Technical TrainingParticipant’s Guide CMT0949-EN-PG Updated 2/2008 Revision History v1.00 (12/2006) 1. Initial draft for product launch QTQ 2007 v1.01 (1/2007) 2. Updated Draft for ASTC 2007 3. Updated version v2.00 (1/2008) 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 1302 Module Table of Contents Preface: 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: The introduction describes the audience, the purpose, and the structure of the training module. Introduction to the PowerCommand Control 1.1, the PowerCommand Control 1302 control board and its options: This lesson presents an overview of the PowerCommand Control 1302. The participant will learn to identify the main features of the PowerCommand Control 1302, its standard features and options. PowerCommand Control 1.1 HMI 211 Service Menus: This lesson presents the Setup and Calibration menu system used in the PCC1.1 and HMI 211 PowerCommand Control 1.1 Sequence of Operation: This lesson presents sequence of operation and feature operation and performance information about the PowerCommand Control 1302. PowerCommand Control 1302 Installation: This section provides installation information, procedures, and requirements for the PowerCommand Control 1302. PowerCommand Control 1302 Control Setup and InPower: This lesson covers adjustments and configuration details using InPower as the setup tool. PCCNet Network for the PCC 1302: This lesson presents an introduction to the PCCNet network and components used with the PCC 1302, I II 1 2 3 4 5 6 PowerCommand Control 1302 ModBus: This lesson presents the basic concepts of ModBus communications, the ModBus feature on the PCC 1302, and some of the available tools to use with this feature. PowerCommand Control 1302 PGICAN: This section introduces the basics about the J1939 CAN communications available on the PCC 1302, for use with Full Authority Engine controls. Glossary: This section lists the most common terms used throughout this training module pertaining to the PowerCommand family of Controls. Activities: Copies of Participant In-class and Homework Activities, and each Section Quiz are found in this section. Appendix: This section contains several useful guides and lists. Diagrams: This section has copies of all prints used in the course. 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 have a copy of this sheet as the last page in their Participant Guide, but if you need a master we provide one here. 7 8 9 10 11 12 13 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 Naming System PCC 1.X PCC 2.X PCC 3.X PCC 1302 PCC 2300 PCC 3300 PCC 1.1 (HMI 211) PCC 1.2 (HMI 220) Phase 1 (2.2) (FAE) - HMI 220, HMI 112 or 114, HMI 113 Phase 2 (2.3) (HM) - HMI 220 or 320, HMI 112 or 114, HMI 113, AUX 101/102, AUX 104 Phase 1 (3.X) - HMI 220 or 320, ?????????????? Phase 2 (3.X) - HMI 220 or 320, ?????????????? 1 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 2.X = PCC 2300 control board 3.X = PCC 3300 control board Participant’s Guide Title & Introduction Page5 X.1 = HMI 211 X.2 = HMI 220 X.3 = HMI 320 The PCC 2.X and 3.X 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.X 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.X 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.X FAE training will be a prerequisite to any future training program Participant’s Guide Title & Introduction Page6 Introduction Welcome! Welcome to the Instructor’s Guide for the PowerCommand Control 1302 module! This guide was written by the Cummins Power Generation Sales and 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 PowerCommand Control 1302 module is to help you, the Cummins Power Generation distributor service technician, understand the PowerCommand Control 1302 which is going to replace the specialized Onan gen set control modules (e.g., DN, GN). It is also expected that the PowerCommand Control 1302 will be used on many of the Cummins−powered gensets with Full Authority Engines (FAE) and the hydro−mechanical fuel systems up to 1500 kW. 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. 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 follows the presentation; it gives participants the chance to practice new skills or work with new ideas. Participant’s Guide Title & Introduction Page7 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 Sales and Technical Training OUJ3 1400 73rd Avenue NE Minneapolis, MN 55432 Preparing for the Training Session To simplify your preparations for the training session, we’ve broken out your major tasks. Coordinate the session • • • • Arrange for a location, date, and time convenient for the session participants. Plan the session as far in advance as possible. Try to arrange for a quiet, seminar-type meeting place, away from the participants’ regular work area. Do as much as possible to help make participants comfortable. Arrange for refreshments and meals, if appropriate. 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. Participant’s Guide Title & Introduction Page8 Practice your presentation−−You’ll feel more at ease if you practice the presentation portion of each lesson at least once before the session. The participants will also be more attentive if you appear organized and prepared. Organize and prepare the module training materials−−Make copies of the module assessment and the module comment forms (found at the back of this trainer’s guide) for each participant to complete at the end of the module. • Review the Materials Needed section at the beginning of each lesson and order the appropriate number of participant’s guides, sales literature, and materials in advance from Onan’s Literature department using a copy of the form found at the end of this section. Note: We recommend you order materials two to three weeks in advance of your session. Note: You will also have to order kits of InPower service software, a manual, and a hardware or software lock for the training participants. • • Arrange for training equipment−−For most Service Training lessons, you will need an overhead or slide projector and screen (with remote control, if available), a flipchart stand with paper and markers (or a whiteboard or blackboard and chalk), and specific hardware to use as a demonstrator unit for the lesson. Since each technician attending the course will be bringing a laptop PC and using the PC during the course of instruction, you may want to alert your IS department in case the technicians’ PCs need tweaking to operate properly. Confirm attendance−−A few days before the session, verify who will be attending. We recommend conducting the session with three to ten participants. Set up the room−−Plan to arrive at least 30 minutes before the session begins. Check the lighting, acoustics, and temperature of the room. Find out how to adjust the lighting and temperature. • • Make sure all equipment (such as slide and overhead projectors, extra bulbs, flipchart stands) is in place and in working order before the session begins. If possible, have tables large enough for three participants to have their guides and a demonstrator on the table at the same time. Participant’s Guide Title & Introduction Page9 Conducting the Training Session Introductions At the beginning of the session, have each person introduce himself or herself and say a few words about his or her experience with the subject to be covered. As an alternative, you might want to let participants interview each other and introduce the person they interviewed to the group. If participants do not know each other, make name tags and table top name tents and ask participants to use them throughout the session. Expectations After introductions, label a flipchart page with the word Expectations. Ask the participants what expectations they have for the session, then explain which of their expectations you will be able to address. If you will not be able to address all of the participants’ expectations, arrange to follow up on their concerns at a later date. Lessons The first time you conduct the training for this module, follow the step-by-step lesson instructions. Feel free to add comments from your own experience, but follow the structure of the module. Once you are familiar with the module you can modify the session for the specific needs of the group. Participant’s Guide Title & Introduction Page10 Participant Check List Use this check list to help you prepare for the training session. Before You Begin Review the Participant guide and understand the lesson objectives. Prepare yourself to gain the most from the training session. Participants The training does not end when you are dismissed at the end of the day. Read ahead and prepare for the next days instruction Practice and be comfortable using InPower software. Materials (See Materials Needed section at beginning of each lesson) Each section lists the materials needed. Notify the Instruction if you find that you are missing important materials. Is your Participant Guides complete? Do you have materials for taking proper notes? Equipment (See Equipment Needed section at beginning of each lesson) Do you have a working laptop with the necessary software as required for the course? PC with InPower, dongle, and RS485 cable. You should have been notified in advance if you needed any supporting equipment (meters, small hand tools, etc…) for this course. Be aware of the electrical power systems and the wall power supply. You may need to provide you own converters and/or transformer systems for you to operate your computer on wall power. Extension cords – you may need to provide one for powering your computer. Practice Review the lesson instructions and practice what you have learned. Refer to your of the training materials and note in your review Room Setup Participant’s Guide Title & Introduction Page11 This Page Intentionally Left Blank Participant’s Guide Title & Introduction Page12 PCC 1.1 & PowerCommand Control 1302 Introduction and Options PowerCommand Control 1.X Section 1 Introduction to the PowerCommand Control 1.1 Visual 1-1 PowerCommand Control Participant’s Guide Section 1 Page1 PCC 1.1 & PowerCommand Control 1302 Introduction and Options Section 1 Introduction to the PCC 1.1, the PowerCommand Control 1302 control board and its options. Estimated Time: 4 hours Equipment Needed Highlighter, Post-it note pads, Notepad and pencil PowerCommand Control 1302, HMI 211, and simulator for each pair of participants Materials Needed One for each participant: PowerCommand Control 1302 Participant’s Guide Guide CMT0949-EN-PG Participant’s Guide Section 1 Page2 PCC 1.1 & PowerCommand Control 1302 Warm Up Introduction and Options In this lesson we are going to learn about the PowerCommand Control 1302 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 1.1 standard components. Identify the PCC 1.1 & PowerCommand Control 1302 optional components. Describe the main functions of the PowerCommand Control 1302 and its features. Describe the e standard operator interface (switch and LED). Use the Operator menus on the optional control panel. Participant’s Guide Section 1 Page3 PCC 1.1 & PowerCommand Control 1302 Introduction and Options PowerCommand Control 1302 Single-Board Control for Gas sets J1939 CAN Link for FAE sets Optional governor amp. for non-FAE sets PCC 1302 is a superset of the PCC 1301 J1939 CAN Link, PMG Input, and Common wiring harness with “3-series” controls 2 Visual 1-2 Introduction to the PowerCommand Control 1302 Participant’s Text The PowerCommand Control 1302 is a single integrated control providing complete genset control and protection. Single-board control for gaseous gensets and Diesel FAE engine-driven sets Governor amplifier needed for diesel sets equipped with electric acutator. Multiple applications: • • Non-Cummins engines Cummins engines Notes Participant’s Guide Section 1 Page4 PCC 1.1 & PowerCommand Control 1302 Introduction and Options PCC 1302 Control Board 3 Visual 1-3 The PCC 1302 Control Board Participant’s Text Single board in large potting shell More connectors than the PCC 1301 • • • Connectors are common among all “3series” controls. PCC 1302, PCC 2300, PCC 3300 This allows customers to upgrade genset capabilities by just purchasing and installing a new Control Board. Notes Participant’s Guide Section 1 Page5 PCC 1.1 & PowerCommand Control 1302 Introduction and Options PCC 1302 Connectors J18- Excitation Power TB1- Customer Connections J17- Field Output J22- Genset Voltage Sense DS1 LED Status Indicator J12- Genset CTs J25 – Display Connection TB15- RS485 / MODBUS J20- Genset Accessories J11 – Engine Harness 4 Visual 1-4 Control Board Connectors Participant’s Guide J11 − Connections to the engine harness and/or the ECM. J12 − CT Inputs J17 − Exciter Field Output J18 − AVR Power Supply J20 − Genset Accessories Harness J22 − Genset Voltage Sense J25 − Operator Panel (HMI) Harness TB1 − Customer Connections TB15 − RS485 / Service Tool Connections DS1 − Status indicator. DS1 flashes to let you know the control board is operating properly. Trainer’s Guide Participant’s Guide Section 1 Page6 PCC 1.1 & PowerCommand Control 1302 Introduction and Options HMI 211 Operator Panel 5 Visual 1-5 Optional operator panel Participant’s Text Six LEDs for operator information Not in Auto Shutdown Warning Remote Start Auto Manual Run Graphical display for menus and information display. Four “soft” buttons Two “Fixed” buttons Notes Participant’s Guide Section 1 Page7 PCC 1.1 & PowerCommand Control 1302 Introduction and Options Operator Panel Menus System Messages Adjusting Settings Saving Changes Operator Menus Selecting Auto or Manual Mode 6 Visual 1-6 Operator Panel Menus Participant’s Text Refer to the 900-0661 Operator/Installation Manual for the menus used with the PCC 1302 Operator Panel. The panel allows easy scrolling for monitoring of the following parameters. • • • • • Engine Temp / Oil Pressure / Battery VDC Load kVA / Frequency / Speed L1-L2 V / L2-L3 V / L3-L1 V L1-N V / L2-N V / L3-N V L1 Amps / L2 Amps / L3 Amps Notes Participant’s Guide Section 1 Page8 PCC 1.1 & PowerCommand Control 1302 Introduction and Options Visual 1-7 PCC 1302 Operator Menus — see back of Operator Manual for larger version. Participant’s Guide Section 1 Page9 PCC 1.1 & PowerCommand Control 1302 Introduction and Options AUX104 Governor Module 8 Visual 1-8 Governor Output Module 0327-1507 Participant’s Text The Governor Output Module is used with all diesel gensets. J1 Pinout: • • • • • 1 Governor Drive + 2 Governor Drive − 3 Battery + 4 Governor Out to EFC 5 Battery − Notes J1 connects to J11 and TB1 on the 1302 Control Board. Participant’s Guide Section 1 Page10 PCC 1.1 & PowerCommand Control 1302 Introduction and Options Optional PCCNet Components 0541-1291 AUX101 I/O Base Module 0541-0772 AUX102 I/O Expansion Module 0300-6014 HMI211 Operator Panel 0300-5929-01 HMI113 Annunciator 0300-5929-02 HMI113 Annunciator with box 0300-6050-01 Bargraph with kW (With PF) 0300-6050-02 Bargraph with KVA (No PF) 9 Visual 1-9 PCC 1302 Optional Components Participant’s Text 0327-1536 Input/Output Module This module is similar to the DIM used in the FT-10 network. It can use the 327-1527 DIM Expansion module to increase the number of relays. 0300-6014 HMI211 Operator Panel This is the optional Operator Panel for the PCC 1302. 0300-6050 Bargraph Module This module allows the customer to have a readout of current load, kW load, Frequency, and Voltage. 0300-5929-01 or -02 Annunciator • • The -01 is a flush-mount annunciator. The -02 is in a steel enclosure box Notes Participant’s Guide Section 1 Page11 PCC 1.1 & PowerCommand Control 1302 Introduction and Options PowerCommand Control 1.X Activity 1-1: Intro to PowerCommand 1302 and Options 10 Visual 1-10 Activities for Lesson 1 Participant’s Text Turn to Section 9 and complete Activity 1-1. At this time I would like you to work as teams to complete these activities. Notes Participant’s Guide Section 1 Page12 PCC 1.1 & PowerCommand Control 1302 Introduction and Options Wrap-Up In this lesson we have learned about the PCC 1302 control boards. First we talked about the PCC 1302 Control, where it is used, and where it may be used in the future. Next we talked about the control board and the connectors that join the harness to the board: J11 Engine Harness Connector J12 CT Inputs J17 Exciter field J18 AVR Power (PMG) J20 Genset Accessories Harness J22 Voltage Sensing J25 Operator Panel Harness TB1 Customer Connections TB15 PCCNet / Modbus / PC Tool Next we talked about the HMI 211 operator interface to the PCC 1.1 control. After introduction of the operator panel we talked about the Operator Panel Menus and looked at the menus in the manuals. 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 1.1 controls we have not yet covered? The following sections will delve deeper into all of the items introduced here. Participant’s Guide Section 1 Page13 THIS PAGE IS INTENTIONALLY LEFT BLANK PCC 1.1 & HMI 211 Service Menus PowerCommand Control 1.1 HMI 211 Section 2: PCC1.1 HMI 211 Service Menus Visual 2-1 Participant Guide Section 2 Page1 PCC 1.1 & HMI 211 Service Menus Section 2 PCC 1.1 HMI 211 Service Menus: Estimated Time: 2 hours Presentation of this lesson will very short, however there is a long period of hands on activity for participants to become familiar with the HMI. Equipment Needed Highlighter, Post-it note pads, Notepad and pencil PowerCommand Control 1302, HMI 211, and simulator for each pair of participants Materials Needed Module overhead set or slide set One for each participant: PowerCommand Control 1302 Participant’s Guide Operator Installation Manual – 1302 Series Genset Control Guide CMT0949-EN-PG 0900-0661 Participant Guide Section 2 Page2 PCC 1.1 & HMI 211 Service Menus Warm Up In this lesson we are going to learn about the Service and Setup Menus for thePCC1.1 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 After completing this lesson, the participants should be able to: • Locate and identify the front panel buttons used in navigating the PCC 1.1 HMI 211 menus. • Identify the menu choices accessible without using the Application password. • Use the Setup menu − Genset Service to view and/adjust Service menus. • Use the Setup menu − Genset Setup to view and/adjust Setup menus. Participant Guide Section 2 Page3 PCC 1.1 & HMI 211 Service Menus Standard Operator Panel 2 Slide 2-2 Participant’s Text We saw the optional Operator Panel in lesson 1. In this lesson we will look at the Service Menus available to the technician. After we look at the basic menus in the Participant’s Guide, we will move to the Operator/Installation Manual for the rest of the lesson. Notes . Participant Guide Section 2 Page4 PCC 1.1 & HMI 211 Service Menus Setup Menu Access 3 Slide 2-3 Setup Menu Access. Participant’s Text The Service Menus are hidden from casual view with a two-button combination. Press and hold the Up and Down buttons together for two seconds to get to the 1st Service Menu (Page 4-20 & 21in O/I Manual). If you then select 1 – Setup Menu, you will see a Password menu. If you enter the correct password, you will be able to change the setup parameters. Notes Participant Guide Section 2 Page5 PCC 1.1 & HMI 211 Service Menus Service Menu 4 Slide 2-4 Participant’s Guide Two-Finger Salute Service Menu This is the first menu you see after pressing the Up an Down buttons together to get into the Setup Menus. Selecting button 1 will take you to the Password menu. Selecting other buttons will take you to more service screens and displays. Later activities will allow you to visit these pages to satisfy your curiosity. Trainer’s Guide Participant Guide Section 2 Page6 PCC 1.1 & HMI 211 Service Menus Setup Menus 5 Slide 2-5 Genset Setup Menus Participant’s Guide Starting at the Setup Menus we see the first two picks: • Genset Service Menus, and, • Genset Setup Menus This time we will select the Service Menus pick (1) This will take us to additional selections of screens Trainer’s Guide Participant Guide Section 2 Page7 PCC 1.1 & HMI 211 Service Menus Genset Service Menu 6 Slide 2-6 Genset Service Menu Participant’s Text The four buttons at the bottom of the PCC 1302 Operator Panel lead to menus. • 1 - Genset Setup • 2 - Customer Input/Output • 3 - Meter Calibration • • 4 -Second Service Menu Notes Participant Guide Section 2 Page8 PCC 1.1 & HMI 211 Service Menus Setup Menus 7 Slide 2-7 Genset Setup Menus Participant’s Text Going back to the Setup Menus we see the first two picks again: • Service Menus, and, • Setup Menus This time we will select the Setup Menus pick (2) This will take us to the Setup Password Menu. This password is 1−2−0−9. Notes Participant Guide Section 2 Page9 PCC 1.1 & HMI 211 Service Menus Genset Setup Menu 8 Slide 2-8 Genset Setup Menus Participant’s Guide These menus have “low-level” parameters that are set up on a generator set that does not have a calibration developed for it. These are not normally adjusted by a technician except if setting of a new control when InPower is not available. Trainer’s Guide Participant Guide Section 2 Page10 PCC 1.1 & HMI 211 Service Menus Activities 2-1 Menu Hands On Activity 2-2 Menu Hands On Activity 2-3 Menu Hands On Activity 2-4 Menu Hands On Activity 2-5 Menu Hands On Activity 2-6 Menu Hands On Activity 2-7-8 Menu Hands On Activity 2-9 Menu Hands On Activity 9 Slide 2-9 Activities Listing for Lesson 2 Participant’s Text At this time I would like you to work as teams to complete these activities. These activities should be fairly easy for you, but take your time to become comfortable with the button pushing sequences. Notes Participant Guide Section 2 Page11 PCC 1.1 & HMI 211 Wrap-Up Service Menus In this lesson we have learned about the Service Menus for the PCC 1.1 and PCC1302/HMI 211 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 No Adjustments View Setup Menus 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 1302 control. Participant Guide Section 2 Page12 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation PowerCommand Control 1.1 1302 & HMI 211 Section 3: PCC1.1 1302 & HMI 211 Sequence of Operation Visual 3-1 Participant Guide Section 3 Page1 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Section 3 PowerCommand Control 1302 Sequence of Operation. Estimated Time: 2 hours Equipment Needed Highlighter, Post-it note pads, Notepad and pencil PowerCommand Control 1302 and simulator for each pair of participants (Optional for this section) Materials Needed Module overhead set One for each participant: • • • PowerCommand Control 1302 Participant’s Guide PC with InPower v 5.50 or later installed Operator/Installation Manual #900-0661 Guide (CMT0949-EN-PG) Participant Guide Section 3 Page2 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Warm Up In this lesson we are going to learn the operating features and sequence for the PowerCommand Control 1302. What we learn in this lesson will be applied in the troubleshooting lesson and in both the written and performance examinations. First, let’s look at the objectives for this lesson: Objectives After completing this lesson, the participants should be able to: • • • • • Point out the connections on the Base Board used in operating a genset with a PCC 1302 control. Create an understanding of the operation and functions of each connection used during the sequence of operation from preheat to shutdown. Describe how to isolate a failure in the operation of the PCC 1.1 and find the failed part. Use the Operator/Installation Manual #900-0661 to understand the function of various connections. Use the InPower service tool to adjust parameters used in the operation of the PCC 1302. Participant Guide Section 3 Page3 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation PCC 1302 Control Board 2 Visual 3-2 PCC 1302 Base Board Participant’s Text Nine connection points: • • • • • • • • • . J11 − Engine, Operator Interface, G1 Alt J12 − Current Transformer input J17 − Exciter Field J18 − AVR Power (PMG) J20 − Accessories J22 − Voltage Sensing J25 − Operator Panel TB1 − Customer Connections TB15 − Modbus and/or Service Tool Notes Participant Guide Section 3 Page4 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Standard Operator Panel 4 soft buttons 3 2 Fixed buttons Visual 3.2 Optional Operator Panel Participant’s Text The Operator Panel is optional and is referred to as the HMI. The HMI offers operator interface to the digital voltage regulation, engine speed governing, and remote start/stop control, and protective functions. Six preset LEDs: • • • • • • Not in Auto Shutdown Fault Warning Fault Remote Start Input Auto mode Manual Run mode Notes . Two preset buttons: • • Home (Arrow Button) Start/Stop (0 Button) Participant Guide Section 3 Page5 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Operation Sequence 4 Visual 3-4 PCC 1.X Sequence of Operation Participant’s Text Manual Operation 1. Operator presses switch to START / PREHEAT side to preheat engine. If engine temperature is low enough, the control heats the glow plugs if so equipped. After the preheat TD completes, the control cranks the engine. 2. If the engine rotates, the control keeps cranking. If the engine does not rotate, the control stops cranking for 2 second, then cranks again. If the engine still does not rotate, the control faults out on Fail to Crank. Notes Participant Guide Section 3 Page6 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Participant’s Text 3. If the engine rotates, the fuel system will deliver fuel to the cylinders and the engine will start running. 4. Once the engine reaches a high enough speed, the Battery Charge Alternator will deliver a 7 Volt DC voltage to the board and will disconnect the starter. 5. The engine will accelerate to rated speed, and regulate there. 6. As the engine approaches rated speed the Voltage Regulator will start exciting the exciter stator and the output voltage will start to build up to rated value. 7. When the main Alternator output nears the rated value, the regulator will start to reduce the excitation to the exciter stator and the output voltage will even out at rated value. 8. The operator will apply a load to the generator set that does not exceed the ratings of the engine and alternator. 9. When the generator is no longer needed, the operator will remove the load and allow the engine/generator to cool down at rated speed with no load for approximately five minutes. 10. At the end of the cooldown period the operator will move the switch to the STOP position and the genset will stop. Notes Participant Guide Section 3 Page7 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Fault Handling & Acknowledgement There are two ways to reset faults on the PCC1302. Local Fault Reset: Faults are reset at the HMI by pressing the button Or by placing the Auto/Manual/Off switch into the off position. Remote Fault Reset: Must be enabled by a software trim. Uses one of the configurable inputs. In auto mode: -The remote start signal must be removed. -And the remote fault reset input must be activated. The remote fault reset input has no effect if the Auto/Manual/Off switch is not in the Auto Position. 5 Visual 3-5 PCC 1302 Sequence of Operation Participant’s Text Fault Acknowledgement IF the control is equipped with an operator panel, press the button. Notes If the control is not equipped with an operator panel, place the Auto/Off/Manual Run switch in the Off position Refer to page 4-6 of 900-0661 Operator/Installation Manual for more information about Reset and Acknowledgement. Fault Acknowledgement can be activated remotely and can also be activated via a ModBus command. Participant Guide Section 3 Page8 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Bi-directional System Wakeup. The PCC1302 has implemented a wakeup scheme using the Bi-directional wakeup pin (J25-5 and TB15-5). 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. 6 Visual 3-6 PCC 1302 Wakeup Sequence Participant’s Text The PCC1302 will wake up with a command from other PCCNET devices on the network. Depending on the type of PCCNET device, it will have the ability to go to sleep if it is inactive for a prescribed period. Once awaked, it will send out a wakeup command to the rest of the PCCNET devices on the network. The PCCNET devices will also go to sleep if there are no other devices sending a wakeup signal. At this time, only the HMI and the PCC 1302 control board are the only 2 devices employing the bi-directional wake up. Notes Participant Guide Section 3 Page9 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Participant’s Text The PCC 1302 power consumption changes depending which of mode of sleep or wake it is in. Running - .750 amp ( 750 mAmp) Parade Rest Mode (awake but not running) .15 amp ( 150 mAmp) Sleep Mode- .06 amp ( 60 mAmp) Parade Rest Mode (previously called Idle Mode) describes a state of operation when the control is awake but the genset is not running. The control can be in this power consumption mode if it is in manual or Awake in Auto. Awake in Auto will be discussed a few pages ahead. Notes Participant Guide Section 3 Page10 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Bi-directional System Wakeup Bi-directional System Wakeup Logic. PCCNet devices are awakened by the PCC1302 wake-up command 7 Visual 3-7 PCC 1.1 Bidirectional Wakeup Participant’s Text If the PCC 1302 is in the SLEEP mode and it receives a input such as: Remote start Local or Remote E-Stop Configurable Input #3 Configurable Input #4 Command to enter Manual Mode The control will awaken and send a wake up command to the HMI. Notes Participant Guide Section 3 Page11 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Bi-directional System Wakeup Waiting for Power down: Local Wakeup Inputs are Inactive Start Counting the sleep timer Ready for Power Down: Sleep Timer has expired. Heartbeat LED is Flashed Faster. Stop driving Bi-direction wakeup pin. Power Down: Bi-directional wakeup is inactive Save periodic data Power down. 8 Visual 3-8 PCC 1.1 Bidirectional System Wakeup Participant’s Text After completing the wake up process described in the previous page, either the control will be in a running mode or parade rest mode until that process ends. Then the system will begin a countdown to sleep. Visual 3-8 describes the process involve while falling asleep. Notes Participant Guide Section 3 Page12 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Wake In Auto Wake-up In Auto is now a InPower software trim (adjustment) that sets or clears a continually powered latch to store the Wake-Up In Auto configuration. No DIP switch as in the PCC1301. 9 Visual 3-9 PCC 1302 Wake in Auto Participant’s Text The PCC1302 does not have a dipswitch for configuring the Wake In Auto function. Awake in Auto is a trim adjustment found in InPower under Adjustments >> Features>> Genset Setup >---- Wake In Auto Enabled {enable/disable} Notes Participant Guide Section 3 Page13 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Limited PGI CAN Support The PCC1302 supports PGI CAN, and these Fault Codes: Intake Manifold High, warning and shutdown level Intake Manifold OOR, low and high. Water In Fuel. Water In Fuel OOR. Coolant Level Low, warning and shutdown. Coolant Level OOR, low and High Engine Over Speed. Engine Oil Pressure Low, warning and shutdown. Engine Oil Temperature High Engine Temperature High, warning and shutdown. All other engine fault codes are announced as Fault Code # 1246 10 Visual 3-10 PCC 1302 and PGICAN Participant’s Text PGI CAN is a form of SAE J1939 CAN communications between the Cummins ECM and the PowerCommand Control. SAE J1939 CAN communications list thousands of fault code for many engine functions and faults. Most of the fault codes are not important to the average generator operator or technician and most would confuse operators. PGI CAN is only concern about certain faults so any serious faults or warnings not listed above are communicated as Fault Code #1246, which is referred to as a General Engine Fault. Notes Participant Guide Section 3 Page14 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Limited PGI CAN Support Data Messages the PCC1302 Supports: Intake Manifold Temperature Engine Oil Temperature Engine Oil Pressure Fuel Rate. Engine Coolant Temp Engine Speed. Engine Running Time. Water In Fuel Indicator *** IMT, Engine Oil Temperature, and Fuel Rate are not viewable from the HMI211. 11 Visual 3-11 PCC 1302 PGICAN Participant’s Text In addition to the ability of the ECM to communicate engine faults to the PCC 1302, the PCC 1302 also recognizes the engine operating information list above. The ECM processes information from the various engine sensors and then sends digital messages to the PCC 1302. These messages are processed for display by the HMI or InPower, or be retransmitted as a ModBus or PCCNET message. Intake Manifold Temperature, Engine Oil Temperature and Fuel Rate are not available for display on the HMI211, but they are available for viewing on InPower or over the ModBus network. Notes Participant Guide Section 3 Page15 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation PMG and Self Excitation The PCC1302 switches the positive side of the incoming excitation source and sends a portion (measured in percent duty cycle) of it back to the field winding. Excitation Source Input Field Output By adjusting how much we send to the field winding we can control the output voltage. Zero Cross 12 % Duty Cycle From AVR Visual 3-12 PCC 1302 Excitation Participant’s Text The PCC 1302 provides a excitation DC output that varies in amplitude and on time. This is NOT a pwm signal and this is different from some other PCC controls, but it is very similar to some of the other Cummins Generator Technologies automatic voltage regulators. As can be noticed in the above image, if the on time increases, the voltage will increase. This relationship is called the “% Duty Cycle” and is found in the Monitor >>Alternator >> Regulator section of InPower and is labeled AVR% Notes Participant Guide Section 3 Page16 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Over Excitation Protection As on time increases, excitation voltage increases. Over Excitation is handled using reference to excitation on time – Duty Cycle. Excitation Duty Cycle of 46% or 70vrms or more for 8 seconds will activate the over excitation fault. Voltage increase with increased Duty Cycle 13 Visual 3-13 PCC 1302 Over Excitation Participant’s Text Over Excitation Protection The PCC 1302 has built in algorithms that constantly calculates and monitors the output voltage, excitation voltage, excitation current, and Duty Cycle. If the control determines the excitation system is operating beyond safe limits, it will shut down the regulator output and engage the Over Excitation Fault. This protection system is an improvement over using fuses or field breakers. With analog AVRs, these protection devices often contribute to AVR failures because when they open, it instantly removes the load from the AVR and internal voltages can spike high enough to damage the internal AVR components. Notes Participant Guide Section 3 Page17 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Participant’s Text The new PCC1302 system simply turns off the thyristor (SCR) thereby extinguishing the field output. Therefore, the PCC 1302 does not experience internal voltage spikes. Notes Participant Guide Section 3 Page18 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Activities: Quiz: PCC 1302 Sequence of Operation 14 Visual 3-14 PCC 1302 Activities - Sequence of Operation Participant’s Text Work through the Quiz found in the Activity portion of Section 10. Notes Participant Guide Section 3 Page19 PCC 1.1 & PowerCommand Control 1302 PowerCommand Control 1302 Sequence of Operation Wrap-Up In this lesson we have learned about the operation information about the PCC 1302 control board. First we talked about the PCC 1302 Control board connections and the HMI 211 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 fault handling on the PCC 1.1 control. Then we went on to talk about the Wakeup system used on PCC 1.X controls. Next we talked about the PGI CAN feature and some details. Finally, we looked at the new excitation operation system and its protection ability. Are there any questions that you have about the operation of PCC 1.X controls we have not yet covered? The following section will look at installation, and connections details. Participant Guide Section 3 Page20 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation PowerCommand Control 1.1 Section 4: Control Installation Visual 4-1 Participant Guide Section 4 Page1 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation Section 4 PowerCommand Control 1302 Installation Estimated Time: 3 hours Equipment Needed Highlighter, Post-it note pads, Notepad and pencil PowerCommand Control 1302, HMI 211 and simulator for each pair of participants Optional: AUX 101, AUX 104, HMI 113, and/or Bar graph display Materials Needed One for each participant: Wiring Diagram PowerCommand Control 1302 Participant’s Guide Operator/Installation Guide #0630-3440 Sheets 1 thru 5 Guide (CMT0949-EN-PG) #900-0661 Participant Guide Section 4 Page2 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation Warm Up In this lesson we are going to look at the optional devices that can be used with the PowerCommand Control 1302. We will also give you a chance to work with the optional devices with the controls at your workstations. First, let’s look at the objectives for this lesson: Objectives After completing this lesson, the participants should be able to: • • • Understand options for the PowerCommand Control 1302. Identify the correct connection points on options and the PCC 1302 control module. Install options for the PowerCommand Control 1302. Participant Guide Section 4 Page3 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation Control and Option Installation Physical Installation Requirements Identify each of the connectors Input and Output Connections 2 Visual 4-2 Control and Option Installation. Control Installation Participant’s Text Most technicians will encounter the PCC1302 when it is already installed onto a factory built generator set. However, there will be situations when technicians will need to know about proper installation of the PCC 1302, such as instances when an old/obsolete control needs to be replaced or when troubleshooting, or if adding more features or options. Notes Participant Guide Section 4 Page4 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation Installation Steps for Options Battery Disconnected Static Wrist Strap Install Option, (module, HMI, card, etc.) Install Wiring Harness Battery Connected Download Proper Calibration Test Generator Set 3 Visual 4-3 Installation Steps for PowerCommand Control 1302 Options Participant’s Text Installing Options The PowerCommand Control 1302 cannot be powered down except by disconnecting the battery cable. 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. Notes Participant Guide Section 4 Page5 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation Participant’s Text Remove control-housing cover(s) and connect your wrist strap. Install the new option or card or other modules, etc. Install the wiring harness for the option. Reconnect battery and enable the battery charger. 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. Notes Additional Notes or Comments _______________________________________________________________________________ Participant Guide Section 4 Page6 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation Connector Location J18- Excitation Power TB1- Customer Connections J17- Field Output J22- Genset Voltage Sense J25 – Display Connection J12- Genset CTs TB15- RS485 / MODBUS J20- Genset Accessories J11 – Engine Harness 3 Visual 4-4 Connector Location -r PowerCommand Control 1302 Participant’s Text The PowerCommand Control 1302 is one of the new series of controls that uses the 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. Notes Participant Guide Section 4 Page7 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation TB1 Connections 5 Visual 4-5 Control Board TB1 Connections Participant’s Text Customer Connections go to TB1 terminals 10 − Signal Return for Remote Start 11 − Remote Start input 12 − Configurable #1 input (customer input) 13 − Configurable input (COMMON) 14 − Configurable #2 input (customer input) 15 − Signal Return for Remote Emergency Stop 16 − Remote Emergency Stop input Signal Ground IS NOT THE SAME AS BATTERY GROUND! Notes Participant Guide Section 4 Page8 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation J11 Inputs & Outputs 6 Visual 4-6 J11 Inputs and Outputs Participant’s Text When using an Analog configuration, the sensors and switches must meet the specifications as listed in Operator/Installation manual #900-0661 PGI CAN Link is a proprietary communication protocol that is used to communicating with Cummins ECMs. SAE-J1939 allows for certain variations between manufactures of smart engine controls, so PGI CAN Link is not necessarily the same as or compatible other J1939 communication systems. Signal Ground IS NOT THE SAME AS BATTERY GROUND! Notes Participant Guide Section 4 Page9 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation Analog Signal Connections J11 INPUTS 1 2 3 8 9 10 11 12 Oil Pressure Sender (+5vdc) Oil Pressure Sender or Switch Return Oil Pressure Sender (signal) Mag Pickup Shield Mag Pickup Supply Mag Pickup Return Coolant Temp Sender Coolant Temp Return J11 OUTPUTS 4 5 6 7 21 22 Governor Drive – Governor Drive + Relay Coil + Relay Coil Return (-) Keyswitch High Side Driver Keyswitch Low Side Driver PGI CAN Link Connections J11 17 18 19 20 21 22 ECM CAN Shield ECM B+ Return ECM CAN Low ECM CAN High Keyswitch High Side Driver Keyswitch Low Side Driver Trainer’s Personal Comments Participant Guide Section 4 Page10 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation J20 Inputs & Outputs 7 Visual 4-7 J20 Inputs and Outputs Participant’s Text J20 provides inputs and outputs for various items and drivers relevant to the genset application. Refer to Table 3-11 and the wiring diagrams in Section 7 of the Operator/Installation manual #900-0661 Signal Ground IS NOT THE SAME AS BATTERY GROUND! B+ RETURN = Battery Negative B+ RETURN IS NOT EQUAL TO GROUND Notes Participant Guide Section 4 Page11 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation Analog Signal Connections J20 INPUTS 1 9 10 20 21 2 4 7 12 11 5 17 6 18 Chassis Ground Fused Battery B+ Fused Battery B+ Fused Battery B+ Fused Battery B+ Battery BBattery BBattery BBattery BStarter Disconnect Input Configurable Input #3 Return Configurable Input #3 Supply Configurable Input #4 Return Configurable Input #4 Supply Additional Notes or Comments J20 OUTPUTS 3 13 15 14 22 Relay Driver ( low side – 250mA ) Relay Driver ( relay coil B+ supply ) Relay Driver (coil low side – 250mA ) Relay Driver (coil low side – 250mA ) Battery Alternator Flash Participant Guide Section 4 Page12 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation J25 Display Connections 8 Visual 4-8 J25 Display Connection Participant’s Text J25 provides connection for PCCNET display connection. Refer to Table 3-13 and the wiring diagrams in Section 7 of Operator/Installation manual #900-0661 Notes Participant Guide Section 4 Page13 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation J17 & 18 Inputs & Outputs J17 J18 Maximum input is 240 VAC J18 9 Visual 4-9 J17 - 18 Inputs and Outputs J17 Excitation Field Power Participant’s Text J17-1 supplies excitation positive to X1 (F1) J17-2 supplies excitation negative to X1 (F1) Notes Participant Guide Section 4 Page14 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation J18 Voltage Regulation Power Supply - maximum input is 240 VAC Participant’s Text The PCC 1302 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. 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. In certain applications, UL certification requires a fast acting UL certified ceramic fuse with a rating of 10 Amp that shall be placed in line with the J18-1 & 2 inputs. Notes Participant Guide Section 4 Page15 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation J22 Inputs J22 Maximum Input is 600VAC 10 Visual 4-10 J22 Inputs Participant’s Text J22 is used for generator output sense. The PCC 1302 can be used on single phase or 3 phase applications The MAXIMUM input voltage is 600 VAC. Refer to Section 3 of the Operator/Installation manual #900-0661 for proper connection information. Notes Participant Guide Section 4 Page16 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation HMI211 Operator Panel 11 Visual 4-11 Operator Panel Installation Participant’s Text The HMI211 is optional and is not used on all applications. Refer to Section 3-2 of the Operator/Installation manual #900-0661 for proper installation. The manual offers valuable information about tolerable vibration and temperature levels. Refer to Section 3-2 of the Operator/Installation manual #900-0661 for proper connection and wire information. Notes Participant Guide Section 4 Page17 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation HMI211 Installation PCCNET communication connections are attached to either JI or J2 or both. 12 Visual 4-12 Installation HMI211 Participant’s Text Refer to Operator/Installation manual #9000661 Section 2-4 for proper connection information. After you install an option, you MAY have to activate it with InPower software. The HMI211 automatically INITIALIZES itself when the control is powered up. Notes Participant Guide Section 4 Page18 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation AUX 104 Governor Module Governor Module “P” Connections 14 Visual 4-13 Installation AUX104 Participant’s Text Refer to Operator/Installation manual #9000661 Section 3-15 for proper connection information. The AUX-104 is available in Accessory Kit 541-1231. This kit includes instruction sheet C689. The AUX 104 is PWM signal amplifier used with higher current draw of electric actuator type governors. Refer to Operator/Installation manual #9000661 Section 3-15. Figure 3-13 shows a simple schematic illustrating installation in relation to the PCC 1302. Notes Participant Guide Section 4 Page19 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation Extract from 0630-3440 Participant’s Text Refer to page 3 of print 0630-3440. This print is located in Section 12 –Diagrams. The PCC 1302 control can be connected directly to a low current electronic governor system. If the current draw from this actuator is too high, the PCC 1302 control board will be damaged. The J11 -5 & 4 governor driver of the PCC 1302 are limited to 20mA (.02 Amp). Notes Participant Guide Section 4 Page20 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation Common Connector Scheme 0630-3440 Participant’s Text The PC 1, 2, & 3 generation of PowerCommand Controls will use a new Common Connector Scheme. Find prints 0630-3440 pages 1 through 11 in Section 12 – Diagrams. This set of prints covers all current adaptations of the PC 1, 2, & 3 controls, both FAE and hydramechanical. 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. Notes Participant Guide Section 4 Page21 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Installation Operation Activities Section 4: In-Class Quiz 14 Visual 4-14 Quiz Listing for Section 4 Participant’s Text At this time I would like you to work alone to complete the quiz. Notes Participant Guide Section 4 Page22 PCC 1.1 and PowerCommand Control 1302 Installation PowerCommand Control 1302 Wrap-Up In this lesson, we have learned about installation of the PCC 1302 genset control and important connection locations. First, we talked about the procedure for installing options to the control on a genset. Then, we covered each individual connector and the connections available from the control to the genset components and why each is important. We also were introduced to the new Common Connector Scheme diagrams. Q. Are there any questions we have not yet covered about installation of the PCC 1302? Participant Guide Section 4 Page23 THIS PAGE IS INTENTIONALLY LEFT BLANK PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower PowerCommand Control 1.X Section 5: Control Setup and InPower Visual 5-1 Control Setup & InPower Participant Guide Section 5 Page1 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Section 5 PowerCommand Control 1302 Control Setup and InPower Estimated Time: 4 hours Equipment Needed Highlighter, Post-it note pads, Notepad and pencil. PowerCommand Control 1302 and simulator for each pair of participants Materials Needed One for each participant: PowerCommand Control 1302 Participant’s Guide Guide PC with InPower v 5.50 or later installed Registered Dongle InPower Connection Cable Kit #0541-1199 (CMT0949-EN-PG) Participant Guide Section 5 Page2 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Warm Up In this lesson we are going to learn about the InPower parameters for the PowerCommandControl 1302. You will have a chance to use InPower with the training controls 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 After completing this lesson, participants should be able to: • • • • • • Connect a PC running InPower service tool software to a PowerCommand Control 1302. Download a capture file from the control to your PC. Identify the parameters used in setting up a PowerCommand Control 1302. Identify the parameters used in troubleshooting a PowerCommand Control 1302. Identify the parameters used in testing a PowerCommand Control 1302. If your dongle allows, download a calibration to a PowerCommand Control 1302. Participant Guide Section 5 Page3 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Connecting to a PCC 1302 2 Visual 5-2 Connecting to a PCC 1302 with InPower software Participant’s Text 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 CD-ROM training program. Attach the converter and cable of Communication Kit #0541-1199 Notes Participant Guide Section 5 Page4 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower THIS PAGE IS INTENTIONALLY LEFT BLANK Participant Guide Section 5 Page5 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower InPower Service Tool Software 3 Visual 5-3 In-Power service software connected to a PCC 1302 control Participant’s Text InPower v 5.50 parameters for the PCC 1302 are shown in the graphic on this page. InPower v5.5 or higher will recognize the PCC 1302 When you connect to a PowerCommand Control 1302 you will see four major headings of parameters: • • • • Adjustments Faults Monitor, and Test Notes Participant Guide Section 5 Page6 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower THIS PAGE IS INTENTIONALLY LEFT BLANK Participant Guide Section 5 Page7 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower InPower Parameters Adjustments Faults Monitor Test 4 Visual 5-4 InPower Parameters Participant’s Text InPower has four main sections when connected to the PCC 1302: • • • • Adjustments Faults Monitor Test Notes Make sure that you save a capture file from the 1302 Control Board when you connect to it. That capture file will help you reset parameters you modify in class. Participant Guide Section 5 Page8 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Engine Protection Adjustments 5 Visual 5-5 Engine Protection Adjustments Participant’s Text Engine Protection Adjustments allow you to adjust parameters or parameter ranges for • • • • • • Overspeed Shutdown LOP Shutdown pressure and delay LOP Warning pressure and delay LCT warning temperature HCT shutdown temperature and delay HCT warning temperature and delay Notes Participant Guide Section 5 Page9 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Shutdown Override Adjustment 6 Visual 5-6 Battle Short Participant’s Text Battle Short allows the technician or operator to bypass all but a few faults: Loss of Excitation Speed Sense Failure Overcrank Once you enable the Battle Short input the customer can use it. • If the customer has a failure while Battle Short is on, they might not have warranty on the set. When the customer turns the Battle Short input off the 1302 saves that data. Notes • Participant Guide Section 5 Page10 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Customer Switch Settings 7 Visual 5-7 Customer Switch Settings Participant’s Text The Customer Switch Setting Adjustments allow you to set these customer switches 1 and 2 for these parameters: • • • Enable or Disable Active Closed or Open Response of None, Warning, or ShutdownEvent Name (two lines of text) Notes You can also view the state of the customer switch input • Active or Inactive Participant Guide Section 5 Page11 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Annunciator Switch Settings 8 Visual 5-8 Annunciator Switch Settings Participant’s Text These are the settings for the three customer inputs to the Universal Annunciator. These are PCCNet inputs to the PCC-1302 Genset Control Board. Many times these will be used to annunciate Generator Supplying Load inputs from transfer switches. Notes Participant Guide Section 5 Page12 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Faults 9 Visual 5-9 Faults Participant’s Text The Faults folder shows you the active and inactive faults in the PCC 1302 memory. • • • • Active Fault Number Data Table of Fault History Data Table of Shutdown Faults Data Table of Warning Faults Notes The Data Table history is limited to 5 faults. Participant Guide Section 5 Page13 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Customer Output Tests 10 Visual 5-10 Test / Customer Outputs Participant’s Text These parameters allow you to override the Customer Inputs when troubleshooting the PCC 1302 control system. When the Test is enabled, the PCC 1302 will not look at the physical input to the Customer Input pins. Notes Participant Guide Section 5 Page14 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Annunciator Output Relays 11 Visual 5-11 Annunciator Output Relays Participant’s Text These parameters allow you to use the Annunciator Relays as output relays for the PCC 1302. The output function for each relay can be set through the Control Panel Menus. The driver for each relay can be enabled or disabled in InPower, and The Output Relay can be enabled or disabled. Notes Participant Guide Section 5 Page15 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Test – Engine Parameters 12 Visual 5-12 Test − Engine Parameters Participant’s Text This folder allows you to test the following Engine parameters: • • • Starter Override Fuel Shutoff driver Glow Plug Driver Notes Participant Guide Section 5 Page16 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Test - Overvoltage 13 Visual 5-13 Test − Overvoltage Participant’s Text In this parameter folder you can test the Alternator output for Phases A and B. You can make these changes: • • • • Override the L1 and L2 sensing voltages, and Determine what the voltage level will be when you override the sense voltage. Change the High Voltage Threshold between 105% to 125% Change the Overvoltage delay from 1.0 to 10.0 seconds Notes Participant Guide Section 5 Page17 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Test – Engine Protection (LOP) 14 Visual 5-14 Test − Engine Protection (LOP) Participant’s Text The Oil Pressure Protection test folder allows you to change these parameters: • • • • • • • Oil Pressure Sensor Type LOP Shutdown Threshold LOP Shutdown Delay LOP Warning Threshold LOP Warning Delay Oil Pressure Override, and Oil Pressure PSIG the control sees. Notes Participant Guide Section 5 Page18 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Activities 5-1 PC 1.X Setup and InPower Parameters 15 Visual 5-15Activities Listing for Lesson 1 Participant’s Guide You will find Section 5 Activities in Section 10 of your guide. Please find the Activities and at this time I would like you to work as teams to complete these activities. The activities are intended to enable participants to become familiar with InPower and the features of the PCC 1302. Notes Participant Guide Section 5 Page19 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Setup and InPower Wrap-Up In this lesson we have reviewed using InPower version 5.5 or later with the PCC 1302. First we talked about connecting to the PCC 1302 control at TB15 with the RS-485 to RS-232 adapter and the Cummins cable. Next we talked about the main InPower folders and parameters available when connected. We then discussed the Engine protection adjustments. Then we looked at what happens when you change the “Battle Short” settings for a fault, and which three faults cannot be bypassed. • • • Overcrank Loss of Speed Sensor Loss of Excitation Lastly we looked at the test parameters for the PCC 1302. Q. Are there any questions we have not yet covered that you may have? In the next lesson we will learn about the PCC 1302 PCCNet Communications. Participant Guide Section 5 Page20 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PowerCommand Control 1.X Section 6:PCCNet for the PCC 1302 Visual 6-1 PCCNet Participant Guide Section6 Page1 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Section 6 PCCNet Network for the PCC 1302 Estimated Time: 3 hours Equipment Needed Highlighter, Post-it note pads, Notepad and pencil PowerCommand Control 1302 and simulator for each pair of participants Several HMI113 and/or Aux101 & 102 modules for installation practice. Materials Needed One for each participant: PowerCommand Control 1302 Participant’s Guide Universal Annunciator Operator’s Manual Universal Annunciator Quick Reference Card (optional) (CMT0949-EN-PG) (900-0301) (900-0304) (C693a) Installation and Setup instructions for I/O Module Kit 0541-1291 Instructor’s Note: This lesson presents information on the PCCNet modules used with the PowerCommand Control 1302: Universal Annunciator, Control Panel, and the I/O Module. Warm Up In this lesson, we are going to look at the optional devices that communicate with the PowerCommand Control 1302. 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: Participant Guide Section6 Page2 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Objectives After completing this lesson, the participants should be able to: Understand the basic operation of PCCNet communications Identify the PCCNet devices common to PCC 1302 installations. Connect the Universal Annunciator and/or AUX 101 to the PCC 1302 genset control and simulator. Configure the Universal Annunciator and/or AUX 101 used with PCCNet and the simulator. Test the Universal Annunciator and/or AUX 101 with the PCC 1302 genset control and simulator. Participant Guide Section6 Page3 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PCCNET Overview and PCC 1302 PCCNET is a flexible communication system that uses a standardized proprietary protocol unique to Cummins Power Generation PCCNET provides device to device connectivity and is supported by the PCC 1302. It is a dynamic system that consists of 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. 2 Visual 6-2 Participant’s Text PCCNet is a proprietary communication system used on PCC 1302 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. At this time, there are approximately 12 different PCCNet devices available, with expectations for more in the future. Notes Participant Guide Section6 Page4 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PowerCommand PCCNET Overview 2-Wire RS-485 Data Connection 2-Wire Power Connection Up to 4,000 feet network data wire length No Termination Required Total of 20 PCCNET devices on one network. 3 Visual 6-3 Participant’s Text PCCNet Basics on the PCC 1302: Two Data Wires and Two Power wires needed. Data terminals are TB1-1 and TB1-2 DATA TERMINALS ARE POLARITY SENSITIVE! Power Terminals are TB1-5 (+) and TB13 (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. J25 connects to PCCNet system using a factory built harness. Participant Guide Notes Section6 Page5 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET 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 devices, and this exceeds 10 seconds, ALL other devices arbitrate again. 4 Visual 6-4 PCCNet Operation Participant’s Text Broadcast Messages are output messages from a device that has a hard-wired input. Small amounts of data Broadcast messages are sent out: • • every time the input changes, or every five seconds. Notes Gensets broadcast NFPA-110 data to the network. Annunciators will 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. Participant Guide Section6 Page6 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PCCNET Devices – PCC 1302 PCC 1302 communicates with these devices HMI 211 HMI 220 (Specific applications only) AUX101 & 102 Module (Max. 1 set) HMI 112 (Bar Graph) HMI 113 (Universal Annunciator) Analog display gauges This list may change with the addition of new or special devices 5 Visual 6-5 PCCNet Devices Participant’s Text These are the most common devices that you can expect to encounter on a PCC 1302 application. HMI 211 – 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 1302 AUX 101 & 102 – Remote relay device with expansion module. The PCC 1302 will not recognize more than 1 AUX 101 & 102. HMI 112 – Bar graph display. PCC 1302 does NOT calculate power factor, so only the P/N 0300-6050-02 will be found with PCC 1302 controls. Notes Participant Guide Section6 Page7 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Participant’s Text 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. Analog Display Gauges – At this time, there are 6 gauges available and there will likely be more available in the future. Presently we offer: Engine Coolant Temperature LTA Coolant Temperature Exhaust Temperature Oil Pressure Fuel Pressure % Dirty Fuel Notes PCCNET Connection – PCC 1302 HMI211 HMI112 HMI113 AUX101&102 J25 Display TB1 Connection Connection Analog Gauges 6 Visual 6-6 PCCNet Devices Participant Guide Section6 Page8 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Universal Annunciator 7 Visual 6-7 Universal Annunciator Participant’s Text The PCCNet Universal Annunciator has Network and Physical inputs. This annunciator supports both Network wiring and discrete wiring terminals 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 a quick reference card (900-0304) that provides configuration notes. The PCCNet Universal Annunciator has Multicolor color LEDs for warning and shutdowns that will display in Green, Amber, or Red. Participant Guide Notes Section6 Page9 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Participant’s Text There are three Terminal Blocks: TB1 Customer Inputs 1-8, B+, & Gnd TB2 Customer Inputs 9-20 TB3 Relay Outputs K3-K6 There is a connector: J2 PCCNet Connections There are three push switches and three LEDs on the back of the Annunciator: The three Switches are used to move through the configuration menu picks as shown in the Universal Annunciator Manual The three LEDs are used to show what mode the Annunciator is in, and how each LED is configured: Red, Orange, or Green, Steady or Flashing Horn or Silent Positive or Negative Input Normal or Inverted display Global Horn Notes Participant Guide Section6 Page10 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Configuring the Annunciator 8 Visual 6-8 Configuring the Universal Annunciator Participant’s Text Power up the Universal Annunciator at your workstation: • • B+ to TB1-16 Gnd to TB1-15 Notes Press and hold S1 in for 5 seconds − N3 LED goes out Refer to the Universal Annunciator Configuration Table on the later page to see the changes you can make in the Annunciator. Make sure you look at DS1 − DS20 as you configure the Annunciator. Participant Guide Section6 Page11 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Participant’s Text After powering up the Annunciator, note that the N3 LED flashes once per second. Press and Hold S1 in for at least five (5) seconds. N1, N2, and N3 LEDs should be out. • • • S3 selects Predefined Configuration S1 moves you through the table from top to bottom. S2 cycles through each of the 20 LEDs in sequence from DS1 to DS20. Notes Predefined Configurations are: • • • No Change Legacy NFPA-110 (Factory Default) NFPA-110 for PCCNet Pressing S1 once will take you to the ’Report Battery Voltage’ decision. • The N1 LED will light Pressing S1 once more will take you to the ’Neg./Pos Input’ decision. • The N2 LED will light If you do not press any buttons for a tenminute timeframe, the Annunciator will automatically take itself out of Configuration mode. Any changes will be saved. Each Genset’s Annunciator(s) must be hardwired to only that one genset. Participant Guide Section6 Page12 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Universal Annunciator Configuration Table Visual 6-9 Configuring the Universal Annunciator Participant Guide Section6 Page13 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PCCNet 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 1302 control. 10 Visual 6-10 Configuring the Universal Annunciator Participant’s Text InPower can be used for configuration of the relay feature on the Annunciator. Do not be mislead in to believing that InPower is communicating to the Annunciator. It is configuring the PCC 1302 control to understand what the annunciator is experiencing from its customer inputs. Image 6-9 shows the settings for the customer inputs available from the Annunciator to the PCC 1302. The description of the input can be configured to provide up to 2 lines of text description on the HMI211 screen. Notes Participant Guide Section6 Page14 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PCCNet Annunciator Output Setup PCCNet Annunciator Output Setup 11 Visual 6-11 Configuring the Universal Annunciator Output Setup Participant’s Text The annunciator output relays can be configured with InPower also. Again, InPower is not configuring the Annunciator, it is configuring the PCC 1302 to tell the Annunciator relays how and when to actuate for a given event. As you may notice in Visual 6-10 & 11, the annunciator inputs and relay outputs are configured in different folder areas of the ADJUSTMENT folder. Notes Participant Guide Section6 Page15 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET AUX101 & AUX102 AUX102 12 AUX101 Visual 6-12 I/O modules Participant’s Text The AUX101 & AUX102 Input/Output Module (I/O Module) is a 2 module set of components that provides a way to monitor and control customer equipment. Its operation is similar to the DIM used in the FT−10 networks and/or the Terminal I/O devices used in ModBus PLC networks. They are remote input and output devices for their respective network. Notes Participant Guide Section6 Page16 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET AUX101 & AUX102 Features Provides additional and expandable Input/Output Multiple boards provide cost effective I/O solutions AUX101 provides Analog Inputs AUX101 & AUX102 provide Digital Inputs Easy to Use “Plug & Play” or custom configurable through the the HMI or InPower 13 Visual 6-13 AUX I/O module features Participant’s Text The AUX 101 & 102 module set offer powerful solutions for transmitting information to the PCC control or from the control. The AUX 101 is the base module The AUX 102 is an add on module that must be connected to the AUX101. The AUX 102 module can not be used as a stand alone device. The AUX modules can be used in a 12 or 24 volt DC system. InPower can be used to custom configure the output relays of both modules. Notes Participant Guide Section6 Page17 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET AUX101 Features CAN Port – J1939 Engine Interface for use with select FAE engines Inputs – 8 Analog or Digital – Inputs can be configured to be Analog or Digital – If Digital, the inputs can be configured to be warnings or shutdowns – If Analog, the inputs can be configured to be • • • • • • Speed/Voltage bias inputs Fuel Level sender input Alternator RTD sender input Oil temperature sender input Exhaust temperature sender input Ambient Temperature sender input Outputs – 8 form-C Relays – Outputs are configurable to activate on specific shutdown or warning – Default output configuration is 1) Low Oil Pressure Shutdown 2) High Engine Temp Shutdown 3) Charger AC Failure 4) Battery (low, high, weak) 5) OverSpeed Shutdown 6) Fail to Start 7 ) Not in Auto 8 ) Run Sensor Power Outputs – Used to provide current for up to four resistive senders 14 Visual 6-14 AUX 101 module features Participant’s Text The AUX 101 & 102 module set offer powerful solutions for transmitting information to the PCC control or from the control. The AUX 101 is the base module The original AUX 101 module was built with a J1939 CAN communication feature for use with the PCC 1301 control. This feature is not compatible with the PCC 1302 so do not attempt to use this feature with it. The relays are labeled on their surface as capable of handling 5 amps, however the board is limited to a maximum of 2 amp per relay. Notes Participant Guide Section6 Page18 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET AUX102 Features Inputs – 4 Digital – The inputs can be configured to be warnings or shutdowns Outputs – 8 form-C Relays – Outputs are configurable to activate on specific shutdown or warning – Default output configuration is 9 ) Pre-Low Oil Pressure 10) Pre-High Temp 11) Low Coolant Level 12) Low Fuel Level 13) Low Coolant Temp 15 Visual 6-15 AUX 102 module features Participant’s Text The AUX 102 is the add-on module and cannot be utilized as a stand-alone device. It MUST be attached to a AUX 101 to work. This device does not have analog capabilities. The output relays can be configured to activate on other faults The relays are labeled on their surface as capable of handling 5 amps; however the board is limited to a maximum of 2 amps per relay. Notes Participant Guide Section6 Page19 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PCCNet I/O Device Setup This image does not show all 56 lines of Analog adjustments available on the AUX101 & 102 device. 16 Visual 6-16 Configuration of the AUX 101 & 102 module Participant’s Text Configuration of the AUX 101 & 102 is easily accomplished using InPower. InPower version 5.5 or newer supports the PCC 1302 and AUX modules. Several InPower folders need to be accessed to completely adjust the modules. InPower is not setting up the AUX modules. It is configuring the PCC 1302 to comprehend the information that is coming from the AUX modules.. Notes Participant Guide Section6 Page20 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PCCNet I/O Device Setup 17 Visual 6-17 InPower Configuration of the AUX 101 & 102 module Participant’s Text The AUX 101 does not read load current values from CTs. This is not a feature to support remote load monitoring. Look at Figure 12 - I/O Module Wiring Diagram on page 43 of Instruction Sheet C693a. Some sensors such as RTDs may require a current source for sense power and reference. J11 – 3, 4, 5, & 6 serve this function. Adjust the Current Source value as required by the sensor requirements. The value of these sources is dependent upon the type of the input chosen. The InPower value range is from 10 to 200 mA. The default value is 20mA. Notes Participant Guide Section6 Page21 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PCCNet I/O Device Setup The AUX102 module must be attached to utilize these 4 additional Discrete Inputs. The AUX101 discrete inputs are listed on the Analog Input folder. 18 Visual 6-18 InPower Configuration of the AUX 101 & 102 module Participant’s Text Discrete inputs are simple and straightforward to adjust and configure on the AUX 102 module when InPower is used. This device does not have analog capabilities. Instructions how to enable and configure these inputs using the HMI211 can be found in Instruction Sheet C693. Notes Participant Guide Section6 Page22 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PCCNET Analog Gauges Analog Gauge Power Supply Gauge Harness Analog Gauges 19 TB1 Connection Visual 6-19 Analog Gauges Participant’s Text The PCCNet Analog Gauges will be installed on several specific factory supplied applications. They may become available as an Accessory Kit in the future. The PCC 1302 must have version 2.11 firmware or higher installed for the PCCNet system to recognize these devices. These are the gauge devices that are available with PCCNet. Engine Coolant Temperature LTA Coolant Temperature Exhaust Temperature Oil Pressure Fuel Pressure % Dirty Fuel Notes Participant Guide Section6 Page23 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Participant’s Text The gauges require a 5-volt power supply and cannot accept direct power supply from the TB1-5 & TB1-3 connection point. The power supply module will come with a pre-connected plug & harness arrangement that connects the power supply module to the TB1 connections at one end and then to the first gauge in the series. Between each gauge, there is another preconnected plug & harness that will daisy chain each of the subsequent gauges together. The gauges have a self-test during power-up. The needle will rapidly swing to the minimum stop, - stop there for a moment - then swing to the maximum stop, - stop there for a moment – swing to the 0 (zero) point - stop there for a moment – then finally swing to the proper position as commanded by the PCC control. If the gauge does not receive a command from the PCC control, it will wait at the 0 (zero) point for a while, and then the needle will swing to the minimum stop and stay there. InPower is used to conduct any configuration that may be necessary. Each gauge in the Network is viewable with InPower version 5.5 or higher, under the ADJUSTMENT FEATURE ANALOG GAUGE section Notes Participant Guide Section6 Page24 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PCCNET HMI112 Bar Graph 20 Visual 6-20 HMI112 Participant’s Text The HMI112 is optional and has previously been referred to as the Bar Graph display. The PCC 1302 does not calculate Power Factor, therefore only the optional P/N 0300-6050-02 HMI112 is used. You will sometimes hear of this device as the 8 line bar graph. There are no setup parameters for this device in InPower or in the HMI 211 setup screens. This device is truly plug & play. Notes Participant Guide Section6 Page25 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET PCCNET Troubleshooting Tools are available for troubleshooting PCCNET networks. Commercially available protocol analyzing tools InPower HMI display capabilities Technician Ingenuity and Reason available) (Most powerful troubleshooting tool 21 Visual 6-21 Troubleshooting PCCNet systems. Participant’s Text 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. Notes Participant Guide Section6 Page26 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Participant’s Text 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 1302 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 1302, or until the Network begins to work again. Retrieve all the devices in the Network and bring them all close to the 1302 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. Notes Participant Guide Section6 Page27 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Participant’s Text 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! Notes Participant Guide Section6 Page28 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 PCCNET Activities 6-1 6-2 6-3 6-4 6-5 6-6 Universal Annunciator Connections Configure Annunciator for NFPA 110 & Test AUX101 & 102 Connections Configure AUX 101 & 102 and Test Analog Gauge Connections and Test PCCNET Quiz 22 Visual 6-22 Activities Participant’s Text The Activity Guide for Section 6 PCCNet exercises is found in Section 10. At this time, please work as teams to complete these activities. Notes Participant Guide Section6 Page29 PCC 1.1 and PowerCommand Control 1302 PCCNET PowerCommand Control 1302 Wrap-Up In this lesson we have learned about the PCCNet network and devices used with the PCC 1302. First we talked about the basics of PCCNet communications and some of the specific information about how the system works. Next we talked about the HMI113 Universal Annunciator used with PCCNet, its connectors and LEDs, configuration chart, and configuration modes, and InPower setup. Next we talked about the AUX 101 & 102 modules, their configuration and InPower setup. Then we talked about the other PCCNet options that can be used with the PCC 1302, followed by a short presentation on troubleshooting PCCNet system problems. Lastly we went through the process of configuring HMI 113 annnciators, AUX 101 & 102 modules, Analog gauges, and a quiz was taken. This lesson gave us the opportunity to learn about the about installation of the PCC 1302 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 1302? Participant Guide Section6 Page30 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus PowerCommand Control 1.X Section 7:PCC 1302 ModBus Communication Visual 7-1 ModBus Communications Participant Guide Section 7 Page1 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus Section 7: ModBus and the PCC 1302. Estimated Time: 4 hours Equipment Needed Highlighter, Post-it note pads, Notepad and pencil PowerCommand Control 1302 and simulator for each pair of participants Materials Needed One for each participant: PowerCommand Control 1302 Participant’s Guide Appendix A - PCC1300 SERIES MODBUS REGISTER MAP Appendix B – Using ModScan Software Computer: must meet system requirement to effectively operated InPower 5.5 or higher. InPower Connection Cable (P/N: 0541-1199) (CMT0949-EN-PG) Participant Guide Section 7 Page2 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus Warm Up In this lesson, we are going to look at the on board ModBus system that communicates information from the PowerCommand Control 1302. First, let us look at the objectives for this lesson: Objectives After completing this lesson, the participants should be able to: Understand the basic operation of ModBus communications Identify the ModBus port on the PCC 1302 control. Connect to the ModBus port on the PCC 1302 control. Configure and setup the ModBus port on the PCC 1302 control using InPower or the HMI211. Test the ModBus communications. Participant Guide Section 7 Page3 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus ModBus Overview ModBus is a industrial communication protocol system that is not controlled by or influenced by Cummins Power 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 Power Generation genset controls, it is usually used as a communication protocol that enables others to gain communication access to the generator set control. 2 Visual 7-2 ModBus overview Participant’s Text ModBus is an open communication system available onboard the PCC 1302 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.) Notes Participant Guide Section 7 Page4 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus ModBus Overview CPG uses ModBus over Serial Line Protocol. ModBus Serial 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.X controls are a Slave Node. A bus can accommodate 32 devices without repeaters, but up maximum of 247 slave nodes can exist on a large ModBus network bus. ModBus can communicate using many different physical media. The PCC 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. 3 Visual 7-3 ModBus overview Participant’s Text The PCC 1302 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 1302) ModBus is a Master – Slave communication system There can only be 1 master. There can be up to 247 slave devices. The PCC 1302 can ONLY be a slave device. The slave address can be assigned in the field. Notes Participant Guide Section 7 Page5 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus Participant’s Text 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 1302 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 3rd party, you will need to work with them to identify and resolve the problem. Notes Participant Guide Section 7 Page6 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus TB15 ModBus Connection TB15 ModBus Connection Pin #1 Pin #5 4 Visual 7-4 ModBus Connection Participant’s Text 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. Notes 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 page 5 or the diagram figure 7-1 of the 900-0661 manual. Participant Guide Section 7 Page7 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus ModBus wire and PCC 1302 The ModBus network wire type and length is specified by ModBus standards, not by Cummins Power Generation. 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 PCC 1302, refer to the iWatch installation guide for information about the proper wire. 5 Visual 7-5 ModBus Cable Participant’s Text 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 1302, 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. Notes Participant Guide Section 7 Page8 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus ModBus Setup with InPower 6 Visual 7-6 InPower Configuration of the ModBus port Participant’s Text There is a ModBus Setup folder located under the Adjustment folder of InPower. There are 4 adjustments found in the ModBus Setup folder: • ModBus Enable • ModBus Node Address • ModBus Baud Rate • ModBus Parity The factory default setting is Disable. Connect InPower using the normal 541-1199 tool connected to TB15. InPower will continue communicating after ModBus is enabled. Notes Participant Guide Section 7 Page9 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus ModBus Setup with InPower 7 Visual 7-7 InPower Configuration of the ModBus port Participant’s Text Each of the adjustment parameters has a drop box in the value field. The ModBus Node Address is default as 1; however it may need to change. Recall that a ModBus network may contain up to 247 nodes. This node address identifies which of those 247 devices is the PCC 1302. The ModBus Baud Rate adjusts the speed of communication that the PCC 1302 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. Participant Guide Section 7 Page10 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus ModBus Settings The ModBus adjustments and settings are also accessible through the HMI 211. 8 Visual 7-8 ModBus Setting at HMI211 Participant’s Text Refer to section 5, “1302 Control Panel Service Menus” of the Operator/Installation Manual #900-0661. Figure 5-3 on page 5-5 and figure 5-4 on page 5-7 describes the navigation through the Genset Service Menus and how to gain access to the ModBus setup screens. On page 5-33, all the ModBus submenus are presented. The illustration shows the process involved with changing the ModBus Enable setting and the Address, Baud Rate, and Parity 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. Notes Participant Guide Section 7 Page11 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus ModBus Testing & Troubleshooting ModBus Register Map – Provided by CPG ModScan – Available as freeware InPower – Has some minor test capability. 9 Visual 7-9 Testing ModBus systems. Participant’s Text The ModBus register map is available from CPG. A copy is attached to this training guide, and can be found in Appendix A. ModScan is a 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. Notes Participant Guide Section 7 Page12 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus ModBus Register Map NFPA110 bitmap (Register 40016) NFPA 110 Description Common Alarm Genset Supplying Load Genset Running Not in Auto High Battery Voltage Low Battery Voltage Charger AC Failure Fail to Start Low Coolant Temperature Pre–High Engine Temperature High Engine Temperature Pre–Low Oil Pressure Low Oil Pressure Overspeed Low Coolant Level Low Fuel Level 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Bit (MSB) (LSB) 10 MSB = Most Significant Bit LSG = Least Significant Bit Visual 7-10 ModBus Register Map Participant’s Text Register maps are specific to the product. The register map for a PCC 1302 control is the same as the map for the PCC 1301 control, but it is different from many other PowerCommand type control. Be sure you are referencing the proper map. The register map may change from time to time. It is normal for control features or applications to evolve during the product life, so pay attention to the version of control and 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. Notes Participant Guide Section 7 Page13 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus ModScan testing Slave address Register Type ModScan requests to communicate Device responses to ModScan requests Register address to begin polling Number of registers to be polled ModBus register and the data communicated from the device 11 Visual 7-11 ModScan Software Participant’s Text 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 and reliable tool that satisfies CPG. Notes Participant Guide Section 7 Page14 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus Participant’s Text 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 1302, 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 1302 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. Notes Participant Guide Section 7 Page15 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus 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. 12 Visual 7-12 ModScan software Participant’s Text 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. Notes . Participant Guide Section 7 Page16 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus InPower - Monitor - Modbus 13 Visual 7-13 InPower monitor software Participant’s Text 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 1302 has been polled by the Master. Slave Message Count – this is the number of times the PCC 1302 has responded to polls. No Response Count – this is the number of times the PCC 1302 HAS NOT been able to respond. Notes Participant Guide Section 7 Page17 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus Participant’s Text InPower 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. Notes Participant Guide Section 7 Page18 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus Activities 7-1 7-2 7-3 Connect InPower and Configure Configure at the HMI Connect with ModScan (optional) 14 Visual 7-14 Activities Participant’s Text Find the Section 7 activities in the Section 10. Work with partners to complete each activity. Notes Participant Guide Section 7 Page19 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 ModBus Wrap-Up In this lesson we have learned about the ModBus communication system and the ModBus feature built into the PCC 1302. 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 1302, its connectors and wire information. Next we talked about the setup and configuration using InPower and the HMI211 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 1302. 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 1302? Participant Guide Section 7 Page20 PCC 1.1 and PowerCommand Control 1302 PGI PowerCommand Control 1.X Section 8: PGICAN Visual 8-1 PGI CAN Communications Participant Guide Section 8 Page 1 PCC 1.1 and PowerCommand Control 1302 PGI Section 8 PowerCommand Control 1302 & PGI Estimated Time: 4 hours Equipment Needed Highlighter, Post-it note pads, Notepad and pencil PowerCommand Control 1302 and simulator for each pair of participants Materials Needed One for each participant: • • • • • • • PowerCommand Control 1302Participant’s Guide PC with InPower v6.0 installed Registered Dongle InPower Connection Cable INSITE v6.0 or higher installed Peak System Adapter and associated software/drivers installed Inline Adapter Kit w/Software and Drivers Installed Kit #541-1199 Guide (CMT0949-EN-PG) Participant Guide Section 8 Page 2 PCC 1.1 and PowerCommand Control 1302 PGI Warm Up In this lesson we are going to learn about the Power Generation Interface (PGI) for the PowerCommandControl 1302. First, let’s look at the objectives for this lesson: 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 1302. 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. Participant Guide Section 8 Page 3 PCC 1.1 and PowerCommand Control 1302 PGI 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) 2 Visual 8-2 What is PGI? Participant’s Text 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 Notes 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. Participant Guide Section 8 Page 4 PCC 1.1 and PowerCommand Control 1302 PGI Past Control Product PCC3200 (1 Box) PCC3201 (1 Box & 2Box) PCC2100 (1 Box & 2 Box) PCC1301 (1Box) AVR Corporate Genset PCC 1.x, 2.x and 3.x Product PCC3300 w/ CAN PCC2300 w/ CAN PCC1302 w/ CAN AVR CMxxx CMYYY GCS CMxxx FAE / Mech. Engine CMxxx With PGI Alternator CMYYY W/o PGI FAE / Mech. Engine Alternator OEM Control GCS OEM Control w/ CAN CMxxx OEM Control FAE / Mech. Engine G-Drive OEM 3 FAE / Mech. Engine No GCS !!! Visual 8-3 PGI Architecture Participant’s Text 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 1302 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. Notes Participant Guide Section 8 Page 5 Interface CAN/J1939 PCC 1.1 and PowerCommand Control 1302 PGI Required Hardware/Software Inline 4/5 Datalink Adapter - INLINE 4 Kit P/N - 4918190 - INLINE 5 USB Kit P/N – 4918416 (note: Inline 2 will work with CPG products and you do not need to install drivers with this product) 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 4 Visual 8-4 Hardware/Software Participant’s Text 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 1302 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. Notes Participant Guide Section 8 Page 6 PCC 1.1 and PowerCommand Control 1302 PGI INSITETM - Monitor & adjust parameters and features 5 Visual 8-5 INSITE Participant’s Text 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 Notes Participant Guide Section 8 Page 7 PCC 1.1 and PowerCommand Control 1302 PGI INPOWERTM – Adjustments 6 Visual 8-6 InPower Participant’s Text 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. Notes Participant Guide Section 8 Page 8 PCC 1.1 and PowerCommand Control 1302 PGI Peak System Adapter 7 Visual 8-7 Peak System Adapter Participant’s Text 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) Notes Participant Guide Section 8 Page 9 PCC 1.1 and PowerCommand Control 1302 PGI Participant’s Text 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) Notes 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. Participant Guide Section 8 Page 10 PCC 1.1 and PowerCommand Control 1302 PGI Physical Datalink J1939 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 J1939 support (no battery voltage supply) Pin A B C Signal J1939 Datalink (+) J1939 Datalink (-) J1939 Datalink (Shield) 8 Visual 8-8 J1939 Connector Participant’s Text 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. Notes Participant Guide Section 8 Page 11 PCC 1.1 and PowerCommand Control 1302 PGI Basic J1939 Backbone and Stub Configuration 9 Visual 8-9 J1939 Backbone Participant’s Text 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. Notes Participant Guide Section 8 Page 12 PCC 1.1 and PowerCommand Control 1302 PGI Extending length of J1939 backbone 10 Visual 8-10 Extending J1939 Participant’s Text 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. Notes Participant Guide Section 8 Page 13 PCC 1.1 and PowerCommand Control 1302 PGI J1939 Topology Coolant Level Switch Fuel/Water Separator 11 Visual 8-11 J1939 Typology Participant’s Text 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 one point only. You must also connect shield at each device. Notes Participant Guide Section 8 Page 14 PCC 1.1 and PowerCommand Control 1302 PGI Harness Block Diagram Engine Harness Coolant level 4-pin connector (Plug) 3-pin J1939 connector with 120 Ohm resistor 16-pin power connector (Receptacle) 16-pin power connector (Plug) Genset Harness Controller harness ‘Y-pin’ connector PCC Harness Engine harness connector 50-pin OEM 60-pin engine connector connector ECM power PCC Board ECM 9-pin service connector J1939 3-pin connector (Plug) Pedestal J1939 3-pin connector (Receptacle) 3-pin J1939 connector with 120 Ohm resistor Starter relay Extension Harness 12 Alternator HMI Battery ‘X-pin’ Connector to mate with extension harness Visual 8-12 Harness Block Diagram Participant’s Text 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. Notes Participant Guide Section 8 Page 15 PCC 1.1 and PowerCommand Control 1302 PGI 9-Pin Deutsch Pin A B C D E F G ID Datalink Return Datalink Power J1939 Datalink (+) J1939 Datalink (-) Datalink Shield Unconnected Unconnected Unconnected Unconnected Service connector 9-pin Receptacle Cummins P/N: 3163295 Deutsch HD10-9-1939P Location: Engine Harness H J 13 Visual 8-13 9-Pin Deutsch Participant’s Text 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. Notes Participant Guide Section 8 Page 16 PCC 1.1 and PowerCommand Control 1302 PGI Troubleshooting Datalinks Check Topology Check Back Bone is not longer than 40m Check there is 120 Ohm resistor at each end of the back bone. 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 Check that the J1939 high and J1939 low are not shorted to ground Check that the ground wire is not open circuit Check that sheiding wire is not open ciruit Check that all grounds are the same Check all ECM are communicating 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. < 10 ohms > 100k ohms < 10 ohms < 10 ohms 55 - 65 Ohm 14 Visual 8-14 Troubleshooting Datalinks Participant’s Text 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. Notes Participant Guide Section 8 Page 17 PCC 1.1 and PowerCommand Control 1302 PGI Participant’s Text 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 J1120. 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-tonoise 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 communication is not possible. CAN_H is Shorted to CAN_L - Data communication is not possible. Loss of Termination Resistor - Data communication via the bus may be possible, but with reduced signal-to-noise ratio. Notes Participant Guide Section 8 Page 18 PCC 1.1 and PowerCommand Control 1302 PGI Participant’s Text 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 Notes Participant Guide Section 8 Page 19 PCC 1.1 and PowerCommand Control 1302 PGI CM850 – QSB5/7, QSL9, J3 QSK19/38/50/60 J1 J2 J1 Connector Function Engine OEM Battery Power Connector Type 60 Pin 50 Pin P/N 3163071 4 Pin P/N 3165121 Connector Name J1 J2 J3 J2 J3 Note: J3 only required for QSB 5/7 and QSL 9 15 * Please Refer to the appropriate Harness Wiring Diagram for Pinouts of J1, J2, and J3 Visual 8-15 CM850 ECM Participant’s Text 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 Notes • • • • Participant Guide Section 8 Page 20 PCC 1.1 and PowerCommand Control 1302 PGI CM876 – QSM11 T3 Connector Function Engine OEM Battery Power Connector Type 60 Pin 50 Pin P/N 3163071 4 Pin P/N 3165121 Connector Name J1 J2 J3 16 Visual 8-16 CM876 ECM Participant’s Text 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. Notes Participant Guide Section 8 Page 21 PCC 1.1 and PowerCommand Control 1302 PGI 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 Participant’s Text 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. Notes Participant Guide Section 8 Page 22 PCC 1.1 and PowerCommand Control 1302 PGI Signals Nominal Values 0 J1939 high J1939 low V differential 2.5 v 2.5 v 0v 1 3.5v 1.5v 2v 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 Participant’s Text 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”. Notes Participant Guide Section 8 Page 23 PCC 1.1 and PowerCommand Control 1302 PGI Activities 8-1 PGI Written Quiz 19 Visual 8-19 Activities Participant’s Guide Find the Section 8 Quiz in Section 10. Work with partners to complete each activity. Trainer’s Guide Participant Guide Section 8 Page 24 PCC 1.1 and PowerCommand Control 1302 PGI Wrap-Up In this lesson we introduced the Power Generation Interface (PGI) usage with the PCC 1302 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? Participant Guide Section 8 Page 25 PCC 1.1 and PowerCommand Control 1302 PGI THIS PAGE IS INTENTIONALLY LEFT BLANK Participant Guide Section 8 Page 26 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Glossary SECTION 12 -- Glossary Alarm Used generically to indicate either a warning or a shutdown fault. 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.) Alternator Rating Effect Annunciation Any means of communicating to a user or operator the status of the power system. Especially important in the event of an alarm. Includes audible alarms, LEDs, visual displays, PC software notification, and pagers. 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. 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. 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. Participant Guide Section 9 Page1 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Glossary 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. 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. 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. 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. 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. 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. Acronym for Genset Control System. This is usually found on generator sets built by other, yet they use engines and controls built by Cummins. GCS Participant Guide Section 9 Page2 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Glossary HMI Human Machine Interface: Commonly referred to as touch panel, or control display, and now includes reference to the annunciator. Initial Calibration Downloading a data set to a PowerCommand Control 2100 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”. 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. 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 Side Driver MODBUS MODBUS® Protocol 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. The PCC1302 control has the ability to communicate via MODBUS RTU using a RS485 transmission standard. 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. Nominal Value 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. PC 1.X Acronym designationfor PowerCommand Control 1302 with one of several HMI versions. 1.1 = HMI 211, 1.2 = HMI 220. Participant Guide Section 9 Page3 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Glossary 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. PGI CAN Acronym for Power Generation Interface to Cummins J1939 CAN communication systems. 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. Pilot Relay 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. Participant Guide Section 9 Page4 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Glossary 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. Rated Current To be calculated based on rated power (kW) and nominal voltage. 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. Rated kW 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. Reference Value Register A ModBus communication packet of information. Cummins Power Generation uses 40000 level designations for most genset data. 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. Save and Restore Calibration Self Excitation A method whereby the output of the AC alternator is utilized for powering the voltage regulation circuit. Sometimes the incorrect term “Shunt Excitation” will be found in some product literature. 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. Shutdown A type of fault that causes the Genset to shut off immediately or prevents it from starting. Participant Guide Section 9 Page5 PCC 1.1 and PowerCommand Control 1302 PowerCommand Control 1302 Glossary 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. Slave 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. Token In digital communications, this is a “permission to speak” bit that passes from network member to member in a specific sequence at specific intervals. Trim Non-volatile adjustment made in the field by an operator, user, or service technician. TP/XF-78 Network An older transceiver system used in PowerCommand Networks. TP/XF-78 stands for “TwistedPair, 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.” 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). Participant Guide Section 9 Page6 PowerCommand 1.1 & PowerCommand Control 1302 Activities & Quiz ________________________________________________________________ Section 10: PC 1.X & PCC 1302 Quiz and Activities This section contains each quiz and the sets of activities called for in each of the previous sections. Section 1. Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Quiz Activities 1 thru 9 Quiz Quiz Activity Activities 1 thru 4 Activities 1, 2 & 3 Quiz Trainers Guide Section 10 PowerCommand 1.1 & PowerCommand Control 1302 Activities & Quiz ________________________________________________________________ THIS PAGE IS INTENTIONALLY LEFT BLANK Trainers Guide Section 10 PowerCommand 1.1 & PowerCommand Control 1302 Activities & Quiz ________________________________________________________________ Section 1- Quiz: Introduction to the PC 1.X & PCC 1302 Quiz Match the functions and components / switches; use the demonstrator or Participants’ Guide. _____ 1 PCCNET _____ 2 Control Panel _____ 3 Shutdown LED _____ 4 J22 _____ 5 Warning LED _____ 6 J12 _____ 7 Base Card _____ 8 Bar graph Module _____ 9 Single Arrow Button _____ 10 Customer Connections _____ 11 Connects to Service Tool _____ 12 Microprocessor _____ 13 Digital Display _____ 14 AUX 104 _____ 15 “O” Button A. B. C. D. E. F. G. H. I. J. K. L. Acknowledge Shutdowns here Red LED Change to “Off” Mode Amber LED Return to Home Menu Shows 125% Current Governor Drive Current Input On Base card Simple Network TB15 TB1 Terminals M. Voltage Input N. O. HMI Non – Repairable Participants Guide Section 10 PowerCommand 1.1 & PowerCommand Control 1302 Activities & Quiz ________________________________________________________________ THIS PAGE IS INTENTIONALLY LEFT BLANK Trainers Guide Section 10 PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 2-1: PC1.1 Operator Menus Work through the Menus on the Operator Panel 1. Change from Top-Level to Operator Menus. 2. History / About ____________________ Number of Starts ____________________ Number of Hours ____________________ Control Hours ____________________ Genset Model Number ____________________ Standby kVA Rating ____________________ Control Part Number ____________________ Control Serial Number ____________________ Software Part Number ____________________ Software Version Number ____________________ Display Part Number ____________________ Display Software Version Number ____________________ Screen Part Number ____________________ Screen Version 3. Adjust Screen ____________________ Contrast ____________________ Brightness ____________________ Units Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 2-1: PC1.1 Operator Menus 4. Fault History Fault 1 __________ Fault Number __________ Fault History at # Hours _____________________Fault Name Fault 2 Fault 5 __________ Fault Number __________ Fault Number __________ Fault History at # Hours __________ Fault History at # Hours ____________________ Fault Name Fault 3 __________ Fault Number __________ Fault History at # Hours ____________________ Fault Name ______________________ Fault Name Fault 4 __________ Fault Number __________ Fault History at # Hours ______________________ Fault Name Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 2-1: PC1.1 Operator Menus 5. Status ____________________ AVR Duty Cycle % ____________________ Governor Duty Cycle % 6. Lamp Test 7. Network Status ____________________ Annunciators ____________________ Bar Graphs ____________________ Controls ____________________ I/O Modules ____________________ Operator Panels Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 2-2: PC1.1 Set Up Menus Work through the Menus on the Operator Panel 1. Change from Top-Level to Setup Menus ____________________ Password 2. Genset Part 1 ____________________ Volts AC ____________________ Hertz ____________________ Number of Phases ____________________ Phase Connection 3. Genset Part 2 ____________________ Glow Plug ____________________ Charging Alt Enable 4. Start / Stop Delay ____________________ Start Delay ____________________ Stop Delay 5. Cycle Crank ____________________ Cycle Crank Attempts ____________________ Crank Time ____________________ Rest Time 6. Battle Short ____________________ Battle Short 7. AVR Setup If Enabled, you will see Step 8 Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 If Disabled, you will see Step 10 ____________________ AVR Enable 8. V/Hz Setup ____________________ V/Hz Roll-off ____________________ V/Hz Knee 9. Regulator ____________________ Gain ____________________ Integral ____________________ D 10. Elect. Governor If Enabled, you will see Step 11 If Disabled, you will see Step 15 ____________________ Governor Enable 11. Governor Crank Fuel ____________________ Initial Duty Cycle ____________________ Initial Time (seconds) ____________________ Ramp Rate ____________________ Maximum Duty Cycle 12. Electronic Governor ____________________ Gain ____________________ Integral ____________________ D 13. Electronic Governor Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 ____________________ Crank Exit Fuel Duty Cycle ____________________ Dither Factor ____________________ Ramp Time 14. Electronic Governor ____________________ Enable Speed ____ RPM ____________________ Minimum Governor Duty Cycle ____________________ Maximum Governor Duty Cycle 15. Genset Number ____________________ Model Number ____________________ Serial Number 16. Display Setup ____________________ Connection ____________________ Access Code ____________________ Symbols Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 ________________________________________________________________ Activity 2-3: PC 1.1 Customer I/O Menus Work through the Menus on the Operator Panel 1. Customer Input 1 ____________________ Customer Input 1 Text ____________________ Type 2. Customer Input 2 ____________________ Customer Input 2 Text ____________________ Type 3. Customer Output 1 Map ____________________ Output 1 Fault Number ____________________ Customer Output 1 Text 4. Customer Output 2 Map ____________________ Output 2 Fault Number ____________________ Customer Output 2 Text Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 ________________________________________________________________ THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 2-4: PC 1.1 Meter Calibration Menus Work through the Menus on the Operator Panel 1. Meter Calibration ____________________ Regulator Voltage Adjust ____________________ Voltage 2. Frequency Adjust ____________________ Frequency Adjust ____________________ Frequency 3. Metering Voltage Adjust ____________________ L1−N ____________________ L2−N ____________________ L3−N 4. Metering Current Adjust ____________________ L1 ____________________ L2 ____________________ L3 Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 2-5: PC 1.1 Annunciator Menus Work through the Menus on the Operator Panel 1. Fault 1 ____________________ Type ____________________ Text 2. Fault 2 ____________________ Type ____________________ Text 3. Fault 3 ____________________ Type ____________________ Text 4. Output 1 Map ____________________ Fault Number ____________________ Number of Faults 5. Output 2 Map ____________________ Fault Number ____________________ Number of Faults 6. Output 3 Map ____________________ Fault Number ____________________ Number of Faults 7. Output 4 Map ____________________ Fault Number ____________________ Number of Faults Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 2-6: PC 1.1 Genset Setup Menus Work through the Menus on the Operator Panel 1. Genset ____________________ CT Ratio ____________________ MPU Enable ____________________ Flywheel Teeth ____________________ RPM/Hz Ratio 2. Application Rating Select ____________________ Application Rating 3. kVA (Standby) ____________________ 3 Ph/60 Hz ____________________ 3 Ph 50 Hz ____________________ 1 Ph/60 Hz ____________________ 1 Ph 50 Hz 4. kVA (Prime) ____________________ 3 Ph/60 Hz ____________________ 3 Ph 50 Hz ____________________ 1 Ph/60 Hz ____________________ 1 Ph 50 Hz 5. Battery Select ____________________ Nominal Battery Voltage 6. Battery Thresholds (12 or 24 Volt) ____________________ Low Battery ____________________ High Battery ____________________ Weak Battery 7. Battery Delay Setup Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 ____________________ Low Battery Time Delay ____________________ High Battery Time Delay ____________________ Weak Battery Time Delay 8. Oil Pressure Setup ____________________ Sensor Type ____________________ Sensor Polarity ____________________ Sender Type Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 2-7: PC 1.1 Voltage Protection Setup Menus Work through the Menus on the Operator Panel 1. Voltage Protection ____________________ High AC Voltage Threshold ____________________ High AC Voltage Time Delay 2. Voltage Protection ____________________ Low AC Voltage Threshold ____________________ Low AC Voltage Time Delay 3. Voltage Protection ____________________ Overfrequency Threshold ____________________ Overfrequency Time Delay 4. Voltage Protection ____________________ Underfrequency Threshold ____________________ Underfrequency Time Delay Activity 2-8: PC 1.1 Current Protection Setup Menus Work through the Menus on the Operator Panel 1. Current Protection ____________________ High Current Warning Threshold ____________________ High Current Warning Time Delay Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 2-9: PC 1.1 Engine Protection Setup Menus Work through the Menus on the Operator Panel 1. Engine Protection ____________________ Overspeed 50 Hz Threshold ____________________ Overspeed 60 Hz Threshold 2. Engine Protection ____________________ Speed/Frequency Fault Threshold ____________________ Speed/Frequency Fault Time Delay 3. Engine Protection ____________________ LOP Warning Threshold ____________________ LOP Warning Time Delay 4. Engine Protection ____________________ LOP Shutdown Threshold ____________________ LOP Shutdown Time Delay 5. Engine Protection ____________________ HCT Warning Threshold ____________________ HCT Warning Time Delay 6. Engine Protection ____________________ HCT Shutdown Threshold ____________________ HCT Shutdown Time Delay 7. Engine Protection ____________________ LCT Warning Threshold ____________________ LCT Warning Time Delay 8. Engine Protection ____________________ Charger Failed Low Threshold ____________________ Charger Failed Time Delay Participants Guide Section 10 Activity PCC 1.1 and PowerCommand Control 1302 Activity Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 Activity PC 1.1 & PowerCommand Control 1302 Activities & Quiz ________________________________________________________________ Section 3 - Quiz: PCC 1302 Sequence of Operation Quiz Match the functions and components / switches; use the demonstrator or Participants’ Guide. 1. What happens when you apply a ground to pin 11 of J25? 2. What happens when you apply a ground to pin 10 of J25? 3. What voltage is present at J25-12 in normal standby mode? 4. What voltage is present at J11--7 when the genset is preheating? 5. What voltage is present at J20-15 when the genset is cranking? 6. What voltage is present at J20-13 when the genset is running? 7. What voltage is present at J20-3 when the genset is running? 8. What voltage at J20-11 can be used to disconnect the starter? Trainers Guide Section 10 ________________________________________________________________ PC 1.1 & PowerCommand Control 1302 Activities & Quiz ________________________________________________________________ THIS PAGE IS INTENTIONALLY LEFT BLANK Trainers Guide Section 10 ________________________________________________________________ PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Section 4- Quiz: PCC 1302 Installation Quiz Use the Participant Guide and/or the Operator/Installation Manual to answer the following questions. Circle the correct answer. 1. What is the Common Connector Scheme? A. All connectors on the control look the same. B. AC and DC signals are found in the same connector C. The harness connections from the engine and alternator are the same on the PC 1.X, 2.X and 3.X controls. D. The connectors are the same as any you would find in a local hardware store. 2. Signal Return is: A. the same as battery negative. B. not the same as battery ground. C. only used by the E-Stop switch. D. configurable for various voltages through InPower. 3. A customer wants a local and remote Operator Panel installed. The technician must A. determine how far apart the panels will be. B. determine a likely power supply for the Remote panel. C. make sure the data terminals are connected properly. D. All of the above are correct. 4. J18 Voltage input for voltage regulation is limited to a maximum of 240 volts AC. How can this control be used on 600vac generator set? A. It needs to be connected to a special winding tap provided on 600vac alternators built by Cummins Generator Technologies. B. It cannot be used on a 600vac alternator. C. Both A & D D. Use a PMG option installed on the alternator. 5. What is the maximum output amperage rating for J20-3, -14 & -15? A. 10 Amp dc B. 250mA dc C. .5 Amp dc D. 750mA dc Participants Guide Section 10 Quiz PCC 1.1 and PowerCommand Control 1302 Activity Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 Quiz PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 5-1: PC 1.X Setup and InPower Using your InPower Service cable (communication kit #541-1199), connect your computer to the PCC 1302 at the TB-15 port. 1. Open a site and take a capture file of the control. Give it an appropriate name so you can overlay this capture file back to the control at the end of this activity. Expand the “Adjustment” folder Open the”Engine Protection Adjustments” folder. Change the LOP Warning Delay value to 30 seconds and write this to the control With your simulator in Manual, start the unit. Turn the oil pressure pot down to 15 PSI displayed on the HMI screen. What changes in genset operation? ________________________________________________________________ ________________________________________________________________ Return the PSI value to approximately 45 psi and reset the warning Reset the LOP Warning Delay value back to 5 seconds and write (save) this to the control. 2. Expand the “Feature” folder. Open the “Battery Voltage Setup” folder Change the voltage to 12vDC and write this to the control With your simulator in Manual, and powered up, view the HMI screen. What fault is generated? ________________________________________________________________ ________________________________________________________________ Return the voltage setting to 24vDC and reset the warning 3. Remain in the “Feature” folder. Open the “Shutdown Override” folder What adjustments are listed? ________________________________________________________________ Participants Guide Section 10 Activities PCC 1.1 and PowerCommand Control 1302 Activity Section 10 What values are adjustable and what can these adjustments be set too? ________________________________________________________________ Open the “PGI CAN Parameters” folder. Do not make any adjustments to this folder at this time. Section 8 will cover PGI CAN in greater detail. What adjustments are listed? ________________________________________________________________ What values are adjustable and what can these adjustments be set too? ________________________________________________________________ 4. Minimize the “Feature” folder, and then expand the “Test” folder. Open the “Protection Verification” folder. Open the “Engine Protection Test” folder. Open the “Overspeeding” folder What adjustments are available and what can these adjustments be set to? ________________________________________________________________ What monitor functions are available? ________________________________________________________________ What switch functions are available? ________________________________________________________________ The simulator calibration file is configured for engine inputs, NOT PGI CAN, therefore the engine protection test functions will be different if the PCC 1302 is installed on and communicating engine functions via a CAN link. 5. Spend some free time inspecting various folders and view some of the myriad of functions available. Look in the “Fault” folder. You will notice the PCC 1302 stores few faults. Also look in the “Monitor” folder. We have not covered any monitor functions in this section, so use this time for exploring and self teaching. Ask questions about various things you find interesting or confusing, the entire class will benefit. Participants Guide Section 10 Activities PCC 1.1 and PowerCommand Control 1302 Activity 6-1 Section 10 Activity 6-1: PCCNet HMI 113 Annunciator Connection Activity 1. Power Off all power supplies, turn off the power switch on the simulator. 2. Put on your wrist strap. 3. Turn to the diagram on page 4 of the Control Wire Diagram #0630-3440. 4. Connect the Universal Annunciator to TB1 in the PCC 1302: _ Connect Data−A (TB1- 1 in the PCC 1302) to Data−A (J2-3 on the Annunciator) _ Connect Data−B (TB1 - 2 in the PCC 1302) to Data−B (J2-4 on the Annunciator) _ Connect Fused B+ (TB1 - 5 in the PCC 1302) to B+ (TB1-16 on the Annunciator) _ Connect B+ Return (TB1 - 3 in the PCC 1302) to Ground (TB1-15 on the Annunciator) 5. Recheck all connections. 6. Turn simulator power on, the Annunciator should show a “waterfall of color” as it powers up. 7. Switch PC1.1 from the Auto to the Manual mode position; Not in Auto LED on the Annunciator should light. Participants Guide Activity 6-1 Section 10 PCC 1.1 and PowerCommand Control 1302 Activity 6-1 Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Activity 6-1 Section 10 PCC 1.1 and PowerCommand Control 1302 Activity 6-2 Section 10 Activity 6-2: Configure a PCCNet HMI 113 Annunciator 1. Configure the Annunciator for Legacy NFPA 110 annunciation. 2. Demonstrate these three faults with the PC1.1 and Universal Simulator. ________ Low Oil Pressure − Pre-Alarm, not Shutdown alarm. ________ High Coolant Temperature − Pre-Alarm, not Shutdown alarm. ________ Overspeed shutdown. 3. Demonstrate Customer Fault 1 on the Universal Simulator. ________ Instructor Checkpoint 4. Configure Relay #1 on the Annunciator for “Not in Auto” fault. 5. Demonstrate the operation of this relay by placing the Mode Switch or Operator Panel in the Manual or Off mode. ________ Instructor Checkpoint 6. Change back to standard operation by downloading the capture file you took before starting this exercise ack into the PCC 1302 control. 7. Demonstrate that the relay does not operate on “Not in Auto” fault. ________ Instructor Checkpoint Participants Guide Activity 6-2 Section 10 PCC 1.1 and PowerCommand Control 1302 Activity 6-2 Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Activity 6-2 Section 10 PCC 1.1 and PowerCommand Control 1302 Activity 6-3 Section 10 Activity 6-3: PCCNet AUX101 & 102 Connections 1. Power Off all power supplies, turn off the power switch on the simulator. 2. Put on your wrist strap. 3. Turn to the diagram on page 4 of the Control Wire Diagram #0630-3440. 4. Connect the AUX 101 remote I/O to TB1 in the PCC 1302: _ Connect Data−A (TB1- 1 in the PCC 1302) to Data−A (J1-3 on the AUX 101) _ Connect Data−B (TB1 - 2 in the PCC 1302) to Data−B (J1-4 on the AUX 101) _ Connect Fused B+ (TB1 - 5 in the PCC 1302) to B+ J6-1 on the AUX 101) _ Connect B+ Return (TB1 - 3 in the PCC 1302) to J6-1 on the AUX 101) 5. Recheck all connections. 6. Turn simulator power on, the AUX101 should show “Green” DS1 LED as it powers up. 7. Open Instruction sheet C639a to page 6 & 7 and verify all the processes 1 through 14. Participants Guide Activity 6-3 Section 10 PCC 1.1 and PowerCommand Control 1302 Activity 6-3 Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Activity 6-3 Section 10 PCC 1.1 and PowerCommand Control 1302 Activity 6-4 Section 10 Activity 6-4: Configure a PCCNet AUX 101 (& 102 optional) This activity will allow you to configure the AUX 101 & 102 using the HMI. Pages 10 through 41 of Instruction Sheet C693a can be used as reference for this exercise. The HMI configuration references in C693a are for the control panel used on the PCC 1301, however many of the screens and functions are the same. 1. Demonstrate that you can gain access to the I/O Module menu and choose -1) Inputs. Follow the procedures listed on pages 14 through 19 Only configure Input #1 Configure Input #1 as a “Warning” Name the Input “CLASS 1”. Experiment with the processes involved with setting the configuration for Switch and Voltage Bias. ________ Instructor Checkpoint 2. Demonstrate that you are able to access and configure Relay Output functions. Follow the procedures listed on pages 32 through 35. Pay attention to the “Or’d” functions. As you can see on page 34 &35, you are able to configure Output #4 to activate on multiple faults. ________ Instructor Checkpoint 3. Demonstrate that you are able to access and configure the Senders functions. Reference to this function and navigation of these submenus are found on pages 36 through 41. Familiarize yourself with each of the Sender submenus and their setup. Participants Guide Activity 6-4 Section 10 PCC 1.1 and PowerCommand Control 1302 Activity 6-4 Section 10 ________ Instructor Checkpoint 4. Look at wire diagram 630-3142 on page 43 and answer the following questions. ________ What is J14-2? ________ Which Note tells you – “RTD senders can only be used on Inputs 3 -6” ________ What is the switch position between J2-11 and J2-12? ________ Which connection is the ground reference for sender 4? Participants Guide Activity 6-4 Section 10 PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 7-2: PCC 1302 ModBus – Configuring with the HMI. This exercise will verify the settings that had been completed in the previous exercise and we will be preparing for the next exercise. 1. 2. 3. Expand the “Adjustment” folder and find the “ModBus Setup” folder. Open it. Set the Parameters as follows: ModBus Enable ModBus Node Address ModBus Baud Rate ModBus Parity Value = Enable Value = 1 Value = 19200 Value =Even Participants Guide Section 10 Quiz PCC 1.1 and PowerCommand Control 1302 Activity Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 Quiz PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 7-1: PCC 1302 ModBus – Configuring with InPower 1. 2. 3. Connect your InPower service cable to TB15 and establish communication. Expand the “Adjustment” folder and find the “ModBus Setup” folder. Open it. Set the Parameters as follows: ModBus Enable ModBus Node Address ModBus Baud Rate ModBus Parity Value = Enable Value = 5 Value = 9600 Value =Odd Participants Guide Section 10 Quiz PCC 1.1 and PowerCommand Control 1302 Activity Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 Quiz PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Activity 7-3: PCC 1302 ModBus – Monitor with Modscan. This exercise will verify the settings that had been completed in the previous exercises, and we will monitor the ModBus communications. 1. Refer to Appendix B – Using ModScan Software. This Appendix is located in Section 11 of your guide. 2. Review the Appendix B document to become familiar with the setup and operation of the software. If you have ModScan installed on your computer, open it. 3. Remember from the last exercise the PC 1.X ModBus Parameters should have been set as follows: ModBus Enable ModBus Node Address ModBus Baud Rate ModBus Parity Value = Enable Value = 1 Value = 19200 Value =Even 4. Follow the directions that accompany figures 1through 4-2 and establish communication from your computer to the control. You will be using the standard InPower rs485 cable (Communication Kit #0541-1199) as your communication link. 5. Refer to Appendix A - ModBus Register Map. Find and record the following ModBus information. A. B. C. D. E. Engine Oil Pressure. NFPA Fault Register. Engine Coolant Temperature. Engine Run Time. Genset Run/Stop/Auto Switch Position. 6. Finding the information above proves that ModBus communications are viable. This exercise is similar to the activity a technician will encounter at a customer site. This exercise is complete, so shut down ModScan and disconnect your equipment. Participants Guide Section 10 Quiz PCC 1.1 and PowerCommand Control 1302 Activity Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 Quiz PCC 1.1 and PowerCommand Control 1302 Activity Section 10 Section 8: PGI Quiz PowerCommand Control 1302 & PGI CAN. Answer the following questions about functions and components; use the simulator, Participant’s Guide or Operator/Installation Guide 900-0661. 1. If you were to measure resistance between pins C and D at the 9-pin Deutsch service connector, what would your resistance read? _______________________________________________________________________ 2. What is the terminating resistors rated resistance, and how many are in a CAN network? ________________________________________________________________________ 3. Is there a difference between PGI CAN and J1939 standards? ________________________________________________________________________ 4. If monitoring CAN communications with a PEAK System Adapter, what is the priority and source of message 1CFEA300H? ________________________________________________________________________ 5. Is InPower able to monitor CAN message traffic? ________________________________________________________________________ 6. What is the maximum length of any stub on a CAN backbone? ________________________________________________________________________ 7. How many stubs can be installed on a CAN backbone? ________________________________________________________________________ 8. Is it possible to extend the length of a CAN backbone? ________________________________________________________________________ Participants Guide Section 10 PCC 1.1 and PowerCommand Control 1302 Activity Section 10 THIS PAGE IS INTENTIONALLY LEFT BLANK Participants Guide Section 10 PowerCommand 1.1 & PowerCommand Control 1302 Appendix Section 11 Section 11: PC 1.X & PCC 1302 Appendix This section contains several useful guides and instructions. Appendix A Appendix B Appendix C Appendix D PCC 1300 ModBus Register Map ModScan Operation Guide Instruction C713 Inline 5 Instructions Participant Guide Section 11 PowerCommand 1.1 & PowerCommand Control 1302 Appendix Section 11 THIS PAGE IS INTENTIONALLY LEFT BLANK Participant Guide Section 11 Appendix A PCC1300 SERIES MODBUS REGISTER MAP The 1301 and 1302 genset control contains data that can be read using a remote device communicating with the 1301 series via Modbus RTU protocol on a two-wire RS485 master/slave multi-drop bus. In this arrangement the remote device is the master and the 1300 series is the slave. The 1300 series is configured to communicate at a baud rate of 19,200, 8 data bits, even parity and 1 stop bit. Default slave address is 1. Parity, baud rate and slave address may be adjusted with InPower. For more information about the Modbus protocol, refer to Modbus Application Protocol v1.1a and Modbus Serial Line Implementation Guide v1.0, both available at www.modbus.org. Hi(+) TB2-3 Multi-Drop Network Mode PCC1300 Series Pins Lo (-) TB2-4 Shield TB2-1 Register Map Description Save adjustments Address 40004 Read/ Write Read and Write Scale Units Type Unsigned integer 0=No action Notes 1=Save adjustments Save adjustments saves to non volital memory all the write parameters listed in this table Genset control run/off/auto switch position Genset operating state 40010 Read Switch position Unsigned integer 0=off 1=Run/Manual 2=Auto 0=Stopped 1=Start Pending 2=Warm-up at Idle 3=Running 4=Cool down at Rated 5=Cool down at Idle 40011 Read Operating state Unsigned integer Fault Code 40012 Read Event code Unsigned integer This register contains the fault code number of currently active fault. See service manual for list of supported fault codes. Fault Type 40013 Read Fault type Unsigned integer This register contains the fault type of currently active fault 0=Normal 1=Warning 2=Derate 2/2/2008 Page 1 of 8 Appendix A PCC1300 SERIES MODBUS REGISTER MAP Description Address Read/ Write Scale Units Type Notes 3=Shutdown with Cool down 4=Shutdown NFPA 110 fault register Extended Annunciation fault register Alternator output voltage line to neutral (a phase) Alternator output voltage line to neutral (b phase) Alternator output voltage line to neutral (c phase) Alternator output voltage line to line (a to b phase) Alternator output voltage line to line (b to c phase) Alternator output voltage line to line (c to a phase) Alternator output voltage (used for voltage regulation) Alternator output current (phase a) Alternator output current (phase b) Alternator output current (phase c) Alternator output average current Alternator output voltamperes (phase a) Alternator output voltamperes (phase b) Alternator output voltamperes (phase c) Alternator output voltamperes (total) Alternator frequency Alternator output current (phase a) Alternator output current (phase b) Alternator output current (phase c) Control battery voltage Engine oil pressure Engine coolant temperature 40061 40062 40064 Read Read Read 0.1 1.0 0.1 40060 Read 0.1 40059 Read 0.1 40044 40058 Read Read 0.1 0.1 Hz 40043 Read 0.1 kVA 40042 Read 0.1 kVA 40041 Read 0.1 kVA 40040 Read 0.1 kVA 40029 Read 0.1 AC Amps 40028 Read 0.1 AC Amps 40027 Read 0.1 AC Amps 40026 Read 0.1 AC Amps 40025 Read 1.0 AC Volts 40024 Read 1.0 AC Volts 40023 Read 1.0 AC Volts 40022 Read 1.0 AC Volts 40020 Read 1.0 AC Volts 40019 Read 1.0 AC Volts 40018 Read 1.0 AC Volts Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer 40016 40017 Read Read bitmap bitmap See NFPA110 bitmap See extended annunciation bitmap Unsigned integer % of nominal Unsigned integer % of nominal Unsigned integer % of nominal Unsigned integer DC Volts kPa Degrees Celsius Unsigned integer Unsigned integer Unsigned integer 2/2/2008 Page 2 of 8 Appendix A PCC1300 SERIES MODBUS REGISTER MAP Description Engine speed Number of engine starts Engine runtime (high byte) Engine Runtime (Low byte) Genset start stop control via Modbus Genset E-stop switch via Modbus Nominal alternator voltage setting Nominal alternator frequency setting Alternator phase setting Alternator connection setting Glow plug driver feature enable Battery charging alternator fault enable Remote start time delay Remote stop time delay 43006 43007 43005 43004 43002 43003 43001 43000 40302 Address 40068 40069 40070 40071 40300 Read/ Write Read Read Read Read Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Scale 1.0 1.0 1.0 1.0 Units RPM Number of starts Sec Sec Type Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Notes 0 – Stop 1- Start 0 – Estop not active 1 – Estop active 1.0 AC Volts Hz # of phases Alternator connection Feature enabled Feature enabled Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer 0 =Inactive 1 = Active 0= None 1=Customer Input 1 2=Customer Input 2 3=Operator Panel 0 = 60 1 = 50 0=1 1 =3 1=Wye 0= Delta 0 = No 1 = Yes 0 = No 1 = Yes 1.0 1.0 1.0 1.0 1.0 Sec Sec Number of attempts Sec Sec Feature enabled Switch assignment Engine starting - cycle crank 43008 attempts setting Engine starting - cycle crank 43009 time setting Engine starting - cycle crank 43010 rest time setting Fault bypass (battle short) feature enable Fault bypass (battle short) switch input assignment 43012 43011 Automatic voltage regulator 43013 Enable Automatic voltage regulator 43014 volts per hertz roll off knee setting Automatic voltage regulator 43015 volts per hertz roll off slope setting Automatic voltage regulator 43016 Read and Write Read and Write 0.1 Feature enabled Hz Unsigned integer Unsigned integer 0 = No 1 = Yes Read and Write Read and 0.1 %V/Hz Unsigned integer 1.0 % Unsigned integer 2/2/2008 Page 3 of 8 Appendix A PCC1300 SERIES MODBUS REGISTER MAP Description gain setting Automatic voltage regulator 43017 integral setting Automatic voltage regulator 43018 derivative setting Electronic governing enable 43019 Electronic governing initial duty cycle setting Electronic governing initial duty cycle time Electronic governing start ramp duty cycle setting Electronic governing maximum duty cycle setting Electronic governing gain setting Electronic governing integral setting Electronic governing derivative setting Electronic governing crank exit fuel duty cycle setting Electronic governing dither factor setting Electronic governing start ramp time setting Electronic governing enable 43030 engine speed Electronic governing minimum duty cycle setting Electronic governing maximum duty cycle setting Model number character #1 Model number character #2 Model number character #3 Model number character #4 Model number character #5 Model number character #6 Model number character #7 43034 43035 43036 43037 43038 43039 43033 43032 43031 43029 43028 43027 43026 43025 43024 Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Character Character Character Character Character Character 1.0 % 1.0 % 0.01 1.0 Sec RPM 1.0 % 1.0 0.1 % % 1.0 % 1.0 % Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Character 43023 43022 43021 43020 Address Read/ Write Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Scale Units Type Notes 1.0 1.0 1.0 0.1 0.1 0.1 0.1 % % Feature enabled % Sec % % Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer 0 = No 1 = Yes 2/2/2008 Page 4 of 8 Appendix A PCC1300 SERIES MODBUS REGISTER MAP Description Model number character #8 Model number character #9 Model number character #10 Model number character #11 Model number character #12 Model number character #13 Model number character #14 Model number character #15 Model number character #16 Serial number character #1 Serial number character #2 Serial number character #3 Serial number character #4 Serial number character #5 Serial number character #6 Serial number character #7 Serial number character #8 Serial number character #9 43049 43050 43051 43052 43053 43054 43055 43056 43057 43048 43047 43046 43045 43044 43043 Address 43040 43041 43042 Read/ Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Scale Units Type Character Character Character Character Character Character Character Character Character Character Character Character Character Character Character Character Character Character Character Character Character Character Character Character Character Notes Serial number character #10 43058 Serial number character #11 43059 Serial number character #12 43060 Serial number character #13 43061 Serial number character #14 43062 Serial number character #15 43063 Serial number character #16 43064 2/2/2008 Page 5 of 8 Appendix A PCC1300 SERIES MODBUS REGISTER MAP Description Address Read/ Write Write Configurable input #1 type: 43065 Read and Write Configurable input #2 type: 43066 Read and Write Configurable output #1 event code number: Configurable output #2 fault 43068 event number: 60 Hz alternator output voltage adjust % 50 Hz alternator output voltage adjust % Alternator frequency adjustment % 60 Hz line 1 to neutral metering voltage calibration 60 Hz line 2 to neutral metering voltage calibration 60 Hz line 3 to neutral metering voltage calibration 50 Hz line 1 to neutral metering voltage calibration 50 Hz line 2 to neutral metering voltage calibration 50 Hz line 3 to neutral metering voltage calibration 60 Hz line 1 metering current calibration 60 Hz line 2 metering current calibration 60 Hz line 3 metering current calibration 50 Hz line 1 metering current calibration 50 Hz line 2 metering current calibration 50 Hz line 3 metering current calibration Annunciator configurable input #1 type: Annunciator configurable input #2 type: Annunciator configurable 43086 43085 43084 43083 43082 43081 43080 43079 43078 43077 43076 43075 43074 43073 43072 43071 43070 43069 43067 Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Read and Write Input type 0.001 % 0.001 0.001 % % 0.001 % 0.001 0.001 % % 0.0001 % 0.0001 0.0001 % % 0.0001 0.0001 % % 0.0001 % Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer Unsigned integer 0 = Event 1 = Warning 2 = Shutdown Read and Write Read and . Input type Input type Unsigned integer 0 = Event 1 = Warning 2 = Shutdown Unsigned integer 0 = Event 0.1 0.1 % % 0.1 % 1.0 1.0 Event code Event code Input type Input type Unsigned integer 0 = Event 1 = Warning 2 = Shutdown Unsigned integer 0 = Event 1 = Warning 2 = Shutdown Unsigned integer Unsigned integer Unsigned integer Unsigned integer Integer Scale Units Type Notes 2/2/2008 Page 6 of 8 Appendix A PCC1300 SERIES MODBUS REGISTER MAP Description input #3 type: Annunciator configurable output #1 event code number: Annunciator configurable output #2 event code number: Annunciator configurable output #3 event code number Annunciator configurable output #4 event code number 43090 Read and Write 1.0 Event code Unsigned integer 43089 Read and Write 1.0 Event code Unsigned integer 43088 Read and Write 1.0 Event code Unsigned integer 43087 Address Read/ Write Write Scale Units Type 1 = Warning 2 = Shutdown Notes Read and Write 1.0 Event code Unsigned integer NFPA110 bitmap (Register 40016) NFPA 110 Description Bit 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 (LSB) (MSB) Common Alarm Genset Supplying Load Genset Running Not in Auto High Battery Voltage Low Battery Voltage Charger AC Failure Fail to Start Low Coolant Temperature Pre–High Engine Temperature High Engine Temperature Pre–Low Oil Pressure Low Oil Pressure Overspeed Low Coolant Level Low Fuel Level Extended Annunciation Bitmap (Register 40017) Description Bit 0 (MSB) Check Genset 2/2/2008 Page 7 of 8 Appendix A PCC1300 SERIES MODBUS REGISTER MAP Ground Fault High AC Voltage Low AC Voltage Under Frequency Overload Overcurrent Short Circuit Reverse KW Reverse KVAR Fail to Sync Fail to Close Load Demand Genset Circuit Breaker Tripped Utility Circuit Breaker Tripped Emergency Stop 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 (LSB) 2/2/2008 Page 8 of 8 Appendix B PCC 1302 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 Appendix B PCC 1302 ModBus 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 Appendix B PCC 1302 ModBus FIGURE 3. FT–10 NETWORK CONNECTION DETAILS DIALOG BOX 3. Click on the “Protocol Selections” 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 Appendix B 4.Click “OK” on the two open dialog boxes. PCC 1302 ModBus 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. ModScan is not satisfied if it polls a group of registers and finds one in the sequence that is not programmed, it will display a “Exception Response” as in Figure 4-2. Minimize the number of registers polled to a sequential length as listed in the register map. WARNING 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) Page 4 40070 is Eng Runtime (value will be displayed in seconds) 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. 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 the Auto mode, the genset WILL start. WARNING 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 Appendix B PCC 1302 ModBus 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 Appendix B PCC 1302 ModBus 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 Appendix B PCC 1302 ModBus THIS PAGE IS INTENTIONALLY LEFT BLANK Page 8 Instruction Sheet C713 8−2006 Remote Mount Panel Kit 541−1394 GENERAL INFORMATION This instruction sheet describes the installation of a remote display panel (see Figure 1) for use with a PCC1302 controller. 24VDC power supply is required to power the display. Mounting The HMI211 can be mounted a total of 4000 feet (1219.2 meters) (total cable length) from the PCC1302 controller. TABLE 1. WIRE TYPES Maximum Mounting Distance B+ and GND From the Generator Set in Wiring Feet (Meters) 14 AWG 16 AWG 18 AWG 500 (152.4) 200 (61) 100 (30.5) REMOTE PANEL INSTALLATION 1. Make sure the generator set is shut down and disabled. FIGURE 1. HMI211 DISPLAY PANEL WARNING This kit must be installed by trained and experienced service personnel only or equipment failure and damage and severe personal injury can result. a. Place the genset O/Manual/Auto switch in the O (OFF) position. b. Turn off and disconnect the battery charger (if equipped). c. Disconnect the negative (−) cable from the battery to prevent accidental starting. 2. Mark and cut out an area for mounting the display panel, using the template inclued in Figure 5. Drill holes for securing the display panel. 3. Mount the Operator Panel and secure it with four M4 flat washers, lock washers, and hex nuts. NOTE: For steps 4 thru 6, complete wiring connections by soldering or by using a terminal block or connector. 4. Depending upon the distance from the Remote Display to the PCC1302 controller, select the appropriate wiring from Table 1 to complete the B+ and GND connections from the Display Panel harness (see Figure 2) to the PCC1302 controller or the separate power supply. Refer to the wiring diagram in Figure 3. Page 1 of 5 The following parts are included in this kit. Part Description Display (HMI211) Dsiplay Panel Harness Qty 1 1 Read these installation instructions completely and become familiar with safety warnings, cautions, and the installation procedure before starting. INSTALLATION GUIDELINES Power If mounted within 500 feet (152.4 meters) of the genset starting batteries, the HMI211 can be powered from the starting batteries. If mounted more than 500 feet from the genset, an isolated 12 or PRELIMINARY FIGURE 2. DISPLAY PANEL WIRING HARNESS 5. Use Class 5, 22 gauge shielded stranded twisted pair wire to complete the RS485 (Data+ and Data−) connections from the Display Panel harness to the Generator Set harness. 6. Use 18 AWG wire to complete the Wakeup and Remote Start connections from the Display Panel to the PCC1302 controller. 7. Reconnect the genset as follows. a. Connect the negative (−) cable to the battery. b. Reconnect the battery charger (if used). 8. Configure the remote HMI211 for remote operation (see Figure 4). a. To view the first Service Menu, simultaneously press the and selection buttons for two seconds. DISPLAY PANEL HARNESS HMI211 J1-1 J1-2 b. Press the (1) button to view the Setup Password menu. c. Enter the password (574) and press the . The Setup arrow selection button menu is displayed. d. Press the (1) button to view the main Genset Service menu. e. Press the (1) button again to view the first genset submenu. button repeatedly until the f. Press the Display Setup menu is displayed. g. Press the ADJUST button. h. Use the + or − symbol buttons to change the Connection from “Local” to “Remote.” i. Press the SAVE button to save your changes. TWISTED PAIR SHIELDED WIRING PCC NetA PCC NetB SHIELD TB1-1 TB1-2 PCC1302 CONTROLLER POWER SUPPLY (IF GREATER THAN 500 FEET) J1-4 J1-7 JOIN B+ TB1-5 TB1-3 OR GND WAKEUP REMOTE START TB15-5 TB1-10 FIGURE 3. WIRING SCHEMATIC C713 Page 2 of 5 PRELIMINARY OR A CONTINUED ON THE FOLLOWING PAGE FIGURE 4. CONFIGURING THE REMOTE DISPLAY PANEL (SHEET 1 OF 2) C713 Page 3 of 5 PRELIMINARY A YES OR NO YES OR NO FIGURE 4. CONFIGURING THE REMOTE DISPLAY PANEL (SHEET 2 OF 2) C713 Page 4 of 5 PRELIMINARY 0.1” (2.6 MM) 4X 0.16” DIA (4 MM) 3.94” (0.29 MM) NOTE: Not all printers produce accurate copies of drawings. If you use this drawing as a template, be sure to check the dimensions before cutting or drilling. 3.94” (100 MM) 3.35” (85 MM) DIMENSIONS ARE IN INCHES (MILLIMETERS) 4.92” (125 MM) 5.12” (130 MM) FIGURE 5. PANEL FOOTPRINT C713 Page 5 of 5 THIS PAGE IS INTENTIONALLY LEFT BLANK JOBNAME: No Job Name PAGE: 1 SESS: 2 OUTPUT: Wed Aug 3 10:21:11 2005 Service Tool Instruction Description INLINE™ 5 Datalink Adapter Kit Part Number Date: Bulletin Number 4918416 03-Aug-2005 3400205 This document provides information for the INLINE™ 5 Datalink Adapter Kit, Part Number 4918416, and the associated cables to connect a personal computer to the datalink adapter. The INLINE™ 5 datalink adapter is designed for use with the SAE J1708 and J1939 standard protocols. The INLINE™ 5 datalink adapter is used with software applications such as INSITE™ Electronic Service Tool 6.3 and later versions, to communicate with the B5.9G, B5.9LPG, B Gas Plus, B LPG Plus, ISB, ISBe (4 and 6 cylinder), QSB3.9-30, QSB4.5-30, QSB5.9-30, QSB5.9 Marine, QSB5.9-44, C Gas Plus, ISC, QSC8.3, L10, L10 Gas, ISL, QSL9, L Gas Plus, M11, N14, Signature, ISX, QSX15, ISM, ISMe, QSM11, QSK19, QSK19G, QSK23, QST30, QSK45, QSK45G, QSK60, QSK60G, and QSK78 engines. Item Number 1 2 3 3 Not shown Not shown Not shown Not shown Table 1, INLINE™ 5 Datalink Adapter Kit, Part Number 4918416 Part Number Description 3165033 INLINE™ 5 datalink adapter 4918419 USB cable, (2 M [6.56 feet]) 3165160 Datalink cable (DB25F 6-Pin Deutsch connector) 3165159 Datalink cable (DB25F 9-Pin Deutsch connector) 3165143 Storage case 4918417 INLINE™ 5 software compact disc 4918418 DB9F-DB9M serial cable, (1.83 M [6 feet]) 4918436 INLINE™ 4 and 5 Ruggedized protective boot Quantity 1 1 1 1 1 1 1 1 Table 2, Items Used with INLINE™ 5 Datalink Adapter Kit, Part Number 4918416, Purchased Separately Item Number Part Number Description Quantity Not shown 3165141 DB25F 2-Pin Weather-Pack and 3-Pin Deutsch 1 with Cigarette Plug connector Not shown 3824440 DB25F 8-Pin AMP connector 1 Not shown 3162851 Extension DB9F to DB9M (30.48 M [100 feet]) 1 Not shown 3163096 J1939 backbone adapter 1 Not shown 3163597 J1939 gender change adapter 1 Not shown 3165017 Palm universal cable 1 Not shown 3162850 DB9F-DB9M serial cable 1 Not shown 4918591 USB cable, (5 M [16.4 feet]) 1 Registered Office: Unit 1-B Uniongate, Ridgeway Trading Estate, Iver, Buckinghamshire SL0 9HX, England Registered No. 573951 England Copyright 2005 Cummins Inc. All rights reserved Cummins Inc., Box 3005, Columbus, Indiana 47202-3005 Cummins Engine Co. Ltd., Daventry, Northants, England NN11 5NU Page 1 of 3 JOBNAME: No Job Name PAGE: 2 SESS: 2 OUTPUT: Wed Aug 3 10:21:11 2005 Page 2 NOTE: A fully populated USB cable, Part Number 4918419, or DB9F–DB9M, serial cable, Part Number 4918418, must be used. Connect the DB9F–DB9M serial cable, Part Number 4918418, or USB cable, Part Number 4918419 to the RS232 serial port or the USB port of the computer and to the INLINE™ 5 datalink adapter, Part Number 3165033. The INLINE™ 5 datalink adapter requires +8 VDC to +50 VDC at 250mA that can be supplied through the OEM connector or by a separate power source. Connect the appropriate datalink cable to the INLINE™ 5 datalink adapter, Part Number 3165033. With the datalink cable connected to the INLINE™ 5 datalink adapter, connect the other end of the datalink cable to the vehicle cab or engine compartment datalink connector. Launch the electronic service tool application software. JOBNAME: No Job Name PAGE: 3 SESS: 2 OUTPUT: Wed Aug 3 10:21:11 2005 Page 3 INLINE™ 5 Datalink Adapter Indicator Lamp Functions • Power Lamp When the power lamp is continuously illuminated, DC power is being supplied to the adapter at the proper voltage level. The INLINE™ 5 datalink adapter requires +8 VDC to +50 VDC at 250mA that can be supplied through the OEM connector or by a separate power source. When the power lamp is flashing, improper DC power is being supplied to the adapter. A slow flashing power lamp indicates VDC is less than +8 VDC. A fast flashing power lamp indicates VDC is greater than +50 VDC. If the power lamp is not illuminated, check for power at the vehicle connector and check for correct polarity. • J1939 Lamp A J1939 fast flashing lamp indicates the adapter is connected to a J1939 datalink, the vehicle key switch is in the ON position, and communications are being received. A J1939 slow flashing lamp indicates the adapter is transmitting over a J1939 datalink, but is not receiving any messages. • J1708 Lamp A J1708 fast flashing lamp indicates the adapter is connected to a J1708 datalink, the vehicle key switch is in the ON position, and communications are being received. A J1708 slow flashing lamp indicates the adapter is transmitting over a J1708 datalink, but is not receiving any messages. • RS–232 Lamp A RS–232 fast flashing lamp indicates the adapter is connected to a RS–232 port, the vehicle key switch is in the ON position, and communications are being received. A RS–232 slow flashing lamp indicates the adapter is transmitting over a RS–232 port, but is not receiving any messages. • USB Lamp A USB fast flashing lamp indicates the adapter is connected to a USB port, the vehicle key switch is in the ON position, and communications are being received. A USB slow flashing lamp indicates the adapter is transmitting over a USB port, but is not receiving any messages. THIS PAGE IS INTENTIONALLY LEFT BLANK PowerCommand 1.1 & PowerCommand Control 1302 Diagrams ________________________________________________________________ Section 12: PC 1.X & PCC 1302 Diagram This section contains Common Connector wire diagrams. Visual Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram 630-3440 Instruction Diagram 630-3440 Sheet 1 630-3440 Sheet 2 630-3440 Sheet 3 630-3440 Sheet 4 630-3440 Sheet 5 630-3440 Sheet 6 630-3440 Sheet 7 630-3440 Sheet 8 630-3440 Sheet 9 630-3440 Sheet 10 630-3440 Sheet 11 Trainers Guide Section 12 PowerCommand 1.1 & PowerCommand Control 1302 Diagrams ________________________________________________________________ THIS PAGE IS INTENTIONALLY LEFT BLANK Trainers Guide Section 12 Header indicates the type of Engine controls Notice Battery Negitive terminology: B+ Return Baseboard connector and connection point list. Option connector and connection point list. Pilot Relay drivers limited to 250 milliamp. Component part numbers are now listed in call out boxes instead of material lists. Self Excitation This Terminator Resistor may be located far from the engine. This Terminator Resistor is part of the Engine harness and is located very close to the ECM. Fuse. Installed on the power supply side. Do not install these on the AVR output (J17) side. THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK PowerCommand 1.1 & PowerCommand Control 1302 Section 13 Section 13: PC 1.X & PCC 1302 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 have a copy of this sheet as the last page in their Participant Guide, but if you need a master we provide one here. Participant Guide Section 13 PowerCommand 1.1 & PowerCommand Control 1302 Section 13 THIS PAGE IS INTENTIONALLY LEFT BLANK Participant Guide Section 13 PowerCommand 1.1 & PowerCommand Control 1302 Section 13 Module Comment Form Now that you have completed the PC 1.X & PowerCommand Control 1302 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 Performance Area Understanding the CPG model and component naming system. Selection of proper Section topics and Section content. Your Skill level Before the program No skill 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 High Skill 3 3 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 After the program No skill 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 High Skill 3 3 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 Use of Installation guides, Instruction 0 Sheets, Guides, and Appendix Material. Operating the HMI, and navigating the control system. Operation of the HMI for configuration processes and setup. Operation and connection of InPower for configuration processes and setup. Understanding Common Connector Scheme and new schematics. Understanding connector locations and functions. Understanding features and commonality of options. Setup various PCCNet components and install them. Setup the ModBus feature, test it and understand its basic operation. Identify PGI CAN system components and understand their operation. Troubleshoot CAN genset control systems. Converse about genset communication ability with Building Management System installers. 0 0 0 0 0 0 0 0 0 0 0 Participant Guide Section 13 PowerCommand 1.1 & PowerCommand Control 1302 Section 13 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 Agree 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. Agree Disagree Strongly Disagree Overall, how do you rate this training module? (circle one) 1 Poor (Over) 2 3 4 5 6 7 8 9 10 Outstanding Participant Guide Section 13 PowerCommand 1.1 & PowerCommand Control 1302 Section 13 Use this page to add any comments or suggestions for course improvement. Comments and Suggestions: Participant Guide Section 13 Cummins Power Generation 1400 73rd Avenue N.E. Minneapolis, MN 55432 1-800-888-6266 763-574-5000 International Use Fax: 763-574-8087 Cummins is a registered trademark of Cummins Inc.