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Service Manual

Control
MCM3320
SYNC1320

English
Original Instructions

5-2012

A029Y787 (Issue 1)

Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS .......................................................................................
1.1 Warning, Caution and Note Styles Used In This Manual .......................................................
1.2 General Safety Precautions....................................................................................................
1.3 High Ambient Temperatures ...................................................................................................
1.4 Equipment Safety Code ..........................................................................................................
1.5 Moving Parts Can Cause Severe Personal Injury Or Death ..................................................
1.6 Electrical Shock Can Cause Severe Personal Injury Or Death..............................................
1.7 Medium Voltage Equipment (601 V to 15 kV) ........................................................................
1.8 Multiple Sources of Electrical Power ......................................................................................
1.9 Do Not Tip the Equipment ......................................................................................................

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2. INTRODUCTION............................................................................................................................
2.1 Training Required for Service .................................................................................................
2.2 Tools Required for Service .....................................................................................................
2.3 About This Manual..................................................................................................................
2.3.1 Organization of This Manual ........................................................................................
2.4 About the MCM3320...............................................................................................................
2.4.1 SYNC1320 ...................................................................................................................
2.4.2 Codes and Standards ..................................................................................................
2.5 How to Obtain Service ............................................................................................................
2.6 Schedule of Abbreviations ......................................................................................................

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3. BASIC CONCEPTS........................................................................................................................
3.1 System Topology ....................................................................................................................
3.1.1 Topologies....................................................................................................................
3.1.2 Typical System Components (Isolated Bus Without Generator Set Main
Breaker) .......................................................................................................................
3.1.3 Typical System Components (Isolated Bus with Generator Set Main Breaker) ........
3.1.4 Typical System Components (Common Bus) ............................................................
3.1.5 Typical System Components (Transfer Pair) .............................................................
3.1.6 Master Synchronize Only...........................................................................................
3.1.7 Component Mode.......................................................................................................
3.2 Transition Type .....................................................................................................................
3.2.1 Open Transition..........................................................................................................
3.2.2 Soft-closed Transition ................................................................................................
3.2.3 Hard-closed Transition...............................................................................................
3.2.4 PTC Operating Transition Type .................................................................................
3.3 System State.........................................................................................................................
3.4 Generator Set Availability State............................................................................................
3.5 Total Number of Generator Sets Online ...............................................................................
3.6 Total Online Capacity............................................................................................................
3.7 Total Load Demand Online Capacity....................................................................................
3.8 Override Enable and Override Command ............................................................................

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3.9 Summary of Settings (Basic Concepts) ................................................................................

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4. COMPONENTS............................................................................................................................
4.1 MCM3320 Base Board..........................................................................................................
4.1.1 Hardware Version ......................................................................................................
4.1.2 Summary of Connections...........................................................................................
4.1.3 CT1-CT6 Connections ...............................................................................................
4.1.4 J14 Connections ........................................................................................................
4.1.5 TB1 Connections........................................................................................................
4.1.6 TB2 Connections........................................................................................................
4.1.7 TB3 Connections........................................................................................................
4.1.8 TB6 Connections........................................................................................................
4.1.9 TB7 Connections........................................................................................................
4.1.10 TB8 Connections......................................................................................................
4.1.11 TB9 Connections......................................................................................................
4.1.12 TB10 Connections....................................................................................................
4.1.13 TB15 Connections....................................................................................................
4.1.14 Power-down Mode ...................................................................................................
4.1.15 System and Diagnostic Indicators............................................................................
4.1.16 Repairing Circuit Boards ..........................................................................................
4.2 SYNC1320 Base Board ........................................................................................................
4.2.1 Summary of Connections...........................................................................................
4.2.2 TB1 Connections........................................................................................................
4.2.3 TB2 Connections........................................................................................................
4.2.4 TB3 Connections........................................................................................................
4.2.5 TB6 Connections........................................................................................................
4.2.6 TB7 Connections........................................................................................................
4.2.7 TB9 Connections........................................................................................................
4.2.8 TB10 Connections......................................................................................................
4.2.9 TB15 Connections......................................................................................................
4.2.10 Power-down Mode ...................................................................................................
4.2.11 System and Diagnostic Indicators............................................................................
4.2.12 Repairing Circuit Boards ..........................................................................................
4.3 Operator Panel......................................................................................................................
4.3.1 Back Panel.................................................................................................................
4.3.2 Front Panel.................................................................................................................
4.3.3 Compatible Software Versions (Operator Panel).......................................................
4.3.4 Main Screen...............................................................................................................
4.3.5 Levels of Security.......................................................................................................
4.4 Supplementary Interface Device (SID) .................................................................................
4.4.1 Generator Sets by SID...............................................................................................
4.4.2 Loads by SID .............................................................................................................
4.4.3 SID Required..............................................................................................................
4.4.4 Legacy SID Override (Before V2.00) .........................................................................
4.4.5 Compatible Software Versions (AUX 101).................................................................
4.4.6 Configuring the AUX 101 and AUX 102 with the MCM3320 .....................................

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4.4.7 Summary of Monitor Points (AUX 101/102)...............................................................


4.4.8 AUX 101 Board ..........................................................................................................
4.4.9 AUX 102 Board ..........................................................................................................
4.4.10 Troubleshooting .......................................................................................................
4.4.11 Connecting to an AUX 101 or AUX 102 Using InPower ..........................................
4.4.12 Repairing Circuit Boards ..........................................................................................
4.5 Bar Graphs............................................................................................................................
4.5.1 Generator Set Bus Current Percentage.....................................................................
4.5.2 Utility Current Percentage..........................................................................................
4.5.3 Utility Total kW Percentage........................................................................................
4.5.4 Compatible Software Versions (Bar Graph) ..............................................................
4.5.5 Setting up a Bar Graph ..............................................................................................
4.6 Universal Annunciator...........................................................................................................
4.6.1 Compatible Software Versions (Universal Annunciator) ............................................
4.6.2 Basic Status Annunciator...........................................................................................
4.6.3 Load Add/Shed Annunciator ......................................................................................
4.6.4 Setting up an Annunciator Using the Operator Panel................................................

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5. SOURCE AVAILABILITY .............................................................................................................


5.1 Power Transfer Control (PTC) Sensors................................................................................
5.1.1 Generator Set Undervoltage Sensor..........................................................................
5.1.2 Generator Set Overvoltage Sensor............................................................................
5.1.3 Generator Set Frequency Sensor ..............................................................................
5.1.4 Generator Set Loss of Phase Sensor ........................................................................
5.1.5 Generator Set Phase Rotation Sensor ......................................................................
5.1.6 Utility Undervoltage Sensor .......................................................................................
5.1.7 Utility Overvoltage Sensor .........................................................................................
5.1.8 Utility Frequency Sensor............................................................................................
5.1.9 Utility Loss of Phase Sensor......................................................................................
5.1.10 Utility Phase Rotation Sensor ..................................................................................
5.2 Generator Set Availability .....................................................................................................
5.2.1 Generator Set Availability (Three-phase Applications in Isolated Bus Without
Generator Set Main Breaker and Common Bus Topologies)......................................
5.2.2 Generator Set Availability (Three-phase Applications in Isolated Bus with
Generator Set Main Breaker and Transfer Pair Topologies).......................................
5.2.3 Generator Set Online Capacity Sensor .....................................................................
5.3 Utility Availability ...................................................................................................................
5.3.1 Utility Availability (Three-phase Applications in Common Bus and Transfer Pair
Topologies) ..................................................................................................................
5.3.2 Utility Source Failure Switch ......................................................................................
5.4 Current Based Breaker Position ...........................................................................................
5.5 Summary of Settings (Source Availability)............................................................................

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6. POWER TRANSFER CONTROL (PTC) STATE .........................................................................


6.1 Generator Sets Connected ...................................................................................................
6.1.1 Connecting the Generator Sets .................................................................................
6.1.2 Disconnecting the Generator Sets .............................................................................

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6.1.3 Generator Set Connections and Legacy SID Override..............................................


6.1.4 Generator Set Breaker Inhibit ....................................................................................
6.2 Utility Connected...................................................................................................................
6.2.1 Connecting the Utility .................................................................................................
6.2.2 Disconnecting the Utility.............................................................................................
6.2.3 Utility Main Breaker Inhibit .........................................................................................
6.3 Summary of Settings (PTC State) ........................................................................................

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7. POWER TRANSFER CONTROL (PTC) OPERATING MODE ....................................................


7.1 PTC Logic and Source Availability........................................................................................
7.2 Priority of PTC Operating Modes..........................................................................................
7.3 Utility Fail ..............................................................................................................................
7.3.1 Conditions for Entering Utility Fail..............................................................................
7.3.2 Utility Source Failure Switch ......................................................................................
7.3.3 Conditions for Leaving Utility Fail ..............................................................................
7.4 Normal Override....................................................................................................................
7.4.1 Conditions for Entering Normal Override ...................................................................
7.4.2 Conditions for Leaving Normal Override....................................................................
7.5 Extended Parallel..................................................................................................................
7.5.1 Conditions for Entering Extended Parallel .................................................................
7.5.2 Extended Parallel Switch ...........................................................................................
7.5.3 Conditions for Leaving Extended Parallel..................................................................
7.6 Test .......................................................................................................................................
7.6.1 Conditions for Entering Test ......................................................................................
7.6.2 Test Start Switch........................................................................................................
7.6.3 Conditions for Leaving Test .......................................................................................
7.7 Normal ..................................................................................................................................
7.7.1 Conditions for Entering Normal..................................................................................
7.7.2 Conditions for Leaving Normal...................................................................................
7.8 Summary of Settings (PTC Operating Mode) .......................................................................

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8. BREAKER CONTROL..................................................................................................................
8.1 PTC Transfer Pair Operating Mode ......................................................................................
8.2 Breaker Control in Manual ....................................................................................................
8.3 Breaker Control in Utility Fail ................................................................................................
8.4 Breaker Control in Normal Override .....................................................................................
8.5 Breaker Control in Extended Parallel....................................................................................
8.6 Breaker Control in Test.........................................................................................................
8.6.1 Test with Load Command ........................................................................................
8.7 Breaker Control in Normal ..................................................................................................
8.7.1 Open-transition Retransfer After Fail To Synchronize .............................................
8.8 Timers .................................................................................................................................
8.8.1 Transfer Time Delay ................................................................................................
8.8.2 Retransfer Time Delay .............................................................................................
8.8.3 Programmed Transition Time Delay ........................................................................
8.8.4 Maximum Parallel Timer ..........................................................................................
8.8.5 Summary of Settings (PTC Timers) .........................................................................

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8.9 Inhibits.................................................................................................................................
8.9.1 Master Inhibit............................................................................................................
8.9.2 Transfer Inhibit .........................................................................................................
8.9.3 Retransfer Inhibit......................................................................................................
8.9.4 Override Switch........................................................................................................
8.9.5 Generator Set Breaker Inhibit ..................................................................................
8.9.6 Utility Main Breaker Inhibit .......................................................................................
8.10 Fail to Disconnect Enable .................................................................................................
8.11 Output Signals for Breakers..............................................................................................
8.12 Summary of Settings (Breaker Control)............................................................................

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9. GENERATOR SET CONTROL ..................................................................................................


9.1 PTC Generator Set Operating Mode ..................................................................................
9.2 Generator Set Control in Utility Fail, Extended Parallel, and Test......................................
9.3 Generator Set Control in Normal Override .........................................................................
9.4 Generator Set Control in Normal ........................................................................................
9.5 Start Delay ..........................................................................................................................
9.6 Stop Delay ..........................................................................................................................
9.7 Summary of Settings (Generator Set Control)....................................................................

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10. LOAD CONTROL .....................................................................................................................


10.1 Associated Pins ................................................................................................................
10.2 Extended Parallel..............................................................................................................
10.2.1 Conditions for Load Control in Extended Parallel ..................................................
10.2.2 kW Control .............................................................................................................
10.2.3 kVAR Control .........................................................................................................
10.2.4 Extended Parallel Ramp Load Time ......................................................................
10.2.5 Open-loop Methods and Closed-loop Methods .....................................................
10.2.6 Load Ramping During Extended Parallel...............................................................
10.2.7 Summary of Settings (kW Load Control) ...............................................................
10.2.8 Summary of Settings (kVAR Load Control) ...........................................................
10.3 Soft-closed Transition .......................................................................................................
10.3.1 Load Control During Soft-closed Transitions .........................................................
10.4 Load Control at Other Times ............................................................................................
10.5 Load Control Output Enable by Hardware Version ..........................................................
10.5.1 Code 1534 - Load Control Output Event ...............................................................

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11. SYNCHRONIZER .....................................................................................................................


11.1 Synchronizer Status..........................................................................................................
11.1.1 Fail to Synchronize Lockout Enable ......................................................................
11.1.2 Master Inhibit..........................................................................................................
11.2 Frequency Matching .........................................................................................................
11.2.1 Phase Match ..........................................................................................................
11.2.2 Slip Frequency .......................................................................................................
11.2.3 Proportional-integral (PI) Loop...............................................................................
11.3 Voltage Match ...................................................................................................................
11.3.1 Voltage Match Test Offset .....................................................................................

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11.3.2 kVAR Load Share Protection and Voltage Match Fail...........................................


11.3.3 Proportional-integral (PI) Loop...............................................................................
11.4 Synchronizer Check Close Allowed..................................................................................
11.4.1 Permissive Close Allowed......................................................................................
11.5 Summary of Settings (Synchronizer) ................................................................................

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12. LOAD ADD/SHED ....................................................................................................................


12.1 Load Add/Shed Enable .....................................................................................................
12.2 Loads by SID ....................................................................................................................
12.2.1 Unavailable SID and Load Add/Shed ....................................................................
12.3 Load-add Levels ...............................................................................................................
12.4 Load-shed Levels..............................................................................................................
12.5 Load Add and the Generator Set Main Breaker ...............................................................
12.6 Load Add Shed Operating State.......................................................................................
12.7 Automatic Load Add..........................................................................................................
12.7.1 Required Online Capacity ......................................................................................
12.7.2 Conditions for Automatic Load Add .......................................................................
12.7.3 Automatic Load Add and Legacy SID Override .....................................................
12.8 Automatic Load Shed........................................................................................................
12.8.1 Conditions for Automatic Load Shed .....................................................................
12.8.2 Automatic Load Shed During Open-transition Transfers .......................................
12.8.3 Open Transition Retransfer Load Shed .................................................................
12.9 Conditions for Manual Load Add/Shed .............................................................................
12.10 Utility Load Add...............................................................................................................
12.10.1 Conditions for Utility Load Add ............................................................................
12.11 Maximum Number of Loads by Firmware Version .........................................................
12.12 Output Signals for Feeder Breakers ...............................................................................
12.13 Output Signals for Automatic Transfer Switches (ATS)..................................................
12.14 Summary of Settings (Load Add/Share) .........................................................................

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13. LOAD DEMAND .......................................................................................................................


13.1 Load Demand Enable .......................................................................................................
13.2 Generator Sets by SID......................................................................................................
13.2.1 Unavailable SID and Load Demand ......................................................................
13.3 Generator Set Support for Load Demand in Extended Parallel .......................................
13.4 Initial Time Delay ..............................................................................................................
13.5 When a Generator Set Is Shut Down ...............................................................................
13.5.1 Shutdown Percentage............................................................................................
13.5.2 Shutdown Threshold ..............................................................................................
13.5.3 Shutdown Percentage or Shutdown Threshold .....................................................
13.5.4 Shutdown Delay .....................................................................................................
13.5.5 Minimum Online Capacity ......................................................................................
13.6 When a Generator Set Is Restarted .................................................................................
13.6.1 Restart Percentage ................................................................................................
13.6.2 Relationship Between Shutdown Percentage and Restart Percentage.................
13.6.3 Restart Threshold...................................................................................................
13.6.4 Relationship Between Shutdown Threshold and Restart Threshold .....................

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13.6.5 Restart Delay .........................................................................................................


13.7 Which Generator Set Shuts Down or Restarts .................................................................
13.7.1 Fixed Sequence Method ........................................................................................
13.7.2 Example: Fixed Sequence Method ........................................................................
13.7.3 Setting a Fixed Sequence in InPower....................................................................
13.7.4 Run Hours Method.................................................................................................
13.7.5 Source of Run Hours for the Run Hours Method...................................................
13.7.6 Example: Run Hours Method.................................................................................
13.7.7 Generator Set Online Time ....................................................................................
13.7.8 Generator Set Fail Time.........................................................................................
13.8 Load Demand and Generator Set Overload .....................................................................
13.9 Summary of Settings (Load Demand) ..............................................................................

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14. SCHEDULER............................................................................................................................
14.1 Real-time Clock.................................................................................................................
14.1.1 Daylight Saving Time .............................................................................................
14.1.2 Daylight Saving Time Enable.................................................................................
14.1.3 Summary of Settings (Real-time Clock).................................................................
14.1.4 Code 1689 - Real-time Clock Power Interrupt .......................................................
14.1.5 Effects of Code 1689 .............................................................................................
14.2 Scheduler Enable..............................................................................................................
14.2.1 Automatic Changes of System Scheduler Enable .................................................
14.3 Scheduled Programs ........................................................................................................
14.4 Exceptions ........................................................................................................................
14.5 Scheduler Specifications...................................................................................................
14.6 Summary of Settings (Scheduler).....................................................................................

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15. MANUAL MODE .......................................................................................................................


15.1 Conditions for Entering Manual Mode ..............................................................................
15.2 Conditions for Leaving Manual Mode ...............................................................................
15.3 Auto/Manual Switch ..........................................................................................................
15.4 Monitoring Breaker Position in Manual Mode ...................................................................
15.5 Commit to Transfer in Manual Mode ................................................................................
15.6 Breaker Control in Manual Mode ......................................................................................
15.6.1 Programmed Transition Time Delay ......................................................................
15.6.2 Maximum Parallel Timer in Manual Mode .............................................................
15.6.3 Master Inhibit..........................................................................................................
15.6.4 Generator Set Breaker Inhibit ................................................................................
15.6.5 Utility Main Breaker Inhibit .....................................................................................
15.6.6 Fail to Disconnect Enable ......................................................................................
15.7 Generator Set Control in Manual Mode ............................................................................
15.8 Load Control in Manual Mode...........................................................................................
15.8.1 Load Control at Other Times .................................................................................
15.9 Synchronizer Status in Manual Mode ...............................................................................
15.9.1 Synchronizer Enable Switch ..................................................................................
15.10 Load Add/Shed in Manual Mode ....................................................................................
15.11 Load Demand in Manual Mode.......................................................................................

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15.12 Scheduler in Manual Mode .............................................................................................


15.13 Summary of Settings (Manual Mode) .............................................................................

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16. MASTER SYNCHRONIZE ONLY.............................................................................................


16.1 Generator Set Availability (Three-phase Applications in Master Synchronize Only or
Component Mode)...............................................................................................................
16.2 Utility Availability (Three-phase Applications in Master Synchronize Only and
Component Mode)...............................................................................................................
16.3 PTC State and PTC Operating Mode in Master Synchronize Only..................................
16.4 Synchronizer Status in Master Synchronize Only and Component Mode........................
16.5 Synchronizer Status in Manual Mode ...............................................................................
16.5.1 Synchronizer Enable Switch ..................................................................................
16.6 Synchronizer Check in Master Synchronize Only or Component Mode ..........................

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17. SYNC1320................................................................................................................................
17.1 Generator Set Availability (Single-phase Applications) ....................................................
17.2 Utility Availability (Single-phase Applications) ..................................................................
17.3 Synchronizer in the SYNC1320 ........................................................................................

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18. COMPONENT MODE...............................................................................................................


18.1 Generator Set Availability (Three-phase Applications in Master Synchronize Only or
Component Mode)...............................................................................................................
18.2 Utility Availability (Three-phase Applications in Master Synchronize Only and
Component Mode)...............................................................................................................
18.3 PTC State and PTC Operating Mode in Component Mode .............................................
18.4 Synchronizer Status in Master Synchronize Only and Component Mode........................
18.5 Synchronizer Status in Manual Mode ...............................................................................
18.5.1 Synchronizer Enable Switch ..................................................................................
18.6 Synchronizer Check in Master Synchronize Only or Component Mode ..........................
18.7 Load Control in Component Mode....................................................................................
18.8 Load Control Based on PTC State and PTC Operating Mode .........................................
18.9 Load Control in Manual Mode...........................................................................................

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19. TROUBLESHOOTING..............................................................................................................
19.1 Events ...............................................................................................................................
19.1.1 Code 1222 - Not in Automatic................................................................................
19.1.2 Code 1483 - Common Alarm .................................................................................
19.1.3 Code 1534 - Load Control Output Event ...............................................................
19.1.4 Code 1916 - Synchronized Event ..........................................................................
19.1.5 Code 2328 - Utility Bus Available Event ................................................................
19.1.6 Code 2332 - Utility Bus Connected Event .............................................................
19.1.7 Code 2333 - Generator Set Bus Connected Event ...............................................
19.1.8 Code 2779 - Utility Unloaded Event.......................................................................
19.1.9 Code 2781 - Genset Unloaded Event....................................................................
19.1.10 Code 2965 - Generator Set Bus Available Event ................................................
19.1.11 Code 2971 - Test/Extended Parallel Event..........................................................
19.1.12 Code 3226 - Genset Bus Base Load Event.........................................................
19.1.13 Code 3227 - Utility Peak Shave Event.................................................................

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19.2 Faults ................................................................................................................................


19.2.1 Fault Reset.............................................................................................................
19.2.2 System Lockout Status ..........................................................................................
19.2.3 Conditions for System Lockout Status...................................................................
19.3 Troubleshooting Procedures.............................................................................................
19.3.1 No Code - AUX 101 Does Not Communicate........................................................
19.3.2 No Code - Fault Codes Do Not Reset ...................................................................
19.3.3 No Code - Incorrect Generator Set Bus Metering .................................................
19.3.4 No Code - Incorrect Utility Metering.......................................................................
19.3.5 No Code - Operator Panel Is Not Communicating ................................................
19.3.6 Code 343 - Hardware Failure MCM3320...............................................................
19.3.7 Code 353 - EEPROM Write Error ..........................................................................
19.3.8 Code 441 - Low Battery Voltage............................................................................
19.3.9 Code 442 - High Battery Voltage ...........................................................................
19.3.10 Code 1121 - Fail to Disconnect ...........................................................................
19.3.11 Code 1219 - Utility Main Breaker Tripped............................................................
19.3.12 Code 1223 - Utility Bus Frequency ......................................................................
19.3.13 Code 1224 - Generator Set Bus Over Voltage ....................................................
19.3.14 Code 1225 - Generator Set Bus Under Voltage ..................................................
19.3.15 Code 1226 - Generator Set Bus Frequency ........................................................
19.3.16 Code 1328 - Generator Set Main Breaker Tripped..............................................
19.3.17 Code 1335 - AC Metering Out of Range .............................................................
19.3.18 Code 1444 - Generator Set Bus Overload...........................................................
19.3.19 Code 1452 - Generator Set Main Breaker Fail to Close (Isolated Bus Without
Generator Set Main Breaker or Common Bus) .........................................................
19.3.20 Code 1452 - Generator Set Main Breaker Fail to Close (Isolated Bus with
Generator Set Main Breaker or Transfer Pair) ..........................................................
19.3.21 Code 1453 - Generator Set Main Breaker Fail to Open (Isolated Bus Without
Generator Set Main Breaker or Common Bus) .........................................................
19.3.22 Code 1453 - Generator Set Main Breaker Fail to Open (Isolated Bus with
Generator Set Main Breaker or Transfer Pair) ..........................................................
19.3.23 Code 1454 - Generator Set Main Breaker Position Contact................................
19.3.24 Code 1455 - Utility Main Breaker Position Contact (Isolated Bus Without
Generator Set Main Breaker or Isolated Bus with Generator Set Main Breaker) .....
19.3.25 Code 1455 - Utility Main Breaker Position Contact (Common Bus or Transfer
Pair) ...........................................................................................................................
19.3.26 Code 1456 - Synchronizer Output Limit...............................................................
19.3.27 Code 1457 - Fail to Synchronize Warning ...........................................................
19.3.28 Code 1458 - Synchronizer Phase Rotation Mismatch .........................................
19.3.29 Code 1541 - Generator Set Failed to Come Online ............................................
19.3.30 Code 1689 - Real-time Clock Power Interrupt .....................................................
19.3.31 Code 1912 - Utility Bus Loss of Phase ................................................................
19.3.32 Code 1913 - Generator Set Bus Loss of Phase ..................................................
19.3.33 Code 1914 - Utility Bus Phase Rotation ..............................................................
19.3.34 Code 1915 - Generator Set Bus Phase Rotation ................................................
19.3.35 Code 1989 - kW Load Control Output Limit.........................................................
19.3.36 Code 1991 - kVAR Load Control Output Limit.....................................................
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178
178
178
179
179
179
180
180
181
181
182
182
183
184
185
185
186
188
191
193
195
196
198
200
201
203
204
205
207
208
210
211
212
214
215
215
217
218
219
221
222
ix

Table of Contents

19.3.37
19.3.38
19.3.39
19.3.40
19.3.41
19.3.42
19.3.43
19.3.44
19.3.45
19.3.46
19.3.47

5-2012

Maximum Parallel Time ..................................................................


Utility Bus Under Voltage ................................................................
Utility Bus Over Voltage ..................................................................
Utility Main Breaker Fail to Close....................................................
Utility Main Breaker Fail to Open ....................................................
Calibration Checksum.....................................................................
Load Demand Setup Warning.........................................................
Remote I/O Comm Failure Warning ...............................................
Modbus Communication Failure Warning.......................................
Utility Reverse kW Fault..................................................................
Advanced Grid Protection Fault ......................................................

223
224
226
228
230
232
233
234
235
236
236

20. PARTS LIST .............................................................................................................................

239

21. MANUFACTURING FACILITIES ..............................................................................................


21.1 How to Obtain Service ......................................................................................................

241
241

APPENDIX A. INTERCONNECT DRAWINGS ...............................................................................


A.1 0630-3133 (MCM3320 Interconnect Drawing) ...................................................................
A.2 0630-3136 (SYNC1320 Interconnect Drawing)..................................................................

243
245
273

APPENDIX B. SEQUENCE DIAGRAMS ........................................................................................


B.1 Sequence Diagrams ...........................................................................................................

277
279

Code
Code
Code
Code
Code
Code
Code
Code
Code
Code
Code

1999
2331
2358
2396
2397
2416
2647
2648
2939
3924
4137

A029Y787 (Issue 1)

Important Safety Instructions


SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be
followed during installation, operation, and maintenance of the equipment.
Safe and efficient operation can be achieved only if the equipment is properly operated
and maintained. Many accidents are caused by failure to follow fundamental rules and
precautions.

1.1

Warning, Caution and Note Styles Used In This


Manual
The following safety styles and symbols found throughout this manual indicate potentially
hazardous conditions to the operator, service personnel or the equipment.

DANGER: Warns of a hazard that will result in severe personal injury or death .
WARNING: Warns of a hazard that may result in severe personal injury or death .
CAUTION: Warns of a hazard or an unsafe practice that can result in product or property
damage .
NOTE:

1.2

A short piece of text giving information that augments the current text .

General Safety Precautions


Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible
materials such as wood and cloth; Class B fires involve combustible and flammable liquid
fuels and gaseous fuels; Class C fires involve live electrical equipment. (ref. NFPA No. 10).
Keep the equipment and the surrounding area clean and free from obstructions. Prevent
materials from accumulating under the product. Remove any unused equipment, and keep
the floor clean and dry.
Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the equipment. A
fire or explosion could result.
Do not work on this equipment when mentally or physically fatigued, or after consuming
any alcohol or drug that makes the operation of equipment unsafe.
Make sure all guards, fasteners, supports, doors, and panels are in place and secure.
Use appropriate personal protective equipment, such as safety glasses, gloves, and
footwear when working with this equipment.

1.3

High Ambient Temperatures


WARNING: In the presence of high ambient temperatures, some surfaces may become
hot. Contact with hot surfaces may cause burns resulting in personal injury.
Make sure you are wearing appropriate personal protective equipment before
touching the equipment.

A029Y787 (Issue 1)

1. Important Safety Instructions

1.4

5-2012

Equipment Safety Code


Before operating the equipment, read the manuals and become familiar with them and the
equipment. Safe and efficient operation can be achieved only if the equipment is properly
operated and maintained. Many accidents are caused by failure to follow fundamental rules
and precautions.
WARNING: Improper operation and maintenance can lead to severe personal injury or
loss of life and property. Read and follow all Safety Precautions, Warnings
and Cautions throughout this manual and the documentation supplied with
your equipment.
WARNING: Lifting and repositioning of the equipment must only be carried out using
suitable lifting equipment, shackles, and spreader bars, in accordance with
local guidelines and legislation, by suitably trained and experienced
personnel. Incorrect lifting can result in severe personal injury, death and/or
equipment damage. For more information, contact your authorized
distributor.

1.5

Moving Parts Can Cause Severe Personal Injury Or


Death
Keep your hands, clothing, and jewelry away from moving parts.
Make sure that fasteners on the equipment are secure. Tighten supports and clamps; keep
guards in position.
Do not wear loose clothing or jewelry in the vicinity of moving parts or while working on
electrical equipment. Loose clothing and jewelry can become caught in moving parts.

1.6

Electrical Shock Can Cause Severe Personal Injury


Or Death
Remove electric power before removing protective shields or touching electrical
equipment. Use rubber insulative mats placed on dry wood platforms over floors that are
metal or concrete when around electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surface to be damp when handling electrical
equipment. Do not wear jewelry. Jewelry can short out electrical contacts and cause shock
or burning.
Use extreme caution when working on electrical components. High voltages can cause
injury or death. DO NOT tamper with interlocks.
Follow all applicable state and local electrical codes. Have all electrical installations
performed by a qualified licensed electrician. Tag and lock open switches to avoid
accidental closure.

1.7

Medium Voltage Equipment (601 V to 15 kV)


Medium voltage acts differently than low voltage. Special equipment and training is
required to work on or around medium voltage equipment. Operation and maintenance
must be done only by persons trained and experienced to work on such devices. Improper
use or procedures will result in severe personal injury or death.

A029Y787 (Issue 1)

5-2012

1. Important Safety Instructions

Do not work on energized equipment. Unauthorized personnel must not be permitted near
energized equipment. Due to the nature of medium voltage electrical equipment, induced
voltage remains even after the equipment is disconnected from the power source. Plan the
time for maintenance with authorized personnel so that the equipment can be de-energized
and safely grounded.

1.8

Multiple Sources of Electrical Power


WARNING: The equipment may have more than one source of electrical energy.
Disconnecting one source without disconnecting the others presents a
shock hazard that can result in severe personal injury or death. Before
working on the equipment, disconnect all sources of electrical energy, and
verify that all sources of electrical energy have been removed.

1.9

Do Not Tip the Equipment

WARNING: Tipping equipment can cause equipment damage, personal injury, or death.
Keep the equipment on a level surface, make sure guards and fasteners are
in place, and do not tip the equipment.

A029Y787 (Issue 1)

1. Important Safety Instructions

5-2012

This page is intentionally blank.

A029Y787 (Issue 1)

Introduction

2.1

Training Required for Service


WARNING: Many troubleshooting procedures or replacement of parts present hazards
that can result in equipment damage and severe personal injury or death.
Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform service procedures.
Review the Safety Precautions section of this manual.
Only qualified service technicians with the appropriate personal protective equipment should
work on the equipment. Contact your authorized distributor for more information about becoming
a qualified service technician.
In addition, you should have the following knowledge about the site.
A basic understanding of the power distribution system at your site
A basic understanding of the loads at your site
Knowledge of the codes and standards that are applicable at your site
The licenses required to perform the work at your site
In addition, read all of the manuals provided with the product and other equipment in the power
distribution system, such as generator sets, automatic transfer switches, and circuit breakers.
You should be familiar with the warnings and operating procedures. Contact your authorized
distributor for more information regarding related literature for this product or for equipment in
the power distribution system.

2.2

Tools Required for Service


Personal protective equipment
True RMS meter for accurate measurement of small AC and DC voltages
Phase rotation meter
Tools for stripping and connecting wires
InPowerTM (PC-based service tool)
ModScan (or other tools for monitoring Modbus networks)
Any tools required for local codes and standards

2.3

About This Manual


This manual provides information to help you service the MCM3320 safely and correctly.
Hardware
Main features
Troubleshooting codes and symptoms
Engineering drawings and sequence diagrams

A029Y787 (Issue 1)

2. Introduction

5-2012

This manual does not provide information about operation, installation, or warranty. It also does
not provide information about other components in the power distribution system. Contact your
distributor for any of this information.

2.3.1

Organization of This Manual


Chapter 1 through Chapter 3 provide important information for all readers.
Chapter 4 provides information about the hardware.
Chapter 5 through Chapter 14 describe the main features of the MCM3320 when it acts
as a master paralleling control. These chapters apply when the topology is Isolated Bus
Without Generator Set Main Breaker, Isolated Bus with Generator Set Main Breaker,
Common Bus, or Transfer Pair and when the MCM3320 is running in Auto mode.
Chapter 15 through Chapter 18 discuss the differences in the MCM3320 when the
topology is Master Synchronize Only or Component Mode or when the MCM3320 is
running in Manual mode. It also introduces the SYNC1320 by comparing it to the
MCM3320.
Chapter 19 and Chapter 20 provide basic troubleshooting and parts information.
The appendices provide engineering drawings and sequence diagrams for reference.

2.4

About the MCM3320


The MCM3320 (Master Control Module) is a master paralleling control. It is designed to manage
power distribution systems with:
Paralleling generator sets from Cummins Power Generation
Multiple loads
To manage these systems, the MCM3320 has features such as breaker control, generator set
start/stop, load control, synchronizing, load add/shed, and load demand.
Alternatively, the MCM3320 can be used as a component in more complex systems. As a
component, the MCM3320 offers synchronizing and load control.

2.4.1

SYNC1320
The SYNC1320 is a MCM3320 in which the topology is Master Synchronize Only.
The SYNC1320 base board is a depopulated MCM3320 base board. Depopulation reduces the
capabilities of the SYNC1320 compared to a MCM3320 in Master Synchronize Only.
No current sensing
No Modbus connections
No PCCNet connections, including the operator panel
Starting with software version 1.29, the SYNC1320 can be used in single-phase applications as
well as three-phase applications. This has an impact on the synchronizer, which only supports
three-phase applications in the MCM3320. In addition, when the SYNC1320 is used in singlephase applications, source availability is different.
See 0900-0662 for more information about the SYNC1320.

A029Y787 (Issue 1)

5-2012

2. Introduction

2.4.2

Codes and Standards


The MCM3320 meets or exceeds the requirements of these codes and standards.
UL508 recognized
CE Mark
EN 61000-2
EN 61000-4
ISO 7637, pulses #2, 3a, 3b, 5, 7
The MCM3320 is designed and manufactured in ISO9001-certified facilities.

2.5

How to Obtain Service


When a product requires servicing, contact your nearest Cummins Power Generation distributor.
To locate your local Cummins Power Generation distributor, refer to www.cumminspower.com
and select Distributor Locator. When contacting your distributor, always supply the complete
Model, Specification, and Serial Number as shown on the nameplate.

2.6

Schedule of Abbreviations
This list is not exhaustive. For example, it does not identify units of measure or acronyms that
appear only in parameters, event/fault names, or part/accessory names.
TABLE 1.

Abbreviation

SCHEDULE OF ABBREVIATIONS

Description

AC

Alternating Current

ATS

Automatic Transfer Switch

CB

Circuit Breaker

CE

Conformit Europenne

CT

Current Transformer

CSA

Canadian Standards Association

CSV

Comma-separated Values

DC

Direct Current

DHCP

Dynamic Host Configuration Protocol

DMC

Digital Master Control

DNS

Domain Name Server

FTP

File Transfer Protocol

HMI

Human-machine Interface

IEC

International Electrotechnical Commission

IP

Internet Protocol

LAN

Local Area Network

MCM

Master Control Module

A029Y787 (Issue 1)

2. Introduction

Abbreviation

Description

NAT

Network Address Translation

NEC

National Electric Code

NFPA

National Fire Protection Agency

OSHPD
PC
PCC
PT

Office of Statewide Health Planning and Development


Personal Computer
PowerCommand Control
Potential Transformer

PTC

Power Transfer Control

RMS

Root-mean Square

RSL

Recommended Spares List

RTU

Remote Terminal Unit

TCP

Transmission Control Protocol

TDEN

Time Delay Emergency to Normal

TDMP

Time Delay Maximum Parallel

TDNE

Time Delay Normal to Emergency

TDPT

Time Delay Programmed Transition

UL

5-2012

Underwriters Laboratories

UPS

Uninterruptible Power Supply

USB

Universal Serial Bus

WAN

Wide Area Network

A029Y787 (Issue 1)

Basic Concepts

3.1

System Topology
If the MCM3320 is operating as a master control, System Topology is the topology of the power
distribution system. If the MCM3320 has a different role, System Topology determines the role
the MCM3320 plays in the power distribution system.
NOTE:

3.1.1

This setting can be changed only when the MCM3320 is in Manual mode.

Topologies
A topology is based on the presence or absence of a utility main breaker and a generator set
main breaker.

TABLE 2.

TOPOLOGY BASED ON PRESENCE OF UTILITY MAIN BREAKER AND GENERATOR SET


MAIN BREAKER

Utility Main Breaker

Generator Set Main Breaker

Topology

No

No

Isolated Bus Without Generator Set


Main Breaker

No

Yes

Isolated Bus with Generator Set Main


Breaker

Yes

No

Common Bus

Yes

Yes

Transfer Pair

A029Y787 (Issue 1)

3. Basic Concepts

3.1.2

5-2012

Typical System Components (Isolated Bus Without


Generator Set Main Breaker)

No. Description

No. Description

Generator sets

Generator set bus, load bus

Generator set paralleling breakers

Feeder breakers or ATS (connected to the loads)

FIGURE 1.

10

TYPICAL SYSTEM COMPONENTS (ISOLATED BUS WITHOUT GENERATOR SET MAIN


BREAKER)

A029Y787 (Issue 1)

5-2012

3.1.3

3. Basic Concepts

Typical System Components (Isolated Bus with Generator


Set Main Breaker)

No. Description

No. Description

Generator sets

Generator set main breaker

Generator set paralleling breakers

Load bus

Generator set bus

Feeder breakers or ATS (connected to the loads)

FIGURE 2.

TYPICAL SYSTEM COMPONENTS (ISOLATED BUS WITH GENERATOR SET MAIN


BREAKER)

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11

3. Basic Concepts

3.1.4

5-2012

Typical System Components (Common Bus)

No. Description

No. Description

Generator sets

Feeder breakers or ATS (connected to the loads)

Generator set paralleling breakers

Utility main breaker

Generator set bus, load bus

Utility

FIGURE 3.

12

TYPICAL SYSTEM COMPONENTS (COMMON BUS)

A029Y787 (Issue 1)

5-2012

3.1.5

3. Basic Concepts

Typical System Components (Transfer Pair)

No. Description

No. Description

Generator sets

Load bus

Generator set paralleling breakers

Feeder breakers or ATS (connected to the loads)

Generator set bus

Utility main breaker

Generator set main breaker

Utility

FIGURE 4.

3.1.6

TYPICAL SYSTEM COMPONENTS (TRANSFER PAIR)

Master Synchronize Only


If the topology is Master Synchronize Only, the synchronizer is available. Other features are not
active.

3.1.7

Component Mode
If the topology is Component Mode, the synchronizer and load control are available. Other
features are not active.

A029Y787 (Issue 1)

13

3. Basic Concepts

3.2

5-2012

Transition Type
Transition Type refers to the way the loads are transferred from one source to another source.

3.2.1

Open Transition
A break-before-make transfer of a load from one source to another. There will be a power
interruption.

3.2.2

Soft-closed Transition
A soft-closed transition is a make-before-break transfer of a load from one source to another.
When the second source is connected in parallel to the first, the load on the first source is
gradually reduced until it falls below a particular threshold, at which point the first source is
disconnected.
There will be no power interruption. Both sources have to be in parallel for this type of transfer.

3.2.3

Hard-closed Transition
A hard-closed transition is a make-before-break transfer of a load from one source to another.
There will be no power interruption, and the loads will not be ramped up or ramped down. Both
sources have to be in parallel for this type of transfer. The sources will be in parallel for no more
than 100 ms.

3.2.4

PTC Operating Transition Type


PTC Operating Transition Type determines how the MCM3320 is currently transferring the loads
from one source to another source. It is the same as Transition Type except in these situations.
If the topology is Isolated Bus Without Generator Set Main Breaker, Isolated Bus with
Generator Set Main Breaker, or Master Synchronize Only, PTC Operating Transition Type
is Open Transition.
If the topology is Common Bus and Transition Type is Hard Closed Transition, PTC
Operating Transition Type is Soft Closed Transition.
If PTC Operating Mode is Extended Parallel, PTC Operating Transition Type is Soft Closed
Transition.

3.3

System State
System State describes what the main purpose of the MCM3320 is at any moment. For
example, the MCM3320 may be synchronizing the generator sets with the utility, waiting for
timers to expire, running in extended parallel, in normal operation, and so on.
System State does not affect the operation of the MCM3320. It is for descriptive purposes only.
It is available over network connections, such as PCCNet, Modbus, or InPower.

3.4

Generator Set Availability State


GenX Availability State, where X identifies the generator set, identifies the current availability of
the generator set. This is used by load demand and by the annunciators.

14

A029Y787 (Issue 1)

5-2012

3. Basic Concepts

TABLE 3.

GENX AVAILABILITY STATE

State
Gen Does Not Exist
Offline
Waiting for Gen

Description
GenX kW Rating is set to 0.
The generator sets are not supposed to be running, or
this generator set has been shut down by load demand.
This generator set is starting or restarting. All of these
conditions are met.

The generator sets are running.


This generator set has not been shut down by load
demand.

The paralleling breaker of this generator is open.

3.5

Online

The paralleling breaker of this generator set is closed.

Failed

This generator set failed to come online. See code 1541.

Total Number of Generator Sets Online


Total Number of Gensets Online is the number of generator sets whose paralleling breakers
have closed.

3.6

Total Online Capacity


Total Online Capacity is the sum of the ratings of the generator sets whose paralleling breakers
are closed.

3.7

Total Load Demand Online Capacity


Total Load Demand Online Capacity includes the capacity in Total Online Capacity, plus the
sum of the ratings of the generator sets that have started or restarted but not come online yet.
This is used by load demand to avoid restarting another generator set until a previouslyrestarted generator set either closes its paralleling breaker or fails to come online.
If a generator set fails to come online (code 1541), it is not included in Total Load Demand
Online Capacity.

3.8

Override Enable and Override Command


Many settings have an override enable and an override command associated with them. If the
override enable is set to Enable, the override command becomes the effective value of the
associated setting. If the override enable is set to Disable, the override command is ignored,
and the measured value or calculated value becomes the effective value of the associated
setting.
Typically, the override enable and override command are used for testing. They may also be
available over network connections, such as PCCNet, Modbus, or InPower.

A029Y787 (Issue 1)

15

3. Basic Concepts

3.9

5-2012

Summary of Settings (Basic Concepts)


TABLE 4.

SUMMARY OF SETTINGS (BASIC CONCEPTS)

Setting

Description

System Topology

Specifies the function of the MCM3320 or the topology of


the system.
Possible values: Master Synchronize Only, Isolated Bus
w/out GM, Isolated Bus w/GM, Common Bus, Transfer
Pair, Component Mode (Default: Master Synchronize
Only)

Transition Type

Specifies the type of transition when the loads are


transferred from one source to another.
Possible values: Open Transition, Hard Closed Transition,
Soft Closed Transition (Default: Open Transition)

TABLE 5.

SUMMARY OF MONITOR POINTS (GENERATOR SET CONTROL)

Setting

Description

PTC Operating Transition Type

Indicates how the loads are currently being transferred


from one source to another source. Usually, this is the
same as Transition Type.

System State

Indicates the main purpose of the MCM3320 at any


moment. This does not affect the operation of the
MCM3320. It is for descriptive purposes only.
Possible values: Not Available, TD Start, TD Stop, TD
Programmed Transition, TD Transfer, TD Retransfer,
Synchronizing, Sync Check OK, Inhibit, Unassigned,
Ramp Unload, Ramp Load, Manual, Utility Failure, Test,
Standby, Factory Test, Extended Parallel

GenX Availability State (X = 1-16)

Indicates the current availability of the generator set. This


is used by load demand and the annunciators.
Possible values: Gen Does Not Exist, Offline, Waiting For
Gen, Online, Failed

Total Number of Gensets Online

Indicates the number of generator sets whose paralleling


breakers have closed.

Total Online Capacity

Indicates the sum of the ratings of the generator sets


whose paralleling breakers
are closed.

Total Load Demand Online Capacity

The capacity in Total Online Capacity plus the sum of the


ratings of the generator sets that have started or restarted
but not come online yet. This is used by load demand to
avoid restarting another generator set until a previouslyrestarted generator set either closes its paralleling
breaker or fails to come online.

16

A029Y787 (Issue 1)

Components

4.1

MCM3320 Base Board


This circuit board contains the microprocessor and the operational software.

FIGURE 5.

4.1.1

MCM3320 BASE BOARD

Hardware Version
Hardware Version indicates the revision of the MCM3320 base board.
TABLE 6.

HARDWARE VERSION

Hardware Version

Hardware Revision

unknown

A or B

A029Y787 (Issue 1)

17

4. Components

4.1.2

5-2012

Hardware Version

Hardware Revision

SYNC1320

255

hardware error

Summary of Connections
TABLE 7.
Connection

Description

CT1-CT6

4.1.3

SUMMARY OF CONNECTIONS

Current sensing

J14

Modbus

TB1

PCCNet, switch inputs

TB2

Power, switch inputs, configurable outputs

TB3

Load demand, inhibits, configurable outputs

TB6

Generator set bus voltage sensing

TB7

Utility voltage sensing

TB8

Breaker control, generator set remote start

TB9

Analog inputs, analog outputs

TB10

Breaker status

TB15

Modbus, InPower

CT1-CT6 Connections

FIGURE 6.

CT1-CT6

This connector is oriented the same way it is oriented in Figure 5.


TABLE 8.

CT1-CT6 ASSIGNMENTS: CURRENT SENSING

Pin

Description

Function / Connects to

CT1

Generator Set Bus Current L1

Generator set bus L1

CT2

Generator Set Bus Current L2

Generator set bus L2

CT3

Generator Set Bus Current L3

Generator set bus L3

CT4

Utility Current L1

Utility L1

CT5

Utility Current L2

Utility L2

CT6

Utility Current L3

Utility L3

Route the external current transformer (CT) secondary wiring through the CT such that current
flows through the onboard CT entering at 1 when the measured source is providing power.

18

A029Y787 (Issue 1)

5-2012

4. Components

4.1.3.1 Calibrating Voltage and Current Measurements


Calibration affects the voltage and current values used in all of its calculations, for example,
power and energy, load control, and synchronization. Calibration also affects the values
provided over network connections, such as PCCNet, Modbus, or InPower.
NOTE:

Use a true, calibrated RMS meter to check the actual output.

Typically, the InPower setup screens are used in the calibration process.
Calibrate voltage and current separately for the generator set bus and for the utility. For each
source, these values can be calibrated.
Current in each phase
Line-to-line voltage between each pair of phases (Line-to-neutral voltage is calculated
based on the calibrated line-to-line voltage.)
It is not possible to calibrate the frequency measurement.

4.1.4

J14 Connections

FIGURE 7.

J14 PINS

This connector is oriented the same way it is oriented in Figure 5.


This DB9 connector for RS-232 communication can be used by Modbus devices. Use a null
modem cable with partial handshaking.
NOTE:

You have to disconnect J14 before you can connect a PC-based service tool
on TB15.

4.1.4.1 DB9 Connections


The standard DB9 connections are shown below:

A029Y787 (Issue 1)

19

4. Components

5-2012

FIGURE 8.

4.1.5

DB9 CONNECTIONS

TB1 Connections

FIGURE 9.

TB1 PINS

This connector is oriented the same way it is oriented in Figure 5.


TABLE 9.
Pin

20

TB1 PIN ASSIGNMENTS: PCCNET, SWITCH INPUTS

Description

Function / Connects to

TB1-1

Fused B+

Power supply for HMI 211

TB1-2

PCCNet A

Network Data A

TB1-3

PCCNet B

Network Data B

TB1-4

PCCNet Shield

PCCNet harness shield

TB1-5

N/A

TB1-6

N/A

TB1-7

N/A

TB1-8

N/A

TB1-9

N/A

TB1-10

Discrete Input Return

Signal return for switch inputs

A029Y787 (Issue 1)

5-2012

Pin

4. Components

Description

Function / Connects to

TB1-11

Synchronizer Enable

Enables synchronizing when the control is in


Manual mode or in Master Synchronize Only
mode

TB1-12

N/A

TB1-13

Discrete Input Return

Signal return for switch inputs

TB1-14

Override

Forces a transfer or retransfer to occur as quickly


as possible; overrides transfer inhibit, retransfer
inhibit, transfer time delay and retransfer time
delay

TB1-15

Discrete Input Return

Signal return for switch inputs

TB1-16

Utility Source Failure

Indicates that the utility has failed; used in


applications in which an external device
determines utility source availability

4.1.5.1 Discrete Inputs


Discrete inputs are inputs that are either active or inactive.
The states may be mapped to different names, such as stop/start or breaker open/breaker
closed.

4.1.5.2 Volatiles for Discrete Inputs


Many discrete inputs have volatiles associated with them. The volatile is a software source for
the discrete input. If the volatile is set to its active value, the discrete input becomes active. If
the volatile is set its to inactive value, the discrete input becomes inactive if none of the other
sources, such as hardware sources, are active.
Volatiles may be available over network connections, such as PCCNet, Modbus, or InPower.

4.1.6

TB2 Connections

FIGURE 10.

TB2 PINS

This connector is oriented the same way it is oriented in Figure 5.

A029Y787 (Issue 1)

21

4. Components

5-2012

TABLE 10.
Pin

TB2 PIN ASSIGNMENTS: POWER, SWITCH INPUTS, CONFIGURABLE OUTPUTS


Description

Function / Connects to

TB2-1

Test Start

Starts and stops a test of the system

TB2-2

Battery

Battery 1 or battery 2 return

TB2-3

Battery

Battery 1 or battery 2 return

TB2-4

Extended Parallel Start

Signal to start extended parallel

TB2-5

Battery

Battery 1 or battery 2 return

TB2-6

Discrete Input Return

Signal return for switch inputs

TB2-7

Battery

Battery 1 or battery 2 return

TB2-8

Battery 1 +

Battery 1 power (+)

TB2-9

Battery 1 +

Battery 1 power (+)

TB2-10

Relay Coil B+ Supply

Switched B+

TB2-11

Battery 2 +

Battery 2 power (+)

TB2-12

Battery 2 +

Battery 2 power (+)

TB2-13

N/A

TB2-14

Fault Reset

Resets faults; if active for 5 seconds, displays


fault codes on the seven-segment display

TB2-15

Configurable Output #1

Defaults to Common Warning; intended to drive a


relay coil

TB2-16

Configurable Output #2

Defaults to Fail to Sync; intended to drive a relay


coil

TB2-17

Configurable Output #3

Defaults to Gen Available; intended to drive a


relay coil

TB2-18

Configurable Output #4

Defaults to Utility Available; intended to drive a


relay coil

TB2-19

Chassis Ground

Connected by short wire to grounded metal


chassis.

Only one battery is required; use the second battery for redundancy.
TB2-15, TB2-16, TB2-17, and TB2-18 are low-side drivers.
TABLE 11.

LOW-SIDE DRIVER SPECIFICATIONS

Description

Value

Maximum voltage

30 VDC

Maximum current

250 mA

Maximum inrush

3A

Leakage current (off-state)

100 uA

4.1.6.1 Configurable Outputs


Configurable outputs are discrete outputs whose state depends on a specified event code or
fault code. If the specified event or fault is active, the configurable output is active. If the
specified event or fault is inactive, the configurable output is inactive.

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TB3 Connections

FIGURE 11.

TB3 PINS

This connector is oriented the same way it is oriented in Figure 5.


TABLE 12.
Pin

TB3 PIN ASSIGNMENTS: LOAD DEMAND, INHIBITS, CONFIGURABLE OUTPUTS


Description

Function / Connects to

TB3-1

Load Govern Enable

Connects to utility circuit breaker position on


generator set controls; tells generator set controls
when generator sets are in parallel with the utility

TB3-2

Load Demand Generator Set 1

Connects to load demand input on generator set


1

TB3-3

N/A

TB3-4

N/A

TB3-5

N/A

TB3-6

Transfer Inhibit

Inhibits transfer of loads to generator sets; in


some situations, it is ignored; it is not the same
as the generator set paralleling breaker inhibit

TB3-7

Retransfer Inhibit

Inhibits transfer of loads to utility; in some


situations, it is ignored; it is not the same as the
utility breaker inhibit

TB3-8

Discrete Input Return

Signal return for switch inputs

TB3-9

Load Demand Generator Set 2

Connects to load demand input on generator set


2

TB3-10

Load Demand Generator Set 3

Connects to load demand input on generator set


3

TB3-11

Load Demand Generator Set 4

Connects to load demand input on generator set


4

TB3-12

Configurable Output #5

Defaults to Fail to Disconnect; intended to drive a


relay coil

TB3-13

Configurable Output #6

Defaults to Synchronized; intended to drive a


relay coil

TB3-14

Configurable Output #7

Defaults to Sync Output Limit; intended to drive a


relay coil

TB3-15

Configurable Output #8

Defaults to Hardware Failure; intended to drive a


relay coil

TB3-16

Generator Set Paralleling Breaker Inhibit

Connects to generator set paralleling breaker


inhibit input on generator set controls

TB3-17

Master Inhibit

Used when there are multiple MCM3320s in a


system; master inhibit for breaker control and
synchronizer; ground/return this signal to activate
inhibit

TB3-12, TB3-13, TB3-14, and TB3-15 are low-side drivers.

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TABLE 13.

LOW-SIDE DRIVER SPECIFICATIONS

Description

Value

Maximum voltage

30 VDC

Maximum current

250 mA

Maximum inrush

3A

Leakage current (off-state)

100 uA

4.1.7.1 Discrete Outputs


Discrete outputs are outputs that are either active or inactive.
The states may be mapped to different names, such as driver off/driver on or open
breaker/close breaker.

4.1.8

TB6 Connections

FIGURE 12.

TB6 PINS

This connector is oriented the same way it is oriented in Figure 5.


TABLE 14.
Pin

TB6 PIN ASSIGNMENTS: GENERATOR SET BUS VOLTAGE

Description

Function / Connects to

TB6-1

Generator Set Bus L1 Voltage

up to 480 VAC (line-to-line)

TB6-2

Generator Set Bus L2 Voltage

up to 480 VAC (line-to-line)

TB6-3

Generator Set Bus L3 Voltage

up to 480 VAC (line-to-line)

TB6-4

Generator Set Bus Neutral Voltage

up to 480 VAC (line-to-line)

If the nominal voltage of the generator set bus is greater than 480 VAC (line-to-line), potential
transformers (PTs) are required to reduce the voltage to less than 480 VAC (line-to-line) before
it enters the control.

4.1.8.1 Calibrating Voltage and Current Measurements


Calibration affects the voltage and current values used in all of its calculations, for example,
power and energy, load control, and synchronization. Calibration also affects the values
provided over network connections, such as PCCNet, Modbus, or InPower.
NOTE:

Use a true, calibrated RMS meter to check the actual output.

Typically, the InPower setup screens are used in the calibration process.

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Calibrate voltage and current separately for the generator set bus and for the utility. For each
source, these values can be calibrated.
Current in each phase
Line-to-line voltage between each pair of phases (Line-to-neutral voltage is calculated
based on the calibrated line-to-line voltage.)
It is not possible to calibrate the frequency measurement.

4.1.9

TB7 Connections

FIGURE 13.

TB7 PINS

This connector is oriented the same way it is oriented in Figure 5.


TABLE 15.
Pin

TB7 PIN ASSIGNMENTS: UTILITY VOLTAGE

Description

Function / Connects to

TB7-1

Utility L1 Voltage

up to 480 VAC (line-to-line)

TB7-2

Utility L2 Voltage

up to 480 VAC (line-to-line)

TB7-3

Utility L3 Voltage

up to 480 VAC (line-to-line)

TB7-4

Utility Neutral Voltage

up to 480 VAC (line-to-line)

If the utility voltage is greater than 480 VAC (line-to-line), potential transformers (PTs) are
required to reduce the voltage to less than 480 VAC (line-to-line) before it enters the control.

4.1.10 TB8 Connections

FIGURE 14.

TB8 PINS

This connector is oriented the same way it is oriented in Figure 5.


TABLE 16.
Pin

TB8 PIN ASSIGNMENTS: BREAKER CONTROL, GENERATOR SET REMOTE START


Description

Function / Connects to

TB8-1

N/A

TB8-2

Generator Set Main Breaker Close 1

Closes the generator set main breaker; normallyopen contacts

TB8-3

Generator Set Main Breaker Close 2

Closes the generator set main breaker; normallyopen contacts

TB8-4

N/A

TB8-5

Generator Set Main Breaker Open 1

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Opens the generator set main breaker; normallyopen contacts

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5-2012

Description

Function / Connects to

TB8-6

Generator Set Main Breaker Open 2

Opens the generator set main breaker; normallyopen contacts

TB8-7

Generator Set Start Relay Normally-closed

Starts the generator sets

TB8-8

Generator Set Start Relay Common

Starts the generator sets

TB8-9

Generator Set Start Relay Normally-open

Starts the generator sets; connect in parallel to


generator set remote start signals

TB8-10

Utility Main Breaker Close 1

Closes the utility main breaker; normally-open


contacts

TB8-11

Utility Main Breaker Close 2

Closes the utility main breaker; normally-open


contacts

TB8-12

Utility Main Breaker Open 1

Opens the utility main breaker; normally-open


contacts

TB8-13

Utility Main Breaker Open 2

Opens the utility main breaker; normally-open


contacts

TABLE 17.

BREAKER CLOSE SPECIFICATIONS

Description

Value

Maximum voltage

30 VDC or 250 VAC

Maximum current

8 A (resistive)
3.5 A (inductive)

Time constant (L/R)

7 ms

TABLE 18.

BREAKER OPEN SPECIFICATIONS

Description

Value

Maximum voltage

30 VDC

Maximum current

8 A (resistive)
3.5 A (inductive)

Time constant (L/R)

7 ms

4.1.11 TB9 Connections

FIGURE 15.

TB9 PINS

This connector is oriented the same way it is oriented in Figure 5.

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TABLE 19.
Pin

TB9 PIN ASSIGNMENTS: ANALOG INPUTS/OUTPUTS

Description

Function / Connects to

TB9-1

kW Load Setpoint

Sets the kW setpoint for base load or peak


shave; 0-5 VDC analog input; 1 VDC
corresponds to 0% load, 4.5 VDC corresponds to
110% load

TB9-2

Analog Return

Signal return for analog inputs

TB9-3

kVAR Load Setpoint

Sets the kVAR setpoint or power factor setpoint


for base load or peak shave; 0-5 VDC analog
input
If this is the kVAR setpoint, 1 VDC corresponds
to 0% load, 4.5 VDC corresponds to 110% load.
If this is the power factor setpoint, this
corresponds to what the kVAR setpoint would
have been. For example, if the kVAR load
setpoint would have been 80%, the power factor
setpoint is 0.80. The power factor setpoint is
limited to 0.7-1.0. If the input signal is outside this
range, the power factor setpoint is set to 0.7 or
1.0 accordingly.

TB9-4

kW Master Load Control

Connected in parallel to generator set kW load


setpoints; sets the generator set kW load govern
level; use shielded twisted pair cable; 0-5 VDC
analog output; 1 VDC corresponds to 0% load,
4.5 VDC corresponds to 110% load

TB9-5

kVAR Master Load Control

Connected in parallel to generator set kVAR load


setpoints; sets the generator set kW load govern
level; use shielded twisted pair cable; 0-5 VDC
analog output; 1 VDC corresponds to 0% load,
4.5 VDC corresponds to 110% load

TB9-6

Analog Return

Signal return for analog inputs

TB9-7

N/A

TB9-8

Master Frequency Bias +

Connected to generator set kW load share line;


synchronizes the generator sets with the utility; 2.5~5 VDC analog input/output

TB9-9

Analog Return

Signal return for analog inputs

TB9-10

Master Voltage Bias +

Connected to generator set kVAR load share line;


synchronizes the generator sets with the utility; 2.5~5 VDC analog input/output

TB9-11

N/A

4.1.11.1 Analog Inputs


Analog inputs are inputs that can have a range of values.
While analog inputs are based on an input voltage, the value may have a different meaning,
such as current or percentage of nominal voltage.

4.1.11.1.1 Process Values of Analog Inputs


The process value of an analog input is the value of the analog input that is used in any
calculations or operations. It is not the value of the analog input that is displayed.

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4.1.11.1.2 Display Values of Analog Inputs


The display values of an analog input are the values of the analog input that are displayed.
They are not the values of the analog input that are used in any calculations or operations.
Typically, display values are updated less frequently than the value used in calculations and
operations.
An analog input can have different types of display values.
Voltage display value: this is the current value of the input for technicians, for example, in
InPower.
Engineering units display value: this is the current value of the input for operators, for
example, in the operator panel.
Raw sample value: this value is the output of the sampling process that converts the
analog signal into a digital signal. It is not affected by the override enable and override
commands as the other types are.

4.1.11.2 Analog Outputs


Analog outputs are outputs that can have a range of values.
While analog outputs are based on an output voltage, the value may have a different meaning
to the device to which it is connected.

4.1.11.2.1 Output Predictor Values


Analog outputs have an output predictor value associated with them. The output predictor value
is the voltage level that the associated analog output is supposed to have.
This value can be used for testing.

4.1.12 TB10 Connections

FIGURE 16.

TB10 PINS

This connector is oriented the same way it is oriented in Figure 5.


TABLE 20.
Pin

28

TB10 PIN ASSIGNMENTS: BREAKER STATUS

Description

Function / Connects to

TB10-1

Generator Set Main Breaker Position A

Input for the position of the "A" contact for the


generator set main breaker

TB10-2

Generator Set Main Breaker Position B

Input for the position of the "B" contact for the


generator set main breaker

TB10-3

Generator Set Main Breaker Tripped

Input that indicates whether or not the generator


set main breaker is tripped

TB10-4

Discrete Input Return

Signal return for switch inputs

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Description

Function / Connects to

TB10-5

Generator Set Breaker Inhibit

Customer input; opens the generator set main


breaker or inhibits the paralleling breakers
depending on the topology

TB10-6

Auto/Manual

Sets the mode of operation of the MCM3320

TB10-7

Utility Main Breaker Position A

Input for the position of the "A" contact for the


utility main breaker

TB10-8

Discrete Input Return

Signal return for switch inputs

TB10-9

Utility Main Breaker Position B

Input for the position of the "B" contact for the


utility main breaker

TB10-10

Utility Main Breaker Tripped

Input that indicates whether or not the utility main


breaker is tripped

TB10-11

Utility Main Breaker Inhibit

Customer input; opens the utility main breaker

TB10-12

Generator Set 1 Paralleling Breaker Position A

Input for the position of the "A" contact for the


generator set 1 paralleling breaker

TB10-13

Discrete Input Return

Signal return for switch inputs

TB10-14

Generator Set 2 Paralleling Breaker Position A

Input for the position of the "A" contact for the


generator set 2 paralleling breaker

TB10-15

Generator Set 3 Paralleling Breaker Position A

Input for the position of the "A" contact for the


generator set 3 paralleling breaker

TB10-16

Generator Set 4 Paralleling Breaker Position A

Input for the position of the "A" contact for the


generator set 4 paralleling breaker

TB10-17

Discrete Input Return

Signal return for switch inputs

TB10-18

Discrete Input Return

Signal return for switch inputs

4.1.13 TB15 Connections

FIGURE 17.

TB15 PINS

This connector is oriented the same way it is oriented in Figure 5.


TABLE 21.
Pin

TB15 PIN ASSIGNMENTS: MODBUS, SERVICE TOOL

Description

Function / Connects to

TB15-1

RS-485 Shield

Network shield

TB15-2

Fused B+ (0.25 A)

Connected to external, low-power devices, such


as a RS-232-to-RS-485 converter or a simple
display

TB15-3

RS-485 Data A

Network data A

TB15-4

RS-485 Data B

Network data B

TB15-5

N/A

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4.1.13.1 Dual-Purpose RS-485 Connection


NOTE:

You have to disconnect J14 before you can connect a PC-based service tool
on TB15.

This RS-485 connection can be used by Modbus or PC-based service tools (MON).
NOTE:

Use J14 if you want to connect to the control with a PC-based service tool
without disconnecting any Modbus devices on TB15.

If the control is using Modbus on the RS-485 connection, the control changes to MON if the
following steps occur.
1. The control receives 5 consecutive bad Modbus packets, or the receiver buffer is full.
2. The control does not receive any valid Modbus packets for 5 seconds.
If the control is using MON on the RS-485 connection, the control changes to Modbus if the
following steps occur.
1. The control receives 5 consecutive bad MON packets.
2. The control does not receive any valid MON packets for 5 seconds.

4.1.13.2 Modbus Connections


NOTE:

See http://www.modbus.org for more information about Modbus and up-todate wire specifications.

The control should be connected to external devices via Modbus RTU (Remote Terminal Unit)
protocol on a two-wire RS-485 master/slave bus. In this arrangement, the external device is the
master, and the control is the slave.
A Modbus over Serial Line Cable must be shielded. One end of the shield must be connected to
protective ground.
A four-wire RS-485 connection can be converted to a two-wire RS-485 connection by shorting
the RX/TX pairs of wires together.

FIGURE 18.

CONVERTING FOUR-WIRE RS-485 CONNECTIONS TO TWO-WIRE RS-485


CONNECTIONS

If you convert a four-wire RS-485 connection to a two-wire RS-485 connection, make sure the
start bit, stop bit, speed, and flow control are synchronized. See http://www.modbus.org for
more information.

4.1.13.3 InPower
InPowerTM is a Windows-based service, maintenance and diagnostic tool. This tool provides
electronic service functions including: adjustments for trims and settings, monitoring, strip chart,
data logging, viewing faults, and report capability.
NOTE:

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The InPower tool also can be used to save a device's trims and settings to a file. The stored
settings can be viewed off-line and they can be used to configure multiple installations of the
same application controller type.
Each copy of InPower is packaged and installed separately. No more than one InPower product
can be installed on the same PC.

4.1.13.4 Connecting an MCM3320


The MCM3320 master control requires an RS-232 to RS-485 data converter and a unique
cable. Figure 19 shows the MCM3320 InPower connection.
Kit number 541-1199 is available for use with the MCM3320. The kit includes the RS-232 to RS485 converter and the cable used for this application.
If the service PC does not have a serial port, a USB-to-serial converter may be required as well.

FIGURE 19.

INPOWER SERIAL CONNECTION WITH MCM3320 CONTROL

4.1.13.5 Configuring the MCM3320


There are two ways to configure the MCM3320 in InPower.
Use the folders in the device explorer, the same way you configure any device.

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Use the MCM3320 setup screens. Right-click on the device to open these screens.

4.1.14 Power-down Mode


The control does not support power-down mode, or sleep mode. It remains awake at all times.

4.1.15 System and Diagnostic Indicators

FIGURE 20.

SYSTEM AND DIAGNOSTIC INDICATORS

TABLE 22.

SYSTEM AND DIAGNOSTIC INDICATORS

Indicator

Name

Description

DS1

Utility Available

The utility is available.

DS2

Utility Connected

The utility is connected to the loads.

DS3

Heartbeat

This flashes regularly when the board is running


normally.

DS4

Generator Set Connected

The generator sets are connected to the loads.

DS5

Generator Set Available

The generator sets are available.

DS6

Common Alarm

At least one fault is active.

DS7

Not In Auto

The control is in Manual mode.


(Blinking green) The system is trying to
synchronize the generator sets with the utility.
Sync Check Close Allowed is Not Allowed.
Code 1457 (Fail to Synchronize Warning) is
inactive.

DS8

Synchronizer

(Green) The system is ready to connect one of


the sources to the loads. Sync Check Close
Allowed is Allowed. Code 1457 (Fail to
Synchronize Warning) is inactive.
(Red) Code 1457 (Fail to Synchronize Warning)
is active.

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Indicator

Name

DS9

Description
The control is receiving a Modbus packet or is
sending a Modbus packet.
In addition, this indicator is on during the 5second wait before changing communication
protocols on TB15.

Modbus Activity

U51 displays different information depending on the mode. The mode is indicated by the
decimal point in the lower right corner. To put U51 in System mode, press the fault reset switch
(TB2-14) for less than five seconds. To put U51 in Diagnostic mode, press the fault reset switch
(TB2-14) for at least five seconds.
TABLE 23.

U51 INFORMATION

Mode

Decimal Point

Display

System

off

Codes for System State (Table 38)

Diagnostic

on

Codes of active faults

Some codes for System State are not available in every topology.
TABLE 24.

U51 CODES FOR SYSTEM STATE

Code

Description

Time delay start

Time delay stop

Time Delay Programmed Transition (TDPT)

Time Delay Normal to Emergency (TDNE)

Time Delay Emergency to Normal (TDEN)

Synchronizing (The synchronizer is running, and Sync Check


Close Allowed is Not Allowed.)

Synchronizer check OK (Sync Check Close Allowed is Allowed.)

Inhibit

Ramp unload

Ramp load

Manual mode

Utility failure

Test

Extended parallel

Standby (PTC Operating Mode is Normal, and the other activity


codes are not applicable.)

Not available

4.1.16 Repairing Circuit Boards


WARNING: Attempting to repair circuit boards can lead to equipment damage, personal
injury, or death. Replace faulty circuit boards. Do not try to repair faulty
circuit boards.

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SYNC1320 Base Board


This circuit board contains the microprocessor and the operational software.

FIGURE 21.

4.2.1

Summary of Connections
TABLE 25.
Connection

34

SYNC1320 BASE BOARD

SUMMARY OF CONNECTIONS

Description

TB1

Synchronizer enable switch

TB2

Power, fault reset, configurable outputs

TB3

Configurable outputs

TB6

Generator set bus voltage sensing

TB7

Utility voltage sensing

TB9

Analog inputs, analog outputs

TB10

Auto/manual switch

TB15

InPower

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TB1 Connections

FIGURE 22.

TB1 PINS

This connector is oriented the same way it is oriented in Figure 21.


TABLE 26.
Pin

TB1 PIN ASSIGNMENTS: SYNCHRONIZER ENABLE SWITCH

Description

Function / Connects to

TB1-1

N/A

TB1-2

N/A

TB1-3

N/A

TB1-4

N/A

TB1-5

N/A

TB1-6

N/A

TB1-7

N/A

TB1-8

N/A

TB1-9

N/A

TB1-10

Discrete Input Return

Signal return for switch inputs

TB1-11

Synchronizer Enable

Enables synchronizing when the control is in


Manual mode or in Master Synchronize Only
mode

TB1-12

N/A

TB1-13

N/A

TB1-14

N/A

TB1-15

N/A

TB1-16

N/A

4.2.2.1 Discrete Inputs


Discrete inputs are inputs that are either active or inactive.
The states may be mapped to different names, such as stop/start or breaker open/breaker
closed.

4.2.2.2 Volatiles for Discrete Inputs


Many discrete inputs have volatiles associated with them. The volatile is a software source for
the discrete input. If the volatile is set to its active value, the discrete input becomes active. If
the volatile is set its to inactive value, the discrete input becomes inactive if none of the other
sources, such as hardware sources, are active.
Volatiles may be available over network connections, such as PCCNet, Modbus, or InPower.

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TB2 Connections

FIGURE 23.

TB2 PINS

This connector is oriented the same way it is oriented in Figure 21.


TABLE 27.
Pin

36

TB2 PIN ASSIGNMENTS: POWER, FAULT RESET, CONFIGURABLE OUTPUTS

Description

Function / Connects to

TB2-1

N/A

TB2-2

Battery

Battery 1 or battery 2 return

TB2-3

Battery

Battery 1 or battery 2 return

TB2-4

N/A

TB2-5

Battery

Battery 1 or battery 2 return

TB2-6

Discrete Input Return

Signal return for switch inputs

TB2-7

Battery

Battery 1 or battery 2 return

TB2-8

Battery 1 +

Battery 1 power (+)

TB2-9

Battery 1 +

Battery 1 power (+)

TB2-10

Relay Coil B+ Supply

Switched B+

TB2-11

Battery 2 +

Battery 2 power (+)

TB2-12

Battery 2 +

Battery 2 power (+)

TB2-13

N/A

TB2-14

Fault Reset

Resets faults; if active for 5 seconds, displays


fault codes on the seven-segment display

TB2-15

Configurable Output #1

Defaults to Common Warning; intended to drive a


relay coil

TB2-16

Configurable Output #2

Defaults to Fail to Sync; intended to drive a relay


coil

TB2-17

Configurable Output #3

Defaults to Gen Available; intended to drive a


relay coil

TB2-18

Configurable Output #4

Defaults to Utility Available; intended to drive a


relay coil

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Pin

Description

TB2-19

Function / Connects to

Chassis Ground

Only one battery is required; use the second battery for redundancy.
TB2-15, TB2-16, TB2-17, and TB2-18 are low-side drivers.
TABLE 28.

LOW-SIDE DRIVER SPECIFICATIONS

Description

Value

Maximum voltage

30 VDC

Maximum current

250 mA

Maximum inrush

3A

Leakage current (off-state)

100 uA

4.2.3.1 Configurable Outputs


Configurable outputs are discrete outputs whose state depends on a specified event code or
fault code. If the specified event or fault is active, the configurable output is active. If the
specified event or fault is inactive, the configurable output is inactive.

4.2.4

TB3 Connections

FIGURE 24.

TB3 PINS

This connector is oriented the same way it is oriented in Figure 21.


TABLE 29.
Pin

TB3 PIN ASSIGNMENTS: CONFIGURABLE OUTPUTS

Description

TB3-1

N/A

TB3-2

N/A

TB3-3

N/A

TB3-4

N/A

TB3-5

N/A

TB3-6

N/A

TB3-7

N/A

TB3-8

N/A

TB3-9

N/A

TB3-10

N/A

TB3-11

N/A

TB3-12

Configurable Output #5

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Function / Connects to

Defaults to Fail to Disconnect; intended to drive a


relay coil

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Pin

Description

Function / Connects to

TB3-13

Configurable Output #6

Defaults to Synchronized; intended to drive a


relay coil

TB3-14

Configurable Output #7

Defaults to Sync Output Limit; intended to drive a


relay coil

TB3-15

Configurable Output #8

Defaults to Hardware Failure; intended to drive a


relay coil

TB3-16

N/A

TB3-17

N/A

TB3-12, TB3-13, TB3-14, and TB3-15 are low-side drivers.


TABLE 30.

LOW-SIDE DRIVER SPECIFICATIONS

Description

Value

Maximum voltage

30 VDC

Maximum current

250 mA

Maximum inrush

3A

Leakage current (off-state)

4.2.5

100 uA

TB6 Connections

FIGURE 25.

TB6 PINS

This connector is oriented the same way it is oriented in Figure 5.


TABLE 31.
Pin

TB6 PIN ASSIGNMENTS: GENERATOR SET BUS VOLTAGE

Description

Function / Connects to

TB6-1

Generator Set Bus L1 Voltage

up to 480 VAC (line-to-line)

TB6-2

Generator Set Bus L2 Voltage

up to 480 VAC (line-to-line)

TB6-3

Generator Set Bus L3 Voltage

up to 480 VAC (line-to-line)

TB6-4

Generator Set Bus Neutral Voltage

up to 480 VAC (line-to-line)

If the nominal voltage of the generator set bus is greater than 480 VAC (line-to-line), potential
transformers (PTs) are required to reduce the voltage to less than 480 VAC (line-to-line) before
it enters the control.

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4.2.5.1 Calibrating Voltage and Current Measurements


Calibration affects the voltage and current values used in all of its calculations, for example,
power and energy, load control, and synchronization. Calibration also affects the values
provided over network connections, such as PCCNet, Modbus, or InPower.
NOTE:

Use a true, calibrated RMS meter to check the actual output.

Typically, the InPower setup screens are used in the calibration process.
Calibrate voltage and current separately for the generator set bus and for the utility. For each
source, these values can be calibrated.
Current in each phase
Line-to-line voltage between each pair of phases (Line-to-neutral voltage is calculated
based on the calibrated line-to-line voltage.)
It is not possible to calibrate the frequency measurement.

4.2.6

TB7 Connections

FIGURE 26.

TB7 PINS

This connector is oriented the same way it is oriented in Figure 5.


TABLE 32.
Pin

TB7 PIN ASSIGNMENTS: UTILITY VOLTAGE

Description

Function / Connects to

TB7-1

Utility L1 Voltage

up to 480 VAC (line-to-line)

TB7-2

Utility L2 Voltage

up to 480 VAC (line-to-line)

TB7-3

Utility L3 Voltage

up to 480 VAC (line-to-line)

TB7-4

Utility Neutral Voltage

up to 480 VAC (line-to-line)

If the utility voltage is greater than 480 VAC (line-to-line), potential transformers (PTs) are
required to reduce the voltage to less than 480 VAC (line-to-line) before it enters the control.

4.2.7

TB9 Connections

FIGURE 27.

TB9 PINS

This connector is oriented the same way it is oriented in Figure 21.


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TABLE 33.
Pin

TB9 PIN ASSIGNMENTS: ANALOG INPUTS/OUTPUTS

Description

Function / Connects to

TB9-1

N/A

TB9-2

N/A

TB9-3

N/A

TB9-4

N/A

TB9-5

N/A

TB9-6

N/A

TB9-7

N/A

TB9-8

Master Frequency Bias +

Connected to generator set kW load share line;


synchronizes the generator sets with the utility; 2.5~5 VDC analog input/output

TB9-9

Analog Return

Signal return for analog inputs

TB9-10

Master Voltage Bias +

Connected to generator set kVAR load share line;


synchronizes the generator sets with the utility; 2.5~5 VDC analog input/output

TB9-11

N/A

4.2.7.1 Analog Inputs


Analog inputs are inputs that can have a range of values.
While analog inputs are based on an input voltage, the value may have a different meaning,
such as current or percentage of nominal voltage.

4.2.7.1.1 Process Values of Analog Inputs


The process value of an analog input is the value of the analog input that is used in any
calculations or operations. It is not the value of the analog input that is displayed.

4.2.7.1.2 Display Values of Analog Inputs


The display values of an analog input are the values of the analog input that are displayed.
They are not the values of the analog input that are used in any calculations or operations.
Typically, display values are updated less frequently than the value used in calculations and
operations.
An analog input can have different types of display values.
Voltage display value: this is the current value of the input for technicians, for example, in
InPower.
Engineering units display value: this is the current value of the input for operators, for
example, in the operator panel.
Raw sample value: this value is the output of the sampling process that converts the
analog signal into a digital signal. It is not affected by the override enable and override
commands as the other types are.

4.2.7.2 Analog Outputs


Analog outputs are outputs that can have a range of values.

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While analog outputs are based on an output voltage, the value may have a different meaning
to the device to which it is connected.

4.2.7.2.1 Output Signals for Analog Outputs


The output signal of an analog output is a pulse-width modulated (PWM) signal. The PWM
signal has a frequency of 4 kHz. If this signal is sampled more quickly than this, it is possible to
measure the incorrect voltage.

4.2.7.2.2 Output Predictor Values


Analog outputs have an output predictor value associated with them. The output predictor value
is the voltage level that the associated analog output is supposed to have.
This value can be used for testing.

4.2.8

TB10 Connections

FIGURE 28.

TB10 PINS

This connector is oriented the same way it is oriented in Figure 21.


TABLE 34.
Pin

TB10 PIN ASSIGNMENTS: AUTO/MANUAL SWITCH

Description

TB10-1

N/A

TB10-2

N/A

TB10-3

N/A

TB10-4

N/A

TB10-5

N/A

TB10-6

Auto/Manual

TB10-7

N/A

TB10-8

Discrete Input Return

TB10-9

N/A

TB10-10

N/A

TB10-11

N/A

TB10-12

N/A

TB10-13

N/A

TB10-14

N/A

TB10-15

N/A

TB10-16

N/A

TB10-17

Discrete Input Return

TB10-18

N/A

A029Y787 (Issue 1)

Function / Connects to

Sets the mode of operation of the MCM3320

Signal return for switch inputs

Signal return for switch inputs

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TB15 Connections

FIGURE 29.

TB15 PINS

This connector is oriented the same way it is oriented in Figure 5.


TABLE 35.
Pin

TB15 PIN ASSIGNMENTS: MODBUS, SERVICE TOOL

Description

Function / Connects to

TB15-1

RS-485 Shield

Network shield

TB15-2

Fused B+ (0.25 A)

Connected to external, low-power devices, such


as a RS-232-to-RS-485 converter or a simple
display

TB15-3

RS-485 Data A

Network data A

TB15-4

RS-485 Data B

Network data B

TB15-5

N/A

4.2.9.1 InPower
InPowerTM is a Windows-based service, maintenance and diagnostic tool. This tool provides
electronic service functions including: adjustments for trims and settings, monitoring, strip chart,
data logging, viewing faults, and report capability.
NOTE:

PowerCommand is a registered trademark of Cummins Inc.

The InPower tool also can be used to save a device's trims and settings to a file. The stored
settings can be viewed off-line and they can be used to configure multiple installations of the
same application controller type.
Each copy of InPower is packaged and installed separately. No more than one InPower product
can be installed on the same PC.

4.2.9.2 Connecting a SYNC1320


Connect to the SYNC1320 the same way you connect to a MCM3320 on TB15.

4.2.9.3 Configuring the SYNC1320


There are two ways to configure the SYNC1320 in InPower.
Use the folders in the device explorer, the same way you configure any device.
Use the SYNC1320 setup screens. Right-click on the device to open these screens.

4.2.10 Power-down Mode


The control does not support power-down mode, or sleep mode. It remains awake at all times.

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4.2.11 System and Diagnostic Indicators

FIGURE 30.

SYSTEM AND DIAGNOSTIC INDICATORS

TABLE 36.

SYSTEM AND DIAGNOSTIC INDICATORS

Indicator

Name

Description

DS1

Utility Available

The utility is available.

DS2

Utility Connected

The utility is connected to the loads.

DS3

Heartbeat

This flashes regularly when the board is running


normally.

DS4

Generator Set Connected

The generator sets are connected to the loads.

DS5

Generator Set Available

The generator sets are available.

DS6

Common Alarm

At least one fault is active.

DS7

Not In Auto

The control is in Manual mode.


(Blinking green) The system is trying to
synchronize the generator sets with the utility.
Sync Check Close Allowed is Not Allowed.
Code 1457 (Fail to Synchronize Warning) is
inactive.

DS8

Synchronizer

(Green) The system is ready to connect one of


the sources to the loads. Sync Check Close
Allowed is Allowed. Code 1457 (Fail to
Synchronize Warning) is inactive.
(Red) Code 1457 (Fail to Synchronize Warning)
is active.

DS9

A029Y787 (Issue 1)

Modbus Activity

The control is receiving a Modbus packet or is


sending a Modbus packet.
In addition, this indicator is on during the 5second wait before changing communication
protocols on TB15.

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U51 displays different information depending on the mode. The mode is indicated by the
decimal point in the lower right corner. To put U51 in System mode, press the fault reset switch
(TB2-14) for less than five seconds. To put U51 in Diagnostic mode, press the fault reset switch
(TB2-14) for at least five seconds.
TABLE 37.

U51 INFORMATION

Mode

Decimal Point

Display

System

off

Codes for System State (Table 38)

Diagnostic

on

Codes of active faults

Some codes for System State are not available in every topology.
TABLE 38.

U51 CODES FOR SYSTEM STATE

Code

Description

Time delay start

Time delay stop

Time Delay Programmed Transition (TDPT)

Time Delay Normal to Emergency (TDNE)

Time Delay Emergency to Normal (TDEN)

Synchronizing (The synchronizer is running, and Sync Check


Close Allowed is Not Allowed.)

Synchronizer check OK (Sync Check Close Allowed is Allowed.)

Inhibit

Ramp unload

Ramp load

Manual mode

Utility failure

Test

Extended parallel

Standby (PTC Operating Mode is Normal, and the other activity


codes are not applicable.)

Not available

4.2.12 Repairing Circuit Boards


WARNING: Attempting to repair circuit boards can lead to equipment damage, personal
injury, or death. Replace faulty circuit boards. Do not try to repair faulty
circuit boards.

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4.3

Operator Panel

4.3.1

Back Panel

FIGURE 31.

BACK PANEL

4.3.1.1 J1/J2 Connections


J1 and J2 are identical. Either connector can be used to connect to the MCM3320. The other
connector can be used to connect additional devices to the PCCNet network.
TABLE 39.
Pin

J1/J2 PIN ASSIGNMENTS

Description

RS-485 Data A

RS-485 Data B

Fused B+ (0.25 A), connected to external, low-power devices, such as a RS-232to-RS-485 converter or a simple display

Not used

Fused B+ return

Not used

Not used

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Pin

Description

4.3.2

Not used

Front Panel

FIGURE 32.

FRONT PANEL

4.3.2.1 Summary of Indicators


TABLE 40.
Indicator

SUMMARY OF INDICATORS
Description

Utility Parallel

PTC State is Paralleled.

Lockout

System Lockout Status is Active.

Warning

Code 1483 (Common Alarm) is active.

Remote Start

The generator set start relay (TB8-7, TB-8, TB8-9) is


active.

Auto

Auto/Manual Sw is Auto.

Manual

Auto/Manual Sw is Manual.

4.3.2.2 Summary of Buttons


TABLE 41.
Button
Soft-key buttons (4)

46

SUMMARY OF BUTTONS
Description
The functions of these buttons vary depending on the
screen. Some buttons may not have any function in a
particular screen.
Press this to return to the previous screen.
Press this to return to the main screen.

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4. Components

Compatible Software Versions (Operator Panel)


TABLE 42.

4.3.4

COMPATIBLE SOFTWARE VERSIONS (OPERATOR PANEL)

MCM3320

Operator Panel

V2.01 or later

V1.20 or later

Main Screen
The main screen provides the status of the system. It depends on the topology.

4.3.4.1 Main Screen (Master Synchronize Only or Component Mode)

FIGURE 33.

EXAMPLE: MAIN SCREEN (MASTER SYNCHRONIZE ONLY OR COMPONENT MODE)

The top of the screen is System State.


The middle of the screen indicates whether or not the utility is available, the synchronizer is
running, and the generator sets are available.
The soft-key buttons provide access to other screens or generate a fault reset.

4.3.4.2 Main Screen (Isolated Bus Without Generator Set Main Breaker or
Isolated Bus with Generator Set Main Breaker)

FIGURE 34. EXAMPLE: MAIN SCREEN (ISOLATED BUS WITHOUT GENERATOR SET MAIN
BREAKER OR ISOLATED BUS WITH GENERATOR SET MAIN BREAKER)
The top of the screen is System State.
The middle of the screen indicates whether or not the generator sets are available and whether
or not the generator sets are connected to the loads. If the generator sets are available and
connected to the loads, the screen also displays the average line-to-line voltage and real power
provided by the generator sets.
The soft-key buttons provide access to other screens or generate a fault reset.

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4.3.4.3 Main Screen (Common Bus or Transfer Pair)

FIGURE 35.

EXAMPLE: MAIN SCREEN (COMMON BUS OR TRANSFER PAIR)

The top of the screen is System State. If System State indicates that a timer is running, the
screen also displays the remaining time.
The middle of the screen indicates whether or not the generator sets are available, the utility is
available, the generator sets are connected are connected to the loads, and the utility is
connected to the loads. In addition, the screen displays additional information depending on the
status of the system.
If PTC State is Paralleled, the screen displays the average line-to-line voltage of the utility,
the frequency of the generator sets, and the real power provided by each source.
If PTC State is Not Connected and no timer is running at the top of the screen, the screen
displays the average line-to-line voltage and frequency of each source, as well as the
phase difference between the sources.
If the synchronizer is running and no timer is running at the top of the screen, the screen
displays the average line-to-line voltage and frequency of each source, as well as the
phase difference between the sources.
Otherwise, the screen displays the average line-to-line voltage, real power, frequency, and
power factor of the source that is connected to the loads.
The soft-key buttons provide access to other screens or generate a fault reset.

4.3.4.4 Fault Announcement


When a fault becomes active, the operator panel announces the fault. The fault is displayed
until the screen is changed by pressing one of the appropriate buttons.
The fault is announced only once regardless of how long it remains active. When the screen
changes, the fault is not displayed anymore, but the fault remains active. The Fault screens can
be used to look at the fault and to reset the fault after the fault is announced.
If more than one fault is active, each fault is announced separately, starting with the mostrecently generated fault.

4.3.4.5 Control Screens


These screens are intended to be used to operate the system after initial setup. For example, it
is possible to start tests or run the system in extended parallel.

4.3.4.6 Adjust Screens


These screens provide most of the settings that are available in the operator panel. They are
intended to be used for initial setup, troubleshooting, and features like the scheduler that are
typically setup once.

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4.3.4.7 Monitor Screens


These screens display the status of the system and the MCM3320. The technician level of
security is required in a few screens to clear counters or reset values.

4.3.4.8 Fault Screens


These screens provide information about events and faults. It is also possible to reset faults in
these screens.

4.3.4.9 About Screens


These screens provide information about the software version used by different devices in the
system. The controller on-time is also available.

4.3.5

Levels of Security
TABLE 43.

LEVELS OF SECURITY

Level

Description

Guest

Operator

Technician

Factory

Guest is the default level of security.


Other levels of security require a user name and password.

4.3.5.1 Passwords
TABLE 44.

PASSWORDS

Level

Password

none

574

1209

not available

4.3.5.2 Auto-logout
The operator panel automatically returns to the guest level of security 15 minutes after the
password is entered correctly.

4.3.5.3 Level of Security Required for Each Screen


The top-level screens are available at all levels of security. Some lower-level screens require
passwords.
NOTE:

A029Y787 (Issue 1)

If a screen is not listed below, it is available at all levels of security.

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TABLE 45.

LEVEL OF SECURITY REQUIRED FOR CONTROL SCREENS

Screen

Level of Security

Test, Settings

Extended Parallel, Settings

Load Demand

Load Add/Shed

TABLE 46.

LEVEL OF SECURITY REQUIRED FOR ADJUST SCREENS

Screen

Level of Security

AC Meter Adjustments

AC Meter Setup

Breakers

Communication

Configurable Outputs

Load Control

Power Transfer Control (PTC)

Synchronizer Check

Synchronizer Adjustments

System

Scheduler

Display

Load Demand

Load Add/Shed

Generator Set Bus Overload

Annunciator Configuration

TABLE 47.

LEVEL OF SECURITY REQUIRED FOR MONITOR SCREENS

Screen

Level of Security

AC Meter Adjustments, Generator Set Energy

AC Meter Adjustments, Utility Energy

Communication

4.4

Supplementary Interface Device (SID)


A supplementary interface device (SID) is the combination of an AUX 101 and its companion
AUX 102. Each SID is the interface for a certain range of generator sets and a certain range of
loads.

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4. Components

Generator Sets by SID


TABLE 48.

4.4.2

GENERATOR SETS BY SID

SID

Generator Sets

none

1-4

SID1

5-8

SID2

9-12

SID3

13-16

Loads by SID
NOTE:

SIDs are connected to loads, not load-add levels or load-shed levels.


TABLE 49.

4.4.3

LOADS BY SID

SID

Loads

SID0

1-6

SID1

7-10

SID2

11-14

SID3

15-18

SID Required
A SID is required if either of these conditions are met.
Gen N kW Rating is not equal to zero, where N is any generator set in the range for that
SID.
Load Add Shed Enable is Enabled, and Load N Device Type is not equal to None, where
N is any load in the range for that SID.
If a SID is required, the MCM must be able to communicate with the AUX 101 and AUX 102. If it
cannot communicate, the MCM cannot control the generator sets and loads to which the SID is
connected, and some features may not be active.

4.4.4

Legacy SID Override (Before V2.00)


Prior to firmware V2.00, it was possible to set up more than four generator sets in the MCM,
though the MCM could sense only four paralleling breakers. To handle this, some paralleling
breakers were connected in parallel with each other to the same set of pins on the MCM,
allowing the MCM to know when at least one of them is closed.
Starting with V2.00, it is not possible to have a different number of generator sets and
paralleling breakers. If V2.00 or later firmware is present in a legacy system that has more than
four generator sets and the generator set paralleling breakers are connected in parallel to the
MCM generator set main breaker position input, set Legacy SID Override to Enable. In this
case, no SIDs are required.

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5-2012

Compatible Software Versions (AUX 101)


TABLE 50.

4.4.6

COMPATIBLE SOFTWARE VERSIONS (AUX 101)

MCM3320

AUX 101

V2.00 or later

V1.48 or later

Configuring the AUX 101 and AUX 102 with the MCM3320
Set up the generator sets and the loads in the MCM3320. If the number of generator sets or
loads requires an AUX 101 and AUX 102, the MCM3320 expects the AUX 101 and AUX 102 to
be connected in a specific way, as indicated in the wiring diagrams.

4.4.7

Summary of Monitor Points (AUX 101/102)


TABLE 51.

SUMMARY OF MONITOR POINTS (AUX 101/102)

Setting

Description

SIDX Status (X = 0-3)

(Software v2.00 and later) Indicates the status of


communication between the MCM3320 and the AUX 101.
Possible values: Missing, Good, Connecting, No Exp
Board, Not Applicable

PCCnet Communications Status

(Prior to software v2.00) Indicates the status of


communication between the MCM3320 and the AUX 101.
Possible values: Failed, Good, Wait

PCCNet Status

(v2.00 and later) Indicates the status of PCCNet


communication.
Possible values: No Connection, Connecting, Connected

Expansion Board CommunicationsX (X = blank, 1, 2, 3)

Indicates whether or not the AUX 102 is detected.


Possible values: Disabled, Enabled

AUX101 Software Version (X = blank, 1, 2, 3)

Indicates the software version the AUX 101 is running.

Node Count for Remote IO

Indicates the number of AUX 101 the MCM3320 sees on


the PCCNet network.

Load X Input 1 (X = 1-18)

If the load type is ATS, this indicates whether or not the


emergency source is connected.
If the load type is Breaker, this indicates the position of
the A contact.
Possible values: Not Available, Open, Closed

Load X Input 2 (X = 1-18)

If the load type is ATS, this indicates whether or not the


normal source is connected.
If the load type is Breaker, this indicates the position of
the over current trip contact.
Possible values: Not Available, Open, Closed

SIDX Input (X = 0-3)

Provides the status of the AUX 101/102 inputs as


received by the MCM3320. This is the packet received by
the MCM3320, whereas the Load X Input settings indicate
the unpacked values.

SIDX Output 1/2 (X = 0-3)

Controls the status of the AUX 101/102 outputs as


requested by the MCM3320. This is the actual packet
sent by the MCM3320.

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4. Components

AUX 101 Board

FIGURE 36.

AUX 101 BOARD

4.4.8.1 AUX 101 S1


The S1 button can be used to change the AUX 101 device number.

4.4.8.2 AUX 101 Device Number Indicator


The AUX 101 device number indicator displays the device number of this particular AUX 101 in
a PCCNet network.
The device number must be unique in the PCCNet network.

4.4.8.3 AUX 101 Device Number by SID


TABLE 52.

A029Y787 (Issue 1)

AUX 101 DEVICE NUMBER BY SID

SID

AUX 101 Device Number

SID0

SID1

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SID

AUX 101 Device Number

SID2

SID3

4.4.8.4 Changing the AUX 101 Device Number


1. Press and hold S1 for at least five seconds. On the AUX 101 device number indicator, a
small dot should appear next to the current device number.
2. Press and release S1 until the desired number is displayed.
3. Wait five seconds. After five seconds of inactivity, the new device number is set, and the
small dot should disappear.
4. Disconnect and reconnect J14 to cycle power to the AUX 101.

4.4.8.5 AUX 101 Indicators


TABLE 53.
Indicator

SID0

AUX 101 INDICATORS


SID1

SID2

SID3

DS1

This is on if the AUX 101 is connected to a PCCNet network and is operating normally.

DS2

This is on if the AUX 101 is not connected to the PCCNet network.

DS3

load 1 add

load 7 add

load 11 add

load 15 add

DS4

load 1 shed

load 7 shed

load 11 shed

load 15 shed

DS5

load 2 add

load 8 add

load 12 add

load 16 add

DS6

load 2 shed

load 8 shed

load 12 shed

load 16 shed

DS7

load 3 add

load 9 add

load 13 add

load 17 add

DS8

load 3 shed

load 9 shed

load 13 shed

load 17 shed

DS9

load 4 add

load 10 add

load 14 add

load 18 add

DS10

load 4 shed

load 10 shed

load 14 shed

load 18 shed

4.4.8.6 AUX 101 Connectors


TABLE 54.
Connector

SID0

J1

AUX 101 CONNECTORS


SID1

SID2

SID3

Connection to controller

J2

load 1 and load 2


add/shed

load 7 and load 8


add/shed

load 11 and load 12


add/shed

load 15 and load 16


add/shed

J3

load 3 add/shed

load 9 add/shed

load 13 add/shed

load 17 add/shed

J4

load 4 add/shed

load 10 add/shed

load 14 add/shed

load 18 add/shed

J5
J11
J14

Connection to AUX 102


load 1-4 input

load 7-10 input

load 11-14 input

load 15-18 input

Power supply

J10 is not connected in MCM3320 applications.

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4.4.8.7 AUX 101 J1

Pin

Description

J1-1

Output power B-

J1-2

Output power B+

J1-3

PCCNet A

J1-4

PCCNet B

J1-5

System wakeup

FIGURE 37.

AUX 101 J1

TABLE 55.

AUX 101 J1

FIGURE 38.

AUX 101 J2

TABLE 56.

AUX 101 J2

4.4.8.8 AUX 101 J2

Pin

Contact

SID0

SID1

SID2

SID3

J2-1

normally-open

load 1 add

load 7 add

load 11 add

load 15 add

J2-2

common

J2-3

normally-closed

J2-4

normally-open

load 1 shed

load 7 shed

load 11 shed

load 15 shed

J2-5

common

J2-6

normally-closed

J2-7

normally-open

load 2 add

load 8 add

load 12 add

load 16 add

J2-8

common

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Pin

Contact

J2-9

normally-closed

J2-10

normally-open

J2-11

common

J2-12

normally-closed

SID0

SID1

SID2

SID3

load 2 shed

load 8 shed

load 12 shed

load 16 shed

4.4.8.9 AUX 101 J3

FIGURE 39.

AUX 101 J3

TABLE 57.

AUX 101 J3

Pin

Contact

SID0

SID1

SID2

SID3

J3-1

normally-open

load 3 add

load 9 add

load 13 add

load 17 add

J3-2

common

J3-3

normally-closed

J3-4

normally-open

load 3 shed

load 9 shed

load 13 shed

load 17 shed

J3-5

common

J3-6

normally-closed

4.4.8.10 AUX 101 J4

FIGURE 40.

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AUX 101 J4

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TABLE 58.

AUX 101 J4

Pin

Contact

SID0

SID1

SID2

SID3

J4-1

normally-open

load 4 add

load 10 add

load 14 add

load 18 add

J4-2

common

J4-3

normally-closed

J4-4

normally-open

load 4 shed

load 10 shed

load 14 shed

load 18 shed

J4-5

common

J4-6

normally-closed

4.4.8.11 AUX 101 J5


If the AUX 101 is connected to an AUX 102, this is connected to J6 on the AUX 102.

FIGURE 41.

AUX 101 J5

There is no pin description for AUX 101 J5.

4.4.8.12 AUX 101 J11

FIGURE 42.

AUX 101 J11

TABLE 59.

AUX 101 J11

Pin

Contact

SID0

SID1

SID2

SID3

J11-1

reference input

load 1

load 7

load 11

load 15

J11-2

position A or
normal source

J11-3

reference input

J11-4

trip or emergency
source

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Pin

Contact

SID0

SID1

SID2

SID3

J11-5

reference input

load 2

load 8

load 12

load 16

J11-6

position A or
normal source

J11-7

reference input

J11-8

trip or emergency
source

J11-9

reference input

load 3

load 9

load 13

load 17

J11-10

position A or
normal source

J11-11

reference input

J11-12

trip or emergency
source

J11-13

reference input

load 4

load 10

load 14

load 18

J11-14

position A or
normal source

J11-15

reference input

J11-16

trip or emergency
source

4.4.8.13 AUX 101 J14

Pin

58

FIGURE 43.

AUX 101 J14

TABLE 60.

AUX 101 J14

Description

J14-1

Input power B+

J14-2

Input power B-

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4. Components

AUX 102 Board

FIGURE 44.

AUX 102 BOARD

4.4.9.1 AUX 102 Indicators


TABLE 61.

AUX 102 INDICATORS

Indicator

SID0

SID1

SID2

SID3

DS1

load 5 add

load demand
generator set 5

load demand
generator set 9

load demand
generator set 13

DS2

load 5 shed

load demand
generator set 6

load demand
generator set 10

load demand
generator set 14

DS3

load 6 add

load demand
generator set 7

load demand
generator set 11

load demand
generator set 15

DS4

load 6 shed

load demand
generator set 8

load demand
generator set 12

load demand
generator set 16

DS5

not used

DS6

not used

DS7

not used

DS8

not used

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4.4.9.2 AUX 102 Connectors


TABLE 62.

AUX 102 CONNECTORS

Connector

SID0

SID1

SID2

SID3

J1

load 5-6 add/shed,


normally-open

load demand
generator set 5-8,
normally-open

load demand
generator set 9-12,
normally-open

load demand
generator set 13-16,
normally-open

J2

load 5-6 add/shed,


common

load demand
generator set 5-8,
common

load demand
generator set 9-12,
common

load demand
generator set 13-16,
common

J3

load 5-6 add/shed,


normally-closed

load demand
generator set 5-8,
normally-closed

load demand
generator set 9-12,
normally-closed

load demand
generator set 13-16,
normally-closed

J4

load 5-6 input

generator set 5-8


paralleling breaker
position

generator set 9-12


paralleling breaker
position

generator set 13-16


paralleling breaker
position

J5

Chassis ground

J6

Connection to AUX 101

4.4.9.3 AUX 102 J1

FIGURE 45.

AUX 102 J1

J1 provides normally-open contacts for the output relays.


TABLE 63.

60

AUX 102 J1

Pin

SID0

SID1

SID2

SID3

J1-1

load 5 add

load demand
generator set 5

load demand
generator set 9

load demand
generator set 13

J1-2

load 5 shed

load demand
generator set 6

load demand
generator set 10

load demand
generator set 14

J1-3

load 6 add

load demand
generator set 7

load demand
generator set 11

load demand
generator set 15

J1-4

load 6 shed

load demand
generator set 8

load demand
generator set 12

load demand
generator set 18

J1-5

not used

J1-6

not used

J1-7

not used

J1-8

not used

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4.4.9.4 AUX 102 J2

FIGURE 46.

AUX 102 J2

J2 provides common contacts for the output relays.


TABLE 64.

AUX 102 J2

Pin

SID0

SID1

SID2

SID3

J2-1

load 5 add

load demand
generator set 5

load demand
generator set 9

load demand
generator set 13

J2-2

load 5 shed

load demand
generator set 6

load demand
generator set 10

load demand
generator set 14

J2-3

load 6 add

load demand
generator set 7

load demand
generator set 11

load demand
generator set 15

J2-4

load 6 shed

load demand
generator set 8

load demand
generator set 12

load demand
generator set 18

J2-5

not used

J2-6

not used

J2-7

not used

J2-8

not used

4.4.9.5 AUX 102 J3

FIGURE 47.

AUX 102 J3

J3 provides normally-closed contacts for the output relays.

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TABLE 65.

AUX 102 J3

Pin

SID0

SID1

SID2

SID3

J3-1

load 5 add

load demand
generator set 5

load demand
generator set 9

load demand
generator set 13

J3-2

load 5 shed

load demand
generator set 6

load demand
generator set 10

load demand
generator set 14

J3-3

load 6 add

load demand
generator set 7

load demand
generator set 11

load demand
generator set 15

J3-4

load 6 shed

load demand
generator set 8

load demand
generator set 12

load demand
generator set 18

J3-5

not used

J3-6

not used

J3-7

not used

J3-8

not used

4.4.9.6 AUX 102 J4

FIGURE 48.

AUX 102 J4

TABLE 66.

AUX 102 J4

Pin

SID0

SID1

SID2

SID3

J4-1

load 5 position A or
normal source
connected

generator set 5
paralleling breaker
position

generator set 9
paralleling breaker
position

generator set 13
paralleling breaker
position

J4-2
J4-3

reference input
load 5 trip or
emergency source
connected

J4-4
J4-5

J4-8

62

generator set 10
paralleling breaker
position

generator set 14
paralleling breaker
position

reference input
load 6 position A or
normal source
connected

J4-6
J4-7

generator set 6
paralleling breaker
position

generator set 7
paralleling breaker
position

generator set 11
paralleling breaker
position

generator set 15
paralleling breaker
position

reference input
load 6 trip or
emergency source
connected

generator set 8
paralleling breaker
position

generator set 12
paralleling breaker
position

generator set 16
paralleling breaker
position

reference input

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4.4.9.7 AUX 102 J5


J5 is connected to a good earth ground.

4.4.9.8 AUX 102 J6


This is connected to J5 on the AUX 101.

FIGURE 49.

AUX 102 J6

There is no pin description for AUX 102 J6.

4.4.10 Troubleshooting
4.4.10.1 DS1 and DS2 Are Off
DS1 and DS2 are off, but the board should have power.

A. Checking the Power Connections


Make sure the power supply wires are connected securely.

B. Checking the Wires


Measure the resistance of each wire.
If the resistance is greater than 10 , check any fuses or breakers in the harness.
Otherwise, replace the wire.

C. Checking the Power Supply


Measure the voltage provided by the power supply.
If the voltage is outside the allowed range, troubleshoot the power supply.

4.4.10.2 DS2 Is On
DS2 is on, but the board should be connected to a PCCNet network.

A. Checking the PCCNet Connections


Make sure the PCCNet wires are connected securely to J1-3 (PCCNet A) and J1-4
(PCCNet B).

B. Checking the Wires


Measure the resistance of each wire.
If the resistance is greater than 10 , replace the wire.
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C. Checking the Device to Which the Board Is Connected


If the device does not appear to be communicating on its port, troubleshoot the device.

4.4.11 Connecting to an AUX 101 or AUX 102 Using InPower


You can use InPower to update the firmware in the AUX 101 or AUX 102. Connect to the AUX
101 using J1.
You cannot connect directly to an AUX 102 using InPower. You should connect to the AUX 101
to which the AUX 102 is connected instead.

4.4.12 Repairing Circuit Boards


WARNING: Attempting to repair circuit boards can lead to equipment damage, personal
injury, or death. Replace faulty circuit boards. Do not try to repair faulty
circuit boards.

4.5

Bar Graphs
The MCM tells the bar graphs which indicator should be lit for each value.
The MCM supports two bar graphs, one for the generator set bus and one for the utility bus.

4.5.1

Generator Set Bus Current Percentage


This value assumes that 100% current is equal to Total System Capacity / (3 x Genset
Nominal Voltage x 0.8).
The calculation does not use the measured power factor. Instead, it uses a power factor of 0.8.

4.5.2

Utility Current Percentage


Utility Available Current should be set to 100% current.

4.5.3

Utility Total kW Percentage


Total Utility Capacity should be set to 100% rated real power.

4.5.4

Compatible Software Versions (Bar Graph)


TABLE 67.

4.5.5

COMPATIBLE SOFTWARE VERSIONS (BAR GRAPH)

MCM3320

Bar Graph

V2.01 or later

V1.80 or later

Setting up a Bar Graph


1. On the back of the bar graph, press the S1 button, and hold it until one or more indicators
are lit in the lower right corner on the front of the bar graph. Typically, you have to hold the
S1 button for about five seconds.

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FIGURE 50.

S1 BUTTON (BACK OF THE BAR GRAPH)

2. When one or more indicators are lit, press the S1 button once to change the number of
indicators that are lit. Keep pressing the S1 button until the number of indicators is correct
for the application.
NOTE:
TABLE 68.

If you do not press the S1 button for 5 seconds, the bar graph returns to
normal operation. Return to step 1.
BAR GRAPH APPLICATION BASED ON NUMBER OF INDICATORS

Number of Indicators

Application

Generator set bus

Utility bus

3. When the number of indicators is correct, wait 5 seconds for the bar graph to return to
normal operation.
If you are setting up a bar graph for the utility bus, follow these steps as well.
1. Connect InPower to the MCM3320.
2. In InPower, right-click on the MCM3320, and select MCM3320 Setup.... The MCM3320
setup screens should appear.
3. In the MCM3320 setup screens, go to Meter setup.

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FIGURE 51.

METER SETUP SCREEN

4. In the Utility bargraph setup section, set the scaling for the bar graph.
5. Save your changes.
This is not necessary if you set up a bar graph for the generator set bus.

4.6

Universal Annunciator
The MCM configures the universal annunciator and tells the universal annunciator which
indicators should be lit.
The MCM does not support the customer relays on the universal annunciator.

4.6.1

Compatible Software Versions (Universal Annunciator)


TABLE 69.

4.6.2

COMPATIBLE SOFTWARE VERSIONS (UNIVERSAL ANNUNCIATOR)


MCM3320

Universal Annunciator

V2.01 or later

V2.10 or later

Basic Status Annunciator


This annunciator shows the general status of the system, including source availability, source
connections, generator sets online, etc.

4.6.2.1 Basic Status Annunciator Configuration


The number of annunciators and the information that is displayed on each one depends on the
number of generator sets. Set Basic Status Annunciator Configuration based on the number of
generator sets that the annunciator monitors.

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TABLE 70.

BASIC STATUS ANNUNCIATORS

Indicator

Generator Sets 1-4

Generator Sets 1-8

Generator Sets 9-16

Utility Available

Utility Available

Generator Set 9 Running

Utility Connected

Utility Connected

Generator Set 10 Running

Generator Set Bus


Available

Generator Set Bus


Available

Generator Set 11 Running

Generator Set Bus


Connected

Generator Set Bus


Connected

Generator Set 12 Running

Not in Auto

Not in Auto

Generator Set 13 Running

Common Alarm

Common Alarm

Generator Set 14 Running

Fail to Synchronize

Fail to Synchronize

Generator Set 15 Running

Generator Set 1 Running

Generator Set 1 Running

Generator Set 16 Running

Generator Set 2 Running

Generator Set 2 Running

Configurable Indicator

10

Generator Set 3 Running

Generator Set 3 Running

Configurable Indicator

11

Generator Set 4 Running

Generator Set 4 Running

Configurable Indicator

12

Test

Generator Set 5 Running

Configurable Indicator

13

Extended Parallel

Generator Set 6 Running

Configurable Indicator

14

Generator Set Bus


Overload

Generator Set 7 Running

Configurable Indicator

15

Load Demand

Generator Set 8 Running

Configurable Indicator

16

Configurable Indicator

Test

Configurable Indicator

17

Configurable Indicator

Extended Parallel

Configurable Indicator

18

Configurable Indicator

Generator Set Bus


Overload

Configurable Indicator

19

Configurable Indicator

Load Demand

Configurable Indicator

20

Configurable Indicator

Configurable Indicator

Configurable Indicator

If the annunciators monitor 9 or more generator sets, two annunciators are required, one for
generator sets 1-8 and one for generator sets 9-16.

4.6.2.2 Configurable Indicators


Configurable indicators can be assigned to any code. If the code is active, the indicator is on.
The color, flashing, and audible alert can also be configured.
For generator sets 1-8, use the Configurable Annunciator LED ## settings to set up configurable
indicators.
For generator sets 9-16, use the Basic Annunciator 2 LED ## settings to set up configurable
indicators.

4.6.2.3 Configurable Indicator 20 in the Operator Panel


If the annunciators monitor 9 or more generator sets, both annunciators (generator sets 1-8 and
generator sets 9-16) have a configurable indicator 20. The operator panel has only one screen
for configurable indicator 20, and this screen displays the settings for configurable indicator 20
in the second annunciator (generator sets 9-16).

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The settings for configurable indicator 20 in the first annunciator (generator sets 1-8) are
available if Basic Status Annunciator Configuration is temporarily set to Up to 8 Gens instead of
Up to 16 Gens.

4.6.2.4 Setting up a Basic Status Annunciator


NOTE:

Only one annunciator should be connected to the MCM3320 on the PCCNet


network during setup.

1. Connect InPower to the MCM3320.


2. In InPower, right-click on the MCM3320, and select MCM3320 Setup.... The MCM3320
setup screens should appear.
3. In the MCM3320 setup screens, go to Annunciator Setup.

FIGURE 52.

ANNUNCIATOR SETUP SCREEN

4. In the Annunciator Type field, select "Basic Annunciator". The Total number of Gensets
in the system field should appear.

FIGURE 53.

68

TOTAL NUMBER OF GENERATOR SETS IN THE SYSTEM

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5. In the Total number of Gensets in the system field, select the number of generator sets
that will be monitored.
If 9 or more generator sets will be monitored, the Select Basic Annunciator field should
appear. Select which annunciator will be setup at this time.

FIGURE 54.

SELECT BASIC ANNUNCIATOR FIELD

Otherwise, go to the next step.


6. In the Basic Annunciator Setup section, set up the configurable indicators for the
annunciator.
7. Click Save Adjustments.
8. On the annunciator, press Silence/Lamp Test. In the Annunciator Configuration section,
the Configuration status should be "Annun Ready for Config".

FIGURE 55.

ANNUNCIATOR READY FOR CONFIGURATION

9. In the Annunciator Configuration section, set Perform Annunciator Configuration to


"Config to Basic Statuses". During configuration, the Configuration status should be
"Performing Configuration".
10. Follow the instructions. At the end of the process, the Configuration status should be
"Annunciator Successfully configured".

FIGURE 56.

ANNUNCIATOR SUCCESSFULLY CONFIGURED

You do not have to click Save Adjustments.

4.6.3

Load Add/Shed Annunciator


This annunciator indicates which load-add levels are being connected and which load-shed
levels are being removed. This is based on load add/shed commands, not the actual status of
the loads. This annunciator does not indicate whether or not the loads are actually connected.

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4.6.3.1 Load Add/Shed Annunciator Configuration


The number of annunciators and the information that is displayed on each one depends on the
number of load add/shed levels, not loads. Set Load Add Shed Annunciator Configuration based
on the number of load add/shed levels that the annunciator monitors.
TABLE 71.

LOAD ADD/SHED ANNUNCIATORS

Indicator

Levels 1-6

Levels 1-10

Levels 1-18

Add Level 1 On

Add Level 1 On

Add Level 11 On

Add Level 2 On

Add Level 2 On

Add Level 12 On

Add Level 3 On

Add Level 3 On

Add Level 13 On

Add Level 4 On

Add Level 4 On

Add Level 14 On

Add Level 5 On

Add Level 5 On

Add Level 15 On

Add Level 6 On

Add Level 6 On

Add Level 16 On

Shed Level 1 On

Add Level 7 On

Add Level 17 On

Shed Level 2 On

Add Level 8 On

Add Level 18 On

Shed Level 3 On

Add Level 9 On

Shed Level 10 On

10

Shed Level 4 On

Add Level 10 On

Shed Level 11 On

11

Shed Level 5 On

Shed Level 1 On

Shed Level 12 On

12

Not used

Shed Level 2 On

Shed Level 13 On

13

Not used

Shed Level 3 On

Shed Level 14 On

14

Not used

Shed Level 4 On

Shed Level 15 On

15

Not used

Shed Level 5 On

Shed Level 16 On

16

Not used

Shed Level 6 On

Shed Level 17 On

17

Not used

Shed Level 7 On

Not used

18

Not used

Shed Level 8 On

Not used

19

Not used

Shed Level 9 On

Not used

20

Not used

Not used

Not used

If the system has 11 or more levels, two annunciators are required, one for levels 1-10 and one
for levels 11-18.

4.6.3.2 Add Level Command


This command indicates whether or not load add/shed is trying to connect the loads assigned to
a specific load-add level.
The command becomes active when the loads are added during automatic load add and
remains active until the generator sets are disconnected.
The command becomes active when the loads are added during utility load add begins
and remains active until the utility is disconnected.
The command becomes active when the loads are added during manual load add and
remains active until the generator sets are disconnected.

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NOTE:

It is possible for the add level command and the shed level command to be
active for the same load at the same time. For example, the load is added by
automatic load add and then removed by automatic load shed when the
generator sets are overloaded. If this occurs, the add level command is
ignored, and the load is removed.

4.6.3.3 Shed Level Command


This command indicates whether or not load add/shed is trying to remove the loads assigned to
a specific load-shed level from the generator sets or the utility.
The command becomes active when the loads are removed during an open-transition
transfer, for example, when the utility is no longer available. The command remains active
until automatic load add begins.
The command becomes active when the loads are removed because code 1444 (Genset
Bus Overload) is active. The command remains active until the generator sets are
disconnected.
If Open Transition Retransfer Load Shed Enable is Enabled, the command becomes active
when the loads are removed during an open-transition retransfer. It remains active until
utility load add begins.
The command becomes active when the loads are removed during manual load shed. It
remains active until the loads are restored or until the generator sets are disconnected.
NOTE:

It is possible for the add level command and the shed level command to be
active for the same load at the same time. For example, the load is added by
automatic load add and then removed by automatic load shed when the
generator sets are overloaded. If this occurs, the add level command is
ignored, and the load is removed.

4.6.3.4 Unused Indicators


Unused indicators can be hardwired if desired. See the manual for the universal annunciator.

4.6.3.5 Setting up a Load Add/Shed Annunciator


NOTE:

Only one annunciator should be connected to the MCM3320 on the PCCNet


network during setup.

1. Connect InPower to the MCM3320.


2. In InPower, right-click on the MCM3320, and select MCM3320 Setup.... The MCM3320
setup screens should appear.
3. In the MCM3320 setup screens, go to Annunciator Setup.

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FIGURE 57.

ANNUNCIATOR SETUP SCREEN

4. In the Annunciator Type field, select "Load Add Shed(LAS) Annunciator". The Total
number of LAS Levels in the system field should appear.

FIGURE 58.

TOTAL NUMBER OF LOAD ADD/SHED LEVELS IN THE SYSTEM

5. In the Total number of LAS Levels in the system field, select the number of load
add/shed levels that will be monitored.
If 11 or more load add/shed levels will be monitored, the Select Load Add Shed
Annunciator field should appear. Select which annunciator will be setup at this time.

FIGURE 59.

72

SELECT LOAD ADD/SHED ANNUNCIATOR FIELD

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Otherwise, go to the next step.


6. On the annunciator, press Silence/Lamp Test. In the Annunciator Configuration section,
the Configuration status should be "Annun Ready for Config".

FIGURE 60.

ANNUNCIATOR READY FOR CONFIGURATION

7. In the Annunciator Configuration section, set Perform Annunciator Configuration to


"Config to Load Add Shed Load statuses". During configuration, the Configuration status
should be "Performing Configuration".
8. Follow the instructions. At the end of the process, the Configuration status should be
"Annunciator Successfully configured".

FIGURE 61.

ANNUNCIATOR SUCCESSFULLY CONFIGURED

You do not have to click Save Adjustments.

4.6.4

Setting up an Annunciator Using the Operator Panel


You can set up an annunciator using the operator panel. Unlike InPower, the operator panel
does not provide on-screen instructions or announce errors.
NOTE:

Only one annunciator should be connected to the MCM3320 on the PCCNet


network during setup.

This procedure describes the main steps.


1. Go to the Config Annun screens. In V1.20, go to Menu > Adjust > More Options (5
times) > 16) Config Annun.
2. Set Annun Type to Basic for a basic status annunciator or to Load Add Shed for a load
add/shed annunciator.
3. For a basic status annunciator, set Basic Annun Type. If the number of generator sets is 9
or more, set Basic Annun Type to "Upto 8 Gens" for the first annunciator or "Upto 16
Gens" for the second annunciator.
For a load add/shed annunciator, set LAS Annun Type. If the number of load add/shed
levels is 11 or more, set LAS Annun Type to "Upto 10 Lvls" for the first annunciator or
"Upto 18 Lvls" for the second annunciator.
4. Press Save.
5. Set up the configurable indicators in the Config LED screens.
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6. Press Save.
7. Go to the Perform Config screen, and press Adjust.
8. On the annunciator, press Silence/Lamp Test. Config Status should change to "Annun
Ready".
9. For a basic status annunciator, set Perform Config to "Basic Status".
For a load add/shed annunciator, set Perform Config to "LD Add Shed".
10. Press Save. At the end of the process, Config Status should change to "Config Success".
11. Disconnect J2 on the annunciator.
12. Wait 15 seconds.
13. Reconnect J2 on the annunciator.

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Source Availability
Source availability refers to whether or not a source is ready to accept loads.

5.1

Power Transfer Control (PTC) Sensors


A PTC sensor looks for a specific condition, such as undervoltage or frequency, that indicates
that a source is not ready to accept loads.
Each sensor has one of these values.
Unknown: The sensor is disabled.
Dropped-out: The sensor has detected the condition for which it looks. For example, if the
generator set undervoltage sensor is Dropped-out, the generator set voltage is too low.
Many sensors require the condition to occur for a specific amount of time before the sensor
becomes Dropped-out.
Picked-up: The sensor has not detected the condition for which it looks. For example, if the
utility frequency sensor is Picked-up, the utility frequency is within an acceptable range.
Many PTC sensors are conditions for faults. For example, if the utility frequency sensor
becomes Dropped-out, code 1123 (Utility Bus Frequency) becomes active.
A PTC sensor and any associated faults operate independently of each other. The status of the
PTC sensor depends on the settings for the specific condition that is being monitored. The
status of the fault depends on all of its fault conditions, which may include conditions other than
the sensor's being Dropped-out, as well as the fault reset. PTC sensors, not faults, are used to
determine source availability.
NOTE:

5.1.1

Many PTC sensors are conditions for faults. A PTC sensor and any
associated faults operate independently of each other. PTC sensors, not
faults, are used to determine source availability.

Generator Set Undervoltage Sensor


This sensor is always enabled.

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Time (t)
initial

Event

Sensor Status

The line-to-line voltage (V) is acceptable.

Picked-Up

t1

The line-to-line voltage (V) falls below the dropped-out threshold


(D, Genset Undervoltage Drop-Out Percentage * Genset
Undervoltage Pick-Up Percentage).

Picked-Up

t1+tD

The line-to-line voltage (V) remains below the dropped-out


threshold (D) for a specified time delay (tD, Genset Undervoltage
Drop-Out Delay).

Dropped-Out
(shaded area)

t2

The line-to-line voltage (V) rises above the picked-up threshold (P,
Genset Undervoltage Pick-Up Percentage).

FIGURE 62.

Picked-Up

GENERATOR SET UNDERVOLTAGE SENSOR

When the synchronizer is active, Genset Undervoltage Drop-Out Percentage is temporarily set
to 75%, and Genset Undervoltage Pick-Up Percentage is temporarily set to 85%. This prevents
the synchronizer from causing nuisance faults.

5.1.2

Generator Set Overvoltage Sensor


Genset Overvoltage Sensor Enable must be set to Enable.

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Time (t)
initial
t1
t1+tD

t2

Event

Sensor Status

The line-to-line voltage (V) is acceptable.

Picked-Up

The line-to-line voltage (V) rises above the dropped-out threshold


(D, Genset Overvoltage Drop-Out Percentage).

Picked-Up

The line-to-line voltage (V) remains above the dropped-out


threshold (D) for a specified time delay (tD, Genset Overvoltage
Drop-Out Delay).
The line-to-line voltage (V) falls below the picked-up threshold (P,
Genset Overvoltage Pick-Up Percentage * Genset Overvoltage
Drop-Out Percentage).

FIGURE 63.

Dropped-Out
(shaded area)
Picked-Up

GENERATOR SET OVERVOLTAGE SENSOR

When the synchronizer is active, Genset Overvoltage Drop-Out Percentage is temporarily set to
120%, and Genset Overvoltage Pick-Up Percentage is temporarily set to 95%. This prevents the
synchronizer from causing nuisance faults.

5.1.3

Generator Set Frequency Sensor


Genset Frequency Sensor Enable must be set to Enable.

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Time (t)
initial
t1

t1+tD

t2

Event

Sensor Status

The frequency (Hz) is acceptable.

Picked-Up

The frequency (Hz) rises above the dropped-out threshold [upper


graph D, Genset Center Frequency + (Genset Frequency Pick-Up
Bandwidth + Genset Frequency Drop-Out Bandwidth)].
OR
The frequency (Hz) falls below the dropped-out threshold [lower
graph D, Genset Center Frequency - (Genset Frequency Pick-Up
Bandwidth + Genset Frequency Drop-Out Bandwidth)].

Picked-Up

The frequency (Hz) remains above or below the dropped-out


threshold (D) for a specified time delay (tD, Genset Frequency
Drop-Out Delay).
The frequency (Hz) falls below the picked-up threshold (P, Genset
Center Frequency + Genset Frequency Pick-Up Bandwidth).
AND
The frequency (Hz) rises above the picked-up threshold (P,
Genset Center Frequency - Genset Frequency Pick-Up
Bandwidth).

FIGURE 64.

Dropped-Out
(shaded area)
Picked-Up

GENERATOR SET FREQUENCY SENSOR

When the synchronizer is active, Genset Frequency Drop-Out Bandwidth is temporarily set to
5%, and Genset Frequency Pick-Up Bandwidth is temporarily set to 20%. This prevents the
synchronizer from causing nuisance faults.

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5.1.4

5. Source Availability

Generator Set Loss of Phase Sensor


TABLE 72.

GENERATOR SET LOSS OF PHASE SENSOR

Sensor enable

Genset Loss of Phase Sensor Enable is Enable


Minimum line-to-line voltage > 60% nominal voltage
Frequency > 30 Hz

Condition for drop-out

Phase difference between any two phases < 90


or phase difference between any two phases > 150

Time delay before drop-out

Genset Loss of Phase Drop-Out Delay

Condition for pick-up

90 <= phase difference between all phases <= 150

5.1.5

Generator Set Phase Rotation Sensor


TABLE 73.

GENERATOR SET PHASE ROTATION SENSOR

Sensor enable

Genset Phase Rotation Sensor Enable is Enable


Minimum line-to-line voltage > 60% nominal voltage
Frequency > 30 Hz

Condition for drop-out

Genset Phase Rotation <> System Phase Rotation

Time delay before drop-out

1 second

Condition for pick-up

Genset Phase Rotation = System Phase Rotation

5.1.6

Utility Undervoltage Sensor


This sensor is always enabled.

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Time (t)
initial
t1

t1+tD

t2

Event
The line-to-line voltage (V) is acceptable.

Picked-Up

The line-to-line voltage (V) falls below the dropped-out threshold


(D, Utility Undervoltage Drop-Out Percentage * Utility
Undervoltage Pick-Up Percentage).

Picked-Up

The line-to-line voltage (V) remains below the dropped-out


threshold (D) for a specified time delay (tD, Utility Undervoltage
Drop-Out Delay).
The line-to-line voltage (V) rises above the picked-up threshold (P,
Utility Undervoltage Pick-Up Percentage).

FIGURE 65.

5.1.7

Sensor Status

Dropped-Out
(shaded area)
Picked-Up

UTILITY UNDERVOLTAGE SENSOR

Utility Overvoltage Sensor


Utility Overvoltage Sensor Enable must be set to Enable.

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Time (t)
initial
t1
t1+tD

t2

Event
The line-to-line voltage (V) is acceptable.

Picked-Up

The line-to-line voltage (V) rises above the dropped-out threshold


(D, Utility Overvoltage Drop-Out Percentage).

Picked-Up

The line-to-line voltage (V) remains above the dropped-out


threshold (D) for a specified time delay (tD, Utility Overvoltage
Drop-Out Delay).
The line-to-line voltage (V) falls below the picked-up threshold (P,
Utility Overvoltage Pick-Up Percentage * Utility Overvoltage DropOut Percentage).

FIGURE 66.

5.1.8

Sensor Status

Dropped-Out
(shaded area)
Picked-Up

UTILITY OVERVOLTAGE SENSOR

Utility Frequency Sensor


Utility Frequency Sensor Enable must be set to Enable.

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Time (t)
initial

Event
The frequency (Hz) is acceptable.

Picked-Up

t1

The frequency (Hz) rises above the dropped-out threshold [upper


graph D, Utility Center Frequency + (Utility Frequency Pick-Up
Bandwidth + Utility Frequency Drop-Out Bandwidth)].
OR
The frequency (Hz) falls below the dropped-out threshold [lower
graph D, Utility Center Frequency - (Utility Frequency Pick-Up
Bandwidth + Utility Frequency Drop-Out Bandwidth)].

Picked-Up

t1+tD

The frequency (Hz) remains above or below the dropped-out


threshold (D) for a specified time delay (tD, Utility Frequency DropOut Delay).

Dropped-Out
(shaded area)

t2

The frequency (Hz) falls below the picked-up threshold (P, Utility
Center Frequency + Utility Frequency Pick-Up Bandwidth).
AND
The frequency (Hz) remains above the picked-up threshold (P,
Utility Center Frequency - Utility Frequency Pick-Up Bandwidth).

FIGURE 67.

82

Sensor Status

Picked-Up

UTILITY FREQUENCY SENSOR

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5.1.9

5. Source Availability

Utility Loss of Phase Sensor


TABLE 74.

UTILITY LOSS OF PHASE SENSOR

Sensor enable

Utility Loss of Phase Sensor Enable is Enable


Minimum line-to-line voltage > 60% nominal voltage
Frequency > 30 Hz

Condition for drop-out

Phase difference between any two phases < 90


or phase difference between any two phases > 150

Time delay before drop-out

Utility Loss of Phase Drop-Out Delay

Condition for pick-up

90 <= phase difference between all phases <= 150

5.1.10 Utility Phase Rotation Sensor


TABLE 75.

UTILITY PHASE ROTATION SENSOR

Sensor enable

Utility Phase Rotation Sensor Enable is Enable


Minimum line-to-line voltage > 60% nominal voltage
Frequency > 30 Hz

Condition for drop-out

Utility Phase Rotation <> System Phase Rotation

Time delay before drop-out

1 second

Condition for pick-up

Utility Phase Rotation = System Phase Rotation

5.2

Generator Set Availability


Generator set availability refers to whether or not the generator sets as a group are ready to
accept loads.

5.2.1

Generator Set Availability (Three-phase Applications in


Isolated Bus Without Generator Set Main Breaker and
Common Bus Topologies)
The generator sets are available when one of these conditions is met.
The generator sets are not connected to the loads, but the generator sets have been
commanded to start.
The generator sets are connected to the loads, and none of the PTC sensors for the
generator sets are Dropped-out.
The generator sets remain available until at least one of these conditions is met.
The generator sets are not connected to the loads, and the generator sets are commanded
to stop.
The generator sets have been connected to the loads for 15 seconds, and at least one of
the PTC sensors is Dropped-out.
Code 1328 (Generator Set Main Breaker Tripped) is active.
Code 1452 (Generator Set Main Breaker Fail to Close) is active.

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5.2.2

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Generator Set Availability (Three-phase Applications in


Isolated Bus with Generator Set Main Breaker and
Transfer Pair Topologies)
The generator sets are available when all of these conditions are met.
None of the PTC sensors for the generator sets are Dropped-out.
Genset Online Capacity Sensor Status is not Dropped-out.
Code 1328 (Generator Set Main Breaker Tripped) is not active.
Code 1454 (Generator Set Breaker Position Contact) is not active.
Code 1452 (Generator Set Main Breaker Fail to Close) is not active.
The generator sets are not available when at least one of these conditions is not met. If code
1454 is active, the generator sets are unavailable only if the generator set main breaker is a
dual-contact breaker and Genset Current Based Breaker Position is Unknown.

5.2.3

Generator Set Online Capacity Sensor


Genset Online Capacity Sensor Status indicates whether or not there is enough generator set
capacity to accept loads. If there is not enough capacity, the generator sets are not considered
available. This avoids transferring the loads to the generator sets only to overload them.
The amount of capacity that is required depends on the situation.
In a hard-closed transition during a test with load, the amount of capacity must be greater
than or equal to the current system load.
If Genset Online Capacity Sensor Selection is Enable, the amount of capacity must be
greater than or equal to Genset Online Capacity Sensor Threshold.
If both situations occur, both conditions must be met. If neither situation occurs, the requirement
is ignored.
If there is enough generator set capacity, the Genset Online Capacity Sensor Status is PickedUp. Otherwise, it is Dropped-Out.

5.3

Utility Availability
Utility availability refers to whether or not the utility is ready to accept loads.

5.3.1

Utility Availability (Three-phase Applications in Common


Bus and Transfer Pair Topologies)
The utility is available when all of these conditions are met.
None of the PTC sensors for the utility are Dropped-out.
The utility source failure switch is inactive.
Code 1219 (Utility Main Breaker Tripped) is not active.
Code 1455 (Utility Main Breaker Position Contact) is not active.
Code 2396 (Utility Main Breaker Fail to Close) is not active.

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The utility is not available when at least one of these conditions is not met. If code 1455 is
active, the utility is unavailable only if the utility main breaker is a dual-contact breaker and
Utility Current Based Breaker Position is Unknown.

5.3.2

Utility Source Failure Switch


This switch is used by an external device that determines whether or not the utility is available.
If this switch is active, the utility is not available.
If there is no external device, this switch should be inactive.
This switch is available in three-phase applications if the topology is Isolated Bus Without
Generator Set Main Breaker, Isolated Bus with Generator Set Main Breaker, Common Bus, or
Transfer Pair. It has no effect in other applications or topologies.

5.4

Current Based Breaker Position


This is a calculation of breaker position based on the current through the breaker. If the current
in all phases is at least Breaker Closed Current Threshold, the breaker is considered closed.
Otherwise, the breaker position is considered unknown.
This check is used to verify the position of single-contact breakers. If the current-based breaker
position disagrees with the pins, the breaker position contact fault is active.
For dual-contact breakers, this check is used to determine utility availability and generator set
availability if the two sets of contacts disagree about the breaker position.
If a breaker position contact fault is active and the current-based breaker position is closed, the
system generates a transfer inhibit or a retransfer inhibit internally to avoid closing the other
breaker. For example, if code 1454 (Genset Main Breaker Position Contact Warning) is active
and Genset Current Based Breaker Position is Closed, the retransfer inhibit is active. This type
of transfer inhibit or retransfer inhibit is not affected by the override switch.

5.5

Summary of Settings (Source Availability)


TABLE 76.

SUMMARY OF SETTINGS (SOURCE AVAILABILITY)

Setting

Description

Breaker Closed Current Threshold

Specifies the minimum amount of current that must be


present in all phases for the breaker to be considered
closed. It is used in certain situations to verify the position
indicated by the breaker position contact.
Possible values: 5-100% (Default: 5%)

Genset Online Capacity Sensor Enable

Enables or disables Genset Online Capacity Sensor


Threshold. Genset Online Capacity Sensor Status
operates during hard-closed transitions regardless of this
setting.
Possible values: Disable, Enable (Default: Disable)

Genset Online Capacity Sensor Threshold

Specifies the minimum amount of generator set capacity


that must be online before the generator sets are
considered available.
Possible values: 0-32000 kW (Default: 0 kW)

Utility Source Failure Vol

Sets the utility source failure switch.


Possible values: Inactive, Active

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TABLE 77.

5-2012

SUMMARY OF MONITOR POINTS (SOURCE AVAILABILITY)

Setting

Description

Utility Source Failure Sw

Indicates the status of the utility source failure switch.

Genset Current Based Breaker Position

Indicates the current position of the generator set main


breaker based on Breaker Closed Current Threshold.
Possible values: Unknown, Closed

Utility Current Based Breaker Position

Indicates the current position of the utility main breaker


based on Breaker Closed Current Threshold.
Possible values: Unknown, Closed

Genset Online Capacity Sensor Selection

Indicates whether or not any conditions for Genset Online


Capacity Sensor Status are active. Possible conditions
include Genset Online Capacity Sensor Enable and hardclosed transitions.
Possible values: Disable, Enable

Genset Online Capacity Sensor Status

Indicates the status of the generator set online capacity


sensor.
Possible values: Unknown, Picked-Up, Dropped-Out

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Power Transfer Control (PTC) State


PTC State identifies which sources are connected to the loads.
TABLE 78.

6.1

PTC STATE

Generator Sets

Utility

PTC State

Disconnected

Disconnected

No Source Connected

Disconnected

Connected

Utility Connected

Connected

Disconnected

Genset Connected

Connected

Connected

Paralleled

Generator Sets Connected


If the topology is Isolated Bus Without Generator Set Main Breaker or Common Bus, the
generator sets are connected if any of the generator set paralleling breakers is closed. The
generator sets are not connected if all of the generator set paralleling breakers are open.
In other topologies, the generator sets are connected if the generator set main breaker is
closed. The generator sets are not connected if the generator set main breaker is open.
If the generator set main breaker is a dual-contact breaker and code 1454 (Generator Set
Breaker Position Contact) is active, the generator set main breaker is considered closed, and
the generator sets are connected. Genset Current Based Breaker Position is not used in this
determination.

6.1.1

Connecting the Generator Sets


If the topology is Isolated Bus Without Generator Set Main Breaker or Common Bus, the
generator sets are connected to the loads by releasing the inhibit on the generator set
paralleling breakers. The generator set paralleling breakers may not close immediately because
they are controlled by the generator sets.
In other topologies, the generator sets are connected to the loads by sending a close signal to
the generator set main breaker. This signal remains active until the generator sets are
connected.
In any topology, the generator sets cannot be connected if code 1455 (Utility Main Breaker
Position Contact) is active.

6.1.2

Disconnecting the Generator Sets


If the topology is Isolated Bus Without Generator Set Main Breaker or Common Bus, the
generator sets are disconnected from the loads by inhibiting the generator set paralleling
breakers.
In other topologies, the generator sets are disconnected from the loads by sending an open
signal to the generator set main breaker. This signal remains active until the generator sets are
disconnected.

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6.1.3

5-2012

Generator Set Connections and Legacy SID Override


NOTE:

Legacy SID Override should be used only in existing installations where the
generator set paralleling breakers are connected in parallel. It should not be
used in new systems.

If Legacy SID Override is Enable, the generator set paralleling breakers are connected in
parallel to the pins of the generator set main breaker. In this case, the connection is treated like
a generator set main breaker. If the generator set main breaker is a dual-contact breaker and
the two sets of contacts disagree about the position, the generator sets are considered
connected, and code 1454 (Genset Main Breaker Position Contact) is active.

6.1.4

Generator Set Breaker Inhibit


This switch may come from any of these sources:
Generator Set Breaker Inhibit connection (TB10-5, TB10-4)
Modbus networks
InPower
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

When this switch becomes active, the generator sets are disconnected from the loads (Section
6.1.2 on page 87).

6.2

Utility Connected
The utility is connected if the utility main breaker is closed. The utility is not connected if the
utility main breaker is open.
If the utility main breaker is a dual-contact breaker and code 1455 (Utility Main Breaker Position
Contact) is active, the utility main breaker is considered closed, and the utility is connected.
Utility Current Based Breaker Position is not used in this determination.

6.2.1

Connecting the Utility


The utility is connected to the loads by sending a close signal to the utility main breaker. This
signal remains active until the utility is connected.
The utility cannot be connected if code 1454 (Generator Set Breaker Position Contact) is active.

6.2.2

Disconnecting the Utility


The utility is disconnected from the loads by sending an open signal to the utility main breaker.
This signal remains active until the utility is disconnected.

6.2.3

Utility Main Breaker Inhibit


This switch may come from any of these sources:
Utility Main Breaker Inhibit connection (TB10-11, TB10-13)

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Modbus networks
InPower
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

When this switch becomes active, the utility is disconnected from the loads (Section 6.2.2 on
page 88).

6.3

Summary of Settings (PTC State)


TABLE 79.

SUMMARY OF SETTINGS (PTC STATE)

Setting

Description

Gen CB Inhibit Vol

Sets the generator set breaker inhibit.


Possible values: No Inhibit, Inhibit

Util CB Inhibit Vol

Sets the utility main breaker inhibit.


Possible values: No Inhibit, Inhibit

TABLE 80.

SUMMARY OF MONITOR POINTS (PTC STATE)

Setting

Description

PTC State

Indicates which sources are connected to the loads.


Possible values: Not Enabled, No Source Connected,
Utility Connected, Genset Connected, Paralleled

Gen CB Inhibit Sw

Indicates the state of the generator set breaker inhibit.

Util CB Inhibit Sw

Indicates the state of the utility main breaker inhibit.

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Power Transfer Control (PTC)


Operating Mode
PTC Operating Mode determines the PTC state to which the system is trying to get. For
example, if the utility is not available, the system tries to get the generator sets connected to the
loads.

7.1

PTC Logic and Source Availability


The power transfer control (PTC) logic will not connect an unavailable source to the loads.
NOTE:

7.2

If the topology is Isolated Bus Without Generator Set Main Breaker or


Isolated Bus with Generator Set Main Breaker, the utility is always
unavailable, so the PTC logic does not try to close the utility main breaker.

Priority of PTC Operating Modes


If the conditions for more than one PTC operating mode are met, the PTC operating mode with
the highest priority becomes active. The priorities of the PTC operating modes, from highest to
lowest, are as follows.
1. Utility Fail
2. Normal Override
3. Extended Parallel
4. Test
5. Normal
For example, if the conditions for extended parallel and the conditions for test are met at the
same time, the PTC operating mode is Extended Parallel.

7.3

Utility Fail
The utility is not available. The system tries to connect the generator sets to the loads.

7.3.1

Conditions for Entering Utility Fail


At least one of these conditions is met.
The utility is not available.
The utility source failure switch is active.

7.3.2

Utility Source Failure Switch


This switch is used by an external device that determines whether or not the utility is available.
If this switch is active, the utility is not available.
If there is no external device, this switch should be inactive.

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This switch is available in three-phase applications if the topology is Isolated Bus Without
Generator Set Main Breaker, Isolated Bus with Generator Set Main Breaker, Common Bus, or
Transfer Pair. It has no effect in other applications or topologies.

7.3.3

Conditions for Leaving Utility Fail


All of these conditions are met.
None of the conditions for entering utility fail are met.
The system is not committed to transferring the loads to the generator sets.

7.3.3.1 Commit to Transfer


This refers to the point in time at which the system commits to transferring the loads to the
generator sets even if the utility becomes available again.

7.3.3.2 Conditions Required for Commit to Transfer


This feature is not active unless all of the following conditions are met.
The topology is Common Bus or Transfer Pair.
The generator set breakers are ready to close. The generator set breaker inhibit is inactive,
and transfer inhibit is inactive. Code 1328 (Genset Main Breaker Tripped), code 1452
(Genset Main Breaker Fail to Close), and code 1454 (Genset Main Breaker Position
Contact) are not active.

7.3.3.3 Commit to Transfer Settings


This feature depends on Commit to Transfer Method.
No Commit: The system stops transferring the loads to the generator sets and returns to
the utility as soon as it is available. This setting should be used in applications that prefer
the utility to provide power to the loads as much as possible. However, the generator sets
can start and stop repeatedly if the utility is intermittent.
Utility Disconnect: The system is committed to transferring the loads to the generator sets
once the utility is disconnected. This setting is typical in applications with uninterruptible
power supplies (UPS) that require a guaranteed amount of generator set time to recharge
the batteries.
Genset Start: The system is committed to transferring the loads to the generator sets once
the generator sets are commanded to start. This setting reduces the likelihood of issues
such as wet stacking.
Once the loads are transferred to the generator sets, the loads will be powered by the generator
sets for at least Retransfer Delay (TDEN).
If the utility is available for Commit to Transfer Timer and the system has not transferred the
loads to the generator sets yet, the system returns to the utility as soon as possible.

7.4

Normal Override
The generator sets became unavailable while they were connected to the loads. The system
tries to connect the utility to the loads as quickly as possible. The system ignores retransfer time
delay and retransfer inhibit.

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7.4.1

7. Power Transfer Control (PTC) Operating Mode

Conditions for Entering Normal Override


All of these conditions are met.
The generator sets are not available.
PTC State is not Utility Connected.

7.4.2

Conditions for Leaving Normal Override


At least one of the conditions for entering normal override are not met.

7.5

Extended Parallel
This is a way to run the generator sets in parallel with the utility. When the generator sets run in
parallel with the utility, you can control the kW and kVAR of the generator sets or the utility.

7.5.1

Conditions for Entering Extended Parallel


All of these conditions are met.
Extended Parallel Enable is Enabled.
The extended parallel switch is active.
PTC State is not Not Connected.
Code 4137 (Advanced Grid Protection Fault) is not active.

7.5.2

Extended Parallel Switch


This switch may come from any of these sources:
Extended Parallel Switch connection (TB2-4, TB2-6)
PCCNet devices
Modbus networks
InPower
Exercise scheduler
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

7.5.3

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

Conditions for Leaving Extended Parallel


At least one of the conditions for entering extended parallel is not met.

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7.6

5-2012

Test
You might run a test for a variety of reasons. In standby applications, you might want to verify
that the system is ready to respond to the loss of the utility. Alternatively, you might run a test to
exercise the generator sets. In prime power applications, this might be the way you start the
generator sets.
You can run a test with load or a test without load.

7.6.1

Conditions for Entering Test


If the topology is Common Bus or Extended Parallel, all of these conditions have to be met.
The test start switch is active.
PTC State is Utility Connected or Genset Connected.
Code 2648 (Remote I/O Comm Failure Warning) and code 4137 (Advanced Grid
Protection Fault) are not active.
If the topology is Isolated Bus Without Generator Set Main Breaker or Isolated Bus with
Generator Set Main Breaker, all of these conditions have to be met.
The test start switch is active.
Code 2648 (Remote I/O Comm Failure Warning) is not active.

7.6.2

Test Start Switch


This switch may come from any of these sources:
Test Start Switch connection (TB2-1, TB2-6)
PCCNet devices
Modbus networks
InPower
Exercise scheduler
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

7.6.3

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

Conditions for Leaving Test


If the topology is Common Bus or Extended Parallel, one of these conditions is met.
The test start switch is not active.
Code 4137 (Advanced Grid Protection Fault) is active.
If the topology is Isolated Bus Without Generator Set Main Breaker or Isolated Bus with
Generator Set Main Breaker, the test start switch is not active.

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7.7

7. Power Transfer Control (PTC) Operating Mode

Normal
This is the typical operating state. The system tries to connect the utility to the loads and shuts
down the generator sets.

7.7.1

Conditions for Entering Normal


The system is not in any of the other PTC operating modes.

7.7.2

Conditions for Leaving Normal


The system is in one of the other PTC operating modes.

7.8

Summary of Settings (PTC Operating Mode)


TABLE 81.

SUMMARY OF SETTINGS (PTC OPERATING MODE)

Setting

Description

Utility Source Failure Vol

Sets the utility source failure switch.


Possible values: Inactive, Active

Commit To Transfer Method

Specifies the point in time at which the system commits to


transferring the loads to the generator sets even if the
utility becomes available again.
Possible values: Utility Disconnect, Genset Start, No
Commit (Default: Utility Disconnect)

Commit To Transfer Timeout

Specifies how long the system waits for the generator


sets to connect to the loads once it is committed to
transferring the loads to the generator sets.
Possible values: 0-3200 seconds (Default: 120 seconds)

Breaker Commitment Time Delay

Specifies the amount of time the MCM3320 waits for the


breaker to respond to a command. If the breaker does not
respond to the command, the MCM3320 does not
necessarily generate a code, but the MCM3320 can
change the command if conditions have changed.
Possible values: 0-5 seconds (Default: 2 seconds)

Extended Parallel Enable

Enables or disables extended parallel.


Possible values: Enabled, Disabled (Default: Disabled)

Extended Parallel Start Vol

Sets the extended parallel switch.


Possible values: Stop, Start

Test Start Vol

Sets the test start switch.


Possible values: Stop, Start

TABLE 82.

SUMMARY OF MONITOR POINTS (PTC OPERATING MODE)

Setting

Description

PTC Operating Mode

Indicates the current PTC operating mode.

Utility Source Failure Sw

Indicates the state of the utility source failure switch.

Commit To Transfer State

Indicates whether or not the system is committed to


transferring the loads to the generator sets.

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Setting

Description

Extended Parallel Start Sw

Indicates the state of the extended parallel switch.

Test Start Sw

Indicates the state of the test start switch.

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Breaker Control
Breaker control decides which breakers should open and close and when each breaker action
should occur to support the PTC Operating Mode.

8.1

PTC Transfer Pair Operating Mode


PTC Transfer Pair Operating Mode determines how the breakers are controlled.
TABLE 83.

8.2

PTC TRANSFER PAIR OPERATING MODE

Mode of Operation

PTC Transfer Pair Operating Mode

Manual

Manual

Auto

PTC Operating Mode

Breaker Control in Manual


See Section 15.6 on page 164.

8.3

Breaker Control in Utility Fail

Disconnect the utility according to Utility Breaker Opening Point.


If Utility Breaker Opening Point is Upon Utility Failure, disconnect the utility immediately.
If Utility Breaker Opening Point is After Transfer Delay, disconnect the utility after Transfer Delay (TDNE)
expires.

Connect the generator sets when the generator sets are available and Programmed Transition Delay (TDPT)
expires.

Disconnect the utility immediately.

FIGURE 68.
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BREAKER CONTROL IN UTILITY FAIL


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8. Breaker Control

8.4

5-2012

Breaker Control in Normal Override

Disconnect the generator sets immediately.

Connect the utility when Programmed Transition Delay (TDPT) expires.

Disconnect the generator sets immediately.

FIGURE 69.

98

BREAKER CONTROL IN NORMAL OVERRIDE

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8.5

8. Breaker Control

Breaker Control in Extended Parallel

1. Retransfer Delay (TDEN) expires.


2. Synchronize the generator sets with the utility.
3. Connect the utility.
Nothing happens unless code 1999 (Maximum Parallel Time) and code 2397 (Utility Main Breaker Fail to Open)
are inactive.
If the topology is Common Bus, let the generator sets close their paralleling breakers when Transfer Delay
(TDNE) expires.
If the topology is Transfer Pair, follow these steps.

1. Transfer Delay (TDNE) expires.


2. Synchronize the generator sets with the utility.
3. Connect the generator sets.
FIGURE 70.

8.6

BREAKER CONTROL IN EXTENDED PARALLEL

Breaker Control in Test


Breaker control depends on Test With Load Cmd and PTC Operating Transition Type. There is
no breaker control in a test without load.
NOTE:

A029Y787 (Issue 1)

If the topology is Isolated Bus Without Generator Set Main Breaker or


Isolated Bus with Generator Set Main Breaker, PTC Operating Transition
Type is always Open Transition.

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8. Breaker Control

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Nothing happens unless code 1999 (Maximum Parallel Time) and code 2397 (Utility Main Breaker Fail to Open)
are inactive.
If the topology is Common Bus, let the generator sets close their paralleling breakers when Transfer Delay
(TDNE) expires.
If the topology is Transfer Pair, follow these steps.

1. Transfer Delay (TDNE) expires.


2. Synchronize the generator sets with the utility.
3. Connect the generator sets.
B

In a soft-closed transition, disconnect the utility when the utility is unloaded.


In a hard-closed transition, disconnect the utility immediately.

FIGURE 71.

100

BREAKER CONTROL IN TEST WITH LOAD (CLOSED TRANSITION)

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Disconnect the utility after Transfer Delay (TDNE) expires.

Connect the generator sets when the generator sets are available and Programmed Transition Delay (TDPT)
expires.

FIGURE 72.

8.6.1

BREAKER CONTROL IN TEST WITH LOAD (OPEN TRANSITION)

Test with Load Command


Test With Load Cmd indicates whether the system is running a test with load or a test without
load. If a test is started by the exercise scheduler, Test With Load Cmd is based on the settings
in the schedule. If a test is not started by the exercise scheduler, Test With Load Cmd is based
on Test with Load Enable.

8.7

Breaker Control in Normal


Breaker control depends on the topology and PTC Operating Transition Type.
If the topology is Isolated Bus Without Generator Set Main Breaker or Isolated Bus with
Generator Set Main Breaker, the system disconnects the generator sets immediately.

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1. Retransfer Delay (TDEN) expires.


2. Synchronize the generator sets with the utility.
3. Connect the utility.

In a soft-closed transition, disconnect the generator sets when the generator sets are unloaded. If Maximum
Parallel Time (TDMP) expires, disconnect the generator sets immediately.
In a hard-closed transition, disconnect the generator sets immediately.

Connect the utility when Programmed Transition Delay (TDPT) expires.

FIGURE 73.

102

BREAKER CONTROL IN NORMAL (CLOSED TRANSITION, COMMON BUS OR


TRANSFER PAIR TOPOLOGY)

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Disconnect the generator sets when Retransfer Delay (TDEN) expires.

Connect the utility when Programmed Transition Delay (TDPT) expires.

Disconnect the generator sets immediately.

FIGURE 74.

8.7.1

BREAKER CONTROL IN NORMAL (OPEN TRANSITION, COMMON BUS OR TRANSFER


PAIR TOPOLOGY)

Open-transition Retransfer After Fail To Synchronize


If the generator sets are unable to synchronize with the utility during a closed-transition
retransfer in Normal mode, set Fail To Sync Open Transition Retransfer Enable to Enabled if
the system should execute an open-transition retransfer.
If Fail To Sync Open Transition Retransfer Enable is Enabled, the generator sets are
disconnected immediately when all of these conditions are met.
PTC Transfer Pair Operating Mode is Normal.
PTC State is Genset Connected.
Code 1457 (Fail to Synchronize Warning) is active.
Retransfer inhibit is inactive.
The rest of the retransfer is the same as an open-transition retransfer in Normal mode.

8.8

Timers

8.8.1

Transfer Time Delay


This gives the generator sets more time to stabilize before accepting loads. It also gives the
utility more time to recover before the loads are transferred to the generator sets.
NOTE:

Set this value to zero if the system has to meet NFPA 110 starting
requirements.

If the generator sets become unavailable, the timer resets.

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This is also known as Time Delay Normal to Emergency (TDNE).

8.8.2

Retransfer Time Delay


This is the amount of time between the time the utility is available again and the time the loads
are transferred from the generator sets to the utility.
This gives the utility more time to stabilize before retransfer.
This is also known as Time Delay Emergency to Normal (TDEN).

8.8.3

Programmed Transition Time Delay


This allows residual voltage from inductive loads to decay to an acceptable level before the
transfer is completed.
This is also known as Time Delay Programmed Transition (TDPT).

8.8.4

Maximum Parallel Timer


This is the maximum amount of time the generator sets can be in parallel with the utility when
PTC Operating Mode is not Extended Parallel.
If the generator sets are in parallel with the utility for this amount of time, code 1999 (Maximum
Parallel Time) is active, and the generator sets are disconnected immediately.
This is also known as Time Delay Maximum Parallel (TDMP).

8.8.5

Summary of Settings (PTC Timers)


TABLE 84.

SUMMARY OF SETTINGS (PTC TIMERS)

Setting

Description

Transfer Delay (TDNE)

Sets the transfer time delay.


Possible values: 0-120 seconds (Default: 10 seconds)

Retransfer Delay (TDEN)

Sets the retransfer time delay


Possible values: 0-1800 seconds (Default: 600 seconds)

Programmed Transition Delay (TDPT)

Sets the programmed-transition time delay.


Possible values: 0-60 seconds (Default: 3 seconds)

Maximum Parallel Time (TDMP)

Sets the maximum parallel time delay.


Possible values: 0-1800 seconds (Default: 20 seconds)

8.9

Inhibits

8.9.1

Master Inhibit
This switch may come from any of these sources:
Master Inhibit connection (TB3-8, TB3-17)
Modbus networks
InPower

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8. Breaker Control

This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

When this switch becomes active, the following features are disabled.
Breaker control when PTC State is No Source Connected, Genset Connected, or Utility
Connected.
Synchronizer
Load control in extended parallel

8.9.2

Transfer Inhibit
This switch may come from any of these sources:
Transfer Inhibit connection (TB3-6, TB3-8)
Modbus networks
InPower
Code 1455 (Utility Main Breaker Position Contact) is active, and Utility Current Based
Breaker Position is Closed.
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

When this switch is active, the following changes occur.


The Transfer Time Delay timer resets and stops running.
If PTC Transfer Pair Operating Mode is Utility Fail, the utility does not disconnect when
PTC State is Utility Connected if Utility Breaker Opening Point is After Transfer Delay.
If PTC Transfer Pair Operating Mode is Test, the MCM3320 does not try to connect or
disconnect sources when PTC State is No Source Connected or Utility Connected.
If PTC Transfer Pair Operating Mode is Extended Parallel, the MCM3320 does not try to
connect or disconnect sources when PTC State is Utility Connected.

8.9.3

Retransfer Inhibit
This switch may come from any of these sources:
Retransfer Inhibit connection (TB3-7, TB3-8)
Modbus networks
InPower
Code 1454 (Genset Main Breaker Position Contact) is active, and Genset Current Based
Breaker Position is Closed.
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.

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There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

This switch has no effect unless the topology is Common Bus or Transfer Pair. When this switch
is active, the following changes occur.
The Retransfer Time Delay timer resets and stops running.
If PTC Transfer Pair Operating Mode is Normal, there is no breaker control when PTC
State is Genset Connected.
If PTC Transfer Pair Operating Mode is Extended Parallel, there is no breaker control
when PTC State is Genset Connected.

8.9.4

Override Switch
This switch may come from any of these sources:
Override Switch connection (TB1-13, TB1-14)
Modbus networks
InPower
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

This switch forces a transfer or retransfer to occur as quickly as possible. When this switch is
active, the following changes occur.
The Start Time Delay timer expires.
The Transfer Time Delay timer expires.
The Retransfer Time Delay timer expires.
Transfer inhibit from external sources is disabled. The transfer inhibit from current-based
breaker position is still enabled.
Retransfer inhibit from external sources is disabled. The retransfer inhibit from currentbased breaker position is still enabled.

8.9.5

Generator Set Breaker Inhibit


This switch may come from any of these sources:
Generator Set Breaker Inhibit connection (TB10-5, TB10-4)
Modbus networks
InPower
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

106

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.
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8. Breaker Control

When this switch becomes active, the generator sets are disconnected from the loads (Section
6.1.2 on page 87).

8.9.6

Utility Main Breaker Inhibit


This switch may come from any of these sources:
Utility Main Breaker Inhibit connection (TB10-11, TB10-13)
Modbus networks
InPower
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

When this switch becomes active, the utility is disconnected from the loads (Section 6.2.2 on
page 88).

8.10

Fail to Disconnect Enable


If Fail to Disconnect Enable is Enabled, the system takes additional actions to try to disconnect
one of the sources when the generator sets are running in parallel with the utility.
If code 1453 (Genset Main Breaker Fail to Open) is active, the utility is disconnected
immediately.
If code 2397 (Utility Main Breaker Fail to Open) is active, the generator sets are
disconnected immediately.
In addition, code 1121 (Fail to Disconnect) is enabled.

8.11

Output Signals for Breakers


For the utility main breaker and generator set main breaker, the output signal remains active
until the breaker position matches the output signal. For example, if the MCM3320 sends a
close signal to the utility main breaker, the close signal remains active until the utility main
breaker closes. This allows for connecting to non-continuous duty-rated trip and close coils.
For the generator set paralleling breakers, the MCM3320 inhibits the breakers when the
generator sets are supposed to be disconnected. This should open the paralleling breakers
immediately. The MCM3320 releases the inhibit when the generator sets are supposed to be
connected, but the generator sets decide when the paralleling breakers actually close.

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Summary of Settings (Breaker Control)


TABLE 85.

SUMMARY OF SETTINGS (BREAKER CONTROL)

Setting

Description

Gen CB Manual Control

Connects or disconnects the generator sets when PTC


Transfer Pair Operating Mode is Manual.
Possible values: Close Requested, No Command, Open
Commanded

Util CB Manual Control

Connects or disconnects the utility when PTC Transfer


Pair Operating Mode is Manual.
Possible values: Close Requested, No Command, Open
Commanded

Utility Breaker Opening Point

Specifies when the MCM3320 opens the utility main


breaker after the utility becomes unavailable. If this is
After Transfer Delay, the action can be prevented by a
transfer inhibit.
Possible values: After Transfer Delay, Upon Utility Failure
(Default: After Transfer Delay)

Genset Unloaded Level

Specifies the maximum load at which the generator sets


are considered unloaded. This is used in soft-closed
transitions.
Possible values: -32768~32767 kW (Default: 50 kW)

Utility Unloaded Level

Specifies the maximum load at which the utility is


considered unloaded. This is used in soft-closed
transitions.
Possible values: -32768~32767 kW (Default: 50 kW)

Network Master Inhibit

Sets the master inhibit.


Possible values: No Inhibit, Inhibit

Transfer Inhibit Vol

Sets the transfer inhibit.


Possible values: No Inhibit, Inhibit

Retransfer Inhibit Vol

Sets the retransfer inhibit.


Possible values: No Inhibit, Inhibit

Override Vol

Sets the override switch.


Possible values: No Override, Override

Gen CB Inhibit Vol

Sets the generator set breaker inhibit.


Possible values: No Inhibit, Inhibit

Util CB Inhibit Vol

Sets the utility main breaker inhibit.


Possible values: No Inhibit, Inhibit

Fail To Disconnect Enable

Enables or disables the ability to take additional actions to


try to disconnect one of the sources when the generator
sets are running in parallel with the utility.
Possible values: Disable, Enable (Default: Enable)

Gen CB Open To Close Delay

Specifies the minimum amount of time the generator set


main breaker must remain open before the MCM3320 can
send a close signal. This is intended to prevent breaker
anti-pump lockout. This has no effect on the generator set
paralleling breakers.
Possible values: 0-1 second (Default: 0.1 seconds)

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Setting

Description

Util CB Open To Close Delay

Specifies the minimum amount of time the utility main


breaker must remain open before the MCM3320 can send
a close signal. This is intended to prevent breaker antipump lockout.
Possible values: 0-1 second (Default: 0.1 seconds)

Gen CB Recharge Delay

Specifies the minimum amount of time between close


signals to the generator set main breaker. This is ignored
if the generator set main breaker does not close in
response to the first close signal. This gives the breaker
time to recharge. This has no effect on the generator set
paralleling breakers.
Possible values: 0-60 seconds (Default: 10 seconds)

Util CB Recharge Delay

Specifies the minimum amount of time between close


signals to the utility main breaker. This is ignored if the
utility main breaker does not close in response to the first
close signal. This gives the breaker time to recharge.
Possible values: 0-60 seconds (Default: 10 seconds)

TABLE 86.

SUMMARY OF MONITOR POINTS (BREAKER CONTROL)

Setting

Description

PTC Transfer Pair Operating Mode

Indicates the current operating mode for breaker control.


This is the same as PTC Operating Mode, except that
PTC Transfer Pair Operating Mode can be Manual.

PTC Util Close Request

Indicates whether or not the PTC logic is requesting the


utility to connect to the loads.
Possible values: Active, Inactive

PTC Util Open Request

Indicates whether or not the PTC logic is requesting the


utility to disconnect from the loads.
Possible values: Active, Inactive

PTC Gen Close Request

Indicates whether or not the PTC logic is requesting the


generator sets to connect to the loads.
Possible values: Active, Inactive

PTC Gen Open Request

Indicates whether or not the PTC logic is requesting the


generator sets to disconnect from the loads.
Possible values: Active, Inactive

PTC Breaker Control Request

Indicates what type of control the PTC logic wants after it


consolidates the PTC requests and considers Breaker
Commitment Time Delay.
Possible values: No Command, Close Utility, Open Utility,
Close Genset, Open Genset

PTC Breaker Control Command

Identical to PTC Breaker Control Request.

Util CB Close Command

Indicates whether or not the MCM3320 is sending a close


signal to the utility main breaker. This signal considers Util
CB Open To Close Delay and Util CB Recharge Delay.
Possible values: Active, Inactive

Util CB Open Command

Indicates whether or not the MCM3320 is sending an


open signal to the utility main breaker. This signal
considers the utility main breaker inhibit and code 1121
(Fail to Disconnect).
Possible values: Active, Inactive

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Setting

Description

Gen CB Close Command

Indicates whether or not the MCM3320 is sending a close


signal to the generator set main breaker. This signal
considers Gen CB Open To Close Delay and Gen CB
Recharge Delay.
Possible values: Active, Inactive

Gen CB Open Command

Indicates whether or not the MCM3320 is sending an


open signal to the generator set main breaker. This signal
considers the generator set breaker inhibit and code 1121
(Fail to Disconnect).
Possible values: Active, Inactive

Virtual Gen Main Breaker Command

Indicates what type of control the MCM3320 wants on the


generator set paralleling breakers as a group. If the
topology is Isolated Bus with Generator Set Main Breaker
or Transfer Pair, this is always Close Breaker.
Possible values: Close Breaker, Open Breaker

Paralleling Gensets Breaker Inhibit Command

Indicates whether or not the MCM3320 is inhibiting the


generator set paralleling breakers. This signal considers
code 1121 (Fail to Disconnect).
Possible values: No Inhibit, Inhibit All Gensets

Master Inhibit

Indicates the status of the master inhibit.


Possible values: No Inhibit, Inhibit

Transfer Inhibit Sw

Indicates the status of the transfer inhibit.


Possible values: No Inhibit, Inhibit

Retransfer Inhibit Sw

Indicates the status of the retransfer inhibit.


Possible values: No Inhibit, Inhibit

Override Sw

Indicates the status of the override switch.


Possible values: No Override, Override

Gen CB Inhibit Sw

Indicates the status of the generator set breaker inhibit.


Possible values: No Inhibit, Inhibit

Util CB Inhibit Sw

Indicates the status of the utility main breaker inhibit.


Possible values: No Inhibit, Inhibit

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Generator Set Control


Generator set control decides whether or not the generator sets should be running to support
the PTC Operating Mode. Generator set control provides a remote start signal to all of the
generator sets; it does not start or stop individual generator sets.
NOTE:

9.1

The generator sets should be in Auto mode.

PTC Generator Set Operating Mode


PTC Genset Operating Mode determines how the generator sets are controlled. It is identical to
PTC Operating Mode.

9.2

Generator Set Control in Utility Fail, Extended


Parallel, and Test
If the generator sets are not running when any of these operating modes are entered, the
generator sets are commanded to start after Start Time Delay expires.
The generator sets will not be stopped.

9.3

Generator Set Control in Normal Override


The generator sets will not be started.
If the generator sets are running when this operating mode is entered, the generator sets
continue to run until PTC State is Utility Connected. Then, the generator sets are commanded to
stop after Stop Time Delay.

9.4

Generator Set Control in Normal


The generator sets will not be started in this operating mode.
If the generator sets are running when this operating mode is entered, the resopnse depends on
the topology.
If the topology is Isolated Bus Without Generator Set Main Breaker or Isolated Bus with
Generator Set Main Breaker, the generator sets are commanded to stop after Stop Time
Delay.
If the topology is Common Bus or Transfer Pair, the generator sets continue to run until
PTC State is Utility Connected. Then, the generator sets are commanded to stop after
Stop Time Delay.

9.5

Start Delay
This gives the utility more time to recover before the loads are transferred to the generator sets.
NOTE:

A029Y787 (Issue 1)

Set this value to zero if the system has to meet NFPA 110 starting
requirements.
111

9. Generator Set Control

NOTE:

9.6

5-2012

This is a different setting than the start delay in each generator set. The
generator sets will not start for the sum of both start delays. For example, the
start delay is 5 seconds, and the start delay in generator set A is 15 seconds.
Generator set A will not start for 20 seconds.

Stop Delay
This gives the generator sets more time to run at rated speed and voltage with no load.
NOTE:

9.7

This is a different setting than the stop delay in each generator set. The
generator sets will not stop for the sum of both stop delays. For example, the
stop delay is 5 seconds, and the stop delay in generator set A is 15 seconds.
Generator set A will run at rated speed and voltage for 20 seconds.

Summary of Settings (Generator Set Control)


TABLE 87.

SUMMARY OF SETTINGS (GENERATOR SET CONTROL)

Setting

Description

Start Time Delay (TDES)

Specifies the start delay for all of the generator sets. This
is a different setting than the one in each generator set.
Possible values: 0-3600 seconds (Default: 0 seconds)

Stop Time Delay (TDEC)

Specifies the stop delay for all of the generator sets. This
is a different setting than the one in each generator set.
Possible values: 0-3600 seconds (Default: 0 seconds)

Start Gensets Relay Active State

Specifies the active state of the relay that is connected to


the generator set remote start input.
Possible values: Active Energized, Active Deenergized
(Default: Active Energized)

TABLE 88.

SUMMARY OF MONITOR POINTS (GENERATOR SET CONTROL)

Setting

Description

PTC Genset Operating Mode

Indicates the current operating mode for generator set


control. This is the same as PTC Operating Mode.

Genset Run Request

Indicates whether or not the MCM3320 wants to run the


generator sets before the MCM3320 considers the time
delays. When this setting becomes Run, Start Time Delay
(TDES) begins. When this setting becomes Stop, Stop
Time Delay (TDEC) begins. This is not the setting that
controls the remote start signal to the generator sets.
Possible values: Stop, Run

Genset Run Command

Indicates whether or not the MCM3320 is sending a


remote start signal to the generator sets.
Possible values: Stop, Run

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Load Control
Load control drives the kW Master Load Control and the kVAR Master Load Control outputs.
These outputs are used to adjusts the real power and the reactive power provided by the
generator sets when the generator sets are running in parallel with the utility. They are also
used to tell the generator sets to ramp up their loads and to ramp down their loads during softclosed transitions.

10.1

Associated Pins
TABLE 89.
Pin

10.2

ASSOCIATED PINS

Description

TB9-1

kW load setpoint

TB9-2

Analog input return

TB9-3

kVAR load setpoint

TB9-4

kW master load control

TB9-5

kVAR master load control

TB9-6

Analog output return

Extended Parallel
This is a way to run the generator sets in parallel with the utility. When the generator sets run in
parallel with the utility, you can control the kW and kVAR of the generator sets or the utility.

10.2.1 Conditions for Load Control in Extended Parallel


Load control is active when all of these conditions are met.
PTC State is Paralleled.
PTC Operating Mode is Extended Parallel.
Code 1121 (Fail to Disconnect) is inactive.

10.2.1.1 Master Inhibit


This switch may come from any of these sources:
Master Inhibit connection (TB3-8, TB3-17)
Modbus networks
InPower
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

A029Y787 (Issue 1)

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

113

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When this switch becomes active, the following features are disabled.
Breaker control when PTC State is No Source Connected, Genset Connected, or Utility
Connected.
Synchronizer
Load control in extended parallel

10.2.2 kW Control
When the generator sets run in parallel with the utility, you can control the real power (kW) of
the generator set bus or the utility.
If the real power of the generator set bus is fixed, this is called base load. The utility handles the
variation in the loads.
If the real power of the utility is fixed, this is called peak shave. The generator sets handle the
variation in the loads until the load on the generator sets exceeds the capacity of the generator
sets.

10.2.2.1 Generator Set Bus Percent Level


With this method, the available generator sets run at a fixed percentage of their rated outputs.
You specify the percentage. If a generator set is not available, the remaining generator sets do
not provide more power to compensate. The utility provides the rest of the power required by
the loads.

No.

Description

kW Real power
t

Time

FIGURE 75.

114

No.

Description

Generator set output

Load

GENERATOR SET BUS PERCENT LEVEL

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10. Load Control

10.2.2.2 Generator Set Bus kW


With this method, the available generator sets provide a fixed amount of real power. You specify
the amount. If a generator set is not available, the remaining generator sets provide more power
to compensate as long as there is enough capacity. The utility provides the rest of the power
required by the loads.

No.

Description

kW Real power
t

Time

FIGURE 76.

No.

Description

Generator set output

Load

GENERATOR SET BUS KW

10.2.2.3 Generator Set Bus kW with Utility Constraint


With this method, the generator sets provide a fixed amount of real power as long as the utility
provides a minimum amount of real power. If the utility starts providing less power than this
minimum amount, this method reduces the amount of power the generator sets provide. You
specify the amount of real power provided by the generator sets, and you specify the minimum
amount of real power provided by the utility.
If you set the minimum amount of real power provided by the utility to a positive value or zero,
this prevents the generator sets from providing power to the utility.
If you set the minimum amount of real power provided by the utility to a negative value, this
allows the generator sets to export power to the utility if the load is less than the amount of real
power provided by the generator sets. For example, if the utility is supposed to provide -500 kW,
the generator sets may export up to 500 kW of power to the utility.

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Description

kW Real power
t

Time

FIGURE 77.

Description

kW Real power
Time

FIGURE 78.

Description

Generator set output

Load

GENERATOR SET BUS KW WITH UTILITY CONSTRAINT (MINIMUM AMOUNT OF REAL


POWER PROVIDED BY UTILITY IS POSITIVE)

No.

No.

No.

Description

Generator set output

Load

GENERATOR SET BUS KW WITH UTILITY CONSTRAINT (MINIMUM AMOUNT OF REAL


POWER PROVIDED BY UTILITY IS NEGATIVE)

10.2.2.4 Utility Bus kW


With this control, the utility provides a fixed amount of real power. You specify the amount. The
generator sets provide the rest of the power required by the loads.

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No.

Description

No.

kW Real power
t

Time

FIGURE 79.

Description

Generator set output

Load

UTILITY BUS KW

10.2.2.5 kW Setpoint Source


The desired kW load for the generator sets or the utility can be set externally by the kW Load
Setpoint input or internally by certain settings. Use the appropriate setting to control the source.
TABLE 90.

APPROPRIATE SETTING FOR KW SETPOINT SOURCE BASED ON KW LOAD


CONTROL TYPE

Extended Paralleling kW Load Control Type

Appropriate Setting

Genset Bus % Level (Open Loop)


Genset Bus kW (Closed Loop)
Genset Bus kW w/Utility Constraint (Closed Loop)

Genset Bus kW Setpoint Source

Utility Bus kW (Closed Loop)

Utility Bus kW Setpoint Source

10.2.3 kVAR Control


When the generator sets run in parallel with the utility, you can control the reactive power (kVAR
or power factor) of the generator set bus or the utility. This control is independent of kW control.
For example, you can run the generator sets in base load while maintaining the power factor of
the utility to avoid penalties due to low power factor.

10.2.3.1 Generator Set Support for kVAR Control


The PCC 3100 supports the Generator Set Controllers method. It does not support any other
kVAR control method.
The PCC 3200, PCC 3201, and PowerCommand 3.3 support all kVAR control methods.

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10.2.3.2 Summary of kVAR Control Methods


The kVAR control methods vary in two ways.
The system target
Whether or not an alarm is generated if the system is off-target for too long
TABLE 91.

SUMMARY OF KVAR CONTROL METHODS

Method

System Target

Alarm?

None

No

Generator Set Bus Percent Level

Generator set bus kVAR

No

Generator Set Bus Power Factor

Generator bus power factor

No

Generator set bus kVAR

Yes

Generator set bus power factor

Yes

Utility kVAR

Yes

Utility power factor

Yes

Generator Set Controllers

Generator Set Bus kVAR


Generator Set Bus Power Factor
Utility Bus kVAR
Utility Bus Power Factor

Additional notes about the kVAR control methods:


With the Generator Set Controllers method, each generator set controls its reactive power.
With the Generator Set Bus Percent Level method, you do not specify a kVAR target. The
available generator sets run at a fixed percentage of their rated outputs. You specify the
percentage. If a generator set is not available, the remaining generator sets do not provide
more power to compensate.

10.2.3.3 kVAR Setpoint Source


The desired kVAR load or power factor for the generator sets or the utility can be set externally
by the kVAR Load Setpoint input or internally by certain settings. Use the appropriate setting to
control the source.
TABLE 92.

APPROPRIATE SETTING FOR KVAR SETPOINT SOURCE BASED ON KVAR LOAD


CONTROL TYPE

Extended Paralleling kVAR Load Control Type

Appropriate Setting

Genset Controllers

Not applicable

Genset Bus % Level (Open Loop)


Genset Bus Power Factor (Open Loop)
Genset Bus kVAR (Closed Loop)
Genset Bus Power Factor (Closed Loop)

Genset Bus kVAR Setpoint Source

Utility Bus kVAR (Closed Loop)


Utility Bus Power Factor (Closed Loop)

Utility Bus kVAR Setpoint Source

10.2.4 Extended Parallel Ramp Load Time


If the previous PTC State was Utility Connected, load control ramps up the generator sets from
zero to the desired load during Extended Parallel Ramp Load Time. If the desired load changes
during Extended Parallel Ramp Load Time, it is possible for the ramp to finish early or late.

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If the previous PTC State was Genset Connected, load control tells the generator sets to run at
the desired load immediately.

10.2.5 Open-loop Methods and Closed-loop Methods


With closed-loop methods, the MCM3320 sends a signal to the generator sets, measures the
output of the generator sets, and uses a proportional-integral (PI) loop to adjust the signal to the
generator sets to drive the output to the desired value. With open-loop methods, the MCM3320
sends a signal to the generator sets but does not monitor the output of the generator sets.

10.2.5.1 Proportional-integral (PI) Loop


A proportional-integral (PI) loop is one way to drive a measured value to a desired value.
A PI loop uses the difference between the measured value and the desired value to calculate
how much to drive the measured value. This calculation is based on several settings.
KP (proportional): This setting considers the current difference between the measured
value and the desired value. The greater the difference, the harder this setting drives the
measured value. KP is also the overall gain.
If this value is too low, it can take a long time for the measured value to reach the desired
value. If this value is too high, the PI loop drives the measured value too hard, and the
measured value becomes unstable.
KI (integral): This setting looks at the historical differences betwen the measured value and
the desired value. It considers both the magnitude of the differences and the duration of
the difference. The longer the difference is consistently higher or consistently lower than
the desired value, the harder this setting drives the measured value. Conversely, if the
measured value is oscillating around the desired value, this setting has less impact.
If this value is too low, it can take a long time for the measured value to reach the desired
value, or the measured value may stabilize at an offset from the desired value. If this value
is too high, the measured value can become unstable.
KA: This setting controls the impact of KI when it is added to KP. The higher this setting, the
greater the impact of KI and the greater the impact of KI relative to KP.
KSAT: This setting limits the impact of KI when the desired value is being ramped up. During
ramp-up, the PI loop drives the measured value at a slower rate in order to minimize the
disturbance on the system. The higher this setting, the less impact KI has during ramp-up.
NOTE:

PI loops are usually tuned appropriately for the system in which they are
used. If the system is not responding appropriately, however, make small
adjustments one setting at a time, and observe the impact on the system
after each change. Large changes or changes to several settings usually
cause a response that is undesirable, unpredictable, and unstable.

10.2.5.2 Adaptive Proportional Gain


An adaptive proportional gain increases Kp at a specified rate if the error is above the adaptive
gain error threshold. This may be used in situations in which a higher gain is required to achieve
the same response at higher errors. For example, load control operates independently of the
number of generator sets that are online. If significantly fewer generator sets are online than is
typical, the error will be higher, and a higher gain is required to drive the available generator
sets to the desired load in the same amount of time.

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Description

No.

Description

Kpa Adaptive proportional gain

Error

Kp Proportional gain (not adaptive)

Adaptive gain error threshold

Adaptive gain slope

FIGURE 80.

ADAPTIVE PROPORTIONAL GAIN

10.2.6 Load Ramping During Extended Parallel


At the beginning of extended parallel, the MCM3320 controls the ramp up of the loads on the
generator sets. At the end of extended parallel, the generator sets control the ramp down of
their loads.
If a new generator set connects after the other generator sets started running in parallel with the
utility, the generator set controls the ramp up of its load. With closed-loop methods, the
MCM3320 begins to adjust its output to compensate for the new generator set. In order to
minimize the impact of the new generator set on the closed-loop method, the ramp load time
should be at least 60 seconds. Similarly, in case a generator set shuts down with cooldown
during extended parallel, the ramp unload time should be at least 60 seconds.

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10.2.7 Summary of Settings (kW Load Control)


TABLE 93.

SUMMARY OF SETTINGS (KW LOAD CONTROL)

Setting

Description

Extended Paralleling kW Load Control Type

Specifies the kW load control method.


Possible values: Genset Bus % Level (Open Loop),
Genset Bus kW (Closed Loop), Genset Bus kW w/Utility
Constraint (Closed Loop), Utility Bus kW (Closed Loop)
(Default: Genset Bus % Level (Open Loop))

Genset Bus kW Setpoint Source

If Extended Paralleling kW Load Control Type is Genset


Bus % Level (Open Loop), Genset Bus kW (Closed
Loop), or Genset Bus kW w/Utility Constraint (Closed
Loop), this specifies how the desired kW load for the
generator sets is specified.
This has no effect for other values of Extended Paralleling
kW Load Control Type.
Possible values: Internal, Analog Input (Default: Internal)

Utility Bus kW Setpoint Source

If Extended Paralleling kW Load Control Type is Utility


Bus kW (Closed Loop), this specifies how the desired kW
load for the utility is specified.
This has no effect for other values of Extended Paralleling
kW Load Control Type.
Possible values: Internal, Analog Input (Default: Internal)

Genset Bus %kW Setpoint

This has no effect if Genset Bus kW Setpoint Source is


Analog Input.
If Extended Paralleling kW Load Control Type is Genset
Bus % Level (Open Loop), this specifies the percentage
of rated load at which the generator sets should run.
This has no effect for other values of Extended Paralleling
kW Load Control Type.
Possible values: -5~105% (Default: 80%)

Genset Bus kW Setpoint

This has no effect if Genset Bus kW Setpoint Source is


Analog Input.
If Extended Paralleling kW Load Control Type is Genset
Bus kW (Closed Loop) or Genset Bus kW w/Utility
Constraint (Closed Loop), this specifies the amount of
real power the generator sets should provide.
This has no effect for other values of Extended Paralleling
kW Load Control Type.
Possible values: 0-32767 kW (Default: 0 kW)

Utility Bus kW Constraint Level

This has no effect if Genset Bus kW Setpoint Source is


Analog Input.
If Extended Paralleling kW Load Control Type is Genset
Bus kW w/Utility Constraint (Closed Loop), this specifies
the minimum amount of real power the utility should
provide regardless of the load on the generator sets. If
this value is negative, the generator sets may export
power to the utility.
This has no effect for other values of Extended Paralleling
kW Load Control Type.
Possible values: -32768~32767 kW (Default: 100 kW)

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Setting

Description

Utility Bus kW Setpoint

This has no effect if Utility Bus kW Setpoint Source is


Analog Input.
If Extended Paralleling kW Load Control Type is Utility
Bus kW (Closed Loop), this specifies the amount of real
power the utility should provide.
This has no effect for other values of Extended Paralleling
kW Load Control Type.
Possible values: -32768~32767 kW (Default: 100 kW)

kW Load Control Maximum %Output

If Extended Paralleling kW Load Control Type is Genset


Bus % Level (Open Loop), this specifies the maximum
output level for kW load control. For other values of
Extended Paralleling kW Load Control Type, the
maximum output level for kW load control is limited to this
value + 5%.
Possible values: 0-100% (Default: 80%)

Extended Parallel Ramp Load Time

Specifies the amount of time load control ramps up the


generator sets to the desired load.
Possible values: 10-900 seconds (Default: 60 seconds)

kW Adaptive Gain Error Threshold

Specifies the error, calculated as a percentage of Total


System Capacity, above which adaptive proportional gain
starts increasing Kp.
Possible values: 0-110% (Default: 10%)

kW Adaptive Gain Slope

Specifies the rate at which Kp increases per 1% error


above kW Adaptive Gain Error Threshold.
Possible values: 0-50 / 1%-error (Default: 0.1 / 1%-error)

kW Ka, Ki, Kp, Ksat

Specifies the gains of the kW load control proportionalintegral (PI) loop. kW Kp Adaptive, not kW Kp, is used in
the PI loop.
Possible values: 12-17 (Default: 15)
Possible values: 0-255 (Default: 60)
Possible values: 0-1000 (Default: 60)
Possible values: 100-65000 (Default: 16384)

TABLE 94.

SUMMARY OF MONITOR POINTS (KW LOAD CONTROL)

Setting

Description

kW Load Target

Indicates the amount of real power the generator sets or


the utility should provide. The calculation is based on
Extended Paralleling kW Load Control Type and kW
setpoint source.

kW Reference Control State

Indicates the current state of kW load control. If the


previous PTC State was not Utility Connected, this is
Track Target.
Possible values: Off, Ramp Load, Track Target

kW Load Reference

Indicates the amount of real power the generator sets or


the utility should provide after adjusting for the ramp up of
the generator sets during Extended Parallel Ramp Load
Time.

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Setting

Description

kW Kp Adaptive

If Extended Paralleling kW Load Control Type is Genset


Bus kW (Closed Loop), Genset Bus kW w/Utility
Constraint (Closed Loop), or Utility Bus kW (Closed
Loop), this indicates the value of Kp calculated by
adaptive proportional gain. This value is used in the PI
loop. For other values of Extended Paralleling kW Load
Control Type, the PI loop is not used, and this is Kp.

kW Load Control Output

Indicates the output of kW load control. The unit of


measure is a percentage for pulse-width modulation.

kW Master Load Control Command

Indicates how much load control is driving the kW master


load control output. The unit of measure is a percentage
for pulse-width modulation. If kW load control is inactive,
this is set by load ramp.

10.2.8 Summary of Settings (kVAR Load Control)


TABLE 95.

SUMMARY OF SETTINGS (KVAR LOAD CONTROL)

Setting

Description

Extended Paralleling kVAR Load Control Type

Specifies the kVAR load control method.


Possible values: Genset Controllers, Genset Bus % Level
(Open Loop), Genset Bus Power Factor (Open Loop),
Genset Bus kVAR (Closed Loop), Genset Bus Power
Factor (Closed Loop), Utility Bus kVAR (Closed Loop),
Utility Bus Power Factor (Closed Loop) (Default: Genset
Controllers)

Genset Bus kVAR Setpoint Source

If Extended Paralleling kVAR Load Control Type is


Genset Bus % Level (Open Loop), Genset Bus Power
Factor (Open Loop), Genset Bus kVAR (Closed Loop), or
Genset Bus Power Factor (Closed Loop), this specifies
how the desired kVAR load for the generator sets is
specified.
This has no effect for other values of Extended Paralleling
kVAR Load Control Type.
Possible values: Internal, Analog Input (Default: Internal)

Utility Bus kVAR Setpoint Source

If Extended Paralleling kVAR Load Control Type is Utility


Bus kVAR (Closed Loop) or Utility Bus Power Factor
(Closed Loop), this specifies how the desired kVAR load
for the utility is specified.
This has no effect for other values of Extended Paralleling
kVAR Load Control Type.
Possible values: Internal, Analog Input (Default: Internal)

Genset Bus %kVAR Setpoint

This has no effect if Genset Bus kVAR Setpoint Source is


Analog Input.
If Extended Paralleling kVAR Load Control Type is
Genset Bus % Level (Open Loop), this specifies the
percentage of rated load at which the generator sets
should run.
This has no effect for other values of Extended Paralleling
kVAR Load Control Type.
Possible values: -5~105% (Default: 0%)

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Setting

Description

Genset Bus kVAR Setpoint

This has no effect if Genset Bus kVAR Setpoint Source is


Analog Input.
If Extended Paralleling kVAR Load Control Type is
Genset Bus kVAR (Closed Loop), this specifies the
amount of reactive power the generator sets should
provide.
This has no effect for other values of Extended Paralleling
kVAR Load Control Type.
Possible values: 0-32767 kW (Default: 0 kW)

Genset Bus Power Factor Setpoint

This has no effect if Genset Bus kVAR Setpoint Source is


Analog Input.
If Extended Paralleling kVAR Load Control Type is
Genset Bus Power Factor (Open Loop) or Genset Bus
Power Factor (Closed Loop), this specifies the power
factor at which the generator sets should run.
This has no effect for other values of Extended Paralleling
kVAR Load Control Type.
Possible values: 0.7-1.0 (Default: 1.0)

Utility Bus kVAR Setpoint

This has no effect if Utility Bus kVAR Setpoint Source is


Analog Input.
If Extended Paralleling kVAR Load Control Type is Utility
Bus kVAR (Closed Loop), this specifies the amount of
reactive power the utility should provide.
This has no effect for other values of Extended Paralleling
kVAR Load Control Type.
Possible values: -32768~32767 kVAR (Default: 100
kVAR)

Utility Bus Power Factor Setpoint

This has no effect if Utility Bus kVAR Setpoint Source is


Analog Input.
If Extended Paralleling kVAR Load Control Type is Utility
Bus Power Factor (Closed Loop), this specifies the power
factor at which the utility should run.
This has no effect for other values of Extended Paralleling
kVAR Load Control Type.
Possible values: 0.7-1.0 (Default: 1.0)

kVAR Load Control Maximum %Output

If Extended Paralleling kVAR Load Control Type is


Genset Bus % Level (Open Loop), this specifies the
maximum output level for kVAR load control. If Extended
Paralleling kVAR Load Control Type is Genset Bus kVAR
(Closed Loop), Genset Bus Power Factor (Closed Loop),
Utility Bus kVAR (Closed Loop), or Utility Bus Power
Factor (Closed Loop), the maximum output level for kW
load control is limited to this value + 5%. For other values
of Extended Paralleling kVAR Load Control Type, this has
no effect.
Possible values: 0-60% (Default: 60%)

Extended Parallel Ramp Load Time

Specifies the amount of time load control ramps up the


generator sets to the desired load.
Possible values: 10-900 seconds (Default: 60 seconds)

kVAR Adaptive Gain Error Threshold

Specifies the error, calculated as a percentage of Total


System Capacity, above which adaptive proportional gain
starts increasing Kp.
Possible values: 0-110% (Default: 10%)

kVAR Adaptive Gain Slope

Specifies the rate at which Kp increases per 1% error


above kVAR Adaptive Gain Error Threshold.
Possible values: 0-50 / 1%-error (Default: 0.1 / 1%-error)

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Setting

Description

kVAR Ka, Ki, Kp, Ksat

Specifies the gains of the kVAR load control proportionalintegral (PI) loop. kVAR Kp Adaptive, not kVAR Kp, is
used in the PI loop.
Possible values: 12-17 (Default: 15)
Possible values: 0-255 (Default: 50)
Possible values: 0-1000 (Default: 120)
Possible values: 100-65000 (Default: 16384)

TABLE 96.

SUMMARY OF MONITOR POINTS (KVAR LOAD CONTROL)

Setting

Description

kVAR Load Target

If Extended Paralleling kVAR Load Control Type is


Genset Bus % Level (Open Loop), Genset Bus kVAR
(Closed Loop), Genset Bus Power Factor (Closed Loop),
Utility Bus kVAR (Closed Loop), or Utility Bus Power
Factor (Closed Loop), this indicates the amount of
reactive power the generator sets or the utility should
provide. The calculation is based on Extended Paralleling
kVAR Load Control Type and kVAR setpoint source.
Power factor is converted to kVAR based on a power
factor of 0.8 at rated load. For other values of Extended
Paralleling kVAR Load Control Type, this is zero.

kVAR Reference Control State

If Extended Paralleling kVAR Load Control Type is


Genset Bus % Level (Open Loop), Genset Bus kVAR
(Closed Loop), Genset Bus Power Factor (Closed Loop),
Utility Bus kVAR (Closed Loop), or Utility Bus Power
Factor (Closed Loop), this indicates the current state of
kVAR load control. If the previous PTC State was not
Utility Connected and for other values of Extended
Paralleling kVAR Load Control Type, this is Track Target.
Possible values: Off, Ramp Load, Track Target

kVAR Load Reference

If Extended Paralleling kVAR Load Control Type is


Genset Bus % Level (Open Loop), Genset Bus kVAR
(Closed Loop), Genset Bus Power Factor (Closed Loop),
Utility Bus kVAR (Closed Loop), or Utility Bus Power
Factor (Closed Loop), this indicates the amount of
reactive power the generator sets or the utility should
provide after adjusting for the ramp up of the generator
sets during Extended Parallel Ramp Load Time. For other
values of Extended Paralleling kVAR Load Control Type,
this is zero.

kVAR Kp Adaptive

If Extended Paralleling kVAR Load Control Type is


Genset Bus kVAR (Closed Loop), Genset Bus Power
Factor (Closed Loop), Utility Bus kVAR (Closed Loop), or
Utility Bus Power Factor (Closed Loop), this indicates the
value of Kp calculated by adaptive proportional gain. This
value is used in the PI loop. For other values of Extended
Paralleling kVAR Load Control Type, the PI loop is not
used, and this is Kp.

kVAR Load Control Output

Indicates the output of kVAR load control. The unit of


measure is a percentage for pulse-width modulation.

kVAR Master Load Control Command

Indicates how much load control is driving the kVAR


master load control output. The unit of measure is a
percentage for pulse-width modulation. If kVAR load
control is inactive, this is set by load ramp.

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Soft-closed Transition
A soft-closed transition is a make-before-break transfer of a load from one source to another.
When the second source is connected in parallel to the first, the load on the first source is
gradually reduced until it falls below a particular threshold, at which point the first source is
disconnected.
There will be no power interruption. Both sources have to be in parallel for this type of transfer.

10.3.1 Load Control During Soft-closed Transitions


During a soft-closed transition transfer from the utility to the generator sets, load control tells the
generator sets to ramp up their loads. During a soft-closed transition retransfer from the
generator sets to the utility, load control tells the generator sets to ramp down their loads.
The generator sets control the rate at which the loads are ramped.
If code 1121 (Fail to Disconnect) is active, load control tells the generator sets to ramp down
their loads.

10.4

Load Control at Other Times


When PTC State is not Paralleled, load control still sends signals to the generator sets. The
generator sets may not respond to these signals depending on the generator set control and its
configuration.
When PTC State is not Paralleled, load control tells the generator sets to ramp up their loads if
these conditions are met.
PTC State is Utility Connected.
PTC Operating Mode is not Extended Parallel.
Otherwise, load control tells the generator sets to ramp down their loads.

10.5

Load Control Output Enable by Hardware Version


If multiple MCM3320s are interconnected for load control, only one MCM3320 should drive the
load share lines at a time. The mechanism to make sure this happens depends on Hardware
Version.
If Hardware Version is 1 or 2, the output signals for load control are active when load control is
active. If multiple MCM3320s are interconnected for load control, map code 1534 (Load Control
Output Event) to a configurable output, and connect this output to a relay through which the
output signals are routed.
If Hardware Version is 3 or 4, the output signals are active if any of these conditions is met.
The master inhibit is inactive.
PTC State is Paralleled.
If neither of these conditions is met, load control is active, but the output signals for load control
are inactive.

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10.5.1 Code 1534 - Load Control Output Event


This is active if any of these conditions is met.
The master inhibit is inactive.
PTC State is Paralleled.

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11

Synchronizer
The synchronizer adjusts the generator set voltage, frequency, and phase to match the utility
voltage, frequency, and phase. This is required before the generator sets can run in parallel with
the utility.
The synchronizer is responsible for synchronization of the generator sets as a group before the
utility main breaker or the generator set main breaker can close. The synchronizer has no effect
on the synchronization done by each generator set control before its paralleling breaker can
close.
If the topology is Common Bus, each generator set synchronizes itself with the utility when
the system executes a closed-transition transfer at the beginning of a test with load. The
synchronizer is responsible for synchronization of the generator sets with the utility when
the system executes a closed-transition retransfer at the end of a test with load.
If the topology is Transfer Pair, each generator set synchronizes itself with the other
generator sets before it closes its paralleling breaker. The synchronizer is responsible for
synchronization of the generator sets as a group with the utility before the generator sets
run in parallel with the utility.
The synchronizer is inactive if the topology is Isolated Bus Without Generator Set Main Breaker
or Isolated Bus with Generator Set Main Breaker.

11.1

Synchronizer Status
Synchronizer Status indicates whether or not the synchronizer is running.
The synchronizer runs if all of these conditions are met.
The utility is available.
The generator sets are available.
Breaker control requires synchronization.

11.1.1 Fail to Synchronize Lockout Enable


If Fail to Sync Lockout Enable is Enable, the synchronizer is not allowed to run when code 1457
(Fail to Synchronize Warning) is active. If Fail to Sync Lockout Enable is Disable, the
synchronizer continues trying to synchronize the generator sets with the utility.

11.1.2 Master Inhibit


This switch may come from any of these sources:
Master Inhibit connection (TB3-8, TB3-17)
Modbus networks
InPower
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.

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There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

When this switch becomes active, the following features are disabled.
Breaker control when PTC State is No Source Connected, Genset Connected, or Utility
Connected.
Synchronizer
Load control in extended parallel

11.2

Frequency Matching
The synchronizer uses a single PI (proportional-integral) loop to calculate Master Frequency
Bias Command, which drives the generator sets on the kW load share lines.
The initial value of Master Frequency Bias Command is the current value on the kW load share
lines. This makes sure that there is a minimal transient when the synchronizer starts. The
synchronizer raises Master Frequency Bias Command linearly from the initial value to the output
of the PI loop during Frequency Match Ramp Rate.
The target frequency is limited to a range of Frequency Match Lower Range Limit to Frequency
Match Upper Range Limit, relative to System Frequency.
Set Synchronize Method to select the method for frequency matching.

11.2.1 Phase Match


Phase match tries to drive the phase difference between the generator sets and the utility to
zero.
In some applications, a phase shift between the generator sets and the utility exists at the
MCM3320, for example, if there is a delta/wye transformer. In these applications, Sync Phase
Offset should be set to account for this phase shift.

11.2.2 Slip Frequency


Slip frequency tries to drive a fixed frequency difference (Slip Frequency) between the generator
sets and the utility. This method is often selected in one of these situations.
It is important that power flows in the desired direction when the generator sets are first
connected in parallel.
The generator sets cannot be controlled well enough to make the generator set phase
match the utility phase, for example, with gas fuel systems.

11.2.3 Proportional-integral (PI) Loop


A proportional-integral (PI) loop is one way to drive a measured value to a desired value.
A PI loop uses the difference between the measured value and the desired value to calculate
how much to drive the measured value. This calculation is based on several settings.
KP (proportional): This setting considers the current difference between the measured
value and the desired value. The greater the difference, the harder this setting drives the
measured value. KP is also the overall gain.

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If this value is too low, it can take a long time for the measured value to reach the desired
value. If this value is too high, the PI loop drives the measured value too hard, and the
measured value becomes unstable.
KI (integral): This setting looks at the historical differences betwen the measured value and
the desired value. It considers both the magnitude of the differences and the duration of
the difference. The longer the difference is consistently higher or consistently lower than
the desired value, the harder this setting drives the measured value. Conversely, if the
measured value is oscillating around the desired value, this setting has less impact.
If this value is too low, it can take a long time for the measured value to reach the desired
value, or the measured value may stabilize at an offset from the desired value. If this value
is too high, the measured value can become unstable.
KA: This setting controls the impact of KI when it is added to KP. The higher this setting, the
greater the impact of KI and the greater the impact of KI relative to KP.
KSAT: This setting limits the impact of KI when the desired value is being ramped up. During
ramp-up, the PI loop drives the measured value at a slower rate in order to minimize the
disturbance on the system. The higher this setting, the less impact KI has during ramp-up.
NOTE:

11.3

PI loops are usually tuned appropriately for the system in which they are
used. If the system is not responding appropriately, however, make small
adjustments one setting at a time, and observe the impact on the system
after each change. Large changes or changes to several settings usually
cause a response that is undesirable, unpredictable, and unstable.

Voltage Match
Voltage match tries to drive the voltage difference between the generator sets and the utility to
zero.
The synchronizer uses a single PI (proportional-integral) loop to calculate Master Voltage Bias
Command, which drives the generator sets on the kVAR load share lines.
The initial value of Master Voltage Bias Command is the current value on the kW load share
lines. This makes sure that there is a minimal transient when the synchronizer starts. The
synchronizer raises Master Voltage Bias Command linearly from the initial value to the output of
the PI loop during Voltage Match Ramp Rate.
The target voltage is limited to a range of Voltage Match Lower Range Limit to Voltage Match
Upper Range Limit, relative to 100% of nominal voltage.

11.3.1 Voltage Match Test Offset


Voltage Match Test Offset allows field testing of the voltage match. When this value is set, it is
added to the measured utility voltage before the error is calculated. For example, if Voltage
Match Test Offset is +5% and the utility is running at 98% of nominal voltage, the synchronizer
tries to drive the generator sets to 103% of nominal voltage. The result is still limited by Voltage
Match Lower Range Limit and Voltage Match Upper Range Limit.
This setting is temporary; it lasts for 30 seconds. After that, the setting returns to 0%.
This setting may come from any of these sources:
PCCNet networks
InPower
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11.3.2 kVAR Load Share Protection and Voltage Match Fail


In some cases, the synchronizer is unable to match the generator set voltage to the utility
voltage. For example, the generator sets are overloaded, and the utility voltage is higher than
nominal voltage. The V/Hz curves inside the generator set controllers are reducing voltage in
response to the overload at the same time the synchronizer is trying to increase voltage to
match the utility voltage. As a result, the output on the kVAR load share lines saturates,
effectively disabling kVAR load sharing. When kVAR load sharing is disabled, one or more
generator sets likely start importing kVAR, ultimately resulting in all of the generator sets
shutting down.
To avoid this scenario, the synchronizer monitors the difference between the generator set
voltage and the utility voltage. If the difference remains above 0.5% for at least 6 seconds, the
synchronizer disables voltage matching. Voltage matching remains disabled until the sources
synchronize anyway or until the synchronizer turns off.
Voltage Match Fail tracks the status of this protection. If it is true, voltage matching is disabled
until the next time the synchronizer turns on.

11.3.3 Proportional-integral (PI) Loop


A proportional-integral (PI) loop is one way to drive a measured value to a desired value.
A PI loop uses the difference between the measured value and the desired value to calculate
how much to drive the measured value. This calculation is based on several settings.
KP (proportional): This setting considers the current difference between the measured
value and the desired value. The greater the difference, the harder this setting drives the
measured value. KP is also the overall gain.
If this value is too low, it can take a long time for the measured value to reach the desired
value. If this value is too high, the PI loop drives the measured value too hard, and the
measured value becomes unstable.
KI (integral): This setting looks at the historical differences betwen the measured value and
the desired value. It considers both the magnitude of the differences and the duration of
the difference. The longer the difference is consistently higher or consistently lower than
the desired value, the harder this setting drives the measured value. Conversely, if the
measured value is oscillating around the desired value, this setting has less impact.
If this value is too low, it can take a long time for the measured value to reach the desired
value, or the measured value may stabilize at an offset from the desired value. If this value
is too high, the measured value can become unstable.
KA: This setting controls the impact of KI when it is added to KP. The higher this setting, the
greater the impact of KI and the greater the impact of KI relative to KP.
KSAT: This setting limits the impact of KI when the desired value is being ramped up. During
ramp-up, the PI loop drives the measured value at a slower rate in order to minimize the
disturbance on the system. The higher this setting, the less impact KI has during ramp-up.
NOTE:

132

PI loops are usually tuned appropriately for the system in which they are
used. If the system is not responding appropriately, however, make small
adjustments one setting at a time, and observe the impact on the system
after each change. Large changes or changes to several settings usually
cause a response that is undesirable, unpredictable, and unstable.

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11. Synchronizer

Synchronizer Check Close Allowed


Sync Check Close Allowed indicates whether or not the system is ready to connect one of the
sources to the loads.

11.4.1 Permissive Close Allowed


Permissive Close Allowed indicates whether or not the two sources are synchronized with each
other.
Permissive Close Allowed becomes Allowed when all of these conditions are met.
The voltage, frequency, and phase are synchronized for Permissive Window Time.
The difference between the generator set voltage and the utility voltage is less than
Permissive Voltage Window. (If the difference is negative, remove the negative sign
before comparing it.)
The difference between the generator set frequency and the utility frequency is less
than Permissive Frequency Window. (If the difference is negative, remove the
negative sign before comparing it.)
The phase difference between the generator sets and the utility is less than
Permissive Phase Window. (If the difference is negative, remove the negative sign
before comparing it.)
At the end of Permissive Window Time, the phase difference between the generator sets
and the utility is less than 10 degrees, or it is decreasing.(If the difference is negative,
remove the negative sign before comparing it.)
Permissive Close Allowed remains Allowed as long as one of these conditions is met.
The voltage, frequency, and phase remain synchronized.
The difference between generator set voltage and utility voltage is less than or equal to
5%, and the phase difference between the generator sets and the utility is less than or
equal to 20 degrees. (If either difference is negative, remove the negative sign before
comparing it.)
One of the breakers has been commanded to close, and the associated fail to close fault is
not active.
Otherwise, Permissive Close Allowed becomes Not Allowed.

11.5

Summary of Settings (Synchronizer)


TABLE 97.

SUMMARY OF SETTINGS (SYNCHRONIZER)

Setting

Description

Synchronize Method

Specifies the frequency matching method.


Possible values: Phase Match, Slip Frequency (Default:
Phase Match)

Slip Frequency

Specifies the fixed frequency difference the synchronizer


tries to drive between the generator sets and the utility
when Synchronize Method is Slip Frequency.
Possible values: -3~3 Hz (Default: 0.1 Hz)

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Setting

Description

Sync Phase Offset

Specifies the fixed phase difference the synchronizer tries


to drive between the generator sets and the utility when
Synchronize Method is Phase Match.
Possible values: -50~50 degrees (Default: 0 degrees)

Frequency Match Ka, Ki, Kp, Ksat

Specifies the gains of the frequency-matching


proportional-integral (PI) loop.
Possible values (Ka): 12-17 (Default: 15)
Possible values (Ki): 0-255 (Default: 20)
Possible values (Kp): 1-300 (Default: 30)
Possible values (Ksat): 1000-65000 (Default: 16384)

Frequency Match Ramp Rate

Specifies the amount of time the synchronizer ramps up


Master Frequency Bias Command when the synchronizer
turns on.
Possible values: 0-60 seconds (Default: 1 second)

Voltage Match Ka, Ki, Kp, Ksat

Specifies the gains of the voltage-matching proportionalintegral (PI) loop.


Possible values (Ka): 12-17 (Default: 15)
Possible values (Ki): 0-255 (Default: 50)
Possible values (Kp): 10-800 (Default: 400)
Possible values (Ksat): 1000-65000 (Default: 16384)

Voltage Match Ramp Rate

Specifies the amount of time the synchronizer ramps up


Master Voltage Bias Command when the synchronizer
turns on.
Possible values: 0-60 seconds (Default: 1 second)

Voltage Match Test Offset

Specifies a temporary adjustment to the voltage match


error. This resets to 0% after 30 seconds.
Possible values: -10~10% (Default: 0%)

Permissive Frequency Window

Specifies the maximum difference in frequency allowed


for synchronization.
Possible values: 0.001-1 Hz (Default: 1 Hz)

Permissive Phase Window

Specifies the maximum difference in phase allowed for


synchronization.
Possible values: 0.1-20 degrees (Default: 10 degrees)

Permissive Voltage Window

Specifies the maximum difference in voltage allowed for


synchronization.
Possible values: 0.5-10% (Default: 5%)

Permissive Window Time

Specifies how long the frequency, phase, and voltage


must remain within the limits allowed for synchronization
before the synchronizer allows the generator sets to run
in parallel with the utility.
Possible values: 0.5-5 seconds (Default: 0.5 seconds)

Network Master Inhibit

Sets the master inhibit


Possible values: No Inhibit, Inhibit

Fail to Sync Lockout Enable

Enables or disables the stopping of the synchronizer


when code 1457 (Fail to Synchronize Warning) is active.
Possible values: Disable, Enable (Default: Disable)

Fail To Synchronize Time

Specifies how long the synchronizer tries to synchronize


the generator sets with the utility before code 1457 (Fail
to Synchronize Warning) becomes active. This is also the
time delay for code 1456 (Synchronizer Output Limit) and
code 1458 (Synchronizer Phase Rotation Mismatch).
Possible values: 10-900 seconds (Default: 120 seconds)

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TABLE 98.

SUMMARY OF MONITOR POINTS (SYNCHRONIZER)

Setting

Description

Synchronizer Status

Indicates whether or not the synchronizer is running.

Single Phase Synchronizer status

Indicates whether or not the single-phase synchronizer is


running.

Dead Bus Close Allowed

Indicates whether or not the conditions for closing to a


dead bus are met.

Frequency Matched

Indicates whether or not the difference in frequency


between the generator sets and the utility is less than
Permissive Frequency Window. This reflects the current
status; it does not consider Permissive Window Time.

Phase Matched

Indicates whether or not the difference in phase between


the generator sets and the utility is less than Permissive
Phase Window. This reflects the current status; it does
not consider Permissive Window Time.

Voltage Matched

Indicates whether or not the difference in voltage between


the generator sets and the utility is less than Permissive
Voltage Window. This reflects the current status; it does
not consider Permissive Window Time.

Time In Window

Indicates how long the frequency, phase, and voltage


have been within the limits allowed by the synchronizer.

Permissive Close Allowed

Indicates whether or not the conditions for closing to a


dead bus are met.

Sync Check Close Allowed

Indicates whether or not the synchronizer allows an


available source to connect to the loads.

Master Frequency Bias Command

Indicates how much the synchronizer is driving the kW


load share lines. The unit of measure is a percentage for
pulse-width modulation.

Master Voltage Bias Command

Indicates how much the synchronizer is driving the kVAR


load share lines. The unit of measure is a percentage for
pulse-width modulation..

Master Inhibit

Indicates the state of the master inhibit.

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Load Add/Shed

12.1

Load Add/Shed Enable


This feature is active if all of these conditions are met.
Load Add Shed Enable is Enabled.
The topology is Isolated Bus Without Generator Set Main Breaker, Isolated Bus with
Generator Set Main Breaker, Common Bus, or Transfer Pair.
The MCM can communicate with at least one SID module.

12.2

Loads by SID
NOTE:

SIDs are connected to loads, not load-add levels or load-shed levels.


TABLE 99.

LOADS BY SID

SID

Loads

SID0

1-6

SID1

7-10

SID2

11-14

SID3

15-18

12.2.1 Unavailable SID and Load Add/Shed


Load add/shed remains active as long as there is contact with at least one SID. If a SID or its
AUX 102 becomes unavailable, load add/shed operates the same way, but the loads that are
connected to the unavailable SID or AUX 102 may not actually be added or removed when
commanded.

12.3

Load-add Levels
Each load is assigned to a specific load-add level. Two or more loads can be assigned to the
same load-add level. It is possible for a load-add level to have no loads assigned to it.

12.4

Load-shed Levels
Each load is assigned to a specific load-shed level. Two or more loads can be assigned to the
same load-shed level. It is possible for a load-shed level to have no loads assigned to it.

12.5

Load Add and the Generator Set Main Breaker


The generator set main breaker closes when the capacity of the available generator sets is at
least Generator Set Online Capacity Sensor Threshold.

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Load add controls which loads are connected to the load bus. Load add does not control the
generator set main breaker, and the position of the generator set main breaker has no effect on
load add.
NOTE:

It is possible for the generator set main breaker to be open as loads are
connected to the load bus. If this happens, the loads will not get any power
from the generator sets until the generator set main breaker is closed.

This is expected behavior. If you plan to add loads manually, wait until the generator set main
breaker is closed before you start adding loads.

12.6

Load Add Shed Operating State


This setting indicates the current state of load add/shed.
TABLE 100.

LOAD ADD SHED OPERATING STATE

State
Off

none

Gen Source Auto Load Add

automatic load add

Gen Source Auto Load Shed

automatic load shed

Manual Load Add Restore


Utility Source Auto Load Add

12.7

Activity

manual load add/shed


utility load add

Automatic Load Add


This is the ability to add loads gradually as generator sets become available. As a result, some
loads can get power before all of the generator sets are available. In addition, if a generator set
does not become available, some loads still get power.
1. When the first generator set closes its paralleling breaker, the loads assigned to load-add
level 1 are connected.
2. When the second generator set closes its paralleling breaker, the loads assigned to loadadd level 2 are connected.
3. When the third generator set closes its paralleling breaker, the loads assigned to load-add
level 3 are connected.
This continues until all of the generator sets close their paralleling breakers.
If there are more load-add levels than generator sets, the loads assigned to the remaining loadadd levels are added one load-add level at a time on a timed basis.
If one or more generator sets do not become available, the loads assigned to the remaining
load-add levels are not added.
If automatic load add is interrupted, for example, because the generator sets become
overloaded, the remaining loads have to be added manually.

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12.7.1 Required Online Capacity


This is the amount of generator set capacity at which the loads assigned to the remaining loadadd levels are added one load-add level at a time on a timed basis whether or not the remaining
generator sets close their paralleling breakers.
For example, there are four generator sets. Each generator set can provide 1000 kW. Required
online capacity is 2000 kW, and the load-add delay is 5 seconds.
1. When the first generator set closes its paralleling breaker, the loads assigned to load-add
level 1 are connected.
2. When the second generator set closes its paralleling breaker, the loads assigned to loadadd level 2 are connected. In addition, the load-add delay timer starts.
3. Five seconds later, the third generator set has not closed its paralleling breaker, but the
loads assigned to load-add level 3 are connected immediately. The load-add delay timer
resets.
4. Five seconds later, the fourth generator set has not closed its paralleling breaker, but the
loads assigned to load-add level 4 are connected immediately.
If there are more load-add levels than generator sets, the loads assigned to the remaining loadadd levels are added one load-add level at a time every 5 seconds. At this point, it does not
matter if the remaining generator sets close their paralleling breakers.
If a generator set closes its paralleling breaker before the load-add delay timer expires, the
loads assigned to the corresponding load-add level are connected immediately, ignoring the
timer. The timer continues, however. When the timer expires, the loads assigned to the next
load-add level are connected. In the example above, suppose the third generator set closes its
paralleling breaker two seconds after the second generator set closes its paralleling breaker.
1. When the first generator set closes its paralleling breaker, the loads assigned to load-add
level 1 are connected.
2. When the second generator set closes its paralleling breaker, the loads assigned to loadadd level 2 are connected. In addition, the load-add delay timer starts.
3. Two seconds later, the third generator set closes its paralleling breaker. The loads
assigned to load-add level 3 are connected immediately. The load-add delay timer
continues.
4. Three seconds later, the fourth generator set has not closed its paralleling breaker, but the
loads assigned to load-add level 4 are connected immediately.

12.7.2 Conditions for Automatic Load Add


Automatic load add starts when all of the following conditions are met.
Load add/shed control (Auto/Manual Load Add Restore Mode) is Auto.
The utility is disconnected.
The first generator set is connected to the loads.*
* - Automatic load add starts when the generator set actually connects to the loads. The
transition from disconnected to connected is the condition for starting automatic load add.
Automatic load add ends when one of the following conditions is met.
All of the loads have been added.

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If one or more loads has not been added, for example, because a generator set did not
come online, automatic load add remains active.
Load add/shed control (Auto/Manual Load Add Restore Mode) is Manual.
The generator sets become overloaded.
The generator sets are no longer available.

12.7.3 Automatic Load Add and Legacy SID Override


NOTE:

Legacy SID Override should be used only in existing installations where the
generator set paralleling breakers are connected in parallel. It should not be
used in new systems.

If Legacy SID Override is Enable, automatic load add works based on the pins, not the
paralleling breakers. If there are two paralleling breakers connected to the same set of pins, the
MCM waits for either of them to close before it adds the loads assigned to the next load addlevel. When the second paralleling breaker closes or if it never closes, it has no effect on
automatic load add.
Since there are four sets of pins, the MCM can add the loads assigned to four load-add levels
this way. Then, the loads assigned to the remaining load-add levels are added one load-add
level at a time on a timed basis.

12.8

Automatic Load Shed


This is the ability to remove lower-priority loads if the generator sets are overloaded. Higherpriority loads still get power. Without it, the system shuts down if the generator sets are
overloaded.
1. If the generator sets are overloaded, the loads assigned to load-shed level 1 are removed.
2. If the generator sets are still overloaded, the loads assigned to load-shed level 2 are
removed.
3. If the generator sets are still overloaded, the loads assigned to load-shed level 3 are
removed.
This continues until all of the loads are removed. If the generator sets are still overloaded, the
system shuts down.
NOTE:

Load-shed level 0 cannot be removed.

Any loads that are removed have to be added manually while the generator sets are running.

12.8.1 Conditions for Automatic Load Shed


Automatic load shed starts when the generator sets become overloaded.
Automatic load shed ends when one of the following conditions is met.
All of the loads have been removed.
The generator sets are no longer overloaded.

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12.8.2 Automatic Load Shed During Open-transition Transfers


If load add/shed is active, all of the loads are removed during an open-transition transfer from
the utility to the generator sets if PTC Operating Mode is Test or Utility Fail.

12.8.3 Open Transition Retransfer Load Shed


This protects loads that cannot handle open transitions or the change in phase that occurs
afterwards.
If Open Transition Retransfer Load Shed Enable is Enabled, all of the loads are removed during
an open-transition retransfer from the generator sets to the utility. The loads are added by loadadd level on a timed basis once the utility is connected.
If Open Transition Retransfer Load Shed Enable is Disabled, the loads remain connected during
the open transition.
This setting has no effect if load add/shed is not active.

12.9

Conditions for Manual Load Add/Shed


Manual load add/shed starts when all of the following conditions are met.
Load add/shed control (Auto/Manual Load Add Restore Mode) is Manual.
PTC State is Genset Connected.
Manual load add/shed ends when one of the following conditions is met.
Load add/shed control (Auto/Manual Load Add Restore Mode) is Auto.
The generator sets become overloaded.
The generator sets are no longer available.
The topology is Common Bus or Transfer Pair, and PTC Operating Mode is Normal.

12.10 Utility Load Add


This is the ability to add loads gradually if some loads are not connected when the loads are
connected to the utility. For example, this might happen if the generator sets overloaded or if
some loads were not added because one or more generator sets did not come online.
NOTE:

This works with breakers. It does not work with automatic transfer switches
(ATS) because ATS handle the retransfer by themselves.

The loads assigned to each remaining load-add level are added one load-add level at a time on
a timed basis. Regardless of which loads might already be connected, this feature starts with
load-add level 1.

12.10.1 Conditions for Utility Load Add


Utility load add starts when all of the following conditions are met.
One or more load-add levels have not been added yet.
The topology is Common Bus or Transfer Pair.
The utility is connected to the loads.*

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* - Utility load add starts when the utility connects to the loads. The transition from disconnected
to connected is the condition for starting utility load add.
Utility load add ends when one of the following conditions is met.
All of the loads have been added.
The utility is no longer connected to the loads.
The utility is no longer available.

12.11 Maximum Number of Loads by Firmware Version


The maximum number of loads is also the maximum number of load-add levels and load-shed
levels.
TABLE 101.

MAXIMUM NUMBER OF LOADS BY FIRMWARE VERSION

Firmware Version

Maximum Number of Loads

before V2.01

2.01 or later

18

12.12 Output Signals for Feeder Breakers


This table describes the output signals sent to feeder breakers for load add/shed.
TABLE 102.
Signal

OUTPUT SIGNALS FOR FEEDER BREAKERS


Description

Add load

Wait for 0.25 seconds, active for 2 seconds

Shed load

Active as long as the load is supposed to be removed

Restore load

Active for 1 second

12.13 Output Signals for Automatic Transfer Switches


(ATS)
This table describes the output signals sent to ATSs for load add/shed.
TABLE 103.

OUTPUT SIGNALS FOR AUTOMATIC TRANSFER SWITCHES (ATS)


Signal

Add load

Active as long as the load is supposed to be connected

Shed load

Active as long as the load is supposed to be removed and


the generator sets are connected to the loads

Restore load

142

Description

Active for 1 second

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12.14 Summary of Settings (Load Add/Share)


TABLE 104.

SUMMARY OF SETTINGS (LOAD ADD/SHARE)

Setting

Description

Load Add Shed Enable

Enables or disables load add/shed.


Default: Disabled

Open Transition Retransfer Load Shed Enable

Enables or disables the shedding of all loads during an


open-transition retransfer.
Default: Disabled

Load N Device Type

Indicates the type of load.


Possible values: None, Breaker, ATS

Load N Add Level

Indicates to which load-add level load N is assigned.


Possible values: 1-18

Load N Shed Level

Indicates to which load-shed level load N is assigned.


Possible values: 0-17

Genset Bus Load Add Delay

Indicates how frequently to add load-add levels when


Load Add Shed Required Online Capacity is online or
when all of the generator sets are online.
Possible values: 0-60 seconds (Default: 1 second)

Load Add Shed Required Online Capacity

Indicates how much generator set capacity must be


online before loads should be added on a timed basis.
Set this to 0 to disable this.
Default value: 0 kW

Utility Bus Load Add Delay

Indicates how frequently to add load-add levels when the


loads are retransferred to the utility.
Possible values: 0-60 seconds (Default: 1 second)

Load Shed Delay

Indicates how frequently to remove load-shed levels when


the generator sets are overloaded.
Possible values: 1-10 seconds (Default: 1 second)

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Load Demand
Load demand is the ability to shut down and restart generator sets automatically to let the
remaining generator sets operate closer to their rated capacity. This decreases fuel
consumption and reduces wear on the generator sets.
NOTE:

13.1

Two or more generator sets must be available for this feature to work.

Load Demand Enable


This feature is active if all of these conditions are met.
Load Demand Enable is Enabled.
Load Demand Type is Fixed Sequence or Run Hours.
The topology is Isolated Bus Without Generator Set Main Breaker, Isolated Bus with
Generator Set Main Breaker, Common Bus, or Transfer Pair.
The generator sets are available and connected to the loads.
The MCM can communicate with all of the required SID modules.
Code 1444 (Genset Bus Overload) is inactive.
Code 1335 (AC Metering Out of Range) is inactive.
If load demand becomes inactive, it restarts any generator sets that have been shut down due
to load demand.

13.2

Generator Sets by SID


TABLE 105.

GENERATOR SETS BY SID

SID

Generator Sets

none

1-4

SID1

5-8

SID2

9-12

SID3

13-16

13.2.1 Unavailable SID and Load Demand


If a SID or AUX 102 becomes unavailable, load demand becomes inactive.

13.3

Generator Set Support for Load Demand in


Extended Parallel
The PCC 3100, PCC 3200, and PCC 3201 do not support load demand while the generator set
is running in extended parallel. These controls support load demand in other situations.
The PowerCommand 3.3 supports load demand in every situation.

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Initial Time Delay


This is the amount of time between the time the first generator set closes its paralleling breaker
and the time load demand becomes active.
This value should allow time for the remaining generator sets to start, ramp up to rated speed
and voltage, and close their paralleling breakers. It should also allow time for the loads to be
connected and to stabilize, if necessary.

13.5

When a Generator Set Is Shut Down

13.5.1 Shutdown Percentage


This value is a percentage of kW capacity of the available generator sets if a generator set is
shut down. If the load is under this percentage, that generator set will be shut down.
For example, there are four generator sets A, B, C, and D. Each generator set can provide 1000
kW.
Initially, all of the generator sets are available. The kW capacity of the available generator
sets is 4000 kW.
If a generator set is shut down, the kW capacity of the available generator sets would be
3000 kW.
The shutdown percentage applies to 3000 kW, not 4000 kW. If the shutdown percentage is
60%, the generator set shuts down if the load becomes less than 1800 kW (60% * 3000 kW).

13.5.2 Shutdown Threshold


This value is the amount of extra kW capacity the available generator sets should have if a
generator set is shut down.
For example, there are four generator sets A, B, C, and D. Each generator set can provide 1000
kW.
Initially, all of the generator sets are available. The kW capacity of the available generator
sets is 4000 kW.
If a generator set is shut down, the kW capacity of the available generator sets would be
3000 kW.
If the shutdown threshold is 1100 kW, the generator set is shut down if the load becomes less
than 1900 kW (3000 kW - 1100 kW).

13.5.3 Shutdown Percentage or Shutdown Threshold


Shutdown threshold tends to run the generator sets more efficiently when there is a larger
number of generator sets.
For example, there are eight generator sets. Each generator set can provide 1000 kW.
Compare the loads at which each generator set shuts down using shutdown percentage (60%)
and using shutdown threshold (1200 kW).

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TABLE 106.

EXAMPLE: SHUTDOWN PERCENTAGE VS. SHUTDOWN THRESHOLD

#Generator Sets Online

60%

1200 kW

4200 kW

5800 kW

3600 kW

4800 kW

3000 kW

3800 kW

2400 kW

2800 kW

1800 kW

1800 kW

1200 kW

800 kW

600 kW

--

Using shutdown percentage, the first generator set does not shut down until the load is less
than 4200 kW, which leaves up to 3800 kW of extra capacity. This is a lot of extra capacity
unless the load is really volatile. In contrast, using shutdown threshold, the first generator set
shuts down when the load is less than 5800 kW.
If there are fewer generator sets in the system, however, shutdown percentage runs the
generator sets more efficiently. Consider the loads at which a generator set shuts down when
there are three generator sets online. Using shutdown percentage, a generator set shuts down
when the load is less than 1200 kW; using shutdown threshold, 800 kW. Furthermore, if there
are two generator sets online, another generator set does not shut down using shutdown
threshold in this example.

13.5.4 Shutdown Delay


This is the amount of time the load must remain low enough before a generator set is shut
down.
One generator set is shut down at a time. If the load is very low, this delay is the amount of time
before it shuts down each generator set.

13.5.5 Minimum Online Capacity


This is the amount of capacity that must be available, regardless of the load. A generator set will
not shut down if the capacity would be less than this value.
NOTE:

13.6

This is a different setting than Required Online Capacity. Required Online


Capacity is related to load add/shed. Minimum Online Capacity prevents a
generator set from shutting down if load demand is active.

When a Generator Set Is Restarted

13.6.1 Restart Percentage


This value is a percentage of kW capacity of the available generator sets. If the load is over this
percentage, a generator set is restarted.
For example, there are four generator sets A, B, C, and D. Each generator set can provide 1000
kW. The restart percentage is 90%. Generator sets C and D have shut down due to load
demand. Generator sets A and B are available. The kW capacity of the available generator sets
is 2000 kW. If the load is over 1800 kW, a generator set is restarted.

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13.6.2 Relationship Between Shutdown Percentage and Restart


Percentage
If the restart percentage is too close to the shutdown percentage, a generator set might shut
down, restart, and repeat this cycle forever.
For example, there are four generator sets. Each generator set can provide 1000 kW.
Load demand is enabled.
The shutdown percentage is 75%.
The restart percentage is 80%.
The load varies between 2200 kW and 2420 kW.
1. All of the generator sets are available. The kW capacity of the available generator sets if a
generator shuts down is 3000 kW. A generator set shuts down when the load falls below
2250 kW (75% * 3000 kW).
2. A generator set has shut down. Three generator sets are available. The kW capacity of the
available generator sets is 3000 kW. The generator set restarts when the load rises above
2400 kW (80% * 3000 kW).
The process repeats as long as the load keeps varying.
There is no rule that can prevent this situation from occurring in every application. The likelihood
that this situation occurs depends on several factors: the number of generator sets in the
system, the kW capacity of each generator set, the load demand sequence, the expected loads,
the variability in the loads, and the difference between the restart percentage and the shutdown
percentage.
NOTE:

To reduce the likelihood of turning a generator set on and off repeatedly, set
the restart percentage at least 20% higher than the shutdown percentage. For
example, if shutdown percentage is 70%, the restart percentage should be at
least 90%.

If this situation does occur in your application, consider these changes.


Increase the difference between the restart percentage and the shutdown percentage.
If the generator sets have different kW capacities, change the load demand sequence.
If the load changes frequently, increase the Shutdown Delay.

13.6.3 Restart Threshold


This value is the minimum amount of extra kW capacity the available generator sets should
have at all times. If the load reduces the extra kW capacity below this value, a generator set
restarts.
For example, there are four generator sets A, B, C, and D. Each generator set can provide 1000
kW. The restart threshold is 400 kW. Generator sets C and D have shut down due to load
demand. Generator sets A and B are available. The kW capacity of the available generator sets
is 2000 kW. If the load is over 1600 kW, a generator set restarts.

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13.6.4 Relationship Between Shutdown Threshold and Restart


Threshold
If the restart threshold is too close to the shutdown percentage, a generator set might shut
down, restart, and repeat this cycle forever.
For example, there are eight generator sets. Each generator set can provide 1000 kW.
Load demand is enabled.
The shutdown threshold is 600 kW.
The restart threshold is 400 kW.
The load varies between 6200 kW and 6820 kW.
1. All of the generator sets are available. The kW capacity of the available generator sets if a
generator is shut down is 7000 kW. A generator set shuts down when the load falls below
6400 kW (7000 kW - 600 kW).
2. A generator set has shut down. Seven generator sets are available. The kW capacity of the
available generator sets is 7000 kW. The generator set restarts when the load rises above
6600 kW (7000 kW - 400 kW).
The process repeats as long as the load keeps varying.
There is no rule that can prevent this situation from occurring in every application. The likelihood
that this situation occurs depends on several factors: the number of generator sets in the
system, the kW capacity of each generator set, the load demand sequence, the expected loads,
the variability in the loads, and the difference between the restart threshold and the shutdown
threshold.
NOTE:

To reduce the likelihood of turning a generator set on and off repeatedly, set
the shutdown threshold at least 50% of the rated capacity of a generator set
higher than the restart threshold. For example, if the restart threshold is 400
kW and each generator set can provide 1000 kW, the shutdown threshold
should be at least 900 kW.

If this situation does occur in your application, consider these changes.


Increase the difference between the restart threshold and the shutdown threshold.
If the generator sets have different kW capacities, change the load demand sequence.
If the load changes frequently, increase the Shutdown Delay.

13.6.5 Restart Delay


This is the amount of time the load must remain high enough before a generator set restarts.
This can be used when there are loads that have a high inrush startup at startup, for example,
chillers and pump motors. This delay helps prevent a generator set from restarting
unnecessarily.
NOTE:

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a delay before a generator set restarts.

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13.7

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Which Generator Set Shuts Down or Restarts

13.7.1 Fixed Sequence Method


With the fixed sequence method, the generator sets shut down in a specific order.
For example, there are four generator sets A, B, C, and D. A is the lead generator set, and you
set the order to (A, B, C, D). If a generator set shuts down, generator set D shuts down first. If
another generator set shuts down, generator C shuts down next.
NOTE:

The lead generator set will not shut down.

The generator sets restart in the reverse order in which they are shut down.
In the previous example, generator sets C and D have shut down. If a generator set restarts, it
will be generator set C.

13.7.2 Example: Fixed Sequence Method


There are four generator sets A, B, C, and D. The generator sets have the following rated
capacities.
TABLE 107.

EXAMPLE: RATED CAPACITIES OF EACH GENERATOR SET

Generator Set

Rated Capacity

600 kW

1000 kW

1200 kW

1500 kW

The kW capacity of the available generator sets is 4300 kW (600 kW + 1000 kW + 1200 kW +
1500 kW).
Load demand is using the fixed sequence method. A is the lead generator set, and the order is
(A, B, C, D).
The shutdown percentage is 60%.
1. All of the generator sets are available. Generator set D is the first generator set that would
shut down. The kW capacity of the available generator sets if generator set D shuts down
is 2800 kW (600 kW + 1000 kW + 1200 kW). If the load is under 1680 kW (2800 kW *
60%), generator set D shuts down.
2. Generator sets A, B, and C are available. Generator set C is the next generator set that
would shut down. The kW capacity of the available generator sets if generator set C shuts
down is 1600 kW (600 kW + 1000 kW). If the load is under 960 kW (1600 kW * 60%),
generator set C shuts down.
3. Generator sets A and B are available. Generator set B is the next generator set that would
shut down. The kW capacity of the available generator sets if generator set B shuts down
is 600 kW. If the load is under 360 kW (600 kW * 60%), generator set B shuts down.
Generator set A will not shut down because generator set A is the lead generator set.

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13.7.3 Setting a Fixed Sequence in InPower


The fixed sequence is stored in Load Demand GenA, Load Demand GenB, Load Demand
GenC, and so on, where Load Demand GenA is the lead generator set.
Each position in the sequence must have a unique value. If you change the generator set that is
assigned to a specific position in the sequence, the MCM automatically moves the original
generator set in that position to the original position of the new generator set. For example, the
fixed sequence is (Gen1, Gen2, Gen4, Gen3).
TABLE 108.

EXAMPLE: INITIAL FIXED SEQUENCE

Setting

Generator Set

Load Demand GenA

Gen1

Load Demand GenB

Gen2

Load Demand GenC

Gen4

Load Demand GenD

Gen3

Then, Load Demand GenA is set to Gen3.


TABLE 109.

EXAMPLE: FIXED SEQUENCE AFTER GEN4 IS ASSIGNED TO LOAD DEMAND GENA


Setting

Generator Set

Load Demand GenA

Gen3

Load Demand GenB

Gen2

Load Demand GenC

Gen4

Load Demand GenD

Gen1

Gen1 is automatically assigned to Load Demand GenD.

13.7.4 Run Hours Method


With this method, load demand balances the run hours of the generator sets.
The initial sequence is based on the current run hours of the generator sets. The generator set
with the fewest run hours is the lead generator set. The lead generator set will not shut down.
The generator set with the most run hours is the first generator set that shuts down.
As the generator sets run, the sequence changes to balance the run hours of the generator
sets. You specify a threshold. If the difference in run hours between two generator sets is
greater than the threshold, the two generator sets change places in the sequence. If necessary,
the generator set with the lower number of run hours restarts, and the generator set with the
higher number of run hours shuts down. The lead generator set can change in this method.

13.7.5 Source of Run Hours for the Run Hours Method


This method is based on the run hours that are maintained by the MCM3320, not the run hours
that are maintained by the generator sets. You can change the run hours of the generator sets
in the MCM3320. If you change the run hours of the generator sets in the MCM3320, the
sequence will change as necessary. If the sequence changes, generator sets will restart and
shut down accordingly.

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If you change the run hours of the generator sets in the MCM3320, generator
sets may restart and shut down immediately.

13.7.6 Example: Run Hours Method


There are four generator sets A, B, C, and D. The current sequence is (A, B, C, D). Generator
sets C and D have shut down because there is extra capacity. The generator sets have the
following run hours.
TABLE 110.

SEQUENCE BEFORE SWITCH 1

Sequence

Run Hours

40

35

25

20

The threshold is 20 run-hours. Generator set A and generator set D change places in the
current sequence. Generator set D restarts, and generator set A shuts down.
TABLE 111.

SEQUENCE AFTER SWITCH 1

Sequence

Run Hours

20

35

25

40

Generator sets D and B run for 10 hours.


TABLE 112.

SEQUENCE BEFORE SWITCH 2

Sequence

Run Hours

30 (20 + 10)

45 (35 + 10)

25

40

Generator set B and generator set C change places in the current sequence. Generator set C
restarts, and generator set B shuts down.
TABLE 113.

152

SEQUENCE AFTER SWITCH 2

Sequence

Run Hours

30

25

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Sequence

Run Hours

40

Generator sets D and C run for 5 hours. Then, all of the generator sets shut down.
The next time a generator set shuts down for load demand, generator set A will shut down.

13.7.7 Generator Set Online Time


GenX Online Time, where X identifies the generator set, tracks the amount of time the
paralleling breaker of the generator set is closed. This value can be set manually.
NOTE:

GenX Online Time is different than the number of run-hours tracked by each
generator set. The values may not be equal.

This value is used by the run hours method in load demand.

13.7.8 Generator Set Fail Time


This is the amount of time a generator set has to close its paralleling breaker after it is
commanded to start. At the end of this time, if the generator set has not closed its paralleling
breaker, the generator set is considered unavailable.
In load demand, this delay applies when a generator set is restarted. At the end of this time, if
the generator set has not closed its paralleling breaker, the next generator set is restarted.
If you set this value too low, a generator set might restart unnecessarily. If you set this value too
high, the system responds more slowly if a generator set does not restart.

13.8

Load Demand and Generator Set Overload


If one or more generator sets is shut down, the available generator sets can be overloaded
more easily. If this happens,
The generator sets that were shut down restart immediately.
Loads are removed based on load-shed levels. This uses the same load shed sequence
that automatic load shed (Section 12.8 on page 140) uses. It does not matter if automatic
load shed is active.

13.9

Summary of Settings (Load Demand)


TABLE 114.

SUMMARY OF SETTINGS (LOAD DEMAND)

Setting

Description

Load Demand Enable

Enables or disables load demand.


Default: Disabled

Load Demand Minimum Online Capacity

Specifies the amount of capacity that must be available,


regardless of the load. Set this to 0 to disable this.
Default: 0 kW

Load Demand Type

Specifies the way the sequence is generated.


Possible values: None, Fixed Sequence, Run Hours
(Default: None)

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Setting

Description

Load Demand GenX (X = A, B, C, ...)

Specifies the fixed sequence, where A is the lead


generator set. This has no effect unless Load Demand
Type is Fixed Sequence.
Possible values: Gen1, Gen2, Gen3, ....

Load Demand Run Hours Differential

If the difference in run hours between two generator sets


is greater than this value, the two generator sets change
places in the sequence. This has no effect unless Load
Demand Type is Run Hours.
Possible values: 1-500 hours (Default: 50 hours)

GenX Online Time (X = 1-16)

Specifies the run hours of the generator set.


Possible values: 0-1193046 hours

Load Demand Refresh Sequence Command

Forces the current sequence to be recalculated, based on


Load Demand Type, the same way it is calculated initially
when load demand becomes active. This has no effect
unless Load Demand Type is Run Hours.
Possible values: Do Nothing, Refresh Sequence

Load Demand Initial Delay

Specifies the amount of time between the time the first


generator set closes its paralleling breaker and the time
load demand becomes active.
Possible values: 1-60 minutes (Default: 5 minutes)

Load Demand Restart Delay

Specifies the amount of time the load must remain high


enough before a generator set restarts.
Possible values: 0-25 seconds (Default: 1 second)

Load Demand Shutdown Delay

Specifies the amount of time the load must remain low


enough before a generator set is shut down.
Possible values: 1-60 minutes (Default: 5 minutes)

Genset Fail Time Delay

Specifies the amount of time a generator set has to close


its paralleling breaker after it is commanded to start.
Possible values: 10-900 seconds (Default: 59 seconds)

Load Demand Threshold Method

Specifies the way the load thresholds for the next


shutdown and the next restart are calculated.
Possible values: %kW, kW (Default: %kW)

Load Demand Shutdown Percent

Specifies a percentage of kW capacity of the available


generator sets if a generator set is shut down. If the load
is under this percentage, that generator set will be shut
down. This has no effect unless Load Demand Threshold
Method is %kW.
Possible values: 20-100% (Default: 60%)

Load Demand Restart Percent

Specifies a percentage of kW capacity of the available


generator sets. If the load is over this percentage, a
generator set is restarted. This has no effect unless Load
Demand Threshold Method is %kW.
Possible values: 20-100% (Default: 80%)

Load Demand Shutdown kW Threshold

Specifies the amount of extra kW capacity the available


generator sets should have if a generator set is shut
down. This has no effect unless Load Demand Threshold
Method is kW.
Default: 1000 kW

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TABLE 115.

SUMMARY OF MONITOR POINTS (LOAD DEMAND)

Setting

Description

GenX (X = A, B, C, ...)

Indicates the current sequence, where A is the lead


generator set, used by load demand.

Next Gen To Restart

Indicates which generator set is the next generator set to


be restarted.

Next Gen Restart Threshold

Indicates at what load level the next generator set will be


restarted.

Next Gen To Shutdown

Indicates which generator set is the next generator set to


be shut down.

Next Gen Shutdown Threshold

Indicates at what load level the next generator set will be


shut down.

Total Load Demand Online Capacity

The capacity in Total Online Capacity plus the sum of the


ratings of the generator sets that have started or restarted
but not come online yet. This is used by load demand to
avoid restarting another generator set until a previouslyrestarted generator set either closes its paralleling
breaker or fails to come online.

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14

Scheduler
The scheduler provides the ability to start the generator sets automatically at preset times. For
example, you might use this to exercise the generators regularly. Alternatively, you might use
this to run in extended parallel during a certain period each day to avoid increased charges from
the utility.
When the generator sets run, the system can run in Test With Load mode, Test Without Load
mode, or Extended Paralleling mode.

14.1

Real-time Clock
The real-time clock tracks the current date and current time. It is used to calculate controller ontime and by the scheduler.
The current date automatically adjusts for months with less than 31 days and for leap years.
The current time is tracked in 24-hour format.

14.1.1 Daylight Saving Time


Daylight saving time, also known as summer time, is the practice of temporarily advancing
clocks during the summertime so that afternoons have more daylight and mornings have less.
Usually, clocks are set ahead one hour in the spring and set back one hour in autumn, but the
specific days and the amount of time varies by location.

14.1.2 Daylight Saving Time Enable


If Daylight Saving Time Enable is Enabled, the real-time clock is automatically adjusted for
daylight saving time.
The real-time clock is set ahead by Daylight Saving Time Adjustment when the current date and
current time meets the following conditions.
Daylight Saving Time Start Month (1-12, 1 = January, 2 = February, etc.)
Daylight Saving Time Start Week (1-5, 1 = first, 2 = second, etc.)
Daylight Saving Time Start Day (0-6, 0 = Sunday, 1 = Monday, etc.)
Daylight Saving Time Start Hour (0-23)
For example, the real-time clock may be set ahead on the third Tuesday in March at 1:00.
The real-time clock is set back by Daylight Saving Time Adjustment when the current date and
current time meets a similar set of conditions at the end of daylight saving time.
If Daylight Saving Time Enable is Disabled before the end of daylight savings time, the real-time
clock is not adjusted.

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14.1.3 Summary of Settings (Real-time Clock)


TABLE 116.

SUMMARY OF SETTINGS (REAL-TIME CLOCK)

Setting

Description

Clock Mode

Specifies the operating mode of the real-time clock.


Possible values:
Normal: The real-time clock is running, and it updates the
current date and the current time.
Set Clock: The real-time clock stops updating the current
date and the current time so that they can be set. The
real-time clock continues to run. If Clock Mode is Normal,
the current date and time are correct.
Save Clock: The current date and the current time are
updated based on the values in the current date and the
current time. The status returns to Normal.

Clock Year
Clock Month
Clock Date

Specifies the current date in the real-time clock. If Clock


Mode is Set Clock, the current date can be set.

Clock Hour
Clock Minute
Clock Second

Specifies the current time in the real-time clock. If Clock


Mode is Set Clock, the current time can be set.

Daylight Saving Time Enable

Enables or disables the adjustment of the real-time clock


due to daylight saving time.
Possible values: -50~50 degrees (Default: 0 degrees)

Daylight Saving Time Start Month, Week, Day, Hour

Specifies the beginning of daylight saving time.

Daylight Saving Time End Month, Week, Day, Hour

Specifies the end of daylight saving time.

Daylight Saving Time Adjustment

Specifies how much the real-time clock is advanced at the


beginning of daylight saving time and set back at the end
of daylight saving time.
Possible values: 0-120 minutes (Default: 60 minutes)

14.1.4 Code 1689 - Real-time Clock Power Interrupt


The real-time clock has not been set after power-up, or the real-time clock lost power for at least
24 hours.
Set the real-time clock to reset this code.

14.1.5 Effects of Code 1689


The scheduler is inactive.

14.2

Scheduler Enable
This feature is active if all of these conditions are met.
System Scheduler Enable is Enabled.
Code 1689 (Real Time Clock Power Interrupt) is inactive.

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14.2.1 Automatic Changes of System Scheduler Enable


System Scheduler Enable is set to Disabled automatically if any of these conditions are met.
Cancel Scheduler If Modbus Fail Enable is Enabled, and code 2939 (Modbus
Communication Failure Warning) is active.
Code 4137 (Advanced Grid Protection Fault) is active.
System Scheduler Enable does not change back to its original value when the conditions above
are no longer met. The setting has to be changed manually.

14.3

Scheduled Programs
Scheduled programs specify when the generator sets should run.
Each scheduled program includes the following information:
When the generator sets should start
How long the generator sets should run
In what mode the generator sets should run
How often the program repeats
The following examples show what happens if two or more scheduled programs overlap.

FIGURE 81.

SCHEDULED PROGRAM P1 BEGINS BEFORE SCHEDULED PROGRAM P2

In Figure 81, scheduled program P1 runs because it starts earlier. Scheduled program P2 does
not run, even if it finishes later.

FIGURE 82.

SCHEDULED PROGRAM P1 AND SCHEDULED PROGRAM P2 BEGIN AT THE SAME


TIME

In Figure 82, scheduled program P1 runs because it has the lowest number. Scheduled
program P2 does not run, even if it finishes later.

14.4

Exceptions
Exceptions prevent scheduled programs from starting during specific times. Exceptions do not
stop a scheduled program that is already running.
Each exception includes the following information:
When the exception begins

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How long the exception lasts


How often the exception repeats
The following examples show what happens when a scheduled program overlaps an exception.

FIGURE 83.

SCHEDULED PROGRAM P1 BEGINS BEFORE EXCEPTION E1

In Figure 83, the scheduled program runs normally because it starts before the exception starts.
Exception E1 has no effect.

FIGURE 84.

SCHEDULED PROGRAM P1 AND EXCEPTION E1 BEGIN AT THE SAME TIME

In Figure 84, the scheduled program is ignored because the exception is active.

FIGURE 85.

SCHEDULED PROGRAM P1 BEGINS AFTER EXCEPTION E1

In Figure 85, the scheduled program is ignored because the exception is active.
If two or more exceptions overlap, they follow the same rules that are followed if two or more
scheduled programs overlap.

14.5

Scheduler Specifications
TABLE 117.

Description

SCHEDULER SPECIFICATIONS
Value

Number of scheduled programs

12

Number of exceptions

160

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14. Scheduler

Summary of Settings (Scheduler)


TABLE 118.

SUMMARY OF SETTINGS (SCHEDULER)

Setting

Description

System Scheduler Enable

Enables or disables the scheduler.


Possible values: Enabled, Disabled (Default: Disabled)

Scheduler Program N Enable, Run Mode, Start Day, Start (N is the number of the scheduled program.) Specifies the
Hour, Start Minute, Duration Hours, Duration Minutes,
scheduled program.
Repeat Interval
Scheduler Exception N Enable, Month, Date, Hour,
(N is the number of the exception.) Specifies the
Minute, Duration Days, Duration Hours, Duration Minutes, exception.
Repeat
Cancel Scheduler If Modbus Fail Enable

Enables or disables the scheduler if code 2939 (Modbus


Communication Failure Warning) is active.
Possible values: Enabled, Disabled (Default: Disabled)

Scheduler Program Select

Selects the scheduled program to put into the Scheduler


Program x settings.

Scheduler Program x Enable, Run Mode, Start Day, Start


Hour, Start Minute, Duration Hours, Duration Minutes,
Repeat Interval

Specifies the scheduled program selected in Scheduler


Program Select. If these values are updated, the
scheduled program is updated.

Scheduler Exception Select

Selects the exception to put into the Scheduler Exception


x settings.

Scheduler Exception x Enable, Month, Date, Hour,


Specifies the exception selected in Scheduler Exception
Minute, Duration Days, Duration Hours, Duration Minutes, Select. If these values are updated, the exception is
Repeat
updated.

TABLE 119.

SUMMARY OF MONITOR POINTS (SCHEDULER)

Setting

Description

Active Schedule

Indicates which scheduled program or exception is


running.

Scheduler Run Command

Indicates what kind of action the scheduler is driving. This


is used in the power transfer control (PTC) logic.
Possible values: Off, No Load, With Load, Extended
Parallel

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15

Manual Mode
In Manual mode, the sources are connected and disconnected manually. The sources are not
connected or disconnected by the power transfer control (PTC) logic.
Manual mode is also required to change System Topology or to upload firmware to the
MCM3320.

15.1

Conditions for Entering Manual Mode


Auto/Manual Sw is Manual.

15.2

Conditions for Leaving Manual Mode


Auto/Manual Sw is Auto.

15.3

Auto/Manual Switch
This switch may come from any of these sources:
Auto/Manual connection (TB10-6, TB10-17)
Modbus networks
InPower
This switch is Manual when any of these sources is active. It remains Manual until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

This switch puts the MCM3320 in Manual mode.

15.4

Monitoring Breaker Position in Manual Mode


In Manual mode, the utility main breaker and the generator set main breaker are treated as
single-contact breakers. This allows breakers to be racked out to the disconnected position or
test position without generating nuisance faults about breaker position contacts.
In general, this has no effect on behavior, though it affects how breaker position contact faults
are generated if the breakers are actually dual-contact breakers.

15.5

Commit to Transfer in Manual Mode


In Manual mode, the system is unable to commit to transferring the loads to the generator sets.
As a result, if PTC Operating Mode becomes Utility Fail, PTC Operating Mode remains in Utility
Fail even if the utility becomes available again.

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Breaker Control in Manual Mode

FIGURE 86.

BREAKER CONTROL IN MANUAL

The breakers are controlled by Gen CB Manual Control and Util CB Manual Control.
Sources can be disconnected immediately.
If PTC State is No Source Connected, the generator sets or the utility can be connected
after Programmed Transition Delay (TDPT) expires.
In order to connect the sources in parallel, the generator sets must be synchronized with
the utility, and PTC Operating Transition Type cannot be Open Transition.
NOTE:

If the topology is Isolated Bus Without Generator Set Main Breaker or


Isolated Bus with Generator Set Main Breaker, PTC Operating Transition
Type is always Open Transition.

15.6.1 Programmed Transition Time Delay


This allows residual voltage from inductive loads to decay to an acceptable level before the
transfer is completed.
This is also known as Time Delay Programmed Transition (TDPT).

15.6.2 Maximum Parallel Timer in Manual Mode


This timer depends on PTC Operating Mode, not PTC Transfer Pair Operating Mode. This timer
will run if PTC Operating Mode is not Extended Parallel. If the timer expires, the generator sets
are not disconnected immediately, however.

15.6.3 Master Inhibit


This switch may come from any of these sources:
Master Inhibit connection (TB3-8, TB3-17)
Modbus networks
InPower

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This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

When this switch becomes active, the following features are disabled.
Breaker control when PTC State is No Source Connected, Genset Connected, or Utility
Connected.
Synchronizer
Load control in extended parallel

15.6.4 Generator Set Breaker Inhibit


This switch may come from any of these sources:
Generator Set Breaker Inhibit connection (TB10-5, TB10-4)
Modbus networks
InPower
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

When this switch becomes active, the generator sets are disconnected from the loads (Section
6.1.2 on page 87).

15.6.5 Utility Main Breaker Inhibit


This switch may come from any of these sources:
Utility Main Breaker Inhibit connection (TB10-11, TB10-13)
Modbus networks
InPower
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

When this switch becomes active, the utility is disconnected from the loads (Section 6.2.2 on
page 88).

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15.6.6 Fail to Disconnect Enable


If Fail to Disconnect Enable is Enabled, the system takes additional actions to try to disconnect
one of the sources when the generator sets are running in parallel with the utility.
If code 1453 (Genset Main Breaker Fail to Open) is active, the utility is disconnected
immediately.
If code 2397 (Utility Main Breaker Fail to Open) is active, the generator sets are
disconnected immediately.
In addition, code 1121 (Fail to Disconnect) is enabled.

15.7

Generator Set Control in Manual Mode


Manual mode has no effect on PTC Genset Operating Mode. The generator sets start and stop
the same way they do in Auto mode.

15.8

Load Control in Manual Mode


When PTC State is Paralleled, load control tells the generator sets to run at 0%. Load control
does not support extended parallel or soft-closed transitions in Manual mode.

15.8.1 Load Control at Other Times


When PTC State is not Paralleled, load control still sends signals to the generator sets. The
generator sets may not respond to these signals depending on the generator set control and its
configuration.
When PTC State is not Paralleled, load control tells the generator sets to ramp up their loads if
these conditions are met.
PTC State is Utility Connected.
PTC Operating Mode is not Extended Parallel.
Otherwise, load control tells the generator sets to ramp down their loads.

15.9

Synchronizer Status in Manual Mode


The synchronizer runs if all of these conditions are met.
The utility is available.
The generator sets are available.
The synchronizer enable switch is active.

15.9.1 Synchronizer Enable Switch


This switch may come from any of these sources:
Synchronizer Enable Switch connection (TB1-10, TB1-11)
Modbus networks
InPower

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This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

15.10 Load Add/Shed in Manual Mode


Load add/shed is available in Manual mode.
Automatic load add can start if the utility main breaker is open when one of these conditions is
met.
If the topology is Isolated Bus Without Generator Set Main Breaker or Common Bus, the
first generator set closes its paralleling breaker.
If the topology is Isolated Bus with Generator Set Main Breaker or Transfer Pair, the
generator set main breaker closes.
If automatic load add does not start, the loads have to be added manually.
The remaining features in load add/shed operate normally.

15.11 Load Demand in Manual Mode


Load demand is available in Manual mode.

15.12 Scheduler in Manual Mode


The scheduler is available in Manual mode. However, breaker control is manual, so every
scheduled program behaves like a test without load.

15.13 Summary of Settings (Manual Mode)


TABLE 120.

SUMMARY OF SETTINGS (MANUAL MODE)

Setting

Description

Auto/Manual Vol

Sets the auto/manual switch.


Possible values: Auto, Manual

Synchronizer Enable Vol

Sets the synchronizer enable switch.


Possible values: Inactive, Active

TABLE 121.

SUMMARY OF MONITOR POINTS (MANUAL MODE)

Setting

Description

Auto/Manual Sw

Indicates the state of the auto/manual switch.

Synchronizer Enable Sw

Indicates the state of the synchronizer enable switch.

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Master Synchronize Only


If the topology is Master Synchronize Only, the synchronizer is available. Other features are not
active.

16.1

Generator Set Availability (Three-phase


Applications in Master Synchronize Only or
Component Mode)
The generator sets are available when all of these conditions are met.
None of the PTC sensors for the generator sets are Dropped-out.
Genset Online Capacity Sensor Status is not Dropped-out.
The generator sets are unavailable when at least one of these conditions is not met.

16.2

Utility Availability (Three-phase Applications in


Master Synchronize Only and Component Mode)
The utility is available when none of the PTC sensors for the utility are Dropped-out.
The utility is not available when at least one of PTC sensors for the utility is Dropped-out.

16.3

PTC State and PTC Operating Mode in Master


Synchronize Only
In this topology, PTC State is PTC Not Enabled, and PTC Operating Mode is Normal.

16.4

Synchronizer Status in Master Synchronize Only


and Component Mode
Synchronizer Status indicates whether or not the synchronizer is running.
The synchronizer runs if all of these conditions are met.
The utility is available.
The generator sets are available.

16.5

Synchronizer Status in Manual Mode


The synchronizer runs if all of these conditions are met.
The utility is available.
The generator sets are available.
The synchronizer enable switch is active.

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16.5.1 Synchronizer Enable Switch


This switch may come from any of these sources:
Synchronizer Enable Switch connection (TB1-10, TB1-11)
Modbus networks
InPower
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

16.6

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

Synchronizer Check in Master Synchronize Only or


Component Mode
If the topology is Master Synchronize Only or Component Mode, Sync Check Close Allowed can
be Allowed in a variety of conditions. Each condition is enabled or disabled by a different
setting.

TABLE 122.

SYNC CHECK CLOSE ALLOWED (MASTER SYNCHRONIZE ONLY OR COMPONENT


MODE)
Setting

170

Condition

Sync Check Dead Utility Dead Genset Enable

The utility bus is dead, and the generator set bus is dead.

Sync Check Dead Utility Live Genset Enable

The utility bus is dead, and the generator sets are


available.

Sync Check Live Utility Dead Genset Enable

The utility is available, and the generator set bus is dead.

Sync Check Live Utility Live Genset Enable

Permissive Close Allowed is Allowed.

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SYNC1320
The SYNC1320 is a MCM3320 in which the topology is Master Synchronize Only.
The SYNC1320 base board is a depopulated MCM3320 base board. Depopulation reduces the
capabilities of the SYNC1320 compared to a MCM3320 in Master Synchronize Only.
No current sensing
No Modbus connections
No PCCNet connections, including the operator panel
Starting with software version 1.29, the SYNC1320 can be used in single-phase applications as
well as three-phase applications. This has an impact on the synchronizer, which only supports
three-phase applications in the MCM3320. In addition, when the SYNC1320 is used in singlephase applications, source availability is different.
See 0900-0662 for more information about the SYNC1320.

17.1

Generator Set Availability (Single-phase


Applications)
The generator sets are available when the generator set voltage is at least 60% of nominal
voltage.
The generator sets are not available when the generator set voltage is less than 60% of nominal
voltage.

17.2

Utility Availability (Single-phase Applications)


The utility is available when the utility voltage is at least 60% of nominal voltage.
The utility is not available when the utility voltage is less than 60% of nominal voltage.

17.3

Synchronizer in the SYNC1320


The synchronizer in the SYNC1320 can support single-phase applications or three-phase
applications. Set Synchronizer Type based on the application.
The single-phase synchronizer and the three-phase synchronizer operate the same way the
synchronizer in the MCM3320 operates.

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Component Mode
If the topology is Component Mode, the synchronizer and load control are available. Other
features are not active.

18.1

Generator Set Availability (Three-phase


Applications in Master Synchronize Only or
Component Mode)
The generator sets are available when all of these conditions are met.
None of the PTC sensors for the generator sets are Dropped-out.
Genset Online Capacity Sensor Status is not Dropped-out.
The generator sets are unavailable when at least one of these conditions is not met.

18.2

Utility Availability (Three-phase Applications in


Master Synchronize Only and Component Mode)
The utility is available when none of the PTC sensors for the utility are Dropped-out.
The utility is not available when at least one of PTC sensors for the utility is Dropped-out.

18.3

PTC State and PTC Operating Mode in Component


Mode
In this topology, PTC State and PTC Operating Mode are writable values. They are used in load
control.
Regardless of PTC State and PTC Operating Mode, there is no breaker control or generator set
control in Component mode.

18.4

Synchronizer Status in Master Synchronize Only


and Component Mode
Synchronizer Status indicates whether or not the synchronizer is running.
The synchronizer runs if all of these conditions are met.
The utility is available.
The generator sets are available.

18.5

Synchronizer Status in Manual Mode


The synchronizer runs if all of these conditions are met.
The utility is available.

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The generator sets are available.


The synchronizer enable switch is active.

18.5.1 Synchronizer Enable Switch


This switch may come from any of these sources:
Synchronizer Enable Switch connection (TB1-10, TB1-11)
Modbus networks
InPower
This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

18.6

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

Synchronizer Check in Master Synchronize Only or


Component Mode
If the topology is Master Synchronize Only or Component Mode, Sync Check Close Allowed can
be Allowed in a variety of conditions. Each condition is enabled or disabled by a different
setting.

TABLE 123.

SYNC CHECK CLOSE ALLOWED (MASTER SYNCHRONIZE ONLY OR COMPONENT


MODE)
Setting

Condition

Sync Check Dead Utility Dead Genset Enable

The utility bus is dead, and the generator set bus is dead.

Sync Check Dead Utility Live Genset Enable

The utility bus is dead, and the generator sets are


available.

Sync Check Live Utility Dead Genset Enable

The utility is available, and the generator set bus is dead.

Sync Check Live Utility Live Genset Enable

Permissive Close Allowed is Allowed.

18.7

Load Control in Component Mode


Load control operates the same in Component mode, but PTC State and PTC Operating Mode
have to be set externally to get the desired behavior.
NOTE:

174

In Component mode, PTC State and PTC Operating Mode are not calculated
internally. Instead, they have to be set externally.

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18.8

18. Component Mode

Load Control Based on PTC State and PTC


Operating Mode
TABLE 124.

LOAD CONTROL BASED ON PTC STATE AND PTC OPERATING MODE

PTC State

PTC Operating Mode

Load Control

PTC Not Enabled


No Source Connected
Genset Connected

any

Ramp down

Utility Connected

Extended Parallel

Ramp down

Utility Connected

any except Extended Parallel

Ramp up

Paralleled

Utility Fail
Normal Override
Normal

Ramp down

Paralleled

Extended Parallel

kW load control and kVAR load


control

Paralleled

Test

Ramp up

If PTC State is Paralleled, the load control that is indicated applies only in Auto mode.

18.9

Load Control in Manual Mode


When PTC State is Paralleled, load control tells the generator sets to run at 0%. Load control
does not support extended parallel or soft-closed transitions in Manual mode.

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19.1

Events
An event becomes active when the event condition becomes true.
The event remains active until the event condition becomes false.

19.1.1 Code 1222 - Not in Automatic


The MCM3320 is in Manual mode.

19.1.2 Code 1483 - Common Alarm


At least one fault is active.

19.1.3 Code 1534 - Load Control Output Event


This is active if any of these conditions is met.
The master inhibit is inactive.
PTC State is Paralleled.

19.1.4 Code 1916 - Synchronized Event


The generator sets are synchronized with the utility.

19.1.5 Code 2328 - Utility Bus Available Event


The utility is available.

19.1.6 Code 2332 - Utility Bus Connected Event


The utility is connected to the loads.

19.1.7 Code 2333 - Generator Set Bus Connected Event


The generator sets are connected to the loads.

19.1.8 Code 2779 - Utility Unloaded Event


The real power provided by the utility is less than Utility Unloaded Level.
This code can be generated when PTC Operating Transition Type is Soft Closed Transition or
the topology is Component Mode.

19.1.9 Code 2781 - Genset Unloaded Event


The real power provided by the generator sets is less than Genset Unloaded Level.
This code can be generated when PTC Operating Transition Type is Soft Closed Transition or
the topology is Component Mode.

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19.1.10 Code 2965 - Generator Set Bus Available Event


The generator sets are available.

19.1.11 Code 2971 - Test/Extended Parallel Event


PTC Operating Mode is Test or Extended Parallel.

19.1.12 Code 3226 - Genset Bus Base Load Event


While the generator sets are running in parallel with the utility in extended parallel mode,
Extended Paralleling kW Load Control Type is Genset Bus % Level, Genset Bus kW, or Genset
Bus kW w/Utility Constraint.

19.1.13 Code 3227 - Utility Peak Shave Event


While the generator sets are running in parallel with the utility in extended parallel mode,
Extended Paralleling kW Load Control Type is Utility Bus kW.

19.2

Faults
A fault becomes active when the fault condition becomes true.
The fault remains active until the fault condition is false and the fault reset signal is active.

19.2.1 Fault Reset


This switch may come from any of these sources:
Fault Reset connection (TB2-14, TB2-5)
Modbus networks (Fault Reset Vol)
InPower (Fault Reset Vol)
NOTE:

When Fault Reset Vol is set to Reset, it is automatically set to Not Reset 0.5
seconds later.

This switch becomes active when any of these sources is active. It remains active until all of the
sources are inactive.
NOTE:

There can be multiple sources for this switch. The switch is active if any
source is active. You have to make all of the sources inactive to make the
switch inactive.

This switch has a different effect depending how long it is active.


If this switch becomes inactive in less than five seconds, this switch resets all active faults.
Each fault becomes inactive if the associated fault condition is no longer true.
If this switch remains active for five seconds, U51 starts displaying the active faults. This
switch has no more effect until the next time it changes from inactive to active.

19.2.2 System Lockout Status


System Lockout Status indicates whether or not one or more active faults are preventing normal
operation. For example, if code 2396 (Utility Main Breaker Fail to Close) is active, the utility is
considered unavailable, and the system responds accordingly.
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System Lockout Status does not affect the operation of the MCM3320. It is for descriptive
purposes only. It is available over network connections, such as PCCNet, Modbus, or InPower.

19.2.3 Conditions for System Lockout Status


System Lockout Status is active if any of these conditions is met.
Code 1219 (Utility Main Breaker Tripped) is active.
Code 1328 (Generator Set Main Breaker Tripped) is active.
Code 1444 (Generator Set Bus Overload) is active, and Load Add Shed Enable is
Enabled.
Code 1444 (Generator Set Bus Overload) is active, and Load Demand Enable is Enabled.
Code 1452 (Generator Set Main Breaker Fail to Close) is active.
Code 1453 (Generator Set Main Breaker Fail to Open) is active.
Code 1454 (Generator Set Main Breaker Position Contact) is active.
Code 1455 (Utility Main Breaker Position Contact) is active.
Code 1457 (Fail to Synchronize Warning) is active, and Fail to Sync Lockout Enable is
Enabled.
Code 1999 (Maximum Parallel Time) is active.
Code 2396 (Utility Main Breaker Fail to Close) is active.
Code 2397 (Utility Main Breaker Fail to Open) is active.
Code 4137 (Advanced Grid Protection Fault) is active.
System Lockout Status is inactive if none of these conditions are met.

19.3

Troubleshooting Procedures

19.3.1 No Code - AUX 101 Does Not Communicate


One or more AUX101 boards are not communicating with the MCM3320.

A. Check System Topology


PCCNet devices will not communicate with the MCM3320 if the System Topology of the
MCM3320 is set to Master Synchronizer Mode or Component Mode. Use InPower to verify
the topologies. Disconnect the J14 connector from the MCM3320, and connect InPower to
the MCM3320. Access Adjustments > System Setup > System Topology.

B. Verify PCCNet Connections


1. Verify PCCNet connections by checking for continuity between the following items:
AUX 101 J1-3, MCM3320 TB1-1, and any corresponding terminal in the PCCNet
network
AUX 101 J1-4, MCM3320 TB1-3, and any corresponding terminal in the PCCNet
network

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2. Verify the proper identifier is displayed on the 7-segment display of the AUX 101
board.
3. Verify the green DS1 indicator is lit on the AUX 101 board. A green light indicates
PCCNet communication.

C. Check Compatibility of Software Versions


Verify that the MCM3320 software version is V2.0 or later. Disconnect the J14 connector
from the MCM3320, and connect InPower to the MCM3320. Access Monitor > Controller
Information > Software Version. Update the calibration if necessary.
Verify that the AUX 101 software version is V1.48 or later. Access Monitor > Controller
Information > AUX101 Software Version. Update the calibration if necessary.
Make sure the AUX 101 and MCM3320 software versions are compatible with each other.
See Section 4.4.5 on page 52.

19.3.2 No Code - Fault Codes Do Not Reset


One or more active faults do not reset.

A. Check Active Faults


Troubleshoot any active faults. Verify the conditions that cause the faults are no longer
present.

B. Check Control Voltage


Verify there is control voltage at TB2-14 in the MCM3320. Measure the voltage across
terminal TB2-14 and a ground terminal (TB2-6).

C. Verify Fault Reset Connections


Verify fault reset connections by checking for continuity between the following items:
TB2-14 (MCM3320) to the corresponding terminal in the switchgear
TB2-6 (MCM3320) to the corresponding terminal in the switchgear
Use the interconnect and switchgear schematics to perform this check.

D. Check Operation of Fault Reset Relay


1. Make sure that there is control voltage at each terminal of the fault reset relay. This
can be done by jumpering each relay terminal across a ground or B+ terminal with a
multimeter.
2. Make sure that there is continuity between the contacts of the fault reset relay. If it is a
normally-open relay, then, when the relay is energized, there will be continuity
between the contacts. If it is a normally closed relay, then, when the relay is
energized, there will be no continuity between the contacts.

19.3.3 No Code - Incorrect Generator Set Bus Metering


The voltage, current, frequency, power, or phase for the generator set bus is missing or
incorrect in the MCM3320.

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A. Check Shorting Block


If there is a shorting block, verify that the shorting block connections are removed from the
shorting block.

B. Check Generator Set Bus Current-sensing Circuit


Verify there are no wiring issues with the current-sensing connections to the MCM3320 by
performing the following steps.
1. Verify that the wire passes through CTs on the MCM3320 once for 5 A units and twice
for 1 A units.
2. Verify that the wires passing through the CTs on the MCM3320 are connected to the
corresponding terminals in the switchgear. Refer to the interconnection and switchgear
schematics for details.
3. Verify there are no broken or loose connections in the current-sensing circuit.

19.3.4 No Code - Incorrect Utility Metering


The voltage, current, frequency, power, or phase for the utility is missing or incorrect in the
MCM3320.

A. Check Shorting Block


If there is a shorting block, verify that the shorting block connections are removed from the
shorting block.

B. Check Utility Current-sensing Circuit


Verify there are no wiring issues with the current-sensing connections to the MCM3320 by
performing the following steps.
1. Verify that the wire passes through CTs on the MCM3320 once for 5 A units and twice
for 1 A units.
2. Verify that the wires passing through the CTs on the MCM3320 are connected to the
corresponding terminals in the switchgear. Refer to the interconnection and switchgear
schematics for details.
3. Verify there are no broken or loose connections in the current-sensing circuit.

19.3.5 No Code - Operator Panel Is Not Communicating


The HMI211 is not communicating with the MCM3320. The HMI211 screen displays the
message Re-establishing communication with control. The indicators on the HMI211 may be
on or off.

A. Verify PCCNet Connections


1. Verify PCCNet connections by checking for continuity between the following items:
HMI 211 J1-2, MCM3320 TB1-1, and any corresponding terminal in the PCCNet
network
HMI 211 J1-33, MCM3320 TB1-3, and any corresponding terminal in the PCCNet
network

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2. Make sure the shield is grounded at TB1-4 in the MCM3320.


3. Verify that there is 120 ohm terminating resistor at each end of the two wire twisted
pair RS485.

B. Check Part Number of HMI 211


The MCM3320 supports part number 0300-6090.

C. Check Communication Settings


1. Disconnect the J14 connector from the MCM3320, and connect InPower to the
MCM3320.
2. Check the communication setting in the MCM3320. Access Adjustments >
Communications Adjustments > Port Protocol Selection > PCCNet.

D. Check System Topology


PCCNet devices will not communicate with the MCM3320 if the System Topology of the
MCM3320 is set to Master Synchronizer Mode or Component Mode. Use InPower to verify
the topologies. Disconnect the J14 connector from the MCM3320, and connect InPower to
the MCM3320. Access Adjustments > System Setup > System Topology.

19.3.6 Code 343 - Hardware Failure MCM3320


Power to the MCM3320 has been lost, or one of the hardware faults is active.
Code 353 (EEPROM Write Error)
Code 1335 (AC Metering Out of Range)
Code 2416 (Calibration Checksum)

A. Cycle Power
Cycle power to the MCM3320 to see if the fault clears.

B. Check Calibration
Perform an update calibration using the InPower service tool. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320.
If unable to perform an update calibration, perform an initial calibration.
If unable to perform an initial calibration, replace the MCM3320 base board.

C. Troubleshoot Related Fault Codes


Troubleshoot the fault codes that are related to this code.

19.3.7 Code 353 - EEPROM Write Error


A current value in RAM memory (a to-be-written value) is different from its post-written value in
EEPROM. An attempt may have been made to save trims in InPower or in the operator panel
and it was not successful. Alternatively, the error may have occurred when the MCM3320 tried
to automatically save data on a periodic basis.

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NOTE:

This fault is more common after major software releases, for example, 1.XX
to 2.XX. If the software was upgraded recently, perform a second initial
calibration, and cycle power.

This code cannot be reset without cycling power to the MCM3320.

19.3.7.1 Effects of Code 353


Any values not saved correctly have to be updated again.

A. Cycle Power
Cycle power to the MCM3320 to see if the fault clears.

B. Check Calibration
Perform an update calibration using the InPower service tool. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320.
If unable to perform an update calibration, perform an initial calibration.
If unable to perform an initial calibration, replace the MCM3320 base board.

19.3.8 Code 441 - Low Battery Voltage


This code depends on Nominal Battery Voltage.
TABLE 125.

NOMINAL BATTERY VOLTAGE

Value

Description

12 V

The battery voltage is less than 12 V Low Battery Voltage Threshold for Low
Battery Voltage Set Time.

24 V

The battery voltage is less than 24 V Low Battery Voltage Threshold for Low
Battery Voltage Set Time.

This code cannot be reset until the battery voltage is above the indicated threshold for Low
Battery Voltage Set Time.

A. Verify Battery Voltage Settings


Verify that the battery voltage matches Nominal Battery Voltage. This setting depends on
the application.
To access the battery voltage setup menu in InPower, go to Adjustments > Battery
Voltage Protection Setup > Nominal Battery Voltage.

B. Verify Battery Connections


Check the connections between the batteries and the MCM.
Battery +: TB2-8, TB2-9, TB2-11, and TB2-12
Battery : TB2-2, TB2-3, TB2-5, and TB2-7
Check for continuity, and make sure there are no broken or loose connections in the wires.
Use the interconnection and switchgear schematics to perform the check.

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C. Verify Batteries Are Charged


Verify that the generator set battery chargers are charging the generator set batteries at an
acceptable charging rate.
Adjust the charging rate of the battery charger if the charging rate is below the
recommendation of the manufacturer. Refer to the battery charger manual for details.

D. Verify Batteries Can Hold Charge


Verify the generator set cranking batteries are able to hold a charge by performing the
following steps.
1. Measure the output voltage of the generator set cranking batteries with a voltmeter.
The measured voltage should be 2328 VDC for a 24-VDC system or 1116 VDC for
a 12-VDC system. If the battery voltage is low, check the electrolyte level (applicable
for lead acid batteries only). Replenish the electrolyte level if it is low, and recharge
the battery.
2. Check the specific gravity of the generator set batteries. The specific gravity of a fullycharged lead-acid battery is approximately 1.260 at 80 F (27 C).
3. Check the battery ground connections to verify proper grounding.
4. Replace the batteries if the generator set batteries still cannot hold a charge.

19.3.9 Code 442 - High Battery Voltage


This code depends on Nominal Battery Voltage.
TABLE 126.

NOMINAL BATTERY VOLTAGE

Value

Description

12 V

The battery voltage is higher than 12 V High Battery Voltage Threshold for High
Battery Voltage Set Time.

24 V

The battery voltage is higher than 24 V High Battery Voltage Threshold for High
Battery Voltage Set Time.

This code cannot be reset until the battery voltage is below the indicated threshold for High
Battery Voltage Set Time.

A. Verify Battery Voltage Settings


Verify that the battery voltage matches Nominal Battery Voltage. This setting depends on
the application.
To access the battery voltage setup menu in InPower, go to Adjustments > Battery
Voltage Protection Setup > Nominal Battery Voltage.

B. Verify Battery Charging Rate


Verify the generator set battery charger is not overcharging the batteries beyond the high
voltage threshold by performing the following steps.
1. Verify the generator set battery charger is charging the generator set batteries at an
acceptable rate.

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2. Adjust the charging rate of the battery charger if the charging rate is above the
recommendation of the manufacturer. Refer to the battery charger manual for details.

19.3.10 Code 1121 - Fail to Disconnect


This code is active if all of these conditions are met.
Fail to Disconnect Enable is Enable.
Code 2397 (Utility Main Breaker Fail to Open) is active.
Code 1453 (Generator Set Main Breaker Fail to Open) is active.

19.3.10.1 Effects of Code 1121


The generator set paralleling breakers are inhibited in a final attempt to disconnect the
generator sets from the utility.
If PTC State is Paralleled, load control tells the generator sets to ramp down to avoid exporting
power to the utility. This also extends the amount of time the generator sets can run so that
there is more time for corrective action.

A. Troubleshoot Related Fault Codes


Troubleshoot the fault codes that are related to this code.

19.3.11 Code 1219 - Utility Main Breaker Tripped


The input for utility main breaker tripped is active.

19.3.11.1 Effects of Code 1219


The utility is not available in three-phase applications. (This effect ends when the conditions that
caused the code are no longer true. The fault does not have to be reset.)

A. Check Tripped Status


Verify the breaker is actually tripped.
If it is tripped, check for over current or short circuits.
If it is not tripped, check the trip feedback contact.

B. Check Over-current or Short Circuit Condition


1. Determine whether an over-current or short circuit condition occurred downstream
from the breaker.
2. If one of the conditions did occur, contact the electrical contractor for the site and wait
until the fault is cleared.
If none of the conditions occurred, check the circuit breaker manual.
3. Reset the circuit breaker manually after the fault is cleared.

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C. Check Utility Main Breaker Trip Feedback Contact


Verify the wiring from the utility main breaker to the tripped status input on the MCM3320
by performing the following steps.
1. Verify the physical status of the utility main breaker at the switchgear by checking the
breaker position indicator and the trip indicator/lock out relay status.
If the breaker position indicator and trip indicator/lock out are inactive state/OFF (i.e.,
utility main breaker is closed), and there still is an active breaker trip feedback to the
MCM3320, proceed with the following steps.
2. Disconnect terminal block TB10 from MCM3320, and check for continuity between
TB10-10 (MCM3320) and the corresponding terminal(s) in the switchgear. Use the
interconnection and switchgear schematics to identify the terminal(s).
3. Disconnect terminal block TB10 from MCM3320, and check for continuity between
TB10-08 (MCM3320) and the corresponding terminal(s) in the switchgear.

19.3.12 Code 1223 - Utility Bus Frequency


Utility Frequency Sensor Status is Dropped-out.

19.3.12.1 Utility Frequency Sensor


Utility Frequency Sensor Enable must be set to Enable.

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Time (t)
initial

Event

Sensor Status

The frequency (Hz) is acceptable.

Picked-Up

t1

The frequency (Hz) rises above the dropped-out threshold [upper


graph D, Utility Center Frequency + (Utility Frequency Pick-Up
Bandwidth + Utility Frequency Drop-Out Bandwidth)].
OR
The frequency (Hz) falls below the dropped-out threshold [lower
graph D, Utility Center Frequency - (Utility Frequency Pick-Up
Bandwidth + Utility Frequency Drop-Out Bandwidth)].

Picked-Up

t1+tD

The frequency (Hz) remains above or below the dropped-out


threshold (D) for a specified time delay (tD, Utility Frequency DropOut Delay).

Dropped-Out
(shaded area)

t2

The frequency (Hz) falls below the picked-up threshold (P, Utility
Center Frequency + Utility Frequency Pick-Up Bandwidth).
AND
The frequency (Hz) remains above the picked-up threshold (P,
Utility Center Frequency - Utility Frequency Pick-Up Bandwidth).

FIGURE 87.

Picked-Up

UTILITY FREQUENCY SENSOR

19.3.12.2 Effects of Code 1223


The utility is not available in three-phase applications. (This effect ends when the conditions that
caused the code are no longer true. The fault does not have to be reset.)

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A. Verify Utility Frequency Sensor Settings


Disconnect the J14 connector from the MCM3320, and connect InPower to the MCM3320.
Access Adjustments > Power Transfer Control Adjustments > Utility Sensor Adjustments,
and check these settings.
Utility Center Frequency; this should match the system frequency.
Utility Frequency Drop-Out Bandwidth and Utility Frequency Pick-Up Bandwidth; these
settings should not be too tight to allow for normal source fluctuation. Settings that are
too tight will activate this fault even for slight variations in frequency, such as ones
resulting from minor transients or the switching of devices.
Utility Frequency Drop-Out Delay; this should not be too short to allow for normal
source fluctuation.
NOTE:

To disable this code, set Utility Frequency Sensor Enable to Disable.

B. Check Utility Frequency Instability


The utility frequency may be unstable. Check with the respective utility company for
variations in frequency, and wait for the utility frequency to stabilize.

19.3.13 Code 1224 - Generator Set Bus Over Voltage


Genset Overvoltage Sensor Status is Dropped-out.

19.3.13.1 Generator Set Overvoltage Sensor


Genset Overvoltage Sensor Enable must be set to Enable.

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Time (t)
initial
t1
t1+tD

t2

Event

Sensor Status

The line-to-line voltage (V) is acceptable.

Picked-Up

The line-to-line voltage (V) rises above the dropped-out threshold


(D, Genset Overvoltage Drop-Out Percentage).

Picked-Up

The line-to-line voltage (V) remains above the dropped-out


threshold (D) for a specified time delay (tD, Genset Overvoltage
Drop-Out Delay).
The line-to-line voltage (V) falls below the picked-up threshold (P,
Genset Overvoltage Pick-Up Percentage * Genset Overvoltage
Drop-Out Percentage).

FIGURE 88.

Dropped-Out
(shaded area)
Picked-Up

GENERATOR SET OVERVOLTAGE SENSOR

When the synchronizer is active, Genset Overvoltage Drop-Out Percentage is temporarily set to
120%, and Genset Overvoltage Pick-Up Percentage is temporarily set to 95%. This prevents the
synchronizer from causing nuisance faults.

19.3.13.2 Effects of Code 1224


The generator sets are not available in three-phase applications. (This effect ends when the
conditions that caused the code are no longer true. The fault does not have to be reset.)

A. Check Generator Set Voltage


Run the generator sets, and measure the output voltage from the suspected generator set.
If the output voltage is high or low, see the generator set service manual. A generator set
can produce too much voltage or too little voltage for many reasons, such as faulty PTs,
faulty AVR, faulty PMG, incorrect PT ratio, incorrect PT connections, etc.

B. Check Generator Set Voltage Sensing Circuit


Verify there are no wiring issues with the generator set voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the generator set bus for
the following terminals:
L1, TB6-1
L2, TB6-2
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L3, TB6-3
2. Measure the line-to-neutral voltage input to the MCM3320 from the generator set bus
for the following terminals:
L1, TB6-1
L2, TB6-2
L3, TB6-3
N, TB6-4
3. Measure the line-to-line voltage input into the Potential Transformer from the
generator set bus. The voltage into the PT should match the generator set bus
voltage.
4. Check for continuity between the following terminals and the corresponding terminal at
the switchgear section.
L1 TB6-1 (MCM3320)
L2 TB6-2 (MCM3320)
L3 TB6-3 (MCM3320)
5. Verify that any breakers in the generator set voltage sensing circuit are operational.
Perform a visual inspection of the breaker position indicators. Use the switchgear
schematics to identify the breakers.

C. Verify System and Generator Set Voltage


Verify the system voltage matches the generator set voltage. Disconnect the J14 connector
from the MCM3320, and connect InPower to the MCM3320.
Adjustments > AC Meter Setup > Genset Nominal Voltage
Adjustments > AC Meter Setup > Utility Nominal Voltage

D. Verify Generator Set Voltage Sensing Setup


Verify the voltage sensing setup, with respect to the primary and secondary PT LL,
matches the PTs in the system. Disconnect the J14 connector from the MCM3320, and
connect InPower to the MCM3320. Access Adjustments > AC Meter Setup and then
access the following settings:
Genset PT Primary Voltage
Genset PT Secondary Voltage

E. Verify Generator Set Over Voltage Settings


Verify the generator set over voltage settings, pick-up, drop-out, and drop-out delay are not
too tight to allow for normal source fluctuations. Disconnect the J14 connector from the
MCM3320, and connect InPower to the MCM3320. Access Adjustments > Power Transfer
Control Adjustments > Genset Sensor Adjustments > Genset Over Voltage Settings.

F. Cycle Power
Cycle power to the MCM3320 to see if the fault clears.

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G. Check Calibration
Perform an update calibration using the InPower service tool. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320.
If unable to perform an update calibration, perform an initial calibration.
If unable to perform an initial calibration, replace the MCM3320 base board.

19.3.14 Code 1225 - Generator Set Bus Under Voltage


These conditions are met.
Genset Undervoltage Sensor Status is Dropped-out.
The generator sets are commanded to run, and Stop Time Delay is not active.

19.3.14.1 Generator Set Undervoltage Sensor


This sensor is always enabled.

Time (t)
initial

Event

Sensor Status

The line-to-line voltage (V) is acceptable.

Picked-Up

t1

The line-to-line voltage (V) falls below the dropped-out threshold


(D, Genset Undervoltage Drop-Out Percentage * Genset
Undervoltage Pick-Up Percentage).

Picked-Up

t1+tD

The line-to-line voltage (V) remains below the dropped-out


threshold (D) for a specified time delay (tD, Genset Undervoltage
Drop-Out Delay).

Dropped-Out
(shaded area)

t2

The line-to-line voltage (V) rises above the picked-up threshold (P,
Genset Undervoltage Pick-Up Percentage).

FIGURE 89.

Picked-Up

GENERATOR SET UNDERVOLTAGE SENSOR

When the synchronizer is active, Genset Undervoltage Drop-Out Percentage is temporarily set
to 75%, and Genset Undervoltage Pick-Up Percentage is temporarily set to 85%. This prevents
the synchronizer from causing nuisance faults.

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19.3.14.2 Effects of Code 1225


The generator sets are not available in three-phase applications. (This effect ends when the
conditions that caused the code are no longer true. The fault does not have to be reset.)

A. Check Generator Set Voltage


Run the generator sets, and measure the output voltage from the suspected generator set.
If the output voltage is low, see the generator set service manual. A generator set can
produce too little voltage for many reasons, such as faulty PTs, faulty AVR, faulty PMG,
incorrect PT ratio, incorrect PT connections, etc.

B. Check Generator Set Voltage Sensing Circuit


Verify there are no wiring issues with the generator set voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the generator set bus for
the following terminals:
L1, TB6-1
L2, TB6-2
L3, TB6-3
2. Measure the line-to-neutral voltage input to the MCM3320 from the generator set bus
for the following terminals:
L1, TB6-1
L2, TB6-2
L3, TB6-3
N, TB6-4
3. Measure the line-to-line voltage input into the Potential Transformer from the
generator set bus. The voltage into the PT should match the generator set bus
voltage.
4. Check for continuity between the following terminals and the corresponding terminal at
the switchgear section.
L1 TB6-1 (MCM3320)
L2 TB6-2 (MCM3320)
L3 TB6-3 (MCM3320)
5. Verify that any breakers in the generator set voltage sensing circuit are operational.
Perform a visual inspection of the breaker position indicators. Use the switchgear
schematics to identify the breakers.

C. Verify System and Generator Set Voltage


Verify the system voltage matches the generator set voltage. Disconnect the J14 connector
from the MCM3320, and connect InPower to the MCM3320.
Adjustments > AC Meter Setup > Genset Nominal Voltage
Adjustments > AC Meter Setup > Utility Nominal Voltage
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D. Verify Generator Set Voltage Sensing Setup


Verify the voltage sensing setup, with respect to the primary and secondary PT LL,
matches the PTs in the system. Disconnect the J14 connector from the MCM3320, and
connect InPower to the MCM3320. Access Adjustments > AC Meter Setup and then
access the following settings:
Genset PT Primary Voltage
Genset PT Secondary Voltage

E. Verify Generator Set Under Voltage Settings


Verify the generator set under voltage settings, pick-up, drop-out, and drop-out delay are
not too tight to allow for normal source fluctuations. Disconnect the J14 connector from the
MCM3320, and connect InPower to the MCM3320. Access Adjustments > Power Transfer
Control Adjustments > Genset Sensor Adjustments > Genset Under Voltage Settings.

F. Cycle Power
Cycle power to the MCM3320 to see if the fault clears.

G. Check Calibration
Perform an update calibration using the InPower service tool. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320.
If unable to perform an update calibration, perform an initial calibration.
If unable to perform an initial calibration, replace the MCM3320 base board.

19.3.15 Code 1226 - Generator Set Bus Frequency


These conditions are met.
Genset Frequency Sensor Status is Dropped-out.
The generator sets are commanded to run, and Stop Time Delay is not active.

19.3.15.1 Generator Set Frequency Sensor


Genset Frequency Sensor Enable must be set to Enable.

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Time (t)
initial
t1

t1+tD

t2

Event

Sensor Status

The frequency (Hz) is acceptable.

Picked-Up

The frequency (Hz) rises above the dropped-out threshold [upper


graph D, Genset Center Frequency + (Genset Frequency Pick-Up
Bandwidth + Genset Frequency Drop-Out Bandwidth)].
OR
The frequency (Hz) falls below the dropped-out threshold [lower
graph D, Genset Center Frequency - (Genset Frequency Pick-Up
Bandwidth + Genset Frequency Drop-Out Bandwidth)].

Picked-Up

The frequency (Hz) remains above or below the dropped-out


threshold (D) for a specified time delay (tD, Genset Frequency
Drop-Out Delay).
The frequency (Hz) falls below the picked-up threshold (P, Genset
Center Frequency + Genset Frequency Pick-Up Bandwidth).
AND
The frequency (Hz) rises above the picked-up threshold (P,
Genset Center Frequency - Genset Frequency Pick-Up
Bandwidth).

FIGURE 90.

Dropped-Out
(shaded area)
Picked-Up

GENERATOR SET FREQUENCY SENSOR

When the synchronizer is active, Genset Frequency Drop-Out Bandwidth is temporarily set to
5%, and Genset Frequency Pick-Up Bandwidth is temporarily set to 20%. This prevents the
synchronizer from causing nuisance faults.

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19.3.15.2 Effects of Code 1226


The generator sets are not available in three-phase applications. (This effect ends when the
conditions that caused the code are no longer true. The fault does not have to be reset.)

A. Check Generator Set Frequency Stability


Determine whether the generator set frequency is stable. If the generator set is hunting or
oscillating, refer to the generator set service manual to address the problem.

B. Verify Generator Set Frequency Sensor Settings


Disconnect the J14 connector from the MCM3320, and connect InPower to the MCM3320.
Access Setup > Paralleling Setup > Power Transfer Control, and check these settings.
Genset Center Frequency; this should match the system frequency.
Genset Frequency Drop-Out Bandwidth and Genset Frequency Pick-Up Bandwidth;
these settings should not be too tight to allow for normal source fluctuation. Settings
that are too tight will activate this fault even for slight variations in frequency, such as
ones resulting from minor transients or the switching of devices.
Genset Frequency Drop-Out Delay; this should not be too short to allow for normal
source fluctuation.
NOTE:

To disable this code, set Genset Frequency Sensor Enable to Disable.

19.3.16 Code 1328 - Generator Set Main Breaker Tripped


The input for generator set main breaker tripped is active.

19.3.16.1 Effects of Code 1328


The generator sets are not available in three-phase applications. (This effect ends when the
conditions that caused the code are no longer true. The fault does not have to be reset.)
The system cannot commit to transferring the loads to the generator sets.

A. Check Tripped Status


Verify the breaker is actually tripped.
If it is tripped, check for over current or short circuits.
If it is not tripped, check the trip feedback contact.

B. Check Over-current or Short Circuit Condition


1. Determine whether an over-current or short circuit condition occurred downstream
from the breaker.
2. If one of the conditions did occur, contact the electrical contractor for the site and wait
until the fault is cleared.
If none of the conditions occurred, check the circuit breaker manual.
3. Reset the circuit breaker manually after the fault is cleared.

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C. Check Trip Feedback Contact for Generator Set Main Breaker


Verify the wiring by performing the following steps.
1. Verify the physical status of the generator set main breaker at the switchgear by
checking the breaker position indicator and the trip indicator/lock out relay status.
If the breaker position indicator and trip indicator/lock out relay are inactive state/OFF
(i.e., generator set main breaker is closed), and there still is an active breaker trip
feedback to the MCM3320, continue with the following steps.
2. Disconnect terminal block TB10 (MCM3320) and check for continuity between
terminals TB10-03 (MCM3320) and the corresponding terminal in the switchgear. Use
the interconnection and switchgear schematics to identify the switchgear terminal.
3. Disconnect terminal block TB10 (MCM3320) and check for continuity between
terminals TB10-04 (MCM3320) and the corresponding terminal in the switchgear. Use
the interconnection and switchgear schematics to identify the switchgear terminal.

19.3.17 Code 1335 - AC Metering Out of Range


The measured value of voltage, current, kW, kVAR, kVA, or power factor is outside the
programmed range. The measured value can be from the generator sets or the utility.

19.3.17.1 Effects of Code 1335


If load demand is active, load demand becomes inactive. Any generator sets that have stopped
due to load demand are restarted.

A. Verify PT and CT Ratio Settings


Verify the PT and CT ratio settings are set correctly. Make adjustments to the settings if
necessary. Disconnect the J14 connector from the MCM3320, and connect InPower to the
MCM3320. Access Adjustments > AC Meter Setup, and then access the following options:
Genset PT Primary Voltage
Genset PT Secondary Voltage
Genset CT Primary Voltage
Genset CT Secondary Voltage
Utility PT Primary Voltage
Utility PT Secondary Voltage
Utility CT Primary Voltage
Utility CT Secondary Voltage

B. Verify Generator Set Ratings


Verify that the Gen KW Rating of the generator sets in the system are set up correctly in
the MCM3320. Disconnect the J14 connector from the MCM3320, and connect InPower to
the MCM3320. Go to Adjustments > System Setup > Genset (s) KW Rating.

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C. Verify System and Generator Set Voltage


Verify the system voltage matches the generator set voltage. Disconnect the J14 connector
from the MCM3320, and connect InPower to the MCM3320.
Adjustments > AC Meter Setup > Genset Nominal Voltage
Adjustments > AC Meter Setup > Utility Nominal Voltage

D. Check Wiring for CT Sensing


Verify the CT sensing wires are run correctly through the onboard CTs in the MCM3320.
Two wires should pass through the CT hole for 1 A
One wire should pass through the CT hole for 5 A

E. Check Generator Set Voltage Sensing Circuit


Verify there are no wiring issues with the generator set voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the generator set bus for
the following terminals:
L1, TB6-1
L2, TB6-2
L3, TB6-3
2. Measure the line-to-neutral voltage input to the MCM3320 from the generator set bus
for the following terminals:
L1, TB6-1
L2, TB6-2
L3, TB6-3
N, TB6-4
3. Measure the line-to-line voltage input into the Potential Transformer from the
generator set bus. The voltage into the PT should match the generator set bus
voltage.
4. Check for continuity between the following terminals and the corresponding terminal at
the switchgear section.
L1 TB6-1 (MCM3320)
L2 TB6-2 (MCM3320)
L3 TB6-3 (MCM3320)
5. Verify that any breakers in the generator set voltage sensing circuit are operational.
Perform a visual inspection of the breaker position indicators. Use the switchgear
schematics to identify the breakers.

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F. Check Utility Voltage Sensing Circuit


Verify there are no wiring issues with the utility voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the Utility Bus for the
following terminals:
L1, TB7-1
L2, TB7-2
L3, TB7-3
2. Measure the line-to-line voltage input to the Potential Transformer (PT) from the Utility
Bus. The voltage into the PT should match the Utility Bus voltage.
3. Check for continuity between the following terminals:
L1 TB7-1 (MCM3320) and the corresponding terminal at the switchgear section
L2 TB7-2 (MCM3320) and the corresponding terminal at the switchgear section
L3 TB7-3 (MCM3320) and the corresponding terminal at the switchgear section
N TB7-4 (MCM3320) and the corresponding terminal at the switchgear section
4. Verify that the breakers in the utility voltage sensing circuit at the switchgear are
operational. Perform a visual inspection of the breaker position indicators. Use the
switchgear schematics to identify the breakers.

G. Check Utility Current-sensing Circuit


Verify there are no wiring issues with the current-sensing connections to the MCM3320 by
performing the following steps.
1. Verify that the wire passes through CTs on the MCM3320 once for 5 A units and twice
for 1 A units.
2. Verify that the wires passing through the CTs on the MCM3320 are connected to the
corresponding terminals in the switchgear. Refer to the interconnection and switchgear
schematics for details.
3. Verify there are no broken or loose connections in the current-sensing circuit.

H. Check Generator Set Bus Current-sensing Circuit


Verify there are no wiring issues with the current-sensing connections to the MCM3320 by
performing the following steps.
1. Verify that the wire passes through CTs on the MCM3320 once for 5 A units and twice
for 1 A units.
2. Verify that the wires passing through the CTs on the MCM3320 are connected to the
corresponding terminals in the switchgear. Refer to the interconnection and switchgear
schematics for details.
3. Verify there are no broken or loose connections in the current-sensing circuit.

19.3.18 Code 1444 - Generator Set Bus Overload


This code depends on Genset Bus kW Overload Detection Method.

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TABLE 127.
Value

GENSET BUS KW OVERLOAD DETECTION METHOD


Description

kW Only

The generator set load is more than Genset Bus %kW Overload Threshold for
more than Genset Bus kW Overload Delay.

Frequency Only

The generator set frequency is less than Genset Bus Underfrequency Overload
Threshold for more than Genset Bus Underfrequency Overload Delay.

Both kW and Frequency

At least one of the other conditions is true.

19.3.18.1 Effects of Code 1444


If load demand is active, load demand becomes inactive. Any generator sets that have stopped
due to load demand are restarted.
If load add/shed is active, automatic load add and manual load add are interrupted, and load
add/shed starts removing loads based on load-shed levels. The loads are removed using the
same load shed sequence that automatic load shed uses. It does not matter if automatic load
shed is active.

A. Verify Generator Set Bus Overload Parameters


Verify the generator set bus overload parameters are set correctly. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320. Access Adjustments
> Genset Bus Overload Adjustments.
Genset Bus Overload Method
%KW Overload Threshold
KW Overload Delay
Underfrequency Overload Delay
Underfrequency Overload Threshold

B. Verify System Load Add Parameter


Verify the System Load Add parameter is configured correctly. Make sure the system load
does not exceed the generating capacity of the generator sets in the system.
Disconnect the J14 connector from the MCM3320, and connect InPower to the MCM3320.
Access the following settings:
Adjustments > Load Control Setup Adjustments > Genset Bus KW Setpoint
Monitor > Genset Bus Overload > Genset Bus Overload Status

C. Check Utility Availability


Determine whether the utility has failed. If it has, wait for power to be restored and become
stable.

D. Check kW Settings
Determine whether the generator set kW settings should be adjusted because the
generator set is installed at a high altitude. Refer to the generator set service manual for
details.

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E. Verify Generator Set Ratings


Verify that the Gen KW Rating of the generator sets in the system are set up correctly in
the MCM3320. Disconnect the J14 connector from the MCM3320, and connect InPower to
the MCM3320. Go to Adjustments > System Setup > Genset (s) KW Rating.

F. Troubleshoot Generator Set Related Fault Codes


Check for faults on the generator sets, and troubleshoot them. Refer to the generator set
service manual.

19.3.19 Code 1452 - Generator Set Main Breaker Fail to Close


(Isolated Bus Without Generator Set Main Breaker or
Common Bus)
The generator sets are expected to close to the generator set bus, but none of the paralleling
breakers closed within Virtual Gen Main Fail to Close Delay.
This cannot be generated in Manual mode.

19.3.19.1 Effects of Code 1452


The generator sets are not available in three-phase applications.
The system cannot commit to transferring the loads to the generator sets.

A. Check Generator Set Paralleling Breaker Status


Check the status of the paralleling breaker at the switchgear by checking the breaker
position indicator and the trip indicator/lock out relay. Proceed based on what you find:
If the paralleling breaker is still open after receiving the close command from the
MCM3320, continue with verifying the generator set controller mode.
If the paralleling breaker is actually closed after receiving the close command from the
MCM3320, but this fault code has been generated, continue with checking the
paralleling breaker close circuit.

B. Verify Generator Set Controller Mode


Verify the generator set controls are in Auto mode; otherwise, a start signal from the
MCM3320 will be ignored, and this fault code will be generated. Also verify that no
shutdown faults are currently active on the generator set controls.

C. Verify Generator Set Paralleling Breaker Functionality


Verify the paralleling breaker is not locked out or tagged out.

D. Check Paralleling Breaker Close Circuit


Check the wiring in the paralleling breaker close circuit by checking for continuity between
the points listed below.
TB3-8 (MCM3320) and the corresponding terminal in the switchgear
TB3-16 (MCM3320) and the corresponding terminal in the switchgear

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E. Check Control Voltage


Verify there is control voltage in the generator set paralleling breaker close circuit and the
paralleling breaker UVR. Check for control voltage at the switchgear terminals that power
up the close coil of the breaker. Refer to the switchgear and breaker schematics.

F. Verify Operation of Breaker Close Coil


Verify the operation of the circuit breaker close coil. Make sure the close coil actually
closes the breaker when energized. This can be done by connecting power across the
terminals of the breaker close coil. Refer to the breaker schematics or breaker manual for
details.

19.3.20 Code 1452 - Generator Set Main Breaker Fail to Close


(Isolated Bus with Generator Set Main Breaker or Transfer
Pair)
A close command was sent to the generator set main breaker, but the breaker did not close
within Gen CB Fail to Close Delay.

19.3.20.1 Effects of Code 1452


The generator sets are not available in three-phase applications.
The system cannot commit to transferring the loads to the generator sets.

A. Check Generator Set Main Breaker Status


Check the status of the generator set main breaker at the switchgear by checking the
breaker position indicator and the trip indicator/lock out relay. Proceed based on what you
find:
If the generator set main breaker is still open after receiving the close command from
the MCM3320, continue with checking the spring charge mechanism.
If the generator set main breaker is actually closed after receiving the close command
from the MCM3320, but this fault code has been generated, continue with checking
the control voltage in the generator set main breaker close circuit.

B. Check Spring Charge Mechanism


Verify the spring charge mechanism of the breaker is operational by performing the
following steps.
1. Check the spring charge indicator of the breaker and determine whether the spring
coil is fully charged. If the spring coil is discharged, it can be confirmed that the spring
charging motor is not charging up the spring coil or the spring coil is bad.
2. Check for control voltage at the spring charging motor. Refer to the breaker
schematics/service manual to determine the cause if there is no control voltage.
3. Manually charge the spring coil by using the spring charging handle.
If the manual charge is successful, the breaker will open and close as
commanded.

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If the manual charge is not successful, the breaker will not change status. Refer
to the breaker schematics/service manual and replace the spring coil. Contact
the breaker manufacturer and distributor regarding the fix (this is required).

C. Check Auxiliary Breaker Position Contacts


Verify auxiliary position contacts 'a' and 'b' are operational by performing the following
steps.
1. Remove existing wires from TB10-1 and TB10-2.
2. Perform a continuity check on both 'a' and 'b' contacts at the breaker.
3. Obtain permission from the facility or customer to interrupt the power supply to the
site.
4. Cycle power to the breaker to make sure the auxiliary contacts change their respective
states with the change in breaker status from open to closed or closed to open.
If the auxiliary contacts do not change states, the breaker is faulty, and it must be
fixed or replaced. Contact the manufacturer, distributor, and electrical contractor to
resolve the problem. Cummins technicians are not responsible for troubleshooting a
faulty circuit breaker.

D. Check Control Voltage


Verify there is control voltage in the generator set main breaker close circuit. Check for
control voltage at the switchgear terminals that power up the close coil of the breaker.
Refer to the switchgear and breaker schematics.

E. Check Generator Set Main Breaker Close Circuit


Check the wiring in the generator set main breaker close circuit by checking for continuity
between the following contacts:
TB8-2 (MCM3320) and the corresponding terminal in the switchgear
TB8-3 (MCM3320) and the corresponding terminal in the switchgear

F. Verify Generator Set Main Breaker Components


Verify the components in the close circuit are operating properly by performing the
following steps.
Obtain permission from the facility to interrupt power to the site. Verify operation of the
breaker close coil by jumpering power across the terminals of the breaker close coil and
making sure it actually closes the breaker when energized. Refer to the breaker
schematics/service manual for details.
Make sure this check is performed in a safe manner so as to avoid damaging electrical
equipment. For example, if generator sets are on the bus, the utility breaker must not be
closed.

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G. Verify Time Delay Setting


Verify the setting for the Fail to Close Time Delay in the generator set main breaker is
based on the breaker specifications. Check the breaker service manual for details and use
InPower to check the setting. Disconnect the J14 connector from the MCM3320, and
connect InPower to the MCM3320. Access Adjustments > Breaker Adjustments > Genset
Main Breaker Adjustments > Gen CB Fail to Close Delay.

19.3.21 Code 1453 - Generator Set Main Breaker Fail to Open


(Isolated Bus Without Generator Set Main Breaker or
Common Bus)
An open command was sent to the generator set paralleling breakers, but at least one of the
paralleling breakers remained closed for Virtual Gen Main Fail to Open Delay.
This cannot be generated in Manual mode.

19.3.21.1 Effects of Code 1453


When PTC State is Genset Connected, the synchronizer cannot start, and the utility cannot
connect to the loads.
If Fail to Disconnect Enable is Enabled and PTC State is Paralleled, the utility is disconnected
immediately. (This effect ends when the conditions that caused the code are no longer true. The
fault does not have to be reset.)
Code 1453 can generate code 1121 (Fail to Disconnect).

A. Check GN Breaker Open Circuit


Check the wiring in the generator set paralleling breaker open circuit by checking for
continuity between the points listed below.
TB3-16 (MCM3320) and the corresponding terminal in the switchgear
TB3-8 (MCM3320) and the corresponding terminal in the switchgear

B. Check Control Voltage


Verify there is a signal in the generator set paralleling breaker open coil. Check for control
voltage at the switchgear terminals that power the open coil of the GN circuit breaker.
Refer to the switchgear and breaker schematics for the interconnections.

C. Verify Operation of Breaker Open Coil


Verify the operation of the generator set paralleling breaker open coil. Make sure the
breaker open coil actually opens the breaker when energized. This can be done by
jumpering power across the terminals of the breaker open coil. Refer to the breaker
schematics/service manual for details.
To perform this check, the technician requires the permission from the facility. This check
must be done in a safe manner to avoid damaging electrical equipments. For example, if
generator sets are on the bus, the utility breaker must not be closed.

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19.3.22 Code 1453 - Generator Set Main Breaker Fail to Open


(Isolated Bus with Generator Set Main Breaker or Transfer
Pair)
An open command was sent to the generator set main breaker, but the breaker did not open
within Gen CB Fail to Open Delay.

19.3.22.1 Effects of Code 1453


When PTC State is Genset Connected, the synchronizer cannot start, and the utility cannot
connect to the loads.
If Fail to Disconnect Enable is Enabled and PTC State is Paralleled, the utility is disconnected
immediately. (This effect ends when the conditions that caused the code are no longer true. The
fault does not have to be reset.)
Code 1453 can generate code 1121 (Fail to Disconnect).

A. Check Breaker Status


Check the breaker position indicator and the trip indicator/lock out relay.
If the breaker is still closed after receiving the open command from the MCM, check
the spring charge mechanism.
If the breaker is actually open after receiving the open command from the MCM,
check the control voltage in the breaker open circuit.

B. Check Spring Charge Mechanism


Verify the spring charge mechanism of the breaker is operational by performing the
following steps.
1. Check the spring charge indicator of the breaker and determine whether the spring
coil is fully charged. If the spring coil is discharged, it can be confirmed that the spring
charging motor is not charging up the spring coil or the spring coil is bad.
2. Check for control voltage at the spring charging motor. Refer to the breaker
schematics/service manual to determine the cause if there is no control voltage.
3. Manually charge the spring coil by using the spring charging handle.
If the manual charge is successful, the breaker will open and close as
commanded.
If the manual charge is not successful, the breaker will not change status. Refer
to the breaker schematics/service manual and replace the spring coil. Contact
the breaker manufacturer and distributor regarding the fix (this is required).

C. Check Auxiliary Breaker Position Contacts


Verify auxiliary position contacts 'a' and 'b' are operational by performing the following
steps.
1. Remove existing wires from TB10-1 and TB10-2.
2. Perform a continuity check on both 'a' and 'b' contacts at the breaker.
3. Obtain permission from the facility or customer to interrupt the power supply to the
site.
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4. Cycle power to the breaker to make sure the auxiliary contacts change their respective
states with the change in breaker status from open to closed or closed to open.
If the auxiliary contacts do not change states, the breaker is faulty, and it must be
fixed or replaced. Contact the manufacturer, distributor, and electrical contractor to
resolve the problem. Cummins technicians are not responsible for troubleshooting a
faulty circuit breaker.

D. Check Generator Set Main Breaker Open Circuit


Check for a signal in the generator set main breaker open circuit.

E. Check Control Voltage


1. Check for control voltage at the switchgear terminals that power up the open coil of
the generator set main breaker. Refer to the switchgear and breaker schematics.
2. Check for continuity in the wiring of the generator set main breaker open circuit. Verify
that there is continuity in the wires running from the MCM3320 to the generator set
main breaker in the switchgear and back from the generator set main breaker to the
MCM3320.

F. Verify Generator Set Main Breaker Components


Verify that the components in the generator set main breaker open circuit are operating
properly.
Verify the operation of the generator set main breaker open coil. Make sure the breaker
open coil actually opens the breaker when energized. This can be done by jumpering
power across the terminals of the breaker open coil. Refer to the breaker
schematics/service manual for details.
To perform this check, the technician requires the permission from the facility. This check
must be done in a safe manner so as to avoid damaging electrical equipments. For
example, if generator sets are on the bus, the utility breaker must not be closed.

G. Verify Time Delay Setting


Verify the setting for the Fail to Open Time Delay in the generator set main breaker is
based on the breaker specifications. Check the breaker manual for details. Disconnect the
J14 connector from the MCM3320, and connect InPower to the MCM3320. Access
Adjustments > Breaker Adjustments > Genset Main Breaker Adjustments > Gen CB Fail to
Open Delay.

19.3.23 Code 1454 - Generator Set Main Breaker Position Contact


This code depends on Genset Breaker Position Contacts.
TABLE 128.
Value

GENSET BREAKER POSITION CONTACTS

Description

Single Contact (a)

The generator set main breaker is open, but there was at least 5% current in all
phases for 2 seconds.

Dual Contact (a/b)

The generator set main breaker position contacts do not agree about the position of
the generator set main breaker for 2 seconds.

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In Manual mode, the generator set main breaker is treated as a single-contact breaker.
NOTE:

Before troubleshooting this code, the system should be in Manual mode, and
the generator sets should be in Off mode.

19.3.23.1 Associated Pins and Expected Values


Expected values are based on a measurement between the indicated pin and a discrete input
return, such as TB10-4.
TABLE 129.

BREAKER POSITION AND EXPECTED VALUES OF BREAKER POSITION CONTACTS

Breaker Position

TB10-1 (Position A)

TB10-2 (Position B)

Open

Open

Closed

Closed

Closed

Open

19.3.23.2 Effects of Code 1454


The utility cannot connect to the loads.
If the topology is Isolated Bus with Generator Set Main Breaker or Transfer Pair, the generator
sets are not available in three-phase applications if the generator set main breaker is a dualcontact breaker and Genset Current Based Breaker Position is Unknown.
If the generator set main breaker is a dual-contact breaker, the generator set main breaker is
considered closed, and the generator sets are considered connected to the loads.
If Genset Current Based Breaker Position is Closed, the MCM generates a retransfer inhibit.
The system cannot commit to transferring the loads to the generator sets.

A. Check Contact Status


Disconnect the J14 connector from the MCM3320, and connect InPower to the MCM3320.
Check position A and position B of the generator set main breaker.
NOTE:

For single-contact breakers, check position A only.

1. Open a monitor window and drag Gen CB Position A SW and Gen CB Position B Sw
to the monitor window.
2. Enable monitoring in InPower.
If Position A is bad, troubleshoot contact A.
If Position B is bad, troubleshoot contact B.

B. Verify Position Contact 'b'


Verify the generator set main breaker position contact 'b' using InPower. Disconnect the
J14 connector from the MCM3320, and connect InPower to the MCM3320. Access Monitor
> Switch Inputs > Genset CB Position B Sw.
If position contact 'b' is not in line with the generator set main breaker (i.e., it is open when
the generator set main breaker is closed, or closed when the generator set main breaker is
open), check the position contact 'b' wiring.

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C. Check Contact 'b' Wiring


1. Disconnect terminal block TB10 (MCM3320).
2. Check for continuity between TB10-2 (MCM3320) and the corresponding terminal in
the switchgear.
3. Check for continuity between TB10-4 (MCM3320) and the corresponding terminal in
the switchgear.
Use the interconnect and switchgear schematics to determine the switchgear terminal.

D. Verify Position Contact 'a'


Verify the generator set main breaker position contact 'a' using InPower. Disconnect the
J14 connector from the MCM3320, and connect InPower to the MCM3320. Access Monitor
> Switch Inputs > Genset CB Position A Sw.
If position contact 'a' is not in line with the generator set main breaker (i.e., it is open when
the generator set main breaker is open, or closed when the generator set main breaker is
closed), check the position contact 'a' wiring.

E. Check Contact 'a' Wiring


1. Disconnect terminal block TB10 (MCM3320).
2. Check for continuity between TB10-1 (MCM3320) and the corresponding terminal in
the switchgear.
3. Check for continuity between TB10-4 (MCM3320) and the corresponding terminal in
the switchgear.
Use the interconnect and switchgear schematics to determine the switchgear terminal.

F. Power Cycle the Generator Set Main Breaker


Make sure the breaker position contacts are changing states according to the standard
operational logic by performing the following steps.
1. Obtain permission from facility management to interrupt power to the facility.
2. Put the system in Manual mode.
3. Power cycle the generator set main breaker.

19.3.24 Code 1455 - Utility Main Breaker Position Contact


(Isolated Bus Without Generator Set Main Breaker or
Isolated Bus with Generator Set Main Breaker)
There is a problem with the utility main breaker position contact inputs. These contact inputs,
namely TB14-U1-05 and TB14-U1-07, must be hard-wired (jumpered) to indicate to the
MCM3320 that the utility main breaker is open. Otherwise, the fault will become active.

19.3.24.1 Effects of Code 1455


The generator set main breaker cannot close.
The generator set paralleling breakers are not allowed to close, but they can remain closed if
they were already closed.

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If the topology is Common Bus or Transfer Pair, the utility is not available in three-phase
applications if the utility main breaker is a dual-contact breaker and Utility Current Based
Breaker Position is Unknown.
If the utility main breaker is a dual-contact breaker, the utility main breaker is considered closed,
and the utility is considered connected to the loads.
If Utility Current Based Breaker Position is Closed, the MCM generates a transfer inhibit.

A. Verify Jumper Connection


There may be no jumper present on the utility main breaker 'b' contact between TB10-8
and TB10-9. Use InPower to monitor the breaker position contact status. Disconnect the
J14 connector from the MCM3320, and connect InPower to the MCM3320. Access Monitor
> Switch Inputs, and then access the following options:
Utility CB Position A Switch
Utility CB Position B Switch
Review the status of each contact and make sure the status of the CB position inputs
matches the connection.

B. Verify No Improper Jumper Connection


A jumper may be incorrectly connected to the utility main breaker 'a' contact input. Make
sure no such jumper connection exists between TB10-7 and TB10-8.

19.3.25 Code 1455 - Utility Main Breaker Position Contact


(Common Bus or Transfer Pair)
This code depends on Utility Breaker Position Contacts.
TABLE 130.
Value

UTILITY BREAKER POSITION CONTACTS

Description

Single Contact (a)

The utility main breaker is open, but there was at least 5% current in all phases for
2 seconds.

Dual Contact (a/b)

The utility main breaker position contacts do not agree about the position of the
utility main breaker for 2 seconds.

In Manual mode, the utility main breaker is treated as a single-contact breaker.

19.3.25.1 Associated Pins and Expected Values


Expected values are based on a measurement between the indicated pin and a discrete input
return, such as TB10-8.
TABLE 131.

208

BREAKER POSITION AND EXPECTED VALUES OF UTILITY BREAKER POSITION


CONTACTS

Breaker Position

TB10-7 (Position A)

TB10-9 (Position B)

Open

Open

Closed

Closed

Closed

Open

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19.3.25.2 Effects of Code 1455


The generator set main breaker cannot close.
The generator set paralleling breakers are not allowed to close, but they can remain closed if
they were already closed.
If the topology is Common Bus or Transfer Pair, the utility is not available in three-phase
applications if the utility main breaker is a dual-contact breaker and Utility Current Based
Breaker Position is Unknown.
If the utility main breaker is a dual-contact breaker, the utility main breaker is considered closed,
and the utility is considered connected to the loads.
If Utility Current Based Breaker Position is Closed, the MCM generates a transfer inhibit.

A. Check Contact Status


Disconnect the J14 connector from the MCM3320, and connect InPower to the MCM3320.
Check position A and position B of the utility main breaker.
NOTE:

For single-contact breakers, check position A only.

1. Open a monitor window and drag Util CB Position A SW and Util CB Position B Sw to
the monitor window.
2. Enable monitoring in InPower.
If Position A is bad, troubleshoot contact A.
If Position B is bad, troubleshoot contact B.

B. Verify Position Contact 'b'


Verify the utility main breaker position contact 'b' using InPower. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320. Access Monitor >
Switch Inputs > Utility CB Position B Sw.
If position contact 'b' is in line with the standard logic (i.e., it is open when the utility
main breaker is closed, or closed when the utility main breaker is open), continue with
verifying position contact 'a.'
If position contact 'b' is not in line with the standard logic, continue with checking
position contact 'b' wiring.

C. Check Contact 'b' Wiring


1. Disconnect terminal block TB10 (MCM3320).
2. Check for continuity between TB10-8 (MCM3320) and the corresponding terminal in
the switchgear.
3. Check for continuity between TB10-9 (MCM3320) and the corresponding terminal in
the switchgear.
Use the interconnect and switchgear schematics to determine the switchgear terminal.

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D. Verify Position Contact 'a'


Verify the utility main breaker position contact 'a' using InPower. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320. Access Monitor >
Switch Inputs > Utility CB Position A Sw.
If position contact 'a' is in line with the standard logic (i.e., it is open when the utility
main breaker is open, or closed when the utility main breaker is closed), continue with
power cycling the utility main breaker.
If position contact 'a' is not in line with the standard logic, continue with checking
position contact 'a' wiring.

E. Check Contact 'a' Wiring


1. Disconnect terminal block TB10 (MCM3320).
2. Check for continuity between TB10-7 (MCM3320) and the corresponding terminal in
the switchgear.
3. Check for continuity between TB10-8 (MCM3320) and the corresponding terminal in
the switchgear.
Use the interconnect and switchgear schematics to determine the switchgear terminal.

F. Power Cycle the Utility Main Breaker


Make sure the breaker position contacts are changing states according to the standard
operational logic by performing the following steps.
1. Obtain permission from facility management to interrupt power to the facility.
2. Power cycle the utility main breaker.

19.3.26 Code 1456 - Synchronizer Output Limit


The synchronizer has been trying to synchronize the generator sets with the utility by putting
voltage and/or frequency bias at extreme values (lowest, highest) for Fail to Synchronize Time.

A. Verify Fail to Synchronize Time Setting


Determine whether the Fail to Synchronize time setting is too short. Using InPower,
disconnect the J14 connector from the MCM3320, and connect InPower to the MCM3320.
Access Adjustments > Sync Check Adjustments > Fail to Synchronize Time.

B. Check Permissive Window Parameters


The sync check function monitors the generator set and system voltage, frequency, and
phase rotation to determine whether the two sources can be paralleled. Any differences in
voltage, frequency, and phase rotation between the generator set and system bus must be
smaller than the permissive window parameters.
1. Set the following parameters appropriately for the specific application using InPower.
Disconnect the J14 connector from the MCM3320, and connect InPower to the
MCM3320. Access Adjustments > Sync Check Adjustments > Permissive Window
Parameters.
Permissive Frequency Window

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Permissive Voltage Window


Permissive Window Time
Permissive Phase Window
2. Use a phase rotation meter to verify the phase rotation of the generator sets and
system.

C. Check Load Share Lines


The load share lines are used to bias the generator sets during synchronization.
1. Verify there are no wiring errors by checking for continuity between the following
terminals:
TB9-10 (MCM3320) and the respective terminal at the generator set control
TB9-9 (MCM3320) and the respective terminal at the generator set control
TB9-8 (MCM3320) and the respective terminal at the generator set control
2. Verify the load share wires running from the MCM3320 to the generator set controls
are connected based on the wire numbers specified in the interconnection and base
schematics.

D. Verify Utility Voltage


Verify the utility voltage is within the synchronizer bias range. The default range is +/- 6%.
To check the voltage using InPower, disconnect the J14 connector from the MCM3320,
and connect InPower to the MCM3320. Access Adjustments > Synchronizer Adjustments >
Voltage Match Limit.

E. Verify Utility Frequency


Verify the utility frequency is within the synchronizer bias range. The default range is +/- 1
Hz. To check the value using InPower, disconnect the J14 connector from the MCM3320,
and connect InPower to the MCM3320. Access Adjustments > Synchronizer Adjustments >
Frequency Match Limit.

19.3.27 Code 1457 - Fail to Synchronize Warning


The synchronizer is active, and the generator sets have not synchronized with the utility for Fail
to Synchronize Time.

19.3.27.1 Effects of Code 1457


If Fail To Sync Open Transition Retransfer Enable is Enabled, the system completes a
retransfer to the utility in Normal mode by open transition.
If Fail To Sync Lockout Enable is Enable, the synchronizer stops running and cannot run until
the fault is reset.

A. Verify Fail to Synchronize Time Setting


Determine whether the Fail to Synchronize time setting is too short. Using InPower,
disconnect the J14 connector from the MCM3320, and connect InPower to the MCM3320.
Access Adjustments > Sync Check Adjustments > Fail to Synchronize Time.

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B. Check Permissive Window Parameters


The sync check function monitors the generator set and system voltage, frequency, and
phase rotation to determine whether the two sources can be paralleled. Any differences in
voltage, frequency, and phase rotation between the generator set and system bus must be
smaller than the permissive window parameters.
1. Set the following parameters appropriately for the specific application using InPower.
Disconnect the J14 connector from the MCM3320, and connect InPower to the
MCM3320. Access Adjustments > Sync Check Adjustments > Permissive Window
Parameters.
Permissive Frequency Window
Permissive Voltage Window
Permissive Window Time
Permissive Phase Window
2. Use a phase rotation meter to verify the phase rotation of the generator sets and
system.

C. Check Load Share Lines


The load share lines are used to bias the generator sets during synchronization.
1. Verify there are no wiring errors by checking for continuity between the following
terminals:
TB9-10 (MCM3320) and the respective terminal at the generator set control
TB9-9 (MCM3320) and the respective terminal at the generator set control
TB9-8 (MCM3320) and the respective terminal at the generator set control
2. Verify the load share wires running from the MCM3320 to the generator set controls
are connected based on the wire numbers specified in the interconnection and base
schematics.

D. Verify Utility Voltage


Verify the utility voltage is within the synchronizer bias range. The default range is +/- 6%.
To check the voltage using InPower, disconnect the J14 connector from the MCM3320,
and connect InPower to the MCM3320. Access Adjustments > Synchronizer Adjustments >
Voltage Match Limit.

E. Verify Utility Frequency


Verify the utility frequency is within the synchronizer bias range. The default range is +/- 1
Hz. To check the value using InPower, disconnect the J14 connector from the MCM3320,
and connect InPower to the MCM3320. Access Adjustments > Synchronizer Adjustments >
Frequency Match Limit.

19.3.28 Code 1458 - Synchronizer Phase Rotation Mismatch


The synchronizer is active, and the phase rotation of the utility has not matched the phase
rotation of the generator set bus for Fail to Synchronize Time.

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19.3.28.1 Effects of Code 1458


Permissive Close Allowed is Not Allowed.

A. Check Utility Voltage Sensing Circuit


Verify there are no wiring issues with the utility voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the Utility Bus for the
following terminals:
L1, TB7-1
L2, TB7-2
L3, TB7-3
2. Measure the line-to-line voltage input to the Potential Transformer (PT) from the Utility
Bus. The voltage into the PT should match the Utility Bus voltage.
3. Check for continuity between the following terminals:
L1 TB7-1 (MCM3320) and the corresponding terminal at the switchgear section
L2 TB7-2 (MCM3320) and the corresponding terminal at the switchgear section
L3 TB7-3 (MCM3320) and the corresponding terminal at the switchgear section
N TB7-4 (MCM3320) and the corresponding terminal at the switchgear section
4. Verify that the breakers in the utility voltage sensing circuit at the switchgear are
operational. Perform a visual inspection of the breaker position indicators. Use the
switchgear schematics to identify the breakers.

B. Check Generator Set Voltage Sensing Circuit


Verify there are no wiring issues with the generator set voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the generator set bus for
the following terminals:
L1, TB6-1
L2, TB6-2
L3, TB6-3
2. Measure the line-to-neutral voltage input to the MCM3320 from the generator set bus
for the following terminals:
L1, TB6-1
L2, TB6-2
L3, TB6-3
N, TB6-4
3. Measure the line-to-line voltage input into the Potential Transformer from the
generator set bus. The voltage into the PT should match the generator set bus
voltage.

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4. Check for continuity between the following terminals and the corresponding terminal at
the switchgear section.
L1 TB6-1 (MCM3320)
L2 TB6-2 (MCM3320)
L3 TB6-3 (MCM3320)
5. Verify that any breakers in the generator set voltage sensing circuit are operational.
Perform a visual inspection of the breaker position indicators. Use the switchgear
schematics to identify the breakers.

C. Verify Power Cable Connections


Verify the utility and generator set power cables are connected in the proper phase
sequence. The desired phase sequence is A-B-C or L1-L2-L3.

D. Check Utility Problem


Determine whether there is any problem with the utility power cables on the utility side,
such as a miswiring or an external utility repair that may have changed the phase rotation.
Contact the facility and respective electrical contractors to fix the phasing of the power
cables.

19.3.29 Code 1541 - Generator Set Failed to Come Online


This code is active if any of these conditions occur.
The generator sets were supposed to start, but one or more generator sets did not close
their paralleling breakers before Genset Fail Time Delay.
A generator set closed its paralleling breaker on time, but, while the generator set was
supposed to remain connected to the load, the paralleling breaker was open for at least 1
second.

19.3.29.1 Effects of Code 1541


The generator set that failed to come online is not included in Total Load Demand Online
Capacity.

A. Troubleshoot Generator Set Related Fault Codes


Check for faults on the generator sets, and troubleshoot them. Refer to the generator set
service manual.

B. Check Paralleling Breaker Close Operation


Verify that the generator set paralleling breaker did not fail to close physically. Perform a
visual inspection, and check the status of the breaker. Check the breaker position indicator
and the trip indicator/lock out relay status. Use the switchgear schematics to identify the
breakers. For a faulty breaker, contact the breaker manufacturer and distributor and the
respective electrical contractor to resolve the issue.

C. Check Paralleling Breaker Position Circuit


Verify the wiring from the generator set paralleling breaker to the MCM3320. Use the
MCM3320, interconnection and switchgear schematics to perform the check.
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For example, to verify the wiring from the paralleling breaker for Generator Set 1, check for
continuity between the following terminals.
TB10-12 (MCM3320) to the corresponding terminal at the paralleling breaker
TB10-13 (MCM3320) to the corresponding terminal at the paralleling breaker

D. Check KW Values for Nonexistent Generator Sets


Determine whether a KW value has been entered for one or more generator sets that
currently do not exist in the system. Disconnect the J14 connector from the MCM3320, and
connect InPower to the MCM3320. Access Adjustments > System Setup > Genset KW
Ratings.

E. Check Generator Set Start Circuit


Verify the functionality of the generator set start circuit by checking for continuity between
TB8-8 (MCM3320) to the corresponding terminal at the generator set control.

F. Verify Generator Set Fail Time Delay Setting


Verify that the Genset Fail Time Delay is not set too low or tight in the MCM3320.
Disconnect the J14 connector from the MCM3320, and connect InPower to the MCM3320.
Access Adjustments > Load Demand Adjustments > Genset Fail Time Delay.

19.3.30 Code 1689 - Real-time Clock Power Interrupt


The real-time clock has not been set after power-up, or the real-time clock lost power for at least
24 hours.
Set the real-time clock to reset this code.

19.3.30.1 Effects of Code 1689


The scheduler is inactive.

A. Reset Real Time Clock


Reset the time and date. Disconnect the J14 connector from the MCM3320, and connect
InPower to the MCM3320. Access System Status > MCM3320 Setup > Set Clock > Date
and Time.

19.3.31 Code 1912 - Utility Bus Loss of Phase


Utility Loss of Phase Sensor Status is Dropped-out.

19.3.31.1 Utility Loss of Phase Sensor


TABLE 132.

UTILITY LOSS OF PHASE SENSOR

Sensor enable

Utility Loss of Phase Sensor Enable is Enable


Minimum line-to-line voltage > 60% nominal voltage
Frequency > 30 Hz

Condition for drop-out

Phase difference between any two phases < 90


or phase difference between any two phases > 150

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Time delay before drop-out

Utility Loss of Phase Drop-Out Delay

Condition for pick-up

90 <= phase difference between all phases <= 150

19.3.31.2 Effects of Code 1912


The utility is not available in three-phase applications. (This effect ends when the conditions that
caused the code are no longer true. The fault does not have to be reset.)

A. Check Loss of Phase in Utility


Determine whether one or more phases of the utility have failed by checking for loss of
phase in the main utility lines and verifying the phase rotation of the utility. Use a phase
rotation meter or a synchronizing light to check phase rotation, and refer to the phase
rotation meter instructions for information about proper phase rotation measurement
procedures.

B. Check for Excessive Load


Verify there is uniform load in all of the three phases using InPower. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320. Access Monitor >
AC Metering > Power, and then access the following three options:
Utility L1 (KW)
Utility L2 (KW)
Utility L3 (KW)

C. Check Utility Voltage Sensing Circuit


Verify there are no wiring issues with the utility voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the Utility Bus for the
following terminals:
L1, TB7-1
L2, TB7-2
L3, TB7-3
2. Measure the line-to-line voltage input to the Potential Transformer (PT) from the Utility
Bus. The voltage into the PT should match the Utility Bus voltage.
3. Check for continuity between the following terminals:
L1 TB7-1 (MCM3320) and the corresponding terminal at the switchgear section
L2 TB7-2 (MCM3320) and the corresponding terminal at the switchgear section
L3 TB7-3 (MCM3320) and the corresponding terminal at the switchgear section
N TB7-4 (MCM3320) and the corresponding terminal at the switchgear section
4. Verify that the breakers in the utility voltage sensing circuit at the switchgear are
operational. Perform a visual inspection of the breaker position indicators. Use the
switchgear schematics to identify the breakers.

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19.3.32 Code 1913 - Generator Set Bus Loss of Phase


These conditions are met.
Genset Loss of Phase Sensor Status is Dropped-out.
The generator sets are commanded to run, and Stop Time Delay is not active.

19.3.32.1 Generator Set Loss of Phase Sensor


TABLE 133.

GENERATOR SET LOSS OF PHASE SENSOR

Sensor enable

Genset Loss of Phase Sensor Enable is Enable


Minimum line-to-line voltage > 60% nominal voltage
Frequency > 30 Hz

Condition for drop-out

Phase difference between any two phases < 90


or phase difference between any two phases > 150

Time delay before drop-out

Genset Loss of Phase Drop-Out Delay

Condition for pick-up

90 <= phase difference between all phases <= 150

19.3.32.2 Effects of Code 1913


The generator sets are not available in three-phase applications. (This effect ends when the
conditions that caused the code are no longer true. The fault does not have to be reset.)

A. Check Loss of Phase in Generator Set Bus


Determine whether one or more phases of the generator set bus have failed by checking
for loss of phase in the main generator set bus lines and verifying the phase rotation of the
generator set bus. Use a phase rotation meter or a synchronizing light to check phase
rotation, and refer to the phase rotation meter instructions for information about proper
phase rotation measurement procedures. Check the generator sets for the availability of
three phases. See the generator set service manual.

B. Check Generator Set Voltage Sensing Circuit


Verify there are no wiring issues with the generator set voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the generator set bus for
the following terminals:
L1, TB6-1
L2, TB6-2
L3, TB6-3
2. Measure the line-to-neutral voltage input to the MCM3320 from the generator set bus
for the following terminals:
L1, TB6-1
L2, TB6-2
L3, TB6-3
N, TB6-4

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3. Measure the line-to-line voltage input into the Potential Transformer from the
generator set bus. The voltage into the PT should match the generator set bus
voltage.
4. Check for continuity between the following terminals and the corresponding terminal at
the switchgear section.
L1 TB6-1 (MCM3320)
L2 TB6-2 (MCM3320)
L3 TB6-3 (MCM3320)
5. Verify that any breakers in the generator set voltage sensing circuit are operational.
Perform a visual inspection of the breaker position indicators. Use the switchgear
schematics to identify the breakers.

C. Verify Power Cable Connections


Perform a visual inspection and verify that power cables on the load side and generator set
side are correctly connected. Make sure that there are no broken or disconnected power
cables. Use the interconnection and vendor switchgear schematics to verify the
connections.

19.3.33 Code 1914 - Utility Bus Phase Rotation


Utility Phase Rotation Sensor Status is Dropped-out.

19.3.33.1 Utility Phase Rotation Sensor


TABLE 134.

UTILITY PHASE ROTATION SENSOR

Sensor enable

Utility Phase Rotation Sensor Enable is Enable


Minimum line-to-line voltage > 60% nominal voltage
Frequency > 30 Hz

Condition for drop-out

Utility Phase Rotation <> System Phase Rotation

Time delay before drop-out

1 second

Condition for pick-up

Utility Phase Rotation = System Phase Rotation

19.3.33.2 Effects of Code 1914


The utility is not available in three-phase applications. (This effect ends when the conditions that
caused the code are no longer true. The fault does not have to be reset.)

A. Verify Utility Phase Rotation Settings


1. Use a phase rotation meter to verify the phase rotation of the system. For proper
phase rotation measurement procedures, refer to the phase rotation meter
instructions.

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2. Verify the utility phase rotation settings in the MCM3320 match the phase rotation
found with the meter. Disconnect the J14 connector from the MCM3320, and connect
InPower to the MCM3320. Access Adjustments, and then access the following
options:
Power Transfer Control Adjustments > Utility Sensor Adjustments > Utility Phase
Sensor Enable
System Setup > System Phase Rotation (L1-L2-L3 should be set)

B. Check Utility Voltage Sensing Circuit


Verify there are no wiring issues with the utility voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the Utility Bus for the
following terminals:
L1, TB7-1
L2, TB7-2
L3, TB7-3
2. Measure the line-to-line voltage input to the Potential Transformer (PT) from the Utility
Bus. The voltage into the PT should match the Utility Bus voltage.
3. Check for continuity between the following terminals:
L1 TB7-1 (MCM3320) and the corresponding terminal at the switchgear section
L2 TB7-2 (MCM3320) and the corresponding terminal at the switchgear section
L3 TB7-3 (MCM3320) and the corresponding terminal at the switchgear section
N TB7-4 (MCM3320) and the corresponding terminal at the switchgear section
4. Verify that the breakers in the utility voltage sensing circuit at the switchgear are
operational. Perform a visual inspection of the breaker position indicators. Use the
switchgear schematics to identify the breakers.

19.3.34 Code 1915 - Generator Set Bus Phase Rotation


Genset Phase Rotation Sensor Status is Dropped-out.

19.3.34.1 Generator Set Phase Rotation Sensor


TABLE 135.

GENERATOR SET PHASE ROTATION SENSOR

Sensor enable

Genset Phase Rotation Sensor Enable is Enable


Minimum line-to-line voltage > 60% nominal voltage
Frequency > 30 Hz

Condition for drop-out

Genset Phase Rotation <> System Phase Rotation

Time delay before drop-out

1 second

Condition for pick-up

Genset Phase Rotation = System Phase Rotation

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19.3.34.2 Effects of Code 1915


The generator sets are not available in three-phase applications. (This effect ends when the
conditions that caused the code are no longer true. The fault does not have to be reset.)

A. Verify Generator Set Phase Rotation Settings


1. Verify the generator set phase rotation settings in the MCM3320 are correct using
InPower. Disconnect the J14 connector from the MCM3320, and connect InPower to
the MCM3320. Access Adjustments > Power Transfer Control Adjustments > Genset
Sensor Adjustments, and then access the following options:
Genset Phase Rotation Sensor Enable
Genset Loss of Phase Sensor Enable
Genset Loss of Phase Drop-out Delay
2. Use a phase rotation meter or a synchronizing light to verify the phase rotation of the
generator sets. For proper phase rotation measurement procedures, refer to the phase
rotation meter instructions.
1. Use a phase rotation meter to verify the phase rotation of the generator sets. For
proper phase rotation measurement procedures, refer to the phase rotation meter
instructions.
2. Verify the utility phase rotation settings in the MCM3320 match the phase rotation
found with the meter. Disconnect the J14 connector from the MCM3320, and connect
InPower to the MCM3320. Access Adjustments, and then access the following
options:
Power Transfer Control Adjustments > Generator Set Sensor Adjustments >
Generator Set Phase Sensor Enable
System Setup > System Phase Rotation (L1-L2-L3 should be set)

B. Check Generator Set Voltage Sensing Circuit


Verify there are no wiring issues with the generator set voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the generator set bus for
the following terminals:
L1, TB6-1
L2, TB6-2
L3, TB6-3
2. Measure the line-to-neutral voltage input to the MCM3320 from the generator set bus
for the following terminals:
L1, TB6-1
L2, TB6-2
L3, TB6-3
N, TB6-4

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3. Measure the line-to-line voltage input into the Potential Transformer from the
generator set bus. The voltage into the PT should match the generator set bus
voltage.
4. Check for continuity between the following terminals and the corresponding terminal at
the switchgear section.
L1 TB6-1 (MCM3320)
L2 TB6-2 (MCM3320)
L3 TB6-3 (MCM3320)
5. Verify that any breakers in the generator set voltage sensing circuit are operational.
Perform a visual inspection of the breaker position indicators. Use the switchgear
schematics to identify the breakers.

C. Verify Power Cable Connections


Perform a visual inspection and verify that power cables on the load side and generator set
side are correctly connected. Make sure that there are no broken or disconnected power
cables. Use the interconnection and vendor switchgear schematics to verify the
connections.

19.3.35 Code 1989 - kW Load Control Output Limit


While in extended parallel mode, load control has been trying to run the generator sets at the
desired kW output by putting a bias at extreme values (lowest, highest) for 60 seconds.
This code can be generated if the load control method is closed-loop.

A. Verify CT and PT Settings


Verify the CT and/or PT configuration for the utility and the generator sets are correct.
Disconnect the J14 connector from the MCM3320, and connect InPower to the MCM3320.
Access AC Meter Setup, and then access the following options:
Genset PT Primary Voltage
Genset PT Secondary Voltage
Genset CT Primary Current
Genset CT Primary Current
Utility PT Primary Voltage
Utility PT Secondary Voltage
Utility CT Primary Current
Utility CT Secondary Current

B. Check CT Connections to Switchgear


Verify that the wire passing through the CTs in the MCM3320 are connected to the correct
terminals in the switchgear. Use the interconnect and switchgear schematics to verify the
correct wiring.

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C. Check Wiring for CT Sensing


Verify the CT sensing wires are run correctly through the onboard CTs in the MCM3320.
Two wires should pass through the CT hole for 1 A
One wire should pass through the CT hole for 5 A

D. Verify Generator Set Availability


Determine whether any generator set in the system is unavailable or is derated because of
a fault condition. Disconnect the J14 connector from the MCM3320, and connect InPower
to the MCM3320. Access Adjustments > Monitor > Load Demand > Gen(s) Availability
State.

E. Verify Generator Set kW Settings


Verify that the demanded kW is not exceeding the capability of the generator sets online.
Disconnect the J14 connector from the MCM3320, and connect InPower to the MCM3320.
Access Adjustments > System Setup > Genset(s) kW Rating.
Verify that the generator sets are set to 100% of rated power.
The generating capacity of a generator set decreases with the altitude of its installation.
Refer to the generator set service manual for the specific derated value.

F. Check Wiring KW Load Control Circuit


Check the wiring of the KW load control circuit by performing continuity checks between the
following terminals. Disconnect wires from terminals TB9-4 and TB9-6 before performing
the checks, and reconnect the wires to their respective terminals after the checks.
TB9-4 (MCM3320) and the corresponding terminal at the generator set control
TB9-6 (MCM3320) and the corresponding terminal at the generator set control
Load govern shield wire

19.3.36 Code 1991 - kVAR Load Control Output Limit


While in extended parallel mode, load control has been trying to run the generator sets at the
desired kVAR output by putting a bias at extreme values (lowest, highest) for 60 seconds.
This code can be generated if the load control method is closed-loop.

A. Verify CT and PT Settings


Verify the CT and/or PT configuration for the utility and the generator sets are correct.
Disconnect the J14 connector from the MCM3320, and connect InPower to the MCM3320.
Access AC Meter Setup, and then access the following options:
Genset PT Primary Voltage
Genset PT Secondary Voltage
Genset CT Primary Current
Genset CT Primary Current
Utility PT Primary Voltage
Utility PT Secondary Voltage
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Utility CT Primary Current


Utility CT Secondary Current

B. Verify Generator Set Availability


Determine whether any generator set in the system is unavailable or is derated because of
a fault condition. Disconnect the J14 connector from the MCM3320, and connect InPower
to the MCM3320. Access Adjustments > Monitor > Load Demand > Gen(s) Availability
State.

C. Verify Generator Set kVAR Settings


Verify that the demanded KVAR is not exceeding the capability of the generator sets
online. To access the generator set KVAR settings in InPower, go to Adjustments > Load
Control Adjustments > Load Control Setup Adjustments > Genset Bus KVAR Setpoint.
In each of the generator sets, verify that the setting Load Govern kVAR Setpoint Source is
set to Analog Input.

D. Check kVAR Load Control Lines


Check wiring of the kVAR load control lines by performing continuity checks between the
following terminals. Disconnect wires from terminals TB9-5 and TB9-6 in the MCM3320
before performing the checks, and reconnect the wires to their respective terminals after
the checks.
TB9-5 (MCM3320) and the corresponding terminal at the generator set control
TB9-6 (MCM3320) and the corresponding terminal at the generator set control
Load govern shield wire

19.3.37 Code 1999 - Maximum Parallel Time


The system is not running in extended paralleling, and the generator sets have been running in
parallel with the utility for longer than Maximum Parallel Time (TDMP).

19.3.37.1 Effects of Code 1999


When PTC State is Utility Connected, the generator sets cannot synchronize with the utility, and
the generator sets cannot connect to the loads.
NOTE:

Maximum Parallel Time (TDMP) and code 1999 have different effects and are
reset differently. When Maximum Parallel Time (TDMP) expires, the generator
sets are disconnected immediately, and code 1999 becomes active. The timer
resets as soon as PTC State leaves Paralleled. In contrast, code 1999
remains active until the fault is reset.

A. Verify Maximum Parallel Time Setting


Verify the maximum parallel time setting in the generator set controllers is less than the
maximum parallel time setting in the MCM3320 using InPower. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320. Access Adjustments
> Power Transfer Control Adjustments > Time Delay Adjustments.
The default value for the MCM3320 is 30 minutes.

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B. Check Wiring KW Load Control Circuit


Check the wiring of the KW load control circuit by performing continuity checks between the
following terminals. Disconnect wires from terminals TB9-4 and TB9-6 before performing
the checks, and reconnect the wires to their respective terminals after the checks.
TB9-4 (MCM3320) and the corresponding terminal at the generator set control
TB9-6 (MCM3320) and the corresponding terminal at the generator set control
Load govern shield wire

C. Check kVAR Load Control Lines


Check wiring of the kVAR load control lines by performing continuity checks between the
following terminals. Disconnect wires from terminals TB9-5 and TB9-6 in the MCM3320
before performing the checks, and reconnect the wires to their respective terminals after
the checks.
TB9-5 (MCM3320) and the corresponding terminal at the generator set control
TB9-6 (MCM3320) and the corresponding terminal at the generator set control
Load govern shield wire

D. Cycle Power
Cycle power to the MCM3320 to see if the fault clears.

E. Check Calibration
Perform an update calibration using the InPower service tool. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320.
If unable to perform an update calibration, perform an initial calibration.
If unable to perform an initial calibration, replace the MCM3320 base board.

19.3.38 Code 2331 - Utility Bus Under Voltage


Utility Undervoltage Sensor Status is Dropped-out.

19.3.38.1 Utility Undervoltage Sensor


This sensor is always enabled.

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Time (t)
initial
t1

t1+tD

t2

Event

Sensor Status

The line-to-line voltage (V) is acceptable.

Picked-Up

The line-to-line voltage (V) falls below the dropped-out threshold


(D, Utility Undervoltage Drop-Out Percentage * Utility
Undervoltage Pick-Up Percentage).

Picked-Up

The line-to-line voltage (V) remains below the dropped-out


threshold (D) for a specified time delay (tD, Utility Undervoltage
Drop-Out Delay).
The line-to-line voltage (V) rises above the picked-up threshold (P,
Utility Undervoltage Pick-Up Percentage).

FIGURE 91.

Dropped-Out
(shaded area)
Picked-Up

UTILITY UNDERVOLTAGE SENSOR

19.3.38.2 Effects of Code 2331


The utility is not available in three-phase applications. (This effect ends when the conditions that
caused the code are no longer true. The fault does not have to be reset.)

A. Check Utility Bus Voltage Instability


The utility voltage may be unstable. Check with the respective utility company to determine
when the unstable condition is no longer active, and wait for the utility voltage to stabilize.

B. Verify Utility Voltage Sensing Setup


Verify the voltage sensing setup, with respect to the primary and secondary PT LL,
matches the PTs in the system. Disconnect the J14 connector from the MCM3320, and
connect InPower to the MCM3320. Access Adjustments > AC Meter Setup and then
access the following settings:
Utility PT Primary Voltage
Utility PT Secondary Voltage

C. Verify Utility Under Voltage Settings


Verify the utility under voltage settings, pick-up, drop-out, and drop-out delay are not too
tight to allow for normal source fluctuations using InPower. Disconnect the J14 connector
from the MCM3320, and connect InPower to the MCM3320. Access Adjustments > Power
Transfer Control Adjustments > Utility Sensor Adjustments > Utility Under Voltage Settings.
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D. Check Utility Voltage Sensing Circuit


Verify there are no wiring issues with the utility voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the Utility Bus for the
following terminals:
L1, TB7-1
L2, TB7-2
L3, TB7-3
2. Measure the line-to-line voltage input to the Potential Transformer (PT) from the Utility
Bus. The voltage into the PT should match the Utility Bus voltage.
3. Check for continuity between the following terminals:
L1 TB7-1 (MCM3320) and the corresponding terminal at the switchgear section
L2 TB7-2 (MCM3320) and the corresponding terminal at the switchgear section
L3 TB7-3 (MCM3320) and the corresponding terminal at the switchgear section
N TB7-4 (MCM3320) and the corresponding terminal at the switchgear section
4. Verify that the breakers in the utility voltage sensing circuit at the switchgear are
operational. Perform a visual inspection of the breaker position indicators. Use the
switchgear schematics to identify the breakers.

E. Verify System and Utility Voltage


Verify the system voltage matches the utility nominal voltage. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320. Access Adjustments
> AC Meter Setup > Utility Nominal Voltage.

F. Cycle Power
Cycle power to the MCM3320 to see if the fault clears.

G. Check Calibration
Perform an update calibration using the InPower service tool. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320.
If unable to perform an update calibration, perform an initial calibration.
If unable to perform an initial calibration, replace the MCM3320 base board.

19.3.39 Code 2358 - Utility Bus Over Voltage


Utility Overvoltage Sensor Status is Dropped-out.

19.3.39.1 Utility Overvoltage Sensor


Utility Overvoltage Sensor Enable must be set to Enable.

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Time (t)
initial
t1
t1+tD

t2

Event

Sensor Status

The line-to-line voltage (V) is acceptable.

Picked-Up

The line-to-line voltage (V) rises above the dropped-out threshold


(D, Utility Overvoltage Drop-Out Percentage).

Picked-Up

The line-to-line voltage (V) remains above the dropped-out


threshold (D) for a specified time delay (tD, Utility Overvoltage
Drop-Out Delay).
The line-to-line voltage (V) falls below the picked-up threshold (P,
Utility Overvoltage Pick-Up Percentage * Utility Overvoltage DropOut Percentage).

FIGURE 92.

Dropped-Out
(shaded area)
Picked-Up

UTILITY OVERVOLTAGE SENSOR

19.3.39.2 Effects of Code 2358


The utility is not available in three-phase applications. (This effect ends when the conditions that
caused the code are no longer true. The fault does not have to be reset.)

A. Check Utility Bus Voltage Instability


The utility voltage may be unstable. Check with the respective utility company to determine
when the unstable condition is no longer active, and wait for the utility voltage to stabilize.

B. Verify System and Utility Voltage


Verify the system voltage matches the utility nominal voltage. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320. Access Adjustments
> AC Meter Setup > Utility Nominal Voltage.

C. Verify Utility Over Voltage Settings


Verify the utility over voltage settings, pick-up, drop-out, and drop-out delay are not too
tight to allow for normal source fluctuations using InPower. Disconnect the J14 connector
from the MCM3320, and connect InPower to the MCM3320. Access Adjustments > Power
Transfer Control Adjustments > Utility Sensor Adjustments > Utility Over Voltage Settings.

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D. Verify Utility Voltage Sensing Setup


Verify the voltage sensing setup, with respect to the primary and secondary PT LL,
matches the PTs in the system. Disconnect the J14 connector from the MCM3320, and
connect InPower to the MCM3320. Access Adjustments > AC Meter Setup and then
access the following settings:
Utility PT Primary Voltage
Utility PT Secondary Voltage

E. Check Utility Voltage Sensing Circuit


Verify there are no wiring issues with the utility voltage sensing connections to the
MCM3320 by performing the following steps.
1. Measure the line-to-line voltage input to the MCM3320 from the Utility Bus for the
following terminals:
L1, TB7-1
L2, TB7-2
L3, TB7-3
2. Measure the line-to-line voltage input to the Potential Transformer (PT) from the Utility
Bus. The voltage into the PT should match the Utility Bus voltage.
3. Check for continuity between the following terminals:
L1 TB7-1 (MCM3320) and the corresponding terminal at the switchgear section
L2 TB7-2 (MCM3320) and the corresponding terminal at the switchgear section
L3 TB7-3 (MCM3320) and the corresponding terminal at the switchgear section
N TB7-4 (MCM3320) and the corresponding terminal at the switchgear section
4. Verify that the breakers in the utility voltage sensing circuit at the switchgear are
operational. Perform a visual inspection of the breaker position indicators. Use the
switchgear schematics to identify the breakers.

F. Cycle Power
Cycle power to the MCM3320 to see if the fault clears.

G. Check Calibration
Perform an update calibration using the InPower service tool. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320.
If unable to perform an update calibration, perform an initial calibration.
If unable to perform an initial calibration, replace the MCM3320 base board.

19.3.40 Code 2396 - Utility Main Breaker Fail to Close


A close command was sent to the utility main breaker, but the breaker did not close within Util
CB Fail to Close Delay.

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19.3.40.1 Effects of Code 2396


The utility is not available in three-phase applications.
In certain situations, this can also cause Permissive Close Allowed to become Not Allowed.

A. Check Utility Main Breaker Status


Check the status of the utility main breaker at the switchgear by checking the breaker
position indicator and the trip indicator/lock out relay. Proceed based on what you find:
If the utility main breaker is still open after receiving the close command from the
MCM3320, continue with checking the spring charge mechanism.
If the utility main breaker is actually closed after receiving the closed command from
the MCM3320, but this fault code has been generated, continue with checking the
control voltage in the utility main breaker close circuit.

B. Check Spring Charge Mechanism


Verify the spring charge mechanism of the circuit breaker is operational by performing the
following steps.
1. Check the spring charge indicator of the breaker and determine whether the spring
coil is fully charged. If the spring coil is discharged, it can be confirmed that the spring
charging motor is not charging up the spring coil or the spring coil is bad.
2. Check for control voltage at the spring charging motor. Refer to the breaker
schematics/service manual to determine the cause if there is no control voltage.
3. Manually charge the spring coil by using the spring charging handle.
If the manual charge is successful, the breaker will open and close as
commanded.
If the manual charge is not successful, the breaker will not change status. Refer
to the breaker schematics/service manual and replace the spring coil. Contact
the breaker manufacturer and distributor regarding the fix (this is required).

C. Check Auxiliary Breaker Position Contacts


Verify auxiliary position contacts 'a' and 'b' are operational by performing the following
steps.
1. Place the MCM3320 in Manual mode, and rack out the breaker to the test position.
2. Remove existing wires from TB10-7, TB10-8, and TB10-9.
3. Perform a continuity check on both 'a' and 'b' contacts at the breaker.
4. Obtain permission from the facility or customer to interrupt the power supply to the
site.
5. Cycle power to the breaker to make sure the auxiliary contacts change their respective
states with the change in breaker status from open to closed or closed to open.
If the auxiliary contacts do not change states, the breaker is faulty, and it must be
fixed or replaced. Contact the manufacturer, distributor, and electrical contractor to
resolve the problem. Cummins technicians are not responsible for troubleshooting a
faulty circuit breaker.

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D. Check Control Voltage


Verify there is control voltage in the close circuit by performing the following steps.
1. Check for control voltage in the utility main breaker close circuit. Use the interconnect
and switchgear schematics to perform this check.
2. Check for control voltage at the switchgear terminals that power the close coil of the
utility main breaker. Refer to the switchgear and breaker schematics.

E. Check Utility Main Breaker Close Circuit


Check the wiring in the close circuit by checking for continuity between the following
contacts:
TB10-7 (MCM3320) and the corresponding terminal in the switchgear
TB10-8 (MCM3320) and the corresponding terminal in the switchgear
TB10-9 (MCM3320) and the corresponding terminal in the switchgear
Use the interconnect and switchgear schematics to perform this check.

F. Verify Utility Main Breaker Components


1. Verify that the components in the utility main breaker closed circuit are operating
properly.
2. Verify the operation of the utility main breaker close coil. Make sure the breaker close
coil actually closes the breaker when energized. This can be done by jumpering power
across the terminals of the breaker close coil. Refer to the breaker schematics/service
manual for details.
To perform this check, the technician requires permission from the facility. This check
must be done in a safe manner so as to avoid damaging electrical equipments. For
example, if generator sets are on the bus, the utility breaker must not be closed.

G. Verify Time Delay Setting


Verify the setting for the Fail to Close Time Delay in the utility main breaker is based on the
breaker specifications. Check the breaker service manual for details. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320. Access Adjustments
> Breaker Adjustments > Utility Main Breaker Adjustments > Utility CB Fail to Close Delay.

19.3.41 Code 2397 - Utility Main Breaker Fail to Open


An open command was sent to the utility main breaker, but the breaker did not open within Util
CB Fail to Open Delay.

19.3.41.1 Effects of Code 2397


When PTC State is Utility Connected, the synchronizer cannot start, and the generator sets
cannot connect to the loads.
If Fail to Disconnect Enable is Enabled and PTC State is Paralleled, the generator sets are
disconnected immediately. (This effect ends when the conditions that caused the code are no
longer true. The fault does not have to be reset.)
Code 2397 can generate code 1121 (Fail to Disconnect).

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A. Check Utility Main Breaker Status


Check the status of the utility main breaker at the switchgear by checking the breaker
position indicator and the trip indicator/lock out relay. Proceed based on what you find:
If the utility main breaker is still closed after receiving the open command from the
MCM3320, continue with checking the spring charge mechanism.
If the utility main breaker is actually open after receiving the open command from the
MCM3320, but this fault code has been generated, continue with checking the control
voltage in the utility main breaker open circuit.

B. Check Spring Charge Mechanism


Verify the spring charge mechanism of the circuit breaker is operational by performing the
following steps.
1. Check the spring charge indicator of the breaker and determine whether the spring
coil is fully charged. If the spring coil is discharged, it can be confirmed that the spring
charging motor is not charging up the spring coil or the spring coil is bad.
2. Check for control voltage at the spring charging motor. Refer to the breaker
schematics/service manual to determine the cause if there is no control voltage.
3. Manually charge the spring coil by using the spring charging handle.
If the manual charge is successful, the breaker will open and close as
commanded.
If the manual charge is not successful, the breaker will not change status. Refer
to the breaker schematics/service manual and replace the spring coil. Contact
the breaker manufacturer and distributor regarding the fix (this is required).

C. Check Auxiliary Breaker Position Contacts


Verify auxiliary position contacts 'a' and 'b' are operational by performing the following
steps.
1. Place the MCM3320 in Manual mode, and rack out the breaker to the test position.
2. Remove existing wires from TB10-7, TB10-8, and TB10-9.
3. Perform a continuity check on both 'a' and 'b' contacts at the breaker.
4. Obtain permission from the facility or customer to interrupt the power supply to the
site.
5. Cycle power to the breaker to make sure the auxiliary contacts change their respective
states with the change in breaker status from open to closed or closed to open.
If the auxiliary contacts do not change states, the breaker is faulty, and it must be
fixed or replaced. Contact the manufacturer, distributor, and electrical contractor to
resolve the problem. Cummins technicians are not responsible for troubleshooting a
faulty circuit breaker.

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D. Check Control Voltage


Verify there is control voltage in the circuit breaker open circuit by performing the following
steps.
1. Check for control voltage in the utility main breaker open circuit. Use the interconnect
and switchgear schematics to perform this check.
2. Check for control voltage at the switchgear terminals that power the open coil of the
circuit breaker. Refer to the switchgear and breaker schematics.

E. Check Utility Main Breaker Open Circuit


Check the wiring in the breaker open circuit by checking for continuity between the
following contacts:
TB10-8 (MCM3320) to the corresponding terminal in the switchgear
TB10-7 (MCM3320) to the corresponding terminal in the switchgear
TB10-9 (MCM3320) to the corresponding terminal in the switchgear
Use the MCM3320, interconnection and switchgear schematics to perform this check.

F. Verify Utility Main Breaker Components


1. Verify that the components in the utility main breaker open circuit are operating
properly.
2. Verify the operation of the utility main breaker open coil. Make sure the breaker open
coil actually opens the breaker when energized. This can be done by jumpering power
across the terminals of the breaker open coil. Refer to the breaker schematics/service
manual for details.
To perform this check, the Techs would require permission from the facility as there
will be power interruption for a certain amount of time.

G. Verify Time Delay Setting


Verify the setting for the Fail to Open Time Delay in the utility main breaker is based on the
breaker specifications. Check the breaker manual for details. Disconnect the J14 connector
from the MCM3320, and connect InPower to the MCM3320. Access Adjustments > Breaker
Adjustments > Utility Main Breaker Adjustments > Utility CB Fail to Open Delay.

19.3.42 Code 2416 - Calibration Checksum


Internal data on the microprocessor has been compared and a mismatch has been found.
After a major firmware release, this may happen because a large number of new parameters
get added to the firmware and some parameters are moved to a different location to optimize
the code.

A. Cycle Power
Cycle power to the MCM3320 to see if the fault clears.

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B. Check Calibration
Perform an update calibration using the InPower service tool. Disconnect the J14
connector from the MCM3320, and connect InPower to the MCM3320.
If unable to perform an update calibration, perform an initial calibration.
If unable to perform an initial calibration, replace the MCM3320 base board.

19.3.43 Code 2647 - Load Demand Setup Warning


When load demand is enabled, all of these conditions must be true.
There must be at least two generator sets.
Load Demand Threshold Method is %kW, and Load Demand Restart Percent is at least
5% higher than Load Demand Shutdown Percent. (The recommended difference is 20% or
higher in most applications.)
Load Demand Threshold Method is kW, and Load Demand Restart kW Threshold is lower
than Load Demand Shutdown kW Threshold.
Genset Fail Time Delay is less than Load Demand Initial Delay.
Genset Fail Time Delay is less than Load Demand Shutdown Delay.
This code is active if one or more conditions are not true.

A. Verify Generator Set Ratings


Verify there are at least two generator sets in the system. The generator sets must have a
non-zero kW rating. Disconnect the J14 connector from the MCM3320, and connect
InPower to the MCM3320. Go to Adjustments > System Setup > Genset (s) KW Rating.

B. Verify Generator Set Load Demand Threshold


Verify the generator set load demand threshold by performing the following steps.
1. Disconnect the J14 connector from the MCM3320, and connect InPower to the
MCM3320.
2. Determine whether the %kW threshold method or kW threshold method is being used
for this site.
3. Take the appropriate action based on which method is being used.
For %kW Method - Verify the Restart (pick-up) and Shutdown (drop-out)
percentages are at least 5% different from one another (20% is the
recommended value). Change the value as needed to fall within the guidelines.
Also, verify the value entered for Shutdown is greater than the value entered for
Restart. Access Adjustments > Load Demand Adjustments > Load Demand
Restart Percent and Adjustments > Load Demand Adjustments > Load Demand
Shutdown Percent.
For kW Method - Verify the value entered for Shutdown (drop-out) is greater than
the value entered for Restart (pick-up). Access Adjustments > Load Demand
Adjustments> Load Demand Shutdown (KW) and Adjustments > Load Demand
Adjustments > Load Demand Restart (KW).

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C. Verify Generator Set Fail Time Delay Setting


Verify the value entered for the Genset Fail Time Delay is lower than the value for the Load
Demand Initial Delay and the Load Demand Shutdown Delay. Use InPower to access the
settings.
1. Adjustments > Load demand Adjustments > Genset Fail Time Delay
2. Adjustments > Load Demand Adjustments > Load Demand Initial Delay
3. Adjustments > Load Demand Adjustments > Load Demand Shutdown Delay

19.3.44 Code 2648 - Remote I/O Comm Failure Warning


At least one of these conditions is met.
The MCM cannot communicate with one of the required SID or its AUX 102.
Two or more AUX 101 have the same AUX 101 device number.
One or more AUX 101 have an AUX 101 device number of 4 or higher.

19.3.44.1 Effects of Code 2648


No test can start, but a test can continue. PTC Operating Mode cannot become Test. If PTC
Operating Mode is already Test, there is no effect.

A. Verify AUX 101 Configuration


Verify the device number for the AUX 101 is set properly based on what is required for
usage in this unit. If necessary, use the AUX 101 Installation/Setup instructions to configure
the AUX 101 board.

B. Verify PCCNet Connections


1. Verify PCCNet connections by checking for continuity between the following items:
AUX 101 J1-3, MCM3320 TB1-1, and any corresponding terminal in the PCCNet
network
AUX 101 J1-4, MCM3320 TB1-3, and any corresponding terminal in the PCCNet
network
2. Verify the proper identifier is displayed on the 7-segment display of the AUX 101
board.
3. Verify the green DS1 indicator is lit on the AUX 101 board. A green light indicates
PCCNet communication.

C. Verify Connection between AUX 101 and AUX 102


Verify there is a connection between AUX 101 and AUX 102 by performing the following
steps.
1. Make sure the 20-wire ribbon cable attached to AUX 102 is connected to connector J5
on AUX 101.
2. Make sure the 20-wire ribbon cable is fully seated.
3. Make sure there are no cuts or nicks in the ribbon cable.

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D. Check System Topology


PCCNet devices will not communicate with the MCM3320 if the System Topology of the
MCM3320 is set to Master Synchronizer Mode or Component Mode. Use InPower to verify
the topologies. Disconnect the J14 connector from the MCM3320, and connect InPower to
the MCM3320. Access Adjustments > System Setup > System Topology.

E. Check Compatibility of Software Versions


Verify that the MCM3320 software version is V2.0 or later. Disconnect the J14 connector
from the MCM3320, and connect InPower to the MCM3320. Access Monitor > Controller
Information > Software Version. Update the calibration if necessary.
Verify that the AUX 101 software version is V1.48 or later. Access Monitor > Controller
Information > AUX101 Software Version. Update the calibration if necessary.
Make sure the AUX 101 and MCM3320 software versions are compatible with each other.
See Section 4.4.5 on page 52.

19.3.45 Code 2939 - Modbus Communication Failure Warning


The RS-485 connection is using Modbus, but no Modbus packets have been received for
Modbus Failure Time Delay.

19.3.45.1 Effects of Code 2939


If Cancel Scheduler If Modbus Fail Enable is Enabled, System Scheduler Enable is
automatically set to Disabled to disable the scheduler.

A. Check Wiring of Modbus Network


Verify the wiring is correct.
1. Verify that the Modbus connection at TB15 or J14 is tight.
2. Verify that there are no open or short circuits at TB15-3 (RS485 A) and TB15-4
(RS485 B).
3. Verify that there is 120- terminating resistor at each end of the Modbus network.
4. Verify that the shield is grounded at TB15-1 in the MCM3320.

B. Check Other Modbus Devices


1. Verify the Modbus master device is transmitting information to the MCM3320. If the
Modbus device is faulty and has stopped communication, then either repair or replace
the Modbus device. Disconnect the J14 connector from the MCM3320, and connect
InPower to the MCM3320. Access Monitor > LED Outputs > Modbus Activity LED
Status > Active.
2. If there are other Modbus devices, make sure all the devices are active and
communicating. Check the connection of the Modbus devices on the Modbus network.
Make sure the connections are correct and tight.
3. Make sure all Modbus devices are programmed/configured correctly. Refer to the
documentation for the Modbus devices.

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C. Check Polling Rate


Verify that the polling rate is not too fast. The MCM3320 will respond in 100 msec when
receiving a request from a master device.

D. Verify Modbus Register Mapping


Verify that the master device has the correct register map for the MCM3320.

E. Reduce Number of Devices on Network


If there are a lot of devices on the network, there may be too much traffic for
communication to reach the MCM3320. Reduce the number of devices if possible.

19.3.46 Code 3924 - Utility Reverse kW Fault


The utility load is less than Utility Reverse kW Threshold for Utility Reverse kW Time Delay.

19.3.46.1 Effects of Code 3924


Code 3924 can generate code 4137 (Advanced Grid Protection Fault).

A. Check Reverse kW Settings


1. Verify that Utility Total KW is greater than Utility Reverse KW Threshold. Disconnect
the J14 connector from the MCM3320, and connect InPower to the MCM3320. Access
Adjustments > Power Transfer Control Adjustments > Utility Sensor Adjustments
> Utility Total KW
Adjustments > Power Transfer Control Adjustments > Utility Sensor Adjustments
> Utility Reverse KW Threshold
2. Verify that Utility Reverse KW Time Delay is not set too tight. Use InPower to verify
the setting. Access Adjustments > Power Transfer Control Adjustments > Time Delay
Adjustments > Utility Reverse KW Time Delay.

B. Check Utility CT Wiring


1. Verify that the wire passing through the Utility CTs (CT4, CT5, and CT6) on the
MCM3320 are connected to the correct terminals in the switchgear. Use the
interconnect and switchgear schematics to verify the wiring.
2. Verify that 2 wire passes through the CT for 1 A and 1 wire pass through CT for 5 A.

19.3.47 Code 4137 - Advanced Grid Protection Fault


This feature provides a way to prevent the generator sets from exporting power to the utility.
If Advanced Grid Protection Option Enable is Enable, at least one of the following conditions is
true.
The real power provided by the system has been less than Low System Load Threshold
for Low System Load Time Delay.
Code 3924 (Utility Reverse kVAR) is active.
NOTE:

236

If code 4137 becomes active due to code 3924, you have to reset faults twice,
once to clear code 3924 and a second time to clear code 4137.
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19.3.47.1 Effects of Code 4137


System Scheduler Enable is automatically set to Disabled to disable the scheduler.
If the topology is Common Bus or Transfer Pair, the following changes also occur.
PTC Operating Mode cannot be Extended Parallel or Test. (If PTC Operating Mode
becomes Normal, the generator sets are disconnected from the loads.)
The generator sets are disconnected immediately if the system is executing a soft-closed
transition retransfer.

A. Troubleshoot Related Fault Codes


Troubleshoot the fault codes that are related to this code.

B. Check System Load Settings


Verify that System Load settings are correct. Disconnect the J14 connector from the
MCM3320, and connect InPower to the MCM3320. Access the following settings.
Adjustments > Power Transfer Control Adjustments > Utility Sensor Adjustments >
Utility Total KW
Adjustments > Power Transfer Control Adjustments > Genset Sensor Adjustments >
Genset Total KW
Adjustments > Power Transfer Control Adjustments > Time Delay Adjustments.

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20

Parts List
TABLE 136.

Description
MCM3320 base board

PART NUMBERS
Part Number
0327-1520-01
0327-1520-03 (simulator)

MCM3320 software

0326-6650

HMI 211 (operator panel)

0300-6014

HMI 211 software

0326-6796

SYNC1320 base board


SYNC1320 software
InPower Pro service tool
InPower harness

A029Y787 (Issue 1)

0327-1520-02
0326-6650
0998-0077-02 (existing user)
0998-0077-04 (new user)
0541-1199

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21

Manufacturing Facilities

NORTH AMERICA

EMEA, CIS

ASIA PACIFIC

Cummins Power Generation Limited


1400 73rd Ave. NE
Minneapolis, MN 55432 USA

Cummins Power Generation Limited


Columbus Avenue
Manston Park
Manston, Ramsgate
Kent CT12 5BF
United Kingdom

Cummins Power Generation Limited


10 Toh Guan Road #07-01
TT International Tradepark
Singapore 608838

Phone +1 763 574 5000


Toll Free +1 800 888 6626
Fax +1 763 574 5298

Phone +44 1843 255000


Fax +44 1843 255902

Phone +65 6417 2388


Fax +65 6417 2399

BRAZIL

CHINA

INDIA

Rua Jati, 310, Cumbica


Guarulhos, SP 07180-900
Brazil

Cummins Power Generation


2 Rongchang East Street,
Beijing Economic Technological
Development Area
Beijing 100176, P.R.China

35A/1/2, Erandawana
Pune 411 038
India

Phone +55 11 2186 4195


Fax +55 11 2186 4729

Phone +86 10 5902 3000


Fax +86 10 5902 3199

Phone +91 020 6602 7525


Fax +91 020 6602 8090

LATIN AMERICA

MEXICO

3350 Southwest 148th Ave.


Suite 205
Miramar, FL 33027
USA

Eje 122 No. 200 Zona Industrial


San Luis Potosi, S.L.P. 78395
Mexico

Phone +1 954 431 551


Fax +1 954 433 5797

Phone +52 444 870 6700


Fax +52 444 824 0082

21.1

How to Obtain Service


When a product requires servicing, contact your nearest Cummins Power Generation distributor.
To locate your local Cummins Power Generation distributor, refer to www.cumminspower.com
and select Distributor Locator. When contacting your distributor, always supply the complete
Model, Specification, and Serial Number as shown on the nameplate.

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Appendix A. Interconnect Drawings


Table of Contents
Figure 93. 0630-3133, Sheet 1 ................................................................................................................... 245
Figure 94. 0630-3133, Sheet 2 ................................................................................................................... 246
Figure 95. 0630-3133, Sheet 3 ................................................................................................................... 247
Figure 96. 0630-3133, Sheet 4 ................................................................................................................... 248
Figure 97. 0630-3133, Sheet 5 ................................................................................................................... 249
Figure 98. 0630-3133, Sheet 6 ................................................................................................................... 250
Figure 99. 0630-3133, Sheet 7 ................................................................................................................... 251
Figure 100. 0630-3133, Sheet 8 ................................................................................................................. 252
Figure 101. 0630-3133, Sheet 9 ................................................................................................................. 253
Figure 102. 0630-3133, Sheet 10 ............................................................................................................... 254
Figure 103. 0630-3133, Sheet 11 ............................................................................................................... 255
Figure 104. 0630-3133, Sheet 12 ............................................................................................................... 256
Figure 105. 0630-3133, Sheet 13 ............................................................................................................... 257
Figure 106. 0630-3133, Sheet 14 ............................................................................................................... 258
Figure 107. 0630-3133, Sheet 15 ............................................................................................................... 259
Figure 108. 0630-3133, Sheet 16 ............................................................................................................... 260
Figure 109. 0630-3133, Sheet 17 ............................................................................................................... 261
Figure 110. 0630-3133, Sheet 18 ............................................................................................................... 262
Figure 111. 0630-3133, Sheet 19 ............................................................................................................... 263
Figure 112. 0630-3133, Sheet 20 ............................................................................................................... 264
Figure 113. 0630-3133, Sheet 21 ............................................................................................................... 265
Figure 114. 0630-3133, Sheet 22 ............................................................................................................... 266
Figure 115. 0630-3133, Sheet 23 ............................................................................................................... 267
Figure 116. 0630-3133, Sheet 24 ............................................................................................................... 268
Figure 117. 0630-3133, Sheet 25 ............................................................................................................... 269
Figure 118. 0630-3133, Sheet 26 ............................................................................................................... 270
Figure 119. 0630-3133, Sheet 27 ............................................................................................................... 271
Figure 120. 0630-3133, Sheet 28 ............................................................................................................... 272
Figure 121. 0630-3136, Sheet 1 ................................................................................................................. 273
Figure 122. 0630-3136, Sheet 2 ................................................................................................................. 274
Figure 123. 0630-3136, Sheet 3 ................................................................................................................. 275
Figure 124. 0630-3136, Sheet 4 ................................................................................................................. 276

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Appendix A.

Interconnect Drawings

NOTE:

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The drawings included in this section are representative. For current


complete information, refer to the drawing package that was shipped with the
unit.

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Appendix A.

A.1

0630-3133 (MCM3320 Interconnect Drawing)

FIGURE 93.

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Interconnect Drawings

0630-3133, SHEET 1

245

Appendix A.

Interconnect Drawings

5-2012

FIGURE 94.

246

0630-3133, SHEET 2

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Appendix A.

FIGURE 95.

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Interconnect Drawings

0630-3133, SHEET 3

247

Appendix A.

Interconnect Drawings

5-2012

FIGURE 96.

248

0630-3133, SHEET 4

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Appendix A.

FIGURE 97.

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Interconnect Drawings

0630-3133, SHEET 5

249

Appendix A.

Interconnect Drawings

5-2012

FIGURE 98.

250

0630-3133, SHEET 6

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Appendix A.

FIGURE 99.

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Interconnect Drawings

0630-3133, SHEET 7

251

Appendix A.

Interconnect Drawings

5-2012

FIGURE 100.

252

0630-3133, SHEET 8

A029Y787 (Issue 1)

5-2012

Appendix A.

FIGURE 101.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3133, SHEET 9

253

Appendix A.

Interconnect Drawings

5-2012

FIGURE 102.

254

0630-3133, SHEET 10

A029Y787 (Issue 1)

5-2012

Appendix A.

FIGURE 103.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3133, SHEET 11

255

Appendix A.

Interconnect Drawings

5-2012

FIGURE 104.

256

0630-3133, SHEET 12

A029Y787 (Issue 1)

5-2012

Appendix A.

FIGURE 105.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3133, SHEET 13

257

Appendix A.

Interconnect Drawings

5-2012

FIGURE 106.

258

0630-3133, SHEET 14

A029Y787 (Issue 1)

5-2012

Appendix A.

FIGURE 107.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3133, SHEET 15

259

Appendix A.

Interconnect Drawings

5-2012

FIGURE 108.

260

0630-3133, SHEET 16

A029Y787 (Issue 1)

5-2012

Appendix A.

FIGURE 109.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3133, SHEET 17

261

Appendix A.

Interconnect Drawings

5-2012

FIGURE 110.

262

0630-3133, SHEET 18

A029Y787 (Issue 1)

5-2012

Appendix A.

FIGURE 111.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3133, SHEET 19

263

Appendix A.

Interconnect Drawings

5-2012

FIGURE 112.

264

0630-3133, SHEET 20

A029Y787 (Issue 1)

5-2012

Appendix A.

FIGURE 113.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3133, SHEET 21

265

Appendix A.

Interconnect Drawings

5-2012

FIGURE 114.

266

0630-3133, SHEET 22

A029Y787 (Issue 1)

5-2012

Appendix A.

FIGURE 115.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3133, SHEET 23

267

Appendix A.

Interconnect Drawings

5-2012

FIGURE 116.

268

0630-3133, SHEET 24

A029Y787 (Issue 1)

5-2012

Appendix A.

FIGURE 117.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3133, SHEET 25

269

Appendix A.

Interconnect Drawings

5-2012

FIGURE 118.

270

0630-3133, SHEET 26

A029Y787 (Issue 1)

5-2012

Appendix A.

FIGURE 119.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3133, SHEET 27

271

Appendix A.

Interconnect Drawings

5-2012

FIGURE 120.

272

0630-3133, SHEET 28

A029Y787 (Issue 1)

5-2012

Appendix A.

A.2

0630-3136 (SYNC1320 Interconnect Drawing)

FIGURE 121.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3136, SHEET 1

273

Appendix A.

Interconnect Drawings

5-2012

FIGURE 122.

274

0630-3136, SHEET 2

A029Y787 (Issue 1)

5-2012

Appendix A.

FIGURE 123.

A029Y787 (Issue 1)

Interconnect Drawings

0630-3136, SHEET 3

275

Appendix A.

Interconnect Drawings

5-2012

FIGURE 124.

276

0630-3136, SHEET 4

A029Y787 (Issue 1)

Appendix B. Sequence Diagrams


Table of Contents
Figure 125. Legend .................................................................................................................................... 279
Figure 126. Isolated Bus Without Generator Set Main Breaker Topology, Loss of Utility and Return of
Utility ........................................................................................................................................................... 280
Figure 127. Isolated Bus Without Generator Set Main Breaker Topology, Test .................................. 281
Figure 128. Isolated Bus with Generator Set Main Breaker Topology, Loss of Utility and Return of
Utility ........................................................................................................................................................... 282
Figure 129. Isolated Bus with Generator Set Main Breaker Topology, Test ........................................ 283
Figure 130. Common Bus Topology, Open Transition, Loss of Utility and Return of Utility ............. 284
Figure 131. Common Bus Topology, Open Transition, Test ................................................................. 285
Figure 132. Common Bus Topology, Soft-closed Transition, Loss of Utility and Return of Utility ... 286
Figure 133. Common Bus Topology, Soft-closed Transition, Test ....................................................... 287
Figure 134. Common Bus Topology, Extended Parallel ........................................................................ 288
Figure 135. Transfer Pair Topology, Open Transition, Loss of Utility and Return of Utility .............. 289
Figure 136. Transfer Pair Topology, Open Transition, Test .................................................................. 290
Figure 137. Transfer Pair Topology, Hard-closed Transition, Loss of Utility and Return of Utility ... 291
Figure 138. Transfer Pair Topology, Hard-closed Transition, Test ....................................................... 292
Figure 139. Transfer Pair Topology, Soft-closed Transition, Loss of Utility and Return of Utility .... 293
Figure 140. Transfer Pair Topology, Soft-closed Transition, Test ........................................................ 294
Figure 141. Transfer Pair Topology, Extended Parallel .......................................................................... 295
Figure 142. Load Add, Load Shed (Generator Sets Connected) ........................................................... 296
Figure 143. Utility Load Add ..................................................................................................................... 297
Figure 144. Load Demand ......................................................................................................................... 298

A029Y787 (Issue 1)

277

Appendix B.

Sequence Diagrams

5-2012

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278

A029Y787 (Issue 1)

5-2012

Appendix B.

B.1

Sequence Diagrams

FIGURE 125.

A029Y787 (Issue 1)

Sequence Diagrams

LEGEND

279

Appendix B.

Sequence Diagrams

5-2012

FIGURE 126.

280

ISOLATED BUS WITHOUT GENERATOR SET MAIN BREAKER TOPOLOGY, LOSS OF UTILITY AND RETURN OF UTILITY

A029Y787 (Issue 1)

5-2012

Appendix B.

FIGURE 127.

A029Y787 (Issue 1)

Sequence Diagrams

ISOLATED BUS WITHOUT GENERATOR SET MAIN BREAKER TOPOLOGY, TEST

281

Appendix B.

Sequence Diagrams

5-2012

FIGURE 128.

282

ISOLATED BUS WITH GENERATOR SET MAIN BREAKER TOPOLOGY, LOSS OF UTILITY AND RETURN OF UTILITY

A029Y787 (Issue 1)

5-2012

Appendix B.

FIGURE 129.

A029Y787 (Issue 1)

Sequence Diagrams

ISOLATED BUS WITH GENERATOR SET MAIN BREAKER TOPOLOGY, TEST

283

Appendix B.

Sequence Diagrams

5-2012

FIGURE 130.

284

COMMON BUS TOPOLOGY, OPEN TRANSITION, LOSS OF UTILITY AND RETURN OF UTILITY

A029Y787 (Issue 1)

5-2012

Appendix B.

FIGURE 131.

A029Y787 (Issue 1)

Sequence Diagrams

COMMON BUS TOPOLOGY, OPEN TRANSITION, TEST

285

Appendix B.

Sequence Diagrams

5-2012

FIGURE 132.

286

COMMON BUS TOPOLOGY, SOFT-CLOSED TRANSITION, LOSS OF UTILITY AND RETURN OF UTILITY

A029Y787 (Issue 1)

5-2012

Appendix B.

FIGURE 133.

A029Y787 (Issue 1)

Sequence Diagrams

COMMON BUS TOPOLOGY, SOFT-CLOSED TRANSITION, TEST

287

Appendix B.

Sequence Diagrams

5-2012

FIGURE 134.

288

COMMON BUS TOPOLOGY, EXTENDED PARALLEL

A029Y787 (Issue 1)

5-2012

Appendix B.

FIGURE 135.

A029Y787 (Issue 1)

Sequence Diagrams

TRANSFER PAIR TOPOLOGY, OPEN TRANSITION, LOSS OF UTILITY AND RETURN OF UTILITY

289

Appendix B.

Sequence Diagrams

5-2012

FIGURE 136.

290

TRANSFER PAIR TOPOLOGY, OPEN TRANSITION, TEST

A029Y787 (Issue 1)

5-2012

Appendix B.

FIGURE 137.

A029Y787 (Issue 1)

Sequence Diagrams

TRANSFER PAIR TOPOLOGY, HARD-CLOSED TRANSITION, LOSS OF UTILITY AND RETURN OF UTILITY

291

Appendix B.

Sequence Diagrams

5-2012

FIGURE 138.

292

TRANSFER PAIR TOPOLOGY, HARD-CLOSED TRANSITION, TEST

A029Y787 (Issue 1)

5-2012

Appendix B.

FIGURE 139.

A029Y787 (Issue 1)

Sequence Diagrams

TRANSFER PAIR TOPOLOGY, SOFT-CLOSED TRANSITION, LOSS OF UTILITY AND RETURN OF UTILITY

293

Appendix B.

Sequence Diagrams

5-2012

FIGURE 140.

294

TRANSFER PAIR TOPOLOGY, SOFT-CLOSED TRANSITION, TEST

A029Y787 (Issue 1)

5-2012

Appendix B.

FIGURE 141.

A029Y787 (Issue 1)

Sequence Diagrams

TRANSFER PAIR TOPOLOGY, EXTENDED PARALLEL

295

Appendix B.

Sequence Diagrams

5-2012

FIGURE 142.

296

LOAD ADD, LOAD SHED (GENERATOR SETS CONNECTED)

A029Y787 (Issue 1)

5-2012

Appendix B.

FIGURE 143.

A029Y787 (Issue 1)

Sequence Diagrams

UTILITY LOAD ADD

297

Appendix B.

Sequence Diagrams

5-2012

FIGURE 144.

298

LOAD DEMAND

A029Y787 (Issue 1)

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