Index
1. Cold Checks - Part Nos. of Various Components of PCC. 2. Wiring Checks - Engine Wiring Harness , PT/CT Harness , Customer Interface Harness 3. PCC Fault Codes & thresholds 4. PCC Calibration - Initial Calibration , Frequency Calibration, Voltage Calibration,Meters Calibration 5. Settings on the PCC -Factory Settings 6. PCC Terminal Strip ( TB1-60) at a glance 7. Detailed Terminal Strip connections of Inputs / Outputs from PCC
Commissioning report for PCC Engine ESN:
Model:
Name of the Commissioning Engineer : Date Of Commissioning: Parts & their Sr.Nos. ( Kindly Confirm by actual Inspection) Parts Cummins Part No ONAN Part No. PCC 4084008 300-4615-05 Governor O/p Module 4084020 300-4625 Regulator O.P module 4084021 300-4634 PT/CT Module 4084022 300-4626-02 Bus PT Module 4084009 300-4767-02 Engine interface Board AX1002266 300-4083 Customer Interface Board AX1004536 300-4462-01 Digital Board AX1002262 300-4079 Analog Board AX1002264 300-4080-02 Display Board AX1002249 300-4286 Master first Start Sensor CT's ( All Three) As per Engine Model
Customer:
OEM:
Name of the OEM Engineer
Sr.No.
Parts Water Temp.Sensor ( RB /LB) Lube Oil Pressure Sensor Oil Temp.Sensor Engine Temp. Sensor MPU Magnetic Switch Engine Wiring Harness Alternator Wiring Harness PT/CT Harness Low Coolant Level Switch PCC O & M Manual
Cummins Part No 4084030 4084031 4084030
ONAN Part No. Sr.No. 193-0432 193-0444 193-0432
3231404 4084033 307-2621-01 As per Engine Model As per Engine Model 4084230 4084762 3243804
Version: L-L Voltage Parallel / Single Software Version Note : A separate table giving the Details of Version / CT Part nos w.r.t engine model is given below. Cummins ENGINE KVA KW FILE CT PART ONAN PART MODEL RATING Rating NAME RATIO NOS. NO. KTA50G8 1500 1200 DFLF-50 4420/1 4084989 302-2058-15 Location KTA50G3 1250 1000 DFLC-50 3867/1 4084245 302-2058-12 KTA38G5 1000 800 DFJD-50 2839/1 4084175 302-2058-08 Engine Interface KTA2300G 750 600 DFJB-50 2141/1 4084244 302-2058-03 Engine Interface VTA28G5 625 500 DFGC-50 1893/1 4107379 302-2058-01 VTA28G3 600 500 DFGC-50 1893/1 4107379 302-2058-01 Governor Output Module KTA19G4 500 400 DFED-50 1419/1 4104378 302-2057-31 KTA19G3 450 360 DFEC-50 1262/1 4104388 302-2057-29 Governor Output Module KTA1150G 380 300 DFEB-50 1070/1 4104377 302-2057-26 KT1150G 320 300 DFEB-50 946/1 4104376 302-2057-24 Governor Output Module NTA855G2 320 250 DFCB-50 946/1 4104376 302-2057-24 NT855G6 285 227 DFBF-50 789/1 4104389 302-2057-21 TB-Bat (Engine Harness NT855G5 250 200 DFBE-50 725/1 4104390 302-2057-19 Assembly) NT855G4 225 180 DFBD 50 631/1 4104391 302 2057 17
PCC FUSES-- Check if in doubt
Nomenc Rating Function lature A31-F1 5 Amp PCC Control B + (Ve) A31-F3 5 Amp Aux. B+ (For panel lights, run & start relays) A38-F1 10 Amp Network B+ (to TB1 customer terminal block) A38-F2 10 Amp Switched B+ ( to TB1 customer terminal block) A38-F3 10 Amp Governor B+ (power for governor output module & actuator) F1 20 Amp Customer B+ ( to TB1 customer terminal block
Visual Inspection 1. Engine Wiring Harness: The entire wiring should be clamped appropriately, with no loose wires hanging LCL if connected , should be wir ed up as follows: LCL Wires-----------------Engine Wiring Harness Red------------------------------- S7 + ( TB Bat +Ve) Black----------------------------- S7 - ( TB Bat -Ve) Blue------------------------------- S7-Sig (P4-7) Plugs / Connectors ,Customer Interface Harness P4 - Grey -- Connects on the Engine Interface Board ( Back Side of PCC) --While Fixing this plug first match the notch & push it in so that you hear a click sound. P5 - White Connector on the Engine Interface board ( Back Side of PCC) --DO -------------------P6 - Grey ---Connects to the Governor O/P module ( On the accessory Box) -------DO P7 -White ---Connects to the Regulator O/p Module ( on the acc. Box) P10 - White ---Connects to the Regulator O/p Module ( on the acc. Box) PMG wires : PMGP2, PMG3 , PMG4---Connect this wire to the PMG wire coming out from the Main Alternator ( See that length of this adquate. DO NOT EXTEND THESE WIRES, IF THESE WIRES ARE SHORT IN LENGTH----If required bring these wires to a terminal strip , securely mounted on the alternator frame inside & connect the Alternator PMG wires on the terminal strip> X+, XX --These are field winding wires ----Connect the field winding wires from the main alternator to these wires ( F1 to X+ & F2 to XX J-12 - Grey -- Connects to the Alternator Wiring Harness on Plug -12 ( Located in the Acc.Box) Starter Connections looped ( Shorted). Similarly the negative terminals of both the starters are looped (shorted & connected to Engine body)
Main Alternator Wiring Harness : Plugs : P1 - Black ---Match the Socket which has a similar Black colour -- On the Customer Interface board ( On the back Side of PCC) P2 - Grey ---Match the Socket which has a similar Grey colour -- On the Customer Interface board ( On the back Side of PCC) P3 - Blue ---Match the Socket which has a similar blue colour -- On the Customer Interface board ( On the back Side of PCC) P8 - Grey -- Connects to the PT / CT Module P12 - Connects to J12 of the engine harness connector Six Wires to Bus PT Module on terminal strip - A39 - TB2-1, A39 - TB2-2, A39 - TB2-3, A39 - TB2-4, A39 - TB2-5, A39 - TB2-6,
PT/CT Harness One end gets connected to the PT/CT Module --White Plug & the other end has ten wires.-CT Connections 1 - Neutral ( Neutral Phase Connection) 1 2 3 2 - VB ( B Phase Connection) 3 - VY ( Y Phase Connection) 4 - VR ( R Phase Connection) 5 - Not Used 6 - IB2 (B Phase CT Connection) 10 11 12 7 - IB1 (B Phase CT Connection) 8 - IR2 (R Phase CT Connection) 9 - IR1 (R Phase CT Connection) PT CT harness Connector 10- IY2 (Y Phase CT Connection) 11- IY1 (YPhase CT Connection) 12- Not Used
PCC - Fault Thresholds Fault Code 200
Status W arning
Description Low Lub Oil Pressure
201
Shutdown
Low Lub Oil Pressure
211 212 214 215 223 231 230 232 301 303 313 320 321 322 330
W arning Shutdown W arning Shutdown Shutdown Warning Warning Warning Shutdown Shutdown Shutdown Warning Shutdown Shutdown Warning
Hi Coolant Tem perature Hi Coolant Tem perature Low Coolant W ater Level Low Coolant W ater Level Engine Overspeed Hi DC Voltage Low DC Voltage Weak Battery Hi AC Voltage Low AC Voltage Under Frequency Over Current Over Current Short Circuit Overload
335 337
Shutdown Shutdown
Reverse Power Loss Of Excitation
Thresholds 40 PSI / 276 kPa / 2.75 bar @ 1500 RPM 15 PSI / 103 kPa / 1.03 bar @ 800 RPM 35 PSI / 241 kPa / 2.41 bar @ 1500 RPM 10 PSI / 69 kPa / 0.68 bar @ 800 RPM 207 Deg F / 97 Deg C 215 Deg F / 101 Deg C Low Level @ 800 RPM Low Level @ 1500 RPM 115% of 1500 RPM i.e. 1725 RPM +/-1 RPM Batt. Volt > 32 V DC Batt. Volt< 24 V DC Rated Volt < 60% i.e. 14.4 V DC Rated Volt > 130% i.e. 540.8 V AC Rated Volt < 85% i.e. 353.60 V AC, for 10 Sec. Rated Freq. < 90% i.e.45 Hz for 10 Sec. Rated Current > 110% for 60 Sec. Rated Current > 110% as per PCC IDMT Curve Rated Current > 175% Instantaneous Rated Current > 115%, after 5 Sec. The load dump O/P will get activated. (-) Kw Power > 10% of Rated Kw for 3 Sec 2 seconds
Factory Settings of PCC Parameter Version Voltage/ Frequency Selection Prime / Standby Delta / WYE S 5 Switch ( On Digital Board) Start Delay Stop Delay Idle Speed Gov.Regulator Menu Gov. Gain Gov Integral Gov Ramp Reg Gain Reg Integral Reg. VHZ Set-Up Menu Cycle Crank No. Of Cycles Crank Time - Sec Rest Time - Sec System Of Units Customer Fault 1 Customer Fault 2 Customer Fault 3 Customer Fault 4 EGT - L EGT - R Low Coolant LVL Language Parallel -ISO BUS Sync Time Limit
Factory Settings As per Eng.Model 416V / 50 HZ Prime Always WYE always Awake mode 0 0 800Rpm
Range
100% 100% 1 100% 100% 11
3% to 1276% 33% to 1 to 10
ON 5 15 15 Imperial Warning Ground Fault - Warning Rupture Basin- Warning High Gen Temo - Warning No No Shutdown English
ON / OFF 3 to 6 7 to 20 7 to 20 Imperial / Metric Warning / Shutdown Warning / Shutdown Warning / Shutdown Warning / Shutdown Yes / No Yes / No Warning / Shutdown English/ Spanish
120
10 - 120
190V to 13.8 KV / 50/60Hz Prime/ Standby Delta / WYE Sleep / Awake 0-300 seconds 0-600 seconds 700-900 Rpm
Deviation if Any
PCC - Terminal Strip TB1-1 Details at a Glance Into The PCC
O/P From PCC to the Main Panel
Into The PCC
O/P From PCC to the Main Panel
TB BAT-F1
1
1
B+(20A FUSED)
A34-P1-19
31
31
PRE-LOW OIL PRESSURE
P12-2
2
2
SWITCHED B+(10A FUSED)
A34-P1-20
32
32
LOW OIL PRESSURE
GND-ENG
3
3
GROUND
A34-P3-19
33
33
COMMON
GND-ENG
4
4
GROUND
A34-P1-18
34
34
RETURN
A34-P1-13
5
5
REMOTE START
P12-9
35
35
RUPTURE BASIN
A34-P1-7
6
6
REMOTE EMERGENCY STOP
CONT HTR1
36
36
A34-P2-10
7
7
Common Shutdown(N/O)
CONT HTR2
37
37
120 OR 240 VAC
A34-P2-9
8
8
(COM)
A34-P2-14
38
38
A34-P2-11
9
9
(N/C)
A34-P2-13
39
39
(N/O) READY TO LOAD (N/C) LOAD DUMP
A34-P2-4
10
10
Breaker Close (N/O)
A34-P2-12
40
40
COMMON
A34-P2-3
11
11
Breaker Close (N/O)
A34-P2-8
41
41
Common Warning(N/O)
P12-5
12
12
NET POWER(+)
A34-P2-7
42
42
Common Warning (N/O)
P12-6
13
13
NET POWER(-)
A34-P2-5
43
43
Common Warning (N/C)
P12-7 (RED)
14
14
NET DATA 1
A34-P2-6
44
44
Common Warning (N/C)
P12-8 (BLACK)
15
15
NET DATA 2
45
45
P12-1/A34-P1-9
16
16
CUSTOMER FAULT 1
A34-P3-9
46
46
B+IN
A34-P1-12
17
17
CUSTOMER FAULT 2
A34-P3-1
47
47
UTILITY CB AUX
A34-P1-6
18
18
CUSTOMER FAULT 3
A34-P2-16
48
48
Breaker Trip(N/C)
A34-P1-16
19
19
CUSTOMER FAULT 4
A34-P2-2
49
49
Breaker Trip(N/C)
A34-P1-2
20
20
FAULT RESET
A34-P1-17
50
50
MASTER START SENSOR/SYNC ENABLE
A34-P1-10
21
21
ENGINE IDLE
A34-P1-3
51
51
LOAD DEMAND/UTILITY SINGLE
A34-P1-5
22
22
LOW FUEL
A34-P1-11
52
52
CB OPEN/CLOSE INHIBIT
A34-P3-2
23
23
NOT ON AUTO
A34-P1-4
53
53
CB POSITION
A34-P3-10
24
24
PRE-HIGH ENGINE TEMP
A34-P1-22(GREE
54
54
GREEN(KVAR-)
A34-P3-11
25
25
HIGH ENGINE TEMP
A34-P1-23(RED)
55
55
RED (KVAR+)
A34-P3-12
26
26
OVERSPEED
A34-P1-8(BLACK
56
56
BLACK (KW-)
A34-P3-16
27
27
OVERCRANK
A34-P1-15(WHIT
57
57
WHITE(KW+)
A34-P3-17
28
28
LOW ENGINE TEMP
A34-P1-1
58
58
SHEILD
A34-P3-18
29
29
LOW FUEL
A34-P2-15
59
59
EXTERNAL LOAD SET +
A34-P1-21
30
30
LOW COOLANT
A34-P2-23
60
60
EXTERNAL LOAD SET -
PCC Checks / pmp
PCC TB1-1 Connectons upto the Main Control Panel Note : The Left Hand side connections go into the PCC. The Right hand side connections represent the OEM side connections or the Customer side connections to be taken out on the Main panel Sample Drawings related to each terminal of the 60 pin terminal strip are given below. All the connections shown need not be used, the Mandatory connections are mentioned in BOLD
Positive 24 VDC This is a permanent + 24VDC supply --can be used for looping
TB1 TB BAT-F1
1
1
B+(20A FUSED)
P12-2
2
2
SWITCHED B+(10A FUSED) This supply 24vdc will be available only when engine
starts running and can be used to drive. Sample drawing for running Raw water Pump NO 1 R1 TB1 M P12-2 2 2 Common B-ve ( TB1-3
Engine Ground
230V
TB1
GND-ENG
3
3
any Ground looping in the PCC Panel can be taken from here
GND-ENG
4
4
any Ground looping in the PCC Panel can be taken from here
Remote Start (
Mandatory) TB1
A34-P1-13
5
5
REMOTE START ( IF PCC RUN /OFF/AUTO Switch is in AUTO &
if Ground is connected to terminal No.5 then engine will remotely start Main Panel TB1
Common Shut Down ( A34-P2-10 A34-P2-9 A34-P2-11
Mandatory) 7 8 9
7 8 9
(N/O) Common shut down (COM) Common
(N/C)
TB1 Common shut Down ---Indication on Panel TB1 A34-P2-10 7 7 A34-P2-9 TB BAT-F1
8
8
1
1
Main Panel
If the Engine Shuts down due to any fault then the "NO" contact between 7 & 8 TB-1 -3 will close & indicating Lamp on the panel 24Vdc will glow. Note : Either Use Indicating lamp or Anounciator ( As shown ahead)
Sample Drawing of Common shut Down ---Audible Hooter TB1 A34-P2-10 7 7 A34-P2-9
8
8 24Vdc
TB BAT-F1
1
1 24vdc or 230 vac supply for hooter
Breaker Control ( A34-P2-4 A34-P2-3
Mandatory) TB1 10 10 11 11
(N/O)
(N/O)
Sample Drawing for Breaker Closing TB1 A34-P2-4 10 10
Breaker Closing
Aux.NC contact of Brkr Closing Coil
If the Engine Shuts down due to any fault then the "NO" contact between 7 & 8 will close & Hooter on the panel will turn ON
CUTOMER FAULTS 1,2,3 & 4 (
Earth Fault Protection Mandatory , Others Optional)
TB1 P12-1/A34-P1-9 CUSTOMER FAULT 1 ------Default Programed as Customer Fault 1 --shutdown 16 16 A34-P1-12 CUSTOMER FAULT 2 ------Default Programed as Ground Fault--Shutdown 17 17 18 18 A34-P1-6 CUSTOMER FAULT 3 ------Default Programed as Day Tank--Shutdown 19 19 A34-P1-16 CUSTOMER FAULT 1 ------Default Programed as High Gen Temp--Shutdown These are customer configurable inputs to the PCC, they can be either configured for Warning or Shutdown In PCC there is no inbuilt protection for Earth Fault. An earth fault relay has to be externally used for this Purpose, the out put of which can be brought into the PCC for shutting down the engine. For this Customer Fault No2 (Ground Fault) has to be used. Main Panel TB1 Relay Activated By Earth Fault A34-P1-12 17 17 GND-ENG
3
3
Whenever there is an Earth fault,the relay will pick up & the NO contact of the relay will connect Ground to Terminal No.17 The PCC will now display Ground Fault & will trip the engine (since it it programed for Shutdown) Example No. 2 If the Circuit Breaker trips due to an internal electrical fault then this input can be brought into the PCC & the engine can be tripped. Program the Customer Fault No 1 to ' Breaker Trip ' or ' Electrical Fault' ----Program it for Shutdown (Through PCC menus) TB1 P12-1/A34-P1-9 16 16 Aux. Contact of Breaker GND-ENG
3
3 Main Panel
Fault Reset: This can be use to reset Warning Faults from Remote or Main Panel TB1
Low Fuel : Not in CIL Scope A34-P1-5 22 22 TB1 A34-P1-10
22
Low Fuel Fuel Tank
22 Float Switch
GND-ENG
3
3
Grounding terminal No. 21 will initiate Low fuel warning on the PCC. Note :Float Switch is not a Standard scope of supply
TB1
Anounciator Outputs From PCC TB1 23 23 A34-P3-2 24 24 A34-P3-10 A34-P3-11 25 25 A34-P3-12 26 26 A34-P3-16 27 27 A34-P3-17 28 28 A34-P3-18 29 29 A34-P1-21 30 30 A34-P1-19 31 31 A34-P1-20 32 32 A34-P3-19 33 33
A34-P3-2
TB1 23 23
A34-P3-10
24
24
A34-P3-11
25
25
A34-P3-12
26
26
Mandatory Anounciations : NOT ON AUTO PRE-HIGH ENGINE TEMP HIGH ENGINE TEMP OVERSPEED OVERCRANK LOW ENGINE TEMP LOW FUEL LOW COOLANT
1.High engine Temp. 2.OverSpeed 3.Over Crank ( Only for AMF Sets) 4.Low Coolant 5.Low Oil Pressure On any of the above fault the No contact associated with that fault will close &24VDC will be applied to the particular anounciator Window
PRE-LOW OIL PRESSURE LOW OIL PRESSURE COMMON
16 Window Anounciator
Not in Auto
PRE HWT
Over Crank
L.E.T
HWT
LCL
O.S
PRE LOP
Ready To Load : This NO Contact is activated by PCC when the Frequency & Voltage reach 90% of Rated. This can be used for Anounciation or can be used for Advanced Load Management system. TB1 38 38 A34-P2-14 READY TO LOAD ( Anounciator) A34-P2-12
40
40
TB BAT-F1
1
1
COMMON
24VDC from Terminal No 1.
Load Dump : This No Contact is activated by the PCC whenever there is an overload condition This can be used for Anounciation or can be used for cutting off non essential loads if wired up. TB1 A34-P2-13 LOAD DUMP (Anounciator) or to a Relay for cutting off non essential loads in an overload 39 39 condition COMMON 40 40 24 vdc supply from terminal no.1 TB BAT-F1 1 1
Common Warning ( A34-P2-8 A34-P2-7 A34-P2-5 A34-P2-6
Mandatory Announciation) TB1 41 42 43 44
41 42 43 44
41
41
42
42
(N/O)
(N/O)
(N/C)
(N/C)
Common Warning ( Anounciator)
24 vdc supply from terminal no.1
Breaker Tripping ---- Use Shunt Trip Coil Only ( Coil Rating 24VDC)
A34-P2-2
TB1 48 48 49 49
A34-P2-16
TB1 48 48
A34-P2-16
A34-P2-2 TB BAT-F1
(N/C)
(N/C)
Mandatory
Bkr. Aux.N/O
49
49
Shunt Trip Coil of Brkr
1
1
24 vdc supply from terminal no.1
NC contacts are provided foe tri pping the breaker. These contacts are activated by the PCC no sooner the engine speed & voltage reach 90% of the rated.
Master First Start Sensor / Sync Enable TB1 A34-P1-17 MASTER START SENSOR/SYNC ENABLE 50 50 Master First Start Unit 50 50 A34-P1-17
This is used for Multiple Engines with PCC in island mode of operation. This unit gives pulsed o/p to the Genset to be started first online.Not a Standard scope of supply ( Optional) FOR SINGLE SET With UTILITY PARALLEL mode follow the drawing Below TB1 50 50 By giving 24vdc to this terminal when single set is paralled with utility, the Synchroinser is enabled TB BAT-F1 1 1 24 vdc supply from terminal no.1
Circuit Breaker Open / Close Inhibit: ( Mandatory) This is used when it is required to work on the the Ckt breaker / Busbars for maintenance to ensure that breaker doesnot close even if the PCC is set in AUTO mode. To Inhibit the breaker closure apply Ground to terminal No.52 A34-P1-11 52 52 CB Open/Close Inhibit If the Breaker is Closed & if ground is applied to terminal No.52 this will result in TB1 Main Panel opening the breaker A34-P1-11 52 52 Breaker Closure Inhibit through Switch
GND-ENG
3
3 TB1
Circuit Breaker Position : (Mandatory) Giving a ground through the Aux. NO. contact of the Breaker wi ll ensure that the Breaker is physically closed. If this feedback doesnot come to the PCC then the Engine will shutdown on "Fail to Close' Fault. TB1 A34-P1-4 53 53 CB Position
A34-P1-4
Main Panel
TB1 53 53
Aux. Contact of Genset Breaker
GND-ENG
Load Share Lines ( A34-P1-22(GREEN) A34-P1-23(RED) A34-P1-8(BLACK) A34-P1-15(WHITE)
3
3
Mandatory for Parallel Operation) TB1 54 55 56 57
54 55 56 57
GREEN(KVAR-) RED (KVAR+) BLACK (KW-) WHITE(KW+)
By installing the resistances in these terminals, the PCC will operate in Droop Mode. NOTE : This Just enables the PCC for Droop operation, to set the exact % of droop please refer the Graph of % Speed Droop Vs KW Loadshare Gain Or follow the tables given below : Table for Speed Droop Table for Voltage Droop Desired % Droop KW Load Share Gain 1 2 3 4 5
% Droop
4 6 8 10 12
3 4 5 6
KVAR Load Share Gain 300 330 420 480
Procedure for Droop Paralleling Setup 1.Insert the 5 K Ohm resistor as shown above. 2. Set KW & Kvar balance = 0 ( In the PCC Parallel set , Isolated bus Menu) 3. Set the No Load Voltage & fr equency to the desired value. 4. Set KW & KVAR load share gains to the desired value ( In the PCC Parallel set , Isolated bus Menu)as per the tables given above. NOTE : All PCC's are by Default set for Isochronous operation. Inputs to Control Generator Load in Utility Parallel Mode ( Mandatory for Utility Paralleling) A34-P2-15 EXTERNAL LOAD SET + 59 59 A34-P2-23 EXTERNAL LOAD SET 60 60 TB1 0-5Vdc input voltage when given to these terminals ( When Paralleled with Utili ty Mains), the Load on the Generator can be either increased or decreased. + 5 vdc Ve
A34-P2-15
59
59 0-5vdc Source
A34-P2-23
60 60 TB1
- Ve
Instrumention Required for PCC Commissioning 1 2 3 4 5
PCC Manual Calibrated & standards Clip On meter Phase Sequence Meter Wrist Strap Alternator Control Panel as built Wiring Diagram
Requirment in the Control Panel 1 2 3 4 5 6 7 8 9 10
Kwh meter Electricaly Closing / tripping / Spring charging Circuit Breaker. 16 Channels Alarm Annunciator. High db Hooter for Audio Alarm. Earth Fault Protection Relay Selector Actuator switch for Remote Start / Stop. Selector Actuator switch for Breaker Open / Close. Selector Actuator switch for DG Unloading Emmergency trip P.B. Lamp test / Acknoledge / Reset Push Button
11 12
* 0-5 V DC regulated variable power source in case of Utility Parralleling Df / Dt protection Relay in case of Utility Paralleling.
Sample GA Drawing of the Control Panel to be supplied with PCC Genset
Busbar Chamber H
CB ON CB OFF
Kwh
E/F AA
A
ASS
DCA
PB1
DCV
PB2
V
PB3 VSS
P.B. SA1 SA2 SA3 SA4 S1
AMF / SYN & Iso-Load Sharing Control panel with PCC CB - EDO Type Circuit Breaker With U/V Coil, Shunt Trip Coil, Closing Coil, & C.B. Tripped P.F. contact E/F - Earth Fault Relay VSR - Mains Voltage Sensing Relay Battery Charger Kwh - Energy Meter A - Ammeter & Ammeter Selector Switch V - Voltmeter & Voltmeter Selector Switch DCV - DC Voltmeter for Battery Voltage DCA - DC Ammeter for battery charging Current. CTs - For Metering & E/F Protection S1 - Battery Charging Mode Selector Switch CB ON/OFF - Indicating Lamp AA - 16 Windows Alarm Annunciator PB - Emergency Stop Push Button PB1,2,3 - Lamp Test/ Ack / Reset Push Button SA1 - Engine Start / Stop Switch SA2 - Ckt Bkr. Close / Open Switch SA3 - DG Load / Unload Switch SA4 - Rated/Idle Switch
Mandatory Connections from the PCC to the Main panel for : Single PCC Set Without AMF Single PCC Set With AMF Multiple PCC Sets for Parallel Operation Single PCC Set with Droop Operation Single PCC Set Paralleled with Non PCC Sets Single PCC Set Paralleled with Utility Multiple PCC Sets Paralleled with Utility Bare Minimum Mandatory Connections : Single PCC Set Without AMF 1. Remote Start Switch on Main Panel 2. Remote Emergency Stop on Main Panel 3. Common Shutdown Indication on Main Panel ( Hooter) 4. Customer Fault No.2 -Earth Fault Relay 5. Not On Auto Indication on Main Panel 6. High Engine Temp. Indication on main Panel 7. Over Speed Indication on Main Panel 8.. Low Coolant Level Indication on Main panel 9.. Low Lube Oil Pressure Indication on main Panel 10. Closing Coil connections for Breaker ( 24vdc Closing Coil) 11.Common Warning Indication on Main Panel (Hooter) 12. CB Open /Close Inhibit Switch on Main Panel 13. Shunt Trip Connections for Breaker ( 24Vdc Shunt Trip Coil)
Multiple Sets for parallel Operation 1. Remote Start Switch on Main Panel 2. Remote Emergency Stop on Main Panel 3. Co Shutdo Indi ti Main Pa
l ( Hoot )
Single PCC Set With AMF 1.Remote Start Connections Wired up through V. S. Relay 2. Remote Emergency Stop on Main Panel 3. Common Shutdown Indication on Main Panel ( Hooter) 4. Customer Fault No.2 -Earth Fault Relay 5. Not On Auto Indication on Main Panel 6. High Engine Temp. Indication on main Panel 7. Over Speed Indication on Main Panel 8.. Low Coolant Level Indication on Main panel 9.. Low Lube Oil Pressure Indication on main Panel 10.Over Crank Indication on Main Panel 11. Closing Coil for Breaker ( 24vdc Closing Coil) 12.Common Warning Indication on Main Panel (Hooter) 13. CB Open /Close Inhibit Switch on Main Panel 14. Shunt Trip coil for Breaker ( 24Vdc Shunt Trip Coil) Single PCC Set with Droop Operation 1. Remote Start Switch on Main Panel 2. Remote Emergency Stop on Main Panel 3. Co Shutdo Indi ti Main Pa
l ( Hoot )
Mandatory Connections from the PCC to the Main panel for : Single PCC Set Paralleled with Non PCC Sets 1. Remote Start Switch on Main Panel 2. Remote Emergency Stop on Main Panel 3. Common Shutdown Indication on Main Panel ( Hooter) 4. Customer Fault No.2 -Earth Fault Relay 5. Not On Auto Indication on Main Panel 6. High Engine Temp. Indication on main Panel 7. Over Speed Indication on Main Panel 8.. Low Coolant Level Indication on Main panel 9.. Low Lube Oil Pressure Indication on main Panel 10. Closing Coil connections for Breaker ( 24vdc Closing Coil) 11.Common Warning Indication on Main Panel (Hooter) 12. CB Open /Close Inhibit Switch on Main Panel 13. Shunt Trip Connections for Breaker ( 24Vdc Shunt Trip Coil) 14. 5 Kilo Ohm Resistances between terminals 54,55 & 56,57 15.Synchronising panel
Multiple PCC Sets Paralleled with Utility 1. Remote Start Switch on Main Panel 2. Remote Emergency Stop on Main Panel 3. Common Shutdown Indication on Main Panel ( Hooter) 4. Customer Fault No.2 -Earth Fault Relay 5. Not On Auto Indication on Main Panel 6. High Engine Temp. Indication on main Panel 7. Over Speed Indication on Main Panel
Single PCC Set Paralleled with Utility 1. Remote Start Switch on Main Panel 2. Remote Emergency Stop on Main Panel 3. Common Shutdown Indication on Main Panel ( Hooter) 4. Customer Fault No.2 -Earth Fault Relay 5. Not On Auto Indication on Main Panel 6. High Engine Temp. Indication on main Panel 7. Over Speed Indication on Main Panel 8.. Low Coolant Level Indication on Main panel 9.. Low Lube Oil Pressure Indication on main Panel 10. Closing Coil for Breaker ( 24vdc Closing Coil) 11.Common Warning Indication on Main Panel (Hooter) 12. CB Open /Close Inhibit Switch on Main Panel 13. Shunt Trip for Breaker ( 24Vdc Shunt Trip Coil) 14.Ground Connection Of terminal No.51 15.24Vdc to Terminal no.50 to enable Synchroniser 16.Ext.l Load set terminal Nos.59 & 60 ( 0-5 Vdc) I/p to PCC 17.24Vdc Supply to terminal No.46. 18.Ground conn. through Utility Breaker Aux. NO Contact
Parameters to be logged on Hourly basis
DG No. Time
Voltage Cool.Te mp. Eng.R No. of Lube Oil Lube Right/Le Batty. un Hrs Starts Temp. Oil Pr. ft Volt. RPM Gov % Reg% L12 L23 L31
L1
Current
L2
L3
KW
PF
KWh
%Load %Amps
