MCM3320 Brochure

8/14/2019 MCM3320 Brochure

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© 2006 Cummins Power Generation Specifications Subject to Change S1475 051706

GenSet Controls

PowerCommandMaster Control Module

For Bus Paralleling & Power Transfer

DescriptionThe PowerCommand™ Master Control Module(MCM3320) is a microprocessor-based system controlcomponent that is optimized for use with PowerCommandDigital Paralleling genset controls. The MCM3320integrates master functions into a single control system,providing enhanced reliability and performance comparedto conventional control systems.

The MCM3320 will directly read AC voltages up to480VAC, and can be configured for any frequency,voltage, and power connection configuration from 110 to35,000 VAC.

The MCM3320 is designed for switchgear mounting, but isenvironmentally protected for operation in severeapplications. Optional operator panel and bargraphs areavailable, or the equipment can be directly monitored with

conventional meters, switches, and control monitoringlamps.

Control power for the MCM3320 will typically be derivedfrom the generator set starting batteries. The module canbe connected to two independent DC sources forredundancy. The control functions over a voltage rangefrom 9VDC to 32VDC and requires less than 1Amp.

PowerCommand Controls are supported by a worldwidenetwork of independent distributors who provide parts,certified service and warranty support.

FeaturesThe MCM3320 is configurable for a number of differentoperating arrangements, with all the operation versionsdesigned to provide a wide variety of features andfunctionality for the equipment as applied.

Bus Synchronizing, allows one or more gensets withPowerCommand Digital Paralleling Controls operating ona common bus to be actively synchronized to anothersystem bus. Synchronizing function provides forfrequency/phase angle and voltage matching.

Dual Source Bus AC Metering provides simultaneousmetering of the genset bus and secondary bus for voltage,frequency, power, and energy functions.Power Transfer Control provides load transfer operationin open transition, closed transition, or soft (ramping)transfer modes.Automatic Mains Failure automatically starts thegensets and transfers the load when the normal sourcefails.Test Mode starts gensets with option to transfer the loadto the genset bus.Extended Paralleling (Peak Shave / Base Load)regulates the generator set real and reactive power outputwhile paralleled to the utility. Power can be regulated ateither the genset bus monitoring point or at the utilitysource monitoring point.Scheduler with integrated Real Time Clock provides 12programs and 6 exceptions for automatically initiating atest without load, test with load, or a Base Load or PeakShave session.Load Demand controls the number of generators setsoperating to optimize system operating cost.Load Add/Shed Control Provides signals to controlremote loads so that bus overload is avoided on blackstart, or due to system overloads while in operation.System Topologies supported include transfer pair,common bus (no Gen Main Breaker), and isolated bus.Sync Check - The sync check function has adjustmentsfor phase angle window, voltage window, frequencywindow, and time delay.Diagnostics A full suite of built-in diagnostics allowsaccurate and quick system troubleshooting.Modbus RTU Interface allows easy system monitoring bymany 3 rd party devices.Advanced Serviceability using InPower, a PC-basedsoftware service tool, as well as a comprehensivepackage of visual condition displays that are integratedonto the control board.




ConstructionThe MCM3320 is a single board, potted control modulethat interfaces to external components through lockingplug-in terminal blocks suitable for wiring up to 12 gauge(2.5 mm).

Status IndicatorsThe MCM3320 includes a series of integrated operatordisplay functions.On-board LEDs provides the following status indications:

Control Operating (green flashing) Utility Connected (green) Utility Available (green) Generator Bus Connected (amber) Generator Bus Available (amber) Common Warning (amber) Not in Auto (red flashing) Fail to Synchronize (red) Synchronizing (green flashing) Sync Check OK (green)

An on-board alphanumeric coded display provides the

following status indications: Timing to start Timing to stop Timing program transition Timing to transfer Timing to retransfer Synchronizing OK to Close Base Load Mode Peak Shave Mode Ramping Load On Ramping Load Off Manual Mode

Standby Mode Utility Failed Test Mode

FunctionsBus Synchronizing – Control incorporates a digitalmaster synchronizing function to force a bus of connectedgenerator sets to match the frequency, phase and voltageof another source such as a utility grid. The synchronizerincludes provisions to provide proper operation even withhighly distorted bus voltage waveforms and willaccomodate up to a minimum of 20 gensets. Thesynchronizer can match other sources over a range of 90-110% of nominal voltage and up to plus or minus 3 hertz.The synchronizer function is optionally configurable forslip frequency synchronizing for applications requiring aknown direction of power flow at instant of breaker closureor for applications where phase synchronizationperformance is otherwise inadequate.

Sync Check – The sync check function decides whenpermissive conditions have been met to allow breakerclosure. Adjustable criteria are: phase difference from

0.1-20deg, frequency difference from 0.001-1.0Hz,voltage difference from 0.5-10%, and a dwell time from0.5-5.0sec. Internally the sync check is used to performclosed transition operations. An external sync checkoutput is also available. In Master Sync Only applications,sync check can also be configured individually to activatein live-dead, dead-live, and dead-dead bus conditions.

Dual Source Bus AC Metering – the control providescomprehensive three phase AC metering functions forboth monitored sources, including: 3-phase voltage (L-L

and L-N) and current, frequency, phase rotation, individualphase and totalized values of kW, kVAR, kVA and PowerFactor; totalized positive and negative kW-hours, kVAR-hours, and kVA-hours. Three wire or four wire voltageconnection with direct sensing of voltages to 480V, and upto 35kV with external transformers. Current sensing witheither 5A or 1A secondaries and up to 10,000A primary.Maximum power readings are 32000kW/kVAR/kVA.

Power Transfer Control - provides integrated automaticpower transfer functions including source availabilitysensing, gensets start/stop and transfer pair monitoringand control. The transfer/retransfer is configurable foropen transition, fast closed transition (<100msec overlap),or soft closed transition (load ramping) sequences ofoperation. Utility source failure will automatically startgensets and transfer load, retransferring when utilitysource returns. Test will start gensets and transfer load iftest with load is enabled. Sensors and timers include: Undervoltage Sensor: 3-phase L-N or L-L under

voltage sensing adjustable for pickup from 85-100%of nominal. Dropout adjustable from 75-98% ofpickup. Dropout delay adjustable from 0.1-30 sec.

Overvoltage Sensor: Optionally enabled sensor. 3-phase L-N or L-L over voltage sensing adjustable forpickup from 95-99% of dropout. Dropout adjustablefrom 105-135% of nominal. Dropout delay adjustablefrom 0.5-120 sec.

Over/UnderFrequency Sensor: Optionally enabledsensor. Center frequency adjustable from 45-65Hz.Dropout bandwidth adjustable from 0.3-5% of centerfrequency beyond pickup bandwidth. Pickupbandwidth adjustable from 0.3-20% of centerfrequency.

Loss of Phase Sensor: Optionally enabled sensor.Detects out of range voltage phase anglerelationship.

Phase Rotation Sensor: Optionally enabled sensor.Checks for valid phase rotation of source.

Breaker Tripped: If the breaker tripped input is active,

the source will be considered as unavailable. Genset Online Capacity Sensor: Optionally enabled

sensor. Use to require minimum kW capacity onlinebefore closing gen main breaker.

Timers: Control provides adjustable start delay from0-3600sec, stop delay from 0-3600sec, transfer delayfrom 0-120sec, retransfer delay from 0-1800sec,programmed transition delay from 0-60sec, andmaximum parallel time from 0-1800sec.




Breaker Control – Utility Main and Genset Main breakerinterfaces include separate relays for opening and closingbreaker, as well as inputs for both 'a' and 'b' breakerposition contacts and tripped status. Breaker diagnosticsinclude Contact Failure, Fail to Close, Fail to Open, Fail toDisconnect, and Tripped. Upon breaker failure,appropriate control action is taken to maintain systemintegrity.

Extended Paralleling – Optionally enabled. In extendedparalleling mode, controller will start gensets and parallel

to a utility source and then govern the real and reactivepower output of the gensets based on the desired controlpoint. Function will support up to 20 gensets with a totalrating of up to 32000kW. The control point for the realpower (kW) can be configured for either the genset busmetering point ("Base Load") or the utility metering point("Peak Shave"). The control point for the reactive power(kVAR or Power Factor) can also be independentlyconfigured for either the genset bus metering point or theutility metering point. This flexibility for example wouldallow base kW load from the gensets, while maintainingthe utility power factor at a reasonable value to avoidpenalties due to low power factor. System alwaysoperates within genset ratings. Control point can bechanged on the fly if desired. Setpoints can be adjustedvia hardwired analog input, or adjusted through anoperator panel display or service tool.

Scheduler – Optionally enabled. The scheduler allowssystem to be operated at preset times in either testwithout load, test with load, or extended parallel mode. AReal Time Clock is built in. Up to 12 different programscan be set for day of week, time of day, duration, repeatinterval, and mode. For example, a test with load for 1hours every Tuesday at 2AM can be programmed. Up to6 different exceptions can also be set up to block aprogram from running during a specific date/time period.

Load Demand – Optionally enabled. Load demand willattempt to match generating capacity to load. LoadDemand function will support from 2 to 4 gensets.Shutdown sequence can either be a Fixed Sequence orcan be based on Running Hours. With fixed sequencemethod, the sequence can be changed on the fly.Running Hours method will attempt to equalize gensethours over time by swapping stopped and runninggensets. To protect system integrity, Load Demand willrestart all gensets whenever an overload condition isdetected. The minimum amount of capacity to maintainonline is adjustable. Initial Delay for load demand to start

operating is adjustable from 1-60 minutes. ShutdownThreshold is adjustable from 20-100% of online capacityminus one. Shutdown delay is adjustable from 1-60minutes. Restart Threshold is adjustable from 20-100% ofonline capacity. Run Hours Differential is adjustable from1-500 hours.

Load Add / Shed – Optionally enabled. Load add/shedwill control and monitor up to 6 feeder breaker orautomatic transfer switches (in any combination). Up to 6levels of Add, and up to 6 levels of Shed may be defined.

Load Add Shed function will support up to 4 gensets.Loads can be added as gensets come online as well ason a timed basis. Loads are shed on a timed basis whenan overload condition is detected, protecting systemintegrity. Shed loads can be restored through operatoraction. Manual load add and shed is also provided. Load

Add Delay is adjustable from 1-60sec. Load Shed Delayis adjustable from 1-10sec.

System Topologies – Controller is configured tooperating in one of five possible system topologies:

Transfer Pair : system consists of a breaker pair, one agen main and the other a utility main. MCM3320 controlsboth breakers.

Load

G1 G2 G3 G4

UM GM

MCM3320

Common Bus: system consists of a utility main breaker,but no gen main breaker (only individual gensetparalleling breakers). MCM3320 controls utility mainbreaker and genset paralleling breakers (via inhibit).

Load

G1 G2 G3 G4

UM

MCM3320

Isolated Bus w/Gen Main: system consists of an isolatedbus and a genset main breaker. MCM3320 controlsgenset main breaker.

Load

G1 G2 G3 G4

GM

MCM3320




Isolated Bus w/out Gen Main: system consists of anisolated bus and no gen main breaker.

Load

G1 G2 G3 G4

MCM3320

Master Synchronize Only: controller will only performmetering, synchronizing, sync check, and Modbusfunctions. Intended for use in systems where the onlyfunctions desired are metering and synchronizing.

Source

G1 G2 G3 G4

MCM

3320

SyncCheck

Modbus RTU – Controller is a Modbus RTU slave devicecapable of communication on either RS232 or RS485.Modbus address is configurable allowing multipleMCM3320 slaves on a single RS485 bus. Baud rates upto 19200 are supported. A vast array of system control,adjustments, and monitoring data are available and aredocumented in a published register map.

Protective Functions and Diagnostics

Data Logging - The control maintains a record of controloperations, warning conditions, and other events.Records are time stamped.

Fault Simulation Mode – The MCM3320 in conjunctionwith InPower software, will accept commands to allow atechnician to verify the proper operation of the control andits interface by simulating failure modes or by forcing thecontrol to operate outside of its normal operating ranges.

InPower also provides a complete list of faults andsettings for the protective functions provided by thecontroller.

Protective Functions - PowerCommand provides thefollowing system protective functions for each breaker orbus. Note that each protective function will cause thecontrol to take intelligent corrective action to best resolvethe problem until an operator can address it. See theIntelligent Protective Action section for details.Diagnostics can be mapped to any of 8 configurable low-

side driver outputs for external use such as driving relays,lamps or as signals to other system devices. Breaker Fail To Close Warning - When the

MCM3320 signals a circuit breaker to close, it willmonitor the breaker auxiliary contacts and verify thatthe breaker has closed. If the control does not sensea breaker closure within an adjustable time periodafter the close signal, the fail to close warning will beinitiated.

Breaker Position Contact Warning – The controllerwill monitor both 'a' and 'b' position contacts from the

breaker. If the contacts diagree as to the breakerposition, the breaker position contact warning will beinitiated.

Breaker Fail To Open Warning - The controlsystem monitors the operation of breakers that havebeen signaled to open. If the breaker does not openwithin and adjustable time delay, a Breaker Fail toOpen warning is initiated.

Breaker Tripped Warning – The control acceptsinputs to monitor breaker trip / bell alarm contact andwill initiate a breaker tripped warning if it shouldactivate.

Fail to Disconnect Warning – If the controller isunable to open either breaker, a fail to disconnectwarning is initiated. Typically this would be mappedto a configurable output, allowing an external deviceto trip a breaker.

Fail To Synchronize Warning - Indicates that thegenerator set bus could not be brought tosynchronization with the system bus. Configurablefor adjustable for time delay of 10-120 seconds.

Bus Overload Warning – The control monitorsgenset bus load relative to the online capacity. Italso monitors bus frequency. On a configurablebasis, control will initiate a Bus Overload Warning ifthe bus kW load exceeds an adjustable threshold(80-140%) for an adjustable delay (0-120s) or thebus frequency falls below an adjustable threshold(0.1-10Hz) for an adjustable delay (0-20s). Option toselect either or both kW and frequency as triggers.

Maximum Parallel Time Warning – During closedtransition load transfers, control independentlymonitors paralleled time. If time is exceeded,warning is initiated and genset bus is disconnected.

Intelligent Protective ActionWhen abnormal situations are diagnosed by the control, itwill provide as much corrective action as possible to keepthe system operating.

Utility Main Breaker Fail To Close Warning –Control will start the gensets and transfer load to thegenset bus and remain there until operator resets thefault condition and resolves the problem.

Genset Main Breaker Fail To Close Warning –Control will return to the utility source and will not retryuntil operator resets the fault condition and resolvesthe problem.

Breaker Position Contact Warning – Control willcheck for current above a threshold on all 3 phases. If




criteria is met, control will remain on the source. Ifnot, control will attempt to transfer to other source.

Fail To Synchronize Warning – If control trying toperform a closed transition retransfer, but fail to syncoccurs, optionally the control can be configured toperform the retransfer using open transition.

Control InterfaceINPUTS Synchronize Enable – manual mode sync on/offUtility Source Failure – use with external protective relayTransfer Inhibit – prevents transfer to gensetsRetransfer Inhibit – prevents retransfer to utility*Override – overrides delays and transfer/retransfer inhibitManual – prevents automatic breaker operationTest – initiates a test (with or without load as configured)Extended Parallel – initiates a base load or peak shaveReset Faults – resets latched faultsMain Breaker Positions (2/4) – 'a' or 'a/b' position inputsMain Breaker Tripped (2) – from breaker bell alarmMain Breaker Inhibits (2) – open/inhibit close of breakersGenset Breaker Positions (4) – monitor gensets onlinekW Set Point – 0-5V for base load / peak shavekVAR / PF Set Point – 0-5V for kVAR or Power Factor3 Phase Voltages (2) – 3 or 4 wire voltage sensing3 Phase Currents (2) – 5 Amp or 1 Amp scale*except in case of genset bus failure

OUTPUTS Configurable Customer Outputs - Control includes (8)output signals (low-side relay drivers) for use by externalequipment. These may be mapped to any control warningor event. Defaults settings are: common warning, fail tosync, gen bus available, util bus available, fail todisconnect, sync check ok, sync output limit, andhardware failure. External relays can be powered from

control.Generator Set Signals - For each generator set in thesystem, the control provides start command, loaddemand, load govern enable, paralleling breaker inhibitand fuel rate and excitation control signals.Genset Main and Utility Main Breaker Interfaces -Dedicated separate relays are provided for breaker openand breaker close circuits.

NETWORK CONNECTIONS Serial Interface - This communication port allows thecontrol to communicate with a personal computer runningInPower service and maintenance software.

Modbus RTU Interface . Provides a standard registermap of system data, for use in monitoring by a remotePLC. Includes settable address and is configurable forRS232 or RS485 physical connection.PCCnet Proprietary serial interface to Operator PanelDisplays, Auxiliary IO Module, and Bargraph Displays.

Optional Operator Interface (HMI211)The control is available with an optional operator panelthat may be either locally or remotely mounted. Up to two

panels may be used with a single MCM3320 control. Thedisplay is composed of a backlit LCD display, with aseries of 6 status LED lamps. The display isaccompanied by six tactile feel membrane switches thatare used by the operator to navigate through menus forsystem control, monitoring, and adjustments. A mainscreen one-line diagram with AC data gives a quickoverview of current system status. Control andadjustments are password protected. The graphicaldisplay is capable of displaying up to 9 lines of data withapproximately 27 characters per line. It is adjustable for

screen contrast and brightness.

LED Indicating Lamps - The optional display panelincludes LED indicating lamps for the following functions:

Utility Parallel Lockout Warning Remote Start Auto Manual

Home Screen – The home screen provides information ina one-line format relevant to the current system operatingstate. Information includes source availability, sourceconnected status, voltage, frequency, and power data.Faults can also be reset from the home screen.System Status – The top line provides the current systemstatus as well as countdown of any timer that is currentlyin effect such as a retransfer timer.System Control – The control menus allow initiating atest, base load, or peak shave operation as well as easyaccess to adjustments for relevant operating setpoints.Adjustments – The adjustment screens allow complete

configuring, setup, and fine tuning of the controllersettings.Monitoring – The monitor screens provide orgranizedaccess to all controller data ranging from AC data, to loaddemand status information, to breaker positioninformation, to analog and discrete io readings.Faults – Diagnostics pop-up on the display when theyoccur and can be acknowledged with a single key press.Fault history information can be viewed through the menunavigation.




Optional Bargraph Interface (HMI112)The control is available with optional bargraph displays.Two displays are used with one MCM3320 control. Onebargraph will be dedicated to the utility source, and theother to the genset bus. Bargraphs provide the followingreadings for each source:

L1 Current Percent L2 Current Percent L3 Current Percent Total kW Percent Power Factor Frequency Percent L1L2 Voltage Percent L2L3 Voltage Percent L3L1 Voltage Percent

Load Add / Shed Modules (AUX101,AUX102)To utilize the Load Add and Load Shed feature, the

AUX101 and AUX102 modules are required. Thesemodules provide the relay outputs and switch positioninputs for controlling and monitoring up to 6 load feederbreakers or 6 ATS. The modules communicate with theMCM3320 over a proprietary datalink.

Part NumbersMCM3320 (Control) 0327-1520-01HMI211 (Operator Panel) 0300-6090Operator Panel Harness 0338-4747HMI112 (Bargraph) 0300-6050-01

AUX101/2 (Load Add Shed) 0541-1342 Interconnect Wiring Diagram 0630-3133

CertificationsPowerCommand SYNC1320 meets or exceeds therequirements of the following codes and standards:UL508 RecognizedCE MarkEN 61000-6-2 EN 61000-6-4ISO 7637, pulses #2, 3a, 3b, 5, 7

PowerCommand control systems are designed andmanufactured in ISO9001 certified facilities.

EnvironmentThe control is designed for proper operation without

recalibration in ambient temperatures from –40C to +70C,and for storage from –40C to +80C. Control will operatewith humidity up to 95%, non-condensing, and at altitudesup to 13,000 feet (5000 meters).

The control system is specifically designed for resistanceto RFI/EMI, and to resist the effects of vibration to providea long reliable life when installed in harsh environment.The control includes transient voltage surge suppressionto provide compliance to referenced standards.

The optional display panel is designed for properoperation in ambient temperatures from –20 Deg C to +70Deg C, and for storage from –30 Deg C to +80 Deg C.

SoftwareInPower

InPower is a PC-based software service tool that isdesigned to directly communicate to PowerCommandproducts to facilitate setup, service and monitoring ofthese products.

WarrantyPowerCommand control systems are a part of completepower systems provided by Cummins Onan, and arecovered by a one-year limited warranty as a standardfeature.

Extended warranty options are available for coverage upto 10 years.

MCM3320 Brochure

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