PowerCommand 1302 Digital Generator Set Control Kit And .
PowerCommand 1302digital generator set control kitand optional upgrade kitsDescriptionFeaturesThe 1302 control is a microprocessor-based generatorset monitoring, metering and control system.12 and 24 VDC battery operation.The control provides a simple operator interface to thegenerator set, digital voltage regulation, digital enginespeed governing, start/stop control, 12 V/24 V batteryoperation and generator set protective functions. The1302 control also features support for full authority,electronically-controlled engines. The integration of allfunctions into a single control system provides enhancedreliability and performance compared to conventionalgenerator set control systems.The 1302 generator set control is designed for mountingdirectly on the generator set and is suitable for use on awide range of generator sets in non-parallelingapplications. It is compatible with reconnectablealternators up to 600 VAC line-to-line and can beconfigured for any frequency, voltage and powerconnection configuration from 120-600 VAC line-to-line,and is compatible with shunt and PMG excitationmethods. It functions over a voltage range from 8 VDCto 30 VDC.The control offers a wide range of standard and optionalfeatures so custom control configurations are not neededto meet application specifications.Power for the control is derived from the generator setstarting batteries.Digital voltage regulation - Full wave rectified singlephase (line-to-line) sensing using shunt or PMG inputpower.Digital engine speed governing (optional) Provides isochronous frequency regulation.Full authority engine support - Providescommunication and control between the engine controlmodule and the 1302 control.Generator set monitoring - Monitors status of allcritical engine and alternator functions. Configurable forsingle or three phase AC metering.Engine starting - Includes relay drivers for starter, fuelshut off (FSO), glow plug/spark ignition power and switchB applications.Generator set protection - Protects engine andalternator.Operator display panel - Provides easy-to-usesymbolic operator display of critical generator setparameters and operating history.Advanced serviceability - Utilizing InPower , a PCbased software service tool.Environmental protection - The control system isdesigned for reliable operation in harsh environments.The core control board is an encapsulated module that isfully protected from the elements.Configurable inputs and outputs - Four discreteinputs and two dry contact relay outputs.Certifications - Suitable for use on generator sets thatare designed, manufactured, tested and certified torelevant UL, NFPA, ISO, IEC, Mil Std. and CE standards.Warranty and service - Backed by a comprehensivewarranty and worldwide distributor service network. 2010 Cummins Power Generation Inc. All rights reserved. Specifications are subject to change without notice. Cummins Power Generationand Cummins are registered trademarks of Cummins Inc. InPower and “Our energy working for you.” are trademarks of Cummins PowerGeneration. Other company, product, or service names may be trademarks or service marks of others.S-1555 (6/10)
Control systemThe standard control system includes a control boardwith an external control switch and status indicator. Thecontrol board includes all functions necessary to locallyor remotely start and stop, regulate voltage and protectthe generator set.Optional engine speed governingThe control is available with an optional governor powerstage. This power stage amplifies control signals todirectly drive an engine fuel control valve.Generator set hardware data - Access to the controland software part number, generator set rating in KVAand generator set model number is provided from theoptional display panel or InPower.Data logs - Engine run time, controller on time, numberof runs and number of start attempts are available fromthe optional display panel.Fault history - Provides a record of the most recentfault conditions with control hours time stamp. Up to 10events are stored in the control non-volatile memory.Alternator data- Voltage (single or three phase line-to-line and line-toneutral)- Current (3-phase)- KVA- FrequencyEngine data- Starting battery voltage- Engine speedDisplay panelThe display panel may be either locally or remotelymounted. The operator screens are made up ofinternationally accepted symbols so translations are notrequired. The display is composed of a backlit LCDdisplay with a series of 6 generator set status LED lamps.The display is accompanied by six tactile-feel membraneswitches that are used by the operator to navigatethrough control menus and to make control adjustments.It is configurable for units of measurement and hasadjustable screen contrast and brightness.The run/off/auto switch function is integrated into thedisplay panel; therefore, an external switch is notrequired with the display panel option.All data on the control can be viewed by scrollingthrough screens with the navigation keys.The control displays the current active fault and a timeordered history of the five previous faults.LED indicating lamps - The display panel includesLED indicating lamps for the following functions:- Not in auto- Shutdown- Warning- Remote start- Auto- RunOperator adjustments - The optional display panelincludes provisions for many set up and adjustmentfunctions via raise/lower switches.- Engine temperature- Engine oil pressureService adjustments - The operator panel includesprovisions for adjustment and calibration of generator setcontrol functions. Adjustments are protected by apassword. Functions include:- Engine speed governor adjustments- 12 VDC/24 VDC battery operations- Voltage regulation adjustments- Cycle cranking- Configurable fault set up- Configurable output set up- Meter calibration- Display language and units of measurementOther information- Control not communicating- Pop-up timers to indicate time remaining on timedelays in the systemInternal control functionsEngine control12 VDC/24 VDC battery operations - Will operateeither on 12 VDC or 24 VDC batteries.Isochronous governing (optional) - Controls enginespeed within 0.25% for any steady state load from noload to full load. Frequency drift will not exceed 0.5%for a 33 C (60 F) change in ambient temperature overan 8 hour period.Temperature dependent governing dynamics(with governing option) - Modifies the enginegoverning control parameters as a function of enginetemperature. Allows engine to be more responsive whenwarm and more stable when operating at lowertemperature levels. 2010 Cummins Power Generation Inc. All rights reserved. Specifications are subject to change without notice. Cummins Power Generationand Cummins are registered trademarks of Cummins Inc. InPower and “Our energy working for you.” are trademarks of Cummins PowerGeneration. Other company, product, or service names may be trademarks or service marks of others.S-1555 (6/10)
Remote start mode - 1302 accepts a ground signalfrom remote devices to automatically start the generatorset and immediately accelerate to rated speed andvoltage. The remote start signal will also wake up thecontrol from sleep mode. The control can incorporate atime delay start and stop. 1.5% for a 40 ºC (104 ºF) change in temperature in an 8hour period. On engine starting, or sudden loadacceptance, voltage is controlled to a maximum of 5%overshoot over nominal level.Remote and local emergency stop - The controlaccepts a ground signal from an external remoteemergency stop switch to cause the generator set toimmediately shut down. The generator set is preventedfrom running or cranking with the switch engaged. Thecontrol also accepts a ground signal from an externallocal emergency stop switch. If in sleep mode, activationof either emergency stop switch will wake up the control.Torque-matched V/Hz overload control - The voltage rolloff set point and rate of decay (i.e., the slope of the V/Hzcurve) is adjustable in the control.The automatic voltage regulator feature can be disabledto allow the use of an external voltage regulator.Sleep mode - The control is configured to include asleep mode. When the mode select switch is in the offposition, the control will revert to a low-powerconsumption mode until the run/off/auto control switchor any button on the optional display panel is operated.The control can be configured to go to sleep while inauto mode in order to conserve the generator startingbatteries in applications that do not have batterychargers.Protective functionsEngine starting - The control system supportsautomatic engine starting. Primary and backup startdisconnects are achieved by one of three methods;magnetic pickup, battery charging alternator feedback,or main alternator output frequency. The control alsosupports programmable glow plug control. This featurecan be disabled when not required.System protective functionsCycle cranking - Configurable for number of startingcycles (1 to 7) and duration of crank and rest periods.Control includes starter protection algorithms to preventthe operator from specifying a starting sequence thatmight be damaging.Time delay start and stop (cooldown) Configurable for time delay of 0-300 seconds prior tostarting after receiving a remote start signal and for timedelay of 0-600 seconds prior to shut down after signal tostop in normal operation modes. Default for both timedelay periods is 0 seconds.On operation of a protective function the display panelwill indicate fault description and time of occurrence.The corresponding warning or shutdown LED will beilluminated. The service manual and InPower service toolprovide service keys and procedures based on the faultcodes provided.Configurable alarm and status inputs - 1302 willaccept up to four alarm or status inputs (configurablecontact closed to ground or open) to indicate customerspecified conditions. The control is programmable forwarning, shutdown or status indication and for labelingthe input.Emergency stop - Annunciated whenever eitheremergency stop signal is received from external switch.Hydro mechanical full system engineprotectionOver speed shutdown - Default setting is 115% ofnominal.When paired with a full authority, electronically controlledengine, the 1302 can communicate with and control thegenerator set.Low lube oil pressure warning/shutdown - Level ispreset (configurable with InPower) to match thecapabilities of the engine used. Control includes timedelays to prevent nuisance shutdown signals.Alternator controlLow coolant temperature warning - Indicates thatengine temperature may not be high enough for a 10second start or proper load acceptance.The 1302 includes an integrated line-to-line sensingvoltage regulation system that is compatible with shuntor PMG excitation systems. The voltage regulationsystem is full wave rectified and has an SCR output forgood motor starting capability.Major system features include:Digital output voltage regulation - 1302 will regulateoutput voltage to within 1.0% for any loads between noload and full load. Voltage drift will not exceedHigh engine temperature warning/shutdown Level is preset (configurable with InPower) to match thecapabilities of the engine used. Control includes timedelays to prevent nuisance shutdown signals.Sensor failure indication - Logic is provided on thebase control to detect analog sensor or interconnectingwiring failures. 2010 Cummins Power Generation Inc. All rights reserved. Specifications are subject to change without notice. Cummins Power Generationand Cummins are registered trademarks of Cummins Inc. InPower and “Our energy working for you.” are trademarks of Cummins PowerGeneration. Other company, product, or service names may be trademarks or service marks of others.S-1555 (6/10)
Full authority electronic engine protectionEngine protection and fault announcement is handledinside the engine control module. The 1302 announcesactive faults from the engine control module via the CANdata link.General engine protectionLow and high battery voltage warning - Indicatesstatus of battery charging system (failure) bycontinuously monitoring battery voltage.Weak battery warning - The control system will testthe battery each time the generator set is signaled tostart and indicate a warning if the battery indicatesimpending failure.Fail to start (overcrank) shutdown.Fail to crank shutdown - Control has signaled starterto crank engine but engine does not rotate.Cranking lockout - The control will not allow thestarter to attempt to engage or to crank the engine whenthe engine is rotating.Alternator protectionHigh/low AC voltage shutdown - High default to110% for 10 seconds, instantaneous 130%. Low defaultto 85% for 10 seconds.Overcurrent warning/shutdown - Implementation ofthe thermal damage curve with instantaneous trip levelcalculated based on current transformer ratio andapplication power rating.Under/over frequency - Under default to -6 Hz for 10seconds. Over default 6 Hz for 10 seconds.Loss of sensing voltage shutdown.Field overload shutdown - uses field voltage toshutdown generator set when a field overload conditionoccurs.EnvironmentThe control is designed for proper operation withoutrecalibration in ambient temperatures from -40 ºC to 70 ºC (-40 ºF to 158 ºF) and for storage from -55 ºC to 80 ºC (-67 ºF to 176 ºF). Control will operate withhumidity up to 95%, non-condensing.The optional display panel is designed for properoperation in ambient temperatures from -20 ºC to 70 ºC (-4 ºF to 158 ºF) and for storage from -30 ºC to 80 ºC (-22 ºF to 176 ºF).The control board is fully encapsulated to providesuperior resistance to dust and moisture. The displaypanel has a single membrane surface, which isimpervious to effects of dust, moisture, oil and exhaustfumes. This panel uses a sealed membrane to providelong reliable service life in harsh environments.The control system is specifically designed and tested forresistance to RFI/EMI and to resist effects of vibration toprovide a long reliable life when mounted on a generatorset. The control includes transient voltage surgesuppression to provide compliance to referencedstandards.Control interfaceInput signals to the base controlAlternatorthermaldamage curveOvercurrentprotection curve10Remote start signalLocal and remote emergency stopConfigurable inputs - Include (4) input signals fromcustomer discrete devices that are configurable forwarning, shutdown or status indication, as well asmessage displayed.Output signals from the controlSecondsConfigurable relay outputs - Control includes (2)relay outputs rated at 2 amps. These outputs can beconfigured to activate on any control warning orshutdown fault, as well as ready-to-load, not-in-auto,common alarm, common warning and commonshutdown.10 .0 3110Amps ( x rated)Ready to load (generator set running) signal Operates when the generator set has reached 90% ofrated speed and voltage and latches until generator set isswitched to off or idle modeCommunications connections Modbus interface - This RS-485 port allows thecontrol to communicate with external devices like PLCon Modbus protocol. 2010 Cummins Power Generation Inc. All rights reserved. Specifications are subject to change without notice. Cummins Power Generationand Cummins are registered trademarks of Cummins Inc. InPower and “Our energy working for you.” are trademarks of Cummins PowerGeneration. Other company, product, or service names may be trademarks or service marks of others.S-1555 (6/10)
PC tool interface - This RS-485 communication portallows the control to communicate with a personalcomputer running InPower.Note - An RS-485 converter is required forcommunication between PC to control.Networking - This RS-485 communication port allowsconnection from the control to the other Cummins PowerGeneration productsSoftwareInPower (beyond 5.5 version) is a PC-based softwareservice tool that is designed to directly communicate tothe 1302 generator set control components to facilitateservice and monitoring of these products.CertificationsThe 1301 control meets or exceeds the requirements ofthe following codes and standards:NFPA 110: For Level 1 or 2 systems.ISO 8528-4: 1993 compliance, Controls andSwitchgear.CE Mark: The control system is suitable for use ongenerator sets to be CE Marked.EN 50081-1, 2: Residential/Light Industrial Emissionsor Industrial Emissions.EN 50082-1, 2: Residential/Light Industrial or IndustrialSusceptibility.ISO 7637-2, level 2: DC Supply Surge Voltage Test.Mil Std 202C, Method 101 and ASTM B117: SaltFog Test.ISO9001: These control systems and generator sets aredesigned and manufactured in ISO9001 certifiedfacilities.UL 508: Recognized or Listed and suitable for use ongenerator sets that are UL 2200 Listed.Current transformers – Kits include 3 CTs foralternator current metering/protection, part number 05411263-01 through -09, depending on ratio.The 1302 is compatible with standard 5 amp secondaryCTs. The primary CT rating is sized to produce rated CTsecondary current of 2.5 amps at rated genset load (at0.8 pf). To select the proper CT ratio you must firstcalculate the lower and upper bound of the primaryrating. Once this is done, you select a CT turns ratiowithin these bounds.Part numberTurns ratioTap 1 - 2(Primary / secondary)Tap 1 – 3P/N 0541-1263-01P/N 0541-1263-02P/N 0541-1263-03P/N 0541-1263-04P/N 0541-1263-05P/N 0541-1263-06P/N 0541-1263-07P/N 0541-1263-08P/N 0541-1263-0950 / 575 / 5100 / 5150 / 5200 / 5250 / 5375 / 5400 / 5500 / 5100 / 5150 / 5200 / 5300 / 5400 / 5500 / 5750 / 5800 / 51000 / 5The lower bound of the primary ratio is calculated bymultiplying the maximum rated current by two (perphase).Min CT Ratio 2 * Max Rated Current : 5eq. 3.1.1The upper bound of the primary ratio is calculated bymultiplying the maximum rated current by five (perphase).Max CT Ratio 5 * Min Rated Current : 5eq. 3.1.2Current is calculated by:Current 3 *VoltageWarrantyorAll components and subsystems are covered by anexpress limited 90 day warranty. Other optional andextended factory warranties and local distributormaintenance agreements are available.Current 1302 Control1302 genset control kit (non electronic engine) Includes a 1302 control module, operator interface, oilpressure sender, coolant temperature sender and allrequired harnesses. Part number 0541-1414-01.Electronic governing power stage – (Required for1302 use with a non-electronic engine.) Includes anactuator driver power stage compatible with the 1302control system. Part number 0541-1231. This kit isrequired for electronic governing. Care should be takento ensure compatibility with fuel actuator.1302 genset control kit (electronic engine) Includes a 1302 control module, operator interface andall required harnesses. Part number 0541-1414-02.Power (VA)Power (W )3 * Power Factor *VoltageIn non-reconnectable genset applications theMax Rated Current and Min Rated Current will be thesame. In reconnectable genset applications they will bedifferent.Example of CT sizing (non-reconnectable):A 250 kVA rated genset application at 240 V producingrated output current of 602 amps/phase. This wouldyield a Min CT Ratio of 1204:5 and a Max CT Ratio of3010:5. Any CT with a ratio between these would besufficient for this application.Example of CT sizing (reconnectable):A reconnectable generator capable of 208-240/416-480V outputs with a 125 kVA 3 phase only rating.We first need to find the current in each phase for eachoutput voltage. This is done using the following formula:eq. 3.1.3 2010 Cummins Power Generation Inc. All rights reserved. Specifications are subject to change without notice. Cummins Power Generationand Cummins are registered trademarks of Cummins Inc. InPower and “Our energy working for you.” are trademarks of Cummins PowerGeneration. Other company, product, or service names may be trademarks or service marks of others.S-1555 (6/10)
Using this equation above, the current in each phase iscompu
Other company, product, or service names may be trademarks or service marks of others. S-1555 (6/10) PowerCommand 1302 digital generator set control kit and optional upgrade kits Description The 1302 control is a microprocessor-based generator set monitoring, metering and control system. The control provides a simple operator interface to the
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