are negligible in the region of interest. In
the free field, the sound pressure level decreases 6 dB for each doubling of the distance from a
point source.
Frequency
Frequency is the number of complete cycles per unit of time of any periodically varying quantity,
such as alternating voltage or current. It is usually expressed as (Hz) Hertz or CPS (cycles per
second).
Frequency Adjust Potentiometer

A frequency adjust potentiometer is used to manually bring the frequency (speed) of the incoming
set to that of the bus for synchronizing purposes. When the generator set is paralleled, operation of
this potentiometer will adjust the kW load assumed by the generator set.

Frequency Regulation
Frequency regulation is a measure that states the difference between no-load and full-load
frequency as a percentage of full-load frequency.
FT-10 Network
FT-10, sometimes described as FTT-10, is the large network transceiver system used with
Cummins Power Generation systems employing the LonWorks protocol. FTT-10 stands for “Free
Topology Type - 10Mbaud.” The Free Topology protocol allows multiple topologies to be used in
one network. The maximum network cable length in a free topology network is 500 meters. If the
network is designed and installed using a multi-drop bus topology the maximum distance is 4,000
feet.
Fusible Switch
A fusible switch is an isolating switch and overcurrent protective device used for feeder or transfer
switch isolation and protection. It is typically a manually operated, stored energy opening and
closing, bolted compression blade switch, with provisions for installing current limited fuses.
Gateway
A device that acts as an interface between two different communication protocols. The Network
Gateway Module (NGM) provides a communication protocol that a PC can understand. Other
gateway devices may be used to interface between our Lontalk protocol and other systems such as a
SCADA or Building Automation System. Typically, a gateway becomes necessary when a SCADA
or BAS does not have a driver developed for Lontalk.
Generator
A generator is a machine which converts rotating mechanical energy into electrical energy.
Genset Communication Module (GCM)

The GCM provides a communication gateway between the Model 3100 PowerCommand Control
(PCCI) and the network. The GCM communicates with the PCCI control over a serial data link.
The GCM gets data from the PCCI controls such as voltage, current, engine speed, oil temperature,
etc. and then sends it out on the network if another network node is bound to it or requesting data.
GCS
Acronym for Genset Control System. This is usually found on generator sets built by other, yet
they use engines and controls built by Cummins.
Governor
A governor is a device on the engine which controls fuel to maintain a constant engine speed under
various load conditions. The governor must have provision for adjusting speed (generator
frequency) and speed droop (no load to full load).

Grid
The utility-owned power distribution system.
Ground
A ground is a connection, either intentional or accidental, between an electrical circuit and the earth
or some conducting body serving in place of the earth.
Ground Fault Protection

This function trips (opens) a circuit breaker or sounds an alarm in the event that there is an
electrical fault between one or more of the phase conductors and ground (earth). This ground fault
protection function may be incorporated into a circuit breaker.
Ground Return
Ground return is a method of ground fault detection that employs a single sensor (CT) encircling
the main bonding jumper between the power system neutral and ground. This device in itself is not
capable of locating the faulted circuit but when used in conjunction with ground fault sensors on all
feeders and source connections, can provide bus fault protection when properly coordinated
(delayed).
Grounded Neutral
A grounded neutral is the intentionally grounded center point of a Y-connected, four-wire
generator, or the mid-winding point of a single phase generator.
Hall Effect Sensor

A Hall effect sensor is a transducer that varies its output voltage in response to changes in
magnetic field. Hall sensors are used for proximity switching, positioning, speed detection, and
current sensing applications.
Harmonic Distortion (Total Harmonic Distortion)

Total harmonic distortion is an expression of the total harmonic content of a voltage waveform. The
harmonic distortion (or harmonic content) of a waveform is usually expressed as the square root of
the sum of the squares of each of the harmonic amplitudes (with amplitudes as a percent of the
fundamental voltage amplitude).
Harmonics
Harmonics are voltage or current components which operate at integral multiples of the
fundamental frequency of a power system (50 or 60 Hertz). Harmonic currents have the effect of
distorting the shape of the voltage wave form from that of a pure sine wave.
Hertz (Hz)
The term Hertz is the preferred designation for cycles per second (CPS) and is used to describe
frequency.

HMI
Human Machine Interface: Commonly referred to as touch panel, or control display, and now
includes reference to the annunciator and bargraph .
Hub
A common connection point for devices or nodes in a network or sub-network. Hubs are commonly
used to connect segments of a LAN and contain multiple ports.
Hunting
Hunting is a phenomenon that can occur upon load changes in which the frequency or the voltage
continues to rise above and fall below the desired value without reaching a steady-state value. It is
caused by insufficient damping.
Incoming Set
This is the generator set that is about to be connected to (paralleled with) the energized bus.
Initial Calibration
Downloading a data set to a PowerCommand Control to set up the operation of the control. In this
type of calibration the technician has to manually enter the dataplate information for the genset into
InPower software. If a capture file is not downloaded into the control after this type of calibration is
performed, all parameters will be reset to their “factory settings”.
Insulated Case Circuit Breaker

An insulated case circuit breaker is a power circuit breaker that is provided in a preformed case,
similar to a molded case breaker.
Insulation
Insulation is non-conductive material used to prevent leakage of electric current from a conductor.
There are several classes of insulation in use for generator construction, each recognized for a
maximum continuous-duty temperature.
Internal Voltage
The internal voltage is the voltage a generator would develop at no load if it were not connected in
a parallel operation. Excitation of the generator field controls internal voltage.
Interoperability
Design to allow one product to work with another product without modification.
Interruptible
This refers to the practice of operating on-site power systems, at the request of a utility, to reduce
electrical demand on the utility grid during periods of high consumption. Interruptible facilities
may also be disconnected from all electrical service in the event of high demand on the utility grid,
even if no on site power system is available.

Interrupting Capacity
Interrupting capacity is the magnitude of electrical current that a device can safely interrupt (open
against), without failure of the component.
kW Load Sensor
The kW load sensor is an electronic device provided to sense kW level at various points in a
system, for use in control functions within the system, such as kW load alarms, or load demand.
kVA (kilo-Volt-Amperes)
kVA is a term for rating electrical devices. A device's kVA rating is equal to its rated output in
amperes multiplied by its rated operating voltage. In the case of three-phase generator sets, kVA is
the kW ouput rating divided by 0.8, the rated power factor. kVA is the vector sum of the active
power (kW) and the reactive power (kVAR) flowing in a circuit.
kVAR (kilo-Volt-Amperes Reactive)

kVAR is the product of the voltage and the amperage required to excite inductive circuits. It is
associated with the reactive power which flows between paralleled generator windings and between
generators and load windings that supply the magnetizing currents necessary in the operation of
transformers, motors and other electromagnetic loads. Reactive power does not load the generator
set's engine but does limit the generator thermally.
kW
This is an abbreviation for kilowatt, an alternate term for rating electrical devices. Generator sets in
the United States are usually rated in kW. Sometimes called active power, kW loads the generator
set engine.
kW-h(kilo-Watt-hour)
This is a unit of electric energy. It is equivalent to one kW of electric power supplied for one hour.
Lagging Power Factor

Lagging power factor in AC circuits (a power factor of less than 1.0) is caused by inductive loads,
such as motors and transformers, which cause the current to lag behind the voltage. See Power
Factor.
Lead Unit
In a paralleling system that has a load demand feature, the lead unit is the last unit to be shut down
in the event that load demand mode is in operation.
Leading Power Factor

Leading power factor in AC circuits (0.0 to -1.0) is caused by capacitive loads or overexcited
synchronous motors which cause the current to lead the voltage. See Power Factor.

Leg
A leg is a phase winding of a generator, or a phase conductor of a distribution system.
Line-To-Line Voltage
Line-to-line voltage is the voltage between any two phases of an AC generator.
Line-To-Neutral Voltage
In a 3-phase, 4-wire, Y-connected generator, line-to-neutral voltage is the voltage between a phase
and the common neutral where the three phases are tied together.
Load Demand
Load Demand is a paralleling system operating mode in which the system monitors the total kW
output of the generator sets, and controls the number of operating sets as a function of the total load
on the system. The purpose of load demand controls is to reduce fuel consumption and limit
problems caused by light load operation of reciprocating diesel generator sets.
Load Dump
Signal output from a genset which is activated by the genset when it enters an overload and/or
underfrequency condition. In today’s systems, this tells the master control that it needs to shed
some load.
Load Factor
The load factor is the ratio of the average load to the generator set power rating.
Load Management
Load management is the overall control of load connected to match available generator capacity.
Priority control and load shedding are the two features required for load management.
Load Shedding
Load shedding is the process by which the total load on a paralleling system is reduced, on
overload of the system bus, so that the most critical loads continue to be provided with reliable
electrical service.
Local Loop
A method of branching out or creating a stub on the network. The maximum distance this stub can
be is 10ft. (3m) from the main network bus. Effectively the node is "daisy-chained" into the
network. This involves two wires, one that goes to the node and another that returns to the main
network bus. The total local loop distance must be added to the total network length. This becomes
important when the main network bus nears the 4,600 ft. length and requires the use of Routers.
Local-Area Network (LAN)

A computer network that spans a relatively small area. Most LANs are confined to a single building
or group of buildings.

Locations
Locations are subdivisions of a network that can be selected for easier organization. Locations may
designate physical places, but are not required to do so. For example, network devices in one
location may communicate with network devices in another location when requested to do so.
Low Side Driver

DC loads have a positive side and a negative side. On the PCC 1302, the Low Side Driver is the
switched negative side of a load when the circuit operates because of a internal power supply. It
may not have direct connection to chassis ground or battery negative.
Low Voltage
AC system operating voltages from 120 to 600 VAC.
Main Breaker
A main breaker is a circuit breaker at the input or output of the bus, through which all of the bus
power must flow. The generator main breaker is the device, usually mounted on the generator set,
that interrupts the genset's power output. Main breakers provide overcurrent protection and a single
disconnect point for all power in a switchboard or device.
Mains
Mains is a term used extensively outside of the United States to describe the normal power service
(utility).
Master Control
A control section in a typical paralleling system that provides total system metering and the
interface point between the paralleling system and the facility.
Media
The main network bus defined by two characteristics: 1) The electrical signal level and 2) the
characteristics of the wiring they will travel over. Typically, our standard PowerCommand Network
uses 22 AWG Unshielded Twisted-Pair (UTP) wire operating at 78 KBPS.
Medium Voltage
AC system operating voltages from 601 to 15000 VAC.
MODBUS
MODBUS ®Protocol An industrial networking system that uses RS-232 serial master-slave
communications at data transfer rate of up to 19.2 KBPS and is a messaging structure developed by
Modicon in 1979, used to establish master-slave/client-server communication between intelligent
industrial devices. There are multiple variations of the protocol.

Modbus II
An industrial networking system that uses token-passing peer-to-peer communications at data
transfer rates of five megabits per second (MBPS). The network medium is coaxial cable.
Modbus Plus
An industrial networking system that uses token-passing peer-to-peer communications at data
transfer rates of one megabit per second (MBPS). The network media is shielded twisted-pair cable.
Modules
Modules are also called nodes or devices. These are devices such as Genset Communication
Modules (GCMs), Control Communication Modules (CCMs), and Digital Input/Output Modules
(DIMs).
Molded Case Circuit Breaker

A molded case circuit breaker automatically interrupts the current flowing through it when the
current exceeds the trip rating of the breaker. Molded case refers to the use of molded plastic as the
medium of electrical insulation for enclosing the mechanisms, and for separating conducting
surfaces from one another and from grounded (earthed) metal parts. Molded case circuit breakers
usually contain thermal-magnetic trip units, although larger sizes can be equipped with solid state
trip sensors.
Motoring
In paralleling applications, unless a generator set is disconnected from the bus when its engine fails
(usually as a result of a fuel system problem), the generator will drive (motor) the engine, drawing
power from the bus. Reverse power protection which automatically disconnects a failed set from
the bus is essential for paralleling systems. Also, in certain applications such as elevators, the load
can motor the generator set if insufficient additional load is present.
Multi-drop Bus Topology

The wiring arrangement used for the network data. The bus starts at one point and ends at another.
Both the start and end of a network must be terminated through the use of a terminate switch. The
maximum stub length (See Definition of Local Loop) must not exceed 10ft. and must be included
in the total length of the main network bus.
NEC (National Electrical Code)

This document is the most commonly referenced general electrical standard in the United States.
NEMA
National Electrical Manufacturers Association
NEMA 1 Enclosure
This enclosure designation is for indoor use only-where dirt, dust, and water are not a
consideration. Personnel protection is the primary purpose of this type of enclosure.

NFPA
National Fire Protection Association
NFPA 110
National Fire Protection Agency Section 110 (NFPA 110) deals with the regulations concerning
Emergency Power Systems (EPS). This section deals with regulations on installation, operation,
and monitoring of EPS.
Network
A collection of Nodes that communicate with one another over a common medium.
Network Annunciator Module (NAM)

A device providing LED indication in the event of an alarm condition on a PowerCommand
Network device. For example, we can provide NFPA 110-alarm annunciation for gensets with the
use of a NAM.
Network Bus
The main "backbone" of the network data wire. It must be terminated at both the start and end of
the network. Stubs off the main bus wire cannot exceed 10ft. (3m.). The wire is "daisy-chained"
from one node to the next. The bus cannot exceed 4,600ft. without the use of a router. Bus can also
refer to the devices that connect the generators and loads to a system.
Network Communication Module (NCM ATS)

An optional module located inside the OTPC PowerCommand Control. This module allows the
transferswitch to be a node on the network and communicate with the rest of the network devices.
Network Communication Module (NCM Gen)

An optional module located inside the PowerCommand Control 2100. This module allows the PCC
2100 to be a node on the network and communicate with the rest of the network devices.
Network Data
A signal that carries messages between nodes. PowerCommand Networks use Manchester
Encoding that makes the signal insensitive to polarity. The signal is transformer-coupled to the
network data wire at a rate of 78 KBPS.
Network Data Wire

Unshielded-Twisted Pair (UTP) cable that carries the network data over the main network bus. The
maximum network length is 4,600 ft. without the use of routers.
Network Gateway Module

A device acting as an interface between a modem or PC and the network wire. The Gateway takes
the UTP wire and then provides an RS-232 port for connection to either a modem or PC.

Neutral
Neutral refers to the common point of a Y-connected AC generator, a conductor connected to that
point or to the mid-winding point of a single-phase AC generator.
Neutral Current
Neutral current is the current that flows in the neutral leg of a paralleling system. Often, this term is
used in reference to circulating currents or cross currents.
Node
A module that can communicate over the network data to other modules. A module contains a
Neuron Chip. Certain devices are nodes such as Genset Communication Modules (GCMs) and
Control Communication Modules (CCMs). Other devices are not nodes, as they cannot
communicate with other devices, but only receive messages. An example is the Network
Annunciator Module (NAM).
Nominal Value
A value which has not been trimmed. An example would be normal line frequency of 60.0 Hz. The
nominal value is 60.0 Hz.
Nonlinear Load
A nonlinear load is a load for which the relationship between voltage and current is not a linear
function. Some common nonlinear loads are fluorescent lighting, SCR motor starters and UPS
systems. Nonlinear loads cause abnormal conductor heating and voltage distortion.
Normal Standby Mode

In the normal standby mode, power to the load is supplied by the utility. The paralleling system is
ready to provide power to the load in the event of utility failure.
Octave Band
In sound pressure measurements (using an octave band analyzer), octave bands are the eight
divisions of the measured sound frequency spectrum, where the highest frequency of each band is
twice that of its lowest frequency. The octave bands are specified by their center frequencies,
typically: 63, 125, 250, 500, 1,000, 2,000, 4,000 and 8,000 Hz (cycles per second).
Ohm
The ohm is a unit of electrical resistance. One volt will cause a current of one ampere to flow
through a resistance of one ohm.
On-Set Paralleling
On-set paralleling is a manual paralleling system that is built onto the generator set, no additional
switchboards are required.

One-Line Diagram
A one-line diagram is a schematic diagram of a three-phase power distribution system which uses
one line to show all three phases. It is understood when using this easy to read drawing that one line
represents three.
Operating Source
An operating source is a source of electrical power that is delivering power to a load. The operating
source can be either a generator set or a commercial (utility bus) power line.
Out-Of-Phase
Out-Of-Phase refers to alternating currents or voltages of the same frequency which are not passing
through their zero points at the same time.
Overcrank
Overcrank is an alarm function provided with most generator sets that indicate that the generator
set has failed to start.
Overload Rating
The overload rating of a device is the load in excess of the nominal rating the device can carry for a
specified length of time without being damaged.
Overshoot
Overshoot refers to the amount by which voltage or frequency exceeds the nominal value as the
voltage regulator or governor responds to changes in load.
Parallel Operation
Parallel Operation is the operation of two or more sources of AC electrical power whose output
leads are connected to a common load. Connection of the power sources is made so that the sources
electrically function as a single source of power. Parallel Operation requires that the two sources of
electrical power must match in voltage, frequency, and number of phases.
Paralleling Breaker
A paralleling breaker is the circuit breaker that connects the generator set to the emergency bus,
and across which all the individual generator synchronizing functions occur.
Paralleling Control
A paralleling control contains the electrical equipment provided in a paralleling system for control
of a single generator set.
Paralleling Suppressers
Paralleling suppressors are semiconductor devices that protect the silicon diodes on a brushless
excitation system from damaging overvoltages. Overvoltages, usually of short duration, occur when
a generator is paralleled out of phase with the energized bus.

Parameter
Monitored values or settings in the PCC or the Operator Panel that can be looked at and, in some
cases, adjusted. Some parameters are protected by passwords.
Parity
In error detecting schemes, a Bit (even or odd) that represents the binary sum of the data
transmitted. Primarily used when transmitting data over a long distance. For example, when
transmitting information using modems.
Pass Thru
Refers to a junction box connection where the network bus comes to a connector and then
continues straight on through. In most Pass Thru connections, very little input and output is done.
An example of this connection is the Junction Box/Terminator (JBT).
PC 1.X
Acronym designationfor PowerCommand Control 1302 with one of several HMI versions. 1.1 =
HMI 211, 1.2 = HMI 220.
PCC
Acronym for PowerCommand Control.
PCCNet
An RS-485 based networking scheme that allows PowerCommand gensets, transfer switches,
paralleling switchgear, and monitoring/control modules to work without operator intervention on
setup or restart.
Per Unit (PU)

Definition #1: A unitless quantity that is the ratio of the current operating value to the
rated/nominal value. For example, a standby rated genset of 250 kW, 0.8 power factor with a load
of +260 kW, −50 kVAR would have +1.04pu kW, −0.26pu kVAR.
Definition #2: Alternator capability curves calculate per unit kW as the ratio of kW to rated kVA.
Per unit kVAR is calculated as the ratio of rated kVAR to rated kVA.
PETS
Acronym for Production Engine Test System.
Peak Load
Peak load is the highest point in the kilowatt demand curve of a facility. This is used as the basis
for the utility company's demand charge.

Peer-To-Peer
A network operating system where any device on the main network bus can initiate
communication.
Phase
Phase refers to the windings of an AC generator. In a three-phase generator there are three
windings, typically designated as A-B-C, R-S-T or U-V-W. The phases are 120 degrees out of
phase with each other. That is, the instants at which the three phase voltages pass through zero or
reach their maximums are 120 degrees apart, where one complete cycle is considered 360 degrees.
A single-phase generator has only one winding.
Phase Angle
Phase angle refers to the relation between two sine waves which do not pass through zero at the
same time. Considering one full cycle to be 360 degrees, the phase angle expresses how far apart
the two waves are in relation to each other in degrees.
Phase Rotation
Phase rotation (or phase sequence) describes the order (A-B-C, R-S-T, or U-V-W) of the phase
voltages at the output terminals of a three-phase generator. The generator phase rotation must
match the facility phase rotation. This must be checked prior to operation of the electrical loads in a
facility with an on-site generator.
PGI CAN
Acronym for Power Generation Interface to Cummins J1939 CAN communication systems.
Pilot Relay
A Pilot Relay is a simple relay which uses a low current coil that activates high current contacts.
The PCC 1302 control board has limited output power and it can be damage if it is connected
directly to high power DC loads such as fuel shut off solenoids or starter solenoids.
Pitch
Pitch is a mechanical design characteristic of a generator that indicates the ratio of the number of
winding slots per generator pole to the number of slots enclosed by each coil. The generator
designer may use the pitch of a machine to optimize the generator cost versus the quality of the
voltage waveform generated.
Pole
Pole is used in reference to magnets, which are bipolar. The poles of a magnet are designated North
and South. Because magnets are bipolar, all generators have an even number of poles. The number
of poles determines how fast the generator will have to be turned to obtain the specified frequency .
For example, a generator with a 4-pole field would have to be run at 1800 rpm to obtain a
frequency of 60 Hz (1500 rpm for 50 Hz). Pole can also refer to the electrodes of a battery or to the
number of phases served by a switch or breaker.

Port
The external connector on a device at which the network cable or medium is attached.
Power
Power refers to the rate of performing work or of expending energy. Typically, mechanical power
is expressed in terms of horsepower and electrical power in terms of kilowatts. One kW equals 1.34
hp.
Power Circuit Breaker

A power circuit breaker is a circuit breaker whose contacts are forced closed via a spring-charged,
over-center mechanism to achieve fast closing (5-cycle) and high withstand and interrupting
ratings. A power circuit breaker can be an insulated case or power air circuit breaker.
PowerCommand Control 1302

The base line control developed by Cummins Power Generation which will be used to replace the
“One-Off” controls used on Cummins Power Generation sets. The smaller kW range sets
commonly have non-Cummins engines. The PCC 1302 control operates on 12 Volt or 24 Volt
battery systems. It can be used without extra componentry on gaseous fuel gensets. When used on
some Diesel gensets, an external governor signal amplifier is needed. The PCC 1302 is intended to
be available for use on all non-paralleling Cummins gensets up to 1,500 kW in 2008.
PowerCommand Network
A communication network for moving information electrically among various Onan on-site power
generation modules. The PowerCommand Network will utilize Echelon LonWorks for system
module interconnection.
Power Factor
Power factor is the cosine of the angle between the active power (kW) and apparent power (kVA)
in a circuit.
Prime Power
Prime Power describes an application where the generator set(s) must supply power on a
continuous basis and for long periods of time between shutdowns. No utility service is present in
typical prime power applications.
Priority Control
Priority control is the process by which the total loads on the bus is limited to the most critical
loads in the system until adequate generation capacity is available to serve all loads.
Protocol
A set of rules used mutually by two or more devices to communicate. Also, known as the
"language" used in a network.

Pulse Alarms
Pulse alarms are alarm logic systems that allow all alarms to be annunciated, even if a previous
alarm has been silenced but is still present in the system.
RAM
Random-Access Memory. This is the memory that the PowerCommand Control uses to actually
operate the generator set. This memory requires power to maintain its content.
Radio Frequency (RF)

Any frequency within the electromagnetic spectrum associated with radio wave propagation.
Radio Interference
Radio interference refers to the interference with radio reception caused by a generator set.
Radio Interference Suppression

Radio interference suppression refers to the methods employed to minimize radio interference.
Random Access Paralleling

Random access paralleling is a paralleling operation where any generator may be the first unit to
close to the bus on startup of the system. Random access systems use active synchronizing to force
the second and all subsequent generator sets to close to the bus as fast as possible.
Rated Current
To be calculated based on rated power (kW) and nominal voltage.
Rated kW
Definition #1: This is set by the end application — standby, limited time prime, unlimited time
prime, or continuous.
Definition #2: Determined by the rated current and voltage programmed into the Base card by the
Manufacturing Tool or calibration downloaded by InPower software. This is the maximum kilowatt
load the generator set can provide.
Reference Value
A value in a control loop which determines to what value the control loop is attempting to drive the
output. An example situation would be when a synchronizing control loop is attempting to drive the
genset frequency to match the bus frequency. Perhaps the genset nominal frequency is 60.0 Hz, the
genset set point frequency is 61.5 Hz, but the bus frequency is 59.0 Hz because it is overloaded.
Prior to closing the circuit breaker, the genset will set its reference frequency to 59.0 to allow it to
match the bus. At this time, the reference value is 59.0 Hz.

Register
A ModBus communication packet of information. Cummins Power Generation uses 40000 level
designations for most genset data.
RMS(Root Mean Square)

The RMS values of a measured quantity such as AC voltage, current and power are considered the
"effective" values of the quantities. See Watt.
RPM
Revolutions Per Minute.
Reactance
Reactance is the opposition to the flow of current in AC circuits caused by inductances and
capacitances. It is expressed in terms of ohms and its symbol is X.
Reactive Differential Compensation

Reactive differential compensation (also called cross current compensation)is a method of
controlling the reactive power supplied by generators in a paralleling system so that they equally
share the total reactive load on the bus, without inducing significant voltage droop in the system.
Reactive Droop Compensation

Reactive droop compensation is one method used in paralleled generator sets to enable them to
share reactive power supplied to a load. This system causes a drop in the internal voltage of a set
when reactive currents flow from that generator. Typically, at full load, 0.8 PF, the output voltage
of a set is reduced by 4% from that at no load when reactive droop compensation is used.
Reactive Power
Reactive power is power that flows back and forth between the inductive windings of the generator
and the inductive windings of motors, transformers, etc., which are part of the electrical load. This
power does no useful work in the electrical load nor does it present load to the engine. It does apply
load to the generator and limits the capacity of the generator.
Reactor
A reactor is an electrical device that applies only reactive load to a system.
Real Power
Real power is the product of current, voltage and power factor (the cosine of the angle by which
current leads or lags voltage) and is expressed as W (watts).
Resistance
Resistance is the opposition to the flow of current in DC and AC circuits. It is expressed in ohms
and its symbol is R.

Reverse Power Relay

A reverse power relay is a relay with a wattmeter movement that senses the direction of power
flow. In paralleled sets, a flow of reverse power (i.e., power flow into set) will actuate the reverse
power relay and disconnect the set from the system. If one set stops and reverse power protection is
not provided, the set still running will drive the set that has stopped. The generator on the set that
has stopped will act as a motor.
Risers
Risers are rectangular copper or aluminum bars that connect circuit breakers, fusible switches, and
transfer switches with the main system bus. As with bus bars, they are sized and assembled in
multiples according to the current they must carry.
Rotor
A rotor is the rotating element of a motor or generator.
Router
A device for passing network messages over another media and sometimes protocol. Our network
router is programmed as a "repeater" to create another channel on the main network bus. Each
channel can have a 4,600 ft. network bus and is capable of having 44 nodes. The PowerCommand
Network can have up to twenty (20) channels.
Save and Restore Calibration

Downloading a data set to the PCC 2100 to update the operation of the control. In this type of
calibration, the data plate information for the genset comes from the stored data in the Base board.
All previous settings are restored.
SCR
Silicon Controlled Rectifier -- a three-electrode solid-state device which permits current to flow in
one direction only, and does this only when a suitable potential is applied to the third electrode,
called the gate.
Selective Coordination
Selective coordination is the selective application of overcurrent devices such that short circuit
faults are cleared by the device immediately on the line side of the fault, and only by that device.
Self Excitation
A method whereby the output of the AC alternator is utilized for powering the voltage regulation
circuit. Sometimes the term “Shunt Excitation” will be found in some product literature.
Separately Derived
A separately derived on-site power system has no direct neutral connection with the neutral of the
normal electrical service.

Sequential Paralleling
Sequential paralleling is a type of automatic paralleling system where the generators in a system
close to the bus in a prescribed order, typically by use of a single synchronizer.
Service Entrance
The service entrance is the point where the utility service enters the facility. In low voltage systems
the neutral is grounded at the service entrance.
Set point Value

A value which is the result of a trim made to a nominal value. An example would be if the operator
adjusted a nominal frequency of 60.0 Hz to 61.5 Hz. The set point value is 61.5 Hz.
Short Circuit
A short circuit is generally an unintended electrical connection between current carrying parts.
Shunt Trip
Shunt trip is a feature added to a circuit breaker or fusible switch to permit the remote opening of
the breaker or switch by an electrical signal.
Shutdown
A type of fault that causes the Genset to shut off immediately or prevents it from starting .
Sine Wave
A sine wave is a graphical representation of a sine function, where the sine values (usually the y
axis) are plotted against the angles (x axis) to which they correspond. AC voltage and current wave
shapes approximate such a curve.
Site
A single instance where a network has been installed.
Slave
A networked device that is controlled by another device. Slave devices do not initiate data
transmission. They respond to commands or requests initiated by a master device. In digital
communication systems such as ModBus, this would be a device that is not capable of originating
or initiating communications. It can only respond when asked for information.
Soft Loading
Soft loading refers to the ramping of load onto or off of a generator in a gradual fashion for the
purpose of minimizing voltage and frequency transients on the system.

Sound
Sound is considered both in terms of the sound pressure waves travelling in air (pressures
superimposed on the atmospheric pressure) and the corresponding aural sensation. Sound can be
"structure-borne", that is, transmitted through any solid elastic medium, but is audible only at
points where the solid medium "radiates" the pressure waves into the air.
Sound Level Meter

A sound level meter measures sound pressure level. It has several frequency-weighted decibel (dB)
scales (A, B, C) to cover different portions of the range of measured loudness. Sound level meters
indicate RMS sound, unless the measurements are qualified as instantaneous or peak sound level.
Sound Pressure Level (SPL)

Sound pressure level is a measurement of the pressure fluctuations of a sound wave as it propagates
through the air. Because of the wide range of pressures to which the ear responds, a logarithmic
scale is used and is expressed as a ratio of the measured pressure referenced to a pressure of 2x10-5
N/m2 (20 m Pa) which is the threshold of human hearing at 1000 Hz. The measure is expressed in
decibels (dB). The Bel unit is named after Alexander Graham Bell.
Standby System
A standby system is an independent power system that allows operation of a facility in the event of
normal power failure.
Star Connection
See Wye Connection.
Star Topology
A topology where all the devices must connect to a central hub. Star topologies are relatively easy
to install and manage, but can have bottlenecks occur as all the information must pass through the
hub.
Starting Current
The initial value of current drawn by a motor when it is started from standstill.
Stator
The stator is the stationary part of a generator or motor. See Armature.
Status
An indication of state used for informative purposes only — not a warning or shutdown alarm.
Typically a status indication does not require any action to be taken.
Steady State Rating

Steady state rating is the maximum load that a generator set or paralleling system can carry, on a
continuous basis, for the duration of a utility power outage.

Surge
Surge is the sudden rise in voltage in a system, usually caused by load disconnect.
Surge Rating
Surge rating is the rating of a machine, usually in excess of its normal operating level, for which it
can provide power for a very short time.
Surge Suppressor
Surge suppressors are devices capable of conducting high transient voltages. They are used for
protecting other devices that could be destroyed by the transient voltages.
Switching Hub
Short for port-switching hub, a special type of hub that actually forwards information to the
appropriate port based on the IP address assigned. Conventional hubs simply rebroadcast
information to every port. Switching hubs forward information only to the required port.
Sync Check Relay

A sync check relay is an electrical device that monitors the phase relationship between two voltage
sources and provides a signal when the voltage sources are within specific preset parameters.
Synchronization
In a paralleling application, synchronization is obtained when an incoming generator set is matched
with and in step to the same frequency, voltage, and phase sequence as the operating power source.
Synchronizer
A synchronizer is an electronic device that monitors the phase relationship between two voltage
sources and provides a connection signal to an engine governor, to force the generator set to
synchronize to the system bus.
Synchronizing Lights
Synchronizing lights are lamps connected across the line contactor of the incoming generator set.
The lights indicate when the voltage waveforms of the incoming and operating power sources
coincide and paralleling can be completed.
Synchronous Generator
A synchronous generator is an AC generator having a DC exciter. Synchronous generators are used
as stand-alone generators for emergency power and can also be paralleled with other synchronous
generators and the utility system.

Synchroscope
A synchroscope is a meter that indicates the relative phase angle between an incoming set voltage
and the bus voltage. The synchroscope pointer indicates whether the set is faster or slower than the
bus and allows the operator to adjust the frequency (speed) accordingly before manually paralleling
to the bus.
Telephone Influence Factor (TIF)

The higher harmonics in the voltage wave shape of a generator can cause undesirable effects on
telephone communications when power lines parallel telephone lines. The telephone influence
factor is calculated by squaring the weighted RMS values of the fundamental and the non-triple
series of harmonics, adding them together and then taking the square root of the sum. The ratio of
this value to the RMS value of the no-load voltage wave is called the Balanced TIF. The ratio of
this value to three times the RMS value of the no-load phase-to-neutral voltage is called the
Residual Component RIF.
Termination
Both ends of the main network bus must be terminated to avoid transmission reflections. The
effective network data bus may be made up of several different physical buses. The Terminator is a
RC circuit that matches the impedance of the physical media.
Terminator
A resistive load placed at the end of a cable to prevent data signals from reflecting back into the
data path.
Token
In digital data transmission communications, this is a “permission to speak” bit that passes from
network member to member in a specific sequence at specific intervals.
Token-Ring Topology
All of the devices or nodes are connected to one another in the shape of a closed loop. Ring
topologies are relatively expensive to install, but they offer high bandwidth and can span larger
distances.
Topology
The physical shape of a network. There are three principal topologies: multi-drop bus, token-ring,
and star.
Transfer Switch
A transfer switch is an electrical device for switching loads between alternate power sources. An
automatic transfer switch monitors the condition of the sources and connects the load to the
alternate source if the preferred source fails.

Trim
Non-volatile adjustment made in the field by an operator, user, or service technician. It is a subset
of parameters that can be adjusted, as opposed to parameters that can only be monitored.
TP/XF-78 Network
An older transceiver system used in PowerCommand Networks. TP/XF-78 stands for “Twisted-
Pair, Transformer-Coupled, 78 kbaud speed network.” The TP/XF-78 network has been replaced
by PCCNet network in small systems and by the FT-10 network in larger systems.
Utility
The primary producer/distributor of electric power. In some countries it’s called the utility source;
in some others it is called the mains or “hydro.”
Undershoot
Undershoot refers to the amount by which voltage or frequency drops below the nominal value as
the voltage regulator or governor responds to changes in load.
Volt
The volt is a unit of electrical potential. A potential of one volt will cause a current of one ampere
to flow through a resistance of one ohm.
Voltage Control
The voltage control is a rheostat that sets the operating point of the voltage regulator and therefore
controls the output voltage of the generator set, within its design limits.
Voltage Dip
Voltage dip is the dip in voltage that results when a load is added, occurring before the regulator
can correct it, or resulting from the functioning of the voltage regulator to unload an overloaded
engine-generator.
Voltage Regulation
Voltage regulation is a measure that states the difference between maximum and minimum steady-
state voltage as a percentage of nominal voltage.
Warning
A type of fault which does not shut down the engine or generator set, but is meant to warn the user
or operator of an out of normal condition which could eventually adversely affect operation of the
Genset (i.e. could shut it down or prevent it from starting or operating properly).

Watt
The watt is a unit of electric power. In direct current (DC) circuits, wattage equals voltage times
amperage. In alternating current (AC) circuits, wattage equals effective (RMS) voltage times
effective (RMS) amperage times power factor times a constant dependent on the number of phases.
1,000 watts equal one kW.
Watt-Hour Demand Meter

A watt-hour demand meter is similar to a watt-hour meter except that it also provides an indication
of the highest kW load level achieved during operation.
Watt-Hour Meter
A watt-hour meter records the total power output at a specific point in a system. Typical recording
increment is in kW-hours.
Wattmeter
A wattmeter records power being delivered from a source to the load. Wattmeters for paralleling
systems are calibrated in kilowatts (kW).
Wide-Area Network
A system of LANs connected over a large distance via a fiber optic line, telephone line, or radio
wave.
Wye Connections
A Wye connection is the same as a star connection. It is a method of interconnecting the phases of a
three-phase system to form a configuration resembling the letter Y. A fourth (neutral) wire can be
connected at the center point.
Zero Sequence
Zero sequence is a method of ground fault detection that utilizes a sensor (CT) that encircles all the
phase conductors as well as the neutral conductors. The sensor will produce an output proportional
to the imbalance of ground fault current in the circuit. This output is then measured by a relay to
initiate circuit breaker tripping or ground fault alarm.
Zones of Protection
Zones of protection are defined areas within a distribution system that are protected by specific
groups.

PCC 3.3 & PowerCommand Control 3300 Participants’ Activity Section 15 I

____ ______ ______ ______ ______ ______ ____ ______ ______ ______ ______ ______ _
Section 15:
PC 3.3 & PCC 3300 Activities
This section provides Activities and Quiz’s to the previous 13 Sections.
Section 1 Introduction Quiz. 15-3
Section 2 - 1 Menu Activities 15-5
Section 3 Sequence of Operation Quiz 15-17
Section 4 Installation Quiz 15-19
Section 5 - 1 Setup and InPower Quiz 15-21
Section 5 - 2 Setup and InPower Activities 15-23
Section 6 - 1 PCCNet Quiz 15-25
Section 6 - 2 PCCNet Activities 15-26
Section 7 ModBus Activities 15-27
Section 8 PGI Quiz 15-29
Section 9 Paralleling Intro Quiz 15-31
Section 10 Standalone Quiz 15-33
Section 11 Synchronize Only Quiz 15-35
Section 12 Isolated Bus Quiz 15-37
Section 13 Troubleshooting Quiz 15-39
Final Test {will be distributed by trainer at end of Module} 15-41
Participants’ Guide Section 15 - 1


____ ______ ______ ______ ______ ______ ____ ______ ______ ______ ______ ______ _


____ ______ ______ ______ ______ ______ ____ ______ ______ ______ ______ ______ _
Activity 1-1:
Section 1 Quiz:
Introduction to the PC 3.3 & PCC 3300 Quiz
Match and identify the image and components; use the Service Manual or Participants’
Guide. Images are located on the next page
_____ 1) TB-5 Breaker Control Connection _____ 12) DSx LED Status Indicators
_____ 2) J19 Control Board Interconnection _____ 13) Onboard CT’s
_____ 3) TB-7 Bus Voltage Sense _____ 14) J26 AUX105 Connections
_____ 4) AUX 105 Power Stage _____ 15) J22 Genset Voltage Sense
_____ 5) J14 Service Tool Port _____ 16) TB-9 Analog I/O
_____ 6) J12 Genset CT Input _____ 17) TB-10 Breaker Status Connections
_____ 7) TB-8 Customer Connections _____ 18) J18 – Power Input
_____ 8) J20 Genset Connections _____ 19) Chassis Ground Wire
_____ 9) TB-1 Customer Connections _____ 20) TB-3 Customer Input/Output
_____ 10) J17 – Field Output _____ 21) J25 Display Connections
_____ 11) TB-15 ModBus/RS485 Service Port _____ 22) PCC 3300

PCC 3.3 and PowerCommand Control 3300 Participants’ Activity Section 15
A B C D
P E
F
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L K J I
Q U

Activity 2-1:
PC3.3 Menu Navigation

Work through the Menus on the Operator Panel
1. Press the Home button and begin this activity from the Home Menus.
2. History / About
____________________ Number of Starts
____________________ Engine Hours
____________________ Control Hours
____________________ Genset Model Number
____________________ Kw Hours
____________________ ECM Code
____________________ Wye/Delta
____________________ Control Type
____________________HMI Boot Version
____________________ %kW Hours @ 40% @ 50Hz
____________________ “ Relative load % x 10” is displayed on which page?
____________________ %kW Hours @ 4% @ 60 Hz
3. Faults Screens
____________________ Number of Active Shutdowns
____________________ Number of Active Warning
____________________ First listed Fault History fault code

4. Fault History
Fault Index 1 Fault Index 2
__________ Fault Number __________ Fault Number
__________ Fault History at # Hours __________ Fault History at # Hours
_____________________Fault Name ______________________ Fault Name
Fault Index 3 Fault Index 4
__________ Fault Number __________ Fault Number
__________ Fault History at # Hours __________ Fault History at # Hours
____________________ Fault Name ______________________ Fault Name
5. Paralleling Status
____________________ How many Paralleling Status screens exist
________________________ What screen appears if you press “Basic” soft key?
6. Genset Data
____________________ How many Genset Data screens are available?
____________________ % Torque /Duty
____________________ Genset Standby Rated Current?

Activity 2-2:
PC3.3 Set Up Menus

Work through the Menus on the Operator Panel
1. Navigate to the HOME 2/2 Level to Setup Menus
________________________________________________________________________
______________________________ List the menu choices on the HOME 2/2 screen.
2. Adjust
____________________ Exercise Switch
____________________ Keyswitch override
____________________ Governor Gain
____________________ Stop Delay
3. Genset Setup
____________________ Nominal Voltage
____________________ Auto Sleep Enable
____________________ Start Delay
____________________ Disconnect Speed
____________________ Prelube Timeout
____________________ Controlled Shutdown Unload Time
____________________ Scheduler Program Run Mode
____________________ Exception Program Repeat Interval
____________________ Load Dump UF Set Time
____________________ Delay off FSO

4. Paralleling Setup - Basic
____________________ Gen Application Type
____________________ Voltage Match Kp
____________________ Sync Check Phase
____________________ Load Share Speed Droop Frequency Adjust
____________________ Load Share kVAR Gain
____________________ Load Govern kVAR Kp
____________________ Frequency Match Kp
5. OEM Setup Genset
Insert Serial Number GenSet _____5A124a_______________
Set Prime Standby to ______Prime______________
____________________ Fault Reset/#10 (locked or unlocked)
____________________ Backup Start disconnect/#33 (locked or unlocked)
____________________ Utility Energy Meter - Reset
____________________ Delay Shutdown Delay
____________________ Standby KVA Rating 3PH/60Hz
____________________ Reset Runs
____________________ Genset CB Tripped/#27
____________________ Load Demand Stop/#31
____________________ Voltage Bias Output/AO #2 (locked or unlocked)
____________________ Remote Fault Reset
6. OEM Setup Engine

____________________ Keyswitch Retries
____________________ V/Hz Slope
____________________ Data Save Delay
____________________ Weak Battery Set Time
____________________ Fault 1117 Enable
____________________ V/Hz Knee
____________________ Nominal Battery Volt
____________________ Freq/Speed
____________________ Prelube Enable
7. OEM Setup Alternator
____________________ Excitation Source
____________________ Max Field Time
____________________ AVR Enable
____________________ PT Primary
____________________ PT Secondary
____________________ AVR 60Hz Gains – K1
____________________ AC Voltage Fault High Threshold
____________________ Over frequency Fault Threshold
____________________ Under frequency Fault Threshold
____________________ Speed / Frequency Fault Threshold
____________________ CT Secondary

8. PCCNetSetup
____________________ PCCNet Failure Response – HMI320
____________________ PCCNet Failure Response – HMI113
____________________ HMI113 Output #2 Fault/Event
____________________ HMI113 Faults #3 Text
9. ModBus Setup
____________________ Baud Rate
____________________ Lost Response
____________________ CRC Response
____________________ Clear Counters
10. Display Options
____________________ Language
____________________ Sleep Timer
____________________ Mode Change
____________________ Temperature
____________________ Fluid Pressure
____________________ Fluid Volume
11. Clock Setup
___Present time of day___ Set the real time clock
___Present day, month, year___ Set the real time calendar
____________________ Daylight Saving Time
____________________ Daylight Saving Time End
12. Configurable I/O

___Louvers Open___ Change Configurable Input Fault#1 – Text
____________________ Low Fuel #6 - Response
____________________ Start Type/Input #11 - Active
____________________ Configurable Output #2 – Event Code
____________________ Oil Priming Pump/Output #6 - Invert Bypass
____________________ Genset CB Inhibit/Input#28 - Active
____________________ Speed Bias/AO#1 – Output High Setpoint
____________________ Voltage Bias/AO #2 – Function Output Low Setpoint
13. Calibration
____________________ Genset 1 Phase Voltage Cal – L1-N Calibration
____________________ Genset Bus Voltage Cal – L2-L3 Calibration
____________________ Utility Voltage Cal – L1-L2 Calibration
14. Save/Restore
Report all that you are able to view:

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________


Activity 2-3: Soft Key Menu Navigation
Using theSoft Keys at the bottomof the Home screen, work through theMenus on the
Operator Panel
1. Genset Data
______ ______ ______ __ Avg Current
______ ______ ______ __ Coolant Temp
______ ______ ______ __ %Torq?Duty
______ ______ ______ __ Total Fuel Consumption
______ ______ ______ __ Genset Standby KVA rating
2. Alternator Data
______ ______ ______ __ Frequency
______ ______ ______ __ AVR Duty Cycle
3. Engine Data
______ ______ ______ __ Oil Pressure
______ ______ ______ __ Ambient Pressure
______ ______ ______ __ Coolant Temperature
______ ______ ______ __ Aftercooler Temperature
______ ______ ______ __ Engine Hours
______ ______ ______ __ Battery Voltage
4. Paralleling

______ ______ ______ __ Gen breaker position
______ ______ ______ __ Load Demand Stop:
______ ______ ______ __ Synchronizer Bus Status
______ ______ ______ __ Genset CB Status - Tripped
______ ______ ______ __ Bus Metering - Frequency
______ ______ ______ __ Bus Energy Metering – Net kWhr
______ ______ ______ __ PhaseDifference – L1-L 2
5. %Alternator
______ ______ ______ __ Standby %Load – Total KW
______ ______ ______ __ Genset Energy Metering – Net kWhr
______ ______ ______ __ % Standby Current – L2
______ ______ ______ __ PrelubeMode
______ ______ ______ __ Number of Bargraphs
______ ______ ______ __ Phase Rotation
6. Advance Control
______ ______ ______ __ Exercise Time Remaining
______ ______ ______ __ High Alternator Temp
______ ______ ______ __ Active Start TypeInPuts
______ ______ ______ __ Load Dump/#11
______ ______ ______ __ Analog Input – Speed Bias
______ ______ ______ __ Active External Parallel Inputs
7. Advance Engine
______ ______ ______ __ Turbo 1 Speed - RPM:

______ ______ ______ __ Exhaust Port Temp #2
______ ______ ______ __ Exhaust Port Temp #20
______ ______ ______ __ Governor Ramp State
______ ______ ______ __ Battery Charger Voltage


Activity 3-1:
PC3.3 Sequence of Operation Quiz
Answer the following questions about functions and components; use the
demonstrator, Participants’ Guide or Operator Manual 900-0670.
1. The PMG can provide the backup start disconnect. At what voltage does it activate?
AC or DC?
_______________________________________________________________________
2. In order to keep the devices awake at all times, what jumper do you make on the HMI
320?
_______________________________________________________________________
3. If the genset is running and then enters Manual operation, how long do you have to
push the Manual Button before it will do a hard shutdown?
_______________________________________________________________________
4. What is the Prelube Cycle Time default setting?
_______________________________________________________________________
5. Start Time Delay can be set to what range of values?
_______________________________________________________________________
6. What terminal block and pin will the ground input remote start signal enter the
PowerCommand 3.3?
_______________________________________________________________________
7. Is motor starting performance better using self excitation? Why?
_______________________________________________________________________
8. When running in Parallel Mode @ idle, what button push will cause the breaker to
close?
_______________________________________________________________________


Activity 4-1:
PC3.3 Installation Quiz

1. When powering down the PCC 3300, it is important to press the local Emergency
Stop button and wait approximately 30 seconds before removing battery power.
Why?
A. To ensure that the ECM has time to cool down before power down
B. To ensure that the ECM has had enough time to save data in memory before
power down.
C. To prevent static discharge damage to the control boards. .
D. All of the above
2. The PCC3300 processor receives alternator field information (F1 and F2) through
A. J17-1 and J17-2

B. J20-11 and J20-22
C. J26-7 and J26-14
D. None of the above
3. Which of the following is a true statement?
A. Low side is the same as battery ground

B. B+ return is the same as battery negative
C. B+ return is the same as ground
Match each of the following components in column A to its corresponding function in

column B
Column A (Component) Column B (Function)

4. _______CT1, CT2, CT3 A. Provides analog paralleling load management input
and output
5. _______J26 B. Monitor the Bus current
6. _______TB5 C. Monitor the genset current
7. _______HMI320 D. Connection to the engine and AVR Power Stage
8. _______TB9 E. Connection to the circuit breaker controls
F. Interface to the generator and controller functions


Activity 5-1:
PC3.3 Setup and InPower Quiz
1. Kit 0541-1199 allows the technician to connect InPower to both the Operator Panel
and the Base Board at the same time.
A. True
B. False
2. Which of the following is true with regard to connecting InPower to the HMI?
A. The HMI needs to powered by a DC source via connector 15

B. Communication takes place through J28 on the HMI
C. The HMI can be powered through the control board via connector 15
Match each of the following feature folders in column A to its corresponding function in
column B
Column A (Component) Column B (Function)

3. _______Advanced Status A. Allows the user to view fault information and set
fault configurations
4. _______Alternator Data B. Allows the user set and perform tests such as
witness testing
5. _______Engine Data C. Allows the user to monitor engine, alternator, genset

and fuel system performance and data
6. _______Faults D. Allows the user to monitor engine performance data

only
7. _______Test E. Contains functions that used to be found in the

adjustments folder.
F. Allows the user to monitor alternator performance

data only

8. The snapshot feature allows the user to select a particular fault and then view data for
the preceding few seconds before that fault becomes active.
A. True
B. False
9. Why is it important to save a capture file before making any changes or adjustments?
_______________________________________________________________________
________________________________________________________________________
10. When viewing the setup wizard, the Enable Setup Mode button seen on the setup
screens must be highlighted in order to be able to make any adjustments/changes.
A. True
B. False

Activity 5-2:
PC3.3 Setup Activity

Work through the Menus on the Operator Panel to adjust the Real Time Clock
and Exercise setup. Use Appendix C of the Participants’ Guide and/or Operator
Manual 900-0670.
1. Set the Real Time Clock to the present time.
2. Set the Calendar to the present Day, Month, and Year
3. Set the Daylight Savings time, day, month and hour and all settings for the year.
4 . Set the exerciser Scheduler to exercise the genset every Thursday morning at
10:00AM for 30 minutes and on Friday afternoon at 12:30 for 10 minutes.
5. Set the Exception for Thursday & Friday November 27 & 28 beginning in the year
2008.
6. Can all of these setting be achieved? YES______ NO_______
7. If InPower is available, check all the setting that were been made during this exercise.


Activity 6-1:
PC3.3 PCCNet Quiz

1. The recommended data cable for the data and power wires used with PCCNET is
Beldin #9729.
A. True
B. False
2. The maximum number of devices in the network is 20 and should not span more than
4000ft of data wire.
A. True
B. False
3. Which of the following is NOT true about PCCNET?
A. It is a flexible communication system that provides device to device connectivity.

B. It is a communication system that uses a proprietary protocol unique to CPG
products.
C. It is a system for monitoring or building management systems
D. It is a token passing network
4. List 4 devices that the PCC 3300 communicates with

5. Which of the following is true about the Universal Annunciator?
A. PCCNET allows for up to four annunciator’s in a network

B. The Annunciator supports both network and discrete wiring terminals
C. PCCNet Annunciator Switch Settings can only be changed when the device is
connecting with the PCC Genset
D. Both A and B
E. All of the above
Activity 6-2:
PC3.3 PCCNet Activity

It is optional to include configuration of the HMI 113 - Universal Annunciator. This
activity is not required. The setup procedures are exactly the same as found in
the PC 2.X training course.
More activities will be offered in the PHASE 2 training. More

PCCNet devices will be available at that time. The skills and
experience of setup and installation of the PHASE 2 devices will
be more valuable at that time .

Activity 7-1:
PC3.3 ModBus Quiz
1. Since the PowerCommand 3.3 follows the master-slave protocol, would the
PowerCommand 3.3 be configured as a master or a slave? Why?
__
____________________________________________ __________________________
2. Does the PowerCommand 3.3 use ModBus RTU or ModBus ASCII?
__ _______________________________________________________
_______________
3. On what PCC 3300 connector would you make your ModBus connections?
__
__________________ ____________________________________________________
4. Can you change the communication Baud rate on the PCC 3300 base board?
__ ________________________________________________________________
______
5. Via the HMI 320, what screens would you use/navigate to find the ModBus setup
information?
________________________________________________________________________
6. What is the Fasted Baud Rate available for the PowerCommand 3.3?
__ _______________________________________________________
_______________
7. With the PowerCommand 3.3 ModBus Register Map, what ModBus Address is Genset
LL Average Voltage?
________________________________________________________________________
8. What software can be used to help troubleshoot the PowerCommand 3.3 ModBus
communication?
________________________________________________________________________


Activity 8-1:
PC3.3 PGI CAN Communication Quiz
1. What connector and pins would you check the backbone for proper resistance values?
What should be the value between those pins if the circuit is good?
_______________________________________________________________________
2. What is the maximum length of a PGI backbone?
_______________________________________________________________________
3. Can you perform Witness Testing Procedures if you are connected to the PCC 2300
base board with InPower?
_______________________________________________________________________
4. If you were connected with a Peak System Adapter and did not see DC as part of any
source address, what would this mean?
_______________________________________________________________________
5. Do you need to ground your backbone shield? If so, where?
_______________________________________________________________________
6. Where would you find B+ on the 9-Pin Service Tool connector?
_______________________________________________________________________
7. Can your system communicate with only one terminating resistor?
__
____________________________________________________ __________________
8. What is the communication speed of the PGI system?
_______________________________________________________________________


Activity 9-1:
PC3.3 Parallel Intro Quiz

1. The PC3.3 comes fully configurable and there is no requirement to purchase new
codes or additional features.
_____True
_____False
2. In what mode would you use Load Govern?
A. Standby
B. Isolated Bus
C. Utility Single
D. Utility Multiple
E. C & D
3. Load Share is a feature that allows?
A. The amount of KVAR sharing

B. the generator to supply a portion of KW power.
C. the unit to operate in speed droop.
D. synchronization in all paralleling modes.
4. Which connector is not used when configuring the control for paralleling modes?
A. TB10
B. TB1
C. TB5
D. TB3
5. There are many adjustments and few monitor screens in the paralleling setup folder.
_____True
_____False


Activity 10-1:
PC3.3 Standalone Paralleling Quiz

1. The password used for changing the Genset Application Type from the HMI is?
A. 121
B. No password is required
C. 574
D. 1209
2. CT1 can only read Neutral Bus current in Standalone Mode.
_____True
_____False
3. The fault code generated when Genset CB Tripped is active is?
A. 1213
B. 1454
C. 1456
D. 1209
4. Configurable Input #27 is commonly used for Ground Fault Protection.
_____True
_____False
5. TB10-2 & 10 must be connected to the:
A. Utility disconnect breaker.

B. it is an optional connection and does not need to be attached to anything.
C. the ground fault relay
D. breaker trip relay.


Activity 11-1:
PC3.3 Synchronize Only Quiz
1. Synchronize only mode cannot be used with a transferswitch.
_____True
_____False
2. CT2 can only read Neutral Bus current in Synchronize only Mode.
_____True
_____False
3. Which ModBus register will initiate the Synchronizer when in Synchronize only
mode?
A. 40954
B. 43954
C. The synchronizer can only be enabled through TB10 – 13 & 19.
D. The Synchronizer is always enabled when in Synchronizer only mode.
4. In Synchronize only mode, the breaker close command is connected to?
A. TB10 – 13 &17

B. It is not connected anywhere because the PCC does not close the breaker in
Synchronizer only mode.
C. TB10 – 13 & 19.
D. TB 5 – 1 & 2.
5. Slip Frequency synchronizing is initiated how?
A. ModBus input command

B. InPower
C. Configurable Input #30.
D. after the control fails to Phase Match synchronizes for 10 consecutive seconds.


Activity 12-1:
PC3.3 Isolated Bus Paralleling Quiz

1. The genset circuit breaker close control output is provided at terminals?
A. TB10 – 8 & TB10 - 2

B. TB5 – 1 & TB5 - 2
C. TB10 – 9 & TB10 - 11.
2. Which connector is used for circuit breaker control?
A. TB3
B. TB7
C. TB5
3. Which connector inputs are used for First Start Arbitration?
A. TB3-9 & TB3-1

B. TB10 - 13 & TB10 - 17
C. TB10 – 13 & TB10 - 19.
D. TB3 – 12 & TB3 - 11.
4. Which of the following statements is true for the Bus CTs?
A. The wire may be looped through the CT twice.

B. The wire may be routed through the CT in either direction.
C. There should be shorting blocks installed in the system.
D. All of the above.
5. For a 120/240 volt 3 phase installation, where do the generator bus inputs land on the
PCC3300 control board?
A. TB9- pins 7, 8, 10, & 11

B. TB7 – pins 1, 2, 3, and 4
C. TB7 – pins 5, 6, 7, and 8.
D. TB7 – pins 1, 2, and 3


Activity 13-1:
PC3.3 Troubleshooting Quiz

1. The InPower Snapshot feature can only be used for alternator fault codes?
_____True
_____False
2. InPower cannot monitor the control during the Prelube cycle?
_____True
_____False
3. All faults codes available from the PCC3300 control can be reset by the ModBus reset
register.
_____True
_____False
4. Exciter Field voltage limits are listed on the Common Connector Wire Diagram ?
_____True
_____False
5. is found on which page in the service

manual?
A. A-5
B. A-7
C. A-5, 6, 7, and 8.
D. A-12


PCC 3.3 and PowerCommand Control 3300 Appendix Section 16
Section 16:
PC 3.3 Appendix
This section provides additional technical information to assist with understanding
several sections.
Appendix A Setting the Real Time Clock . . 16-3
Appendix B Using ModScan Software 16-10
Participants’ Guide Section 16 Appendix

PCC 3.3 and PowerCommand Control 3300 Appendix Section 16
Participants’ Guide Section 16 Appendix

PC 3.3 REAL TIME CLOCK & EXERCISE Appendix A
PC 3.3
Real Time Clock
The PCC3300 control system includes a real time clock function. The Real Time Clock (RTC) is used for
calculating controller on time, recording fault occurrence times, supporting factory test, and for the automatic
scheduler feature. Once programmed, the real time clock accurately* calculates seconds, minutes, hours,
date of the month, month, day of the week, and year with leap year compensation valid up to 2100. The
clock operates in 24 hour format and automatically adjusts the end of the month for months fewer than 31
days.
When battery power is removed from the PCC3300, the RTC remains powered via internal circuitry on the
PCC3300. The internal circuitry will provide power to the RTC for about one hour, after which the RTC will
become reset to 0 Seconds, 0 Hour, 0 Minutes, 0 Month, 0 Date, 0 Year. Under this condition, the “RTC
Power Interrupt” Fault (1689) will become active indicating that the clock needs to be reset.
The RTC also has supports Daylights Savings Time, which is a convention used to advance the time by one
hour so afternoons have more daylight then mornings. The DST logic adds the DST Adjustment time to the
current time when the current time is equal to the DST Start Time. The DST logic subtracts the DST
Adjustment time from the current time when the current time is equal to the DST End Time. To Enable DST,
the trim Daylight Savings Enabled needs to be set to Enabled. To setup DST, specify the values for the
following trims.
Trim Value Meaning

Daylight Savings End Day Monday - Sunday Calendar Day in which DST Ends
Daylight Savings End Hour 02 – 19 hours Hour (24 Hr) in which DST Ends
Daylight Savings End Month 1 – 12 months Month in which DST Ends
Daylight Savings End Week First Occurrence – Last Occurrence of Daylight Savings End
Occurrence in Month Occurrence Day in which DST Ends
Daylight Savings Start Day Monday - Sunday Calendar Day in which DST Starts
Daylight Savings Start Hour 02 – 19 hours Hour (24 Hr) in which DST Starts
Daylight Savings Start Month 1 – 12 months Month in which DST Starts
Daylight Savings Start Week First Occurrence – Last Occurrence of Daylight Savings End
Occurrence in Month Occurrence Day in which DST Starts
Daylight Savings Time Adjustment 0 – 120 minutes Amount of time to be added or

subtracted from current time for DST
adjustment.
PC 3.3 Training Guide Appendix A Page1

nd
For Example: If DST Ends on the 1st Wednesday in April at 02:00 AM every year, and DST Starts on the 2
Thursday in September at 3:00 PM every year, and DST Adjusts the clock by 1 hour each time, the
parameters should be set to the following values.
Trim Value
Daylight Savings End Day Wednesday
Daylight Savings End Hour 02
Daylight Savings End Month 4
Daylight Savings End Week First Occurrence
Occurrence in Month
Daylight Savings Start Day Thursday
Daylight Savings Start Hour 15
Daylight Savings Start Month 9
Daylight Savings Start Week Second Occurrence
Occurrence in Month
Daylight Savings Time Adjustment 60
*The real time clock is accurate with 30 minutes over the course of 1 calendar year.
PC 3.3
Exercise Scheduler
The exercise scheduler is a feature that automatically starts the genset for exercise. This feature prevents
common problems which result from mechanical equipment sitting for long periods of time. In order for the
automatic exerciser to work, the PCC3.3 control system needs to be in ‘Auto’ mode, the RTC needs to be
set (Fault 1689 is not active), and the trim Exercise Scheduler Enable needs to be set to Enable.
The PCC3.3 can be programmed to run up to 12 independent programs, all which can either be one time
events or repeating events. Furthermore, each program can be programmed to exercise the genset in two
run modes, no load and with Load.
Each independent program has the following trims which establish its behavior. “X” can have a value from 1
thru 12, once for each available program.

Trim Value Meaning

Scheduler Program x Enable Enable – Disable Enables or Disables Schedule X
Scheduler Program x Start Minute 0 – 59 Specifies at what minute Program X
with start.
Scheduler Program x Start Hour 0 – 23 Specifies at what hour Program X will
start.
Scheduler Program x Start Day Monday – Sunday Specifies at what day Program X will
start.
Scheduler Program x Run Mode No Load / Load Specifies if Program X will exercise
the genset with Load or No Load.
Scheduler Program x Repeat Once, Twice… Specifies the repeating behavior of
Interval Program X
Scheduler Program x Duration 0 – 23 Specifies how many hours Program X
Hours will run.
Scheduler Program X Duration 1 – 59 Specifies how many minutes Program
Minutes X will run.
For example, if it was desired to have a Program that ran on every Monday at 8:12 AM for 1 Hour and 30
Minutes with Load the trims should be defined like this
Trim Value
Scheduler Program x Enable Enable
Scheduler Program x Start Minute 12
Scheduler Program x Start Hour 8
Scheduler Program x Start Day Monday
Scheduler Program x Run Mode Load
Scheduler Program x Repeat Every Week

Interval
Scheduler Program x Duration 1
Hours
Scheduler Program X Duration 30
Minutes

The following table is the Exercise Scheduler table which contains the information for Programs 1 thru 12.
Scheduler Scheduler Start Time Scheduler Scheduler Schedule Repeat

Program Program Program Program Interval
Enable Start Day Duration Run Mode
Hr Min Hr Min Week
Program 1
Program 2
Program 3
Program 4
Program 5
Program 6
Program 7
Program 8
Program 9
Program 10
Program 11
Program 12
Another sub-feature of the Exercise Scheduler is the ability to program exceptions to the scheduler
programs. Exceptions are anti-programs and can either be on time events or repeating. The PCC3.3 can
have up to 6 independent exceptions. The following are the trims needed to define an exception.
Each independent program has the following trims which establish its behavior. “X” can have a value from 1
thru 12, once for each available program.
Trim Value Meaning
Scheduler Exception x Enable Enable – Disable Enables or Disables Exception X
Scheduler Exception x Minute 0 – 59 Specifies at what minute Exception X
with start.
Scheduler Exception x Hour 0 – 23 Specifies at what hour Exception X
will start.
Scheduler Exception x Date 0 - 31 Specifies the date in which Exception
X will start.
Scheduler Exception x Month 0 - 12 Specifies which Month Exception X
will start.
Scheduler Exception x Repeat Once, Every Year. Specifies the repeating behavior of
Exception X
Scheduler Exception x Duration 0 – 23 Specifies how many hours Exception
Hours X will be valid for.

Scheduler Exception X Duration 1 – 59 Specifies how many minutes

Minutes Exception X will be valid for.
Scheduler Exception X Duration 0 – 44 Specifies how many days Exception X
Days will be valid for.
For example, if it was desired to have an Exception that stopped all programmed activity from December
th nd
25 at 1:00 AM until J an 2 the trims should be defined like this
Trim Value
Scheduler Exception x Enable Enable
Scheduler Exception x Minute 0
Scheduler Exception x Hour 1
Scheduler Exception x Date 25
Scheduler Exception x Month 12
Scheduler Exception x Repeat Every Year.
Scheduler Exception x Duration 23

Hours
Scheduler Exception X Duration 1
Minutes
Scheduler Exception X Duration 7
Days
The following is the Exercise Scheduler which contains all the exceptions 1 - 6.
Scheduler Scheduler Scheduler Exception Schedul

Scheduler Exception Exception Time Duration er
Exception Exceptio
Enable n Repeat
Month Date (Interval)
Hour Minute Days Hours Minute
s
Exception 1
Exception 2
Exception 3
Exception 4
Exception 5
Exception 6

The following are a set of rules used to define schedules and exceptions –
1. If there is a running program and the next programmed program(s) overlap with the existing
running program, the existing program will run as it is and next overlapping program(s) will not
start even, if the first program is expires before the next overlapping program is scheduled to
stop.
2. If program is running and exception becomes active, the PCC3.3 control system will ignore the
newly activated exception(s) and will continue to run the active program expires.
3. If there is an active exception and the next exception(s) overlap with the existing active
exception, the existing exception will continue to be active as it is and the next exception(s) will
be ignored.
4. If an exception and program are scheduled to become active at the same time, then the
exception will become active and the program will be ignored.
5. If a program is active and running (or an exception is active) and control system loses power
before the program or exception can expire, the active program or exception will not be started
again when power is restored to the control system even if there is time remaining in the
program/exception.
Remote Start command behavior on exercise scheduler –

While in exercise scheduler mode, { ie a scheduled program is active and control system is in ‘Auto’ mode,} if the
PCC3.3 control system receives a remote start command, the genset will continue to run. If remote start
command is removed and the exercise scheduler program is still active, the genset will continue to run until
scheduler time lapses.

Appendix B PC 3.3 ModBus
USING MODSCAN SOFTWARE
ModScan is a software tool that can help you verify ModBus communications from the
PowerCommand control. It is not a Cummins Power Generation product, it is a product designed
by WinTech for general use in any ModBus serial communication system. The use of ModScan
enables a CPG technician to prove ModBus communications from a CPG controls system to a
neutral third party software.
The following directions and examples apply to using ModScan with PCC 1301 and 1302 genset
controls.
Refer to the appropriate register map for specific registers available.
FIGURE 1. MAIN MODSCAN SCREEN

Use ModScan software after you have enabled your ModBus setup in the control. A standard
PCC 1300 series service cable must be installed between the PC serial port and the TB-15
connector on the PCC 1302 control board. PC serial ports communicate using RS232 so a
RS485 converter must be used. Figure 1 show the initial screen displayed upon launching the
program.
Page 1

FIGURE 2. MAIN MODSCAN SCREEN

1. From the tool bar, select:
Connection
Connect.
The Connection Details dialog box is displayed (see Figure 3). The “Connect Using” is used to designate
the proper communication port on your computer.
2. Use the pull down menu under “Connect Using” to select the comm port you wish to use.
A typical configuration would be set to:
Baud Rate: 19200,
Word Length:8,
Parity: None,
Stop Bits: 1,
(as shown in Figure 3.)
Use the pull down menus to change these settings as necessary.
Page 2

FIGURE 3. FT–10 NETWORK CONNECTION DETAIL S DIALOG BOX
3. Click on the “Protocol Selection s ” button and change the Transmission Mode to “RTU”
(see Figure 4). Do not be concerned with settings in the other boxes. Click “OK ” button.
FIGURE 4. MODBUS PROTOCOL SELECTION DIALOG BOX
Page 3


4.Click “OK” on the two open dialog boxes.
You should notice in the upper right of the dialog box, the “Number of Polls” counter
incrementing.
Notice the message at the top of the register list captured by **____**. In Figure 4-2 the
message **MODBUS Exception Response from Slave Device ** is indicating the device has
responded, but there is a problem with one or more messages in the poll length.
If the **____** line states **MODBUS Message TIME-OUT** ModScan is not able to find
anything at the other end of the communication wire. There could be many reasons for this.
Check your computer comm.. port, the wire, if the PCC 1302 is powered up, if ModBus is
“Enabled”, or if the PCC 1302 “ModBus Setup” matches the Protocol settings on Figure 3 & 4.
FIGURE 4-2. MODBUS DIALOG BOX INFORMATION
5. On the main ModScan screen (see Figure 5), Change the Address to 0064, the Length to 1.
WARNING ModScan is not satisfied if it polls a group of registers and finds one in the
sequence that is not pr ogrammed, it will d isplay a “ Exception Response” as in Figure 4-2.
Minimize the number of r egisters polled to a sequential length as listed in th e register
map.
6. From the MODBUS Point Type pull down menu, select “03: HOLDING REGISTER.”
The PCC 1300 series communicates all registers as a HOLDING REGISTER. Refer to any of the
preceding mapping registers to view different pieces of data.
The “Valid Slave Responses” should now be incrementing as the data on the screen is updated.
You should see a single register displayed with a 5 digit value. Poll the following register
addresses for the Genset.
40061 is Battery voltage at the control.
40064 is Coolant Temp. (This value will be displayed in Celsius ONLY)
40070 is Eng Runtime (value will be displayed in seconds)
Page 4

FIGURE 5. MODBUS POINT TYPE = HOLDING REGISTER
7. On the main ModScan menu (see Figure 6), change the Length to 1. Refer to the warning in
step 5.
WARNING Accidental starting of the generator set can cause severe personal injury or
death. During step 8, a “ start” command is sent to the genset. If the genset is in t he Auto
mode, the genset WILL s tart.
8.To output a value to the genset control, poll the desired address, (In this case we want to test
the start command which is register #40300) double click on register 40300. The Write Register
dialog box is displayed (see Figure 6).
If you enter a value of “1” and select “Update,” Genset #1 starts and runs. If you double click on
register 40300 again, enter a value of “0,” and selecting “Update;” the Genset stops.
9. Review the mapping register information for other coils that you can manipulate.
Page 5

FIGURE 6. WRITE COIL DIALOG BOX
ModScan Read & Write Commands

ModScan has more ability to test and command ModBus devices than is presented in this guide. There
are other features used on some of the other PowerCommand ModBus systems, but the processes and
examples so far listed will enable a technician prove to a customer or system integrator that the PCC 1301
or 1302 will communicated properly.
Page 6

Notes
The following notes apply to using ModScan with PCC 1301 and 1302 genset controls.
Refer to the appropriate register map for specific registers available.
Genset Control
 Start/Stop - When this register is set to “1,” the genset starts, and ramps to operating speed.
As long as this register remains a “1,” the genset will continue to run. When this register is set
to “0,” the genset stops.
 Fault Reset - This should be a momentary signal of about 2 seconds duration. Entering a “1” in
the fault reset register resets any non–active warning and, If there is not a remote start on the
genset, it resets any non–active shutdown except the Emergency Stop.
 Emergency Stop - When this register is set to “1,” the emergency stop is active at the
PowerCommand control. The emergency stop cannot be rest until this register is set to “0.”
After the register is reset to “0,” the emergency stop must be reset at the PowerCommand
control. It cannot be reset remotely.
Miscellaneous
 Fault State - As part of Gen Status State, digital value 4 (Fault State 1) = shutdown with an
active run command (cannot be remotely reset) and digital value 5 (Fault State 2) = shutdown
with no active run command (can be remotely reset).
 Fault Code - This register contains the fault code number of the currently active fault. See
service manual for list of supported fault codes.
 Fault Type - This register contains the fault type of currently active fault
0=Normal
1=Warning
2=Derate (this is a feature NOT currently supported by the PCC 1300 series)
3=Shutdown with Cool down
4=Shutdown
 Fault bypass (battle short) feature enable – Activation of battle short via ModBus is just as
serious as any other activation of battle short.
Page 7

Page 8

PCC 3.3 and PowerCommand Control 3300 Diagrams Section 17
Section 17:
PC 3.3 Sequence Diagrams
This section contains Common Connector wire diagrams and Sequence
Diagrams.
Diagram 630-3440 Rev D Sheet 1 - 11
Diagram 630-3440 Rev D Sheet 12 - 19
Parallel Mode Sequence Diagram Symbols
Parallel Mode Sequence Diagram Synchronize Only
Parallel Mode Sequence Diagram Isolated Bus Only
Participants’ Guide Section 17 Sequence Diagrams


Sheet 1 of 1

Sheet 2 of 2

Sheet 3 of 3

Sheet 4 of 4

Sheet 5 of 5

Sheet 6 of 6

Sheet 7 of 7

Sheet 8 of 8

Sheet 9 of 9

Sheet 10 of 10

Sheet 11 of 11

Sheet 12 of 12

Sheet 13 of 13

Sheet 14 of 14

Sheet 15 of 15

Sheet 16 of 16

Sheet 17 of 17

Sheet 18 of 18

PARALLELING SEQUENCES LEGEND
B-3

SYNCHRONIZE ONLY
B-4

ISOLATED BUS ONLY
B-5


PowerCommand
____ 3.3 & PowerCommand
______ ______ ______ ______Control
______ 3300
____ ______Section
______ 18____ ______ ____
Section 18:
PC 3.3 & PCC 3300 Module Comment Sheet
Participants are requested to turn in the Comment Sheet at the

end of the course to help update the course materials as
needed.
Participants’ Guide Section 18

PowerCommand
______ ______ ______ ______Control
______ 3300
____ ______Section
______ 18____ ______ ____

PowerCommand
______ ______ ______ ______Control
______ 3300
____ ______Section
______ 18____ ______ ____
Module Comment Form

Now that you have completed the PC 3.3 & PowerCommand Control 3300 training module,
we would like you to assess your skills before and after the training program.
Circle the appropriate number on both scales for each performance area.
Your Skill level Your Skill level
Performance Area Before the program After the program

No skill High Skill No skill High Skill
Understanding the CPG model and

0 1 2 3 4 5 0 1 2 3 4 5
component naming system.
Selection of proper Section topics and
0 1 2 3 4 5 0 1 2 3 4 5
Section content.
Use of Installation guides, Instruction
0 1 2 3 4 5 0 1 2 3 4 5
Sheets, Guides, and Appendix Material.
Operating the HMI, and navigating the
0 1 2 3 4 5 0 1 2 3 4 5
control system.
Operation of the HMI for configuration
processes and setup. 0 1 2 3 4 5 0 1 2 3 4 5
Operation and connection of InPower

for configuration processes and setup. 0 1 2 3 4 5 0 1 2 3 4 5
Understanding Common Connector

Scheme and new schematics. 0 1 2 3 4 5 0 1 2 3 4 5
Understanding connector locations and

functions. 0 1 2 3 4 5 0 1 2 3 4 5
Understanding features and

commonality of options. 0 1 2 3 4 5 0 1 2 3 4 5
Setup various PCCNet components and

install them. 0 1 2 3 4 5 0 1 2 3 4 5
Setup the ModBus feature, test it and

understand its basic operation. 0 1 2 3 4 5 0 1 2 3 4 5
Identify PGI CAN system components

and understand their operation. 0 1 2 3 4 5 0 1 2 3 4 5
Troubleshoot CAN genset control

systems. 0 1 2 3 4 5 0 1 2 3 4 5
Converse about genset communication

ability with Building Management 0 1 2 3 4 5 0 1 2 3 4 5
System installers.

PowerCommand
______ ______ ______ ______Control
______ 3300
____ ______Section
______ 18____ ______ ____
We are interested in your opinion about the effectiveness and usefulness of this training
module. We will use the results of your response to help improve and modify training
modules and the effectiveness of their delivery. Please fill out the form by placing a mark on
the scale next to each statement.
Strongly Strongly
Agree Disagree
Agree Disagree
1. The Purpose of the module was clear

to me.
2. The lesson objectives were
appropriate.
3. The proper amount of information
was presented
4. The module content was at an
appropriate level for my background
and experience
5. The visuals were helpful in

explaining the topic.
6. The module followed a logical and

meaningful sequence.
7. The module activities gave me a
chance to practice new skills or work
with new ideas.
8. I will be able to apply what I have

learned from this module.
Overall, how do you rate this training module? (circle one)

1 2 3 4 5 6 7 8 9 10
Poor Outstanding
(Over)

PowerCommand
______ ______ ______ ______Control
______ 3300
____ ______Section
______ 18____ ______ ____
Use this page to add any comments or suggestions for course improvement.
Comments and Suggestions:

PowerCommand
______ ______ ______ ______Control
______ 3300
____ ______Section
______ 18____ ______ ____

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PowerCommand Control 3300 & HMI 320

Introduction to the PowerCommand Control 3.3, the PowerCommand

PowerCommand 3.3 & HMI 320 Operation and Service Menus: 2

PowerCommand Control 3.3 Sequence of Operation: 3

PowerCommand Control 3300 Installation: 4

PowerCommand Control 3300 Control Setup and InPower: 5

PCCNet Network for the PC3.3: 6

PowerCommand Control 3300 ModBus: 7

PowerCommand Control 3300 PGICAN: 8

PowerCommand Control 3300 Paralleling Introduction: 9

PowerCommand Control 3300 Paralleling - Standalone: 10

PowerCommand Control 3300 Paralleling - Synchronizer: 11

PowerCommand Control 3300 Paralleling – Isolated Bus: 12

PowerCommand Control 3300 Paralleling Troubleshooting: 13

Module Comment Sheet: 18

PowerCommand 1.X PowerCommand 2.X Pow erCommand 3.3

PCC 1302 PCC 2300 PCC 3300

PowerCommand 1.1 PowerCommand 2.2 PowerCommand 3.3

PowerCommand 2.2 PowerCommand 3.3

Here is a list showing how they are structured:

1.X = PCC 1302 control board

Participants’ Guide Title & Introduction Page6

X.1 = HMI 211

Participants’ Guide Title & Introduction Page7

Participants’ Guide Title & Introduction Page8

Module Comment Form

Cummins Power Generation

Participants’ Guide Title & Introduction Page9

PCC 3.3 & PowerCommand Control 3300 Section last page

THIS PAGE IS INTENTIONALLY LEFT BLANK

Participants’ Guide Section Last Page

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

Section 1 Introduction to the

Participants’ Guide Section 1 Page1

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

Introduction to the PCC 3.3, the PowerCommand

Participants’ Guide Section 1 Page2

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

After completing this lesson, the participants should be able to:

• Identify the PCC 3.3 standard components.

Participants’ Guide Section 1 Page3

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

PowerComm and Control 3300

 Premium Paralleling Genset Control

 Integrated J 1939 CAN Link for FAE sets

 Optional governor amp. for non-FAE sets (Phase 2)

 Separate module for AVR (Voltage Regulation)

 Common wiring harness with “3-series”controls

Visual 1-2 Introduction to the PowerCommand Control 3300

Participant’s Text Notes:

The PowerCommand Control 3300 is a

The Phase 1 release of this new control will

The phase 2 release will support a governor

Participants’ Guide Section 1 Page4

PCC 3.3 & PowerCommand Control 3300 Introduction and Options

PCC 3300 Control Boards

AUX 103 Power Stage