GenSet Controls

PowerCommand
Digital Generator Set Control
with Paralleling & Power Transfer

PowerCommand Operator Panel, including

graphical display and analog AC metering.

Description Features
The control offers a wide range of standard control and
The PowerCommand™ Control (3201) is a
digital display features so custom control configurations
microprocessor-based generator set monitoring, metering,
are not needed to meet application specifications.
and control system. The control provides an operator
System reliability is not compromised by use of untested
interface to the genset, digital voltage regulation, digital
special components.
governing, generator set protective functions, and
automatic power transfer functions. The integration of all
the functions into a single control system provides Major Control Features Include:
enhanced reliability and performance compared to • Digital Full Authority Electronic Engine Controls
conventional control systems. for Cummins HPI-PT fuel system, including engine
monitoring and protection, and governing. These
PowerCommand generator set controls are suitable for functions are integrated with voltage regulation, and
use on generator set ranging in size from roughly 20kW to paralleling functions for optimum system
4000 kW. They will directly read AC voltages up to performance.
600VAC, and can be configured for any frequency, • Digital Voltage Regulation
voltage, and power connection configuration from 120- • AmpSentry™ Protection for true alternator
13,800VAC. overcurrent protection.
• Digital Power Transfer Controls, including operation
The PowerCommand control is designed for mounting on in open transition, closed transition, or soft (ramping)
the generator set. The operator panel may also be transfer modes.
remote-mounted from the generator set, and connected • Analog and Digital AC Output Metering.
via an RS485 network connection. • Battery Monitoring System to sense and warn
against a weak battery condition.
Control power for PowerCommand is usually derived from
• Digital Alarm and Status Message Display
the generator set starting batteries. The control functions
• Generator set Monitoring: Displays status of all
over a voltage range from 8VDC to 35VDC.
critical engine and alternator generator set functions.
• Smart Starting Control System: Integrated fuel
ramping to limit black smoke and frequency
overshoot, in addition to optimized cold weather
starting.
• Advanced Serviceability using InPower, a PC-based
software service tool.
• PowerCommand Network (optional).
• Warranty. PowerCommand Controls are supported
by a worldwide network of independent distributors
who provide parts, certified service and warranty
support.

© 2004-2005 Cummins Power Generation Specifications Subject to Change S-1444c (5/05)

 the operator to reset the fault condition. If the fault
Operator Panel condition is not corrected, the fault will reappear, but
will not be logged as a separate event. Multiple
The operator panel provides the user with a complete faults can be logged and displayed at one time.
package of easy to view and use information. It includes ƒ EMERGENCY STOP Control Switch
an enhanced graphical operator panel that allows the user ƒ Operator Adjustments - The control includes
to view up to 9 lines of information, as well as graphical provisions for many set up and adjustment functions
displays of system data. Connections to the operator via raise/lower switches on the operator panel.
panel are sealed locking plug interfaces, for reliable, Functions that can be adjusted by the operator
vibration-resistant interconnection to the generator set include:
wiring harness. Time delay start (0-300 seconds)
Time delay stop (0-600 seconds)
Control Switches and Functions Alternator voltage (plus or minus 5%)
Alternator frequency (plus or minus 3 hertz).
The operator panel can be configured to require an
access code prior to adjusting these values. A
second access code is used to protect the control
from unauthorized service level adjustments.
Voltage and frequency adjustments are disabled
during operation in parallel with a system bus to
prevent inadvertent misadjustment of the paralleling
load sharing functions.

ƒ OFF/MANUAL/AUTO Mode Control Switch - The

NOT IN AUTO lamp will flash when the control is in
the MANUAL or OFF mode. In the AUTO mode, the PowerCommand Analog AC Metering Display
generator set can be started using the exercise push-
button, or with a start signal from a remote device,
such as automatic transfer switches. Analog AC Metering Panel
ƒ MANUAL RUN/STOP Control Switch And
The PowerCommand control is equipped with an analog
Indicating LED - When the mode control switch is in
AC metering panel that simultaneously displays 3-phase
the MANUAL position and the MANUAL RUN /STOP
line to line AC volts and current, kW, power factor, and
switch is pressed, the Generator set will start,
frequency.
bypassing all time delay start. (Time delay idle can
also be bypassed with another control action.) If the
The meter panel is composed of a series of LED’s
generator set is running in the MANUAL mode,
configured in bar graphs for each function. The LED’s are
pressing the RUN/STOP switch will cause the
color coded, with green indicating normal range values,
generator set to shut down. An LED (light emitting
amber for warning levels, and red for shutdown
diode) lamp adjacent to the switch will light to
conditions. Scales for each function are in % of nominal
indicate the generator set is in manual mode.
rated values. Resolution is 1% for values close to
ƒ EXERCISE Control Switch And Indicating LED -
nominal, and increases at increasing values from nominal.
When the mode control switch is in the AUTO mode
the EXERCISE control switch is used to complete a
pre-programmed exercise sequence. All exercise
functions are disabled when an emergency start
command is received by the control. An LED lamp
adjacent to the switch will light to indicate the
generator set is in exercise mode.
ƒ PANEL LAMP/LAMP TEST Control Switch
ƒ FAULT ACKNOWLEDGE/RESET Switch – The
control includes a fault acknowledge function to allow
© 2004-2005 Cummins Power Generation Specifications Subject to Change S-1444c (5/05)
 operating hours on the generator set, and also on the
loads on the generator set since reset.
ƒ Generator Set Output Voltage - all phases, line to
line and line to neutral, accuracy 1%.
ƒ Generator Set Output Current - all phases,
accuracy 1%.
ƒ Generator Set Output Frequency
ƒ Generator Set Power Output - PowerCommand
displays generator set kW and kVA output (average
and individual phase, and direction of flow), and
power factor with leading/lagging indication.
Accuracy 5%.
ƒ Generator Set kWh Power Output - Displays total
kilowatt-hours produced by the generator set, and
Graphical Display Panel total produced since last reset, with time stamp of
time of last reset.
The PowerCommand control is provided with a graphical ƒ Digital Synchroscope - Panel displays bus voltage
display capable of displaying up to 9 lines of data with and frequency, generator set bus voltage and
approximately 27 characters per line. The graphical frequency, the phase angle displacement, and
display is accompanied by a set of six tactile feel provides a signal when the generator is ready to
membrane switches that are used by the operator to close to the bus. A breaker control switch is included
navigate through control menus, and to make control on this panel for convenient operation of the
adjustments. Display is configurable for multiple equipment without switching between viewing
languages. It is configurable for units of measurement. screens.
The display incorporates three levels of operation and ƒ Basic Engine Data - Engine Starting Battery
adjustability. All data on the control can be viewed by Voltage, Engine Lube Oil Pressure, Engine Coolant
scrolling through screens with the navigation keys. The Temperature
top three lines of the display are allocated to mode and ƒ Engine Service Data - Engine Coolant Pressure
status messages that continuously display the operating Engine Fuel Rail Temperature and Pressure, Engine
mode of the control system, as well as any faults or Fuel Input And Output Temperature, Intake Manifold
warning conditions that may be present on the controller. Temperature And Pressure, Ambient Air Pressure,
If more than one fault or warning message is present the Crankcase Blowby Flow, Aftercooler Inlet Coolant
messages will scroll to allow the operator to view all active Temperature
messages in the system. ƒ Engine Fuel Consumption - The fuel consumed by
the engine is determined by algorithms based on
ƒ Generator Set Hardware Data - Generator set parameters monitored by the fuel system. Accuracy
rating in kVA, complete Generator set model number is + 5% for load levels over 30% of standby rating.
and serial number, engine model and serial number, Data provided includes overall average fuel
and alternator model and serial number. The control consumed, consumption since reset. This information
also displays the part number of the control and the is read with InPower.
software version present in the control. ƒ Engine Exhaust Temperature (optional)
• Data Logs - Number of start attempts and number of ƒ Utility (Mains) Source Data – Displays line to line
start attempts since reset. Number of times and line to neutral voltage of utility (mains) source,
generator set has run, and number of times since frequency, and estimated amps, kW, and kVA
reset. Duration of generator set running time, and supplied by utility (mains) source.
duration of running time since last reset. Generator ƒ System Status Information – Provides graphical
set kWh produced, and kWh produced since last system status display showing availability of sources
reset. and positions of each contactor.
ƒ Adjustment History - Provides a record of ƒ System Control – Allows operator to view status of
adjustment and setting changes made on the control, system, and manually control operation of the
and identifies whether adjustment was made via the system. Provides manual adjustment capability for
operator panel or with a service tool. If a service tool time delay start, stop, transfer, and retransfer, as well
is used, the control provides a record of the serial as time delays for program transition (when used)
number of the tool used. This information is read and power transfer overlap time.
with InPower.
ƒ Fault History - Provides a record of the most recent
fault conditions with time stamp, along with the
number of times each fault has occurred. At least 20
events are stored in the control memory.
ƒ Load Profile Data - Provides data indicating the
operating hours at percent of load, in 10%
increments. The data is presented based on total
© 2004-2005 Cummins Power Generation Specifications Subject to Change S-1444c (5/05)
Internal Control Functions Synchronizer - PowerCommand incorporates a digital
synchronizing function to force the generator set to match
the phase relationship and voltage of the generator set
General Functions output with the utility grid. The synchronizer includes
Emergency Start Mode - PowerCommand accepts a provisions to provide proper operation even with highly
ground signal from remote devices or a network signal to distorted bus voltage waveforms. The synchronizer
automatically start the generator set and immediately operates over a range of 60-110% of nominal voltage and
accelerate to rated speed and voltage. frequency, and includes adjustments for phase angle
window (5-20 degrees) and time delay (0.5-5 seconds).
PowerCommand includes a Smart StartingTM system, that
is designed to quickly start the engine, minimize black Load Govern Mode - When PowerCommand receives a
smoke, and minimize voltage and frequency overshoot signal indicating that the generator set is paralleled with
and oscillations on starting. The control system does this an infinite source, such as a utility (mains) service, the
by careful simultaneous control of the engine fuel system generator set will operate in load govern mode. In this
and alternator excitation system. mode, the generator set will synchronize and close to the
bus, and ramp to a pre-programmed kW and kVar load
Non-Emergency Start Mode - The control is provided level, and then operate at that point. Control is adjustable
with a separate remote start input or a network signal to for kW values from 0-100% of standby rating, and 0.7-1.0
start the generator set via the programmable idle control. power factor (leading). Default setting is 80% of standby
Using the non-emergency mode, the generator set takes and 1.0 power factor. The control includes inputs to allow
longer to start, but there is less wear on the engine. In independent control of kW and kVar load sharing level by
this start mode, the generator set will start, operate at idle a remote device while in the load govern mode. The rate
speed for a predefined time period or until the engine of load increase and decrease is also adjustable in the
reaches operating temperature (whichever is time is control.
shorter), and then ramp to rated speed and voltage. Time
delay is adjustable from 0-300 seconds, and default is 10 Engine Control
seconds. The control also monitors and records the ƒ Engine Starting - The control operates a factory-
source of start signals, when that information is available. supplied fuel valve that enables engine starting.
The control automatically exits idle mode if an emergency ƒ Cycle Cranking - Configurable for number of starting
remote start signal is received at the control. cycles (1 to 7) and duration of crank and rest periods.
Screen-Saver Mode - PowerCommand can be Control includes starter protection algorithms to
programmed to automatically switch off the operator panel prevent the operator from specifying a starting
displays to reduce battery voltage drain when the control sequence that might be damaging. Default setting is
is not being used and the generator set is not running. for (3) start cycles composed of 15 seconds of
Depressing any button on the operator panel, new fault cranking, and 15 seconds of rest.
conditions or receipt of a remote signal at the control will ƒ Programmable Idle Speed Control - In this mode
“wake up” the control. the generator set would start and run to idle speed.
Data Logging - The control maintains a record of manual It would operate at that speed for a programmed time
control operations, warning and shutdown conditions, and period, then ramp to rated speed. When the control
other events. It uses the control “ON” time as the time gets a signal to stop, it will ramp to idle, operate for
stamp means when a real time clock is not included with the programmed period at idle, and then shut down.
the control. The control also stores critical engine and During idle mode engine protective functions are
alternator data before and after a fault occurs, for use by adjusted for the lower engine speed, and alternator
InPower and the technician in evaluating the root causes function is disabled.
for the fault condition. ƒ Time Delay Start And Stop (cooldown) -
Configurable for time delay of 0-300 seconds prior to
Fault Simulation Mode - PowerCommand, in conjunction starting after receiving a remote start signal, and for
with InPower software, will accept commands to allow a time delay of 0-600 seconds prior to ramp to idle or
technician to verify the proper operation of all protective shut down after signal to stop in normal operation
functions of the control, by simulating failure modes or by modes. The generator set control will monitor the
forcing the control to operate outside of its normal load during operation of the generator set, and if the
operating ranges. InPower also provides a complete list total load on the set is less than 10% of rated, it will
of faults and settings for the protective functions of the reduce the operation time for the time delay stop to
specific generator set it is communicating with. prevent extended operation of the engine at very light
load levels. Default for both time delay periods is 0
Built In Test - The control system automatically tests seconds.
itself, and all the sensors, actuators and harnesses in the
control system on a startup signal. The test can also be
initiated from InPower, and can be accomplished either
local to the generator set or remotely.

© 2004-2005 Cummins Power Generation Specifications Subject to Change S-1444c (5/05)

Engine Governing On a shutdown condition, the control will light the
shutdown LED on the control panel, display the fault
ƒ Isochronous Governing - Controls engine speed
name and code, and initiate shut down and lock out the
within plus or minus 0.25% for any steady state load
generator set. The shutdown sequence of the generator
from no load to full load. Frequency drift will not
set includes programmable cooldown at idle for fault
exceed plus or minus 0.5% for a 60F (33C) change
conditions that do not endanger the engine. The control
in ambient temperature over an 8 hour period.
maintains a data log of all fault conditions as they occur,
ƒ Droop Governing - Control can be adjusted to droop
and time stamps them with the controller run time and
from 0 to 10% from no load to full load, using
engine operating hours data. Adjustments to most set
InPower.
points are made using the InPowerTM service tool.
ƒ Temperature Dynamics - Modifies the engine fuel
system control parameters as a function of engine
The control system includes a “fault bypass” mode that
temperature. Allows engine to be more responsive
forces the system to function regardless of the status of
when warm, and more stable when operating at
protective functions. In this mode the only protective
lower temperature levels.
functions that are operational are Overspeed, loss of both
ƒ Isochronous Load Sharing Control – see General
speed sensors, or moving the control switch to the off
Functions.
position, or pressing the EMERGENCY STOP switch.
ƒ Droop Load Sharing Control– see General
The control maintains a record of the time that the mode
Functions.
is enabled, and all warning or shutdown conditions that
ƒ Idle Mode - Engine governing can be regulated at an
have occurred while in the “fault bypass” mode.
idle speed for a programmed period on start or stop
of the engine. When the engine is operating at idle
Many protective functions within the control system are
speed, the alternator excitation is automatically
configurable for warning, shutdown, or both (2 levels).
switched off.
Exceptions to this include functions such as overspeed
conditions, and loss of speed sensing. In addition, some
Alternator Control warning functions can incorporate control functions as a
ƒ Digital Output Voltage Regulation - consequence of a fault.
PowerCommand will regulate output voltage to within PowerCommand provides the following system protective
0.5% for any loads between no load and full load. functions:
Voltage drift will not exceed plus or minus 0.5% for a
60F (33C) change in temperature in an 8 hour ƒ Ground Fault Warning (option- 600VAC class
period. On engine starting, or sudden load generator sets) - Ground (Earth) fault sensing is
acceptance, voltage is controlled to a maximum of adjustable over a range of 100-1200 amps, with time
5% overshoot over nominal level. delays of 0-1 second. May be configured for
ƒ Torque-Matched Volts/Hz Overload Control - The shutdown rather than alarm.
voltage roll-off set point and rate of decay (i.e., the ƒ Configurable Alarm And Status Inputs -
slope of the volts/hertz curve) is adjustable in the PowerCommand will accept up to four alarm or
control. This function is automatically disabled when status inputs (contact closed to ground) to indicate
the control is in a synchronizing mode. customer-specified conditions. The control is
ƒ Fault Current Regulation - PowerCommand will programmable for warning, shutdown or status
regulate the output current on any phase to a indication, and for labeling the input (up to 24
maximum of 3 times rated current under fault characters). Four additional faults can be input to the
conditions for both single phase and three phase control via the network.
faults. In conjunction with a permanent magnet ƒ Breaker Fail To Close And Breaker Auxiliary
generator, it will provide 3 times rated current on all Contact Warning Or Shutdown - When the
phases for motor starting and short circuit paralleling control signals a circuit breaker to close, it
coordination purposes. will monitor the breaker auxiliary contacts and verify
ƒ Isochronous (kVar) Load Sharing Control – see that the breaker has connected the generator set to
General Functions. the system bus. If the control does not sense a
ƒ Droop (kVar) Load Sharing Control – see General breaker closure within 1 second of the close signal,
Functions. the control will monitor the phase relationship
between the generator set and the bus. If this
Protective Functions indicates that the generator set is not closed to the
bus, the Breaker Fail to Close alarm will be indicated,
On a warning condition the control will indicate a fault by
the breaker will be opened, and the generator set
lighting the warning LED on the control panel, and
shut down. If the phase relationship monitor
displaying the fault name and code on the operator
indicates that the generator set is in parallel with the
display panel. The nature of the fault and time of
bus, the Breaker Auxiliary Contact Failure will be
occurrence are logged in the control. The service manual
indicated, and the generator set will continue to run
and InPower service tool provide service keys and
in normal operation mode.
procedures based on the service codes provided.
© 2004-2005 Cummins Power Generation Specifications Subject to Change S-1444c (5/05)
ƒ Breaker Fail To Open Warning - The control ƒ Over Current Shutdown (51) - Output current on
system monitors the operation of breakers that have any phase is more than 110%, less than 175% of
been signaled to open. If the breaker does not open rating, and approaching thermal damage point of
within 1 second of initiation of signal, a Breaker Fail alternator. Control includes algorithms to protect
to Open warning is initiated. The control will logically alternator from repeated over current conditions over
allow the generator set to continue to run if shutdown a short period of time.
of the generator set with the breaker closed will ƒ Short Circuit Shutdown (51V) -Output current on
cause potential damage or operating problems. any phase is more than 110%, more than 175% of
ƒ Bus Or Generator Set PT Input Calibration Error - rating, and approaching thermal damage point of
The control system monitors the sensed voltage from alternator. Control includes algorithms to protect
the bus and generator set output voltage potential alternator from repeated over current conditions over
transformers, and will indicate a warning condition a short period of time.
when they read different values when the paralleling ƒ High AC Voltage Shutdown (59) - Output voltage
breaker is closed. on any phase exceeds preset values. Time to trip is
ƒ Emergency Stop - Annunciated whenever the local inversely proportional to amount above threshold.
or remote emergency stop signal is received. Alarm Values adjustable from 105-125% of nominal
panel distinguishes between local or remote voltage, with time delay adjustable from 0.25-10
operation. seconds. Default value is 110% for 10 seconds.
ƒ Low AC Voltage Shutdown (27) - Voltage on any
phase has dropped below a preset value. Adjustable
over a range of 50-95% of reference voltage, time
delay 2-10 seconds. Default value is 85% for 10
ALTERNATOR seconds. Function tracks reference voltage. Control
THERMAL does not nuisance trip when voltage varies due to the
DAMAGE control directing voltage to drop, such as during a
CURVE voltage roll-off during synchronizing.
ƒ Under Frequency Shutdown (81u) - Generator set
output frequency cannot be maintained. Settings are
AMPSENTRY adjustable from 0-10 hertz below nominal governor
10 OVERCURRENT set point, for a 0-20 second time delay. Default: 6Hz,
PROTECTION 10 seconds. Under frequency protection is disabled
Second CURVE when excitation is switched off (such as when engine
s is operating in idle speed mode or the synchronizer is
1 enabled).
ƒ Over Frequency Shutdown/Warning (81o) -
Generator set is operating at a potentially damaging
frequency level. Defaults: Disabled.
ƒ Over Load (kW) Warning - Provides a warning
indication when engine is operating at a load level
over a set point. Adjustment range: 80-140% of
0.03 rated kW, 0-120 second delay. Defaults: 105%, 60
seconds.
ƒ Reverse Power Shutdown (32) - Adjustment range:
5-20% of standby kW rating, delay 1-15 seconds.
1 10 Amps ( x rated) Defaults: 10%, 3 seconds.
ƒ Sync Check (25) - Verifies that the generator set is
operating in synchronism with the system bus prior to
AmpSentryTM allowing the paralleling breaker to close. Includes
AmpSentry is a comprehensive monitoring and control dead bus sensing capability.
system integral to the PowerCommand control that guards ƒ Fail To Synchronize Warning Or Shutdown -
the electrical integrity of the alternator and power system Indicates that the generator set could not be brought
by providing protection against a wide array of fault to synchronization with the system bus. Configurable
conditions in the generator set or in the load. It also for warning or shutdown, and adjustable for time
provides single and 3-phase fault current regulation, so delay of 10-120 seconds. Default is 120 seconds.
that downstream protective devices have the maximum ƒ Phase Sequence Sensing Shutdown - Verifies that
current available to quickly clear fault conditions, without the generator set phase sequence matches the bus
subjecting the alternator to potentially catastrophic failure prior to allowing the paralleling breaker to close. The
conditions. Functions included: generator set will shutdown if the generator set and
ƒ Over Current Warning - Output current on any bus phase sequence does not match.
phase at more than 110% of rating for more than 60 ƒ Reverse Var Shutdown - Shutdown level is
seconds. adjustable: 15-50% of rated Var output, delay 10-60
seconds. Defaults: 20%, 10 seconds.
© 2004-2005 Cummins Power Generation Specifications Subject to Change S-1444c (5/05)
ƒ High Alternator Temperature (Option) • 3-phase (line to neutral) close differential under
voltage sensing for utility (mains) service. Sensing for
Engine Protection pickup in an adjustable range from 85-100% of
nominal, with default at 95% of dropout setting.
ƒ Overspeed Shutdown - Default setting is 115% of
Dropout is configurable 75-98% of pickup, with default
nominal.
at 85%.
ƒ Low Lube Oil Pressure Shutdown - Level is preset
to match the capabilities of each engine. Control • 3-phase over voltage sensing for normal utility service
includes time delays to prevent nuisance shutdown adjustable for pickup at 95-105% of dropout, and
signals. dropout configurable for 105-135% of nominal. Time
ƒ Low Lube Oil Pressure Warning - Level is preset to delay is adjustable in a range of 0.5-120 seconds.
match the capabilities of each engine. Control Default is disabled, and is enabled using InPower.
includes time delays to prevent nuisance shutdown
• Under frequency sensing for normal utility service.
signals.
Adjustment range is 80-95% of nominal. Default is
ƒ High Coolant Temperature Shutdown
disabled, and is enabled using InPower.
ƒ High Coolant Temperature Warning
ƒ Low Coolant Pressure Warning/Shutdown • Configurable sequence of operation with or without
ƒ Low Coolant Level Warning/Shutdown adjustable program-transition capability. Adjustment
ƒ Low Coolant Temperature Warning. Indicates that range is 0-60 seconds.
engine temperature may not be high enough for a 10
• Remote Exercise feature. Accepts a remote signal to
second start or proper load pickup.
initiate with or without load testing; or testing can be
ƒ Low and High Battery Voltage Warning - Indicates
initiated by the operator. Test sequence may include
battery charging system failure by continuously
a programmed idle period prior to acceleration to
monitoring battery voltage and indicating a problem
rated voltage and frequency and after cooldown. Test
when voltage is outside a preset acceptance band.
may be configured to be performed with load or
ƒ Discharged Battery Protection. When DC voltage
without load.
is below a preset threshold the control will shut down
to avoid completely discharging the battery. • Time delays: time delay start and stop as described in
ƒ Weak Battery Warning - The control system will test this document; time delay transfer adjustable in a
the battery bank each time the generator set is range of 0-120 seconds, and retransfer in a range of
signaled to start, and indicate a warning if the 0-1800 seconds; all in 1-second increments.
generator set battery indicates impending failure.
• Fail to disconnect timer. The control includes a fail to
ƒ Fail to Start (Overcrank) Shutdown
disconnect timer that is adjustable in a range of 0.1 to
ƒ Fail to Crank Shutdown - Control has signaled
120 seconds.
starter to crank engine but engine does not rotate.
ƒ Redundant Starter Disconnect
ƒ Redundant Speed Sensors - Loss of one sensor Control Interface
results in a Mag Pickup sensor warning. Loss of
both sensors results in Mag Pickup Failure. Input signals to the PowerCommand control include:
ƒ Low Fuel-Day Tank and Low Fuel-Main Tank ƒ Remote Start signal. May be connected via either
warning. discrete signal or Lon network, or both for premium
ƒ Cranking Lockout. The control will not allow the reliability. Discrete signal is normally open contact to
starter to attempt to engage or to crank the engine ground, or normally closed contact that opens to
when the engine is rotating. indicate start signal. Separate signal inputs available
ƒ Sensor Failure Indication. All analog sensors are for emergency start and non-emergency start.
provided with sensor failure logic to indicate if the ƒ Remote Emergency Stop
sensor or interconnecting wiring has failed. Separate ƒ Configurable Customer Inputs. Control includes
indication is provided for fail high or low. provisions for (4) input signals from customer
ƒ High Crankcase Blowby Level Warning discrete devices.
ƒ High Fuel Temperature Warning ƒ Low Main or Daytank Fuel Level warning.
ƒ High Intake Manifold Temperature/Pressure ƒ Remote Alarm Reset.
ƒ Aftercooler Cooler Inlet Over Temperature ƒ Load Demand Stop.
ƒ Utility Parallel (Load Govern) Mode command.
Power Transfer Control
Output signals from the control include:
The Power Transfer Control feature allows ƒ Generator Set Running signal. Fused normally
PowerCommand to provide integrated automatic power open contact rated 5A @ 30VDC/180VAC, closes to
transfer functions including source availability sensing and indicate generator set is running.
transfer device monitoring and control. The control is ƒ Generator Set Common Shutdown signal. Self-
configurable for open transition, fast (100 mS) transfer, or protected relay driver.
soft (ramping) sequences of operation. Standard ƒ Load Shed signal. Self-protected relay driver.
functions include: Operation is configurable for under frequency or over
kW load, or both. Adjustment range is 80-140% of
© 2004-2005 Cummins Power Generation Specifications Subject to Change S-1444c (5/05)
 standby rating, with time delay of 0-120 seconds. moisture, oil, and exhaust fumes. The panel uses sealed
Default settings are: overload: 105%, 60 sec; under membrane or oil-tight switches to provide long reliable
frequency: 3 Hz below governor reference for 3 service life in harsh environments.
seconds.
ƒ Ready to Load signal. Self-protected relay driver. The control system is specifically designed for resistance
Operates when the generators sets has reached to RFI/EMI, and to resist the effects of vibration to provide
90% of rated speed and voltage and latches until a long reliable life when mounted on a generator set. The
generator set is switched to off or idle mode. control includes transient voltage surge suppression to
ƒ Modem Control signal. Self-protected relay driver. provide compliance to referenced standards.
ƒ Paralleling Breaker Interface. Fused normally open
relay contact (5A, 30Vdc/180Vac) for parallel breaker Software
close signal, and normally open contact for parallel
breaker open signal.
InPower
Control power for auxiliary devices is available from the InPower is a PC-based software service tool that is
controller. designed to directly communicate to PowerCommand
generator sets and transfer switches to facilitate service
Network connections include: and monitoring of these products.
ƒ Serial Interface. This communication port is to allow
the control to communicate with a personal computer PowerCommand for Windows
running InPower service and maintenance software.
ƒ Echelon LonWorks Interface (Option). PowerCommand for Windows is a software tool that is
PowerCommand generator sets incorporating this used to remotely monitor and control generator sets,
option are LonMarkTM compliant. transfer switches, and other on-site power system
devices.
Certifications
PowerCommand meets or exceeds the requirements of
the following codes and standards:
ƒ NFPA110 for level 1 systems.
ƒ UL508 Listed, Category NIWT7 for US and Canada.
ƒ CSA C282-M1999 Compliance
ƒ CSA 22.2 No. 14 M91 Industrial Controls.
ƒ ISO 8528-4: 1993 Compliance, Controls and
Switchgear
ƒ NFPA99: Standard for Health Care Facilities
ƒ CE Marking
ƒ EN 50081-1 Residential, commercial, light industrial
ƒ EN 50081-2 Industrial
ƒ EN 50082-1 Residential, commercial, light industrial
ƒ EN 50082-2 Industrial
ƒ ISO 7637, pulses #2b, 4; DC supply surge voltage
test.
ƒ Mil Std 202C, Method 101 Salt Fog test
ƒ ANSI C62.41 Surge Withstand
ƒ Mil Std 461
ƒ IEC 801.2, 3, 4, 5
ƒ IEEE 587
PowerCommand control systems and generator sets are
designed and manufactured in ISO9001 certified facilities.

Environment
The control is designed for proper operation without
recalibration in ambient temperatures from –40C to +70C,
and for storage from –40C to +80C. Control will operate
with humidity up to 95%, non-condensing, and at altitudes
up to 13,000 feet (5000 meters).

The operator control panel is a NEMA 3R/IP53 enclosure.

The operator control panel has a single membrane
surface, which is impervious to the effects of dust,
© 2004-2005 Cummins Power Generation Specifications Subject to Change S-1444c (5/05)
Options and Accessories ‰ Closed Transition (Ramping) Power Transfer
Control. Control will operate two circuit breakers to
‰ Key-type Mode Select Switch. provide power transfer between a normal source and
‰ Ground Fault Alarm Module. generator in a “make before break” sequence
‰ Utility Protective Relaying. Gensets can be between live sources, and “break before make” from a
provided with power switching mechanisms and utility failed source. Overlap time between sources is
grade protective relaying to meet local grid protection configurable, and control ramps load from source to
requirements. source to minimize disturbances on transfer.
‰ Isolated Bus Paralleling. Provides all automatic and ‰ Exhaust Temperature Monitoring
manual paralleling functions for systems that operate ‰ Alternator Temperature Monitoring
isolated from the utility service. ‰ Digital Remote Annunciator
‰ Full Function Paralleling. Provides all paralleling ‰ Digital Output Relay Module
functions, including automatic and manual operation,
‰ ILSI (Isochronous Load Sharing Interface). Allows
protection, and other features described in this
PowerCommand to share real load with other load
document.
sharing systems that incorporate analog load sharing
‰ Open Transition Power Transfer Control. Control lines.
will operate two circuit breakers to provide power
transfer between a normal source and a generator in
a “break before make” sequence. Warranty
‰ Fast Closed Transition Power Transfer Control. PowerCommand control systems are a part of complete
Control will operate two circuit breakers to provide power systems provided by Cummins Onan, and are
power transfer between a normal source and covered by a one-year limited warranty as a standard
generator in a “make before break” sequence feature.
between live sources, and “break before make” from a
failed source. Overlap between sources is 100mS or Extended warranty options are available for coverage up
less. to 10 years.

See your distributor for more information

Cummins Power Generation

1400 73rd Avenue N.E.
Minneapolis, MN 55432
763.574.5000
Fax: 763.574.5298

Cummins Power Generation is a subsidiary of Cummins Inc.

PowerCommand is a registered trademark of Cummins Inc.
AmpSentry is a trademark of Cummins Inc.
Windows is a registered trademark of Microsoft.
LONWORKS AND LONMARK are registered trademarks of Echelon

Warning: Backfeed to a utility system can cause electrocution and/or property damage. Do not connect to any building's electrical system
except through an approved device or after building main switch is open.

© 2004-2005 Cummins Power Generation Specifications Subject to Change S-1444c (5/05)