Instruction Sheet

Instruction Sheet
A072D657 (Issue 1) 4-2022
Installation Instructions for PCC3200/PCC3201 to PCC3300V1

Upgrade Kit on Generator Sets with QSK60 Engine
1 Introduction
This instruction sheet includes information on how to install the PCC3300V1 control system for the
products shown below.
Recommended tooling is also provided.
TABLE 1. PCC3200/PCC3201 TO PCC3300V1 UPGRADE KIT
PCC3100 to PCC3300V1 Upgrade Kit Generator Set Engine Kit Part Number
Models
Includes: All required controls, harnessing, C2000D5, QSK60 - HPI A066R260
sensors, labels, and a quick start guide C2000D5E, fuel system
necessary to upgrade a generator set housing C2000D6,
mounted with a PCC3200/PCC3201 to the
C2250D5,
PCC3300V1 control system (PCC3300V1 MLD
board).** C2250D6A,
C2500D5,
C2500D5A,
DQKB, DQKC,
DQKD, DQKH
DQKAA, DQKAB QSK60 - MCRS A067R990*
fuel system
*CDUC part number is A059J425.
**For PCC3300V1 non MLD – order the PCC3300V1 board separately.
TABLE 2. RECOMMENDED TOOLING
Tools/Consumables Details
Knock Out Punch Set (hole saw may be used) For use with customer connection on new box
Unibit For creating guide holes for punch out tool
Metal File For cleaning the edges caused by drilled holes
Wire Label For use if wiring is not properly labeled
Miscellaneous Wire Connectors For use with excitation and PMG leads
Miscellaneous Zip Ties For securing harnesses
11/32 inch Backing Wrench, or Equivalent For removing CT wiring
English
- Original Instructions
A072D657 (Issue 1) Page 1 of 36 Copyright © 2022 Cummins Inc.
2 Safety Precautions
2.1 General Safety Precautions

WARNING
Hot Pressurized Liquid
Contact with hot liquid can cause severe burns.
Do not open the pressure cap while the engine is running. Let the engine cool down before
removing the cap. Turn the cap slowly and do not open it fully until the pressure has been
relieved.
WARNING
Moving Parts
Moving parts can cause severe personal injury.
Use extreme caution around moving parts. All guards must be properly fastened to prevent
unintended contact.
WARNING
Toxic Hazard
Used engine oils have been identified by some state and federal agencies to cause cancer or
reproductive toxicity.
Do not ingest, breathe the fumes, or contact used oil when checking or changing engine oil.
Wear protective gloves and face guard.
WARNING
Toxic Hazard
Ethylene glycol, used as an engine coolant, is toxic to humans and animals.
Wear appropriate PPE. Clean up coolant spills and dispose of used coolant in accordance with
local environmental regulations.
WARNING
Electrical Generating Equipment
Incorrect operation can cause severe personal injury or death.
Do not operate equipment when fatigued, or after consuming any alcohol or drug.
WARNING
Toxic Gases
Substances in exhaust gases have been identified by some state and federal agencies to cause
cancer or reproductive toxicity.
Do not breathe in or come into contact with exhaust gases.

WARNING
Combustible Liquid
Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or
death.
Do not store fuel, cleaners, oil, etc., near the generator set.
WARNING
High Noise Level
Generator sets in operation emit noise, which can cause hearing damage.
Wear appropriate ear protection at all times.
WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns.
The unit is to be installed so that the risk of hot surface contact by people is minimized. Wear
appropriate PPE when working on hot equipment and avoid contact with hot surfaces.
WARNING
Incorrect operation and maintenance can result in severe personal injury or death.
Make sure that only suitably trained and experienced service personnel perform electrical and/or
mechanical service.
WARNING
Automated Machinery
Accidental or remote starting of the generator set can cause severe personal injury or death.
Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery
cables (negative [–] first).
WARNING
Fire Hazard
Materials drawn into the generator set are a fire hazard. Fire can cause severe burns or death.
Keep the generator set and the surrounding area clean and free from obstructions.
WARNING
Fire Hazard
Materials drawn into the generator set are a fire hazard. Fire can cause severe burns or death.
Make sure the generator set is mounted in a manner to prevent combustible materials from
accumulating under the unit.

WARNING
Fire Hazard
Accumulated grease and oil are a fire hazard. Fire can cause severe burns or death.
Keep the generator set and the surrounding area clean and free from obstructions. Repair oil
leaks promptly.
WARNING
Incorrect service or replacement of parts can result in severe personal injury or death, and/or
equipment damage. Service personnel must be trained and experienced to perform electrical and
mechanical service.
NOTICE
Keep multi-type ABC fire extinguishers close by. 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. (Refer to NFPA No. 10 in the
applicable region.)
NOTICE
Before performing maintenance and service procedures on enclosed generator sets, make sure
the service access doors are secured open.
NOTICE
Stepping on the generator set can cause parts to bend or break, leading to electrical shorts, or to
fuel leaks, coolant leaks, or exhaust leaks. Do not step on the generator set when entering or
leaving the generator set room.
WARNING
Combustible Gases
Ignition of battery gases is a fire and explosion hazard which can cause severe personal injury or
death.
Arcing can occur when cable is removed or reconnected, or when negative (–) battery cable is
connected and a tool used to connect or disconnect positive (+) battery cable touches frame or
other grounded metal part of the set. Always remove negative (–) cable first, and reconnect it
last. Make certain hydrogen from battery, engine fuel, and other explosive fumes are fully
dissipated. This is especially important if battery has been connected to a battery charger. Make
certain the battery area has been well-ventilated before servicing the battery.
WARNING
Hazardous Voltage
Contact with high voltages can cause severe electrical shock, burns, or death.
The equipment may have more than one source of electrical energy. Disconnecting one source
without disconnecting the others presents a shock hazard. Before

CAUTION
Electrostatic Discharge Sensitive Components
Printed circuit boards/cards contain components that are sensitive to static electricity. Always
wear an antistatic wrist strap connected to a metal surface to channel static electricity to ground
when handling printed circuit boards/cards.
Failure to comply may cause damage to equipment.
NOTICE
Always disconnect a battery charger from the AC source before disconnecting the battery
cables. Otherwise, disconnecting the battery cables can result in voltage spikes high enough to
damage the DC control circuits of the set.
2.2 Electrical Shocks and Arc Flashes Can Cause Severe Personal
Injury or Death
WARNING
Electric Shock Hazard
Voltages and currents present an electrical shock hazard that can cause severe burns or death.
Contact with exposed energized circuits with potentials of 50 Volts AC or 75 Volts DC or higher
can cause electrical shock and electrical arc flash. Refer to standard NFPA 70E or equivalent
safety standards in corresponding regions for details of the dangers involved and for the safety
requirements.
Guidelines to follow when working on de-energized electrical systems:

• Use proper PPE. Do not wear jewelry and make sure that any conductive items are removed from
pockets as these items can fall into equipment and the resulting short circuit can cause shock or
burning. Refer to standard NFPA 70E for PPE standards.
• De-energize and lockout/tagout electrical systems prior to working on them. Lockout/Tagout is
intended to prevent injury due to unexpected start-up of equipment or the release of stored energy.
• De-energize and lockout/tagout all circuits and devices before removing any protective shields or
making any measurements on electrical equipment.
• Follow all applicable regional electrical and safety codes.
In summary:
• Do not tamper with or bypass interlocks unless you are authorized to do so.
• Understand and assess the risks - use proper PPE.
• Make sure that an accompanying person who can undertake a rescue is nearby.
2.2.1 Medium Voltage Equipment (601 V to 15 kV - U.S. and Canada)

• 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.

• 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.
2.3 Generator Set Safety Code

Before operating the generator set, 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
Incorrect operation and maintenance can result in severe personal injury or death.
Read and follow all Safety Precautions, Warnings, and Cautions throughout this manual and the
documentation supplied with the generator set.
2.4 Certifications
The PCC3200/PCC3201 to PCC3300V1 upgrade kits are currently available for sale in North America,
LatAm (Latin America), NESEA (North-East South-East Asia) regions. Kit can be used on Cummins
generator sets that are already UL certified and/or CSA certified.
2.5 Service Support

Cummins Inc. provides a 24-hour, toll-free telephone number to aid in technical and emergency service.
Call the toll-free number and escalate your request through Cummins Care channel to obtain assistance
with technical queries.
For North America:
1-800-CUMMINSTM (1-800-286-6467)
For LatAm:
1-800-CUMMINSTM (1-800-286-6467)
For NESEA:
8000-CUMMINS
Or submit an electronic request at care.cummins.com
Please note that aftermarket support is only for installations on Cummins generator sets.
2.6 Additional Service Literature

Reference documents available on QuickServe Online (QSOL):
• PowerCommand 3.3 Controller Service Manual (0900-0670)
• Upgrade Instructions from PCC3300 or PCC3300V2 to PCC3300 MLD or PCC3300V2 MLD
(A044X528)
• AUX101/102 Owner Manual (A030K737)
• Paralleling with PC3.x Controller Genset (CPGF-S-00000045-2)
• PCC3200 Service Manual (A034T571)

• PCC3201 Service Manual (A034T572)
• Fail Code Manual (F1115C)
• Optional kits, refer below:
Optional Accessory Kits
Depending on the engine and the installation, the following optional kits may be required.
TABLE 3. OPTIONAL ACCESSORY KITS
Description Application Kit part number

12V relay kit Require when applying the upgrade A040B144
kit to a 12V generator set
RS485 Network Connection Kit Require when connecting generator A040U145
set to remote Modbus RTU network
Lonworks Connection Kit: FT-10 Required in addition to the Network A040G225
Connection Kit A040U145 if See document 0900-0529 for the FT-
connecting generator set to an 10 Installation Manual and a list of
existing Lonworks FT-10 network additional required equipment
Lonworks Connection Kit: TP-78 Required in addition to the Network A040G225
Connection Kit A040U145 if See document 0900-0366 and C577
connecting generator set to an for the TB-78 Installation Manual and
existing Lonworks TP-78 network a list of additional required equipment.
(i.e. Lonworks router 300-4919-01).
HMI LCD Heater Kit Required for LCD operation below -20 A026J556
°C
Remote HMI kit Additional HMI for remote mounting A041J589
Aux 101 kit I/O expansion module A030K633
Annunciator kit Annunciator kit without enclosure 0300-5929-01
Annunciator kit Annunciator kit with enclosure 0300-5929-02
2.7 Parts List

TABLE 4. KIT A066R260 – FOR GENERATOR SETS WITH QSK60 ENGINES – HPI FUEL SYSTEM
Part Description Part Number

Kit for generator sets with QSK60 engines – MCRS fuel A067R990
system
Control, engine A066R257
Wiring diagram part number, page 6 A065N551
TABLE 5. KIT A067R990 – FOR GENERATOR SETS WITH QSK60 ENGINES – MCRS FUEL SYSTEM
Part Description Part Number

PANEL,CONTROL BOX A068F373

HARNESS,INTERFACE A068F375
BRACKET, CONTROL BOX A068F377
BRACKET,SUPPORT A068F378
ISOLATOR,VIBRATION A068F379
ISOLATOR,VIBRATION A068F380
Switch, Emergency Stop A065C322
Harness, Alternator A065C327
Switch, emergency Stop A065C328
Display, Control; HMI 114 0300-6366-02
Display, Control 0300-6315-02
Board, Module Printed Circuit 0327-1265
Control, Governor; Aux 103,PCB ASSY 0327-1593
Control, Engine; PCB ASSY (CNTRL 3300) MLD A041W736
Control; Aux 101 0327-1536
Decal, Datatag; Power Unit/Module (IH) CDUC part number - A058N396
Label, Safety; Shock, Pinch CDUC part number - A071W631
Ground Strap, 1/4" Wide; 12" Hole Centers CDUC part number - 15197
Diode CDUC part number - A058Z294
Bracket, Adapter, PCC3300; HMI upgrade CDUC part number - A066E237
PCC3100 to PCC3300 HMI mounting bracket, if required, needs to be ordered separately – Part number
is A050N431
2.8 Standar Repair Times

Remove old controller and install kit – 21 hours each for 2 individuals.
For rental and paralleling applications, additional time may be required.
2.9 Warranty
Refer to the Global Warranty Statement – Parts and Accessories (Global Literature Number - A049K309)
for the applicable warranty.
3 Removal and Installation Instructions

NOTICE
Only Qualified Level 3 Cummins Technicians should perform this upgrade.

Before beginning to remove and install, make sure that there are no PCC fault codes and/or ECM fault
codes. Document if any discrepancies are noticed and let the customer know. Troubleshoot accordingly
and check for normal operation of the generator set before beginning the installation of upgrade kit. To
inspect the health, it is recommended to run the unit with load.
3.1 Export PCC3200/PCC3201 Settings

While the PCC3200/PCC3201 is still connected and powered on, collect the following information and
record in an excel file for later use on PCC3300V1. Use the PCC3200/PCC3201 Service Manual as a
reference for locations of below parameters.
• Capture file
• FT10 devices – customer interface connections, datapoints, etc.
• Total Engine Run Hours
• Generator Set Serial Number
• Alternator Serial Number
• Engine Serial Number
• Customer Inputs and Outputs
• Paralleling breaker AUX controller settings
• Voltage
• kW rating/kVA rating
• CT ratio
• Frequency
3.2 Hardware
CAUTION
Automated Electrical Generating Equipment
Improper service or replacement of parts could lead to severe personal injury or death and
damage to equipment and property.
Service personnel must be qualified to perform electrical and mechanical service.
3.2.1 PCC3200/PCC3201 Hardware Removal

NOTICE
Before removing the Bus PT, label wires A, B, C, and N accordingly.
New controls may come with additional customer connections that provide additional functionality.
To remove existing PCC3200/PCC3201 hardware:
1. Disconnect the power by removing the return battery connection from the PCC3200/PCC3201
control.
2. Follow the appropriate lockout/tagout procedures.
3. Open the generator set breaker to isolate it from the system, lockout/tagout the breaker.

4. Gain access to the sides of the PCC3200/PCC3201.
5. Disconnect all cables attached to the PCC3200/PCC3201.
6. Make sure that the wiring is properly labeled. Label the wire if not labeled.
7. Pull the customer wiring and tie them out of the way.
8. Fully disconnect the PCC3200/PCC3201 control box from the generator set.
9. Leave the DC alternator-feed harness.
10. Disconnect block heater circuit at J3 connector.
11. Disconnect the mag-pickup sensor (speed sensor).
12. Disconnect and remove the AC harness.
a. Use caution when removing CT wiring. To prevent damage to the CT terminal, use a 11/32inch
backing wrench or equivalent.
b. Label the alternator wiring for the PMG and excitation leads, if not already done.
13. Measure and record the dimensions for the customer connection ports on the PCC3200/PCC3201
box.
14. Disconnect and remove the engine harness from the generator set. Retain the p-clips for later use.
15. Remove the engine sensors: low coolant, coolant temperature (left and right side), oil pressure, and
oil temperature.
NOTICE
When removing the coolant temperature, oil pressure, and oil temperature sensors, use
caution to make sure the o-rings are also removed. Also, be cautious of potential oil leaks.
CAUTION
Hot Fluids
Contact with hot fluids can cause severe burns.
Wear appropriate PPE
16. Properly dispose-off the sensors.
NOTICE
For HPI – secure spacers and bolts while removal as that will be used later in installation
NOTICE
For FT10 devices: FT-10 devices, if any, need to be replaced with PCCnet/Modbus devices. Refer
to document A045T065 (installation instructions to replace ModLon II with Protonode) for details.

3.2.2 PCC3300V1 Pre-Installation
NOTICE
Sheet metal needs to be cut for pre-installation. Use appropriate protection.
1. Prepare the new site-specific conduit holes.

a. Using the original site-specific conduit layout from the PCC3200/3201 box, measure the
diameter and position of the conduit holes.
b. On the PCC3300V1 control box provided in the kit, measure and mark the customer site
specific conduit hole location(s).
NOTICE
Use masking sheets to prevent any metal shavings from entering the wiring and
boards in the PCC3300V1 control box. Metal shaving can damage the equipment. Also,
remove any wiring and boards near the knockout locations to prevent damage.
c. Create a punch mark.

d. Use the appropriate knockout tools and create the holes.
e. Buff out any rough edges.
f. Touch up the edges with Onan green paint.
g. Inspect the PCC3300V1 control box and remove any shavings.
3.2.3 PCC3300V1 Installation

NOTICE
Parts for the installation are provided in the installation kit.
1. Install the new engine harness using the original p-clips.

a. aSecure the harness along the engine, bundle any extra length, and secure it to the generator
set.
b. Connect the flying leads to J3 connector on new engine harness.
c. For generator sets with a QSK60 engine, remove the DC charging alternator guards and route
the harness around it to connect the DC charging alternator. Reinstall the guards.
2. Install the new PCC3300V1 control box with the vibration isolator kit. Torque the bolts to 28 Nm
(247.82 in-lb).
3. For generator sets with a QSK60 – HPI fuel system, install the CM2250 ECM, the new engine
harness and sensors provided with kit A066R260.
4. Install the site-specific customer conduit(s) through the PCC3300V1 control box.
5. Reconnect the customer connections to TB2.
6. Connect the AC harness.
a. Connect the wires for voltage sensing, excitation, CTs, and PMG.
b. Securely tie off harness inside the alternator terminal box.

NOTICE
Use best practices for tie off points when securing wiring and harnesses. Do not use
sticky strip holders as they can heat up and cause the wire to fall.
7. Install the HMI320, bargraph, and emergency stop panel in the same location as the
PCC3200/PCC3201.
FIGURE 1. HMI320, BARGRAPH, AND EMERGENCY STOP PANEL

8. Run the HMI harness through the alternator terminal box and into the PCC3300V1 control box.
a. Connect the HMI connector to the PCC3300V1.
b. Securely tie off the harness inside the alternator terminal box.
9. Remove the lockout tagout, engage the emergency stop, and reconnect battery power.
3.3 Software Installation/Calibration

NOTICE
Make sure to download all of the latest commercial generator set calibration files from the InCal
website and run the InPower InCal extractor utility. Make sure to download the latest revision of
ECM calibration from QSOL.
1. PCC3300V1 is shipped with base calibration from factory.

a. Connect the PCC3300V1 to InPower.
b. Update the calibration to the latest revision.
c. Enter the generator set, alternator, and engine serial numbers in the History/About section in
InPower.
d. Input the CT ratio (found on physical CT).
e. Select the site voltage (default calibration on PC3.x inside the kit is 480 V).
2. Update calibration on HMI320 to its latest revision along with applicable PCCnet devices in the
network.

3. Connect to the ECM using Insite.
a. Perform an update calibration to the latest revision.
b. Enter the engine run hours.
4. Check all setup screens (OEM/PAR/IO) and make necessary modifications.
3.3.1 Voltage Sense

If the alternator is connected in series configuration (high voltage connection), make sure the generator
set voltage sense leads are connected to the AC output terminals, not the center taps.
690V L-L (Line-to-Line) generator sets require the addition of a potential step-down transformer to reduce
the voltage into the PCC3300V1 control between 120 and 600V L-L.
If the alternator is connected in the delta configuration, remove the neutral wire from the voltage sense
harness.
The neutral wire on the bus voltage sense may cause disturbances in the voltage readings and therefore
may cause various problems when paralleling. The neutral sense wire is not required and should be
removed if these issues are encountered.
NOTICE
Generator set voltage calibration is required on all medium and high voltage conversions due to
inaccuracies in the generator step-down transformer. The step-down transformers can introduce
as much as 5% variation. Calibration line voltage reference equipment is therefore required.
3.3.2 Engine Idle

The engine idle switch input is not available on the PCC3300V1 control. The generator set can be
manually set to idle speed with the Rated/Idle Sw setting on the Adjust screen of the Operator Panel.
3.3.3 First Start Arbitration (for Generator Set Application Types Isolated
Bus and Utility Multiple)
Where the first start arbitration is not connected, add a 10k pull-up resistor to the first start + line to
prevent a first start backup fault from occurring during dead bus closure. Do not do this if multiple
generator sets can close to a dead bus.
3.3.4 How to Activate PCC3300V1 Sleep Mode

To activate the PCC3300V1 Sleep Mode, certain conditions must be met. After the conditions have been
satisfied the Power Down Mode Timer (adjustable from 0-600 seconds) must time-out before the control is
converted to Sleep Mode Conditions.
• Generator set stopped
• Manual Run Input = Inactive
• Remote Start Switch = Inactive
• No Active Shutdowns or Warnings
• Power Down Mode Enable = Enable
• Auto Mode Inactive OR Auto Sleep Enable = Enable
• System Wakeup = Inactive
◦ Jumper J5 removed from HMI114

◦ HMI320 set to Sleep Mode Enable, Sleep Timer set to 1 minute
◦ PC Tool cable removed from TB15
• Fault Reset Switch = Inactive
• Rupture Basin Switch = Inactive
• Low Fuel Switch = Inactive
• Coolant Level Switch = Inactive
• Generator Application Type != (not equal to) Power Transfer Control or Utility Single
• Prelube Cycle Enable = Disable
• Modbus Communications = Inactive
• No Exercise Run commands
3.3.5 Aux101 Node Address

Set the AUX101 node address = 0. This is done by pressing and holding the button near the 7-segment
node address display (while powered) until the LEDs light up. Then release and press the button
momentarily until 0 is displayed.
NOTICE
If a second AUX101 is used, it must be set to node address 1.
3.4 Mode Select Protection

In the PCC3300V1 Control, this feature is implemented using a password-protected screen. Thus the
technician is required to enter a password every time the mode is changed on the generator set.
NOTICE
This option can only be enabled via the HMI.
FIGURE 2. HMI320 HOME SCREEN (1 OF 2)

FIGURE 3. HMI320 HOME SCREEN (2 OF 2)
By pressing the Home key on the operator panel, the display is shown in Figure 2. Press the down key
which is shown on the bottom-right corner of Figure 2. This leads to the second Home screen as shown in
Figure 3. Move the cursor to Display Options and press OK.
FIGURE 4. DISPLAY OPTIONS

In the Display Options screen, move the cursor to navigate to the Mode Change parameter. Press OK,
enter the required password, and change the value from Disabled to Enable. After changing the
parameter to Enable, the technician will now be required to enter a password every time the mode is
changed in the PCC3300V1 control. If Mode Change is set to Enabled, technician has to enter the
password 121 to change the mode of operation.
3.5 PCC3200/PCC3201 to PCC3300V1 Conversion Inspection Test

This inspection test is to make sure the generator set is operating properly, and all fail safe mechanisms
are working after conversion to a PCC3300V1 control. Before starting the generator set, make sure the
generator set is disconnected from any customer load. Also, take precautions against any accidental
paralleling breaker closure by disconnecting or disabling the breaker.
3.5.1 E-stop
This verifies the generator set shuts down in an emergency.
Trigger an emergency shutdown using the local and remote E-stop buttons. E-stop faults should be
displayed on the operator panel.

3.5.2 Fault Inputs
Test the following inputs by forcing the switch if possible or shorting the input to ground as close to the
switch as possible. If applicable, allow the control to sleep and make sure the input wakes the control and
the fault is announced.
TABLE 6. FAULT INPUTS
Low Engine Temperature Disconnect the switch from the harness.

Low Coolant Take the coolant level sensor out of the coolant.
Level
Low Day Tank Take the low fuel switch out of fuel tank or disconnect the
Fuel* switch from the harness.
Rupture Basin* Disconnect the switch from the harness.

* The generator set may not be fitted with a low day tank fuel or a rupture basin switch.
3.5.3 AC Metering and Regulation

To verify the generator set generates and meters AC power:
1. With the generator set breaker disconnected from any load, or disabled, start the generator set and
verify the correct voltage and frequency is generated and displays the correct values on the displays
and bar-graph. Calibrate voltage and frequency if necessary.
2. Apply a test load and verify the proper %kW, PF, and line current readings.
3.5.4 Sensor Readings

Check and verify functionality of the following sensors:
• Coolant Temparature
• Oil Temperature
• Exhaust Temperature
• Oil Pressure
Use the breakout board harness connection (if available) to control the sensor values and verify the
shutdown occurs at the proper threshold. Some faults will not occur unless the generator set is running.
TABLE 7. THRESHOLD VALUE
Threshold Value
LOP Warning Threshold Refer to LOP Table
LOP Shutdown Threshold Refer to LOP Table
LOP Idle Warning Threshold Refer to LOP Table
LOP Idle Shutdown Threshold Refer to LOP Table
TABLE 8. HIGH COOLANT TEMPERATURE (HCT) THRESHOLD
Threshold Value

HCT Warning Threshold 215 °F (Standby) or 207 °F (Prime)
HCT Shutdown Threshold 223 °F (Standby) or 215 °F (Prime)
3.5.5 Customer I/O

Verify that the generator set customer inputs and outputs are correct.
3.5.5.1 Customer Status Outputs

Verify the following generator set customer status outputs:
• Switched B+ (active when a Run command is active)
• Ready to Load (active when 90% speed and voltage is initially reached, and the generator set is
running)
• Load Dump (active when an overload or an under-frequency condition occurs)
• Load Dump test method:
◦ Make sure the generator set is not and will not connect to the site.
◦ Connect to the AUX105 via InPower.
◦ Start the generator set in Manual mode.
◦ Observe Gov Duty Cycle % at steady state, no load.
◦ Set the Governor PWM Override Command value to 1/2 the observed steady-state value.
◦ Set Governor PWM Override Enable = Enable.
◦ The load dump signal should activate with the Load Dump announcement (FC 1464).
3.5.5.2 Customer Alarm Outputs

Verify the following generator set customer alarm outputs:
• Common Warning (active when a warning fault is active)
• Common Shutdown (active when a shutdown fault is active)
• Annunciator outputs (individual output active when corresponding fault condition is active) ◦
Overcrank Test Method:
◦ Make sure the cycle crank settings are appropriate for the generator set.
◦ Set the Governor PWM Override Command = 0 ▪ Set Governor PWM Override Enable =
Enable
◦ Initiate a manual start. The generator set should complete the crank sequence without starting
and announce Overcrank or Fail to Start (FC 359).
• Overspeed Test Method:
◦ Make sure the generator set is not and will not connect to the site.
◦ Make sure the Overspeed protection settings are appropriate for the generator set.
◦ Start the generator set in Manual mode.
◦ Observe Gov Duty Cycle % at steady state, no load.
◦ Set the Governor PWM Override Command value slightly higher than the observed steady-
state value.

◦ Set Governor PWM Override Enable = Enable.
◦ Incrementally increase the Governor PWM Override Command until the generator set shuts
down and announces Overspeed (FC 234).
3.5.5.3 Customer Inputs

Verify the following generator set customer inputs:
• Customer Fault Inputs
• Remote Fault Reset
• Remote Start
3.5.6 Paralleling (If Applicable)

Complete the following checks with a load bank before putting the generator set into service.
Generator set to Generator set:
• Generator set Breaker Control Outputs
• Generator set Breaker Inhibit
• Load Share/Load Govern Stability
Generator set to Utility:
• Sync to Utility
• External Load Set
• Utility CB Status
Generator set to Utility Multiple:
• Sync to Generator set Bus
• Master first start system
3.6 Final Checks

1. Before putting the generator set into service:
a. Test with a load bank and verify speed, frequency, CT and voltage readings match with the
load (use external measuring instruments).
b. Test for block load, surge underload, paralleling features like load govern, load share (if
applicable).
2. After putting the generator set into service:
a. Check if the CT and voltage readings match with the building load readings.

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Appendix A. Wiring Diagram
Table of Contents
Figure 5. Sheet 1 of 7 ................................................................................................................................... 24
Figure 6. Sheet 2 of 7 ................................................................................................................................... 26
Figure 7. Sheet 3 of 7 ................................................................................................................................... 28
Figure 8. Sheet 4 of 7 ................................................................................................................................... 30
Figure 9. Sheet 5 of 7 ................................................................................................................................... 32
Figure 10. Sheet 6 of 7 ................................................................................................................................. 34
Figure 11. Sheet 7 of 7 ................................................................................................................................. 36


A.0 A065N551 Wiring Diagram


FIGURE 5. SHEET 1 OF 7













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A072D657 (Issue 1) 4-2022

Installation Instructions for PCC3200/PCC3201 to PCC3300V1

TABLE 1. PCC3200/PCC3201 TO PCC3300V1 UPGRADE KIT

TABLE 2. RECOMMENDED TOOLING

2.1 General Safety Precautions

A072D657 (Issue 1) Page 2 of 36 Copyright © 2022 Cummins Inc.

A072D657 (Issue 1) Page 3 of 36 Copyright © 2022 Cummins Inc.

A072D657 (Issue 1) Page 4 of 36 Copyright © 2022 Cummins Inc.

Guidelines to follow when working on de-energized electrical systems:

2.2.1 Medium Voltage Equipment (601 V to 15 kV - U.S. and Canada)

A072D657 (Issue 1) Page 5 of 36 Copyright © 2022 Cummins Inc.

2.3 Generator Set Safety Code

2.5 Service Support

2.6 Additional Service Literature

A072D657 (Issue 1) Page 6 of 36 Copyright © 2022 Cummins Inc.

TABLE 3. OPTIONAL ACCESSORY KITS

Description Application Kit part number

2.7 Parts List

Part Description Part Number

Part Description Part Number

A072D657 (Issue 1) Page 7 of 36 Copyright © 2022 Cummins Inc.

2.8 Standar Repair Times

3 Removal and Installation Instructions

A072D657 (Issue 1) Page 8 of 36 Copyright © 2022 Cummins Inc.

3.1 Export PCC3200/PCC3201 Settings

3.2.1 PCC3200/PCC3201 Hardware Removal

A072D657 (Issue 1) Page 9 of 36 Copyright © 2022 Cummins Inc.

16. Properly dispose-off the sensors.

A072D657 (Issue 1) Page 10 of 36 Copyright © 2022 Cummins Inc.

1. Prepare the new site-specific conduit holes.

c. Create a punch mark.

3.2.3 PCC3300V1 Installation

1. Install the new engine harness using the original p-clips.

A072D657 (Issue 1) Page 11 of 36 Copyright © 2022 Cummins Inc.

FIGURE 1. HMI320, BARGRAPH, AND EMERGENCY STOP PANEL

3.3 Software Installation/Calibration

1. PCC3300V1 is shipped with base calibration from factory.

A072D657 (Issue 1) Page 12 of 36 Copyright © 2022 Cummins Inc.

3.3.1 Voltage Sense

3.3.2 Engine Idle

3.3.4 How to Activate PCC3300V1 Sleep Mode

A072D657 (Issue 1) Page 13 of 36 Copyright © 2022 Cummins Inc.

3.3.5 Aux101 Node Address

3.4 Mode Select Protection

FIGURE 2. HMI320 HOME SCREEN (1 OF 2)

A072D657 (Issue 1) Page 14 of 36 Copyright © 2022 Cummins Inc.

FIGURE 4. DISPLAY OPTIONS

3.5 PCC3200/PCC3201 to PCC3300V1 Conversion Inspection Test

A072D657 (Issue 1) Page 15 of 36 Copyright © 2022 Cummins Inc.

TABLE 6. FAULT INPUTS

Low Engine Temperature Disconnect the switch from the harness.

Rupture Basin* Disconnect the switch from the harness.

3.5.3 AC Metering and Regulation

3.5.4 Sensor Readings

TABLE 7. THRESHOLD VALUE

TABLE 8. HIGH COOLANT TEMPERATURE (HCT) THRESHOLD

A072D657 (Issue 1) Page 16 of 36 Copyright © 2022 Cummins Inc.

3.5.5 Customer I/O