A035j931 I3 201710

Installation Manual
PowerCommand®3.3 Control Upgrade Kit

Upgrade from PCC3100 or Detector/Sentinel Controls
English
Original Instructions 10-2017 A035J931 (Issue 3)
Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1
1.1 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1
1.2 General Information ................................................................................................................ 1
1.2.1 General Safety Precautions ......................................................................................... 2
1.3 Generator Set Safety Code .................................................................................................... 4
1.3.1 Moving Parts Can Cause Severe Personal Injury or Death ........................................ 4
1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 5
1.4.1 Medium Voltage Equipment (601 V to 15 kV - U.S. and Canada) .............................. 6
2. INTRODUCTION............................................................................................................................ 7
2.1 Applicable Generator Set Models ........................................................................................... 7
3. PRE-SOFTWARE UPGRADE........................................................................................................ 9
3.1 Required Equipment ............................................................................................................... 9
3.2 Required Control Calibration................................................................................................... 9
3.3 InPower Pro Terminology ..................................................................................................... 11
4. EXPORT PCC3100 SETTINGS INTO A CSV FILE..................................................................... 13

4.1 Additional Settings to Extract Information from the PCC3100.............................................. 14
4.1.1 ................................................................................................................................... 15
5. USING A PC3.3 UPGRADE MACRO .......................................................................................... 17
6. HARDWARE ................................................................................................................................ 19
6.1 Safety Precautions................................................................................................................ 19
6.2 Installation............................................................................................................................. 19
6.2.1 PCC3100 Hardware Removal.................................................................................... 19
6.2.2 PC3.3 Hardware Installation ...................................................................................... 23
6.2.3 Small A40 Box - HC4/HC5/UC Installation ................................................................ 28
6.2.4 Large A40 Box HC6/HC7/HC8/P7 Installation ........................................................... 31
6.2.5 AC Housing Installation.............................................................................................. 33
6.2.6 Control Box Connections ........................................................................................... 34
6.2.7 Required Position of New Labels............................................................................... 35
6.2.8 Rupture Basin Input ................................................................................................... 36
6.2.9 Voltage Sense............................................................................................................ 36
6.2.10 Engine Idle ............................................................................................................... 36
6.2.11 Mode Change Protection ......................................................................................... 36
6.2.12 First Start (for Generator Set Application Types Isolated Bus and Utility
Multiple) ....................................................................................................................... 36
6.2.13 How to Activate PC3.3 Sleep Mode......................................................................... 37
6.2.14 Aux101 Node Address ............................................................................................. 37
7. PC3.3 CONTROL SOFTWARE UPGRADE ................................................................................ 39

7.1 Perform Initial Calibration and Load Latest Software ........................................................... 39
A035J931 (Issue 3) i Copyright © 2017 Cummins Inc.

Table of Contents 10-2017
7.2 Installation of Feature Code.................................................................................................. 39

7.3 Translating PCC3100 Settings to the PC3.3 ........................................................................ 41
8. OPTIONAL SETTINGS ................................................................................................................ 45

8.1 Mode Select Protection......................................................................................................... 45
9. PCC3100 TO PC3.3 CONVERSION INSPECTION TEST .......................................................... 47

9.1 E-stop.................................................................................................................................... 47
9.2 Fault Inputs ........................................................................................................................... 47
9.3 AC Metering and Regulation................................................................................................. 47
9.4 Sensor Readings .................................................................................................................. 47
9.4.1 Generator Set Sensor and Switch Locations............................................................. 49
9.5 Customer I/O......................................................................................................................... 53
9.5.1 Status Outputs ........................................................................................................... 53
9.5.2 Alarm Outputs ............................................................................................................ 54
9.5.3 Inputs ......................................................................................................................... 54
9.6 Paralleling (If Applicable) ...................................................................................................... 54
APPENDIX A. PARTS....................................................................................................................... 57
A.0 Display Panel........................................................................................................................ 58
A.1 Side Panel (HC4/HC5/UC Box)............................................................................................ 59
A.2 Main Panel (HC4/HC5/UC Box) ........................................................................................... 60
A.3 Main Panel (HC6/HC7/HC8/P7 Box).................................................................................... 61
A.4 Side Panel (HC6/HC7/HC8/P7 Box) .................................................................................... 62
A.5 Fuse Block Assembly ........................................................................................................... 63
B.0 Wiring Diagram..................................................................................................................... 67
Copyright © 2017 Cummins Inc. ii A035J931 (Issue 3)

1 IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS. This manual contains important instructions that should be followed
during installation and maintenance of the generator set and batteries.
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 equipment.
DANGER
Indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates information considered important, but not hazard-related (e.g., messages relating to
property damage).
1.2 General Information

This manual should form part of the documentation package supplied by Cummins with specific generator
sets. In the event that this manual has been supplied in isolation please contact your authorized
distributor.
NOTICE
It is in the operator’s interest to read and understand all warnings and cautions contained within
the documentation relevant to the generator set, its operation and daily maintenance.
A035J931 (Issue 3) 1 Copyright © 2017 Cummins Inc.

1. IMPORTANT SAFETY INSTRUCTIONS 10-2017
1.2.1 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
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.
Copyright © 2017 Cummins Inc. 2 A035J931 (Issue 3)

10-2017 1. IMPORTANT SAFETY INSTRUCTIONS
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
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
Combustible Liquid
Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or
death.
Do not use combustible liquids like ether.
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.
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
Fall Hazard
Falls can result in severe personal injury or death.
Make sure that suitable equipment for performing tasks at height are used in accordance with
local guidelines and legislation.
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.
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, coolant, or exhaust leaks. Do not step on the generator set when entering or leaving the
generator set room.
1.3 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.
1.3.1 Moving Parts Can Cause Severe Personal Injury or Death

• Keep hands, clothing, and jewelry away from moving parts.
• Before starting work on the generator set, disconnect the battery charger from its AC source, then
disconnect the starting batteries using an insulated wrench, negative (–) cable first. This will prevent
accidental starting.

10-2017 1. IMPORTANT SAFETY INSTRUCTIONS
• Make sure that fasteners on the generator set are secure. Tighten supports and clamps; keep
guards in position over fans, drive belts, etc.
• 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.
• If any adjustments must be made while the unit is running, use extreme caution around hot
manifolds, moving parts, etc.
1.4 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.
Please refer to the lockout/tagout section for more information.
• 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.
Guidelines to follow when working on energized electrical systems:
NOTICE
It is the policy of Cummins Inc. to perform all electrical work in a de-energized state. However,
employees or suppliers may be permitted to occasionally perform work on energized electrical
equipment only when qualified and authorized to do so and when troubleshooting, or if de-
energizing the equipment would create a greater risk or make the task impossible and all other
alternatives have been exhausted.
NOTICE
Exposed energized electrical work is only allowed as per the relevant procedures and must be
undertaken by a Cummins authorized person with any appropriate energized work permit for the
work to be performed while using proper PPE, tools and equipment.
In summary:
• Do not tamper with or bypass interlocks unless you are authorized to do so.

• Understand and assess the risks - 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.
• Make sure that an accompanying person who can undertake a rescue is nearby.
1.4.1 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 Introduction
2.1 Applicable Generator Set Models
This manual includes information on how to install and configure the PC3.3 control system for the engine
platforms in Table 1. Additional equipment may be required, see Table 2 for additional details.
TABLE 1. PCC3100 TO PC3.3 UPGRADE KIT PART NUMBERS
PCC3100 to PC3.3 Upgrade Kit Alternator Frame Size (Supported Engine Types)
Includes: All required controls,
harnessing, mounting hardware, labels,
and documentation necessary to HC6/HC7/HC8/P7 (K19,
HC4/HC5/UC (B, C, L10, 855, K19)
upgrade a generator housing mounted V28, K38, K50)*
with a 3100 control to the PC3.3 control
system*.
Part Number A040H851 A040H852
*Upgrade Kit for QST30 based generator set is not available at this time. This kit, which is designed for use on
generator sets with generator housing mounted controls, is not compatible with generator sets with remote or
pedestal mounted controls.
TABLE 2. OPTIONAL KITS
Optional Kits Kit Number

12V Relay Kit:
Required when applying the upgrade kit to a 12V A040B144
generator set.
Network Connection Kit:
Required when connecting a generator set to a remote A040U145
network Modbus RTU or LonWorks.
LonWorks Connection Kit (FT-10): A040G225
Required in addition to the Network Connection Kit See document (0900-0529) for the FT-10 Network
(A040U145) if connecting generator set to an existing Installation manual and a list of additional required
LonWorks FT-10 network. equipment.
LonWorks Connection Kit (TP-78): A040G225
Required in addition to Network Connection Kit See document (0900-0366 and C577) for the TP-78
(A040U145) when connecting generator set to an existing Network Installation manual and a list of additional
LonWorks TP-78 network. required equipment (i.e. LonWorks Router 0300-4919-01).
Detector Upgrade Accessory Kit:
Required if converting a generator set with a Detector
control.
A040N964
NOTE: Additional parts are needed to convert a generator
set with a Detector control. See Spec Sheet S-1647 for
the full list of parts needed.

2. Introduction 10-2017
Optional Kits Kit Number

PCC3100 Single Generator set to PC3.3 Paralleling
Application:
Additional parts are needed to convert a generator set See Spec Sheet S-1647 for full list of parts needed.
with a non-paralleling PCC3100 control to a paralleling
generator set.

3 Pre-Software Upgrade
3.1 Required Equipment
InPower is required to transfer the settings from the existing controller to the new controller. The following
are required:
• Laptop
◦ RS-232 Port or USB-to-RS-232 adapter
◦ Microsoft Excel
◦ InPower Pro v8.5 or later
◦ Latest calibrations and SRV files
• PC3.x (3300) Upgrade Kit - Parameter Conversion Macro and Instructions (0200-0001) available on
QuickServe Online
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.
• Service Tool Harness Kit (0541-1199)

• PCC3100 Service Tool Harness (0338-3708)
Required Specialty Tools:
• Crimper for terminal block ferrules
Suggested source: American Electrical Inc. TRAP24-10 or SQ28-10
• Heat gun or equivalent
Reference Documents available on QuickServe Online
• PowerCommand 3.3 Controller Service Manual (0900-0670)
• AUX101/102 Owner's Manual (A030K737)
• Paralleling with PC3xxx Controller Genset (CPGF-S-00000045-1)
• PCC3100 Service Manual (A034T570)
• Fail Code Manual (F1115C)
• Spec Sheet S-1647
• PCC3100 to PC3.x (3300) Upgrade Kit Capture Files (CF_00000001)
3.2 Required Control Calibration

This upgrade kit consists of the controls in the table below. Please make sure that all controls have been
upgraded to the minimum firmware version listed in the table below to make sure compatibility with the
upgrade kit. Any control calibrated with a later firmware version should be sufficient.

3. Pre-Software Upgrade 10-2017
TABLE 3. CALIBRATION OF CONTROLS
Name Control Part Number Current Firmware

PCC3300 A005F856 v3.040
AUX105 A028T766 v1.030
AUX101 A005G017 v1.34
AUX104 A005F932 N/A
AUX102 A005F926 N/A
HMI320 (Local) A000A578 v2.20
HMI114 A014T616 v1.10
NOTICE
It is required that the control be updated with the latest firmware (Current Firmware lists the
latest firmware at the time of manual production), the latest calibration file is available on the
InCal website. For assistance, refer to the Web-InCal User Guide in the program menu, under
User Guides next to InPower or refer to Instruction Sheet G755 which details the process on how
to register for the service, find the latest firmware, and help with troubleshooting.
NOTICE
To enter existing engine hours, connect to the AUX105 with InPower and perform an initial
calibration. After selecting the correct calibration a page appears to enter the value.

10-2017 3. Pre-Software Upgrade
3.3 InPower Pro Terminology
FIGURE 1. INPOWER WINDOW INTRODUCTION

3. Pre-Software Upgrade 10-2017
This page is intentionally blank.

4 Export PCC3100 Settings into a CSV
file
Export PCC3100 settings to a Comma Separated Value (CSV) file if the existing PCC3100 control can be
connected to InPower.
A CSV file contains parameters and their associated values.
InPower Pro 8.5 or higher allows the user the flexibility to export all settings or specific portions into a CSV
file. Specific feature names can be selected by right-clicking a group name and choosing Select Feature.
The feature names shown in Figure 2 in the left hand panel are required for the PCC3100 to PC3.3
upgrade CVS file.
NOTICE
If there is a check mark next to a feature name, see Figure 2, it has been selected to be part of
the CSV file.
FIGURE 2. SELECTED FEATURES SHOWN

Once the list of parameters have been selected, right click on the device name PCC 3100 or the right
window-(see Figure 2) and select Prepare CSV file with all Selected Features. Save the CSV file on the
computer desktop.

4. Export PCC3100 Settings into a CSV file 10-2017
4.1 Additional Settings to Extract Information from the

PCC3100
The CSV file does not capture all the required settings. Four configurable input fault texts also need to be
extracted from the PCC3100 display menu system are shown in Figure 3.

10-2017 4. Export PCC3100 Settings into a CSV file
FIGURE 3. SETUP MENU
4.1.1 The CSV file does not capture all the settings that are needed. The four configurable input fault texts
needed to be extracted from the PCC3100 display menu system are shown in Figure 4.

4. Export PCC3100 Settings into a CSV file 10-2017
FIGURE 4. SETUP MENU

5 Using a PC3.3 Upgrade Macro
This step is required to migrate the PCC3100 settings to the PCC3300 control. A spreadsheet macro
(0200-0001) has been created to guide the technician through the software upgrade process. The macro
utilizes the PCC3100 settings (.csv file), and displays the associated PCC3300 parameters and values. All
conversions are handled internally by the macro.
NOTICE
If the .csv file cannot be captured, the upgrade macro can still be used.
As stated in Section 3.1 the macro can be found in QuickServe Online

(https://qsol.cummins.com/info/index.html). Log into QuickServe and click on Literature Search. Type in
the macro part number (0200-0001) then press Search. The macro can be found in the search results.
NOTICE
Before using the macro, read the instructions included in the spreadsheet. The instructions detail
the process on how to import the PCC3100 setting into an Excel file.

5. Using a PC3.3 Upgrade Macro 10-2017
FIGURE 5. MACRO SCREEN
NOTICE
Make sure all macro table values are populated and you have archived a PCC3100 capture file
BEFORE disassembling the control.

6 Hardware
This section refers to the control panel hardware, not the hardware for the rest of the generator set.
WARNING
Incorrect service or replacement of parts can result in severe personal injury, death, and/or
equipment damage. Service personnel must be trained and experienced to perform electrical and
mechanical service. Read the Safety Precautions, and carefully observe all of the instructions
and precautions in this manual.
6.1 Safety Precautions

CAUTION
Electrostatic discharge will damage circuit boards. To prevent this damage, always wear a
grounding wrist strap when handling circuit boards or socket-mounted Integrated Circuits (ICs).
CAUTION
Always disconnect a battery charger from its 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.
WARNING
Accidental starting of the generator set while working on it can cause severe personal injury or
death. Prevent accidental starting by disconnecting the starting battery cables (negative (-) first).
WARNING
Arcing can ignite explosive hydrogen gas given off by batteries, causing severe personal injury.
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 battery charger. Make certain the
battery area has been well-ventilated before servicing battery.
WARNING
AC power presents a shock hazard that can cause severe personal injury or death. Before
servicing the generator set, disconnect all power when multiple disconnection sources are used.
6.2 Installation
New controls may come with additional customer connections that provide additional functionality.
6.2.1 PCC3100 Hardware Removal

New controls may come with additional customer connections that provide additional functionality.

6. Hardware 10-2017
To remove existing PCC3100 hardware:

1. Disconnect power by removing the return battery connection from the PCC3100 control.
2. Follow the appropriate lockout/tagout procedure.
3. Open the generator set breaker to isolate from the system.
4. Remove components to gain access to the connections located in both sides of the PCC3100 control
box.

10-2017 6. Hardware
No. Description No. Description

1 Display Board A35 10 PT/OT Board A36
2 85 Power On/Standby Switch 11 Voltage Regulator Output Module A37
3 Digital Board A32 12 Accessory Box
4 Analog Board A33 13 Optional RTD Relay
5 Customer Interface A34 14 TB1-60
6 Engine Interface A31 15 Optional Run Relays K11, K12, and K13
7 Bus PT Module A39 16 TB1-1
8 Governor Output Module A38 17 Optional Termistor Relay 160°/140° C
9 Optional Common Alarm Relay K14 18 RUN/OFF/AUTO Switch S12
FIGURE 6. CIRCUIT BOARD LOCATIONS

6. Hardware 10-2017
5. Disconnect harness connections from the back of the PCC3100 controller (see Figure 7 and Figure
8).
FIGURE 7. GENERATOR SET WIRING TO CONVERTER BOARD
FIGURE 8. CUSTOMER CONNECTIONS TO TB1

6. Remove the PCC3100 door and the boards inside the control box.
7. Inspect the vibration isolators (0402-0527) and replace as needed.
8. Remove the PCC3100 components from the A40 box.
• DO NOT cut lead to P12 on the existing customer connection harness (TB1 to PCC3100
harness). P12 will remain connected as is to J12 on the engine harness.
• Do not remove TB1 or the mounting hardware.

10-2017 6. Hardware
NOTICE
Before removing the Bus PT, label wires A, B, C, and N accordingly.
6.2.2 PC3.3 Hardware Installation

1. Install the PC3.3 hardware
a. Install the PC3.3 control panel (A035D310) (see Figure 37) onto the control box.
b. Make sure the door is closed when tightening hardware for proper fitting.
2. Install the PCC3100 to PC3.3 Harness Adaptor Printed Circuit Board (PCB) (see Figure 9).
FIGURE 9. HARNESS ADAPTER PCB

3. Attach the PCB Harness Adaptor (A034X183) to mounting surface.
CAUTION
To prevent damage to the alternator, for alternative PCB adapter mounting, removal of the
mounting surface is recommended before drilling holes to eliminate metal shavings entering
the alternator.

6. Hardware 10-2017
FIGURE 10. CONVERTER ON BACK OF PCC3100
NOTICE
For U27/U22 Alternator Housing, use the four corner holes to mount the PCB adaptor on the
back of the PCC3100 box.
4. Install the PC3.3 control assemblies (see Figure 38 and Figure 39 for the small A40 Box and see
Figure 40 and Figure 41 for the large A40 Box).
a. Remove the top or bottom A40 box bolts.
b. Loosen the bottom or side bolts to allow the panel to slide behind the A40 box bolts.
c. Re-Install the bolts to secure the control mounting plate.
5. Install the AC Sense Assembly (A040N891) (see Figure 42).
a. Connect harness to alternator outputs L1, L2, L3, and LN as needed.
b. Install Arc Flash Fuse Holder (A040H606) and harnessing (A034Z465).
NOTICE
The mounting plate and included bolts are designed to use the existing holes in the
generator set housing A40 box mounting plate (see Figure 42).
c. Inspect voltage sense leads and make sure the leads are connected to the AC output and not
to the center taps.
6. Install the Bus AC Sense Harness (A040L134).
7. Install the Voltage Sense Connector Retainer (A041A562). Use the bottom two stand-offs to secure
the retainer. Install the remaining standoff (see Figure 15 or Figure 18).

10-2017 6. Hardware
8. Install the Main Adapter Harness (A035A332)

a. Install relays on the control mounting plate (see Figure 11 and Figure 12).
FIGURE 11. RELAY LOCATION FOR A40 SMALL BOX
FIGURE 12. RELAY LOCATION FOR A40 LARGE BOX

b. Connect to J30 on the interface board Figure 43
9. Rewire the TB1 connections
a. Separate the P12 wiring from TB1 harness Figure 43. P12 will remain connected to the engine
harness. Control heater wires should be disconnected during upgrade process.

6. Hardware 10-2017
b. Cut P1, P2, P3 connectors away from the TB1 harnessing.
NOTICE
Make sure the generator set voltage wiring is connected to TB7 and utility/bus voltage
wiring is connected to J22.
c. Reconnect factory connections side of TB1 to the appropriate terminal location on the
PCC3300, AUX101, AUX102, or AUX105. Refer to the TB1 wiring diagram provided in the
Appendix and TB1 label.
NOTICE
DO NOT connect the external or customer load returns to any point other than TB1-3
or TB1-4 on the customer connection terminal block.
10. Complete connections between A40 box and new displays (see Figure 23).
a. Install PC Tool Harness (A035E193).
b. Install Display Harness (A034Y927).
c. Install hole cover plates (A034Z740).
d. Install bulkhead grommets (0508-1175)
e. Secure the Display Harness (A034X927) to the door using the provided 3/4-inch (19.05 mm) P-
clamp (0307-1056).
11. Install the AVR Harness (A034Z462)
NOTICE
Refer to the wiring diagram (0630-3440) for wiring the PMG.
12. Install the Board Interconnect Harness (A034Y930) (see Figure 15 and Figure 18).
13. Secure the harnesses in the A40 box with the cable ties and clamps provided (see Figure 15 for
small A40 box and Figure 18 for the large A40 box).
14. Install the Shock Hazard Guard (A026M929) over the PCC3300 control board (see Figure 15 and
Figure 18).
15. Secure the wires in AC housing with cable ties and clamp (see Figure 22).
16. Connect J4, J5, and J6 from the PCC3100 engine harness into the wire converter box.
17. Record the CT ratio on the CT labels. This value will be needed to configure the PCC3300 software
(see Figure 13).

10-2017 6. Hardware
FIGURE 13. INSTALLED CT

18. Install a 30-Amp fuse at the DC terminal block on the engine harness. This protects the control from
over current on the battery supply (see Figure 14).
a. Remove the jumper between the large and small wires.
b. Insert the provided fuse holder (A040K987) in place of the jumper located between the large
and small wires.
c. Reposition terminal block connection as needed to make sure all small wires are protected.
FIGURE 14. 30-AMP FUSE ON BATTERY TERMINAL

6. Hardware 10-2017
6.2.3 Small A40 Box - HC4/HC5/UC Installation
No. Part Number Quantity Description

1 0508-1090 2 Grommet
2 A034Z462 1 Harness (AVR)
3 A035E193 1 Harness (PC Tool)
4 0518-0720 1 P-Clamp (3/4-inch) Figure 17
5 A034Y930 1 Harness (Board Interconnect)
6 0337-2845 1 Ground Strap
7 A026M929 1 Guard, Shock Hazard
8 0518-0720 and A026M891 1 P-Clamp (3/4-inch) Figure 17 and
Standoff
9 A040L134 1 Harness (Bus AC Sense)
10 A041A562 1 Retainer - Voltage Sense Connector
11 A040N891 1 AC Sense Assembly
12 0518-0720 and A026M891 1 P-Clamp (3/4-inch) Figure 17 and
Standoff

10-2017 6. Hardware
13 0307-1056-01 1 Relay
14 A035A332 1 *Harness (Main)
15 A034Y927 1 Harness (Display)
*DC fuses labeled F10 and F20 on the Main Harness require 10A and 20A ATC replacements respectively.
FIGURE 15. A40 BOX HC4/HC5/UC
Note Description Note Description

1 Secure the Main, PC Tool, Display, AVR, 3 Secure the harnesses with P-clamps and
and Board Interconnect harnesses together standoffs supplied in this kit
with a cable tie
2 Secure the harnesses with cable ties as 4 Secure the Board Interconnect and Bus
shown Voltage Sense harnesses to the Main
Harness with cable ties as shown
FIGURE 16. A40 BOX ASSEMBLY NOTES

6. Hardware 10-2017
FIGURE 17. SMALL A40 BOX - HC4/HC5/UC CLAMPS

10-2017 6. Hardware
6.2.4 Large A40 Box HC6/HC7/HC8/P7 Installation

1 0307-1056 1 Relay
2 0518-0720 1 P-Clamp (3/4")
4 A034Y927 1 Harness (Display)
5 0518-0757 2 Clamp-Flexible Figure 20
6 A026M929 1 Guard, Shock Hazard
7 A040L134 1 Harness (Bus Voltage Sense)
8 A035E193 1 Harness (PC Tool)
9 A026M891 3 Standoff
10 A041A562 1 Retainer-Voltage Sense Connector
12 A034Y930 1 Harness (Board Interconnect)
13 A035A332 1 *Harness (Main)
14 0503-2984 2 J-Clamp (2")
15 0518-0548-24 2 P-Clamp (2")
16 0337-2845 1 Ground Strap Figure 21
*DC fuses labeled F10 and F20 on the Main Harness require 10A and 20A ATC replacements respectively.
FIGURE 18. LARGE A40 BOX HC6/HC7/HC8/P7

6. Hardware 10-2017
Note Description Note Description

1 Use existing P-Clamps to secure the 4 Secure the PC Tool Harness to standoff with
customer connection and placement of the the cable tie
Remote E-Stop Relay (K6)
2 Secure the P12 connection and Remote E- 5 Secure the Main, Display, and Board
Stop with the P-Clamp provided in the kit Interconnect harnesses together using a
cable tie
3 Secure the customer connections with 6 Secure the AUX101, AUX104, and main
flexible clamp provided in the kit harnesses together using a cable tie
FIGURE 19. LARGE A40 BOX ASSEMBLY NOTES
FIGURE 20. LARGE A40 BOX HC6/HC7/HC8/P7 CLAMPS

10-2017 6. Hardware
FIGURE 21. LARGE A40 BOX HC6/HC7/HC8/P7 GROUND STRAP
6.2.5 AC Housing Installation

1 A035A332 1 Harness (Main Adapter)
2 0503-2984 2 J-Clamp (2 inch)
4 A040C763 3 Fuse (.5A), Class C
6 A034X183 1 Card, Interface
Note A: Secure the harness with cable ties as shown.
Note B: Arc Flash Fuses require .5A fast blow Class C replacements.
FIGURE 22. AC HOUSING INSTALLATION

6. Hardware 10-2017
6.2.6 Control Box Connections

1 A034Z740 2 Plate, Hole Cover
2 0508-1175 2 Grommet, Bulkhead
3 A035E193 1 Harness, PC Tool
4 A034Y927 1 Harness, Display
Not Shown 0518-0720 1 Clamp (3/4 inch)
Not Shown A035D310 1 Door, Control Assembly (see Figure 38)
Not Shown 0821-0004 4 Bolt (Door mounting)
FIGURE 23. CONTROL BOX CONNECTIONS

10-2017 6. Hardware
6.2.7 Required Position of New Labels

1 0098-7273 1 Label, Danger
2 0098-8100 1 Label, Warning
3 0098-8104-06 1 Label, Warning
4 0098-8940 1 Label, Warning
Not Shown A040N782 1 Label, Illustration (not shown)
Not Shown A040B319 1 Label, Illustration (included in kit
A040H851) (not shown)
Not Shown A040B316 1 Label, Illustration (included in kit
A040H852) (not shown)
FIGURE 24. LABEL INSTALLATION (AFTER CONVERSION)

1 A041B131 1 Label, Notice
FIGURE 25. NOTICE LABEL

6. Hardware 10-2017
6.2.8 Rupture Basin Input

If connected from TB1-35 to TB1-16, TB1-17, TB1-18 or TB1-19, remove the loop. The rupture basin is
wired to an OEM connection.
6.2.9 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 PC3.3 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
introduced as much as 5% variation. Calibration line voltage reference equipment is therefore
required.
6.2.10 Engine Idle

The engine idle switch input is not available on the PC3.3 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.
6.2.11 Mode Change Protection

A keyed switch is used on the PCC3100 control to provide mode change protection. Mode change is
configured through the PC3.3 control software. To enable, go to the HMI screen Home (2/2) > Display
Options and set Mode Change to Enabled (see Chapter 8).
6.2.12 First Start (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.
If a PC3300 control is to be paralleled with generator sets that have PCC3100 controls, and a master
control is used to designate first start, the system must be upgraded for integrated first start arbitration. All
PCC3100 system bus PT modules (0300-4309-0X) will need to be replaced by bus PT/First start module
(0300-4985-0X), and the first start arbitration lines must be connected between the individual generator
sets.

10-2017 6. Hardware
6.2.13 How to Activate PC3.3 Sleep Mode

To activate the PC3.3 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
6.2.14 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.

6. Hardware 10-2017

7 PC3.3 Control Software Upgrade
7.1 Perform Initial Calibration and Load Latest Software
It is required that initial calibration be performed and the control be updated with the latest firmware which
can be found using Web-InCal. Refer to Section 3.2 for more information.
NOTICE
To enter existing engine hours, connect to the AUX105 with InPower and perform an initial
calibration. After selecting the correct calibration a page appears to enter the value.
7.2 Installation of Feature Code

The PCC3100 upgrade feature code (A035L579) must be installed on the PC3.3 Control. This should be
installed after an initial calibration and before any settings are adjusted. The settings listed below have
been configured to allow the PC3.3 Control to function like the PCC3100 control. For more information
regarding these parameters, refer to the PowerCommand 3.3 Controller Service Manual (0900-0670).
TABLE 4. FEATURE CODE SETTINGS
PCC3300 Parameter Assigned Value

12v Weak Battery Voltage Threshold 10.0V
24v Weak Battery Voltage Threshold 12.0V
3 ph High Conn Genset Nom Voltage Hi Limit 45000 VAC
3 ph High Conn Genset Nom Voltage Lo Limit 22500 VAC
3 ph Low Conn Genset Nom Voltage Hi Limit 22499 VAC
3 ph Low Conn Genset Nom Voltage Lo Limit 1 VAC
Auto Sleep Enable Sleep in Auto
Aux101 0 Analog Input 3 Function Pointer Exhaust Stack Temperature 1
Aux101 0 Analog Input 3 Sensor Type Analog Input
Aux101 0 Analog Input 4 Function Pointer Exhaust Stack Temperature 2
Aux101 0 Analog Input 4 Sensor Type Analog Input
Aux101 0 Input 2 Function Pointer Low Fuel in Day Tank Switch
Aux101 0 Output 1 Fault/Event 1541
Aux101 0 Output 1 Function Pointer Default

7. PC3.3 Control Software Upgrade 10-2017

Aux101 0 Output 7 Function/Pointer Default
Backup Start Disconnect/Configurable Input #33 Function Pointer Low Engine Temperature Switch
Coolant Temperature 2 Enable Enable
Crank Exit Fuel Duty Cycle 40%
Crank Fueling Ramp Rate 21.5%
Dither Factor 19%
Genset Breaker Position Contacts Single Contact
Genset CT Secondary Current 1 Amp
Governor Enable Engine Speed 1000 RPM
Governor Preload Offset 428
HCT Shutdown With Cooldown Threshold 226 °F

10-2017 7. PC3.3 Control Software Upgrade

High IMT Protection Enable Disabled
HOT Protection Enable Disable
Initial Crank Fueling Duty Cycle 20%
Initial Crank Fueling Period 0 sec
Intake Manifold Temperature Sensor Enable Disable
Legacy Compatible AVR Mode Enable
Load Govern kW Maximum Delayed 100%
Max Crank Fuel Duty Cycle 60%
Maximum Duty Cycle 90%
Minimum Duty Cycle 0%
Overspeed Shutdown Threshold (50Hz) 1800 RPM
Overspeed Shutdown Threshold (60Hz) 2070 RPM
Remote Fault Reset Enabled Enable
Single Phase Genset Nom Voltage Hi Limit 45000 Vac
Single Phase Genset Nom Voltage Low Limit 1 VAC
Starter Disconnect Speed 475 RPM
Utility Breaker Position Contacts Single Contact
7.3 Translating PCC3100 Settings to the PC3.3

1. Connect to the PC3.3 Control using the InPower service tool.
2. Follow the instructions provided in the macro to enter all required settings defined in the macro into
the PC3.3 Control, as shown in Figure 26 and Figure 27.
3. Follow the instructions provided in the macro (0200-0001) to enter all Additional settings as shown
in Figure 28. Note the values for Additional settings will be specific to the installation of the
generator set and will need to be configured on site. Refer to the PowerCommand 3.3 Controller
Service Manual (0900-0670) for additional details on how to configure these parameters.
4. Any setting not listed in the macro or set via the feature file should remain at the PC3.3 Control
default values. Changes to these parameters should not be required. Refer to the PowerCommand
3.3 Controller Service Manual (0900-0670) for additional details on these parameters.
NOTICE
In InPower, Ctrl+F will allow searches for parameter names. Use F3 to scroll through the search
results.

FIGURE 26. EXAMPLE OF PARAMETER IN OEM SETUP

10-2017 7. PC3.3 Control Software Upgrade
FIGURE 27. EXAMPLE OF PARAMETER NOT IN OEM SETUP

FIGURE 28. EXAMPLE OF ADDITIONAL PARAMETER SETTINGS

8 Optional Settings
8.1 Mode Select Protection
The PCC3100 controller has a selector switch to change the mode of the generator set to three options (
OFF, RUN, AUTO). In order to prevent anyone from easily changing the mode of the generator set, a
keyed switch option is available. As a result, the key has to be physically inserted in order to change the
mode of the generator set. In the PC3.3 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 29. HMI320 HOME SCREEN (1 OF 2)
FIGURE 30. HMI320 HOME SCREEN (2 OF 2)

By pressing the Home key on the operator panel, the display is shown in Figure 29. Press the down key
which is shown on the bottom-right corner of Figure 29. This leads to the second Home screen as shown
in Figure 30. Move the cursor to Display Options and press OK.

8. Optional Settings 10-2017
FIGURE 31. 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 PC3.3 control. If Mode Change is set to Enabled, technician has to enter the password
121 to change the mode of operation.

9 PCC3100 to PC3.3 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 PC3.3 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.
9.1 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.
9.2 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 5. FAULT INPUTS
Low Engine Disconnect the switch from the harness.

Temperature
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 switch from the harness.
Fuel*
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.
9.3 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.
9.4 Sensor Readings

Check and verify functionality of the following sensors:
• Coolant Temperature
• Oil Temperature

9. PCC3100 to PC3.3 Conversion Inspection Test 10-2017
• 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 6. 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 7. 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)
TABLE 8. LOW OIL PRESSURE (LOP) THRESHOLD
Engine Type Mode Limit Value

K19 Idle Mode Warning Limit 15 PSI
Shutdown Limit 10 PSI
Base Value Warning Limit 40 PSI
V28 Idle Mode Warning Limit 15 PSI

10-2017 9. PCC3100 to PC3.3 Conversion Inspection Test
9.4.1 Generator Set Sensor and Switch Locations

1 Coolant Temperature Senders (Two) 4 Oil Temperature Sender (Far Side)
2 Low Coolant Temperature Switch 5 Oil Pressure Sender (Far Side)
3 Low Coolant Level Switch
FIGURE 32. KTA38 SERIES


1 Coolant Temperature Senders (Two) 4 Oil Pressure Sender (Far Side)
2 Low Coolant Temperature Switch 5 Oil Temperature Sender (Far Side)
FIGURE 33. KTA19 SERIES


1 Coolant Temperature Sender 4 Oil Temperature Sender (Far Side)
FIGURE 34. NT(A)855


1 Oil Pressure Sender (Far Side) 4 Low Coolant Temperature Switch
2 Oil Temperature Sender (Far Side) 5 Low Coolant Level Switch
3 Coolant Temperature Senders (Two)
FIGURE 35. KT50-G1 AND G2 SERIES


1 Coolant Temperature Senders (Two) 4 Oil Temperature Sender (Far Side)
FIGURE 36. KT50-G3, G8 AND G9 SERIES
9.5 Customer I/O

This verifies the generator set customer inputs and outputs are correct.
9.5.1 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).
9.5.2 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).
9.5.3 Inputs
Verify the following generator set customer inputs:
• Customer Fault Inputs
• Remote Fault Reset
• Remote Start
9.6 Paralleling (If Applicable)

Complete the following checks 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


Appendix A. Parts
Table of Contents
Figure 37. Display Panel (A035D310) ......................................................................................................... 58
Figure 38. Side Panel (A040N901) .............................................................................................................. 59
Figure 39. Main Panel (A040N899) .............................................................................................................. 60
Figure 40. Main Panel (A040N895) .............................................................................................................. 61
Figure 41. Side Panel (A040N897) .............................................................................................................. 62
Figure 42. Fuse Block Assembly (A040N891) ........................................................................................... 63

Appendix A. Parts 10-2017
A.0 Display Panel

1 0300-6315-02 1 HMI320 (6-Button display)
2 0300-6366-02 1 HMI114 (Bar-graph)
FIGURE 37. DISPLAY PANEL (A035D310)

10-2017 Appendix A. Parts
A.1 Side Panel (HC4/HC5/UC Box)

1 0327-1536 1 AUX101
2 0327-1265 1 AUX102
3 0327-1507 1 AUX104
4 A035F591 1 Plate, Mounting
5 0870-2208 14 Nut, Flange
6 323-1678-08 3 Connector, Plug
FIGURE 38. SIDE PANEL (A040N901)

A.2 Main Panel (HC4/HC5/UC Box)

1 0327-1601-01 1 PCC3300
2 A028T766 1 AUX105
3 A035A785 1 Plate, Mounting
4 0503-2984 1 J-Clamp
5 0870-2208 11 Nut, Flange
FIGURE 39. MAIN PANEL (A040N899)

A.3 Main Panel (HC6/HC7/HC8/P7 Box)

1 0327-1601-01 1 PCC3300
2 0327-1507 1 AUX104
3 0327-1536 1 AUX101
4 A028T766 1 AUX105
5 A034Z727 1 Plate, Mounting
6 0518-0548-61 1 P-Clamp
7 0503-2984 3 J-Clamp
8 0870-2208 22 Nut, Flange
FIGURE 40. MAIN PANEL (A040N895)

A.4 Side Panel (HC6/HC7/HC8/P7 Box)

1 0327-1265 1 AUX102
2 A040H812 1 Plate, Mounting
3 0870-2208 4 Nut, Flange

FIGURE 41. SIDE PANEL (A040N897)
A.5 Fuse Block Assembly

1 A034Z725 1 Plate, Mounting
2 A040C763 3 Fuse (0.5A), Class C
3 0526-0003 2 Washer, Flat
4 0823-0002-02 2 Screw, Pan Head Torx
5 A040N814 1 Label, Rating
6 A034Z465 1 Harness, Interface
FIGURE 42. FUSE BLOCK ASSEMBLY (A040N891)


The drawings included in this section are representative. For current complete information,
refer to the drawing package that was shipped with the unit.


B.0 Wiring Diagram
FIGURE 43. 0630-3440 ENGINE CONNECTION

FIGURE 44. 0630-3440 REVISION L; CUSTOMER CONNECTION

power.cummins.com
Copyright © 2017 Cummins Inc. All rights reserved.
Cummins, the "C" logo, PowerCommand, AmpSentry, and InPower are trademarks of Cummins Inc.
Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.

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Installation Manual

PowerCommand®3.3 Control Upgrade Kit

4. EXPORT PCC3100 SETTINGS INTO A CSV FILE..................................................................... 13

5. USING A PC3.3 UPGRADE MACRO .......................................................................................... 17

7. PC3.3 CONTROL SOFTWARE UPGRADE ................................................................................ 39

A035J931 (Issue 3) i Copyright © 2017 Cummins Inc.

7.2 Installation of Feature Code.................................................................................................. 39

8. OPTIONAL SETTINGS ................................................................................................................ 45

9. PCC3100 TO PC3.3 CONVERSION INSPECTION TEST .......................................................... 47

Copyright © 2017 Cummins Inc. ii A035J931 (Issue 3)

1.1 Warning, Caution, and Note Styles Used in This

1.2 General Information

A035J931 (Issue 3) 1 Copyright © 2017 Cummins Inc.

1.2.1 General Safety Precautions

Copyright © 2017 Cummins Inc. 2 A035J931 (Issue 3)

A035J931 (Issue 3) 3 Copyright © 2017 Cummins Inc.

1.3 Generator Set Safety Code

1.3.1 Moving Parts Can Cause Severe Personal Injury or Death

Copyright © 2017 Cummins Inc. 4 A035J931 (Issue 3)

1.4 Electrical Shocks and Arc Flashes Can Cause

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

A035J931 (Issue 3) 5 Copyright © 2017 Cummins Inc.

1.4.1 Medium Voltage Equipment (601 V to 15 kV - U.S. and

Copyright © 2017 Cummins Inc. 6 A035J931 (Issue 3)

TABLE 1. PCC3100 TO PC3.3 UPGRADE KIT PART NUMBERS

TABLE 2. OPTIONAL KITS

Optional Kits Kit Number

A035J931 (Issue 3) 7 Copyright © 2017 Cummins Inc.

Optional Kits Kit Number

Copyright © 2017 Cummins Inc. 8 A035J931 (Issue 3)

• Service Tool Harness Kit (0541-1199)

3.2 Required Control Calibration

A035J931 (Issue 3) 9 Copyright © 2017 Cummins Inc.

TABLE 3. CALIBRATION OF CONTROLS

Name Control Part Number Current Firmware

Copyright © 2017 Cummins Inc. 10 A035J931 (Issue 3)

3.3 InPower Pro Terminology

FIGURE 1. INPOWER WINDOW INTRODUCTION

A035J931 (Issue 3) 11 Copyright © 2017 Cummins Inc.

This page is intentionally blank.

Copyright © 2017 Cummins Inc. 12 A035J931 (Issue 3)

FIGURE 2. SELECTED FEATURES SHOWN

A035J931 (Issue 3) 13 Copyright © 2017 Cummins Inc.

4.1 Additional Settings to Extract Information from the

Copyright © 2017 Cummins Inc. 14 A035J931 (Issue 3)

FIGURE 3. SETUP MENU

A035J931 (Issue 3) 15 Copyright © 2017 Cummins Inc.

FIGURE 4. SETUP MENU

Copyright © 2017 Cummins Inc. 16 A035J931 (Issue 3)

As stated in Section 3.1 the macro can be found in QuickServe Online

A035J931 (Issue 3) 17 Copyright © 2017 Cummins Inc.

FIGURE 5. MACRO SCREEN

Copyright © 2017 Cummins Inc. 18 A035J931 (Issue 3)

6.1 Safety Precautions

6.2.1 PCC3100 Hardware Removal

A035J931 (Issue 3) 19 Copyright © 2017 Cummins Inc.

To remove existing PCC3100 hardware:

Copyright © 2017 Cummins Inc. 20 A035J931 (Issue 3)

No. Description No. Description

FIGURE 6. CIRCUIT BOARD LOCATIONS

A035J931 (Issue 3) 21 Copyright © 2017 Cummins Inc.

FIGURE 7. GENERATOR SET WIRING TO CONVERTER BOARD

FIGURE 8. CUSTOMER CONNECTIONS TO TB1