PowerCommandR 3.
3 Control Upgrade Kit
Quick Start Guide
1 Applicable Models
The PCC3100 to PC3.3 Upgrade Kit includes all required control parts, harnessing,
mounting hardware, labels, and documentation necessary to upgrade a generator set
with a PCC3100 control to the PC3.3 control system.
Alternator Frame Size (Supported Engine Types):
 HC4/HC5/UC (B, C, L10, 855, K19) kit part A040H851
 HC6/HC7/HC8/P7 (K19, V28, K38, K50) kit part A040H852
*An upgrade kit for QST30 based generator sets is not available.
2 Optional Kits
For a list of optional kits, see PowerCommand 3.3 Control Upgrade Manual
(A035J931).
3 Reference Documents
 A035J931 − PowerCommand 3.3 Control Upgrade Manual
 0900−0670 − PowerCommand 3.3 Service Manual (includes wiring diagram)
 A030K737 − AUX101/102 Owner Manual
 CPGF−S−00000045−1 − Paralleling with PC3XXX Controller Genset
 A034T570 − PCC3100 Service Manual
 F1115C − Fail Code Manual
 0200−0001 − Parameter Conversion Macro and Instructions
 PCC3100 to PC3.x (3300) Upgrade Kit Capture Files (CF_00000001)
 Spec Sheet S−1643
NOTE: Make sure the latest issue of manuals are used.
4 Required Control Calibration
It is required that the controls be updated with the latest firmware, 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 for additional information.
5 Export PCC3100 Settings
1. Using the PCC3100 Service Tool harness, connect to the PCC3100 via InPower.
NOTE: Proceed to step 7 if PCC3100 control is not connected or not working. The
setup can still be completed using default values provided in the macro.
2. Double click on PCC3100 to unveil all Feature Names and Groups.
3. Right click on the following items and select Select Feature (a checkmark should
appear on the folder to indicate feature has been selected).
 (a) Adjustments (b) Events (c) About (under Monitor folder)
4. Right click on PCC3100, select Prepare CSV files with all selected features, and
save Excel file to be used later with the Conversion Macro (0200−0001).
NOTE: Reference the PowerCommand 3.3 Control Upgrade Manual for additional infor-
mation.
6 Additional Settings to Extract from PCC3100
The CSV file does not capture all required settings.
Four configurable Input Fault values are also required.
7 Hardware Removal
To Remove existing PCC3100 hardware:
1. Disconnect power by removing return battery wire.
2. Follow appropriate lockout/tagout procedure.
3. Open the generator set circuit to isolate from the system.
4. Remove components to gain access to the connections located in both sides of the
PCC3100 control box.
5. Disconnect harness connections from the back of the PCC3100.
6. Remove PCC3100 door and boards inside the control box.
7. Inspect vibration isolators (0402−0527) and replace as needed.
8. Remove PCC3100 components from the generator housing (A40 box).
E 2015 Cummins Power Generation Inc. All rights reserved.
Cummins Power Generation and Cummins are registered trademarks of Cummins Inc. PowerCommand is a registered trademark of Cummins Power Generation
Upgrade Kit
8 Hardware Installation
1. Install the PC3.3 door (A035D310) onto the control box. Adjust for proper fitting.
2. Mount the PCB Harness Adapter (A034X183).
3. Install the PC3.3 control parts.
a. Remove the top or bottom A40 box bolts.
b. Loosen the bottom or side bolts to allow control panel to slide behind A40 box
bolts.
c. Re−install the bolts to secure control mounting plates.
4. Install the AC Sense Assembly (A040N891).
a. Install the Arc Flash Fuse Holder (A040H606) and harnessing (A034Z465).
b. Inspect the voltage sense leads. Make sure the leads are connected to the AC
output and not the center taps.
5. Install the Bus AC Sense Harness (A040L134).
6. Install the Voltage Sense Connector Retainer (A041A562). Use the bottom two
stand-offs to secure the retainer.
7. Install the Main Adapter Harness (A035A332).
a. Install the relays on the control mounting plate.
b. Connect to J30 on the interface board.
8. Rewire TB1 connections.
a. Separate the P12 wiring from TB1 harness (this should remain connected with
J12). Control heater wires should be disconnected during the upgrade process.
NOTE: Do not cut the lead to the P12 connector on the existing customer connection
harness.
b. Cut P1, P2, P3 connectors away from the TB1 harnessing.
c. Reconnect the factory connections side of TB1 to the appropriate terminal
location. Refer to the wiring diagram provided in the PowerCommand 3.3
Control Upgrade Manual (A035J931).
9. Complete connections between A40 box and new displays.
a. Install the PC Tool Harness (A035E193).
b. Install Display Harness (A034Y927).
c. Install hole cover plates (A034Z740) and grommets (0508−1175) for the PC
Tool Harness and Display Harness.
d. Secure the Display Harness to the door using the provided 3/4 inch P−clamp
(0307−1056)
10. Install the AVR Harness (A034Z462).
11. Install the Board Interconnect Harness (A034Y930).
12. Secure the harnesses in the A40 box with cable ties and clamps.
NOTE: See Figures 1 and 2 for suggested harnesses routing.
13. Install the Shock Hazard Guard (A026M929) over the PCC3300 control board.
14. Secure the wires in the AC housing with cable ties and P−clamp.
15. Connect J4, J5, and J6 from the PCC3100 engine harness into the wire converter
box.
16. Record the CT ratio from the CTs during setup. This will be needed to configure the
PCC3300 software.
17. Install the 30 Amp fuse on the engine harness.
a. Remove jumper between the large and small wires.
b. Insert the provided fuse holder (A040K987) in place of the jumper located
between large and small wires.
18. Install all labels included with the kit (see PowerCommand 3.3 Upgrade Control
Manual).
19. Reconnect battery power.
NOTE: When the installation is completed and tested, all harnessing should be se-
cured such that the generator set vibration causes minimal movement of the
9 harnessing and components.
9 Feature Code Installation
The PCC3100 upgrade feature code (A035L579) must be installed on PCC3300
control. This should be installed after an Initial Calibration and before any settings
are adjusted. Refer to the PowerCommand 3.3 Control Upgrade Manual (A035J931)
and PC3.3 Service Manual (0900−0670).
10
10 Translating PCC3100 Settings to PCC3300
Open the Conversion Macro (0200−0001) and refer to the instructions in the file
regarding how to import the PCC3100 capture file and convert to compatible
PCC3300 values. User will be required to manually enter converted values into
PCC3300 via InPower Pro.
11 PCC3100 to PCC3300 Conversion Inspection
Technician needs to inspect the following components (E−Stops, Fault
Inputs, Customer I/O) and functions (Paralleling, AC Metering and
Regulation, Sensor Readings) to make sure the generator set is operating
properly and all safe mechanisms are working after converting to PC3.3.
Printed in USA 9/2015 A040W325 (Issue 3)
English − Original Instructions
 Figure 1. A40 Box − HC4/HC5/UC − Kit A040H851

Figure 2. A40 Box − HC6/HC7/HC8/P7 − Kit A040H852