PowerCommand - NoOutage
.PowerCommandDigital Generator Set ControlDescriptionFeaturesThe PowerCommand Control (2100) is amicroprocessor-based generator set monitoring,metering, and control system. The control provides anoperator interface to the genset, digital voltageregulation, digital governing, and generator setprotective functions. The integration of all the functionsinto a single control system provides enhancedreliability and performance compared to conventionalcontrol systems.Major Control Features Include:PowerCommand generator set controls are suitable foruse on a wide range of generator sets in non-parallelingapplications. The PowerCommand Control will directlyread AC voltages up to 600VAC, and can be configuredfor any frequency, voltage, and power connectionconfiguration from 120-600VAC. Digital Engine Speed Governing Controls toprovide isochronous frequency regulation.(optional on some genset models) Digital Voltage Regulation, 3-phase sensing AmpSentry Protection for true alternatorovercurrent protection. Analog and Digital AC Output Metering. Battery Monitoring System to sense and warnagainst a weak battery condition. Digital Alarm and Status Message Display Generator set Monitoring: Displays status of allcritical engine and alternator generator setfunctions. Smart Starting Control System: Integrated fuelramping to limit black smoke and frequencyovershoot, in addition to optimized cold weatherstarting. Advanced Serviceability using InPower , a PCbased software service tool. PowerCommand Network (optional) ProvidesLonMark interface to external devices through atwisted pair wire. Integrated Power Transfer Control (optional)Provides automatic power transfer control functionsintegrated into genset control Certifications – Suitable for use on generator setsthat are designed, manufactured, tested, andcertified to relevant UL, NFPA, ISO, IEC, and CSAstandards. Warranty and Service - Backed by acomprehensive warranty and worldwide distributorservice network.The PowerCommand control is designed for mountingon the generator set.Control power for PowerCommand is usually derivedfrom the generator set starting batteries. The controlfunctions over a voltage range from 8VDC to 35VDC.The control offers a wide range of standard control anddigital display features so custom control configurationsare not needed to meet application specifications.System reliability is not compromised by use ofuntested special components. 2002 Cummins Power GenerationSpecifications subject to change without noticeS-1409b (12/03)
.Indicating LampsOperator PanelThe operator panel provides the user with a completepackage of easy to view and use information.Connections to the operator panel are locking pluginterfaces, for reliable, vibration-resistantinterconnection to the generator set wiring harness.Control Switches and Functions OFF/MANUAL/AUTO Mode Control Switch The NOT IN AUTO lamp will flash when thecontrol is in the MANUAL or OFF mode. In theAUTO mode, the generator set can be started witha start signal from a remote device, such as anautomatic transfer switch.MANUAL RUN/STOP Control Switch - When themode control switch is in the MANUAL positionand the MANUAL RUN /STOP switch is pressed,the Generator set will start, bypassing time delaystart. The control is configurable to include an idleperiod on manual start. If the generator set isrunning in the MANUAL mode, pressing theRUN/STOP switch will cause the generator set toshut down after a cooldown at idle period. PANEL LAMP/LAMP TEST Control Switch –Depressing the panel lamp switch will cause thepanel illumination to operate for approximately 10minutes. Pressing and holding the switch willsequentially illuminate all LED lamps on the panelto confirm proper operation of these components. FAULT ACKNOWLEDGE/RESET Switch – Thecontrol includes a fault acknowledge function toallow the operator to reset the fault condition. Ifthe fault condition is not corrected, the fault willreappear, but will not be logged as a separateevent. Multiple faults can be logged and displayedat one time. EMERGENCY STOP Control Switch – Pressingthe emergency stop switch will cause thegenerator set to immediately shut down. Thegenerator set is prevented from running orcranking with the switch pressed in. Operator Adjustments. The control includesprovisions for many set up and adjustmentfunctions via raise/lower switches on the operatorpanel. Functions that can be adjusted by theoperator include:Time delay start (0-300 seconds)Time delay stop (0-600 seconds)The operator panel includes a series of LED indicatinglamps to allow the operator to view the general statusof the generator set. Functions displayed include: Green lamps to indicate generator set running(operating at rated voltage and frequency); remotestart signal received. Red (flashing) lamp to indicate Not-in-Auto mode;and a red lamp to indicate common shutdown. Amber lamp for common warning. (5) Lamps that are configurable for color andfunction. These lamps are configured with InPowerfor any condition monitored by the control. Defaultconfiguration for these lamps include the followingfunctions:Low Oil Pressure WarningHigh Engine Temperature WarningLow Oil Pressure ShutdownOverspeed ShutdownFail To StartAnalog AC Metering Panel (optional)The PowerCommand control can be equipped with ananalog AC metering panel that simultaneously displays3-phase line to line AC volts and current, kW, powerfactor, and frequency.The meter panel is composed of a series of LED’sconfigured in bar graphs for each function. The LED’sare color coded, with green indicating normal rangevalues, amber for warning levels, and red for shutdownconditions. Scales for each function are in % ofnominal rated values. Resolution is 1% for valuesclose to nominal, and increases at values far fromnominal.Alternator voltage (plus or minus 5%)Alternator frequency (plus or minus 5%) 2002 Cummins Power GenerationSpecifications subject to change without noticeS-1409b (12/03)
.Load Profile Data – Control logs data indicating theoperating hours at percent of rated kW load, in 10%increments. The data is presented on the operatorpanel based on total operating hours on the generatorset, based on number of hours under 30% load, andnumber of hours at more than 90% of rated. InPowercan be used to read data in detail (10% increments).Alphanumeric Display PanelGenerator Set Output Voltage - all phases, line to lineand line to neutral, accuracy 1%. Data for all phases isdisplayed simultaneously to allow viewing of voltagebalance.Generator Set Output Current - all phases, accuracy1%. Data for all phases is displayed simultaneously toallow viewing of load balance.The PowerCommand control is provided with analphanumeric display capable of displaying 2 lines ofdata with approximately 20 characters per line. Thedisplay is accompanied by a set of six tactile feelmembrane switches that are used by the operator tonavigate through control menus, and to make controladjustments. (There are no rotary potentiometers inthe control. All adjustments are made via the displaypanel or InPower.) Display is configurable for multiplelanguages. It is configurable for units of measurement.Generator Set Output FrequencyGenerator Set Power Output - PowerCommanddisplays generator set kW and kVA output (averageand individual phase, and direction of flow), and powerfactor with leading/lagging indication. Accuracy 5%.Generator Set kWh Power Output - Displays totalkilowatt-hours produced by the generator set, and totalproduced since last reset, with time stamp of time oflast reset.All data on the control can be viewed by scrollingthrough screens with the navigation keys.Generator Set Control TemperatureThe control displays all active fault conditions with thelatest displayed first. Active and inactive faults aredisplayed.Engine Lube Oil PressureThe display panel includes a screen-saver timer thatwill turn off the display after 30 minutes of inactivity.Touching any key will turn the screen back on.Generator Set Hardware Data - Generator set ratingin kVA, complete generator set model number andprovisions for generator set serial number, enginemodel and serial number, and alternator model andserial number. The control stores the part number ofthe control and the software version present in thecontrol. This information is read using InPower.Data Logs - Number of start attempts and number ofstart attempts since reset. Number of times generatorset has run, and duration of generator set running time.Generator set kWh produced. The control also storesnumber of start attempts, operating hours, and kWhours since each has been reset. This data is readwith InPower.Adjustment History - Provides a record of adjustmentand setting changes made on the control, and identifieswhether adjustment was made via the operator panelor with a service tool. If a service tool is used, thecontrol provides a record of the serial number of thetool used. This information is read with InPower.Engine Starting Battery VoltageEngine Coolant TemperatureEngine Lube Oil Temperature (option on somegenset models)System Data Display – The generator set willexchange data with Cummins transfer switches utilizingPowerCommand transfer controls and other generatorsets using the PowerCommand 2100 control that arelocated on the same site and interconnected using aPowerCommand network. Information displayed fromeach transfer switch in the system includes: transferswitch name (assigned by customer at site), kW load(when fitted with load monitoring equipment), sourcesavailable, source connected, and if any alarmconditions are present on the switch. Genset dataincludes genset name, kW load, status, and name ofany alarm conditions that are present.Service Adjustments – The operator panel includesprovisions for adjustment and set up of all controlfunctions in the generator set. The operator panelFault History - Provides a record of the most recentfault conditions with time stamp, along with the numberof times each fault has occurred. Up to 20 events arestored in the control non-volatile memory. 2002 Cummins Power GenerationSpecifications subject to change without noticeS-1409b (12/03)
.includes an access code that is used to protect thecontrol from unauthorized service level adjustments.Engine GoverningInternal Control FunctionsEngine ControlRemote Start Mode - PowerCommand accepts aground signal from remote devices or a network signalto automatically start the generator set and immediatelyaccelerate to rated speed and voltage.PowerCommand includes a Smart StartingTM system,that is designed to quickly start the engine, minimizeblack smoke, and minimize voltage and frequencyovershoot and oscillations on starting. The controlsystem does this by careful control of the engine fuelsystem and alternator excitation system.The control can incorporate a time delay start and awarm-up period at idle speed. See Engine Governingfor details.Sleep Mode – PowerCommand can be configured toinclude a sleep mode. When enabled, and when themode select switch is in the OFF position, the controlwill revert to a low power consumption mode until acontrol switch on the operator panel is operated(RESET, PANEL LAMP, MANUAL RUN, orEMERGENCY STOP).Data Logging - The control maintains a record ofmanual control operations, warning and shutdownconditions, and other events. The control also storescritical engine and alternator data before and after afault occurs, for use by InPower and the technician inevaluating the root causes for the fault condition.Fault Simulation Mode - PowerCommand, inconjunction with InPower software, will acceptcommands to allow a technician to verify the properoperation of all protective functions of the control, bysimulating failure modes or by forcing the control tooperate outside of its normal operating ranges.Engine Starting – The control system automaticallycontrols the engine starter, and provides proper enginefueling and alternator control to provide fast andefficient starting.Cycle 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 fortime delay of 0-600 seconds prior to ramp to idle orshut down after signal to stop in normal operationmodes. Default for both time delay periods is 0seconds. 2002 Cummins Power GenerationThe PowerCommand control includes integrated digitalgoverning capability, to directly drive an engine fuelcontrol valve. Features of the governing system (whenenabled) include:Isochronous Governing - Controls engine speedwithin plus or minus 0.25% for any steady state loadfrom no load to full load. Frequency drift will notexceed plus or minus 0.5% for a 60F (33C) change inambient temperature over an 8 hour period.Temperature Dynamics - Modifies the engine fuelsystem (governing) control parameters as a function ofengine temperature. Allows engine to be moreresponsive when warm, and more stable whenoperating at lower temperature levels.Smart Idle Mode - Engine governing can be regulatedat an idle speed for a programmed period on automaticstop of the engine or in manual mode. In an automaticmode, the control will bypass the idle period if theengine at a low load level for sufficient duration forcooldown. During idle mode engine protective functionsare adjusted for the lower engine speed, and alternatorfunction and protections are disabled.Idle speed can be initiated by the operator when thegenerator set is running in the manual mode.Glow Plug Control (optional) – Modifies the enginestart cycle to include a programmed time period foroperation of glow plugs. This feature is available ongenerator sets that require glow plug control only.Alternator ControlPowerCommand includes an integrated 3-phase lineto-neutral sensing voltage regulation system that iscompatible with either shunt or PMG type excitationsystems (some generator set models are always PMG).The voltage regulation system is full wave rectified andhas a PWM output for good motor starting capabilityand stability when powering non-linear loads. Majorsystem features include:Digital Output Voltage Regulation - PowerCommandwill regulate output voltage to within 0.5% for any loadsbetween no load and full load. Voltage drift will notexceed plus or minus 0.5% for a 60F (33C) change intemperature in an 8 hour period. On engine starting, orsudden load acceptance, voltage is controlled to amaximum of 5% overshoot over nominal level.Torque-Matched Volts/Hz Overload Control - Thevoltage roll-off set point and rate of decay (i.e., theslope of the volts/hertz curve) is adjustable in thecontrol.Specifications subject to change without noticeS-1409b (12/03)
.Fault Current Regulation - PowerCommand willregulate the output current on any phase to a maximumof 3 times rated current under fault conditions for bothsingle phase and three phase faults. The regulationsystem will drive a permanent magnet generator (PMG)to provide 3 times rated current on all phases for motorstarting and short circuit coordination purposes.Protective FunctionsOn a warning condition the control will indicate a faultby lighting the warning LED on the control panel, anddisplaying the fault name and code on the operatordisplay panel. The nature of the fault and time ofoccurrence are logged in the control. The servicemanual and InPower service tool provide service keysand procedures based on the service codes provided.On a shutdown condition, the control will light theshutdown LED on the control panel, display the faultname and code, and initiate shut down and lock out thegenerator set. The control maintains a data log of allfault conditions as they occur, and time stamps themwith the controller run time and engine operating hoursdata. Adjustments to most set points are made usingthe InPowerTM service tool.The control system includes a “fault bypass” mode thatmay be enabled by a service technician. The faultbypass mode forces the system to function regardlessof the status of protective functions. (Each functionmust be individually bypassed.) In this mode the onlyprotective functions that are operational are overspeed,loss of speed sensor, or moving the control switch tothe off position, or pressing the EMERGENCY STOPswitch. The control maintains a record of the time thatthe mode is enabled, and all warning or shutdownconditions that have occurred while in the “fault bypass”mode. 2002 Cummins Power GenerationThe control system automatically logs the condition ofthe generator set logged parameters on a faultcondition.Many protective functions within the control system areconfigurable for warning, shutdown, or both (2 levels).Exceptions to this include functions such as overspeedconditions, and loss of speed sensing. In addition,some warning functions can incorporate controlfunctions as a consequence of a fault.PowerCommand provides the following systemprotective functions: Ground Fault Warning (option- 600VAC classgenerator sets with solid ground) - Ground faultsensing is adjustable over a range of 100-1200amps, with time delays of 0-1 second. May beconfigured for shutdown rather than alarm. Configurable Alarm and Status Inputs PowerCommand will accept up to four alarm orstatus inputs (configurable contact closed toground or open) to indicate customer-specifiedconditions. The control is programmable forwarning, shutdown or status indication, and forlabeling the input. Eight additional faults can beinput to the control via the network. Emergency Stop - Annunciated whenever thelocal or remote emergency stop signal is received.Alarm panel distinguishes between local or remoteoperation.Specifications subject to change without noticeS-1409b (12/03)
.AmpSentryTMEngine Protection Overspeed Shutdown - Default setting is 115%of nominal. Low Lube Oil Pressure Shutdown - Level ispreset to match the capabilities of each engine.Control includes time delays to prevent nuisanceshutdown signals. Low Lube Oil Pressure Warning - Level is presetto match the capabilities of each engine. Controlincludes time delays to prevent nuisanceshutdown signals. High Coolant Temperature Shutdown- Level ispreset to match the capabilities of each engine.Control includes time delays to prevent nuisanceshutdown signals. High Coolant Temperature Warning - Level ispreset to match the capabilities of each engine.Control includes time delays to prevent nuisanceshutdown signals. High Oil Temperature Warning (option)- Level ispreset to match the capabilities of each engine.Control includes time delays to prevent nuisanceshutdown signals. Low Coolant Level Warning/Shutdown (optionalon some genset models) Low Coolant Temperature Warning - Indicatesthat engine temperature may not be high enoughfor a 10-second start or proper load pickup. Low and High Battery Voltage Warning Indicates battery charging system failure bycontinuously monitoring battery voltage. Weak Battery Warning - The control system willtest the battery bank each time the generator setis signaled to start, and indicate a warning if thegenerator set battery indicates impending failure. Dead Battery Shutdown – Indicates thatgenerator set failed to start due to failed startingbattery. Fail to Start (Overcrank) Shutdown Fail to Crank Shutdown - Control has signaledstarter to crank engine but engine does not rotate. Redundant Starter Disconnect Cranking Lockout - The control will not allow thestarter to attempt to engage or to crank the enginewhen the engine is rotating. Sensor Failure Indication - All analog sensorsare provided with sensor failure logic to indicate ifthe sensor or interconnecting wiring has failed.Separate indication is provided for fail high or low. 2002 Cummins Power GenerationAmpSentry is a comprehensive monitoring and c
PowerCommand Digital Generator Set Control Description Features The PowerCommand Control (2100) is a microprocessor-based generator set monitoring, metering, and control system. The control provides an operator interface to the genset, digital voltage regulation, digital governing, and generator set protective functions.
PowerCommand digital generator set control PCC 2300 Description The PowerCommand generator set control is suitable for use on a wide range of generator sets in non-paralleling applications. The PowerCommand control is compatible with shunt or PMG excitation style. It is suitable for use with reconnectable or non-reconnectable generators, and
PowerCommand Digital Master Controller 2000 Description Features The PowerCommand Digital Master Control is a microprocessor-based paralleling system product designed to directly interface with Cummins Power Generation PowerCommand paralleling generator sets and switchgear. The DMC 2000 is designed for
PowerCommand digital generator set control PCC 1302 Description The PowerCommand generator set control is suitable for use on a wide range of generator sets in non-paralleling applications. The PowerCommand control is compatible with shunt or PMG excitation style. It is suitable for use with reconnectable or non-
PowerCommand digital generator set control PCC 2300 Description The PowerCommand generator set control is suitable for use on a wide range of generator sets in non-paralleling applications. The PowerCommand control is compatible with shunt or PMG excitation style. It is suitable for use with reconnectable or non-
The PowerCommand control is designed for mounting on the generator set. Control power for PowerCommand is usually derived from the generator set starting batteries. The control functions over a voltage range from 8 VDC to 35 VDC. The control offers a wide range of standard control and digital display features so custom control
Digital generator set control PowerCommand 3100 Description The PowerCommand 3100 Control is a microprocessor-based generator set monitoring, metering and control system. The control provides an operator interface to the genset, digital voltage regulation, digital governing and generator set protective functions. The integration of all the
The control may be upgraded to PowerCommand 2100 digital electronic control with NFPA110 compliance and electronic governing. Optional weather-protective enclosures and coolant heaters shield the generator set from extreme operating conditions. Environmental concerns are addressed by low exhaust emission engines, sound-attenuated enclosures .
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