PowerCommand 1301 Digital Generator Set Control Kit And .
PowerCommand 1301digital generator set control kitand optional upgrade kitsDescriptionFeaturesThe 1301 control is a microprocessor-based generatorset monitoring, metering and control system. The controlprovides a simple operator interface to the generator set,digital voltage regulation, digital engine speed governing,start/stop control, 12 V/24 V battery operation andgenerator set protective functions. The integration of allfunctions into a single control system provides enhancedreliability and performance compared to conventionalgenerator set control systems.12 and 24 VDC battery operation.The 1301 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.It functions over a voltage range from 8 VDC to 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.Digital engine speed governing (optional) Provides isochronous frequency regulation.Generator set monitoring - Monitors status of allcritical engine and alternator functions. Configurable forsingle or three phase AC metering.Engine starting - Includes relay drivers for start, fuelshut off (FSO) and glow plug/spark ignition power. Startdisconnect is achieved by monitoring the batterycharging alternator.Generator set protection - Engine and alternator.Operator display panel - Provides easy to usesymbolic/English text operator display of criticalgenerator set parameters 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 thatis fully protected from the elements.Configurable inputs and outputs - Two 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. Cummins Power Generation and Cummins are registered trademarks of CumminsInc. InPower and “Our energy working for you.” are trademarks of Cummins Power Generation. Other company, product, or service namesmay be trademarks or service marks of others. Specifications are subject to change without notice.S-1506d (6/10) Page 1 of 7
Control systemThe 1301 Control system includes all functions necessaryto locally or remotely start and stop, regulate voltage andprotect the generator set.Run/off/auto - In the off mode the generator set isimmediately shut down (if running) and cannot be started.In the run mode the generator set will execute its startsequence and operate at rated speed and voltage. In theauto mode, the generator set can be started with a startsignal from a remote device, such as an automatictransfer switch. Operation of the switch to the offposition also resets faults in the control.Status indications - The control includes a lamp driverfor an external fault/status indication. When this featureis used, it provides the operator with basic statusinformation on the generator set. Functions displayedinclude: The lamp flashes during preheat (when used) and whilethe generator set is starting. The lamp indicatesready to load by flashing until thegenerator set is at rated voltage and frequency, thenglowing continuously. Fault conditions are displayed by flashing a two-digitfault code number.Engine speed governingThe control is available with an optional governor powerstage. This power stage amplifies control signals todirectly drive an engine fuel control valve.The run/off/auto switch function is integrated into thedisplay panel; therefore an external switch is notrequired.All data on the control can be viewed by scrollingthrough screens with the navigation keys.The control displays current active faults and a timeordered history of 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 display panel includesprovisions for many set up and adjustment functions viaraise/lower switches. Functions that can be adjusted bythe operator include:- Time delay start (0-300 seconds)- Time delay stop (0-600 seconds)- Alternator voltage (plus or minus 5%)Generator set hardware data - Access to thecontrol and software part number, generator set rating inkVar and generator set model number is provided fromthe display panel or InPower.Data logs - Engine run time, controller on time, numberof runs and number of start attempts are available fromthe display panel or through InPower.Fault history - Provides a record of the most recentfault conditions with control hours time stamp. Up to 5events are stored in the control non-volatile memory.Display panelThe control includes a digital display panel that may beeither locally or remotely mounted. The operator screensare made up of internationally accepted symbols orEnglish test, so translations are not required. The displayis composed of a backlit LCD display, with a series of 6generator status LED lamps. The display is accompaniedby six tactile-feel membrane switches that are used bythe operator to navigate through control menus and tomake control adjustments. (There are no rotarypotentiometers in the control. All adjustments are madevia the display panel or InPower.) It is configurable forunits of measurement. It is adjustable for screen contrastand brightness.Alternator data- Voltage (single or three phase line-to-line and line-toneutral)- Current (3-phase)- KVA- FrequencyEngine data- Starting battery voltage- Engine speed- Engine temperature- Engine oil pressureService adjustments - The operator panel includesprovisions for adjustment and calibration of generatorset control functions. Adjustments are protected by apassword. Functions include:- Engine speed governor adjustments- 12 VDC/24 VDC battery operations- Voltage regulation adjustmentsOur energy working for you. www.cumminspower.com 2010 Cummins Power Generation Inc. All rights reserved. Cummins Power Generation and Cummins are registered trademarks of CumminsInc. InPower and “Our energy working for you.” are trademarks of Cummins Power Generation. Other company, product, or service namesmay be trademarks or service marks of others. Specifications are subject to change without notice.S-1506d (6/10) Page 2 of 7
-Cycle crankingConfigurable fault set upConfigurable output set upMeter calibrationDisplay 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 - The 1301control will operate either on 12 VDC or 24 VDC batteries.Isochronous governing - Capable of controllingengine speed within 0.25% for any steady state loadfrom no load to full load. Frequency drift will not exceed 0.5% for a 33 C (60 F) change in ambient temperatureover an 8 hour period.The maximum actuator drive current of the electronicgoverning power stage option is 6.0 amps continuousand 10 amps peak for 1 second.This feature can be disabled to allow the use of anexternal governor.Temperature dependent governing dynamics Modifies the engine governing control parameters as afunction of engine temperature. Allows engine to be moreresponsive when warm and more stable when operatingat lower temperature levels.Remote start mode - The 1301 control accepts aCycle 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 ramp to idle or shut downafter signal to stop in normal operation modes. Defaultfor both time delay periods is 0 Sec.Alternator controlThe 1301 control includes an integrated line-to-linesensing voltage regulation system that is compatible withshunt excitation systems. The voltage regulation systemis full wave rectified and has an SCR output for goodmotor starting capability. Major system features include:Digital output voltage regulation - The 1301 controlwill regulate output voltage to within 1.0% for any loadsbetween no load and full load. Voltage drift will notexceed 1.5% for a 40 C (104 F) change in temperaturein an 8 hour period. On engine starting, or sudden loadacceptance, voltage is controlled to a maximum of 5%overshoot over nominal level.The maximum regulator filed drive current is 4.0 ampsRMS continuous and 6.0 amps peak for 10 seconds.This feature can be disabled to allow the use of anexternal voltage regulator.Torque-matched V/Hz overload control - Thevoltage roll-off set point and rate of decay (i.e., the slopeof the V/Hz curve) is adjustable in the control.ground signal from remote devices to automatically startthe generator set and immediately accelerate to ratedspeed and voltage. The control can incorporate a timedelay start.Remote emergency stop - The control accepts aground signal from an external emergency stop switch tocause the generator set to immediately shut down. Thegenerator set is prevented from running or cranking withthe switch engaged.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 any button on the display panelis pressed.Engine starting - The control system supportsautomatic engine starting, including a relay driver for astarter and fuel shutoff pilot relay. Primary and backupstart disconnects are achieved by one of three methods:magnetic pickup, battery charging alternator feedback ormain alternator output frequency. The control alsosupports programmable glow plug control. This featurecan be disabled when not required.Protective functionsOn operation of a protective function the control willindicate warning or shutdown by lighting the appropriateLED. The associated fault symbol/text and fault code willalso be displayed on the digital display. The nature of thefault and time of occurrence are logged in the control.The service manual and InPower service tool provideservice keys and procedures based on the service codesprovided.System protective functions:Configurable alarm and status inputs - The 1301control will accept up to two alarm or status inputs(configurable contact closed to ground or open) toindicate customer-specified conditions. The control isprogrammable for warning, shutdown or status indication,and for labeling the input.Our energy working for you. www.cumminspower.com 2010 Cummins Power Generation Inc. All rights reserved. Cummins Power Generation and Cummins are registered trademarks of CumminsInc. InPower and “Our energy working for you.” are trademarks of Cummins Power Generation. Other company, product, or service namesmay be trademarks or service marks of others. Specifications are subject to change without notice.S-1506d (6/10) Page 3 of 7
Emergency stop - Annunciated whenever theemergency stop signal is received from external switch.Engine protectionOver speed shutdown - Default setting is 115% ofnominal.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.High 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.Low coolant temperature warning - Indicates thatengine temperature may not be high enough for a 10second start or proper load acceptance.The display panel is designed for proper operation inambient temperatures from -20 C to 70 C (-4 F to 158 F) and for storage from -30 C to 80 C (-22 F to 176 F).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 testedfor resistance to RFI/EMI, and to resist effects ofvibration to provide a long reliable life when mounted ona generator set. The control includes transient voltagesurge suppression to provide compliance to referencedstandards.Control interfaceLow and high battery voltage warning - Indicatesstatus of battery charging system (failure) by continuouslymonitoring battery voltage.Input signals to the base control include:Weak battery warning - The control system will testthe battery each time the generator set is signaled to startand indicate a warning if the battery indicates impendingfailure.Remote start signal.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 the starterto attempt to engage or to crank the engine when theengine is rotating.Sensor failure indication - Logic is provided on thebase control to detect analog sensor or interconnectingwiring failures.Alternator protectionHigh/low AC voltage shutdown - High default to110% for 10 seconds, instantaneous 130%. Low defaultto 85% for 10 seconds.Over current warning/shutdown - Warning default to110% for 60 seconds. Shutdown default to 150% for 10seconds. Requires CT option.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.EnvironmentThe control is designed for proper operation withoutrecalibration in ambient temperatures from -40 C to 70 C (-40 F to 158 F) and for storage from -55 C to 80 C (-67 F to 176 F). Control will operate withhumidity up to 95%, non-condensing.Generator set status lamp.Remote emergency stop.Configurable inputs - Control includes (2) inputsignals from customer discrete devices that areconfigurable for warning, shutdown or status indication,as well as message displayed.Output signals from the 1301 control include:Configurable 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.Ready to load (generator set running) signal Operates when the generator set has reached 90% ofrated speed and voltage and latches until generator setis switched to off or idle mode. (B signal output).Communications connections include: Modbus interface - This RS-485 port allows thecontrol to communicate with external devices like PLCon Modbus protocol.PC tool interface - This RS-485 communication portis shard with the Modbus interface mentioned above. Itallows the control to communicate with a personalcomputer running InPower.Note - An RS-232 to RS-485 converter is required forcommunication between PC-to-control.Networking - This RS-485 communication port allowsconnection from the control to the other CumminsPower Generation products.Our energy working for you. www.cumminspower.com 2010 Cummins Power Generation Inc. All rights reserved. Cummins Power Generation and Cummins are registered trademarks of CumminsInc. InPower and “Our energy working for you.” are trademarks of Cummins Power Generation. Other company, product, or service namesmay be trademarks or service marks of others. Specifications are subject to change without notice.S-1506d (6/10) Page 4 of 7
Turns ratio(primary/secondary)SoftwareInPower (beyond 4.5 version) is a PC-based softwareservice tool that is designed to directly communicate tothe 1301 generator set control components to facilitateservice and monitoring of these products.CertificationsThe 1301 control meets or exceeds the requirements ofthe following codes and standards:NFPA110: For Level 1 or 2 systems.ISO 8528-4: 1993 compliance, Controls andSwitchgear.CE marking: 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: PowerCommand control systems andgenerator sets are designed and manufactured inISO9001 certified facilities.UL 508: Recognized or Listed and suitable for use onUL 2200 Listed generator sets.WarrantyAll components and subsystems are covered by anexpress limited 90 day warranty. Other optional andextended factory warranties and local distributormaintenance agreements are available.Part 080541-1263-09Tap 1 – 2Tap 1 - 50/5200/5300/5400/5500/5750/5800/51000/5The 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 Power (VA)3 *VoltageorCurrent 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.1301 ControlExample of CT sizing (non-reconnectable):1301 genset control kit - Includes a 1301 controlmodule, operator interface, oil pressure sender, coolanttemperature sender and all required harnesses. Partnumber 0541-1230.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.Current transformers – Kits include 3 CTs foralternator current metering/protection. Part number0541-1263-01 through -09 depending on ratio.Example of CT sizing (reconnectable):The 1301 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.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. 3.1.3Our energy working for you. www.cumminspower.com 2010 Cummins Power Generation Inc. All rights reserved. Cummins Power Generation and Cummins are registered trademarks of CumminsInc. InPower and “Our energy working for you.” are trademarks of Cummins Power Generation. Other company, product, or service namesmay be trademarks or service marks of others. Specifications are subject to change without notic
PowerCommand 1301 digital generator set control kit and optional upgrade kits Description The 1301 control is a microprocessor-based generator set monitoring, metering and control system. The control provides a simple operator interface to the generator set, digital voltage regulation, digital engine speed governing,
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8 Annual Book of ASTM Standards, Vol 14.02. 9 Annual Book of ASTM Standards, Vol 03.03. 10 Annual Book of ASTM Standards, Vol 03.06. 11 Available from American National Standards Institute (ANSI), 25 W. 43rd St., 4th Floor, New York, NY 10036. 12 Available from American Society of Mechanical Engineers (ASME), ASME International Headquarters, Three Park Ave., New York, NY 10016-5990. 13 .
