Digital Generator Set Control PowerCommand 3100
Digital generator setcontrol PowerCommand 3100DescriptionFeatures The PowerCommand 3100 Control 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 thefunctions into a single control system providesenhanced reliability and performance compared toconventional control systems.The PowerCommand control is designed for mountingon the generator set and is suitable for use on a widerange of generator sets in non-paralleling applications.The PowerCommand Control will directly read ACvoltages up to 600 VAC and can be configured for anyfrequency, voltage and power connection configurationfrom 120-600 VAC. It functions over a voltage rangefrom 8 VDC to 35 VDC.The control offers a wide range of standard control anddigital display features so custom controlconfigurations are not needed to meet applicationspecifications. System reliability is not compromisedby use of untested special components.Power for PowerCommand control is usually derivedfrom the generator set starting batteries.Digital engine speed governing controls Provide isochronous frequency regulation.Digital voltage regulation - 3-phase sensing.AmpSentry protective relay - True alternatorover current protection.Analog and digital AC output metering.Battery monitoring system - Senses and warnsagainst a weak battery condition.Digital alarm and status message display.Generator set monitoring - Displays status of allcritical engine and alternator generator set functions.Smart starting control system - Integrated fuelramping to limit black smoke and frequencyovershoot, in addition to optimized cold weatherstarting.Advanced serviceability - Utilizes InPower , aPC-based software service tool.PowerCommand network (optional) - ProvidesLonMark interface to external devices through atwisted pair wire.Certifications - Suitable for use on generator setsthat are designed, manufactured, tested, and certifiedto relevant UL, NFPA, ISO, IEC, and CSA standards.Warranty and service - Backed by acomprehensive warranty and worldwide distributorservice network. 2007 Cummins Power Generation Inc. All rights reserved Specifications subject to change without notice Cummins PowerGeneration and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry and “Our energy working foryou.” are trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks ofothers.S-1025g (1/08) Page 1 of 8
Operator 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 functionsRun/off/auto mode control switch - The not inauto lamp will flash when the control is in the run or offmode. In the auto mode, the generator set can bestarted with a start signal from a remote device, suchas an automatic transfer switch. In the run position thegenerator set will start and accelerate to rated speedand voltage. In the run mode, the control can beconfigured to operate at idle speed with the excitationswitched off.Panel lamp control switch - Depressing the panellamp switch will cause the panel illumination to operatefor approximately 8 minutes.Emergency stop control switch - Pressing theemergency stop switch will cause the generator set toimmediately shut down. The generator set isprevented from running or cranking with the switchpressed in.Reset switch - Clears the digital display and statuspanel and allows the generator set to be started after afault has been corrected.Self test switch - Prompts the control to perform aself-test of the system and displays all fault messages.Phase select switch - Controls the phase that isdisplayed on the analog AC Instrumentation.Operator adjustments - The control includesprovisions for many set up and adjustment functionsvia raise/lower switches on the operator panel.Functions that can be adjusted by the operatorinclude:-Time delay start (0-300 seconds)Time delay stop (0-600 seconds)Alternator voltage ( 5%)Alternator frequency ( 5%)Analog metering on the control panel provides clearindication of generator set stability including themagnitude of displacement and rate of change duringlead transients which cannot be viewed clearly withdigital metering equipment. These meters are also idealfor “walk-by” status checks by the operator. All metersare 63.5 mm (2.5 in), 90-degree scale. Meter faces UVprotected against discoloration from exposure tosunlight. The kilowatt meter and ammeter are scaled inpercent of AC output for easy recognition of generatorset status and load level (0-90% of rating: green; 90100% of rating: amber; 100% of rating: red).Percent kilowatt meter - Indicates 3-phase ACpower output as a percent of rated load. Provides atrue indication of total kW load on the generator set,regardless of the load power factor. Scale is 0-125%.Accuracy is 5%.Frequency meter - Indicates generator set outputfrequency in hertz. Calculated frequency is based onengine speed and alternator voltage zero-crossing andis not affected by voltage waveform distortion causedby non-linear loads. Scale is 45-65 Hz. Accuracy is 0.5 Hz.AC voltmeter - Dual scale AC voltmeter indicatesalternator output voltage. Accuracy: 2%. Scales: 0300 VAC, 0-600 VAC; 0-400 VAC, 0-750 VAC; 0-5260VAC; or 0-15,000 VAC.% AC ammeter - Indicates current output in percentof maximum rated standby current. Accuracy: 2%.Scale: 0-125%.Alphanumeric display panelThe 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 in thecontrol. All adjustments are made via the display panelor InPower). Display is configurable for multiplelanguages. It is configurable for units of measurement.Indicating lampsAll data on the control can be viewed by scrollingthrough screens with the navigation keys.The operator panel includes a series of LED indicatinglamps to allow the operator to view the general statusof the generator set. Functions displayed include:The control displays all active fault conditions with thelatest displayed first. Active and inactive faults aredisplayed.Red (flashing) lamp to indicate not-in-auto mode and ared lamp to indicate common shutdown.The display panel includes a screen-saver timer that willturn off the display after 10 minutes of inactivity.Touching any key will turn the screen back on.Amber lamp for common warning.Phase and scale indication. Indicates the phase that isdisplayed on the analog AC instruments.Analog AC metering panelThe PowerCommand control is equipped with ananalog AC metering panel that displays 3-phase lineto-line AC volts and current, kW and frequency.Generator set hardware data - Generator set ratingin kVA, generator set model number. The control storesthe software version present in the control.Data logs - Number of start attempts and duration ofgenerator set running time. Generator set kWhproduced.Our energy working for you. www.cumminspower.com 2007 Cummins Power Generation Inc. All rights reserved Specifications subject to change without notice Cummins PowerGeneration and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry and “Our energy working foryou.” are trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks ofothers.S-1025g (1/08) Page 2 of 6
Fault history - Provides a record of the most recent faultconditions with time stamp. Up to 20 events are stored inthe control non-volatile memory.Load profile data - Control logs data indicating theoperating hours at percent of rated kW load in 10%increments. InPower is used to read this.Generator 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.Generator set output frequency.Generator set power output - PowerCommanddisplays generator set kW and power factor withleading/lagging indication. Accuracy 5%.Generator set kWh power output - Displays totalkilowatt-hours produced by the generator set.Engine starting battery voltage.Engine lube oil pressure.Engine coolant temperature.Engine lube oil temperature.Engine exhaust temperature (option).Service adjustments - The operator panel includesprovisions for adjustment and set up of all controlfunctions in the generator set. The operator panel includesan access code that is used to protect the control fromunauthorized service level adjustments.Internal control functionsEngine controlRemote start mode - PowerCommand accepts aground signal from remote devices or a network signal toautomatically start the generator set and immediatelyaccelerate to rated speed and voltage.PowerCommand includes a smart starting system that isdesigned to quickly start the engine, minimize blacksmoke, minimize voltage and frequency overshoot, andoscillations on starting. The control system does this bycareful control of the engine fuel system and alternatorexcitation system.The control can incorporate a time delay start and a warmup period at idle speed. See Engine governing for details.Sleep mode - PowerCommand can be configured toinclude a sleep mode. When enabled, and when the modeselect switch is in the off position, the control will revert toa low power consumption mode until a control switch onthe operator panel is operated or a remote signal isreceived.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 systemautomatically controls the engine starter andprovides proper engine fueling and alternator controlto provide fast and efficient starting.Cycle cranking - Configurable for number ofstarting cycles (1 to 7) and duration of crank andrest periods. Control includes starter protectionalgorithms to prevent the operator from specifying astarting sequence that might be damaging.Time delay start and stop (cool down) Configurable for time delay of 0-300 seconds priorto starting after receiving a remote start signal; andfor time delay of 0-600 seconds prior to ramp-to-idleor shutdown after signal to stop in normal operationmodes. Default for both time delay periods is 0seconds.Engine governingThe PowerCommand control includes integrateddigital governing capability to directly drive anengine fuel control valve. Features of the governingsystem (when enabled) include:Isochronous governing - Controls engine speedwithin 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 ambienttemperature over an 8 hour period.Temperature dynamics - Modifies the enginefuel system (governing) control parameters as afunction of engine temperature. Allows engine to bemore responsive when warm and more stable whenoperating at lower temperature levels.Idle mode - The control system accepts a signal tocontrol engine speed to a preset, adjustable idlespeed when operating in the run mode.Alternator controlPowerCommand includes an integrated 3-phaseline-to-neutral sensing voltage regulation systemthat is compatible with either shunt or PMG typeexcitation systems. The voltage regulation system isfull wave rectified and has a PWM output for goodmotor starting capability and stability whenpowering non-linear loads. Major system featuresinclude:Our energy working for you. www.cumminspower.com 2007 Cummins Power Generation Inc. All rights reserved Specifications subject to change without notice Cummins PowerGeneration and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry and “Our energy working foryou.” are trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks ofothers.S-1025g (1/08) Page 3 of 6
Digital output voltage regulation - PowerCommandwill regulate output voltage to within 0.5% for any loadsbetween no load and full load. Voltage drift will not exceed 0.5% for a 33 C (60 F) 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. Control is configurable foroperation of self-excited or separately-excited alternators.Engine protectionTorque-matched V/Hz overload control - The rate ofdecay (i.e., the slope of the v/Hz curve) is adjustable in thecontrol.Low lube oil pressure warning - Level is presetto match the capabilities of each engine. Controlincludes time delays to prevent nuisance shutdownsignals.Fault current regulation - PowerCommand willregulate the output current on any phase to a maximum of3 times rated current under fault conditions for both singlephase and three phase faults. The regulation system willdrive a permanent magnet generator (PMG) to provide 3times rated current on all phases for motor starting andshort circuit coordination purposes.Protective functionsOn a warning condition the control will indicate a fault bylighting the warning LED on the control panel anddisplaying the fault name and code on the operator displaypanel. The nature of the fault and time of occurrence arelogged in the control. The service manual and InPowerservice tool provide service keys and procedures based onthe service codes provided.On a shutdown condition, the control will light theshutdown LED on the control panel, display the fault nameand code, initiate shutdown and lock out the generator set.The control maintains a data log of all fault conditions asthey occur and time stamps them with the engineoperating hours data.Some protective functions within the control system areconfigurable for warning or shutdown.PowerCommand provides the following systemprotective functions:Ground fault warning (option - 600 VAC classgenerator sets with solid ground) - Ground faultsensing is adjustable over a range of 100-1200 amps withtime delays of 0-1 second. May be configured forshutdown rather than alarm.Configurable alarm and status inputs PowerCommand will accept up to four alarm or statusinputs (configurable contact closed to ground or open) toindicate customer-specified conditions. The control isprogrammable for warning or shutdown and for labelingthe input.Emergency stop - Annunciated whenever the local orremote emergency stop signal is received. Alarm paneldistinguishes between local or remote operation.Over speed 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.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.Low coolant level warning/shutdown.Low coolant temperature warning - Indicatesthat engine temperature may not be high enough fora 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 set issignaled to start and indicate a warning if thegenerator set battery indicates impending failure.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.AmpSentry protective relayA comprehensive monitoring and control systemintegral to the PowerCommand Control System thatguards the electrical integrity of the alternator andpower system by providing protection against awide array of fault conditions in the generator set orin the load. It also provides singleOur energy working for you. www.cumminspower.com 2007 Cummins Power Generation Inc. All rights reserved Specifications subject to change without notice Cummins PowerGeneration and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry and “Our energy working foryou.” are trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks ofothers.S-1025g (1/08) Page 4 of 6
and three phase fault current regulation so thatdownstream protective devices have the maximumcurrent available to quickly clear fault conditions withoutsubjecting the alternator to potentially catastrophicfailure conditions. See document R1053 for a full sizetime overcurrent curve.Over load (kW) warning - Provides a warningindication when engine is operating at a load level over100% for more than 5 seconds. A dedicated outputrelay is provided for use by the customer for loadshedding.High alternator temperature (option).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 Cto 80 C (-67 F to 176 F). Control will operate withhumidity up to 95%, non-condensing and at altitudesup to 5000 m (13,000 feet).Alternatorthermaldamage curveOvercurrentprotection curve10The control system is housed in a NEMA 1/IP23enclosure. The operator control panel has a singlemembrane surface which is impervious to the effectsof dust, moisture, oil and exhaust fumes. The paneluses sealed membrane or oil-tight switches to providelong reliable service life in harsh environments.Seconds1The control system is specifically designed and testedfor resistance to RFI/EMI and to resist the effects ofvibration to provide a long reliable life when mountedon a generator set. The control includes transientvoltage surge suppression to provide compliance toreferenced standards.0.03110Amps ( x rated)R1053Functions include:Over current warning - Output current on any phaseat more than 110% of rating for more than 60 secondsor more than 400% for more than 1 second.Over current shutdown (51) - Output current on anyphase is more than 110%, less than 175% of rating andapproaching thermal damage point of alternator.Control includes algorithms to protect alternator fromrepeated over current conditions over a short period oftime.Short circuit shutdown - Output current on anyphase is more than 110%, more than 175% of rating,and approaching thermal damage point of alternator.Control includes algorithms to protect alternator fromrepeated over current conditions over a short period oftime.High AC voltage shutdown (59) - Output voltage onany phase exceeds preset values. Time to trip isinversely proportional to amount above threshold.Setting is more than 110% for 10 seconds orinstantaneous at more than 130% of nominal voltage.Low AC voltage shutdown (27) - Voltage on anyphase has dropped below a preset value. Setting is85% for 10 seconds.Under frequency shutdown (81
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