PCC Commissioning Guide Lines

8/18/2019 PCC Commissioning Guide Lines

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Index Index Index Index

1. Cold Checks - Part Nos. of Various Components of PCC.1. Cold Checks - Part Nos. of Various Components of PCC.1. Cold Checks - Part Nos. of Various Components of PCC.1. Cold Checks - Part Nos. of Various Components of PCC.

2. Wiring Checks - Engine Wiring Harness , PT/CT Harness ,2. Wiring Checks - Engine Wiring Harness , PT/CT Harness ,2. Wiring Checks - Engine Wiring Harness , PT/CT Harness ,2. Wiring Checks - Engine Wiring Harness , PT/CT Harness ,Customer Interface Harness Customer Interface Harness Customer Interface Harness Customer Interface Harness

3. PCC Fault Codes & thresholds3. PCC Fault Codes & thresholds3. PCC Fault Codes & thresholds3. PCC Fault Codes & thresholds

4. PCC Calibration - Initial Calibration , Frequency Calibration,4. PCC Calibration - Initial Calibration , Frequency Calibration,4. PCC Calibration - Initial Calibration , Frequency Calibration,4. PCC Calibration - Initial Calibration , Frequency Calibration,

Voltage Calibration,Meters Calibration Voltage Calibration,Meters Calibration Voltage Calibration,Meters Calibration Voltage Calibration,Meters Calibration

5. Settings on the PCC -Factory Settings5. Settings on the PCC -Factory Settings5. Settings on the PCC -Factory Settings5. Settings on the PCC -Factory Settings

6. PCC Terminal Strip ( TB1-60) at a glance6. PCC Terminal Strip ( TB1-60) at a glance6. PCC Terminal Strip ( TB1-60) at a glance6. PCC Terminal Strip ( TB1-60) at a glance

7. Detailed Terminal Strip connections of Inputs / Outputs from PCC7. Detailed Terminal Strip connections of Inputs / Outputs from PCC7. Detailed Terminal Strip connections of Inputs / Outputs from PCC7. Detailed Terminal Strip connections of Inputs / Outputs from PCC

with sample Drawings with sample Drawings with sample Drawings with sample Drawings

8. Instrumentation & Cable requirements for a PCC Genset8. Instrumentation & Cable requirements for a PCC Genset8. Instrumentation & Cable requirements for a PCC Genset8. Instrumentation & Cable requirements for a PCC Genset

9. Sample GA Drawing of the Control panel for a PCC Genset9. Sample GA Drawing of the Control panel for a PCC Genset9. Sample GA Drawing of the Control panel for a PCC Genset9. Sample GA Drawing of the Control panel for a PCC Genset

10. List of Bare Minimum connections from the Terminal strip to the10. List of Bare Minimum connections from the Terminal strip to the10. List of Bare Minimum connections from the Terminal strip to the10. List of Bare Minimum connections from the Terminal strip to the

main panel main panel main panel main panel


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Commissioning report for PCC Engine

ESN: Model: Customer: OEM:

Name of the Commissioning Engineer : Name of the OEM Engineer Date Of Commissioning:Parts & their Sr.Nos. ( Kindly Confirm by actual Inspection)Parts Cummins Part No ONAN Part No. Sr.No. Parts Cummins Part No ONAN Part No. Sr.No.PCC 4084008 300-4615-05 Water Temp.Sensor ( RB /LB) 4084030 193-0432Governor O/p Module 4084020 300-4625 Lube Oil Pressure Sensor 4084031 193-0444Regulator O.P module 4084021 300-4634 Oil Temp.Sensor 4084030 193-0432PT/CT Module 4084022 300-4626-02 Engine Temp. Sensor Bus PT Module 4084009 300-4767-02 MPU 3231404Engine interface Board AX1002266 300-4083 Magnetic Switch 4084033 307-2621-01

Customer Interface Board AX1004536 300-4462-01 Engine Wiring Harness As per Engine ModelDigital Board AX1002262 300-4079 Alternator Wiring Harness As per Engine Model

Analog Board AX1002264 300-4080-02 PT/CT Harness 4084230Display Board AX1002249 300-4286 Low Coolant Level Switch 4084762Master first Start Sensor PCC O & M Manual 3243804CT's ( All Three) As per Engine Model

Version:L-L VoltageParallel / SingleSoftware Version

Note : A separate table giving the Details of Version / CT Part nos w.r.t engine model is given below.

Location Nomenc

lature

Rating Function

Engine Interface A31-F1 5 Amp PCC Control B + (Ve)Engine Interface A31-F3 5 Amp Aux. B+ (For panel lights, run & start

relays)Governor Output Module A38-F1 10 Amp Network B+ (to TB1 customer terminal

block)Governor Output Module A38-F2 10 Amp Switched B+ ( to TB1 customer

terminal block)

Governor Output Module A38-F3 10 Amp Governor B+ (power for governoroutput module & actuator)TB-Bat (Engine Harness

Assembly)F1 20 Amp Customer B+ ( to TB1 customer

terminal block

PCC FUSES-- Check if in doubtENGINEMODEL

KVARATING

KWRating

FILENAME

CTRATIO

CumminsPARTNOS.

ONAN PARTNO.

KTA50G8 1500 1200 DFLF-50 4420/1 4084989 302-2058-15

KTA50G3 1250 1000 DFLC-50 3867/1 4084245 302-2058-12KTA38G5 1000 800 DFJD-50 2839/1 4084175 302-2058-08KTA2300G 750 600 DFJB-50 2141/1 4084244 302-2058-03VTA28G5 625 500 DFGC-50 1893/1 4107379 302-2058-01VTA28G3 600 500 DFGC-50 1893/1 4107379 302-2058-01KTA19G4 500 400 DFED-50 1419/1 4104378 302-2057-31KTA19G3 450 360 DFEC-50 1262/1 4104388 302-2057-29KTA1150G 380 300 DFEB-50 1070/1 4104377 302-2057-26KT1150G 320 300 DFEB-50 946/1 4104376 302-2057-24NTA855G2 320 250 DFCB-50 946/1 4104376 302-2057-24NT855G6 285 227 DFBF-50 789/1 4104389 302-2057-21NT855G5 250 200 DFBE-50 725/1 4104390 302-2057-19NT855G4 225 180 DFBD-50 631/1 4104391 302-2057-17

PCC Commissioning checks/pmp


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Visual Inspection

1. Engine Wiring Harness:The entire wiring should be clamped appropriately, with no loose wires hangingLCL if connected , should be wired up as follows:

LCL Wires-----------------Engine Wiring HarnessRed------------------------------- S7 + ( TB Bat +Ve)Black----------------------------- S7 - ( TB Bat -Ve)Blue------------------------------- S7-Sig (P4-7)

Plugs / Connectors ,Customer Interface Harness

P4 - Grey -- Connects on the Engine Interface Board ( Back Side of PCC) --While Fixing this plug first match the notch & push it in so that you hear a click sound.P5 - White Connector on the Engine Interface board ( Back Side of PCC) --- DO --------------------P6 - Grey ---Connects to the Governor O/P module ( On the accessory Box) -------DOP7 -White ---Connects to the Regulator O/p Module ( on the acc. Box)P10 - White ---Connects to the Regulator O/p Module ( on the acc. Box)

PMG wires :PMGP2, PMG3 , PMG4---Connect this wire to the PMG wire coming out from the Main Alternator ( See that length of this adquate.DO NOT EXTEND THESE WIRES, IF THESE WIRES ARE SHORT IN LENGTH----If required bring these wires to a terminal strip , securely mounted on the

alternator frame inside & connect the Alternator PMG wires on the terminal strip>X+, XX --These are field winding wires ----Connect the field winding wires from the main alternator to these wires ( F1 to X+ & F2 to XX

J-12 - Grey -- Connects to the Alternator Wiring Harness on Plug -12 ( Located in the Acc.Box)

Starter Connectionslooped ( Shorted). Similarly the negative terminals of both the starters are looped (shorted & connected to Engine body)

Main Alternator Wiring Harness :Plugs :P1 - Black ---Match the Socket which has a similar Black colour -- On the Customer Interface board ( On the back Side of PCC)P2 - Grey ---Match the Socket which has a similar Grey colour -- On the Customer Interface board ( On the back Side of PCC)P3 - Blue ---Match the Socket which has a similar blue colour -- On the Customer Interface board ( On the back Side of PCC)P8 - Grey -- Connects to the PT / CT ModuleP12 - Connects to J12 of the engine harness connector Six Wires to Bus PT Module on terminal strip - A39 - TB2-1, A39 - TB2-2, A39 - TB2-3, A39 - TB2-4, A39 - TB2-5, A39 - TB2-6,



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PT/CT HarnessOne end gets connected to the PT/CT Module --White Plug & the other end has ten wires.--CT Connections1 - Neutral ( Neutral Phase Connection)2 - VB ( B Phase Connection)3 - VY ( Y Phase Connection)4 - VR ( R Phase Connection)5 - Not Used6 - IB2 (B Phase CT Connection)7 - IB1 (B Phase CT Connection)8 - IR2 (R Phase CT Connection)9 - IR1 (R Phase CT Connection)10- IY2 (Y Phase CT Connection)11- IY1 (YPhase CT Connection)12- Not Used

PCC - Fault Thresholds

1 2 3

10 11 12

PT CT harnessConnector

Fault Code Status Description Thresholds200 Warning Low Lub Oil Pressure 40 PSI / 276 kPa / 2.75 bar @ 1500 RPM

15 PSI / 103 kPa / 1.03 bar @ 800 RPM201 Shutdown Low Lub Oil Pressure 35 PSI / 241 kPa / 2.41 bar @ 1500 RPM

10 PSI / 69 kPa / 0.68 bar @ 800 RPM211 Warning Hi Coolant Temperature 207 Deg F / 97 Deg C212 Shutdown Hi Coolant Tem perature 215 Deg F / 101 Deg C214 Warning Low Coolant Water Level Low Level @ 800 RPM215 Shutdown Low Coolant Water Level Low Level @ 1500 RPM223 Shutdown Engine Overspeed 115% of 1500 RPM i.e. 1725 RPM +/-1 RPM231 Warning Hi DC Voltage Batt. Volt > 32 V DC230 Warning Low DC Voltage Batt. Volt< 24 V DC232 Warning Weak Battery Rated Volt < 60% i.e. 14.4 V DC301 Shutdown Hi AC Voltage Rated Volt > 130% i.e. 540.8 V AC303 Shutdown Low AC Voltage Rated Volt < 85% i.e. 353.60 V AC, for 10 Sec.313 Shutdown Under Frequency Rated Freq. < 90% i.e.45 Hz for 10 Sec.320 Warning Over Current Rated Current > 110% for 60 Sec.321 Shutdown Over Current Rated Current > 110% as per PCC IDMT Curve322 Shutdown Short Circuit Rated Current > 175% Instantaneous330 Warning Overload Rated Current > 115%, after 5 Sec. The load dump

O/P will get activated.335 Shutdown Reverse Power (-) Kw Power > 10% of Rated Kw for 3 Sec337 Shutdown Loss Of Excitation 2 seconds



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Factory Settings of PCC

Parameter Factory Settings Range Deviation if AnyVersion As per Eng.ModelVoltage/ Frequency Selection 416V / 50 HZ 190V to 13.8 KV / 50/60HzPrime / Standby Prime Always Prime/ StandbyDelta / WYE WYE always Delta / WYE

S 5 Switch ( On Digital Board) Awake mode Sleep / AwakeStart Delay 0 0-300 secondsStop Delay 0 0-600 secondsIdle Speed 800Rpm 700-900 RpmGov.Regulator MenuGov. Gain 100% 3% to 1276%Gov Integral 100% 33% toGov Ramp 1 1 to 10Reg Gain 100%Reg Integral 100%Reg. VHZ 11Set-Up MenuCycle Crank ON ON / OFFNo. Of Cycles 5 3 to 6Crank Time - Sec 15 7 to 20Rest Time - Sec 15 7 to 20System Of Units Imperial Imperial / MetricCustomer Fault 1 Warning Warning / ShutdownCustomer Fault 2 Ground Fault - Warning Warning / ShutdownCustomer Fault 3 Rupture Basin- Warning Warning / ShutdownCustomer Fault 4 High Gen Temo - Warning Warning / ShutdownEGT - L No Yes / NoEGT - R No Yes / NoLow Coolant LVL Shutdown Warning / ShutdownLanguage English English/ Spanish

Parallel -ISO BUSSync Time Limit 120 10 - 120Pwr Limit 10 5 to 15Pwr Limit Time 3 1 to 15Perm Win Phase 20 5 to 25Perm Win -Time 0.5 0.5 to 5 secondsSync Gain 95Sync Integral 12KW Balance 165 + 0KVAR Balance 0KW Gain 6 1 to 32KVAR Gain 3001st Start Fail 10Ramp UNLD Time 10Ramp UNLD LEVEL 20


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PCC - Terminal Strip TB1-1 Details at a Glance

Into The PCC O/P From PCC to the Main Panel Into The PCC O/P From PCC to the Main Panel

TB BAT-F1 1 1 B+(20A FUSED) A34-P1-19 31 31 PRE-LOW OIL PRESSURE

P12-2 2 2 SWITCHED B+(10A FUSED) A34-P1-20 32 32 LOW OIL PRESSURE

GND-ENG 3 3 GROUND A34-P3-19 33 33 COMMON

GND-ENG 4 4 GROUND A34-P1-18 34 34 RETURN

A34-P1-13 5 5 REMOTE START P12-9 35 35 RUPTURE BASIN

A34-P1-7 6 6 REMOTE EMERGENCY STOP CONT HTR1 36 36A34-P2-10 7 7 Common Shutdown(N/O) CONT HTR2 37 37

A34-P2-9 8 8 (COM) A34-P2-14 38 38 (N/O) READY TO LOAD

A34-P2-11 9 9 (N/C) A34-P2-13 39 39 (N/C) LOAD DUMP

A34-P2-4 10 10 Breaker Close (N/O) A34-P2-12 40 40 COMMON

A34-P2-3 11 11 Breaker Close (N/O) A34-P2-8 41 41 Common Warning(N/O)

P12-5 12 12 NET POWER(+) A34-P2-7 42 42 Common Warning (N/O)

P12-6 13 13 NET POWER(-) A34-P2-5 43 43 Common Warning (N/C)

P12-7 (RED) 14 14 NET DATA 1 A34-P2-6 44 44 Common Warning (N/C)P12-8 (BLACK) 15 15 NET DATA 2 45 45

P12-1/A34-P1-9 16 16 CUSTOMER FAULT 1 A34-P3-9 46 46 B+IN

A34-P1-12 17 17 CUSTOMER FAULT 2 A34-P3-1 47 47 UTILITY CB AUX

A34-P1-6 18 18 CUSTOMER FAULT 3 A34-P2-16 48 48 Breaker Trip(N/C)

A34-P1-16 19 19 CUSTOMER FAULT 4 A34-P2-2 49 49 Breaker Trip(N/C)

A34-P1-2 20 20 FAULT RESET A34-P1-17 50 50 MASTER START SENSOR/SYNC ENABLE

A34-P1-10 21 21 ENGINE IDLE A34-P1-3 51 51 LOAD DEMAND/UTILITY SINGLE

A34-P1-5 22 22 LOW FUEL A34-P1-11 52 52 CB OPEN/CLOSE INHIBITA34-P3-2 23 23 NOT ON AUTO A34-P1-4 53 53 CB POSITION

A34-P3-10 24 24 PRE-HIGH ENGINE TEMP A34-P1-22(GREE 54 54 GREEN(KVAR-)

A34-P3-11 25 25 HIGH ENGINE TEMP A34-P1-23(RED) 55 55 RED (KVAR+)

A34-P3-12 26 26 OVERSPEED A34-P1-8(BLACK 56 56 BLACK (KW-)

A34-P3-16 27 27 OVERCRANK A34-P1-15(WHIT 57 57 WHITE(KW+)

A34-P3-17 28 28 LOW ENGINE TEMP A34-P1-1 58 58 SHEILD

A34-P3-18 29 29 LOW FUEL A34-P2-15 59 59 EXTERNAL LOAD SET +

A34-P1-21 30 30 LOW COOLANT A34-P2-23 60 60 EXTERNAL LOAD SET -

120 OR 240 VAC

PCC Checks / pmp


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PCC TB1-1 Connectons upto the Main Control Panel

Note : The Left Hand side connections go into the PCC. The Right hand side connections represent the OEMside connections or the Customer side connections to be taken out on the Main panel

Sample Drawings related to each terminal of the 60 pin terminal strip are given below.

All the connections shown need not be used, the Mandatory connections are mentioned in BOLD

Positive 24 VDCThis is a permanent + 24VDC supply --can be used for looping

TB BAT-F1 1 1 B+(20A FUSED)

P12-2 2 2 SWITCHED B+(10A FUSED) This supply 24vdc will be available only when enginestarts running and can be used to drive.

Sample drawing for running Raw water Pump

P12-2 2 2

Engine GroundGND-ENG 3 3 any Ground looping in the PCC Panel can be taken from here

GND-ENG 4 4 any Ground looping in the PCC Panel can be taken from here

Remote Start ( Mandatory)

A34-P1-13 5 5 REMOTE START ( IF PCC RUN /OFF/AUTO Switch is in AUTO & if Ground is connected to terminal No.5 then engine will remotely start

GND-ENG 3 3

A34-P1-13 5 5

Sample Drawing ofr Remote start for AMF Application Main PanelGND-ENG 3 3

A34-P1-13 5 5

Remote Emergency Stop ( Mandatory)

R1

230V

M

Main Panel

VoltageSensingRelay

SEB SUPPLY

NO 1

Common B-ve ( TB1-3

Remote Start Switch

R Y

BN

TB1

TB1

TB1

TB1

TB1

TB1


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Common Shut Down ( Mandatory) A34-P2-10 7 7 (N/O) Common shut down A34-P2-9 8 8 (COM) Common A34-P2-11 9 9 (N/C)

Common shut Down --- Indication on Panel

A34-P2-10 7 7 If the Engine Shuts down due to any faultthen the "NO" contact between 7 & 8

A34-P2-9 8 8 will close & indicating Lamp on the panel will glow.

TB BAT-F1 1 1 Note : Either Use Indicating lamp or Anounciator ( As shown ahead)

Sample Drawing of Common shut Down ---Audible Hooter If the Engine Shuts down due to any fault

A34-P2-10 7 7 then the "NO" contact between 7 & 8will close & Hooter on the panel

A34-P2-9 8 8 will turn ON

TB BAT-F1 1 1

Breaker Control ( Mandatory)

A34-P2-4 10 10 (N/O) A34-P2-3 11 11 (N/O)

Sample Drawing for Breaker Closing

A34-P2-4 10 10

A34-P2-3 11 11

TB BAT-F1 1 1 24 vdc supply from TB1-1

The NO contact between 10 & 11 will close when:A----( Single & NON Paralleling Sets or DEAD BUS)1.In Run Mode, when Engine Speed & Voltage reach 90% of Rated & When the Breaker Close button on PCC is Pressed2.In Auto Mode,When Remote start command is given & only when Speed & Voltage reach 90% of rated Automatically

ORB ------Parallel Operated Sets1.In Run Mode, when Engine Speed & Voltage reach 90% of Rated & only When the synchronise conditions aremet (I.e * Indication on the Synchronouscope screen of PCC) & breaker Close button on PCC is Pressed2 In Auto Mode When Remote start command is given & only e synchronise conditions are met Automatically

24Vdc

24Vdc

24vdc or 230 vacsupply for hooter

Breaker Closing

Closing Coilof Brkr

Aux.NC contactof Brkr

Main Panel

TB-1 -3

TB1

TB1

TB1

TB1

TB1


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CUTOMER FAULTS 1,2,3 & 4 ( Earth Fault Protection Mandatory , Others Optional)

P12-1/A34-P1-9 16 16 CUSTOMER FAULT 1 ------Default Programed as Customer Fault 1 --shutdown A34-P1-12 17 17 CUSTOMER FAULT 2 ------Default Programed as Ground Fault--Shutdown A34-P1-6 18 18 CUSTOMER FAULT 3 ------Default Programed as Day Tank--Shutdown

A34-P1-16 19 19 CUSTOMER FAULT 1 ------Default Programed as High Gen Temp--ShutdownThese are customer configurable inputs to the PCC, they can be either configured for Warning or Shutdown

In PCC there is no inbuilt protection for Earth Fault. An earth fault relay has to be externally used for this Purpose, theout put of which can be brought into the PCC for shutting down the engine. For this Customer Fault No2 (Ground Fault)has to be used.

A34-P1-12 17 17

GND-ENG 3 3

Whenever there is an Earth fault,the relay will pick up & the NO contact of the relay will connect Ground to Terminal No.17The PCC will now display Ground Fault & will trip the engine (since it it programed for Shutdown)

Example No. 2If the Circuit Breaker trips due to an internal electrical fault then this input can be brought into the PCC & the engine canbe tripped.Program the Customer Fault No 1 to ' Breaker Trip ' or ' Electrical Fault' ----Program it for Shutdown (Through PCC menus)

P12-1/A34-P1-9 16 16

GND-ENG 3 3

Fault Reset: This can be use to reset Warning Faults from Remote or Main Panel

A34-P1-2 20 20 FAULT RESETWhen terminal No 20 is grounded ,the

A34-P1-2 20 20 warning fault from a remote location can bereset.

GND-ENG 3 3

Engine Idle

A34-P1-10 21 21 Engine Idle

Relay Activated By Earth Fault

Aux. Contact of Breaker

Main Panel

Main Panel

Main Panel

TB1

TB1

TB1

TB1

TB1

Fault ResetSwitch


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Low Fuel : Not in CIL Scope A34-P1-5 22 22 Low Fuel

Grounding terminal No. 21 will initiate A34-P1-10 22 22 Low fuel warning on the PCC.

Note :Float Switch is not a Standard scopeGND-ENG 3 3 of supply

Anounciator Outputs From PCCMandatory Anounciations :

A34-P3-2 23 23 NOT ON AUTO 1.High engine Temp. A34-P3-10 24 24 PRE-HIGH ENGINE TEMP 2.OverSpeed A34-P3-11 25 25 HIGH ENGINE TEMP 3.Over Crank ( Only for AMF Sets) A34-P3-12 26 26 OVERSPEED 4.Low Coolant A34-P3-16 27 27 OVERCRANK 5.Low Oil Pressure A34-P3-17 28 28 LOW ENGINE TEMP On any of the above fault the No contact associated A34-P3-18 29 29 LOW FUEL with that fault will close &24VDC will be applied to the A34-P1-21 30 30 LOW COOLANT particular anounciator Window A34-P1-19 31 31 PRE-LOW OIL PRESSURE A34-P1-20 32 32 LOW OIL PRESSURE A34-P3-19 33 33 COMMON

A34-P3-2 23 23

A34-P3-10 24 24

A34-P3-11 25 25

A34-P3-12 26 26

A34-P3-16 27 27

A34-P3-17 28 28

A34-P3-18 29 29

A34-P1-21 30 30

A34-P1-19 31 31

A34-P1-20 32 32

A34-P3-19 33 33

Fuel Tank

24Vdc from terminal No.1

16 Window Anounciator

Notin Auto

PREHWT

O.SHWT

Over Crank

L.E.T PRELOP

LCL

LLOP Rdy toload

Com.Sht.Dn

OVRLoad

Com.WRN

Spare

Float Switch

Spare Spare

TB1

TB1

TB1

TB1


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Ready To Load : This NO Contact is activated by PCC when the Frequency & Voltage reach 90% of Rated.This can be used for Anounciation or can be used for Advanced Load Management system.

A34-P2-14 38 38 READY TO LOAD ( Anounciator)

A34-P2-12 40 40 COMMON

TB BAT-F1 1 1

Load Dump : This No Contact is activated by the PCC whenever there is an overload conditionThis can be used for Anounciation or can be used for cutting off non essential loads if wired up.

A34-P2-13 39 39 LOAD DUMP (Anounciator) or to a Relay for cutting off non essential loads in an overloadcondition

40 40 COMMON 24 vdc supply from terminal no.1

TB BAT-F1 1 1

Common Warning ( Mandatory Announciation)

A34-P2-8 41 41 (N/O) A34-P2-7 42 42 (N/O) A34-P2-5 43 43 (N/C) A34-P2-6 44 44 (N/C)

41 41 Common Warning ( Anounciator)

42 42 24 vdc supply from terminal no.1

TB BAT-F1 1 1

There are two set of Contacts given for Common Warning. These contacts change their state whenever there is anywarning Fault on the PCC,The samle drawing shown above is wired up using NO contact. This contact is activated by the PCC whenever thereis any Warning Fault. Thus 24vdc gets connected to the Anounciator for Indication.

Utility Paralleling Connections ( Mandatory For Utility Paralleling ONLY)

A34-P3-9 46 46 B+INA34-P3-1 47 47 UTILITY CB AUX

24VDC from Terminal No 1.

TB1

TB1

TB1

TB1


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Breaker Tripping ---- Use Shunt Trip Coil Only ( Coil Rating 24VDC) Mandatory

A34-P2-16 48 48 (N/C) A34-P2-2 49 49 (N/C)

Bkr. Aux.N/O A34-P2-16 48 48

A34-P2-2 49 49

TB BAT-F1 1 1 24 vdc supply from terminal no.1

NC contacts are provided foe tripping the breaker. These contacts are activated by the PCC no sooner the engine speed& voltage reach 90% of the rated.

Master First Start Sensor / Sync Enable

A34-P1-17 50 50 MASTER START SENSOR/SYNC ENABLE

A34-P1-17 50 50

This is used for Multiple Engines with PCC in island mode of operation. This unit gives pulsed o/p to the Genset to bestarted first online.Not a Standard scope of supply ( Optional)

FOR SINGLE SET With UTILITY PARALLEL mode follow the drawing Below

50 50 By giving 24vdc to this terminal when single set is paralled with utility,

the Synchroinser is enabledTB BAT-F1 1 1 24 vdc supply from terminal no.1

Load Demand / Utility Single

A34-P1-3 51 51

FOR MULTIPLE SETS : When ground signal is given to this terminal then the Genset will slowly transfer the load to the other sets & open its breaker, & go into the cool down cycle ( Stop Delay as set on PCC) & then shutdown with amessage on PCC " LOAD DEMAND SHUTDOWN".

When ground to this terminal is removed, then the genset will start automatically, close its breaker after synchronising &start taking its share of load.

Shunt Trip Coilof Brkr

Master FirstStart Unit

TB1

TB1

TB1

TB1

TB1


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Circuit Breaker Open / Close Inhibit: ( Mandatory)This is used when it is required to work on the the Ckt breaker / Busbars for maintenance to ensure that breaker doesnot close even if the PCC is set in AUTO mode.To Inhibit the breaker closure apply Ground to terminal No.52

A34-P1-11 52 52 CB Open/Close Inhibit If the Breaker is Closed & if ground is

applied to terminal No.52 this will result inopening the breaker

A34-P1-11 52 52

GND-ENG 3 3

Circuit Breaker Position : (Mandatory) Giving a ground through the Aux. NO. contact of the Breaker will ensure that the Breaker is physicallyclosed. If this feedback doesnot come to the PCC then the Engine will shutdown on "Fail to Close' Fault.

A34-P1-4 53 53 CB Position

A34-P1-4 53 53

GND-ENG 3 3

Load Share Lines ( Mandatory for Parallel Operation)

A34-P1-22(GREEN) 54 54 GREEN(KVAR-) A34-P1-23(RED) 55 55 RED (KVAR+) A34-P1-8(BLACK) 56 56 BLACK (KW-) A34-P1-15(WHITE) 57 57 WHITE(KW+) A34-P1-1 58 58 SHEILD

For Parallel Operation with Multiple PCC Sets: Interconnect these terminals form one PCC set to the other as shown below

DG Set No 1. DG Set No.2 DG Set No3. A34-P1-22(GREEN) 54 54 54 54 54 54

A34-P1-23(RED) 55 55 55 55 55 55 A34-P1-8(BLACK) 56 56 56 56 56 56 A34-P1-15(WHITE) 57 57 57 57 57 57 A34-P1-1 58 58 58 58 58 58

Note : Use Four Core Sheilded 18 GA stranded cable only

Breaker Closure Inhibitthrough Switch

Aux. Contact of Genset Breaker

Main Panel

Main Panel

TB1

TB1

TB1

TB1

TB1

TB1


16/21

By installing the resistances in these terminals, the PCC will operate in Droop Mode.NOTE : This Just enables the PCC for Droop operation, to set the exact % of droop please refer the Graph of % SpeedDroop Vs KW Loadshare Gain Or follow the tables given below :Table for Speed Droop

Table for Voltage Droop

Procedure for Droop Paralleling Setup1.Insert the 5 K Ohm resistor as shown above.

2. Set KW & Kvar balance = 0 ( In the PCC Parallel set , Isolated bus Menu)3. Set the No Load Voltage & frequency to the desired value.4. Set KW & KVAR load share gains to the desired value ( In the PCC Parallel set , Isolated bus Menu)as per the tablesgiven above.NOTE : All PCC's are by Default set for Isochronous operation.

Inputs to Control Generator Load in Utility Parallel Mode ( Mandatory for Utility Paralleling) A34-P2-15 59 59 EXTERNAL LOAD SET + A34-P2-23 60 60 EXTERNAL LOAD SET -

0-5Vdc input voltage when given to these terminals ( When Paralleled with Utili ty Mains), the Load on the Generator canbe either increased or decreased.

A34-P2-15 59 59

A34-P2-23 60 60

Desired % Droop KW Load Share Gain

1 42 63 84 105 12

% Droop KVAR Load Share Gain3 3004 3305 4206 480

- Ve

+ 5 vdc Ve

0-5vdc Source

TB1

TB1


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Instrumention Required for PCC Commissioning

1 PCC Manual2 Calibrated & standards Clip On meter3 Phase Sequence Meter4 Wrist Strap5 Alternator Control Panel as built Wiring Diagram

Requirment in the Control Panel

1 Kwh meter2 Electricaly Closing / tripping / Spring charging Circuit Breaker.3 16 Channels Alarm Annunciator.

4 High db Hooter for Audio Alarm.5 Earth Fault Protection Relay6 Selector Actuator switch for Remote Start / Stop.7 Selector Actuator switch for Breaker Open / Close.8 Selector Actuator switch for DG Unloading9 Emmergency trip P.B.

10 Lamp test / Acknoledge / Reset Push Button11 * 0-5 V DC regulated variable power source in case of Utility Parralleling12 Df / Dt protection Relay in case of Utility Paralleling.

Cable requirements for Interconnection Between PCC & Control Panel

1 2 Nos. 16 core 1.5 sq.mm F l e x i b l e cable from PCC Terminal Strip to Control Panel.

2 4 core 1.5 sq.mm. F l e x i b l e cable form DG common (load) Bus to PCC

Bus PT Module.3 4 core 1sq.mm. copper shielded cable from one PCC terminal strip to otherPCC terminal strip for Load Sharing Lines.

* Kindly contact electronics Cell for this requirement


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Sample GA Drawing of the Control Panel to be supplied with PCC Genset

AMF / SYN & Iso-Load Sharing Control panel with PCCCB - EDO Type Circuit Breaker With U/V Coil, ShuntTrip Coil, Closing Coil, & C.B. Tripped P.F. contactE/F - Earth Fault Relay

VSR - Mains Voltage Sensing RelayBattery ChargerKwh - Energy Meter

A - Ammeter & Ammeter Selector Switch V - Voltmeter & Voltmeter Selector SwitchDCV - DC Voltmeter for Battery VoltageDCA - DC Ammeter for battery charging Current.

CTs - For Metering & E/F ProtectionS1 - Battery Charging Mode Selector SwitchCB ON/OFF - Indicating Lamp

AA - 16 Windows Alarm AnnunciatorPB - Emergency Stop Push ButtonPB1,2,3 - Lamp Test/ Ack / Reset Push ButtonSA1 - Engine Start / Stop SwitchSA2 - Ckt Bkr. Close / Open Switch

SA3 - DG Load / Unload SwitchSA4 - Rated/Idle SwitchK1 - Relay for Closing C.B.K2 - Relay for Tripping C.B.F1,F2,F3 - 1 Amp Fuses for giving Supply to Bus PT Module(From Breaker O/G Supply RYBN)H - Hooter

CB ON

AA

DCA

H

PB1 PB2 PB3

SA1 SA2 SA3

CB

Busbar Chamber

DCV

SA4

A V

ASS VSS

CB OFF

P.B.

Kwh E/F

S1


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Mandatory Connections from the PCC to the Main panel for :

Single PCC Set Without AMFSingle PCC Set With AMFMultiple PCC Sets for Parallel OperationSingle PCC Set with Droop OperationSingle PCC Set Paralleled with Non PCC SetsSingle PCC Set Paralleled with UtilityMultiple PCC Sets Paralleled with Utility

Bare Minimum Mandatory Connections :

Single PCC Set Without AMF Single PCC Set With AMF1. Remote Start Switch on Main Panel 1.Remote Start Connections Wired up through V. S. Relay2. Remote Emergency Stop on Main Panel 2. Remote Emergency Stop on Main Panel3. Common Shutdown Indication on Main Panel ( Hooter) 3. Common Shutdown Indication on Main Panel ( Hooter)4. Customer Fault No.2 -Earth Fault Relay 4. Customer Fault No.2 -Earth Fault Relay5. Not On Auto Indication on Main Panel 5. Not On Auto Indication on Main Panel6. High Engine Temp. Indication on main Panel 6. High Engine Temp. Indication on main Panel7. Over Speed Indication on Main Panel 7. Over Speed Indication on Main Panel8.. Low Coolant Level Indication on Main panel 8.. Low Coolant Level Indication on Main panel9.. Low Lube Oil Pressure Indication on main Panel 9.. Low Lube Oil Pressure Indication on main Panel10. Closing Coil connections for Breaker ( 24vdc Closing Coil) 10.Over Crank Indication on Main Panel11.Common Warning Indication on Main Panel (Hooter) 11. Closing Coil for Breaker ( 24vdc Closing Coil)12. CB Open /Close Inhibit Switch on Main Panel 12.Common Warning Indication on Main Panel (Hooter)13. Shunt Trip Connections for Breaker ( 24Vdc Shunt Trip Coil) 13. CB Open /Close Inhibit Switch on Main Panel

14. Shunt Trip coil for Breaker ( 24Vdc Shunt Trip Coil)

Multiple Sets for parallel Operation Single PCC Set with Droop Operation1. Remote Start Switch on Main Panel 1. Remote Start Switch on Main Panel2. Remote Emergency Stop on Main Panel 2. Remote Emergency Stop on Main Panel3. Common Shutdown Indication on Main Panel ( Hooter) 3. Common Shutdown Indication on Main Panel ( Hooter)4. Customer Fault No.2 -Earth Fault Relay 4. Customer Fault No.2 -Earth Fault Relay5. Not On Auto Indication on Main Panel 5. Not On Auto Indication on Main Panel6. High Engine Temp. Indication on main Panel 6. High Engine Temp. Indication on main Panel7. Over Speed Indication on Main Panel 7. Over Speed Indication on Main Panel8.. Low Coolant Level Indication on Main panel 8.. Low Coolant Level Indication on Main panel9.. Low Lube Oil Pressure Indication on main Panel 9.. Low Lube Oil Pressure Indication on main Panel

10. Closing Coil connections for Breaker ( 24vdc Closing Coil) 10. Closing Coil for Breaker ( 24vdc Closing Coil)11.Common Warning Indication on Main Panel (Hooter) 11.Common Warning Indication on Main Panel (Hooter)12. CB Open /Close Inhibit Switch on Main Panel 12. CB Open /Close Inhibit Switch on Main Panel13. Shunt Trip Connections for Breaker ( 24Vdc Shunt Trip Coil) 13. Shunt Trip coil for Breaker ( 24Vdc Shunt Trip Coil)14.Load Share Line Interconnections from Set to set 14. 5 K.Ohm Resistances between terminals 54,55 & 56,57


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Mandatory Connections from the PCC to the Main panel for :

Single PCC Set Paralleled with Non PCC Sets Single PCC Set Paralleled with Utility1. Remote Start Switch on Main Panel 1. Remote Start Switch on Main Panel2. Remote Emergency Stop on Main Panel 2. Remote Emergency Stop on Main Panel3. Common Shutdown Indication on Main Panel ( Hooter) 3. Common Shutdown Indication on Main Panel ( Hooter)4. Customer Fault No.2 -Earth Fault Relay 4. Customer Fault No.2 -Earth Fault Relay5. Not On Auto Indication on Main Panel 5. Not On Auto Indication on Main Panel6. High Engine Temp. Indication on main Panel 6. High Engine Temp. Indication on main Panel7. Over Speed Indication on Main Panel 7. Over Speed Indication on Main Panel8.. Low Coolant Level Indication on Main panel 8.. Low Coolant Level Indication on Main panel

9.. Low Lube Oil Pressure Indication on main Panel 9.. Low Lube Oil Pressure Indication on main Panel10. Closing Coil connections for Breaker ( 24vdc Closing Coil) 10. Closing Coil for Breaker ( 24vdc Closing Coil)11.Common Warning Indication on Main Panel (Hooter) 11.Common Warning Indication on Main Panel (Hooter)12. CB Open /Close Inhibit Switch on Main Panel 12. CB Open /Close Inhibit Switch on Main Panel13. Shunt Trip Connections for Breaker ( 24Vdc Shunt Trip Coil) 13. Shunt Trip for Breaker ( 24Vdc Shunt Trip Coil)14. 5 Kilo Ohm Resistances between terminals 54,55 & 56,57 14.Ground Connection Of terminal No.5115.Synchronising panel 15.24Vdc to Terminal no.50 to enable Synchroniser

16.Ext.l Load set terminal Nos.59 & 60 ( 0-5 Vdc) I/p to PCC17.24Vdc Supply to terminal No.46.18.Ground conn. through Utility Breaker Aux. NO Contact

Multiple PCC Sets Paralleled with Utility1. Remote Start Switch on Main Panel2. Remote Emergency Stop on Main Panel3. Common Shutdown Indication on Main Panel ( Hooter)4. Customer Fault No.2 -Earth Fault Relay5. Not On Auto Indication on Main Panel

6. High Engine Temp. Indication on main Panel7. Over Speed Indication on Main Panel8.. Low Coolant Level Indication on Main panel9.. Low Lube Oil Pressure Indication on main Panel10. Closing Coil connections for Breaker ( 24vdc Closing Coil)11.Common Warning Indication on Main Panel (Hooter)12. CB Open /Close Inhibit Switch on Main Panel13. Shunt Trip Connections for Breaker ( 24Vdc Shunt Trip Coil)14.Load Demand switch ( Terminal No.51)

15.External Load set terminal Nos.59 & 60 ( 0-5 Vdc) I/p to PCC16.24Vdc Supply to terminal No.46.17.Ground connection through Utility Breaker Aux. NO Contact


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Parameters to be logged on Hourly basis

DGNo. Time

Eng.Run Hrs

No. ofStarts

Lube OilTemp.

LubeOil Pr.

Cool.Temp.Right/Left

Batty.Volt. RPM Gov % Reg% L12 L23 L31 L1 L2 L3 KW PF KWh %Load %Amps

Current Voltage

PCC Checks / PMP

PCC Commissioning Guide Lines

Documents

Transcript of PCC Commissioning Guide Lines