MCM3320 Application Training Switchgear Engineer Training 083006 Rev4 New Cummins Template

Rev 1.5 prdJune 13, 2006

MCM3320 QTQ Training

2 Rev 1.5 prdJune 13, 2006

Presentation Outline Introduction Features Hardware Operation System Setup and Simulator (HANDS ON) Operation (continued) Variables Interconnect HMI & Simulator (HANDS ON) InPower Applications (GROUP) Control and Component Mode Panels New Discussion/Questions/Comments

3 Rev 1.5 prdJune 13, 2006

Presentation Goals

What are the capabilities of the MCM3320? What are the board connections? How does it operate? How do I apply it? How do I set it up?

4 Rev 1.5 prdJune 13, 2006

MCM3320 Information

Lotus Notes Database “Commercial ESB Controls”

Sort by “Category”Look for “MCM3320”This presentation and other technical

information located thereAn Application Guide is in the works to provide

a one-stop document

5 Rev 1.5 prdJune 13, 2006

MCM3320 Technical Support

Documentation PGA Controls Engineering:

1. Kevin Aufderhar

2. Paul Dahlen

3. Rich Scroggins

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One-Line Feature Summary (Q2 2006)

FEATURES

G1

G2

G3

G4

Load1 Load2 Load3 Load4 Load5 Load6

MCM3320

AUX101AUX102

HMI211OperatorPanel #2

GM UM

Customer I/O

BreakersorATS

AC MeteringSource FailureGensets Start/StopMain Breaker ControlSync/Volt MatchOpen/Closed TransitionLoad RampingExtended ParallelingkW and kVAR ControlLoad DemandLoad Add / ShedSchedulerModbusDiagnostics

HMI112GensetsBargraph

HMI211UtilityBargraph

HMI211OperatorPanel #1

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Feature Validation

All available features have been testedFirmware testBench test w/simulatorLive test at Fridley Endurance Pad test facilityLive test at Fridley with real Utility Source

(transfers, sync, base load / peak shave)

FEATURES

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AC Metering3 Phase metering of genset bus and utility bus simultaneously

Phase and Total/avg metering of V, A, kW, kVAR, kVA, PF, Hz

Phase and total metering of +kWh, -kWh, +kVARh, -kVARh, kVAh for each source

CT secondaries of 1A or 5APT accepts 0-480VLL directly; external PT for higher

voltages (up to 35000V) PT and CT inputs pre-calibrated

FEATURES

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Master Sync / Volt Matchboth phase synchronization and voltage matching20 genset limit for synchronizer frequency offset range: +/- 1.0 Hz min; up to +/- 3.0Hzoutput voltage offset range: +/- 6% min; up to +/- 10%offset range generally independent of gen bus load

FEATURES

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Master Sync / Volt Match controls frequency and voltage via PCC kW and kVAR

load share lines selectable phase synchronization (default) or slip

frequency synchronization sync enable input for manual control modeoption to invert synchronizer polarity if genset and

utility swap positions in synchronizer only application (via Modbus)

FEATURES

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Permissive Sync Check sync check function is independent of synchronizer adjustable frequency window, phase window, voltage

window, and window time for permissive check includes configurable dead bus logic sync check output fail to synchronize diagnosticphase rotation mismatch diagnostic

FEATURES

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Breaker Control interface for both genset main and utility main close and open control – momentary energization until

desired position is achieveda/b and tripped breaker position inputsadjustable breaker recharge time delay to prevent fail

to close due to inadequate charge time

FEATURES

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Breaker Controlutility paralleling enable outputbreaker inhibit control inputbreaker diagnostics with appropriate system control

reactionadjustable fail to close and fail to open time delaysparalleling fail to disconnect diagnostic with

configurable system control reaction

FEATURES

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Breaker Controlanti-pump avoidance logic – external breaker position

contacts not required in series with trip coilbreaker inhibit output to control individual genset

paralleling breakers in applications with no gen main, and for backup disconnect protection capability

FEATURES

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Power Transfer Controlopen transition w/pgm transition delay, hard closed

transition (<100msec), soft load closed transition sensors (uv, ov, freq, phase rot, loss of phase, gen

bus capacity, and breaker failure)adjustable time delays (pgm transition, transfer,

retransfer, max parallel, gensets start delay, gensets stop delay)

source availability determination for both utility and genset

source connected determination for both utility and genset

FEATURES

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Power Transfer Controlgensets start/stop logic with single relay output transfer and retransfer inhibit inputsoverride input to override timers and

transfer/retransfer inhibits for immediate transfer, retransfer or genset start

auto/manual mode input

FEATURES

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Power Transfer Control test start inputadjustable test with or without loadoption to do open transition retransfer if fail to sync

occurs

FEATURES

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System TopologiesTransfer Pair (UM / GM) Common Bus (UM / no GM) Isolated Bus (GM) Isolated Bus (no GM) Master Synchronizer Only

FEATURES

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System Topologies

Transfer Pair (System Types 2,3,4,8,10,11)

Load

G1 G2 G3 G4

UM GM

MCM3320

FEATURES

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System Topologies

Common Bus (System Type 9)

Load

G1 G2 G3 G4

UM

MCM3320

FEATURES

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System Topologies

Isolated Bus w/GM (System Type 7)

Load

G1 G2 G3 G4

GM

MCM3320

FEATURES

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System Topologies

Isolated Bus Without GM (System Types 5,6)

Load

G1 G2 G3 G4

MCM3320

FEATURES

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System Topologies

Master Synchronizer Only (metering optional)

Source

G1 G2 G3 G4

MCM3320

SyncCheck

FEATURES

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Multiple MCM3320s

master inhibit input will inhibit the synchronizer and power transfer control functions

use in complex systems with multiple transfer pairs and multiple MCM3320s

external logic device is required to assert the master inhibit as required (e.g. during a retransfer sequence of multiple pairs)

future enhancement will allow automatic priority control through interconnected MCM3320s (similar to First Start Bus PT logic)

(External)

FEATURES

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Extended Paralleling MANY options available for controlling kW and kVAR in

extended paralleling mode (kVAR not applicable for PCC3100)

kW and kVAR can be independently controlled in any combination of base load (control the power @ gen bus) or peak shave (control the power @ utility bus)

load control operates independently of the number of gensets that are online

Maximum of 20 gensets kW base load control selectable as open loop or closed

loop kW peak shave control is closed loop only

FEATURES

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Extended Paralleling setpoints can be set from InPower, HMI, Modbus, or via analog

hardware 0-5V inputs extended parallel start input starts/stops the mode soft load ramping separate diagnostic for kW and kVAR if unable to acheive

setpoint within 60 seconds

FEATURES

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System Scheduler

12 program run schedules run schedules configurable for start day, start

time, duration, repeat interval, and run mode run modes: without load, with load, or extended

parallelprovides up to 6 different schedule exceptionsuses on-board Real Time Clock

FEATURES

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Real Time Clock

on-board RTC used by Scheduler function clock keeps track of year, month, day, date, hour,

minute, and second user must set the clock on first power-up clock automatically accounts for leap year configurable automatic Daylight Savings Time clock

correction clock setting will remain valid for at least 24 hours

without B+ to the board diagnostic fault occurs if clock needs to be set (scheduler

won’t run)

FEATURES

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Load Demand

Use to match online generating capacity to load in order to optimize fuel use and genset life

load demand for up to 4 gensets fixed sequence OR run-hours based adjustable shutdown and restart thresholds as well as

time delays and run hour differential 4 load demand driver outputs to connect to PCC genset

control's load demand inputs requires genset paralleling breaker position 'a' contacts

connected to 3320

FEATURES

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Load Add/Shed

adds loads in steps as gensets come online sheds loads to unload an overloaded genset bus Requires external module: AUX101/2 PCCNet I/O

Module for feeder breaker and/or ATS control supports up to 6 levels supports up to 4 gensets control up to 6 feeder breakers or ATS directly in any

combination monitoring of breaker / ATS position provided

FEATURES

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Modbus RTU intended for PLC interface published register map read/write access operational data, control, and setup variables MCM3320 is Modbus slave RS232 or RS485 connection settable address (allowing multiple MCM3320 slaves on RS485) communications setup and diagnostics

FEATURES

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Diagnostics individual On-Board LEDs for:

Utility Available

Utility Connected

Genset Available

Genset Connected

Not In Automatic

Common Warning

Heartbeat

Synchronizing

Synchronized

Fail To Sync

Modbus Communication Activity

FEATURES

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Diagnostics

GensetConnected

UtilityConnected

GensetAvailable

UtilityAvailable

CommonAlarm

Not InAutomatic

Heartbeat(blink)

Fail to Sync

Blink = SyncSolid = Okto Close

LED Indicators

ModbusActivity

FEATURES

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Diagnostics On-Board seven segment LED for indication of:

System State indication of what the control is currently doing

Fault Code Readout (hold fault reset switch active for >5sec to change to fault code readout mode)

FEATURES

35 Rev 1.5 prdJune 13, 2006

Diagnostics

FEATURES

Decimal Point = Off System State

Seven Segment LED IndicatorDecimal Point = On

Active Fault Code Flashout

System State LED Output Character

Not Available - (center segment)TD Start 1TD Stop 2TD Pgm Tran 3TD Transfer 4TD Retransfer 5Synchronizing 6Sync Check OK 7Inhibit 8Unassigned 9Ramp Unload ARamp Load bManual CUtility Failure dTest EStandby JExtended Parallel H

Code Event Name Response343 Hardware Failure Warning Warning353 EEPROM Write Error Warning Warning

1121 Fail To Disconnect Warning Warning1219 Utility Main Breaker Tripped Warning Warning1222 Not In Automatic Event Event1223 Utility Bus Frequency Warning Warning1224 Genset Bus Overvoltage Warning Warning1225 Genset Bus Undervoltage Warning Warning1226 Genset Bus Frequency Warning Warning1328 Genset Main Breaker Tripped Warning Warning1335 AC Metering Out Of Range Warning Warning1444 Genset Bus Overload Warning Warning1452 Genset Main Breaker Fail To Close Warning Warning1453 Genset Main Breaker Fail To Open Warning Warning1454 Genset Main Breaker Position Contact Warning Warning1455 Utility Main Breaker Position Contact Warning Warning1456 Synchronizer Output Limit Warning Warning1457 Fail To Synchronize Warning Warning1458 Synchronizer Phase Rotation Mismatch WarningWarning1483 Common Warning Event Event1534 Load Control Output Event Event1541 Genset Failed To Come Online Warning Warning1689 Real Time Clock Power Interrupt Warning Warning1912 Utility Bus Loss Of Phase Warning Warning1913 Genset Bus Loss Of Phase Warning Warning1914 Utility Bus Phase Rotation Warning Warning1915 Genset Bus Phase Rotation Warning Warning1916 Synchronized Event Event1989 kW Load Control Output Limit Warning Warning1991 kVAR Load Control Output Limit Warning Warning1999 Maximum Parallel Time Warning Warning2328 Utility Bus Available Event Event2331 Utility Bus Undervoltage Warning Warning2332 Utility Bus Connected Event Event2333 Genset Bus Connected Event Event2358 Utility Bus Overvoltage Warning Warning2396 Utility Main Breaker Fail To Close Warning Warning2397 Utility Main Breaker Fail To Open Warning Warning2416 Calibration Checksum Warning Warning2647 Load Demand Setup Warning Warning2648 Remote IO Communication Failure Warning Warning2965 Genset Bus Available Event Event2971 Test / Extended Parallel Event Event

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Diagnostics 42 diagnostics (warnings and events) each event or warning is mappable to 8 customer low side

driver outputs active warning codes can be read out on 7segment LED on

board some warnings alter control operation warnings are latched until user fault reset events are not latched

FEATURES

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DiagnosticsCommon Alarm EventGenset Available EventGenset Connected EventSynchronized EventTest / Extended Parallel EventUtility Available EventUtility Connected EventAC Metering Out of Range WarningCalibration Checksum WarningEEPROM Write Error WarningFail To Disconnect WarningFail To Synchronize WarningGenset Main Breaker Fail To Close WarningGenset Main Breaker Fail To Open WarningGenset Main Breaker Position Contact WarningGenset Main Breaker Tripped WarningGenset Frequency WarningGenset Loss of Phase WarningGenset Overvoltage WarningGenset Phase Rotation WarningGenset Undervoltage WarningHardware Failure Warning

kVAR Load Control Output Limit WarningkW Load Control Output Limit WarningMaximum Parallel Time WarningNot In Automatic WarningReal Time Clock Power InterruptSynchronizer Output Limit WarningSynchronizer Phase Rotation Mismatch WarningUtility Main Breaker Fail To Close WarningUtility Main Breaker Fail To Open WarningUtility Main Breaker Position Contact WarningUtility Main Breaker Tripped WarningUtility Frequency WarningUtility Loss of Phase WarningUtility Overvoltage WarningUtility Phase Rotation WarningUtility Undervoltage WarningLoad Demand Setup WarningRemote IO Communications WarningGenset Bus Overload WarningGenset Failed To Come Online WarningUtility Source Unloaded Event – Coming SoonGenerator Source Unloaded Event – Coming Soon

FEATURES

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InPower V5.5

MON RS485 interface standard InPower folders: Adjustments, Faults,

Monitor, Testbuilt in Setup Tooldownload new firmware capture files

FEATURES

39 Rev 1.5 prdJune 13, 2006

InPower V5.5 Setup Tool

special application to assist with setup of the MCM3320

user friendly screens

help file

FEATURES

40 Rev 1.5 prdJune 13, 2006

MCM3320 FEATURES

High/Low Battery VoltageFlexible TopologyAnnunciator Support

In Development

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High/Low Battery Voltage

Provide faults for high and low battery voltage as sensed at the MCM3320

Details to be determined

FEATURES

42 Rev 1.5 prdJune 13, 2006

Flexible Topology

Make the MCM3320 more flexible for use in complex system topologies

Provide Extended Parallel w/o breaker controlProvide outputs for source unloaded for utility

and generatorEliminates need for Bitronics transducerAllows PLC to control breakers

FEATURES

43 Rev 1.5 prdJune 13, 2006

Feature Limits Quiz

How many gensets can be supported by the following features ?

FEATURES

•AC Metering•Synchronizing•Load Demand•Load Add / Shed•Utility Paralleling

32000kW, 10000A

20

4

4

20

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Annunciator Support

Utility Available

Utility Connected

Gen Bus Available

Gen Bus connected

Not In Auto

Common Alarm

Fail to Sync

Gen 1 Running

Gen 2 Running

Gen 3 Running

Gen 4 Running

Test

Extended Parallel

Gen Bus Overload

Load Demand

FEATURES

Priority 1 Load On

Priority 2 Load On

Priority 3 Load On

Priority 4 Load On

Priority 5 Load On

Priority 6 Load On

Shed Level 1

Shed Level 2

Shed Level 3

Shed Level 4

Shed Level 5

Annunciator 1 Layout Annunciator 2 Layout

45 Rev 1.5 prdJune 13, 2006

Feature Limits Quiz

What can Load Add / Shed support ?

FEATURES

•Load Device Types•Load Add Levels•Load Shed Levels•# of Gensets

Breaker, ATS

6

6

4

46 Rev 1.5 prdJune 13, 2006

HARDWAREMCM3320 HMI211 AUX101/2

InPower Cable HMI Harness HMI112

47 Rev 1.5 prdJune 13, 2006

Part Numbers

HARDWARE

Part Number Model Released? Description

0327-1520-01 MCM3320 Yes fully featured master control module 0327-1520-02 SYNC1320 Yes depopulated/defeatured synchronizer only module 0300-6090 HMI 211 Yes operator interface panel (can use one or two) 300-6050-01 HMI 112 Yes Bargraph panel (use 2 – one for genset bus, one for utility bus) 0541-1342 AUX101/2 Yes PCCNet IO Module with Expansion card for use with Load Add

Shed Feature (one only) 0338-4747 Yes 12 foot harness for connecting HMI to MCM3320; can be cut to

length 0630-3133 Yes MCM3320 Interconnect Wiring Diagram and Outline 0630-3136 Yes SYNC1320 Interconnect Wiring Diagram and Outline 0541-1199 Yes Cable and RS485/232 Converter Kit for connecting to controller

with InPower, Engineering Tool, or Setup Tool (Kit is for PCC1301 product, but will work with MCM3320 or SYNC1320)

48 Rev 1.5 prdJune 13, 2006

MCM3320Genset CT Inputs

(1A or 5A)

Modbus RTU(RS232)

TB6Genset PT Input(480V LL Max)

Utility PT Input(480V LL Max)

Utility CT Inputs(1A or 5A)

TB9Analog IO

TB3

TB1

TB10

TB8TB15

TB2

TB7

L1* L2* L3* L1* L2* L3*

GEN UTILITY

Switch IO / PCCNet (TB1)

Switch IO / CAN (TB3)

Breaker Status Inputs (TB10)

Breaker Control / Start Gensets (TB8)

InPower orModbus RTU

(RS485)

Switch IO /DC Power In

J14

J17

Factory Test Connector (J17)

HARDWARE (MCM3320)

49 Rev 1.5 prdJune 13, 2006

Hardwired IO

Gen Utility

Load

Gen O

penG

en Close

Gen P

ositionA

Extended Para Start

Sync Enable

Utility Source Failure

Transfer Inhibit

Retransfer Inhibit

Gen CB Tripped

Util CB Tripped

Gen P

osition B

Manual

Test Start

Fault Ack/Reset

Gen1 Available

Gen2 Available

Gen3 Available

Gen4 Available

kVAR Load Setpoint

Master Freq Bias

Master Volt Bias

Master Inhibit

Load Govern Enable

Load Demand Gen1

Load Demand Gen2

Load Demand Gen3

Load Demand Gen4

Start Gensets Relay

kW Master Load Control

Gen CB Inhibit

Util CB Inhibit

Cfg Out1 (com warn)

Cfg Out2 (fail to sync)

Cfg Out3 (gen avail)

Cfg Out4 (util avail)

Cfg Out5 (fail to discon)

Cfg Out6 (sync’d)

Cfg Out7

Cfg Out8

Relay Supply

B+ Input1

Gnd

RS485 PCCNet

RS485/232 Mon/MB

B+ Input2

Gnd

CAN (Master)

BIDIRECTIONALB+ POWER

DISCRETEINPUTS

(active low w/pullup)

DISCRETEOUTPUTS

(low side drivers)

ANALOGINPUTS(0-5V)

ANALOGOUTPUTS

GENV/I

BUS/UTILV/I

COMMUNICATIONS

Override

RELAY OUTPUTS

B+ OUTPUTS

P. Dahlen9/8/05

BREAKERINTERFACE

(discrete inputs /relay outputs)

Util O

penU

til Close

Util P

ositionAU

til Position B

Paralleling GensetsBreaker Inhibit

MCM3320 Hardware I/O

kW Load Setpoint

kVAR Master Load Control

HARDWARE (MCM3320)

50 Rev 1.5 prdJune 13, 2006

B+ Power

2 separate B+ power inputs for redundant supply of control; station battery suggested

On-board diode-OR Range: 9-32V Will ride-through starter dip Less than 1 Adc load (no external B+ loads) On-board backup of Real Time Clock (minimum 24

hours) No wakeup input; board is always awake Removal of B+ will not cause loss of any historical data

(controller on-time, kWh, etc.)

HARDWARE (MCM3320)

51 Rev 1.5 prdJune 13, 2006

PT Inputs

Nominal Range 110 – 480 V LLExternal Transformer to 35 kV LLSensing to 125% of Nominal3 Wire or 4 Wire

HARDWARE (MCM3320)

52 Rev 1.5 prdJune 13, 2006

CT Inputs

Primary from 5 to 10000 AmpsSecondary 1 Amp OR 5 AmpNo terminal block; CT on-board with holeRecommend shorting block nearby2 passes through hole for 1 Amp1 pass for 5 AmpSensing to 125%

HARDWARE (MCM3320)

53 Rev 1.5 prdJune 13, 2006

HW Discrete Inputs

22 hardwire switch inputs Inactive State: Open circuit / high impedance

(not B+)Active State: Connect to ReturnCan use local B- for return Inputs are activated by current (opto coupled)

HARDWARE (MCM3320)

54 Rev 1.5 prdJune 13, 2006

HW Discrete Inputs

Discrete Input Active State (to Gnd)

Inactive State (open cicuit)

Description

Fault Reset Reset Not Reset reset faults; engage fault readout Auto/Manual Manual Auto manual or auto breaker / sync operation Test Start Start Stop test load transfer start / stop Extended Parallel Start Start Stop extended paralleling start / stop Synchronizer Enable Active Inactive sync enable (applies in manual only) Utility Source Failure Active Inactive use if external device determines failure Transfer Inhibit Inhibit No Inhibit inhibit transfers to gens (some exceptions) Retransfer Inhibit Inhibit No Inhibit inhibit retransfers to util (some exceptions) Override Override No Override override timers and tran/retran inhibits Gen Main CB Inhibit Inhibit No Inhibit open gen main / inhibit closure Util Main CB Inhibit Inhibit No Inhibit open util main / inhibit closure Gen Main CB Tripped Tripped Not Tripped gen main breaker tripped; source not avail Util Main CB Tripped Tripped Not Tripped util main breaker tripped; source not avail Gen1 CB Position Breaker Closed Breaker Open genset #1 breaker position ('a' contact) Gen2 CB Position Breaker Closed Breaker Open genset #2 breaker position ('a' contact) Gen3 CB Position Breaker Closed Breaker Open genset #3 breaker position ('a' contact) Gen4 CB Position Breaker Closed Breaker Open genset #4 breaker position ('a' contact) Util Main CB PositionA Breaker Closed Breaker Open util main breaker position ('a' contact) Util Main CB PositionB Breaker Open Breaker Closed util main breaker position ('b' contact) Gen Main CB PositionA Breaker Closed Breaker Open gen main breaker position ('a' contact) Gen Main CB PositionB Breaker Open Breaker Closed gen main breaker position ('b' contact) Master Inhibit Inhibit No Inhibit master inhibit for multiple pair operation

HARDWARE (MCM3320)

55 Rev 1.5 prdJune 13, 2006

HW Discrete Outputs

19 hardwire discrete outputs5 relays; 14 low-side drivers low-side drivers can sink 200mAbreaker relays (4) can drive coils directly in

some limited cases; else use interposing relays

HARDWARE (MCM3320)

56 Rev 1.5 prdJune 13, 2006

HW Discrete Outputs

Output Signal Name (hardware)

Active State (Low / Energized)

Inactive State (High Impedance / Deenergized)

Description

Start Gensets Relay Run Stop form C relay to start / stop gensets (via Remote Start) Util Main CB Close Relay Active Inactive N.O. relay contact for utility main close coil Util Main CB Open Relay Active Inactive N.O. relay contact for utility main open coil Gen Main CB Close Relay Active Inactive N.O. relay contact for gen main close coil Gen Main CB Open Relay Active Inactive N.O. relay contact for gen main open coil Load Govern Enable Driver Enabled Disabled low-side driver to PCC genset's util cb position input to

put PCC in load govern mode when utility paralleled Paralleling Gensets Breaker Inhibit Driver

Inhibit All Gensets No Inhibit low-side driver to PCC genset's paralleling breaker inhibit input

Load Demand Gen1 Driver Load Demand Stop Run low-side driver to PCC genset #1 load demand input Load Demand Gen2 Driver Load Demand Stop Run low-side driver to PCC genset #2 load demand input Load Demand Gen3 Driver Load Demand Stop Run low-side driver to PCC genset #3 load demand input Load Demand Gen4 Driver Load Demand Stop Run low-side driver to PCC genset #4 load demand input Configurable Output1 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output2 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output3 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output4 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output5 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output6 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output7 Driver Driver On Driver Off activated by programmable event/warning code Configurable Output8 Driver Driver On Driver Off activated by programmable event/warning code Relay Supply B+ Output B + Output B + output for supplying relay coil high side; low side

connected to a low-side driver output

HARDWARE (MCM3320)

57 Rev 1.5 prdJune 13, 2006

HW Bidirectional Discrete

Bidirectional discrete I/O for priority arbitration (like 1st Start Bus PT)

Used in Phase 2 for priority control among multiple MCM3320s

Same connection as “Master Inhibit” (externally controlled sequencing)

HARDWARE (MCM3320)

58 Rev 1.5 prdJune 13, 2006

HW Analog Inputs

2 hardwire analog inputs kW Load Setpoint (0-5V) kVAR / PF Load Setpoint (0-5V)used for base load / peak shave setpointsalternatively set via Modbus or Trim load setpoint profiles same as

PCC3100/3200/3201

HARDWARE (MCM3320)

59 Rev 1.5 prdJune 13, 2006

HW Analog Outputs

2 hardwire analog outputs kW Master Load Control (0-5V) kVAR Master Load Control (0-5V) Used for load control commands to PCC genset load set

inputs to control soft ramping and base load / peak shave

kVAR control only available on PCC3200/3201, PCC3300 genset controllers

New Rev D board supports interconnection of analog outputs amongst multiple 3320s

HARDWARE (MCM3320)

60 Rev 1.5 prdJune 13, 2006

HW Bidirectional Analog

Two bidirectional analogs for synchronizerMaster Frequency Bias senses/drives kW load

share line to affect gen bus frequencyMaster Voltage Bias senses/drives kVAR load

share line to affect gen bus voltageOutput range -2.5 to + 5.0 Vdrives up to 20 gensets simultaneously

HARDWARE (MCM3320)

61 Rev 1.5 prdJune 13, 2006

Communications

Controller has 2 serial portsPort1

– Protocol Options• PCCNet – for HMI, IO Modules (default protocol)• Mon – for troubleshooting only (cannot download); set to

Mon mode via Modbus on Port2 or through InPower

– Physical• RS485 on TB1• Multidrop for PCCNet

HARDWARE (MCM3320)

62 Rev 1.5 prdJune 13, 2006

Communications

Port2: – Protocol Options

• Modbus RTU (MCM3320 is SLAVE)• Mon (Service Port for InPower/Setup Tools)• Controller automatically detects protocol

– Physical• RS232 on J14 (DB9 pins); Null Modem cable• RS485 2-wire on TB15• RS485 is default; control switches to RS232 when

RS232 RTS to CTS pins are jumpered by cable

HARDWARE (MCM3320)

63 Rev 1.5 prdJune 13, 2006

HMI211 Operator Panel

HMI211 PCCNet interface (4wires):B+ / GNDRS485 A / B

• Up to two HMI211’s can be connected to one MCM3320

• Use harness 0338-4747 to connect; cut to length or extend (12ft / 3.6m)

HARDWARE (HMI211)

64 Rev 1.5 prdJune 13, 2006

HMI112 Bargraph

HMI112 Bargraph PCCNet interface (4wires):B+ / GNDRS485 A / B

• Connect two HMI211’s to one MCM3320 to get both source data

HARDWARE (HMI112)

65 Rev 1.5 prdJune 13, 2006

AUX101/2 IO Module

HARDWARE (AUX101/2)

P11 (Inputs)

P10 (Ground for Inputs)

P2 (Relays)

P3(Relays)

P4(Relays)

P14 (B+ / Gnd)

P1 (PCCNet, Wakeup)

P4 (Inputs)

P3 (Relays - NC)

P2 (Relays - Com)

P1 (Relays - NO)

AUX101

AUX102

Connect to GroundedChassis

Device Number: Must Read “0” forMCM3320 Applications.To Change Device Number, Press andhold pushbutton until decimal point isilluminated. Then push buttonrepeatedly to cycle through numbersuntil it reads “0”.

Green LED: PCCNetCommuncations OK

Red LED: PCCNetCommuncations Not

OK

Relay LEDsON = Energized

Aux102 Board RevisionLevel: First letter on barcode(read from left to right) must

be “C” or higher letter.

Relay LEDsON = Energized

AUX102 connects toLoad Devices #5,6

AUX101 connects to LoadDevices #1,2,3,4

66 Rev 1.5 prdJune 13, 2006

Connections

• Modules required for Load Add Shed feature

• MCM3320 to AUX101 PCCNet interface (4 wires):B+ / GNDRS485 A / B

• 12 discrete inputs used for breaker / ATS position monitoring

• 12 form C relays used for breaker / ATS control

HARDWARE (AUX101/2)

67 Rev 1.5 prdJune 13, 2006

MCM3320 OPERATION

MCM3320 can completely manage simple systems – breaker control, synchronizing, load control, gensets start/stop, diagnostics, etc.

MCM3320 can be used as a component in more complex systems with whichever features are appropriate; a PLC can orchestrate the actions of the MCM3320

68 Rev 1.5 prdJune 13, 2006

MCM3320 FUNCTIONS

MCM3320 Major Functional Blocks– Application Configuration– System Information– IO Processing– AC Metering– Breaker Control– Power Transfer Control– Synchronizer & Sync Check– Load Control– Scheduler– Load Demand– Load Add/Shed– Communications– Diagnostics / History– HMI 211

69 Rev 1.5 prdJune 13, 2006

Application Configuration

Primary Settings:System Topology

Transition Type

Extended Parallel Enable

Test With Load Enable

Settings are trims (can be saved) or can be dynamically set via Modbus, InPower or HMI

FUNCTIONS

70 Rev 1.5 prdJune 13, 2006


MOST IMPORTANT SETTING (set it 1st)

System TopologyTransfer Pair

Common Bus

Isolated Bus with GM

Isolated Bus without GM

Master Synchronize Only (default)

FUNCTIONS

71 Rev 1.5 prdJune 13, 2006


Transition TypeOpen Transition (default)

Hard Closed Transition (<100msec overlap)

Soft Closed Transition

Extended Parallel EnableDisabled (default)

Enabled

Test With Load EnableDisabled (default)

Enabled

FUNCTIONS

72 Rev 1.5 prdJune 13, 2006


Must be in Manual mode to set System Topology

Hard Closed Transition not applicable in Common Bus topology

Transition Type only applies to load transfersThus Transition Type = (Open Transition OR

Hard Closed) is compatible with Extended Parallel Enable = Enabled

FUNCTIONS

73 Rev 1.5 prdJune 13, 2006

System Information

Settings for System Phase Rotation, System Frequency, Individual Genset kW Ratings

Derived Information such as Total System Capacity, Total Online Capacity, Spare Online Capacity, etc. for use in other control function blocks

System State derived variable– Shows what system is currently doing that is most

relevant– Use for information only, not for control decisions

FUNCTIONS

74 Rev 1.5 prdJune 13, 2006

System Information

System Lockout derived variable indicating that normal control logic has been altered due to a fault

Active / Inactive latched until user fault reset must be reset for normal control operation to resume LED on HMI Conditions which make it active:

Utility Breaker Fail to Close Fault State = ActiveUtility Breaker Fail to Open Fault State = ActiveUtility Breaker Position Contact Fault State = ActiveGenset Breaker Fail to Close Fault State = ActiveGenset Breaker Fail to Open Fault State = ActiveGenset Breaker Position Contact Fault State = Active(Fail to Synchronize Fault State = Active AND Fail to Sync Lockout Enable = Enabled)Maximum Parallel Time Fault State = ActiveGenset Bus Overload Fault State = Active AND (Load Demand = Enabled OR Load Add Shed = Enabled)

FUNCTIONS

75 Rev 1.5 prdJune 13, 2006

System Information

Genset Bus Overload is detected by kW level or frequency or both (configurable)

Fault Code 1444 Used internally by Load Demand and Load Shed

functions Adjustable %kW threshold: 80-140% of online

capacity Adjustable kW delay: 0-120 sec Adjustable Hz threshold: 0.1-10 Hz below System

Frequency setting Adjustable Hz delay: 0-20 sec

FUNCTIONS

76 Rev 1.5 prdJune 13, 2006

System Setup1

FUNCTIONS

77 Rev 1.5 prdJune 13, 2006

System Setup2

FUNCTIONS

78 Rev 1.5 prdJune 13, 2006

IO Processing – Discrete Inputs

Most discrete inputs can be controlled from a hardwired input OR from a communications link such as Modbus or InPower (“<name> + Vol”)

Controller will always logically OR the two inputs Result of OR is readable at “<name> + Sw”

HW SW

Conditioning &Level

Detection Sample<Signal Name>

DebounceFunction <Signal Name>

+ " Sw"

< Signal Name > + " Vol"

FUNCTIONS

79 Rev 1.5 prdJune 13, 2006

IO Processing – Discrete Outputs

For testing and troubleshooting purposes, most discrete outputs can be directly overriden using InPower

SW HW

HW UpdateOutput

Register

(enabled)

(disabled)

<Output Signal Name><Input Signal Name>

<Output Signal Name> + " Override Cmd"

<Output Signal Name> + " Override Enable"

<Output Signal Name> + " Status"

FUNCTIONS

80 Rev 1.5 prdJune 13, 2006

AC Metering Setup

PT Primary Voltage = 110-45000 VLLPT Secondary Voltage = 110-500 VLLCT Primary Current = 5-10000 ACT Secondary Current = 5 or 1 ANominal Voltage = 110-45000 VLL

– Used for %volt scaling

FUNCTIONS

81 Rev 1.5 prdJune 13, 2006

AC Metering - Voltage

Hardware inputs autoranging: 120,240,or 480 VLL = 100% at board

Input Range: 5% to 125% of above rangesSampled every line cycle on all 3 phasesLN, LL, LN-Avg, LL-Avg, % of nominal3 or 4 Wire ConnectionsFactory calibrated to better than 1% of full scale;

field adjustable

FUNCTIONS

82 Rev 1.5 prdJune 13, 2006

AC Metering - Current

Hardware inputs autoranging: 5 A or 1A = 100% at board Input Range: 0% to 125% of above ranges Sampled every 10th line cycle L1, L2, L3 and Average True RMS with 14kHz Bandwidth 1A requires two pass thru on-board CT Factory calibrated to better than 1% of full scale; field

adjustable

FUNCTIONS

83 Rev 1.5 prdJune 13, 2006

AC Metering - Power

kW, kVAR, kVA, PF True power readings; 14kHz bandwidth

If harmonics present, kW2 + kVAR2 may not equal kVA2

Sampled every 10th line cycle Per phase and totalized to +/- 32767k Sign Convention is with respect to the Source

– Positive kW = real power delivered by source– Positive kVAR = lagging vars delivered by source– Positive PF = lagging; Negative PF = leading

FUNCTIONS

84 Rev 1.5 prdJune 13, 2006

AC Metering - Energy

kWh positive, negative, net kVARh positive, negative, net kVAh netPer phase and totalized to +/- 231

Permanently storedResettable/Settable

FUNCTIONS

85 Rev 1.5 prdJune 13, 2006

AC Metering – Time Based

Precise frequency reading 25 to 80HzPrecise sync phase angle reading -180 to +180

degreesPrecise voltage phase angle readings

– Used by loss of phase sensor

FUNCTIONS

86 Rev 1.5 prdJune 13, 2006

AC Metering Setup

FUNCTIONS

87 Rev 1.5 prdJune 13, 2006

AC Metering Calibration

FUNCTIONS

• MCM3320 is factory calibrated

• Voltage and Current can be adjusted in the field if needed

88 Rev 1.5 prdJune 13, 2006

Breaker Control

Main Breaker PositionsMain Breaker ControlMain Breaker Diagnostics

FUNCTIONS

89 Rev 1.5 prdJune 13, 2006

Main Breaker Position

‘a’ and ‘b’ contact used to determine position (default) this may change

If conflict between ‘a’ and ‘b’:1. Contact fault active2. If current on all 3 phases > threshold, then breaker

considered closed, else unknown3. Source deemed not available if current based breaker

position is ‘unknown’

Can configure for ‘a’ contact only operation, this may become the default

Breaker rack-out will cause fault and source not available

FUNCTIONS

90 Rev 1.5 prdJune 13, 2006

Main Breaker Position

In applications without GM, a virtual GM is created by collection of genset paralleling breakers

In this case, if any one or more genset paralleling breaker is closed, virtual GM is closed.

IMPORTANT: If #gens <= 4, use individual genset cb position inputs. If #gens > 4 connect cb contacts in parallel to GM position inputs. Refer to 0630-3133 dwg

FUNCTIONS

91 Rev 1.5 prdJune 13, 2006

Main Breaker Control

Separate relays for close and open Relays energize until desired position achieved Adjustable recharge time delay Built-in software interlock for open transition In applications without GM, the MCM3320 controls the

virtual gen main via the paralleling gen cb inhibit inputs on the genset controls

Breakers can be controlled manually when Auto/Manual switch input = Manual

FUNCTIONS

92 Rev 1.5 prdJune 13, 2006

Main Breaker Diagnostics

Breaker Diagnostics:Fail to Close (adjustable delay)

Fail to Open (adjustable delay)

Breaker Contacts

Breaker Tripped

Fail to Disconnect

Diagnostics results in warning and appropriate control reaction

FUNCTIONS

93 Rev 1.5 prdJune 13, 2006

Breaker Setup

FUNCTIONS

94 Rev 1.5 prdJune 13, 2006

Power Transfer Control

Sensors and Source AvailabilityOperating ModePTC State MachineTimers

FUNCTIONS

95 Rev 1.5 prdJune 13, 2006

Sensors

Both sources have these sensors:• Undervoltage

• Overvoltage *

• Under/Over Frequency *

• Phase Rotation *

• Loss of Phase *

• Main Breaker Tripped

• Fail to Close

• Position Contact Failure

If any sensor is dropped-out, the source is not available

(* = optionally enabled)

FUNCTIONS

96 Rev 1.5 prdJune 13, 2006

Sensor - Undervoltage

Sensor is always enabledConfigurable L-L or L-N sensingSettings:

– Dropout Percentage– Pickup Percentage– Dropout Delay

Pickup is instantaneousTake note how settings are converted into

actual voltages (next page)

FUNCTIONS

97 Rev 1.5 prdJune 13, 2006

Sensor - Undervoltage

Voltage, V

UnderVoltageSensorStatus

NominalSystemVoltage(100%)

PickupVoltage

DropoutVoltage

PICKED UP(good)

DROPPED OUT(bad)

Pickup Voltage = Pickup Percentage * Nominal VoltageDropout Voltage = Dropout Percentage * Pickup Percentage * Nominal Voltage

FUNCTIONS

98 Rev 1.5 prdJune 13, 2006

Sensor - Overvoltage

Sensor is optionally enabledConfigurable L-L or L-N sensingSettings:

– Dropout Percentage– Pickup Percentage– Dropout Delay

Pickup is instantaneousTake note how settings are converted into

actual voltages (next page)

FUNCTIONS

99 Rev 1.5 prdJune 13, 2006

Sensor - Overvoltage

Voltage, V

OverVoltageSensorStatus

NominalSystemVoltage(100%)

PickupVoltage

DropoutVoltage

PICKED UP(good)

DROPPED OUT(bad)

Pickup Voltage = Pickup Percentage * Dropout Percentage * Nominal VoltageDropout Voltage = Dropout Percentage * Nominal Voltage

FUNCTIONS

100 Rev 1.5 prdJune 13, 2006

Sensor - Frequency

Sensor is optionally enabled Over and Under combined in one sensor Settings:

– Center Frequency– Dropout Bandwidth– Pickup Bandwidth– Dropout Delay

Pickup is instantaneous Take note how settings are converted into actual

voltages (next page)

FUNCTIONS

101 Rev 1.5 prdJune 13, 2006

Sensor - Frequency

Frequency, Hz

FrequencySensorStatus

CenterFrequency

UpperPickupFreq

LowerPickupFreq

PICKED UP(good)

DROPPED OUT(bad)

Lower Pickup Freq = (1 - Pickup Bandwidth) * Center FrequencyUpper Pickup Freq = (1 + Pickup Bandwidth) * Center FrequencyLower Dropout Freq = (1 - Pickup Bandwidth - Dropout Bandwidth) * Center FrequencyUpper Dropout Freq = (1 + Pickup Bandwidth + Dropout Bandwidth) * Center Frequency

LowerDropoutFreq

UpperDropoutFreq

FUNCTIONS

102 Rev 1.5 prdJune 13, 2006

Sensor – Phase Rotation

Sensor is optionally enabled Compares source’s phase rotation to System Phase

Rotation setting when source is at least 60% voltage and 30Hz

Once sensor is picked up (good), sensor does not recheck until voltage/freq drop below and then back above 60%, 30Hz

Settings:– System Phase Rotation– Dropout Delay

Pickup is instantaneous

FUNCTIONS

103 Rev 1.5 prdJune 13, 2006

Sensor – Loss of Phase

Sensor is optionally enabledDropout (bad) when any phase angle between

LL phasors does not fall within 90 to 150 degrees

Settings:– Dropout Delay

Pickup is instantaneousNot same as negative sequence voltage

FUNCTIONS

104 Rev 1.5 prdJune 13, 2006

Sensors - Misc

If Main Breaker Tripped input is active, source is Not Available

If Main Breaker Fail to Close fault state is active, source is Not Available

If Main Breaker Position Contact fault state is active and current does not indicate breaker is closed, source is Not Available

FUNCTIONS

105 Rev 1.5 prdJune 13, 2006

Sensors – Source Unique

Utility source additional sensor:• Utility Source Failure switch input

Genset source additional sensor:• Genset Online Capacity Sensor *• sensor picks-up when online kW capacity exceeds

threshold. Once gen main is closed, sensor stops checking.

FUNCTIONS

106 Rev 1.5 prdJune 13, 2006

Sensors Setup (utility)

FUNCTIONS

107 Rev 1.5 prdJune 13, 2006

Sensors Setup (genset)

FUNCTIONS

108 Rev 1.5 prdJune 13, 2006

Operating Mode

Evaluates utility source status, test start / stop, and extended parallel start / stop to decides whether or not to start or stop the gensets

Prioritizes and lets PTC core logic know which direction a transfer should be going, if any

FUNCTIONS

109 Rev 1.5 prdJune 13, 2006

PTC State Machine

The core of the power transfer controlFour possible states defined by four possible

combinations of GM and UM breaker positions In each state, logic unique to that state decides

whether to turn on synchronizer and whether to open or close a breaker

FUNCTIONS

110 Rev 1.5 prdJune 13, 2006

PTC State Machine

FUNCTIONS

NoCommand

CloseUtility

CloseGenset

NoCommand

OpenUtility

CloseGenset

NoCommand

CloseUtility

OpenGenset

NoCommand

OpenUtility

OpenGenset

NOSOURCE

CONNECTED

UTILITYCONNECTED

GENSETCONNECTED

PARALLELED

T2B

T1B T4A

T3A

T4B

T1A T2A

T3B

N1N2

N3

N4

U1

U2

U3

U4

P1

P2

P3

P4

G1

G2

G3

G4

PTCNOT

ENABLED

PowerupT-INIT

T99

T0

111 Rev 1.5 prdJune 13, 2006

Timers

Start TimerStop TimerTimer in each PTC State:

– Programmed Transition Timer (No Source Connected)

– Transfer Timer (Utility Connected)

– Retransfer Timer (Genset Connected)

– Maximum Parallel Timer (Paralleled)

FUNCTIONS

112 Rev 1.5 prdJune 13, 2006

Override

Override switch input (hardwired or Modbus) Forces pending action to occur immediately Useful in certain situations / applications Overrides (bypasses) the following:

– Transfer Inhibit– Retransfer Inhibit– Start Delay– Transfer Delay– Retransfer Delay

Does NOT override:– Stop Delay– Programmed Transition Delay– Maximum Parallel Time– Gen Main CB Inhibit– Utility Main CB Inhibit

FUNCTIONS

113 Rev 1.5 prdJune 13, 2006

Synchronizer & Sync Check

Synchronizer On / OffSynchronizer ControlSync CheckSynchronizer Diagnostics

FUNCTIONS

114 Rev 1.5 prdJune 13, 2006

Synchronizer On / Off

In all cases, both sources must be ‘available’ for the synchronizer to run

With PTC function, Synchronizer turns on automatically when needed if in ‘Auto’ mode

In ‘Manual’, Sync Enable input must be active to turn on

FUNCTIONS

115 Rev 1.5 prdJune 13, 2006

Synchronizer Control

Synchronizer matches phase, frequency and voltage of gen bus to utility bus

Freq Match Closed loop PI drives kW load share lines to match freq/phase

Volt Match Closed loop PI drives kVAR load share lines to match voltage

Tuning is fairly tolerant; field adjustment not expected to be required normally

Performance is very good – much improved over existing analog master synchronizer

FUNCTIONS

116 Rev 1.5 prdJune 13, 2006

Synchronizer Control

Two Synchronizing Options:– Phase Sync (default) => gen bus phase is driven to match utility

bus

– Slip Frequency => gen bus frequency is driven to be fixed Hz higher or lower than utility bus (e.g. 0.1Hz)

Use Slip Freq option with difficult to sync applications such as natural gas

Nominal System Frequency = 45-65 Hz– Used by synchronizer – must be set to nominal operating

genset frequency

FUNCTIONS

117 Rev 1.5 prdJune 13, 2006

Sync Check

Permissive sync check with adjustable frequency, phase, voltage and dwell time window

Runs independently of synchronizer PTC function uses this to decide when to close breaker Can get sync check output by mapping sync event to a

configurable output (#6 by default) In synchronizer only applications, can also enable sync

check individually for different dead bus scenarios (dead bus sensor is included)

FUNCTIONS

118 Rev 1.5 prdJune 13, 2006

Synchronizer Diagnostics

Fail to Synchronize Warning = synchronizer has been on for Fail to Sync time (adjustable) without achieving sync check ok

Synchronizer Output Limit Warning = freq bias or volt bias drive output has been at maximum and unable to achieve sync

FUNCTIONS

119 Rev 1.5 prdJune 13, 2006

Sync Setup

FUNCTIONS

120 Rev 1.5 prdJune 13, 2006

Load Control

kW and kVAR are controlled during soft transfers and extended paralleling

MCM3320 has one analog output for kW, one for kVAR

MCM3320 drives all gensets to same % command value

PCC Genset controllers perform ramping and load governing

FUNCTIONS

121 Rev 1.5 prdJune 13, 2006

Load Control

Soft LoadingExtended Paralleling kW Control kVAR ControlDiagnosticsPerformance / Tuning

FUNCTIONS

122 Rev 1.5 prdJune 13, 2006

Soft Loading

Closed transition transfer / retransfer MCM3320 either drives load set line to +5V or 0V

depending on desired ramp direction PCC genset controllers perform the ramp based on their

own ramp time settings PCC genset controllers are doing the closed loop control

of kW and kVAR (load governing) MCM3320 disconnects appropriate source when it

senses kW below threshold

FUNCTIONS

123 Rev 1.5 prdJune 13, 2006

Extended Paralleling

Many options for how / where to control kW and kVAR

Open loop or closed loop optionsControl points at gen bus or utility busSetpoints from analog input, trim setting, or

ModbusMCM3320 controls load without knowledge of

which gensets are online

FUNCTIONS

124 Rev 1.5 prdJune 13, 2006

kW Control Options

Gen Bus % Level (open loop)

» MCM3320 puts out fixed %kW command

Gen Bus kW (closed loop)

» MCM3320 adjusts output command to get desired kW at gen bus metering point

Gen Bus kW w/Utility Constraint (closed loop)

» MCM3320 adjusts output command to get desired kW at gen bus metering point subject to maintaining utility kW greater than a threshold

Utility Bus kW (closed loop)

» MCM3320 adjusts output command to get desired kW at utility bus metering point

FUNCTIONS

125 Rev 1.5 prdJune 13, 2006

kVAR Control Options

Genset Controllers» MCM3320 does nothing» ONLY OPTION WHICH WILL WORK ON PCC3100 GENSETS

Gen Bus % Level (open loop)» MCM3320 puts out fixed %kVAR command

Gen Bus Power Factor (open loop)» MCM3320 puts out %kVAR command based on power factor

setting and what is currently being put out on the %kW command output

Gen Bus kVAR (closed loop)» MCM3320 adjusts output command to get desired kVAR at gen

bus metering point

Gen Bus Power Factor (closed loop)» MCM3320 adjusts output command to get desired power factor at

gen bus metering point

FUNCTIONS

126 Rev 1.5 prdJune 13, 2006

kVAR Control Options (cont.)

Utility Bus kVAR (closed loop)» MCM3320 adjusts output command to get desired

kVAR at utility bus metering point

Utility Bus Power Factor (closed loop)» MCM3320 adjusts output command to get desired

power factor at utility bus metering point

FUNCTIONS

127 Rev 1.5 prdJune 13, 2006

Load Setpoints - Source

kW, kVAR/PF setpoints can come from hardwired analog inputs or internal setting

Internal setting can be changed from Inpower, HMI, or Modbus

analog input (hardwired)

internal

process value

setpoint source

FUNCTIONS

128 Rev 1.5 prdJune 13, 2006

Load Setpoints – Scaling

%kW, kVAR, Power Factor vs. Input Voltage

0

10

20

30

40

50

60

70

80

90

100

110

120

0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 4.25 4.5 4.75 5

Input Voltage, Vdc

%kW

/ %

kVA

R

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

Po

wer

Fac

tor

%kW/kVAR

PowerFactor

FUNCTIONS

129 Rev 1.5 prdJune 13, 2006

Load Setpoints – Scaling

If open loop load control, scaling of hardwired analog input is per graph

If closed loop load control, kW command level = % from graph * Total System Capacity

If power factor control, scaling always follows red line Definitions:

– Total System Capacity = sum of individual genset kW ratings– %kW = kW / Total System Capacity– %kVAR = kVAR / (Total System Capacity / 0.8)

FUNCTIONS

130 Rev 1.5 prdJune 13, 2006

Load Control Diagnostics

kW Load Control Output Limit Warning» kW command output has been at minimum or

maximum value for longer than 60 seconds

» Only applicable to closed loop modes

» means that the desired kW setpoint cannot be achieved either due to inadequate capacity or operator error

kVAR Load Control Output Limit Warning» analogous to kW diagnostic

» Means that the desired kVAR or Power Factor setpoint cannot be achieved either due to inadequate capacity or operator error

FUNCTIONS

131 Rev 1.5 prdJune 13, 2006

Load Control Setup (kW)

FUNCTIONS

132 Rev 1.5 prdJune 13, 2006

Load Control Setup (kVAR)

FUNCTIONS

133 Rev 1.5 prdJune 13, 2006

Scheduler

Scheduler operates based on up to 12 programs and 6 exceptions

Each program specifies a day of the week/time to start, how long to run, how often to repeat, and what mode to run in

Run modes are: test without load, test with load, and extended parallel

Each exception is defined by a start date/time, duration, and repeat interval

An exception will block a scheduled program from starting during the exception period

Scheduler will not run if real time clock has not been set

FUNCTIONS

134 Rev 1.5 prdJune 13, 2006

Scheduler

To use Extended Paralleling with the Scheduler, the Extended Parallel Enable must be set to Enabled

If program run mode = Extended Parallel, but Extended Parallel Enable = Disabled, there will never be extended paralleling (nothing will happen when program becomes active)

Some applications do not allow extended paralleling, so this provides one setting to disable all extended paralleling

FUNCTIONS

Extended Paralleling Clarification

135 Rev 1.5 prdJune 13, 2006

Scheduler

Scheduler will follow the Program Run Mode setting– If Program #1 Run Mode = With Load, system will run with load– If Program #1 Run Mode = Without Load, system will run without

load The setting of Test With Load Enable variable does NOT apply

to Scheduler– E.G. If Test With Load Enable = Disabled, but Program #1 Run

Mode = With Load, program will run with load Test With Load Enable only applies to Test Start switch input

(hardwired or Modbus or HMI) This may be confusing because it is different than how the

Extended Parallel Enable is used by the MCM3320

FUNCTIONS

Test With / Without Load Clarification

136 Rev 1.5 prdJune 13, 2006

Scheduler Setup

FUNCTIONS

137 Rev 1.5 prdJune 13, 2006

Program Overlapping

Do not overlap programs; overlapped program will be ignored

FUNCTIONS

Program1

Program2

Program1 Program2

Program1 Program2

Program1 runs for its entire periodProgram2 does NOT run

Program1 runs and ends. Some timelater Program2 runs and ends.

Program1 runs and ends. Program2 startsat same minute Program1 ends.

138 Rev 1.5 prdJune 13, 2006

Exception Operation

Exceptions only block the START of a program; a program started outside of the exception period will not be canceled by an exception

FUNCTIONS

Program1

Exception1Program1 runs for its entire period

Program1

Exception1Program1 does NOT run

139 Rev 1.5 prdJune 13, 2006

Priorities Utility Failure will supersede any scheduler program An active program will resume when the utility source has become

available again Two examples are shown below

FUNCTIONS

Program1 (no load)

Utility Failed

EXAMPLE#1:Utility fails while gensets running no loaddue to Program1. System will transfer loadto gensets. When utility returns, system loadwill remain on gensets until Program1 ends.(It does NOT retransfer until Program1 ends.)

Program1 (extended parallel)

Utility Failed

EXAMPLE#2:Utility fails while gensets running in parallelto utility due to Program1. System will openutility main breaker. When utility returns,system will sync across utility main, closeutility main and continue in parallel untilProgram1 ends.

UMBreaker

GMBreaker

Closed

Open

Closed

Open

UMBreaker

GMBreaker

Closed

Closed

Open

Open

Open

Open

Closed

Closed

140 Rev 1.5 prdJune 13, 2006

Clock & DST Setup

FUNCTIONS

141 Rev 1.5 prdJune 13, 2006

Operating Sequences

Normal Sequences1

Utility Fail / Return

Extended Parallel

Test (with or without load)

Sequences are affected byTransition Type

Operating priority

Faults2

1Refer to MCM3320 Operating Sequences document for listing of normal sequences2Refer to MCM3320 Abnormal Conditions Operation document for description of control reaction for

fault conditions.

FUNCTIONS

142 Rev 1.5 prdJune 13, 2006

Normal Sequence Example

Scenario:

Transfer Pair; Soft Closed Transition; Utility Fail / Return

1. Utility Failure2. TD Start3. Gensets Start / Close4. Gen Bus Available5. TD Transfer6. Open Utility Main7. TD Program Transition8. Close Gen Main9. Loads Powered by Gen Bus

10.Utility Available11.TD Retransfer12.Synchronizer On13.Sync Check OK14.Close Utility Main15.Ramp Unload Gensets16.Open Gen Main17.TD Stop18.Stop Gensets19. Loads Powered by Utility

FUNCTIONS

143 Rev 1.5 prdJune 13, 2006

Abnormal Condition ExampleScenario: Transfer Pair; Soft Closed Transition; Test With Load; UM Fails to Open

1. Test Start Initiated2. TD Start3. Gensets Start / Close4. Gen Bus Available5. TD Transfer6. Synchronizer On7. Sync Check OK8. Close Gen Main9. Ramp Load Gensets

10.Utility Unloaded11.Open Utility Main12.Utility Main Fails to Open13.Open Gen Main14.Gen Main Opens15.Open Utility Canceled16.Loads Powered by Utility17.Gensets Remain Running18.User Intervention Required

FUNCTIONS

144 Rev 1.5 prdJune 13, 2006

Operating Priorities

Operating priorities from highest to lowest:1. Utility Failure

2. Extended Parallel

3. Test

FUNCTIONS

145 Rev 1.5 prdJune 13, 2006

Load Demand

Supports 2, 3, or 4 genset systems 4 hardwired outputs to drive gensets load demand stop 4 hardwired inputs to read genset paralleling breaker

positions Shuts down/Restarts gensets based on genset bus total

kW load level Adjustable shutdown / restart thresholds and time delays Genset Sequence configurable as Fixed Sequence or

Run Hours Based

FUNCTIONS

146 Rev 1.5 prdJune 13, 2006

Load Demand Interconnect

FUNCTIONS

G1PCC3xxx

G2PCC3xxx

G3PCC3xxx

G4PCC3xxx

Gen1 Load Demand

Gen1 Breaker Position

Gen2 Load Demand


Gen3 Load Demand


Gen4 Load Demand


MCM3320

Genset Bus Currents

Genset Bus Voltages

Remote Start

147 Rev 1.5 prdJune 13, 2006

Load Demand Operation

Genset Sequence defines shutdown order:– GenA, GenB, GenC, GenD

GenA always runs; GenD is first to shut down, last to restart, etc.

Sequence Determination:– Fixed Sequence, or Run Hours Based

Fixed Sequence is set by the operator Run Hours Based Sequence changes dynamically as run

hours accumulate on gensets – system attempts to equalize running hours on all gensets

FUNCTIONS

148 Rev 1.5 prdJune 13, 2006


Fixed Sequence• GenA = Gen2

• GenB = Gen1

• GenC = Gen4

• GenD = Gen3

Sequence can be changed any time – even when load demand is operating

Must issue “Refresh Sequence” command after defining the new sequence in order for it to take effect (HMI211 does this for you).

On change, only the appropriate gensets will restart, then after time delay, unnecessary gensets stop in sequence

FUNCTIONS

149 Rev 1.5 prdJune 13, 2006

Load Demand Operation Run Hours Based Sequence

• Gen1 Online Time = 100 Hr GenA (lowest hr)• Gen2 Online Time = 250 Hr GenC• Gen3 Online Time = 150 Hr GenB• Gen4 Online Time = 400 Hr GenD (highest hr)

Sequence is sorted by Online Time when:• Load Demand Enable changed to Enable• Load Demand Type changed to Run Hours Based• Refresh Sequence command changed to “Refresh”

Run Hours Differential setting will determine how frequently gensets are restarted due to hours accumulation – typically set to 50hr

Online Time is accumulated by the MCM3320 based on amount of time that GenX paralleling breaker is closed

MCM3320 does not get running hours from genset control…but operator can enter hours into MCM3320 as starting point

FUNCTIONS

150 Rev 1.5 prdJune 13, 2006


Normal Operation Steps1. Gensets start and come online2. Gen Main Breaker Closes (if present)3. Load Demand times “Initial Delay”4. Load Demand monitors Load vs. Gensets5. Load Demand times “Shutdown Delay” if load allows

shutting down a genset6. Load Demand tells lowest priority genset to shutdown7. Load Demand continues to monitor load8. Load Demand stops additional gensets as load allows9. Load Demand restarts gensets as load requires10. Load Demand restarts appropriate gensets if sequence

changes due to operator or run hours (as configured)

FUNCTIONS

151 Rev 1.5 prdJune 13, 2006


Shutdown Decision [Genset Bus Load < Shutdown Percent * (Total Online

Capacity – kW Rating of Next Genset to Shutdown)] = true continously for Shutdown Delay

Restart Decision Genset Bus Load > Restart Percent * (Total Online

Capacity) Sequence has changed due to operator or run hours Genset Bus is overloaded Genset(s) have failed Load Demand Enable changed to Disabled MCM3320 has detected a problem with AC metering

FUNCTIONS

152 Rev 1.5 prdJune 13, 2006


FUNCTIONS

Online Capacity vs. Total Load

0

500

1000

1500

2000

2500

3000

3500

4000

4500

0 500 1000 1500 2000 2500 3000 3500 4000

Total Load, kW

On

line

Cap

acit

y, k

W

4 Gensets each rated at 1000kWShutdown Percent = 60%Restart Percent = 80%GenA = Gen1GenB = Gen2GenC = Gen3GenD = Gen4

Gen4 Stop

Gen3 Stop

Gen2 Stop

Gen4 Restart

Gen3 Restart

Gen2 Restart

Load=Capacity

153 Rev 1.5 prdJune 13, 2006


Overload Operation If Genset Bus Overload fault occurs, ALL load demand stopped

gensets will restart Condition is latched until overload no longer exists and operator

resets the fault Individual Genset Failure Operation

If a single genset fails, that genset is removed from the load demand logic; fault occurs

If available, a stopped genset will restart to replace the failed genset

When the failed genset comes back online, it will be readded to load demand logic and normal operation will resume

Genset Bus Failure Operation If the genset bus fails (goes “Not Available”), ALL load demand

stopped gensets will restart

FUNCTIONS

154 Rev 1.5 prdJune 13, 2006


Minimum Online Capacity Optional function allows operator to keep more than one

genset running at all times Minimizes exposure to a single genset failure if load

demand has shut down all except one genset Example: 4 gensets rated at 1000kW each; Set Load

Demand Minimum Online Capacity = 2000kW 2 gensets will always remain running

FUNCTIONS

155 Rev 1.5 prdJune 13, 2006

Load Demand Notes

PCC3100, PCC3200/1 only support load demand in isolated bus mode

PCC3300 will support load demand in utility parallel and isolated bus mode

MCM3320 Load Demand function operates both in isolated and utility parallel modes

FUNCTIONS

156 Rev 1.5 prdJune 13, 2006

Load Demand Setup

FUNCTIONS

157 Rev 1.5 prdJune 13, 2006

Load Add ShedSupports up to 4 gensets, 6 levels of Add, 6 levels of

Shed, and status for up to 6 breakers or ATS Each Breaker or ATS can be assigned to any Add

level and any Shed levelRequires AUX101 and AUX102 moduleAdds levels in sequence as gensets (up to 4) come

online; remaining add levels are timedSheds levels in timed sequence when Genset Bus

Overload condition detected; shed stops when overload is corrected

FUNCTIONS

158 Rev 1.5 prdJune 13, 2006

Load Add Shed Interconnect

FUNCTIONS

MCM3320

Load 1

Add Shed

Load 2Add Shed

Load 3Add Shed

Load 4Add Shed

AUX101 Input1 Input2 Input1 Input2 Input1 Input2 Input1 Input2

Load 5Add Shed

Load 6Add Shed

AUX102 Input1 Input2 Input1 Input2

Ribbon

Cable

'a' contact'tripped'contact

BREAKER ATSnormalsourceposition

emergencysourceposition

Relays are shown in de-energized state.Add relays energize to add load. Two second pulse for Breaker; Continuous for ATS Shed relays energize to shed load. Continuous for both Breaker and ATS.

B+GNDRS485-ARS485-B

PCCNetPort

159 Rev 1.5 prdJune 13, 2006

Load Device = Breaker

FEEDER BREAKER CONTROLAdd and Shed Relays have FormC contactsAdd Relay energizes for 2 seconds to add the load; typically

used to drive breaker close coilShed Relay energizes continuously to shed the load; typically

used to drive breaker open coilUse of breaker pilot relays is recommendedAUX101 Relays: 30Vdc/250Vac,

N.O.=5A N.C.=3AAUX102 Relays: 30Vdc/250Vac, 2A

FUNCTIONS

160 Rev 1.5 prdJune 13, 2006

Load Device = Breaker

FEEDER BREAKER MONITORTwo inputs available to monitor breakerInput 1 for breaker position from ‘a’ contactInput 2 for breaker tripped status from overcurrent trip contactBreaker monitoring is provided for operator benefit only;

connections are OPTIONAL; Load Add Shed function does not use this information

FUNCTIONS

161 Rev 1.5 prdJune 13, 2006

Load Device = ATS

ATS CONTROLAdd and Shed Relays have FormC contactsAdd Relay energizes continuously to add the load; typically

used to tell ATS that it can transfer to gensetShed Relay energizes continously to shed the load; typically

used to tell ATS to shed load (go to neutral position)Use of pilot relays may not be required

FUNCTIONS

162 Rev 1.5 prdJune 13, 2006

Load Device = ATS

ATS MONITORTwo inputs available to monitor ATSInput 1 for Source 1 switch positionInput 2 for Source 2 switch positionATS Position monitor = No Source Connected, Source 1

Connected, Source 2 ConnectedATS monitoring is provided for operator benefit only;

connections are OPTIONAL; Load Add Shed function does not use this information

FUNCTIONS

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Load Level Assignment

6 Add Levels available: 1,2,3,4,5,66 Shed Levels available: 0,1,2,3,4,5Loads can be assigned to any Add Level and any

Shed LevelAdd assignment not required to match Shed

assignmentAdd Levels add in sequence 1,2,3,4,5,6Shed Levels shed in sequence 1,2,3,4,5Loads assigned to Shed Level 0 are never shedLoad Devices can be any combination of Feeder

Breaker or Automatic Transfer Switch (ATS)

FUNCTIONS

164 Rev 1.5 prdJune 13, 2006

Load Level Assignment

FUNCTIONS

165 Rev 1.5 prdJune 13, 2006

Load Add Shed Operation

Load Add Shed ModesAutomatic Genset Load AddAutomatic Genset Load ShedManual Load Add / Shed / RestoreAutomatic Utility Load Add

FUNCTIONS

166 Rev 1.5 prdJune 13, 2006

Automatic Genset Load Add Automatic Genset Load Add Example:

3 gensets; 6 add levels

FUNCTIONS

Gen2Online

Gen1Online

Gen3Online

Level 1Added

Level 2Added

Level 3Added

Level 4Added

Level 5Added

Level 6Added

TIME

Genset BusLoad AddDelay



Timed AddAfter Last GensetIs Online

167 Rev 1.5 prdJune 13, 2006

Automatic Genset Load Add

NOTE: If all gensets do not come online, the Load Add sequence will stop and remaining add levels will not be added automaticallyOption1: Operator gets all gensets running – load add

sequence completes automatically

Option2: Operator manually adds any remaining levels desired

Option3: Configure “Required Online Capacity” to force an automatic timed add of the remaining levels when online capacity is greater than or equal to this setting (assumes total load < this setting)

FUNCTIONS

168 Rev 1.5 prdJune 13, 2006

Automatic Genset Load Shed

Automatic Genset Load Shed Example

FUNCTIONS

GensetBusOverloadCondition =ACTIVE

ShedLevel 2ON

LoadShedDelay

GensetBusOverloadCondition = INACTIVE

LoadShedDelay

TIME

ShedLevel 1ON

169 Rev 1.5 prdJune 13, 2006

Automatic Genset Load Shed

Shed Levels which are ON can only be restored by: Option1: Manual restore by operator

Option2: Retransfer to Utility or Genset Main Breaker (or all genset paralleling breakers) opened and reclosed

FUNCTIONS

170 Rev 1.5 prdJune 13, 2006

Manual Load Add / Shed / Restore

When Load Bus is fed by Genset Bus, Load Add Shed feature can be put into “Manual” mode through HMI, Setup Tool, or Modbus

This is NOT the same setting as the Auto/Manual switch for the Main Breakers

Manual mode allows operator to:Turn ON specific Add Levels which have not addedRestore specific Shed Levels which are ONTurn ON Shed Levels which are OFF

FUNCTIONS

171 Rev 1.5 prdJune 13, 2006

Manual Load Add / Shed / Restore

Restoring a Shed Level does two things:Turns off the shed relays assigned to that Shed LevelTurns on the Add relays assigned to that SHED LEVEL (2

sec pulse for Breaker; continous for ATS)

Manual mode is automatically exited if certain events occur: overload, retransfer to utility, etc…

FUNCTIONS

172 Rev 1.5 prdJune 13, 2006

Automatic Utility Load Add

Upon reconnection to utility source: all Shed Levels will be turned off all Add Levels will be added in sequence

Utility add delay adjustable from 0 to 60 seconds

FUNCTIONS

All ShedLevelsOFF

UtilityMainBreakerCloses

AddLevel 3ON

AddLevel 4ON

AddLevel 5ON

AddLevel 6ON

TIME

Utility BusLoad AddDelay



AddLevel 1ON

AddLevel 2ON



1/4 sec

173 Rev 1.5 prdJune 13, 2006

Load Add Shed Setup

FUNCTIONS

174 Rev 1.5 prdJune 13, 2006

Modbus RTU

RS485 OR RS232MCM3320 is SlaveConfigurable Address, Baud, ParityRegister Map PublishedSetup, Control, and Monitor of MCM3320sSteve Prater has developed some Quantum /

Momentum PLC code

FUNCTIONS

175 Rev 1.5 prdJune 13, 2006

Modbus Register Map

40xxx -- Genset control registers 41xxx -- Transfer switch control registers 42xxx -- Master control registers (MCM3320) 4x0xx -- General data registers for genset bus 4x1xx -- General data registers for utility bus 4x2xx -- Configuration and status registers 4x3xx -- Settings – Block 1 4x4xx -- Settings – Block 2 4x5xx -- Bitmaps 4x6xx -- Switch IO 4x7xx -- Status registers continued

FUNCTIONS

176 Rev 1.5 prdJune 13, 2006

Modbus Register Map

Modbus Address System Name Modbus

Access Specifications Description

42300 System Topology Read/Write

0: Master Synchronize Only 1: Isolated Bus w/out GM 2: Isolated Bus w/GM 3: Common Bus 4: Transfer Pair Default: Master Synchronize Only

Sets the system topology. THIS RESETS OTHER APP CONFIG SETTINGS!

42301 Transition Type Read/Write

0: Open Transition 1: Hard Closed Transition 2: Soft Closed Transition Default: Open Transition

sets the type of transition that will be used

42302 Extended Parallel Enable Read/Write 0: Disabled 1: Enabled Default: Disabled

use to enable extended paralleling operation

FUNCTIONS

177 Rev 1.5 prdJune 13, 2006

Modbus RTU

Diagnostic Tools:• Message Counters• Exception Counter• CRC Counter

Available through InPower or by Modbus Diagnostic Function (code 08)

FUNCTIONS

178 Rev 1.5 prdJune 13, 2006

Faults & Events

There are faults (warnings) and events» Fault Example: UM Fail to Close» Event Example: Utility Bus Available

Each has a code number (see previous slide for list)

Three 32 bit Bitmaps of fault/event states available on Modbus

Code numbers can be used for mapping to any of 8 configurable low-side driver outputs

NOTE: When Fault 343 (Hardware Failure) is mapped to a low-side output, it is inverted. Output is ON when hardware is OK.

Fault states are latched until fault reset and condition is inactive

Events are not latched Common Warning is an event which is active if any fault

states are active

FUNCTIONS

179 Rev 1.5 prdJune 13, 2006

Faults & Events

Fault (Warning) Logic -- Ladder Diagram

Fault Condition

Fault StateReset

Fault State

FUNCTIONS

180 Rev 1.5 prdJune 13, 2006

Faults & Events Variables Available

» Three 32bit Bitmaps of fault / event states» Current Fault Code» Active Fault Code List» Active Event Code List» Historical Information Tables – see ahead

Fault Troubleshooting Document

FUNCTIONS

Code Name Type Meaning Hints

1444 Genset Bus Overload

Warning Total Kw delivered by Genset Bus is greater than or equal to Genset Bus kW Overload Threshold continuously for Genset Bus kW Overload Delay AND/OR Underfrequency Delta ( System frequency - Current Genbus frequency ) is greater than or equal to Genset Bus Underfrequency Overload Threshold continuously for Genset Bus Underfrequency Overload Delay.

Make sure gensets`s Kw power is greater than the one demanded by connected load . Check for faulted gensets. Use different meters from the built-in ones furnished in MCM3320.

Make sure meter calibration is OK. Check PT`s and CT`s ratios are well set in MCM3320. Make

sure PTs and CTs are operating properly. Verify that PT`s and CT`s rated values match the ones set in

MCM3320 and your system actual rated values. Make sure there is no low-frequency conditions on GenBus

due to poor quality fuel. Check your fuel supply for inappropriate conditions at

components – dirty filters, pipe size,etc.

181 Rev 1.5 prdJune 13, 2006

Historical Data

Non-volatile historical data– Controller On-Time

– Fault/Event history

– System state history

– Energy accumulators

Removal of B+ does not result in any loss of data

FUNCTIONS

182 Rev 1.5 prdJune 13, 2006

System State History

System State History» Records 20 most recent system states with COT

stamp

» Can use to track past sequence of events

FUNCTIONS

183 Rev 1.5 prdJune 13, 2006

Energy Accumulators

Per phase quantities recorded for both sources:» +kWh

» -kWh

» +kVARh

» -kVARh

» kVAh

Positive = energy delivered by the source Negative = energy absorbed by the source Accumulators can be reset Totalized values also available (calculated by MCM3320)

FUNCTIONS

184 Rev 1.5 prdJune 13, 2006

HMI 211

FUNCTIONS

185 Rev 1.5 prdJune 13, 2006

HMI 211 - LEDs

Utility Parallel = both breakers closed Lockout = System Lockout is active Warning = any warning fault state active

Remote Start = 3320 start output active Auto = auto/manual switch input = auto Manual = auto/manual switch input = manual

FUNCTIONS

186 Rev 1.5 prdJune 13, 2006

HMI 211 – Home Screen

MENU softkey: enter main navigation treeRESET softkey: reset/ack faults

FUNCTIONS

187 Rev 1.5 prdJune 13, 2006

HMI 211 – Fault PopUp

Faults pop up on screen when they occurAcknowledge with ▼ softkey (does not reset)Reset with RESET softkey

FUNCTIONS

188 Rev 1.5 prdJune 13, 2006

HMI 211 – System Op/Control

CONTROL menu tree includes user friendly screens for starting / stopping system and making operating point adjustments

Password for making Adjustments is “574”

FUNCTIONS

189 Rev 1.5 prdJune 13, 2006

HMI112 Bargraph

Bargraph Hardware Device ID Setup:

1. Press/hold button on back of bargraph until lower right LED(s) illuminate (~5sec).

2. Press again to cycle through 1, 2, 3, 4 LEDs. Genset Bus = 1 LED on, Utility Bus = 2 LEDs on.

3. Number of LEDs illuminated = device ID.

4. Wait 5 sec for control to resume operation.

• Configure Utility Scaling with InPower

• Update rate up to 10Hz; 1Hz minimum

FUNCTIONS

190 Rev 1.5 prdJune 13, 2006

HMI112 Setup

FUNCTIONS

191 Rev 1.5 prdJune 13, 2006

SYSTEM SETUP

InPower V5.5 Setup ToolPCC3xxx Genset Controller Setup

192 Rev 1.5 prdJune 13, 2006

InPower V5.5 Setup Tool

Screen by Screen ReviewUser Participation (Demo Mode or Live with

Controller)Note that Scheduler and Real Time Clock

screens will be available as a patch

SETUP

193 Rev 1.5 prdJune 13, 2006

PCC3xxx Genset Controller Setup

Configure for Utility Multiple even if only one genset Bus PT module connected on load side of genset

paralleling breaker Set TD Start, TD Stop = 0 if want MCM3320 to control

time delays (else time delays are additive) Set Load Govern Ramp Times to be compatible with

Maximum Parallel Time setting in MCM3320

SETUP

194 Rev 1.5 prdJune 13, 2006

PCC3100 Genset Controller Setup

When using MCM3320 with PCC3100s, use InPower to search on PCC3100 for parameter called "Reactive power scale". Change it from 695 to 820. Save it.

If PCC3100 is in system with PCC3200/1, set PCC3100 kVAR Balance = 29 (InPower or front panel Setup)

If these changes are not done, may experience reverse kVAR (loss of field) shutdowns or inability to synchronize

SETUP

195 Rev 1.5 prdJune 13, 2006

MCM3320 Simulator

Simulator OverviewSimulate Operating Scenarios

– Utility Fail / Return Soft CT

– Synchronizer Performance Plotting

– Test With / Without Load

– Extended Paralleling

– Faults

196 Rev 1.5 prdJune 13, 2006

MCM3320 Simulator Overview

Breaker faultsimulation

MCM3320switchinputs

MCM3320switch inputs

Gen is availablewhen genset

breaker closes

Utility buscontrol

SIMULATOR

197 Rev 1.5 prdJune 13, 2006

MCM3320 Simulator Overview

MCM3320 simulator Genset simulator

Load

Alternator

Engine

MCM3320 control PCC3100/3200

Load

Busvoltage

SIMULATOR

198 Rev 1.5 prdJune 13, 2006

InPower

199 Rev 1.5 prdJune 13, 2006

InPower DOWNLOAD

“Initial Calibration”» All trim values will revert to default settings

» Any custom settings will be lost

» Historical data will be lost

» Factory calibration data will NOT be lost

» Field calibration of voltage / current will be lost

“Update Calibration” (recommended)» Use to update controller firmware without altering

your settings or losing historical data

» Field calibration of voltage / current will remain

INPOWER

200 Rev 1.5 prdJune 13, 2006

VARIABLES

Trims (screwdriver symbol)

» Variables which can be permanently saved in EE» Nearly all settings are trims» Writing to a trim variable changes its RAM value

only» Controller always uses RAM value to operate from» Save command required to get RAM value saved in

non-volatile memory» On power-up, RAM value is loaded from EE

Volatiles (light switch symbol)

» Variables which are writeable, but only exist in RAM» On power-up, RAM value is loaded with hard-coded

default

INPOWER

201 Rev 1.5 prdJune 13, 2006

VARIABLES

Monitor Points (magnifying glass symbol)

» Read only variables in RAM

» E.G.: Utility L1-L2 Voltage

INPOWER

202 Rev 1.5 prdJune 13, 2006

Applications

Application FlexibilityParticipant Application Examples

203 Rev 1.5 prdJune 13, 2006

Application Flexibility

MCM3320 is not a PLC MCM3320 is designed to be flexible and work for

most applications Alternatives for special requirements:

1. Use PLC

2. Be clever with 3320 capabilities

3. Ask for changes to 3320

Changes to 3320 will only be implemented if change is universally useful and resources can be assigned to implement the change

APPLICATIONS

204 Rev 1.5 prdJune 13, 2006


Example1: What if the MCM3320 fails ? Map Fault Code 343 (Hardware Failure) to one of

the Configurable Low-Side Outputs (Default = Output 8)

Connect a relay to this output For this particular fault, logic is inverted: output is

energized when fault is Inactive If MCM3320 experiences an internal failure or loses

B+ power, the relay will de-energize Use relay contacts to perform desired action For example, if using Load Demand, use relay to

open circuit all load demand drives so that all gensets will run

APPLICATIONS

205 Rev 1.5 prdJune 13, 2006


Example2: What if I don’t want a Transfer to Gensets to occur if I get an AC Metering Failure (1335) ?

Map Fault Code 1335 to one of the Configurable Low-Side Outputs

Connect this output to the Transfer Inhibit input

APPLICATIONS

206 Rev 1.5 prdJune 13, 2006


Example3: What if I don’t want the Transfer or Retransfer Time Delays to occur for an Extended Parallel run ?

Turn on the Override switch input (hardwired or Modbus) at the same time as turning on the Extended Parallel switch input (hardwired or Modbus)

APPLICATIONS

207 Rev 1.5 prdJune 13, 2006

Application Examples

Participant Examples ?

APPLICATIONS

208 Rev 1.5 prdJune 13, 2006

Project Examples

System Type 10 low voltage 4 diesel gensets 6 feeder breakers with 6 level capacity based load add/shed control Extended Parallel Control Normal Standby Operation Load demand based on engine run hours

Does this system require a PLC?

Utility Source 1

52-UM1

G1

52-G1

52-GM1

GN

52-GN

52-F1 52-FN . . .

. . .

G2

52-G2

YES

209 Rev 1.5 prdJune 13, 2006

Project Examples

System Type 9 medium voltage 5 diesel gensets 6 feeder breakers with simple load add/shed control Extended Parallel Control Normal Standby Operation Load demand based on customer set fixed sequence

Does this system require a PLC? Utility

Source 1

52-UM1

G1

52-G1

G2

52-G2

52-F1 52-FN . . .

. . .

GN

52-GN YES

210 Rev 1.5 prdJune 13, 2006

Project Examples

System Type 10 low voltage 4 diesel gensets 24 feeder breakers with 6 level simple load add/shed control Extended Parallel Control Normal Standby Operation Load demand based on engine run hours


Utility Source 1

52-UM1

G1

52-G1

52-GM1

GN

52-GN

52-F1 52-FN . . .

. . .

G2

52-G2

NO

211 Rev 1.5 prdJune 13, 2006

Project Examples

System Type 10 low voltage 4 gas gensets Extended Parallel Control No Standby Operation CHP application Load demand based on engine run hours


Utility Source 1

52-UM1

G1

52-G1

52-GM1

GN

52-GN

52-F1 52-FN . . .

. . .

G2

52-G2

YES

212 Rev 1.5 prdJune 13, 2006

Project Examples

System Type 9 medium voltage 3 diesel gensets 6 feeder breakers with 6 level simple load add/shed control Extended Parallel Control Normal Standby Operation Load demand based on customer set fixed sequence Utility breaker provided by others

– If we control the breaker NO, if not then YES

Does this system require a PLC? Utility

Source 1

52-UM1

G1

52-G1

G2

52-G2

52-F1 52-FN . . .

. . .

GN

52-GN MAYBE

213 Rev 1.5 prdJune 13, 2006

Project Examples

System Type 7 low voltage 9 diesel gensets Extended Parallel Control Normal Standby Operation


G1

52-G1

52-GM1

GN

52-GN

52-F1 52-FN . . .

. . .

G2

52-G2 NO

214 Rev 1.5 prdJune 13, 2006

Standard Swgr ProjectOverview

MCM3320Genset Interface Board

(Connection to 4 gensests andinterconnect to additional panels)

SID(Load Add Shed Control and Status)

ExpansionBoard

(Load Add ShedControl and Status)

Control Relay Board(24 control relays to include: 12 w/single form C contact and 12 w/4 form C contacts

capable of operation all cirtcuit breaker open/close coils, need to look at manualoption could all relay that switches from MCM inputs to manual switch inputs)

CT Shorting Block

CT Shorting Block

MCM3320Genset Interface Board

(Connection to 4 gensests andinterconnect to additional panels)

CT Shorting Block CT Shorting Block

Control Mode Panel

Component Mode Panel

215 Rev 1.5 prdJune 13, 2006

MCM3320

Questions / Discussion / Comments

Documents

MCM3320 Application Training Switchgear Engineer Training 083006 Rev4 New Cummins Template