Digital Generator Set Control Description
.PowerCommand Digital Generator Set ControlDescriptionThe PowerCommand (1301) Control is amicroprocessor-based generator set monitoring,metering, and control system. The control provides asimple operator interface to the generator set, digitalvoltage regulation, digital engine speed governing, start/ stop control, 12V/24V battery operation and generatorset protective functions. The integration of all functionsinto a single control system provides enhancedreliability and performance compared to conventionalgenerator set control systems.The PowerCommand 1301 generator set control issuitable for use on a wide range of generator sets innon-paralleling applications. The PowerCommand Control is compatible with reconnectable alternators upto 600VAC line to line, and can be configured for anyfrequency, voltage, and power connection configurationfrom 120-600VAC line to line.The PowerCommand 1301 is designed for mountingon the generator set.Power for the control is derived from the generator setstarting batteries. The control functions over a voltagerange from 8VDC to 30 VDC.The control offers a wide range of standard control andoptional display panel features so custom controlconfigurations are not needed to meet applicationspecifications. 2004 Cummins Power GenerationFeatures 12 and 24 VDC Battery Operation. Digital Voltage Regulation Full wave rectifiedsingle phase (line to line) sensing. Digital Engine Speed Governing (optional) toprovide isochronous frequency regulation. Generator Set Monitoring Monitors status ofall critical engine and alternator functions.Configurable for single or three phase ACmetering. Engine Starting includes relay drivers for start,fuel shut off (FSO), and glow plug. Startdisconnect is achieved by monitoring thebattery charging alternator. Generator Set Monitoring. Monitors status ofall critical engine and alternator conditionsfunctions. Generator Set Protection. Engine andalternator. Operator Display Panel (optional). Provideseasy to use symbolic operator display of criticalgenerator set parameters and operatinghistory. Advanced Serviceability using InPower , aPC-based software service tool. Environmental Protection. The controlsystem is designed for reliable operation inharsh environments. The core control board isan encapsulated module that is fully protectedfrom the elements. Configurable Inputs and Outputs. Twodiscrete inputs and two dry contact relayoutputs.Specifications subject to change without noticeS-1468 (04 October 2004)
. Certifications. Suitable for use on generatorsets that are designed, manufactured, tested,and certified to relevant UL, NFPA, ISO, IEC,Mil Std. and CE standards.Warranty and Service. Backed by acomprehensive warranty and worldwidedistributor service network.Control SystemThe standard control system includes a control boardwith an external control switch and status indicator.The control board includes all functions necessary tolocally or remotely start and stop, regulate voltage, andprotect the generator set.Control Switch - RUN/OFF/AUTO - In the OFF modethe generator set is immediately shut down (if running)and cannot be started. In the RUN mode the generatorset will execute its start sequence, and operate at ratedspeed and voltage. In the AUTO mode, the generatorset can be started with a start signal from a remotedevice, such as an automatic transfer switch. Thefault/status lamp will flash until the generator set is atrated speed and voltage. Operation of the switch to theOFF position also resets faults in the control.Status Indications - The control includes a lamp driverfor an external fault/status indication. When thisfeature is used, it provides the operator with basicstatus information on the generator set. Functionsdisplayed include: The lamp flashes during preheat (when used) andwhile the generator set is starting. The lamp indicates “READY TO LOAD” by flashinguntil the generator set is at rated voltage andfrequency, then turning on continuously. Fault conditions are displayed by flashing a twodigit fault code number.Optional Engine Speed GoverningOptional Display PanelThe control is available with an optional display panelthat may be either locally or remotely mounted. Theoperator screens are made up of internationallyaccepted symbols, so translations are not required.The display is composed of a backlit LCD display, witha series of 6 generator status LED lamps. The displayis accompanied by six tactile feel membrane switchesthat are used by the operator to navigate throughcontrol menus, and to make control adjustments.(There are no rotary potentiometers in the control. Alladjustments are made via the display panel orInPower.) It is configurable for units of measurement.It is adjustable for 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 current active faults, and a timeordered history of previous faults.LED Indicating Lamps - The optional display panelincludes LED indicating lamps for the followingfunctions:Not in AutoShutdownWarningRemote StartAutoRunOperator Adjustments - The optional display panelincludes provisions for many set up and adjustmentfunctions via raise/lower switches. Functions that canbe adjusted by the operator include:Time delay start (0-300 seconds)Time delay stop (0-600 seconds)Alternator voltage (plus or minus 5%)The control is available with an optional governorpower stage. This power stage amplifies controlsignals to directly drive an engine fuel control valve.Generator Set Hardware Data - Access to the controland software part number, generator set rating in KVA,and generator set model number is provided from theoptional display panel or Inpower. 2004 Cummins Power GenerationSpecifications subject to change without noticeS-1468 (04 October 2004)
.Data Logs - Engine run time, controller on time,number of runs, and number of start attempts areavailable from the optional display panel or throughInPower.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.Alternator DataVoltage (single or 3 phase Line-Line and LineNeutral)Current (3 phase)KVAFrequencyEngine DataStarting Battery VoltageEngine SpeedEngine TemperatureEngine 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 adjustments12 VDC/24 VDC battery operationsVoltage regulation adjustmentsCycle crankingConfigurable fault set upConfigurable output set upMeter calibrationDisplay language and units of measurementOther Information Control Not CommunicatingPop-up Timers to indicate time remaining ontime delays in the system.Internal Control FunctionsEngine Control12 VDC/24VDC Battery Operations – PowerCommand will operate either on 12 VDC or 24 VDCbatteries.Isochronous Governing – (optional) Controls enginespeed within plus or minus 0.25% for any steady stateload from 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 Dependent Governing Dynamics –(with governing option) Modifies the engine governingcontrol parameters as a function of engine temperature.Allows engine to be more responsive when warm, andmore stable when operating at lower temperaturelevels.Remote Start Mode - Power Command 1301 acceptsa ground signal from remote devices to automaticallystart the generator set and immediately accelerate torated speed and voltage.The control can incorporate a time delay start.Remote Emergency Stop – The control accepts aground signal from an external emergency stop switchto cause the generator set to immediately shut down.The generator set is prevented from running orcranking with the switch engaged.Sleep Mode -The control is configured to include asleep mode. When the mode select switch is in theOFF position, 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.Engine Starting - The control system supportsautomatic engine starting, including a 30 amp relaycontact for the starter motor and fuel shutoff. Primaryand backup start disconnects are achieved by one ofthree methods, magnetic pickup, battery chargingalternator feedback, or main alternator outputfrequency. The control also supports programmableglow plug control. This feature can be disabled whennot required.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 0 Sec.Alternator ControlPower Command 1301 includes an integrated line-toline sensing voltage regulation system that iscompatible with shunt excitation systems. The voltage 2004 Cummins Power GenerationSpecifications subject to change without noticeS-1468 (04 October 2004)
.regulation system is full wave rectified and has a SCRoutput for good motor starting capability. Major systemfeatures include: Low and High Battery Voltage Warning Indicates status of battery charging system(failure) by continuously monitoring batteryvoltage. Weak Battery Warning - The control system willtest the battery each time the generator set issignaled to start, and indicate a warning if thebattery indicates impending failure. Fail to Start (Overcrank) Shutdown This feature can be disabled to allow the use of anexternal voltage regulator.Fail to Crank Shutdown - Control has signaledstarter to crank engine but engine does not rotate. 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.Cranking Lockout - The control will not allow thestarter to attempt to engage or to crank the enginewhen the engine is rotating. Sensor Failure Indication - Logic is provided onthe base control to detect analog sensor orinterconnecting wiring failures.Digital Output Voltage Regulation - Power Command1301 will regulate output voltage to within plus or minus1.0% for any loads between no load and full load.Voltage drift will not exceed plus or minus 1.5% for a104ºF (40ºC) change in temperature in an 8 hourperiod. On engine starting, or sudden load acceptance,voltage is controlled to a maximum of 5% overshootover nominal level.Protective FunctionsOn operation of a protective function the control willindicate a fault by flashing the fault code on the statusLED on the base control board. On systems with anoptional display panel, the warning or shutdown LEDwill light and fault symbol, name, and code will beindicated. 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.PowerCommand provides the following systemprotective functions: Configurable Alarm and Status Inputs –PowerCommand 1301 will accept up to two 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.Emergency Stop - Annunciated whenever theemergency stop signal is received from externalswitch.Engine Protection Overspeed Shutdown - Default setting is 115%of nominal. Low Lube Oil Pressure Warning/Shutdown Level is preset (configurable with InPower) tomatch the capabilities of the engine used. Controlincludes time delays to prevent nuisanceshutdown signals. High Engine Temperature Warning/Shutdown Level is preset (configurable with InPower) tomatch the capabilities of the engine used. Controlincludes time delays to prevent nuisanceshutdown signals. Low Coolant Temperature Warning - Indicatesthat engine temperature may not be high enoughfor a 10-second start or proper load acceptance. 2004 Cummins Power GenerationAlternator Protection High/Low AC Voltage Shutdown - High defaultto 110% for 10 seconds, instantaneous 130%.Low default to 85% for 10 seconds Overcurrent Warning/Shutdown - Warningdefault to 110% for 60 seconds. Shutdown defaultto 150% for 10 seconds. Under/Over Frequency - Under default to -6Hzfor 10 seconds. Over default 6Hz for 10 seconds. Loss Of Sensing Voltage Shutdown Field Overload ShutdownEnvironmentThe control is designed for proper operation withoutrecalibration in ambient temperatures from –40 Deg Cto 70 Deg C, and for storage from –55Deg C to 80Deg C. Control will operate with humidity up to 95%,non-condensing.The optional display panel is designed for properoperation in ambient temperatures from –20 Deg C to 70 Deg C, and for storage from –30 Deg C to 80 DegCThe control board is fully encapsulated to providesuperior resistance to dust and moisture. The optionaldisplay panel 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 mountedon a generator set. The control includes transientvoltage surge suppression to provide compliance toreferenced standards.CertificationsPowerCommand meets or exceeds the requirementsof the following codes and standards:Specifications subject to change without noticeS-1468 (04 October 2004)
. NFPA110 for Level 2 or 3 systems. Remote Start Signal ISO 8528-4: 1993 Compliance, Controls andSwitchgear Remote Emergency Stop CE Marking: The control system is suitable foruse on generator sets to be CE-marked. EN 50081-1,2 Residential/Light Industrialemissions, or Industrial EmissionsConfigurable Inputs - Control includes (2) inputsignals from customer discrete devices that areconfigurable for warning, shutdown, or statusindication, as well as message displayed. EN 50082-1,2 Residential/Light Industrial orIndustrial susceptibility ISO 7637-2, level 2; DC supply surge voltage test. Mil Std 202C, Method 101 and ASTM B117: SaltFog testPowerCommand control systems and generator setsare designed and manufactured in ISO9001 certifiedfacilities. The control is suitable for use on generatorsets that are UL 2200 listed.Output signals from the PowerCommand controlinclude: Configurable relay outputs - Control includes(2) relay outputs rated at 2 amps. These outputscan configured to activate on any control warningor shutdown fault as well as ready to load, not inauto, common alarm, common warning, andcommon shutdown. Ready to Load (generator set running) signal Operates when the generators set has reached90% of rated speed and voltage and latches untilgenerator set is switched to off or idle mode. (B signal output).SoftwareInPowerInPower (beyond 4.5 version) is a PC-based softwareservice tool that is designed to directly communicate toPowerCommand generator sets and transferswitches, to facilitate service and monitoring of theseproducts.Communications connections include: PowerCommand for WindowsPowerCommand for Windows is a software tool thatis used primarily by operators to remotely monitor andcontrol generator sets, transfer switches, and other onsite power system devices.Control InterfaceInput signals to the base control include: Run/Off/Auto Switch - Required when theoptional display panel is not used. Generator Set Status Lamp 2004 Cummins Power GenerationPC Tool Interface - This RS-485 communicationport is to allow the control to communicate with apersonal computer running InPower orPowerCommand for Windows software. Alsothis RS-485 port is to allow the control tocommunicate with external devices like PLC onMODBUS protocol.Note – A RS-232 to RS-485 Converter is requiredfor communication between PC to Control. Networking - This RS-485 communication port isto allow connection from the control to the otherCummins Power Generation products.Options and AccessoriesDisplay Panel - Provides a local or remote operatordisplay of engine and alternator. Includes set up andgenerator set history information.Specifications subject to change without noticeS-1468 (04 October 2004)
.Mechanical Drawings33.5 (1.32)224 (8.82)141 (5.56)PowerCommand111 (4.38)BASIC CONTROL BOARD149 (5.88)OPERATOR PANELDimensions: mm (inches)65 (2.56)100 (3.94)GOVERNOR POWERSTAGE75 (2.95)38 (1.50) 2004 Cummins Power GenerationSpecifications subject to change without noticeS-1468 (04 October 2004)
.Electrical InterconnectionsFuelActuatorMAG PICKUPOIL PRESS SWOR SENDERTEMP SENDERK5DC ALTERNATORSTARTER DISCK4RELAY COIL B OPT. EXT.STARTEROPT. EXT FUELSHUTOFFRUN/OFF/AUTO SWGLOW PLUG SOLSTATUSLAMPALTERNATORGov PowerStageP1K6CHASSISGNDBatteryP13P11OPTIONAL OPERATOR PANELRECONNECTIONBLOCKPOWERCOMMAND 1301P12543Wake-upRS485 - BRS485 - A211615141312111098765TB2B GndREMOTE E-STOPFAULT IN #1FAULT IN #2REMOTE STARTCONFIGURABLEOUTPUTS4321TB1READY TO LOADTOOPERATORPANELP1CT1MODBUS \SERVICETOOL PORT 2004 Cummins Power GenerationSpecifications subject to change without noticeCT2CT3TO CUSTOMERLOADSS-1468 (04 October 2004)
.WarrantyAll components and subsystems are covered by an express limited one-year warranty. Other optional and extended factorywarranties and local distributor maintenance agreements are available. Contact your distributor/dealer for more information.CertificationsISO9001 - This product set was designed and manufactured in facilities certified to ISO9001.PTS - The Prototype Test Support (PTS) program verifies the performance integrity of a generator setdesign. Products bearing the PTS symbol have been subjected to demanding tests in accordance toNFPA 110 to verify the design integrity and performance under both normal and abnormal operatingconditions.UL - The control is suitable for use on generator sets that are listed to UL2200, Stationary EngineGenerator Assemblies.CE - This product is suitable for use on generator sets that are CE marked.See your distributor for more informationCummins Power Generation1400 73rd Avenue N.E.Minneapolis, MN 55432763.574.5000Fax: 763.574.5298www.cumminspowergeneration.comCummins and PowerCommand are registered trademarks of Cummins Inc.InPower and AmpSentry are trademarks of Cummins Inc.Important: Backfeed to a utility system can cause electrocution and/or property damage. Do not connect generator sets to anybuilding electrical system except through an approved device or after building main switch is open. 2004 Cummins Power GenerationSpecifications subject to change without noticeS-1468 (04 October 2004)
Digital Generator Set Control Description The PowerCommand (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, start / stop control, 12V/24V battery operation and .
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