Technical TrainingParticipant’s Guide PowerCommand) Control 2100 with CAN Link CMT0686-EN-PG 11/2005 PowerCommand Control 2100 w/ CAN Link Introduction Revision History v5.00 (11/2005) 1. Removed last mentions of PTC Module – thanks go out to Kurt Rahkola v4.00 (09/2004) 1. Updated CAN Link section. 2. Re-ordered guide sections to put prints just before the Comment Sheet. 3. Added Performance Assessment. v3.00 (04/21/04) 1. Added section on CAN Link to ECS on Cummins G-Drive engines. v2.0 (4/2/04) 1. Updated with changes found by guest instructor during USAF session in January 2004. Thanks Tim. 2. Updated copyright information v1.1 (8/25/02) 1. Numerous revisions found in first QTQ session. Many sections involved in this revision, subtle changes to text and diagrams. v1.00 (7/20/02) 1. Initial draft for first QTQ session in 2002 Cummins, Onan, and PowerCommand are all registered trademarks of Cummins Inc. InPower is a trademark of Cummins Inc. Windowst is a trademark of Microsoft Corporation. Copyright E 2001-2005 by Cummins Power Generation Participant’s Guide i-1 . . . 4-1 This lesson presents the troubleshooting steps and job aids for the PowerCommand Control 2100. . . . . . . . . . . . . . . . . . . . 7-1 This section lists the most common terms used throughout this training module pertaining to the PowerCommand family of Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PowerCommand Control 2100 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 This section has copies of all prints used in the course. The participant will learn to identify the main features of the PowerCommand Control 2100. . . . . . . . . . . . . . . . . . . . . . . . . . . i-2 Participant’s Guide . . . . . . . . . 5-1 This lesson presents the steps required to properly install and setup the optional modules for a PowerCommand Control 2100. . . . 1-1 This lesson presents an overview of the PowerCommand Control 2100. . . . and the structure of the training module. . . Diagrams .Introduction PowerCommand Control 2100 w/ CAN Link PowerCommand Control 2100 with CAN Link Module Table of Contents Introduction . . . InPowert software and the PowerCommand Control 2100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PowerCommand Control 2100 Service Menus . . . . . . . . . . . . . Review of the PowerCommand Control 2100 CBT . . . . . . . . . . . . . . . . . . . I-1 The introduction describes the audience. . . .0 or later. . . . Glossary . . . . 2-1 This lesson presents the Setup and Calibration menu system used in the PowerCommand Control 2100. . . . . . . . . Troubleshooting the PCC 2100 with CAN Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCCNet and the Universal Annunciator . . . . . . . . . . . . . . . . . 6-1 This lesson presents information on the Universal Annunciator that connects to the PCCNet connector (TB2) in the PCC 2100. . the purpose. . . . . . . . . . . . 3-1 This lesson presents the steps required to setup the optional modules for a PowerCommand Control 2100 with InPower v 4. . . . . . . . . . . . . . . . . . . . . . . . Participant’s Guide i-3 . . . . . . . . . . . . . but if you need a master we provide one here. . . . . .PowerCommand Control 2100 w/ CAN Link Introduction Module Comment Sheet . . . . . . . . . . . . . . 9-1 Participants have a copy of this sheet as the last page in their Participant Guide. . . . . . and repair procedures. and activity (or exercise). The presentation portion of the lesson is where participants receive new information. just follow the step-by-step instructions for each lesson. i-4 Participant’s Guide . presentation. understand the PowerCommand Control 2100 with CAN Link which is going to be used on Cummins Power Generation Gensets that use standard Cummins G-Drive engine modules. it gives participants the chance to practice new skills or work with new ideas. Module Structure This module contains lessons on related topics. Each lesson follows a carefully designed training format. Module Purpose The purpose of the PowerCommand Control 2100 with CAN Link module is to help you. With this information. The activity follows the presentation. Module Audience The primary audience for this module is Cummins Power Generation distributor power generation technicians. the Cummins Power Generation distributor service technician. We assume participants have previous experience with or knowledge of Integrated generator set AC and DC control operation.Introduction PowerCommand Control 2100 w/ CAN Link Introduction Welcome! Welcome to the Participant’s Guide for the PowerCommand Control 2100 with CAN Link module! This guide was written by the Cummins Power Generation Sales and Technical Training department for your use and reference. Lesson Format Warm ups help participants focus and begin thinking about the lesson topic. including a warm up. We suggest you read through the entire Introduction to become familiar with the guide’s structure. troubleshooting. our technical force will be better prepared to meet our customers’ varying needs.. Then. The module assessment lets us evaluate the level of knowledge participants have on the topic after completing the module. Participant’s Guide i-5 . participants will complete a module assessment.PowerCommand Control 2100 w/ CAN Link Introduction Module Assessment After completing all the lessons in the module. Module Comment Form Participants will also complete a module comment form. 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. This form gives participants the chance to comment on the usefulness and effectiveness of the training module and make suggestions for improvements. Introduction PowerCommand Control 2100 w/ CAN Link This page intentionally left blank i-6 Participant’s Guide . Guide (CMT0686-EN–PG) Manual (961-0101) CD-ROM (932-0772-CD) Participant’s Guide 1-1 .PowerCommand Control 2100 with CAN Link Introduction & CBT Review Introduction to the PowerCommand) Control 2100 with CAN Link and Review of PCC 2100 CBT. Estimated Time: 4 hours Equipment Needed Overhead projector and screen or PC with LCD Projector and screen PowerCommand Control 2100 and simulator for each pair of participants Materials Needed Module overhead set or slide set One for each participant: PowerCommand ) Control 2100 Participant’s Guide QSX15 set with PCC 2100 Operator’s Manual • PC with PowerCommand ) Control 2100 CD-ROM Instructor’s Note: This lesson presents a review of the lessons learned in the Computer-Based Training (CBT) program completed before participants came to the hands-on class. the participants should be able to: • Describe the function of the CAN Link. • Locate and identify the New PowerCommand Control 2100 panel components. • Identify the New PowerCommand Control 2100. You may want to follow along on the CD-ROM as well as in your Participant’s Guide.Introduction & CBT Review PowerCommand Control 2100 with CAN Link Warm Up In this lesson we are going to introduce you to the PCC 2100 with CAN Link and review the pre-class CD-ROM for the PowerCommand Control 2100. • Describe the sequence of operation for the PowerCommand Control 2100. • Identify the standard and optional component of the PowerCommand Control 2100. We will quickly review the material in the CD-ROM. and add to that information. 1-2 Participant’s Guide . • Use the Operator menus. • Identify components inside the PowerCommand Control 2100. Objectives After completing this lesson. Participant’s Guide 1-3 .PowerCommand Control 2100 with CAN Link Introduction & CBT Review What is a CAN Link? Control Area Network Engine Control System (ECS) Genset Control System (GCS) Communication Path 120 Ohm Resistors at each end of Bus 3 Meter Stubs VIS 1-1 S&TT 09/04 Visual 1-1 What is a CAN Link? Participant's Text Your Notes You completed the PCC 2100 pre-read CDROM before coming to this course. You learned many things about the PCC 2100 and its upgrade. The PCC 2100 communicates over a CAN link with the ECM on the genset GDrive engine. The ECM sends specific governor signals to the engine governor actuator. The PCC 2100 sends specific governor signals to the engine governor actuator. the PCC 2100 in that program. Termination Resistors – 120 Ohm resistors at both ends of the main communications channel. The total resistance is _____ Ohms if measured by an Ohmmeter. These cannot be longer than 3 meters (10 feet). This is the ECM on the engine and the sensors and controls for the engine. GCS – Generator Set Control System. 1-4 Participant’s Guide . Your Notes ECS – Engine Control System. and a series of stub cables to additional devices.Introduction & CBT Review PowerCommand Control 2100 with CAN Link Participant's Text CAN Link – a Control Area Network used to allow an engine-mounted control system to monitor the engine and communicate with a generator set control system. This is the PCC 2100 and the rest of the generator set. Communication Path – a shielded twistedpair cable that has specific resistance terminations at each end of the main communication cable between the ECS and the GCS. Stubs – Short pieces of communication cable connecting other devices into the CAN Link. InPower service tool software can adjust many parameters. and download calibrations. The PCC 2100 is easily upgradeable to FT-10 PowerCommand Network compatibility.PowerCommand Control 2100 with CAN Link Introduction & CBT Review What is the PCC 2100? Engine / Alternator Control InPower service tool software Network Upgradable Everything in one box Smart Starting Plus When will the control NOT go to sleep? 3 Wake up signals VIS 1 2 S&TT 09/04 Visual 1-2 What is the PCC 2100? Participant's Text Your Notes The PCC 2100 controls engine and alternator functions and has preset alarm levels for engine and alternator parameters. Participant’s Guide 1-5 . and then time for shut down. • Move mode switch to Manual or Auto from 0 position. it will ramp the engine down to idle. • The mode switch is in Manual or Auto • Sleep is disabled with the service tool software. • Panel Lamp/ Lamp Test switch pressed for one second. The PowerCommand control 2100 WILL NOT “go to sleep” if: • The Service tool is connected to the control. 1-6 Participant’s Guide . operate at idle speed for a predefined time period or until the engine reaches operating temperature. set with InPower software. • The network Module is installed and activated. These signals will wake up the control: • Remote Start signal input to TB1-1.Introduction & CBT Review PowerCommand Control 2100 with CAN Link Participant's Text Smart Starting Plus • Programmable Idle Function on Start: In this mode. and then ramp to rated speed and voltage. • Cooldown at Idle: When the control gets a signal to stop. generator set will start. Your Notes Wake Up Signals The PowerCommand control will “go to sleep” after a pre-determined time delay. is on a removable panel. The legend panel may be removed and replaced with another panel in a different language. There are two physical switches and nine membrane switches on the switch panel. except the “0” position indicator. Your Notes Participant’s Guide 1-7 .PowerCommand Control 2100 with CAN Link Introduction & CBT Review Basic PCC 2100 Panel VIS 1 3 S&TT 09/04 Visual 1-3 PowerCommand Control 2100 Standard Operator Panel Participant's Text Genset Control – Standard The control panel is mounted on the generator set. All writing. Introduction & CBT Review PowerCommand Control 2100 with CAN Link Participant's Text Physical Switches Emergency Stop Switch. Pressing the Emergency Stop Switch will cause the generator set to immediately shutdown. If the generator set is not running, pressing the emergency stop switch will prevent it from attempting to start. 0/Manual/Auto switch. This switch has several uses in controlling the generator set. • When placed in the “0” position while the generator set is running, the set will shut down immediately. • In the MANUAL position, the control will not complete any automatic sequences. • In the AUTO mode, the generator set can be started by receipt of a start signal from a remote device. The control maintains an internal record of manual control activities performed on the generator set. Your Notes Membrane Switches • Manual Run/Stop switch. Toggles generator set to run/stop mode when the 0/Run/Auto switch is in the RUN position. 1-8 Participant’s Guide PowerCommand Control 2100 with CAN Link Introduction & CBT Review Participant's Text • If the generator set is running in the MANUAL mode, pressing the Manual Run switch again will cause the generator set to shut down after the cooldown time delays. • Fault Acknowledge Switch. Allows the operator to acknowledge warnings and shutdowns from the switch panel. The 0/Run/Auto switch must be in the “0” position to acknowledge shutdown faults. • Panel Lamp/Lamp Test Switch. Allows the operator to switch on LED lamps to illuminate the control. Holding the switch down for two seconds allows the lamps on the panel to be illuminated, so that it can verified that they are operating properly. Continue holding the switch down to cycle the segments on the LED Bargraph, if installed. Your Notes LEDs There are two LEDs on the bottom part of this side of the panel: • Shutdown There is a shutdown condition • Warning There is a non-shutdown condition There are eight LEDs on the top of the panel. Three are preset: • Running The genset is running (Switched B+ indicator). • Remote Start The control sees a remote start signal. Participant’s Guide 1-9 Introduction & CBT Review PowerCommand Control 2100 with CAN Link Participant's Text Your Notes LEDs (continued) • Not in Auto The 0/Run/Auto switch is not in the AUTO position The other five LEDs in the top half of the panel can be set for various functions and colors using InPower service tool software. The digital display panel is capable of displaying up to 2 lines of data with approximately 20 characters per line. It is configurable for units of measurement. The digital display on the Operator panel turns off after 10 minutes if no buttons around it are pressed. This happens to save the screen from burn-in. The display will wake up from the “screen saver” mode when any of the six buttons around it are pressed. The digital display panel incorporates one level of security. • Service level (application) password allows setup and calibration of the control. • As with the PCC 3200, once you input the password, the password “window” stays open for 10 minutes after the last button press. Trainer's Personal Comments 1-10 Participant’s Guide frequency.PowerCommand Control 2100 with CAN Link Introduction & CBT Review PCC 2100 Panel with LED Bargraph VIS 1 4 S&TT 09/04 Visual 1-4 PowerCommand Control 2100 with LED Bargraph option Participant's Text Analog AC metering panel displays simultaneously 3-phase AC line current. • Power Factor is displayed from –.9 (leading) • Frequency and Voltage are displayed from <70% to 110% of nominal value. • Amps and kW are displayed from 0–125% of nominal value. and line-toline voltage. Your Notes Participant’s Guide 1-11 . kW.6 (lagging) to +. power factor. 1-12 Participant’s Guide . and four inside a network PCC 2100 with the Bargraph option. Base Card (standard) (at rear of cabinet) Microprocessor is on this board.Introduction & CBT Review PowerCommand Control 2100 with CAN Link Inside the PCC 2100 Control Digital Display Base Card J10 (CAN Link) LED Board VIS 1 5 Bargraph TB1 S&TT 09/04 Visual 1-5 Inside the PowerCommand Control 2100 Participant's Text Inside the Control 2100 PowerCommand) Your Notes There are two circuit boards inside the standard PCC. Two types of memory hold data. LED Bargraph (optional) (at the bottom of the door) Has one ribbon cable connector that connects to the LED board. From the left side around they are: LED Board (standard) (on the door) Contains LEDs seen on the door. This is really read-write software. RAM Random Access Memory holds data when the PCC 2100 is running. and is updated any time you save changes in the PCC menus.PowerCommand Control 2100 with CAN Link Introduction & CBT Review Participant's Text EEPROM Electrically Erasable Programmable Read-Only memory holds PCC 2100 operation data. and “forgets” what it held when the PCC 2100 is turned off. Your Notes Participant’s Guide 1-13 . Your Notes 1-14 Participant’s Guide . If the customer wants to have the gensets as part of an FT-10 network. they all need to have NCMs in them.Introduction & CBT Review PowerCommand Control 2100 with CAN Link Optional Modules Network Communication Module Network Relay Module Network Annunciator Module Universal (PCCNet) Annunciator Module VIS 1 6 S&TT 09/04 Visual 1-6 Optional modules for the PCC 2100 Control Participant's Text FT-10 Network Communication Module (NCM) • The Network Communication Module allows the PCC 2100 to communicate with other FT-10 network modules. FT-10 Annunciator (LSA) • The FT-10 Annunciator provides a visual and audible indication of the genset and ATS functions and operation. Universal Annunciator (PCCNet) • The PCCNet Annunciator provides a visual and audible indication of the genset and ATS functions and operation. There is also a plug-in module to bring the relay count up to 16. This module allows the PCC 2100 to control up to sixteen customer loads with each having a time delay before the relays are energized. • This annunciator connects to TB2 at the bottom left in the PCC 2100.PowerCommand Control 2100 with CAN Link Introduction & CBT Review Participant's Text FT-10 Relay Module (DIM) • The new relay module is a redesigned DIM with eight standard relays. Your Notes Participant’s Guide 1-15 . Notice that this diagram is laid out based on the diagram that showed the boards inside the PowerCommand Control 3100. This is to help the technician see how the PowerCommand Control 2100 is connected to the genset.Introduction & CBT Review PowerCommand Control 2100 with CAN Link PCCNet Universal Annunciator VIS 1 7 S&TT 09/04 Visual 1-7 PowerCommand Control 2100 System Architecture Participant's Text This diagram is designed to help the technician: S understand how the PowerCommand Control 2100 components connect. and S help determine where a problem might be in the PowerCommand Control 2100 System. Your Notes 1-16 Participant’s Guide . PowerCommand Control 2100 with CAN Link Introduction & CBT Review Participant's Text There are no external standard modules with this control. All components are installed inside the control box, including the optional network module. The only components which are mounted outside the control box are the Crank and Run relays, optional relays, the network-based relay module, and the optional Universal Annunciator. Your Notes Participant’s Guide 1-17 Introduction & CBT Review PowerCommand Control 2100 with CAN Link VIS 1 8 S&TT 09/04 Visual 1-8 PCC 2101 (With CAN Link) Diagram Participant's Text This diagram is designed to help the technician: S understand how the PowerCommand Control 2101 components connect, and S help determine where a problem might be in the PowerCommand Control 2101 System. Notice that this diagram is laid out based on the diagram that showed the boards inside the PowerCommand Control 3100. This is to help the technician see how the PowerCommand Control 2100 is connected to the genset. Your Notes This diagram is like the PCC 2101 diagram showing the external and internal modules. It shows what each connector on the Base Card is used for, and is an aid in troubleshooting the PCC 2100 with CAN Link: J1 Harness for S12/S13 J2 LED Board & Bargraph J3 Membrane switches J4 Digital Display J6 NCM J7 Engine harness J8 AC Generator harness J9 InPower J10 CAN Link 1-18 Participant’s Guide PowerCommand Control 2100 with CAN Link Introduction & CBT Review Participant's Text There are no external standard modules with this control. All components are installed inside the control box, including the optional network module. The only components which are mounted outside the control box are the Crank and Run relays, optional relays, the network-based relay module, and the optional Annunciators (FT-10 and PCCNet). Your Notes Participant’s Guide 1-19 All customer connections are landed here. It has to be connected to the battery terminals.Introduction & CBT Review PowerCommand Control 2100 with CAN Link Customer Connections TB2 TB1 VIS 1 9 S&TT 09/04 Visual 1-9 Customer Connection Terminal Block TB1 Participant's Text The customer connection terminal block (TB1) is located at the bottom of the control box. 1-20 Participant’s Guide . TB2 is the terminal block to the left of TB1. Your Notes DO NOT CONNECT the Battery Charger from the ATS to TB1. It is used for connecting the optional PCCNet Annunciator. PowerCommand Control 2100 with CAN Link Introduction & CBT Review PCC 2100 Main Menu A VIS 1 10 S&TT 09/04 Visual 1-10 Main Menu A Participant's Text The first Main Menu allows the operator to view data on the engine operation. It lastly allows the operator to adjust specific operating parameters of the generator set. and several time delays. Your Notes Participant’s Guide 1-21 . It also allows the operator to view data on the operation of the alternator. Introduction & CBT Review PowerCommand Control 2100 with CAN Link PCC 2100 Main Menu B VIS 1 11 S&TT 09/04 Visual 1-11 Main Menu B Participant's Text The second Main menu allows the operator to view information on the latest and previous warnings and shutdowns (Faults). It also allows the operator to look at the status of other components on the PowerCommand Network (System). It lastly allows the operator to view a list of historical data on the operation of the control. Your Notes 1-22 Participant’s Guide PowerCommand Control 2100 with CAN Link Introduction & CBT Review PCC 2100 Main Menu C VIS 1 12 S&TT 09/04 Visual 1-12 Main Menu C Participant's Text This third Main Menu section allows the operator to view information on the type of generator set the control is operating (About). It lastly allows the operator to view the calibration setup by bypassing the setup password. Your Notes Participant’s Guide 1-23 Introduction & CBT Review PowerCommand Control 2100 with CAN Link Modes of Operation Manual Mode No Time Delays Warm-up at Idle Cooldown at Idle Automatic Mode Time Delay Start & Stop No Idle warm-up Cooldown at Idle VIS 1 13 S&TT 09/04 Visual 1-13 PCC 2100 Modes of Operation Participant's Text Manual Mode • Move Mode switch to Manual position, and • Press Manual Run/Stop switch Your Notes Automatic Mode • Move Mode switch to Auto position • PCC 2100 waits for Remote Start input 1-24 Participant’s Guide 3. 2.PowerCommand Control 2100 with CAN Link Introduction & CBT Review Manual Operation–Basic PCC 2100 LOCAL START (Manual Mode) CONTROL RUN BUTTON WARM-UP @ IDLE 1 or 2 RATED SPEED & VOLTAGE Engine Temperature greater than 100°F to switch from Idle to Rated NOTE: Cooldown at Idle on B-Series sets is set to 0 minutes. VIS 1-14 S&TT 09/04 Visual 1-14 Manual Operation Participant’s Guide 1-25 . 3 STOP NOTES: 1. Cool-down idle with software adjusted time-out. CONTROL STOP BUTTON EMERGENCY STOP BUTTON COOL-DOWN @ IDLE Cooldown at Idle = 10 min. Coolant temperature reaches operating level. Timer expires. 1-26 Participant’s Guide .Introduction & CBT Review PowerCommand Control 2100 with CAN Link Automatic Operation–Basic PCC 2100 REMOTE START (Auto Mode) EMERGENCY START TIME DELAY TO START 1 RATED SPEED & VOLTAGE REMOTE START Removed NOTE: Cooldown at Idle on B-Series sets is set to 0 minutes. VIS 1-15 S&TT 09/04 Visual 1-15 Automatic operation with a remote start signal. Coolant temperature reaches operating level. 2. Cool-down at idle with software adjusted time-out. 3. TIME DELAY TO STOP 1 COOL-DOWN @ IDLE 3 1 EMERGENCY STOP BUTTON Cooldown at Idle = 10 min. STOP NOTES: 1. Timer expires. The CAN Link is an Echelon network.J1939 c. a.TP/XF-78 Participant’s Guide 1-27 . the ECM will use its backup protocol of a. use the demonstrator or Participants’ Guide.True b.PowerCommand Control 2100 with CAN Link Introduction & CBT Review Activity 1-1: PCC 2100 with CAN Link Quiz Match the functions and components / switches. The main communication on the CAN Link is a special variation of ______ Bus. To check the CAN Link with InPower Service Tool you must connect to a. If the J1939 transceiver in the ECM fails. a. 1.J7 b.True b.J9 d.J1939 c. To check the CAN Link with InSite Service tool you must connect the InLine adapter to a.FT–10 d.False 3.C-08 6. a.C-05 b.FT–10 d.J8 c.J1208 b.C-07 d. The CAN Link is terminated with a 120 Ohm resistor at each end of the main channel.J10 5.False 2.J1208 b.TP/XF-78 4.C-06 c. I.Introduction & CBT Review PowerCommand Control 2100 with CAN Link Activity 1-2: Introduction to the PCC 2100 Quiz Match the functions and components / switches. use the demonstrator or Participants’ Guide. H. E. G. F. B. L. N. O. M. K. D. J. Acknowledge Shutdowns here Red LED “Switched B+” available Amber LED Power Amp. for exciter signal Shows 125% Current 2 lines of 20 characters each Feeds signal to Bargraph On Base card 0/Manual/Auto switch here TB2 Spanish on Front Panel TB1 Stops set NOW! Standard without Bargraph 1-28 Participant’s Guide . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PCC 2100 Digital Display Shutdown LED “0” position Warning LED LED Board Base Card Bargraph Module LED Legend Card Customer Connections Connects to PCCNet Annunciator Microprocessor Emergency Stop switch Front Panel Running LED A. C. where it originated. We then discussed the options available for the PCC 2100. We will cover the rest of the menus later in a Service Menu lesson.PowerCommand Control 2100 with CAN Link Introduction & CBT Review Wrap-Up In this lesson we have reviewed the material covered in the CBT on the PCC 2100 control. Next we talked about customer connections. We noticed it’s similar to the PCC 3100 architecture. We reviewed the installation of a PCC 2100 genset with an ATS. Lastly we reviewed the three Sequences of Operation of the PCC 2100 Control: Manual and Automatic Emergency. First we talked about the PCC 200 Control. We will have another lesson on these options later in the course. Next we talked about the system architecture. but all the components are inside the box. Participant’s Guide 1-29 . Next we talked about the control panel and the components inside the control box. Then we reviewed the menus you learned about in the CBT. and how it is different from the Detector Control. Introduction & CBT Review PowerCommand Control 2100 with CAN Link This page intentionally left blank 1-30 Participant’s Guide . Estimated Time: 2 hours Materials Needed One for each participant: PowerCommand ) Control 2100 Participant’s Guide QSX15 set with PCC 2100 Operator’s Manual Guide (CMT0686-EN–PG) Manual (961-0101) Objectives After completing this lesson. • Use the Gov/Reg menu to change governor and AVR parameters.PowerCommand Control 2100 with CAN Link Service Menus PowerCommand) Control 2100 Service Menus. • Identify the menu choices accessible without using the Application password. the participants should be able to: • Locate and identify the front panel buttons used in navigating the PowerCommand Control 2100 menus. • Use the Crank/Idle menu to monitor and change crank and idle parameters. Participant’s Guide 2-1 . The password can be changed using InPower service tool software. The default password is 574.Service Menus PowerCommand Control 2100 with CAN Link Setup Main Menu Main Menu 3 About Pwr Tran Setup More>> +Password – nnn Setup Main Menu Crank/Idle Gov/Reg VIS 2 1 S&TT 09/040 Visual 2-1 Setup Main Menu Participant's Text Once you decide to change any setup parameters. you need the password for that specific control. Your Notes 2-2 Participant’s Guide . press the lower right-hand button again to return to the Navigation Screen. When you have made the change you need. Press the “Home” button to save the changes to EEPROM. When you are at the parameter you want to change. This will change the display to the one having the +/– on the left. press the lower right-hand button next to the arrow pointing to the right.PowerCommand Control 2100 with CAN Link Service Menus Changing Parameters Gov/Reg Setup S1 Voltage L-N Navigation Screen Increase Value Decrease Value Adjustment Screen S1 Voltage L-N 208 VAC Setup Main Menu S1 Voltage L-N To Save Changes VIS 2 2 Navigation Screen S&TT 09/040 Visual 2-2 Changing Parameter Values Participant's Text Select the parameter you want to change using the Up/Down arrows on the left of the Digital Display. Your Notes Participant’s Guide 2-3 . Service Menus PowerCommand Control 2100 with CAN Link Crank/Idle Setup Menus Setup Main Menu Crank/Idle Gov/Reg VIS 2 3 S&TT 09/040 Visual 2-3 Crank/Idle Menu Participant's Text Submenu: Default Crank cycles 3 Crank Time 15 Rest Time 15 Min. 2 2 7 700 Max 7 20 40 1100 Your Notes Idle Speed 800 2-4 Participant’s Guide . PowerCommand Control 2100 with CAN Link Service Menus Gov/Reg Setup Menus Setup Main Menu Crank/Idle Gov/Reg VIS 2 4 S&TT 09/040 Visual 2-4 Gov/Reg Menu Participant's Text The Gov/Reg menu allows you to change the voltage for the control. and governor ramp time. Gain Min. frequency. Reg. Max Your Notes 3 Ph 208 1 Ph 200 3 Ph 600 60 100 50 5 0 5 60 1000 30 sec 1000 Gov Ramp 0 Gov Gain 100 Participant’s Guide 2-5 . regulator and governor gain. Submenu: Default Voltage Freq. Service Menus PowerCommand Control 2100 with CAN Link Controller Configuration Menu Main Menu 1 Engine Alternator Adjust More>> Press both buttons at the same time VIS 2 5 S&TT 09/040 Visual 2-5 Controller Configuration Menu Participant's Text The Controller configuration menu allows the technician to set the language. English Deg F PSI Max French Deg C kPa Your Notes Temp Units Deg F Press Units PSI 2-6 Participant’s Guide . temperature units. Submenu: Default Language English Min. and pressure units displayed by the control. CRANK/IDLE MENU 1. 4. 9.PowerCommand Control 2100 with CAN Link Service Menus Activity 2-1: Service Menus Using your PCC 2100 Generator Set Service Manual and the worksheet that follows. 2. 5. 10. Voltage configuration ______ Alternator frequency Regulator Gain adjust Gov Ramp time Gov Gain adjust ______ ______ ______ ______ Participant’s Guide 2-7 . 7. work through the Technician-level menus on the PowerCommand Control 2100 and simulator at your work station. Cycle Crank Number of crank attempts Crank time Rest time Idle speed ______ ______ ______ ______ ______ GOV/REG SETUP MENU 6. 3. 8. Fill in the blanks with the values you see on the PC 2100 control you are working with. 13. 17. 12. Voltage adjust Frequency adjust Start delay Stop delay Idle start ______ ______ ______ ______ ______ 2-8 Participant’s Guide . 15. 18. 16.Service Menus PowerCommand Control 2100 with CAN Link CONTROLLER CONFIGURATION MENU 11. Language selected Temperature units Pressure units ______ ______ ______ ADJUST/SETUP MENU 14. Gov/Reg d. 10 b. Crank/Idle b.PowerCommand Control 2100 with CAN Link Service Menus Technician-Level Menu Quiz Directions: Using the 960-0165 Operator’s Manual. Pwr Tran c. 100 d. 50 c. Which menu pick will get to the Idle Speed adjustment? a. Pwr Tran c. None of the above 4. Crank/Idle b. 1. 1000 Participant’s Guide 2-9 . Which menu pick will get to the Time Delay Program Transfer adjustment? a. Gov/Reg d. Gov/Reg d. Which menu pick will get to the Isolated Bus Paralleling Menu? a. Pwr Tran c. Pwr Tran c. Crank/Idle b. None of the above 5. None of the above 2. What is the maximum value for Governor Gain? a. Which menu pick will get the operator to the Regulator Gain adjustment? a. Crank/Idle b. complete the following worksheet. None of the above 3. Gov/Reg d. Frequency c. b. c. Amps b. d. how do you know the setting is changeable? a. Volts Line–Line d. 50 c. None of the above are correct. 8. in the lower right-hand corner of the Digital Display. What is the factory setting for Governor Gain? a. What indication WILL NOT be shown when the genset is powering a Delta-connected alternator? a.Service Menus PowerCommand Control 2100 with CAN Link 6. in the left-hand side of the Digital Display. Volts Line–Neutral 2-10 Participant’s Guide . 400 7. When you are in the Setup menus and you want to change a setting. 10 b. 100 d. + – in the left-hand side of the Digital Display. minimum. Are there any questions we have not yet covered on the Service Menus? Participant’s Guide 2-11 . and took a quiz on the Service Menus. First we talked about the password 5-7-4 Next we talked about the three Setup Menus: • • Crank/Idle Gov/Reg Cycle Crank and Idle parameters Governor and Regulator Parameters We then went through the choices available in these two menus. and maximum values available. Lastly we worked through the menus and recorded the settings in the controls you have at your workstations. Then we went through the Controller Configuration menu to cover the choices available in the configuration menu.PowerCommand Control 2100 with CAN Link Service Menus Wrap-Up In this lesson we have learned about the Service Menus for the PCC 2100 control. We covered the factory default settings. Service Menus PowerCommand Control 2100 with CAN Link This page intentionally left blank 2-12 Participant’s Guide . Participant’s Guide 3-1 . • Identify the parameters used in troubleshooting a PowerCommand Control 2100. • If your dongle allows. the participants should be able to: • Connect a PC running InPower service tool software to a PowerCommand Control 2100. download a calibration to a PowerCommand Control 2100.0 or later installed • InPower v 4. • Identify the parameters used in setting up a PowerCommand Control 2100.PowerCommand Control 2100 with CAN Link InPower InPower and the PowerCommand Control 2100 Estimated Time: 2 hours Materials Needed One for each participant: PowerCommand ) Control 2100 Participant’s Guide QSX15 set with PCC 2100 Operator’s Manual • PC with InPower v 4.0 User’s Guide Guide (CMT0686-EN–PG) Manual (961-0101) Provided by Participant Provided by Participant Objectives After completing this lesson. • Download a capture file from the control to your PC. • Identify the parameters used in testing a PowerCommand Control 2100. N. 3163768) Security Dongle VIS 3 1 S&TT 09/04 Visual 3-1 Connecting to a PCC 2100 with InPower software Participant's Text Be careful when connecting to the PCC 2100 with InPower. connect from your serial port to the J9 connector near the lower left corner of the Base board in the PCC 2100. You can shock the Base card enough to kill it if you are not using a wrist strap. Launch InPower and connect to the serial port and the PCC 2100 device. Your Notes 3-2 Participant’sGuide .InPower PowerCommand Control 2100 with CAN Link Connecting to a PCC 2100 PowerCommandR Control 2100 PC Running InPower J9 Connector Service Cable DB9 to DB9 (CUMMINS P. Log in to your PC using one of the security schemes discussed in the InPower class or on the CD-ROM training program. • Connect your hardware lock (dongle) to the parallel port of your PC and start the PC. • Using the Cummins cable 3163768. We will only discuss those parameters that are specific to the PowerCommand Control 2100 in this lesson. Your Notes Participant’s Guide 3-3 . and • Test You learned about the major parts of InPower in the InPower CBT or class you attended.PowerCommand Control 2100 with CAN Link InPower InPower Service Tool Software VIS 3 2 S&TT 09/04 Visual 3-2 In-Power service software connected to a PCC 2100 with CAN Link Capture file Participant's Text When you connect to a PowerCommand Control 2100 with CAN Link you will see six major headings of parameters: • Adjustments • CAN Link • Events and Faults • Faults • Monitor. You can also set the color of the individual LEDs.InPower PowerCommand Control 2100 with CAN Link Features / Custom Displays VIS 3 3 S&TT 09/04 Visual 3-3 Custom Displays Participant's Text The Custom Displays parameters allow you to set the event and/or fault which turns on the five configurable LEDs on the control panel of the PCC 2100. Your Notes On the next page we will look at the table that sets the event or fault which lights the LEDs. and whether the LED is enabled. 3-4 Participant’sGuide . You can set the event or fault number in the right column • Select the cell you want to put data into. Participant’s Guide 3-5 . • The data appears in the correct cell.PowerCommand Control 2100 with CAN Link InPower Configurable Indicators Mapping VIS 3 4 S&TT 09/04 Visual 3-4 Configurable Indicators mapping table Participant's Text You can set the name of the event or fault in the left column. Your Notes Remember to save the data before you close the window. • Enter the data and press on the check mark button. • Go to the cell by the green check mark. InPower PowerCommand Control 2100 with CAN Link Features / Customer Outputs VIS 3 5 S&TT 09/04 Visual 3-5 Customer Outputs Participant's Text These parameters allow you to enable or disable the Customer Outputs. You can also see if the driver is on or off. Your Notes 3-6 Participant’sGuide . • Enter the data and press on the check mark button. Remember to save the data before you close the window.PowerCommand Control 2100 with CAN Link InPower Features / Customer Output Mapping VIS 3 6 S&TT 09/04 Visual 3-6 Customer Output Mapping Participant's Text This table allows you to set the event or fault which activates each of the four Customer Output relays on the Base Board. Your Notes Participant’s Guide 3-7 . You can set the event or fault number in the right column • Select the cell you want to put data into. • Go to the cell by the green check mark. You can set the name of the event or fault in the left column. • The data appears in the correct cell. InPower PowerCommand Control 2100 with CAN Link Features / Power Down Conditions VIS 3 7 S&TT 09/04 Visual 3-7 Power Down Conditions Participant's Text This folder allows you to enable the “sleep” mode for the PCC 2100. Your Notes 3-8 Participant’sGuide . or if the NCM is installed The time delay has to be between 1 and 600 seconds. The PCC 2100 will not go to sleep if the Service tool is connected. and the Idle warmup and cooldown timers.PowerCommand Control 2100 with CAN Link InPower Features / Warmup/Cooldown VIS 3 8 S&TT 09/04 Visual 3-8 Warmup/Cooldown Participant's Text These parameters allow you to set the start and stop delays. • Start Delay Default 0 • Stop Delay Default 0 • Idle Warmup Default 10 • Idle Cool Down Default 10 0 – 300 seconds 0 – 600 seconds 0 – 300 seconds 0 – 30 minutes Your Notes Participant’s Guide 3-9 . • Custom Annunciation Custom Annunciator for LSA or DIM • Customer Outputs Custom Relays for DIM Customer output relays • Device Information for advanced networks • Dialout Information for advanced networks • Fault Settings Annunciation of DIM customer inputs on PCC 2100 3-10 Your Notes Participant’sGuide .InPower PowerCommand Control 2100 with CAN Link Network Parameters VIS 3 9 S&TT 09/04 Visual 3-9 Network parameters in InPower Participant's Text InPower allows technicians to set up several sets of network parameters for use in self-installed or more advanced FT-10 networks. PowerCommand Control 2100 with CAN Link InPower Customer Switch Setup VIS 3 10 S&TT 09/04 Visual 3-10 Customer Switch Setup Participant's Text This folder allows you to set the four Customer Switches: • Enabled or Disabled • Active Closed or Open • The Name displayed on the Digital Display when the event is true. and • High Alt Temp Your Notes Participant’s Guide 3-11 . The default names are: • Customer Fault 1 • Ground Fault • Low Fuel. Your Notes 3-12 Participant’sGuide . The key switch override is used when programming the ECM with InSite Service Tool software.InPower PowerCommand Control 2100 with CAN Link CAN ECM Inputs & Outputs VIS 3 11 S&TT 09/04 Visual 3-11 CAN ECM Inputs & Outputs Participant's Text These parameters display engine sender and sensor values. Your Notes Participant’s Guide 3-13 . you could have a failed device instead of a problem with the CAN Link. If one device can communicate on the Link but the other cannot. it sets a fault that it cannot communicate on the CAN Link. When either the ECS or GCS cannot “hear” the CAN Link.PowerCommand Control 2100 with CAN Link InPower CAN Faults VIS 3 12 S&TT 09/04 Visual 3-12 CAN Faults Participant's Text These parameters are most useful when troubleshooting the CAN Link. • CAN Failure Delay – The delay from loss of communications on the CAN Link until a shutdown Fault occurs.InPower PowerCommand Control 2100 with CAN Link CAN Settings VIS 3 13 S&TT 09/04 Visual 3-13 CAN Settings Participant's Text These parameters are time delays for the CAN Link. Your Notes 3-14 Participant’sGuide . • Key On Time – time after turning the ECM “ON” that the CAN Link is checked for communications. • Reset Delay – The amount of time the ECM is turned off during a Fault Reset. It shows: • Event or Fault Number • A Description of the event or fault • Fault Effect (Shutdown. except for three faults: • • • Your Notes Participant’s Guide 3-15 .PowerCommand Control 2100 with CAN Link InPower Events and Faults VIS 3 14 S&TT 09/04 Visual 3-14 Events and Faults Participant's Text This folder contains a list of all events and faults. Warning. Event. None) • Notification (dialout or not) • Bypass You can set each whether the event or fault is bypassed or not bypassed. Make sure these relays are enabled in InPower. Configure customer output relays 1 and 2 as shown below: Pre-LOP Pre-HET • Relay 1 • Relay 2 6. verify the Warmup and Cooldown delays operate as you have programmed them. Using the simulator and the Test parameters of InPower software. Use a meter on appropriate TB1 terminals to verify relay contact closure. verify the relays operate as you have programmed them. verify the LEDs operate as you have programmed them. Using the simulator and the test parameters of InPower software. Connect to a PowerCommand Control 2100 with InPower software on your PC. Make a capture file of your PCC 2100 before making any adjustments !!! Set the LED parameters as as shown below: Red Green • Configurable LED 1 Color • Configurable LED 3 Color 4. 3. Using the simulator and the Test parameters of InPower software. • Idle warm–up • Idle cooldown 8. 3-16 Participant’sGuide . • Using the simulator and the Test parameters of InPower software. Configure the Warmup/Cooldown parameters as shown below: 5 seconds 1 minute 7. Make sure that these LED indicators are enabled in InPower.InPower PowerCommand Control 2100 with CAN Link Activity 3-1: Adjust PowerCommand Control 2100 parameters: 1. 5. verify the relays operate as you have programmed them. 2. and their factory settings. the control will not go to sleep. or if the S12 Mode switch is not in the “0 position. We changed the color of some of the LEDs on the front of the PCC 2100 and also changed the fault or event they represented. Does anyone remember the three faults that cannot be bypassed? • • • Lastly we looked at the test parameters for the PCC 2100. Participant’s Guide 3-17 . Next we discussed the relay outputs for K1–K4 on the Base Board. Then we talked about Idle warm–up and Cooldown. Then we looked at setting up the nvoCustomAnnun table for binding to an annunciator if your customer wants something other than NFPA110 annunciation.PowerCommand Control 2100 with CAN Link InPower Wrap-Up In this lesson we have reviewed using InPower software with the PCC 2100 and its options for the PowerCommand Network. We also set up the nvoCustomRelays table to operate the DIM relays. First we talked about connecting to the PCC 2100 at J9 with the null-modem cable. Next we talked about the Adjust parameters. Next we looked at setting the “Bypass” setting for an event or fault and the three faults that cannot be bypassed. or if InPower is connected. Next we talked about putting the PCC 2100 to sleep and found that if the NCM is installed. their default uses and how to reset them for other events and faults. You already know that you can set up oil pressure or coolant temperature and override the sensor so the control only sees the test input. InPower PowerCommand Control 2100 with CAN Link This page intentionally left blank 3-18 Participant’sGuide . the participants should be able to: • Locate and use the troubleshooting information in the Service Manual. Estimated Time: 2 hours Materials Needed Module overhead set or slide set One for each participant: PowerCommand ) Control 2100 Participant’s Guide QSX15 set with PCC 2100 Service Manual PC with InPower software Guide (CMT0686-EN-TG) Manual (960-0522) provided by participants Objectives After completing this lesson. • Use the InPower service tool to isolate problems on a generator set to the failed component.PowerCommand Control 2100 with CAN Link Troubleshooting Troubleshooting the PCC 2100 and the PCC 2100 with CAN Link. Participant’s Guide 4-1 . Look at the LEDs on the Switch panel and in the Control Box. and measure.Troubleshooting PowerCommand Control 2100 with CAN Link Key Troubleshooting Points Good Visual and Audible inspection Interpret data and LEDs Proper meter use Static protection – wrist strap Use troubleshooting charts and other data Write down your readings OH4 1 S&TT 12/01 Slide 4-1 Key Troubleshooting Points Participant's Text One of the most important troubleshooting points is to make a good visual inspection of the generator set – see what looks bad. Your Notes 4-2 Particpant’s Guide . You will need to read and interpret wiring diagrams. Listen to the set as it starts. hear. runs. and stops. Look at the graphical display on the Operator panel. Use the troubleshooting charts and other troubleshooting data you receive in school and from other technicians. Write down what you see. Write down what you see before you change the indications. PowerCommand Control 2100 with CAN Link Troubleshooting Troubleshooting Tools InPower service software Fault Listing (Active/Inactive) Strip Chart Test Function True RMS meter CAN Link Troubleshooting Tools InSite Service Tool Software InLine II or InLine IV Adapter OH4 2 S&TT 2/99 Slide 4-2 Troubleshooting tools Participant's Text InPower service software has several nice features which can be very useful in troubleshooting a PowerCommand Control 2100 generator set. Participant’s Guide 4-3 . Your Notes If you use the Test parameters you MUST make sure you disable the override of sensor functions before you leave the set. • InPower also has a test function with which you can tell the control to ignore the reading from the sensor and use a parameter value you input. • List of Active and Inactive faults by time and date of occurrence. This is not available with the 2100 with CAN Link. InPower v 4.50 will remind you to disable tests before you close the port. • Strip chart to look at parameters over a period of time. Troubleshooting PowerCommand Control 2100 with CAN Link Participant's Text True RMS meter Your Notes CAN Link Tools InSite Service Tool Software InLine II or InLine IV Adapter 4-4 Particpant’s Guide . and the generator set. The technician still uses wiring diagrams to determine if the harness is connected properly. The technician still uses schematic diagrams to determine if the control is operating properly.PowerCommand Control 2100 with CAN Link Troubleshooting How is Troubleshooting Similar? Technician has to interpret data Technician has to use a meter properly Technician has to use diagrams Wiring – Parts Placement Schematic – Sequence of Operation OH4 3 S&TT 10/00 Slide 4-3 How is troubleshooting the PCC 2100 similar to troubleshooting other controls? Participant's Text The technician still has to interpret the data given by the customer. operator. The technician still uses a good meter to test voltages. Your Notes Participant’s Guide 4-5 . currents. and resistances. You are generally looking for ground signals. the Operator panel Digital Display. and the InPower service tool. A software tool is needed to check the engine sensors. Your Notes 4-6 Particpant’s Guide . the LEDs on circuit boards and modules. You cannot just remove a fuse to check overcrank problems.Troubleshooting PowerCommand Control 2100 with CAN Link How is troubleshooting different? Static Damage possible Ground signals Test kit for LOP & HET Must crank engine for OC fault Technician uses new diagnostic guide OH4 4 S&TT 10/00 Slide 4-4 How is troubleshooting the PCC 2100 different than troubleshooting other controls? Participant's Text You can be a cause of more damage to the control than the original problem due to static electricity. You cannot ground out the HET and LOP senders to simulate a warning or shutdown. You have to deduce the proper troubleshooting procedure from the Switch panel LEDs. Your Notes Participant’s Guide 4-7 . The Digital Display panel shows the code for that specific fault and gives a short description of the nature of the fault.PowerCommand Control 2100 with CAN Link Troubleshooting Troubleshooting Aids Service Manual Digital Display Operator Manual – Oil Pressure values InPower software InSite software — CAN Link controls InLine Adapter — CAN Link controls OH4 5 S&TT 10/00 Slide 4-5 Troubleshooting tables in the Service Manual Participant's Text The Genset Service Manual for gensets using the PCC 2100 include a troubleshooting section which lists all fault codes and troubleshooting procedures for each fault. The technician uses the InPower service software tool to check signals inside the Base card. The technician uses the Troubleshooting section of the manual to determine where to check for proper and improper indications. Your Notes 4-8 Particpant’s Guide .Troubleshooting PowerCommand Control 2100 with CAN Link Participant's Text The InPower service tool can also be used to troubleshoot problems by replacing a real signal in the genset control with a test signal. A table of Running and Idle Oil Pressure values are shown in the Operator’s Manual for each genset family. Your Notes Participant’s Guide 4-9 . and calibrate the Cummins CM570 ECM on the engine. just because you have a certain shutdown does not mean that the engine or generator information is not available for troubleshooting. Section 9 in the Service Manual has CPG prints that might help you in troubleshooting some problems. InLine Adapter These adapters are needed to allow InSite to communicate with the ECM. currents. engines will have multiple ECMs on them to handle the complex systems on the engine. Remember. The PCC has an RMS-type metering system built in which can display many different voltages. InSite software This software is used to monitor. and pressures to assist you in its troubleshooting. In the future.PowerCommand Control 2100 with CAN Link Troubleshooting Participant's Text Page 2-7 in the Service Manual shows the Main Menus and what is available from the Operator panel menu display. You can use the Sequence of Operation prints to help troubleshoot crank and run problems also. test. the ECM starts to send out signals on the J1939 Bus. Your Notes 4-10 Particpant’s Guide . and turn the Key Switch on. connect the battery. Tests Using InLine Adapter When you connect the InLine II or InLine IV adapter to C-05 on the engine. CAN Status Fault If either the PCC 2100 or the ECM can not “hear” the CAN Link. These two faults have different fault codes so you can tell them apart.Troubleshooting PowerCommand Control 2100 with CAN Link Troubleshooting the CAN Link CAN Status Fault Testing with InLine Adapter Disconnect CAN Link from J10 Monitor PCC 2100 with InPower Monitor ECM with InSite OH4 6 S&TT 2/99 Slide 4-6 Troubleshooting the CAN Link Participant's Text The CAN Link is the communications path between the PCC 2100 and the CM570 ECM on the QSX15 G-Drive engine. they set a fault. If there is no change after re-connecting the CAN Link to J10. you can see if the CAN Link wiring is OK or bad. If the fault goes inactive. Your Notes Participant’s Guide 4-11 . the wiring harness may be bad. you would see the CAN Communication fault set there also. Monitor PCC 2100 with InPower When you monitor the PCC 2100 with InPower. you can see if the CAN Link wiring is OK or bad.PowerCommand Control 2100 with CAN Link Troubleshooting Participant's Text Disconnect J10 in PCC 2100 When you disconnect the CAN Link from the PCC 2100. If the fault goes inactive. If you were to look inside the ECM with InSite. both the PCC 2100 and the ECM will set a CAN Communication Fault. Monitor ECM with InSite When you monitor the ECM with InSite. the wiring harness is OK. If there is no change after reconnecting the CAN Link to J10. the wiring harness is OK. the wiring harness may be bad. Troubleshooting PowerCommand Control 2100 with CAN Link Activity 4-1: Troubleshooting exercises Using the Service Manual (960-0522) and the Sequence of Operation wiring diagrams provided earlier in the course. Problem #1 What is the problem on this unit? The generator set shuts down on low oil pressure. Where should you check for this problem? On what page of the Service Manual did you find a procedure for troubleshooting this problem? What did you check to solve the problem? What should the voltage be at the points you checked – with good oil pressure? What would the voltage be at the points you checked – with 10 PSI of oil pressure? 4-12 Particpant’s Guide . InPower shows the same pressure as the Engine menu – 10 PSI. determine where you would check to solve the problems shown below. You should be able to determine what voltage or resistance would be a good value at the test point you select for each problem. PowerCommand Control 2100 with CAN Link Troubleshooting Problem #2 What is the problem on this unit? The generator set shuts down on high coolant temperature. the Engine menu shows 235° F also. InPower shows 235° F. Where should you check for this problem? On what page of the Service Manual did you find a procedure for troubleshooting this problem? What did you check to solve the problem? What should the voltage be at the points you checked – with good coolant temperature? What would the voltage be at the points you checked – with 235° F coolant temperature? Participant’s Guide 4-13 . InPower shows 265 Deg F.Troubleshooting PowerCommand Control 2100 with CAN Link Problem #3 What is the problem on this unit? The generator set shows a high oil temperature warning. as does the engine menu. Where should you check for this problem? On what page of the Service Manual did you find a procedure for troubleshooting this problem? What did you check to solve the problem? What should the voltage be at the points you checked – with good oil temperature? What would the voltage be at the points you checked – with 265 Degrees F oil temperature? 4-14 Particpant’s Guide . The instructor will be able to change the problems on the demonstrator units as the troubleshooting continues. Using the Service Manual provided by the instructor solve the problems on as many demonstrator units as you can.PowerCommand Control 2100 with CAN Link Troubleshooting Activity 4-2: Troubleshooting PowerCommand Control 2100 systems. Problem #1 What is the problem on this unit? On what page of the Service Manual did you find an explanation of what could cause this problem? On what page of the Service Manual did you find a procedure for troubleshooting this problem? What did you check to solve the problem? What diagrams did you use to help determine how to troubleshoot the problem if there was no procedure in the Service Manual? Participant’s Guide 4-15 . Troubleshooting PowerCommand Control 2100 with CAN Link Problem #2 What is the problem on this unit? On what page of the Service Manual did you find an explanation of what could cause this problem? On what page of the Service Manual did you find a procedure for troubleshooting this problem? What did you check to solve the problem? What diagrams did you use to help determine how to troubleshoot the problem if there was no procedure in the Service Manual? 4-16 Particpant’s Guide . PowerCommand Control 2100 with CAN Link Troubleshooting Problem #3 What is the problem on this unit? On what page of the Service Manual did you find an explanation of what could cause this problem? On what page of the Service Manual did you find a procedure for troubleshooting this problem? What did you check to solve the problem? What diagrams did you use to help determine how to troubleshoot the problem if there was no procedure in the Service Manual? Participant’s Guide 4-17 . Troubleshooting PowerCommand Control 2100 with CAN Link Problem #4 What is the problem on this unit? On what page of the Service Manual did you find an explanation of what could cause this problem? On what page of the Service Manual did you find a procedure for troubleshooting this problem? What did you check to solve the problem? What diagrams did you use to help determine how to troubleshoot the problem if there was no procedure in the Service Manual? 4-18 Particpant’s Guide . PowerCommand Control 2100 with CAN Link Troubleshooting Problem #5 What is the problem on this unit? On what page of the Service Manual did you find an explanation of what could cause this problem? On what page of the Service Manual did you find a procedure for troubleshooting this problem? What did you check to solve the problem? What diagrams did you use to help determine how to troubleshoot the problem if there was no procedure in the Service Manual? Participant’s Guide 4-19 . Troubleshooting PowerCommand Control 2100 with CAN Link Problem #6 What is the problem on this unit? On what page of the Service Manual did you find an explanation of what could cause this problem? On what page of the Service Manual did you find a procedure for troubleshooting this problem? What did you check to solve the problem? What diagrams did you use to help determine how to troubleshoot the problem if there was no procedure in the Service Manual? 4-20 Particpant’s Guide . .With the InLine Adapter connected to the ECM. . The PCC 2100 should display a CAN Link fault after its time delay.Verify that the CAN Link fault in the CM570 ECM has also gone inactive. .PowerCommand Control 2100 with CAN Link Troubleshooting Activity 4-3: CAN Link Troubleshooting Demonstration Connect PC running InSite and InLine II or InLine IV Adapter to C-05 of QSX15-powered genset engine harness. Connect batteries in correct polarity to QSX15-powered genset. disconnect the CAN Link from J10 in the PCC 2100. .Reconnect the CAN Link cable to J10 in the PCC 2100. Verify the PCC 2100 with CAN Link does not display any CAN Faults. acknowledge them to see if they clear. . J1939 LED on InLine Adapter should start flashing as soon as the ECM completes its power up tests.The CAN Link fault in the PCC 2100 should go inactive after a short time delay.Reset all faults. When there are no CAN Faults displayed on the PCC 2100 go to the next step. . Participant’s Guide 4-21 . If there are any CAN Faults.Check in the CM570 ECM on the engine to verify it also shows a CAN Link fault. C-05 to Adapter & PC PCC 2100 ECM CAN Link Cable It helps if you think “big picture” like when you are at the first stages of troubleshooting a genset & transfer switch problem. Lastly we did some actual troubleshooting of controls with troubles installed by the Instructor. Did these problems help you to hone your troubleshooting skills? Are there any questions we have not yet covered on troubleshooting the PCC 2100? 4-22 Particpant’s Guide .Troubleshooting PowerCommand Control 2100 with CAN Link Wrap-Up In this lesson we have reviewed troubleshooting the PCC 2100 control. What type of meter do we recommend? We then went through several troubleshooting scenarios as a group to get some quick experience on the control system and prints. What are some good troubleshooting strategies? S S S Next we talked about troubleshooting tools. First we talked about troubleshooting strategies. remembering how to troubleshoot effectively and efficiently. PowerCommand Control 2100 with CAN Link Options PowerCommand Control 2100 Options Estimated Time: 2 hours Equipment Needed Overhead projector and screen or PC with LCD Projector and screen PowerCommand Control 2100 and simulator for each pair of participants Several NCMs for installation practice. Materials Needed Module overhead set or slide set One for each participant: PowerCommand ) Control 2100 Participant’s Guide QSX15 set with PCC 2100 Service Manual Guide (CMT0686-EN-TG) Manual (960-0522) Participant’s Guide 5-1 . let’s look at the objectives for this lesson: Objectives After completing this lesson.Options PowerCommand Control 2100 with CAN Link Warm Up In this lesson we are going to learn about some of the options available for the PowerCommand Control 2100. • Check out options for the PowerCommand Control 2100. 5-2 Participant’s Guide . the participants should be able to: • Identify options for the PowerCommand Control 2100. We will look at the modules and be able to identify them by the end of the lesson. First. • Install options for the PowerCommand Control 2100. etc. Install Wiring Harness Battery Connected Download Proper Calibration Test Generator Set VIS 5 1 S&TT 09/04 Visual 5-1 Installation Steps for PowerCommand Control 2100 Options Participant's Text Disable the battery charger then disconnect the battery – Negative cable first. Your Notes Participant’s Guide 5-3 . Install the new Base card. etc.PowerCommand Control 2100 with CAN Link Options Installing Options Battery Disconnected Static Wrist Strap Install Option Card. Test the generator set with the new option to verify proper operation. Reconnect battery and enable the battery charger. Using InPower service software enable the feature(s) or set the required parameters. Connect your wrist strap and remove cover(s). Install the wiring harness for the option. Install other modules. The DIM allows the PCC 2100-controlled genset to control customer devices. 5-4 Participant’s Guide . and to receive inputs from other network devices. Your Notes The PCCNet Annunciator can be used alone or with the LonWorks devices.Options PowerCommand Control 2100 with CAN Link PCC 2100 Options FT-10 Network Options Network Communications Module Relay Module (DIM) LonWorks Annunciator (LSA) PCCNet Options Universal Annunciator VIS 5-2 S&TT 04/2004 Visual 5-2 PowerCommand Control 2100 Options Participant's Text The LonWorks card is used to allow this GenSet to operate as a node on the PowerCommand Network. It connects to TB2 in the PCC 2100. and normal operation. The LSA is used with FT-10 networks to let the operator know of warnings. shutdowns. Your Notes Participant’s Guide 5-5 .PowerCommand Control 2100 with CAN Link Options Network Module Connects to J6 on Base card S4 Network Address J32 . The network card must be installed if the customer wants an annunciator or external relays to operate equipment.Network Data cable VIS 5 3 J30 Network Data wires S&TT 09/04 Visual 5-3 Network Communication Module 327-1275 (FTT-10) Participant's Text Network Communication Module (NCM) The NCM is used to let the PCC 2100 communicate on the FT-10 PowerCommand network. The relays can be set up with InPower to have a delay before energizing of up to 255 seconds.Network Expansion Module (optional) J4 .NC J6 .NO S&TT 12/01 Visual 5-4 Network DIM Module Participant's Text DIM Base Module This part of the DIM is required as it has the Neuron chip.Customer Inputs (5–8) J3 .Common J1 .NO VIS 5 4 J2 .Customer Inputs (1–4) J3 .Common J7 . terminator. and network connector.NC J8 . It has eight relays and four customer inputs.Options PowerCommand Control 2100 with CAN Link DIM Connectors Base Module (required) J1 . Your Notes 5-6 Participant’s Guide . the customer has sixteen relays and eight customer inputs. All relays and customer inputs are used as network inputs or outputs for the PCC 2100 when the DIM is configured as a Custom Relay Module. and is called the DIM Expansion Module. Your Notes Participant’s Guide 5-7 . When you have both parts of the DIM connected.PowerCommand Control 2100 with CAN Link Options Participant's Text DIM Expansion Module This part is optional. It has eight relays and four customer inputs. Options PowerCommand Control 2100 with CAN Link LonWorks System Annunciator VIS 5 5 S&TT 09/04 Visual 5-5 LonWorks System Annunciator Participant's Text The LonWorks System Annunciator (LSA) is the annunciator for FT-10 SelfInstalled or LonMaker-installed networks. The annunciator data wires come from the NCM in the genset or ATS control. the genset control and/or transfer switch must have an FT-10 Network Communications Module (NCM). Your Notes Note that this annunciator has the blank spaces at the bottom – that is the recognition factor for the FT-10 annunciator. To use this annunciator. 5-8 Participant’s Guide . It will not work with FT-10 networks. Note that this annunciator has the blank spaces at the top – that is the recognition factor for the PCCNet annunciator. Your Notes The annunciator data wires come from TB2 in the PCC 2100. Participant’s Guide 5-9 . Older PCC 2100s must have an update calibration installed to allow them to communicate on PCCNet.PowerCommand Control 2100 with CAN Link Options Universal (PCCNet) Annunciator PowerCommand Genset Supplying Load Charger AC Failure Low Coolant Level Low Fuel Level Check Genset Not In Auto Genset Running High Battery Voltage Low Battery Voltage Weak Battery Fail to Start Low Coolant Temp Pre-High Engine Temp Silence/ High Engine Temp Lamp Test Pre-Low Oil Pressure Low Oil Pressure Network Overspeed VIS 5 6 S&TT 09/04 Visual 5-6 PCCNet Universal Annunciator Participant's Text This annunciator is used with PCCNet networks. Connect Fused B+ (TB1-1 in the PCC 1301) to B+ (TB1-16 on the Annunciator) . 2. Place PCC 2100 Mode Switch in Off or Manual position. Put on your wrist strap. 7. turn off the power switch on the simulator. 3. Not in Auto LED on the Annunciator should light. Turn simulator power on. Connect the Universal Annunciator to TB1 in the PCC 1301: . Power Off all power supplies When your control has been powered down. 5-10 Participant’s Guide . 6. 4. the Annunciator should show a “waterfall of color” as it powers up.Connect Data–B (TB1-3 in the PCC 1301) to Data–B (J2-4 on the Annunciator) .Connect Ground (TB1-4 in the PCC 1301) to Ground (TB1-15 on the Annunciator) 5.Connect Data–A (TB1-2 in the PCC 1301) to Data–A (J2-3 on the Annunciator) .Options PowerCommand Control 2100 with CAN Link Activity 5-1A: Connecting a Universal Annunciator and a PCC 1301 in a PCCNet network Universal Annunciator 1. Recheck all connections. 3.Connect Fused B+ (TB1-17 in the PCC 2100) to B+ (TB1-16 on the Annunciator) . and a PCC 2100 in a PCCNet network Universal Annunciator 1. turn off the power switch on the simulator. Place PCC 2100 Mode Switch in Off or Manual position. the Annunciator should show a “waterfall of color” as it powers up. Participant’s Guide 5-11 .Connect Data–B (TB2-2 in the PCC 2100) to Data–B (J2-4 on the Annunciator) .Connect Data–A (TB2-1 in the PCC 2100) to Data–A (J2-3 on the Annunciator) . Connect the Universal Annunciator to TB2 and TB1 in the PCC 2100/2101: . Power Off all power supplies When your control has been powered down. Recheck all connections.PowerCommand Control 2100 with CAN Link Options Activity 5-1B: Connecting a Universal Annunciator. 7. Not in Auto LED on the Annunciator should light. Put on your wrist strap.Connect Ground (TB1-22 in the PCC 2100) to Ground (TB1-15 on the Annunciator) 5. 4. Turn simulator power on. 6. 2. not Shutdown alarm.Instructor Checkpoint 4. not Shutdown alarm. .Instructor Checkpoint 7. . Configure the Annunciator for Legacy NFPA 110 annunciation. 2. 5-12 Participant’s Guide .Overspeed shutdown. . Change back to standard operation by downloading the capture file you took before starting this exercise ack into the PCC 1301 control. Configure Relay #1 on the Annunciator for “Not in Auto” fault.Instructor Checkpoint 6. Demonstrate the operation of this relay by placing the Mode Switch or Operator Panel in the Manual or Off mode.High Coolant Temperature – Pre-Alarm. Demonstrate these three faults with the PCC 1301 and Universal Simulator. Demonstrate Customer Fault 1 on the Universal Simulator. Demonstrate that the relay does not operate on “Not in Auto” fault. . . .Options PowerCommand Control 2100 with CAN Link Activity 5-2: Configure a PCCNet Annunciator 1. 3.Low Oil Pressure – Pre-Alarm. 5. and N3 when setting the Annunciator to display battery voltage from only a Weak Battery input? a. Where does the Data A wire connect to the Operator Panel? a. and the PCC 1301 Generic Installation Diagram. Where is Battery B+ normally connected to the Universal Annunciator? a. Where does the Data A wire connect to the Base Board? a. On–Off–Off c. J13 2. J11 c.PowerCommand Control 2100 with CAN Link Options Activity 5-3: PCCNet Quiz Directions: Using the 900-0301 Operator’s Manual. InPower Adjustment parameters. complete the following worksheet. Off–Off–Off b. N2. TB1-2 c. On–Off–On d. TB1-1 Participant’s Guide 5-13 . TB1-4 b. Where does the Universal Annunciator connect to the Base card? a. TB1-16 3. What is the light pattern of N1. TB1-1 b. J1-1 b. TB1-3 c. TB1-2 d. TB1 b. J12 d. TB1-15 d. J1-4 5. On–On–Off 4. J1-3 d. 1. J1-2 c. Where does the Data B wire connect to the Annunciator? a. Red d. 10. the top LED will be a. Off–Off–Off b. To set the color and flash of an LED to “flashing red” in the book. and N3 will be a. the pattern of N1. – c. To configure the Network Configuration Address. the pattern of N1. On–Off–On b. 9. N2. None of the above. First we talked about the optional modules 5-14 Participant’s Guide .Options PowerCommand Control 2100 with CAN Link 6. J2-1 b. you would use the line that shows a. To configure the Universal Annunciator to NFPA 110. Green b. Off–Off–Off c. J2-4 7. None of the above. On–Off–Off c. R b. On–Off–Off d. Off–On–Off d. J2–2 c. To configure the Network Configuration Address. and N3 will be a. On–On–Off Wrap-Up In this lesson we have learned about the optional devices used with the PCC 2100 control. J2-3 d. Amber c. N2. On–On–Off 8. >R< d. PowerCommand Control 2100 with CAN Link Options • NCM • DIM • LSA • Universal Annunciator Next we talked about the module connectors and identification • • • • DIM Base module connectors DIM Expansion module connectors LSA identification factor Universal Annunciator identification factor Lastly we worked through the exercises to see if you understand the information in this lesson. Are there any questions we have not yet covered on the Service Menus? Participant’s Guide 5-15 . Options PowerCommand Control 2100 with CAN Link This page intentionally left blank 5-16 Participant’s Guide . • Test the the Universal Annunciator with the PCC 1301 genset control and simulator. • Configure the Universal Annunciator used with PCCNet and the PCC 1301-controlled gensets. Participant’s Guide 6-1 . the participants should be able to: • Connect the Universal Annunciator to the PCC 1301 genset control and simulator.PowerCommand Control 2100 with CAN Link PCCNet PCCNet Network for the PCC 1301 and PCC 2100 Estimated Time: 2 hours Materials Needed One for each participant: PowerCommand Control 1301 Participant’s Guide Universal Annunciator Operator’s Manual Guide (CMT0948-EN-PG) Manual (900-0301) Objectives After completing this lesson. PCCNet PowerCommand Control 2100 with CAN Link PCCNet and You 2 Wire RS 485 Data Connection 2 Wire Power Connection All wires from TB1 on PCC 1301 Control All wires from TB2 on PCC 2100 Control Up to 4. Configuration switch on Annunciator has three more positions. Standard FT-10 Network cable preferred for data. Only NFPA-110 available now.000 feet maximum network length with no terminations needed. Your Notes 6-2 Participant’sGuide . Present Maximum is 18 devices. This may increase.000 feet network data wire length No Terminations Required 18 Devices Total (12/8/04) NFPA 110 only NOW VIS 6 1 S&TT 10/00 Visual 6-1 PCCNet Information Participant's Text Two Data Wires and Two Power wires needed. Data terminals are TB1-2 and TB1-2 Power Terminals are TB1-1 (+) and TB1-4 Up to 4. PowerCommand Control 2100 with CAN Link PCCNet PCCNet Connection Locations PCC 1301 PCC 2100 VIS 6 2 S&TT 12/04 Participant’s Guide 6-3 . B+. Gnd • TB2 Customer Inputs 9-20 • TB3 Relay Outputs K3-K6 The Connector: • J2 PCCNet Connections Your Notes 6-4 Participant’sGuide .PCCNet PowerCommand Control 2100 with CAN Link Universal Annunciator J2 TB3 Data 1 Data 2 Data 1 and Data 2 are Polarity Sensitive TB1 VIS 6 3 TB2 S&TT 10/00 Visual 6-2 Universal Annunciator Participant's Text The PCCNet Universal Annunciator has Network and Physical inputs. It can replace the 300-4510 and 300-4511 Annunciators. There are three Terminal Blocks: • TB1 Customer Inputs 1-8. and how each LED is configured: • Red. Orange. • Steady or Flashing • Horn or Silent • Positive or Negative Input • Normal or Inverted display • Global Horn Your Notes Participant’s Guide 6-5 . or Green.PowerCommand Control 2100 with CAN Link PCCNet Participant's Text 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. note that the N3 LED flashes once per second. N2.PCCNet PowerCommand Control 2100 with CAN Link Configuring the Annunciator S1 S2 S3 N1. N3 VIS 6 4 S&TT 10/00 Visual 6-3 Configuring the Universal Annunciator Participant's Text After powering up the Annunciator. Your Notes 6-6 Participant’sGuide . Press and Hold S1 in for at least five (5) seconds. Refer to the chart on the next page. and N3 LEDs should be out. • S2 cycles through each of the 20 LEDs in sequence from DS1 to DS20. N2. • S3 selects Predefined Configuration • S1 moves you through the table from top to bottom. N1. /Pos Input Select Network Configuration Address Positive ! Negative ! ** 1 (NFPA 110) 2 3 4 Color and Flash for Individual LEDs Press <S2> to cycle through each of 20 LEDs > > > < < < Solid Green Solid Yellow Solid Red Flashing Green Flashing Yellow Flashing Red Disabled Audible Alert with Individual LEDs Press <S2> to cycle through each of 20 LEDs Press <S2> to cycle through each of 20 LEDs Disabled Enabled Invert Active Signal for Individual Inputs (Change one input to B+ or B–) ** Don’t Invert Invert Global Horn Enable Disabled Enabled-Soft ! Enabled-Loud ! Factory Defined * Default when Legacy Predefined Table Selected ** Default when NFPA 110 Predefined Table Selected Participant’s Guide 6-7 . 12. Bottom LED] <S3> Value Predefined Configuration Table Report Battery Voltage in Status LEDs 11. . 13 No Change ! Legacy NFPA 110 ** Don’t Report ! Report 12 V Report 24 V Report 12V Hi–Low Report 24V Hi–Low Neg. .PowerCommand Control 2100 with CAN Link PCCNet Universal Annunciator Configuration Table Function Config LEDs [N3 N2 N1] <S1> Select Individual Input/LED <S2> Front Panel LED Selection [Top LED . Make sure you look at DS1 – DS20 as you configure the Annunciator.PCCNet PowerCommand Control 2100 with CAN Link Configuring the Annunciator S1 S2 S3 N1. 6-8 Participant’sGuide . N2. N3 VIS 6 5 S&TT 10/00 Visual 6-4 Participant's Text Power up the Universal Annunciator at your workstation: • B+ to TB1-16 • Gnd to TB1-15 Your Notes Press and hold S1 in for 5 seconds – N3 LED goes out Work through the Annunciator Configuration sheet on the previous page to see the changes you can make in the Annunciator. It has a Digital Display area and navigation buttons to use menus to read operating data from the Genset. and Transfer Switches PCC 2100 Universal Annunciator The Universal Annunciator is the new annunciator that can be used for PCCNet or hard-wired applications at the same time.PCC 2100 Input/Output Module Battery Charger Automatic Mains Failure Module Bargraph Module PC ATS 3310 / PCC 3300 Master Command Control 3320 VIS 6 6 S&TT 12/04 Visual 6-5 PCCNet Devices or Modules Participant's Text Keypad The keypad is the PCC 1300 Control Panel.PowerCommand Control 2100 with CAN Link PCCNet PCCNet Devices Keypad (Control Panel) Universal Annunciator . This is the annunciator we are covering in this lesson. Your Notes Participant’s Guide 6-9 . Master Control. It will alert and wake up the genset control when there is a low or high mains (utility) voltage in its section of the campus. It will be the high-end transfer switch control. Automatic Mains Failure (AMF) Module The AMF module operates in a similar fashion to the Area Protection modules used with transfer switches. Your Notes PC ATS 3310 The PC ATS 3310 control will also be based on the MCM 3320 control. PCC 3200. 6-10 Participant’sGuide . Bargraph Module The PCCNet bargraph module will be a smaller version of the bargraph module used on the PCC 2100. Its operation is similar to the DIM used in the FT–10 networks.PCCNet PowerCommand Control 2100 with CAN Link Participant's Text Input/Output Module The I/O Module is a a way to monitor and control customer equipment. and PC Transfer Switches. Battery Charger The PCCNet Battery Charger sends its AC Failure fault over the PCCNet instead of requiring a wire be installed in the transfer switch harness. the new control will be released by the factory. PCC 2300 Genset Control The PCC 2300 will be the standby version of the PCC 3300 paralleling control. and 52GM breakers. The complete genset control (less the AVR amplifier) will be on one potted circuit card.PowerCommand Control 2100 with CAN Link PCCNet Participant's Text PCC 3300 Genset Control The PCC 3300 genset control is the nextgeneration genset control. The MCM 3320 is being released in three or four sequential releases. 52T. The PCC 3300 will be a paralleling genset control. It will be similar to the circuit boards used with the MCM 3320 and PC ATS 3310. The PCC 3300 may be used on all gensets that the PCC 3200 is used on in 2004. As each release becomes mature. Each succeeding control module will reduce the hardware needed to parallel a pair of gensets to the mains (Utility) Your Notes Participant’s Guide 6-11 . It will take the place of all Paralleling hardware except for the 52U. MCM 3320 The Master Command Control is the first of the new three control systems being released by CPG. Master Genset or Master Synchronizer.2. Your Notes 6-12 ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ PCC 1301 and Genset < OR > PCC 2100 and Genset Setup: Keypad or Tool S&TT 12/01 ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’’ ’’’’’ ’’’’’ ’’’’’ ’’’’’ ’’’’’ Participant’sGuide .1. It has the most capabilities and functions. These are like PCC 1301 Control Panels and display system data and Genset information. Keypads. that is the number of those devices you can have in one network. Visual 6-6 PCCNet Devices Participant's Text These are the device types that are available with PCCNet.1.2. If there is a number after an equals sign.1 Bar Graph = 1 Setup: None CFG=0.PCCNet PowerCommand Control 2100 with CAN Link PCCNet Devices for one Genset CFG=0.3 AMF = 4 Setup: Keypad or Tool Keypad = 2 Setup: None I/O = 2 Setup: DIP CFG=0.3 Charger = 1 Annun = 4 Setup:LEDs & Buttons Tool Setup: None VIS 6 7 Colored devices available May 2005. This is the topmost item in the network. They are remote input and output devices for the network. These are similar to the bargraph devices used in the PowerCommand transfer switches and gensets. they will display different information. current. These are like the Terminal I/O devices used in Modbus networks. They allow the customer to have a graphical vie of voltage. Since the network can have up to two gensets (with a Master Control or Master Synchronizer) there is a capability for two battery chargers. They can put one section of a building or campus on emergency power while the rest of the system is still powered by the Utility or Mains. Your Notes Participant’s Guide 6-13 . Automatic Mains Failure devices. power. Bar Graph. There can be up to four annunciators in a network. and frequency. Battery Chargers. These are similar to the Area Protection devices used in older transfer switches. I/O devices. If their Configuration modes are different.PowerCommand Control 2100 with CAN Link PCCNet Participant's Text Annunciators. power factor. Your Notes 6-14 Participant’sGuide .PCCNet PowerCommand Control 2100 with CAN Link PCCNet Communication Broadcast Messages Broadcast = 18 Bytes Maximum Request / Response Messages Request / Response = 30 bytes VIS 6 8 S&TT 10/00 Visual 6-7 Participant's Text Broadcast Messages are output messages from a device that has a hard-wired input. Annunciators broadcast their hard-wired inputs. Small amounts of data Broadcast messages are sent out: • every time the input changes. Gensets broadcast NFPA-110 data to the network. or • every five seconds. • Generator Engine Data • Generator Data. Participant’s Guide 6-15 . The Control Panel (Keypad) requests data for its present screen every second. When the operator presses a button to move to another screen the Control Panel requests the new data before moving to that screen so the data will be displayed on the new screen. etc.PowerCommand Control 2100 with CAN Link PCCNet Participant's Text Request / Response messages are more complex. Your Notes Request / Response messages are 30-byte serial strings of data. Place PCC 1301 Mode Switch in Off or Manual position.Connect Data–B (TB1-3 in the PCC 1301) to Data–B (J2-4 on the Annunciator) . Power Off all power supplies When your control has been powered down. Not in Auto LED on the Annunciator should light.PCCNet PowerCommand Control 2100 with CAN Link Activity 6-1A: Connecting a Universal Annunciator and a PCC 1301 in a PCCNet network Universal Annunciator 1. Connect the Universal Annunciator to TB1 in the PCC 1301: . 6. 6-16 Participant’sGuide . 4. Put on your wrist strap.Connect Fused B+ (TB1-1 in the PCC 1301) to B+ (TB1-16 on the Annunciator) . the Annunciator should show a “waterfall of color” as it powers up. Turn simulator power on. 2. Recheck all connections. turn off the power switch on the simulator.Connect Data–A (TB1-2 in the PCC 1301) to Data–A (J2-3 on the Annunciator) . 3. 7.Connect Ground (TB1-4 in the PCC 1301) to Ground (TB1-15 on the Annunciator) 5. Power Off all power supplies When your control has been powered down.Connect Data–A (TB2-1 in the PCC 2100) to Data–A (J2-3 on the Annunciator) .Connect Ground (TB1-22 in the PCC 2100) to Ground (TB1-15 on the Annunciator) 5.Connect Fused B+ (TB1-17 in the PCC 2100) to B+ (TB1-16 on the Annunciator) . 4. turn off the power switch on the simulator.PowerCommand Control 2100 with CAN Link PCCNet Activity 6-1B: Connecting a Universal Annunciator. Participant’s Guide 6-17 . the Annunciator should show a “waterfall of color” as it powers up. 3. Turn simulator power on. 2. and a PCC 2100 in a PCCNet network Universal Annunciator 1. Place PCC 2100 Mode Switch in Off or Manual position. Not in Auto LED on the Annunciator should light. Put on your wrist strap. Recheck all connections. 6. 7. Connect the Universal Annunciator to TB2 and TB1 in the PCC 2100/2101: .Connect Data–B (TB2-2 in the PCC 2100) to Data–B (J2-4 on the Annunciator) . not Shutdown alarm. 5. . Demonstrate Customer Fault 1 on the Universal Simulator. .PCCNet PowerCommand Control 2100 with CAN Link Activity 6-2: Configure a PCCNet Annunciator Use the Annunciator Operator’s Manual (900–0301) to configure the Annunciator. 1. Configure Relay #1 on the Annunciator for “Not in Auto” fault. 2. 6-18 Participant’sGuide .Instructor Checkpoint 7. Demonstrate these three faults with the PCC 1301 and Universal Simulator.Low Oil Pressure – Pre-Alarm.Instructor Checkpoint 6. Configure the Annunciator for Legacy NFPA 110 annunciation.High Coolant Temperature – Pre-Alarm. .Overspeed shutdown. . Demonstrate the operation of this relay by placing the Mode Switch or Operator Panel in the Manual or Off mode. 3. Change back to standard operation by downloading the capture file you took before starting this exercise ack into the PCC 1301 control. . not Shutdown alarm. Demonstrate that the relay does not operate on “Not in Auto” fault. .Instructor Checkpoint 4. TB1 b. and the PCC 1301 Generic Installation Diagram. N2. TB2-1 b. TB2-3 d. TB1-1 b. InPower Adjustment parameters. TB2-4 Participant’s Guide 6-19 . TB2-3 d. TB2-2 c. and N3 when setting the Annunciator to display battery voltage from only a Weak Battery input? a. On–On–Off 4. Off–Off–Off b. Where does the Universal Annunciator connect to the Base card? a. TB2. J12 d. TB1-15 d. On–Off–On d. complete the following worksheet. Where does the Data B wire connect to the PCC 2100 Base Board? a. Where does the Data A wire connect to the PCC 2100? a. TB1-2 c. J13 2. J11 c. On–Off–Off c. Where is Battery B+ normally connected to the Universal Annunciator? a. TB1-16 3. TB2-1 b. 1. What is the light pattern of N1. TB2-4 5.PowerCommand Control 2100 with CAN Link PCCNet Activity 6-3: PCCNet Quiz Directions: Using the 900-0301 Operator’s Manual.2 c. N2. the top LED will be a. you would use the line that shows a. On–Off–Off d. Off–Off–Off b. On–Off–On b. To set the color and flash of an LED to “flashing red” in the book. To configure the Universal Annunciator to NFPA 110. and N3 will be a. 9. J2–2 c. the pattern of N1. J2-1 b. Green b. On–Off–Off c. the pattern of N1. Red d. None of the above. Off–On–Off d. and N3 will be a. To configure the Network Configuration Address. On–On–Off 8. N2. R b. To configure the Network Configuration Address. >R< d. J2-4 7. – c. Off–Off–Off c. 10.PCCNet PowerCommand Control 2100 with CAN Link 6. None of the above. On–On–Off 6-20 Participant’sGuide . J2-3 d. Where does the Data B wire connect to the Annunciator? a. Amber c. Then we talked about the options that can be set for the Annunciator LEDs (DS1 – DS20) in the Configuration Mode. Are there any questions we have not yet covered on options for the PCC 1301? Participant’s Guide 6-21 . Q. First we talked about the procedure for getting into. its connectors and LEDs. Lastly we went through the process of configuring annnciators and checked the configuration out with the PCC 1301 controls and simulators. Next we talked about the Universal Annunciator used with PCCNet. and out of. Next we talked about configuring the Annunciator and looked at the options we can set in a configuration chart.PowerCommand Control 2100 with CAN Link PCCNet Wrap-Up In this lesson we have learned about the PCCNet network and the Universal Annunciator used with the PCC 1301 and the PCC 2100/2101. the Configuration Mode. PCCNet PowerCommand Control 2100 with CAN Link This page intentionally left blank 6-22 Participant’sGuide . Alternator Rating Effect Some of the alternator protections are inherently related to the alternator capabilities rather than GenSet power rating. is inherently a function of alternator capability. PC software notification. A data set downloaded to a G-Drive or GenSet control to update the operation of the control. interface to the optional PTC Module. This board contains the main power supply for the control. Participant’s Guide 7-1 . If data to an alternator’s capability in these areas is not available.) Annunciation Any means of communicating to a user or operator the status of the power system. Overcurrent is inherently a function of alternator capability. LEDs. Base Card The main processor board of the PowerCommand Control 2100. and pagers. Calibration Non-volatile adjustment made on the factory floor. flash memory for updates to the operating system (calibration download). kW. microprocessor. Control Area Network (CAN) A distributed control system (data network) between a Genset Control System (GCS) and an Engine Control System (ECS) that allows the control systems to communicate directly. (GenSet rating is either engine limited or alternator limited — normally engine limited. Reverse VARs (Loss of Field). the PowerCommand Control will default to basing the limits on the on the GenSet rating — as the previous version of the PowerCommand Control did. and inputs for engine sensor data. For example.PowerCommand Control 2100 with CAN Link Glossary Alarm Used generically to indicate either a warning or a shutdown fault. and Voltage provided by the generator set. and the Power Factor required by the load. Frequency. visual displays. This panel allows the operator to view a display of Amperes. Includes audible alarms. Especially important in the event of an alarm. Bar Graph A metering panel which is optional on the PowerCommand Control 2100. Alternator and genset protection and diagnostics. Fault A condition occurred which caused a warning or shutdown alarm. 7-2 Particpant’s Guide .Glossary PowerCommand Control 2100 with CAN Link Digital Display A small display board powered by the Base Board. Speed governing in cases where performance issues require ECS control. This display module shows menus and timing of time delays as well as showing events and statistics. monitor. Speed governing unless performance issues require the ECS control it. and the fuel system on diesel sets. there will be Engine Control System (ECS) An electronic control system that is part of a CAN Link. and starter control on diesel engine-driven gensets. Genset Control This is the PowerCommand Control used to operate. This is where the PowerCommand Control stores its calibration data. It monitors and controls the engine systems not controlled and monitored by the Genset Control. and control the genset functions. Paralleling functions. and Starter control in natural gas engine-driven gensets. This module is standard. In the QSX15 and QSM11 gensets the CM570 ECM is used. Genset Control System (GCS) An electronic control system that is part of a CAN Link. In future gensets. Speed sensor processing. Engine Control Module (ECM) The ECM is the active portion of the Engine Control System. This memory holds data after the power has been removed. It sends a start or stop command to the ECM to control the fuel and ignition systems on natural gas gensets. The GCS controls Voltage Regulation. The ECS controls Fuel system and combustion control. The service InPower software can write a new calibration into the control flash memory. EEPROM Electrically Erasable Programmable Read Only Memory. Engine protection and diagnostics. but can be changed by writing new data on top of old data. 0. Nominal Value A value which has not been trimmed. –50 kVAR would have +1.0 Hz.PowerCommand Control 2100 with CAN Link Glossary Initial Calibration Downloading a data set to a PowerCommand Control 2100 to set up the operation of the control. PETS Acronym for Production Engine Test System. Definition #2: Alternator capability curves calculate per unit kW as the ratio of kW to rated kVA. In this type of calibration the technician has to manually enter the dataplate information for the genset into InPower software. In today’s systems. An example would be normal line frequency of 60. Per unit kVAR is calculated as the ratio of rated kVAR to rated kVA. Open Tansition The operation of the transfer switch mechanism controlled by the PTC Module. This module allows the PCC 2100 to be a node on the network and communicate with the rest of the network devices.04pu kW. This causes one source to be disconnected from the load before the second source is connected to the load. For example. all parameters will be reset to their “factory settings”.26pu kVAR.8 power factor with a load of +260 kW. this tells the master control that it needs to shed some load. Participant’s Guide 7-3 . Network Communication Module (NCM) An optional module located inside the PowerCommand Control 2100.0 Hz. Per Unit (PU) Definition #1: A unitless quantity that is the ratio of the current operating value to the rated/nominal value. a standby rated genset of 250 kW. The nominal value is 60. –0. Load Dump Signal output from a genset which is activated by the genset when it enters an overload and/or underfrequency condition. If a capture file is not downloaded into the control after this type of calibration is performed. RAM Random-Access Memory. PowerCommand Network A communication network for moving information electrically among various Onan on-site power generation modules. The PTC Module can be configures through the Base board to start the genset at Idle speed and warm up the engine before ramping up to rated speed when the PCC 2100 receives a Remote Start signal when the S1 voltage is Ok. In instances when the S1 voltage is not OK. This memory requires power to maintain its content. 7-4 Particpant’s Guide . Rated Current To be calculated based on rated power (kW) and nominal voltage. The PTC module has an input terminal block for the Source 1 (S1) voltage and sends a representative sample of the S1 voltage to the PCC 2100 Base board.Glossary PowerCommand Control 2100 with CAN Link PowerCommand Control 2100 The newest control developed by Onan which will be used to replace the Detector series of controls Cummins Power Generation generator sets with hydro-mechanical fuel systems. the genset will start and run at rated speed and transfer the load to itself through the transfer switch operated by the PTC Module. after February of 2002 Power Transfer Control (PTC) Module An optional module used with the PCC 2100 that allows the PCC 2100 to control the operation of a non-automatic transfer switch. The PowerCommand Network will utilize Echelon LonWorks for system module interconnection. This is called the “Exercise” mode of operation. The Base board makes a decision whether the S1 voltage is OK or not OK. This is the memory that the PowerCommand Control uses to actually operate the generator set. The PTC Module can be configure to run the set with or without load in the “Exercise” mode. unlimited time prime. Setpoint Value A value which is the result of a trim made to a nominal value. the dataplate information for the genset comes from the stored data in the Base board. An example situation would be when a synchronizing control loop is attempting to drive the genset frequency to match the bus frequency. Shutdown A type of fault which causes the Genset to shut down immediately or prevents it from starting. The setpoint value is 61. An example would be if the operator adjusted a nominal frequency of 60. In this type of calibration. Definition #2:Determined by the rated current and voltage programmed into the Base card by the Manufacturing Tool or calibration downloaded by InPower software. Reference Value A value in a control loop which determines to what value the control loop is attempting to drive the output. Prior to closing the circuit breaker. Participant’s Guide 7-5 .0 Hz to 61. or continuous.5 Hz.0 Hz. All previous settings are restored.5 Hz.0 to allow it to match the bus. Trim Non-volatile adjustment made in the field by an operator. but the bus frequency is 59. or service technician. Perhaps the genset nominal frequency is 60. Status An indication of state used for informative purposes only — not a warning or shutdown alarm. This is the maximum kiloWatt load the generator set can provide. Save and Restore Calibration Downloading a data set to the PCC 2100 to update the operation of the control. limited time prime. the genset will set its reference frequency to 59. the reference value is 59.0 Hz because it is overloaded. user.5 Hz.PowerCommand Control 2100 with CAN Link Glossary Rated kW Definition #1: This is set by the end application — standby.0 Hz. Typically a status indication does not require any action to be taken. the genset setpoint frequency is 61. At this time. Glossary PowerCommand Control 2100 with CAN Link Utility The primary producer/distributor of electric power. 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. In some countries it’s called the utility source.” Warning A type of fault which does not shut down the engine or generator set. could shut it down or prevent it from starting or operating properly). in some others it is called the mains or “hydro.e. 7-6 Particpant’s Guide . All steps with a YES in the Safety Points column must be completed correctly to pass the examination. Here are the points tested in this examination. Connect using InPower and Null-Modem cable. As with other PGG Examinations. Create Capture file named “PerfEx.cap” 8-1 Participant’s Guide . Troubleshooting Problem Safety Points No Yes Complete Step Description Connect using InPower and Null-Modem cable.PowerCommand Control 2100 with CAN Link Performance Examination PCC 2100 Performance Examination This is a Performance Examination on the PCC 2100 with CAN Link This is a Pass/Fail examination. Overlay Capture file named “PerfEx. you will get a second chance to correct and complete your work if the instructor does not find your work passes – except for Safety Points.cap” What is the problem on this unit? Where should you check for solutions to this problem? On what page of the Service Manual did you find a procedure for troubleshooting this problem? What did you check to solve the problem? Safety Points Yes Yes No Yes Complete - Step Description Start genset in Manual mode from control panel. Start genset in Auto mode from Universal Simulator. 8-2 Participant’sGuide .Performance Examination PowerCommand Control 2100 with CAN Link Yes Yes Yes No No - Wiring of modules – Data cable Proper Module selection Proper Terminator selection and use Resetting Network Modules to “Out of Box” condition using the proper manuals Following Instructions Pass Fail If you are told to do so by the instructor (last person on this workstation) Yes Overlay Capture file named “PCC 2100.cap” from Simulator files. after copying to your Capture File folder. . . . . . . . 9-7 Colored sequence of operation diagram set. . . . . . . . . . 9-11 PCC 2100 and PC ATS Interconnect Diagram Trainer’s Guide 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 PCC 2100 Installation diagram 612-6764 Sheet 2 of 3 . . . . . . . . . 9-10 PCC 2100 Base Board 630–1974 Sheet 7 of 8 . . . . . . . . . . . . . . . . . . . . . . 9-6 Colored sequence of operation diagram set. . . . page 2 of 4 PowerCommand Control 2100 Sequence of Operation -3 . . . . . . . . . . . . . 9-5 PCC 2100 Installation diagram PowerCommand Control 2100 Sequence of Operation -1 . . . . . . . . 9-9 Colored sequence of operation diagram set. . . . . . page 4 of 4 300-5381 Sheet 9 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 PCC 2100 Installation diagram 612-6764 Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PowerCommand Control 2100 with CAN Link Diagrams PowerCommand Control 2100 Prints 612-6764 Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . 9-8 Colored sequence of operation diagram set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3 of 4 PowerCommand Control 2100 Sequence of Operation -4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1 of 4 PowerCommand Control 2100 Sequence of Operation -2 . . . . . . . . 9-14 Colored sequence of operation diagram set. page 2 of 6 PowerCommand Control 2101 Sequence of Operation -3 . . . page 1 of 6 PowerCommand Control 2101 Sequence of Operation -2 . . . page 3 of 6 PowerCommand Control 2101 Sequence of Operation -4 . . . . . . . . . . . 9-20 PCC 2100 with CAN Link Base Board 9-2 Trainer’s Guide . . . . . . . . . . . . . . . . 9-19 Colored sequence of operation diagram set. . . . . . . . . . . . . . 9-15 Colored sequence of operation diagram set. . . . . . . and CAN Link components PowerCommand Control 2101 Sequence of Operation -1 . . . . . . page 4 of 6 PowerCommand Control 2101 Sequence of Operation -5 . . . . . . . . . . . . . . .Diagrams PowerCommand Control 2100 with CAN Link PowerCommand Control 2101 with CAN Link Prints CAN Link diagram for the QSX15 gensets using a PCC 2101 control . . . . . . . . ECM. . . . 9-16 Colored sequence of operation diagram set. . . . . . 9-13 Colored diagram showing the GCM. . . . . . . . . . 9-12 Colored diagram showing the GCM. . . . . . . . . . . ECM. . page 5 of 6 PowerCommand Control 2101 Sequence of Operation -4 . . . . . 9-18 Colored sequence of operation diagram set. . and CAN Link components CAN Link diagram for the QSM11 gensets using a PCC 2101 control . . . . . . . page 6 of 6 327-1379 Sheet 9 of 10 . . . . . 9-17 Colored sequence of operation diagram set. Your written comments and recommendations for improving this training are also welcome. circle one (too short/too long) Were there enough exercises in the Classroom/Shop Activities? Will you apply what you learned to your job? Do you think this training was worth your time? Would you recommend this course to your peers? Below Ave Average How would you rate the quality of the training material (Participant Guide. was the Trainer qualified to teach this class? Was the length of the training adequate? If no. etc. How would you rate the Shop Activities? How would your rate the Classroom Activities? How would you rate your Trainer? How would you rate the classroom accommodations? (space to work.). handouts. Place an ”x” in the box that most closely reflects your opinion. restrooms. There are spaces and extra room on the back for comments/ Date: ______________________ Trainer’s Name:____________________________________ Your name (optional): _______________________________Company____________________ No Did the Trainer state the objectives before each lesson? Did the Trainer provide constructive and adequate answers to your questions? Was the content presented in a logical manner? Did the Trainer perform safe practices in the Shop? In your opinion. Help us evaluate the training you just completed by answering each of the following questions.PowerCommand Control 2100 with CAN Link Module Comment Form Module Evaluation Form Your feedback is very important to us. snacks) Additional comments about your Trainer: Excellent Yes Additional comments about the training material/activities: Additional comments in general: Participant’s Guide 10-1 . Module Comment Form PowerCommand Control 2100 with CAN Link 10-2 Participant’s Guide . . Cummins Power Generation 1400 73rd Avenue N.E. MN 55432 1-800-888-6266 763-574-5000 International Use Fax: 763-574-8087 Cummins is a registered trademark of Cummins Inc. . Minneapolis.