PowerCommand® 1.1 control system - Power Suite
Contents
1. 2014 Cummins Power Generation Inc All rights reserved Cummins Power Generation and Cummins are registered trademarks of Cummins Inc PowerCommand InPower and Our energy working for you are trademarks of Cummins Power Generation Other company product or service names may be trademarks or service marks of others Specifications are subject to change without notice S 1566d 1 14 Page 5 of 7 Communications connections include PC tool interface This RS 485 communication port allows the control to communicate with a personal computer running InPower or PowerCommand for Windows software Modbus RS 485 port Allows the control to communicate with external devices such as PLCs using Modbus protocol Note An RS 232 or USB to RS 485 converter is required for communication between PC and control Networking This RS 485 communication port allows connection from the control to the other Cummins Power Generation products Mechanical drawings a 224 8 82 gt 149 5 88 BASIC CONTROL BOARD lt 100 3 94 GOVERNOR POWER STAGE 75 2 95 Power _ Generation PowerCommand human machine interface HMI211 Description This control system includes an intuitive operator interface panel that allows for complete genset control as well as system metering fault annunciation configuration and diagnostics The interface includes five generator set status LED lamps with both internationally acc2. Generation Other company product or service names may be trademarks or service marks of others Specifications are subject to change without notice S 1566d 1 14 Page 6 of 7 Communications connections PC tool interface This RS 485 communication port allows the HMI to communicate with a personal computer running InPower This RS 485 communication port allows the HMI to communicate with the main control board Mechanical drawing 33 5 1 32 141 5 56 gt lt lt Q 111 4 38 HMI Dimensions mm inches Software InPower beyond 6 0 version is a PC based software service tool that is designed to directly communicate to PowerCommand generator sets and transfer switches to facilitate service and monitoring of these products Environment The control is designed for proper operation without recalibration in ambient temperatures from 40 C 40 F to 70 C 158 F and for storage from 55 C 67 F to 80 C 176 F Control will operate with humidity up to 95 non condensing The HMI is designed for proper operation in ambient temperatures from 40 C 40 F to 70 C 158 F and for storage from 40 C 40 F to 80 C 176 F The control board is fully encapsulated to provide superior resistance to dust and moisture Display panel has a single membrane surface which is impervious to effects of dust moisture oil and exhaust fumes This panel uses a sealed
3. Our energy working for you www cumminspower com 2014 Cummins Power Generation Inc All rights reserved Cummins Power Generation and Cummins are registered trademarks of Cummins Inc PowerCommand InPower and Our energy working for you are trademarks of Cummins Power Generation Other company product or service names may be trademarks or service marks of others Specifications are subject to change without notice S 1566d 1 14 Page 3 of 7 Time delay start and stop cooldown Configurable for time delay of 0 300 seconds prior to starting after receiving a remote start signal and for time delay of 0 600 seconds prior to shut down after signal to stop in normal operation modes Default for both time delay periods is 0 seconds Alternator control The control includes an integrated line to line sensing voltage regulation system that is compatible with shunt or PMG excitation systems The voltage regulation system is full wave rectified and has an SCR output for good motor starting capability Major system features include Digital output voltage regulation Capable of regulating output voltage to within 1 0 for any loads between no load and full load Voltage drift will not exceed 1 5 for a 40 C 104 F change in temperature in an eight hour period On engine starting or sudden load acceptance voltage is controlled to a maximum of 5 overshoot over nominal level The automatic voltage regulator feature
4. can be disabled to allow the use of an external voltage regulator Torque matched V Hz overload control The voltage roll off set point and rate of decay i e the slope of the V Hz curve is adjustable in the control Protective functions On operation of a protective function the control will indicate a fault by illuminating the appropriate status LED on the HMI as well as display the fault code and fault description on the LCD The nature of the fault and time of occurrence are logged in the control The service manual and InPower service tool provide service keys and procedures based on the service codes provided Protective functions include Battle short mode When enabled and the battle short switch is active the control will allow some shutdown faults to be bypassed If a bypassed shutdown fault occurs the fault code and description will still be annunciated but the genset will not shutdown This will be followed by a fail to shutdown fault Emergency stop shutdowns and others that are critical for proper operation are not bypassed Please refer to the Control Application Guide or Manual for list of these faults Configurable alarm and status inputs The control accepts up to four alarm or status inputs configurable contact closed to ground or open to indicate a configurable customer specified condition The control is programmable for warning shutdown or status indication and for labeling the input Power Ge
5. for you are trademarks of Cummins Power Generation Other company product or service names may be trademarks or service marks of others Specifications are subject to change without notice S 1566d 1 14 Page 2 of 7 e Supports dual fuel control e Automatic Mains Failure function built in generator set controller Modbus interface for interconnecting to customer equipment Configurable inputs and outputs Four discrete inputs and two dry contact relay outputs Warranty and service Backed by a comprehensive warranty and worldwide distributor service network Certifications Suitable for use on generator sets that are designed manufactured tested and certified to relevant UL NFPA ISO IEC Mil Std CE and CSA standards Base control functions HMI capability Operator adjustments The HMI includes provisions for many set up and adjustment functions Generator set hardware data Access to the control and software part number generator set rating in KVA and generator set model number is provided from the HMI or InPower Data logs Includes engine run time controller on time number of start attempts Fault history Provides a record of the most recent fault conditions with control hours time stamp Up to 10 events are stored in the control non volatile memory Alternator data Voltage single or three phase line to line and line to neutral Current single or three phase KVA three phase and tota
6. membrane to provide long reliable service life in harsh environments The control system is specifically designed and tested for resistance to RFI EMI and to resist effects of vibration to provide a long reliable life when mounted on a generator set The control includes transient voltage surge suppression to provide compliance to referenced standards Heater accessory pn AO40H853 is available for enhanced operation below 20 C Power on Generation Certifications Accessories PowerCommand meets or exceeds the requirements of 1301 1302 Upgrade Kit HM 0541 1431 the following codes and standards PowerCommand 500 LAN A040X126 NFPA 110 for level 1 and 2 systems Remote HMI 211 0541 1394 ISO 8528 4 1993 compliance controls and switchgear Remote HMI 211RS A046K103 CE marking The control system is suitable for use on I O Expansion Aux 101 0541 1291 generator sets to be CE marked HMI Heater Accessory Kit A040H853 EN 50081 1 2 residential light industrial emissions or industrial emissions EN 50082 1 2 residential light industrial or industrial susceptibility Parts ordering information ISO 7637 2 level 2 DC supply surge voltage test 1302 Control Board 0327 1617 02 Mil Std 202C Method 101 and ASTM B117 Salt fog test 1302 control Board Arrow A043W505 PowerCommand control systems and generator sets Aux 104 Governor Control 0327 1507 are designed and manufactured in ISO 9001 certified HMI 214 Witho
7. PowerCommand 1 1 control system 8 O REMOTE START gt Specification sheet Our energy working for you NOT IN AUTO SHUTDOWN WARNING PowerCommand AUTO MANUAL RUN Power Generation Control system description The PowerCommand control system is a microprocessor based generator set monitoring metering and control system designed to meet the demands of today s engine driven generator sets The integration of all control functions into a single control system provides enhanced reliability and performance compared to conventional generator set control systems These control systems have been designed and tested to meet the harsh environment in which gensets are typically applied Our energy working for you www cumminspower com 2014 Cummins Power Generation Inc All rights reserved Cummins Power Generation and Cummins are registered trademarks of Cummins Inc PowerCommand InPower and Our energy working for you are trademarks of Cummins Power Generation Other company product or service names may be trademarks or service marks of others Specifications are subject to change without notice S 1566d 1 14 Page 1 of 7 Features Easy to view HMI 211RS for residential use 128x64 pixel graphic LED backlight LCD Easy to use Tactile buttons for generator set start stop Residential standby display for convenient use Modbus interface Eliminates need for MODLON Progressive protect
8. S Output READY TO LOAD t CONDITION GENSET UTILITY FEEDBACK FEEDBACK l UTILITY VOLTAGE Config I P 2 Config I P 1 MONITORING SENSOR y t TB1 14 TAL 17 B1 REMOTE START 7 I START STOP GENSET CONTROL eee OPERATION Hase Remote HMI A utility voltage monitoring sensor as shown in the AMF diagram above must be connected in order to use the AMF feature on the 1302 control Use Schneider Electric Relay RSB1A120U7 Socket RSZE1S35M Exerciser clock The exerciser clock runs the generator set exerciser routines for dependability of operation Field control interface Input signals to the base control include Remote start Local and emergency stop Configurable inputs Control includes 4 input signals from customer discrete devices that are configurable for warning shutdown or status indication as well as message displayed Output signals from the PowerCommand control include Configurable relay outputs Control includes 2 relay output contacts rated at 2 A These outputs can be configured to activate on any control warning or shutdown fault as well as ready to load not in auto common alarm common warning and common shutdown Ready to load generator set running signal Operates when the generator set has reached 90 of rated speed and voltage and latches until generator set is switched to off or idle mode Our energy working for you www cumminspower com
9. bilities of the engine used Control includes time delays to prevent nuisance alarms Low coolant temperature warning Indicates that engine temperature may not be high enough for a 10 second start or proper load acceptance Sensor failure indication Logic is provided on the base control to detect analog sensor or interconnecting wiring failures Full authority electronic engine protection Engine fault detection is handled inside the engine ECM Fault information is communicated via the SAE J1939 data link for annunciation in the HMI Our energy working for you www cumminspower com 2014 Cummins Power Generation Inc All rights reserved Cummins Power Generation and Cummins are registered trademarks of Cummins Inc PowerCommand InPower and Our energy working for you are trademarks of Cummins Power Generation Other company product or service names may be trademarks or service marks of others Specifications are subject to change without notice S 1566d 1 14 Page 4 of 7 Alternator protection High AC voltage shutdown 59 Output voltage on any phase exceeds preset values Time to trip is inversely proportional to amount above threshold Values adjustable from 105 130 of nominal voltage with time delay adjustable from 0 1 10 seconds Default value is 110 for 10 seconds Low AC voltage shutdown 27 Voltage on any phase has dropped below a preset value Adjustable over a range of 50 95 of referen
10. ce voltage time delay 2 20 seconds Default value is 85 for 10 seconds Overcurrent warning shutdown Implementation of the thermal damage curve with instantaneous trip level calculated based on current transformer ratio and application power rating ALTERNATOR THERMAL OVERCURRENT PROTECTION 0 03 1 10 Amps x rated Under frequency shutdown 81 u Generator set output frequency cannot be maintained Settings are adjustable from 2 10 Hz below nominal governor set point for a 5 20 second time delay Default 6 Hz 10 seconds Over frequency shutdown warning 810 Generator set is operating at a potentially damaging frequency level Settings are adjustable from 2 10 Hz above nominal governor set point for a 1 20 second time delay Default 6 Hz 10 seconds enabled Loss of sensing voltage shutdown Shutdown of generator set will occur on loss of voltage sensing inputs to the control Field overload shutdown Uses field voltage to shutdown generator set when a field overload condition occurs Power Generation Advanced functions Automatic mains failure The built in AMF feature provides the automatic transfer and re transfer of the load from utility to generator set and vice versa Automatically starts stops the generator set in the event of utility failure Annunciates faults GENSET SOURCE 2 UTILITY SOURCE 1 TRANSFER SWITCH Ready to Load AT
11. d InPower and Our energy working for you are trademarks of Cummins Power Generation Other Generation company product or service names may be trademarks or service marks of others Specifications are subject to change without notice S 1566d 1 14 Page 7 of 7 D
12. epted symbols and English text to comply with customer needs The interface also includes an LED backlit LCD display with tactile feel soft switches for easy operation and screen navigation It is configurable for units of measurement and has adjustable screen contrast and brightness The run offvauto switch function is integrated into the interface panel All data on the control can be viewed by scrolling through screens with the navigation keys The control displays the current active fault and a time ordered history of the five previous faults Features e LED indicating lamps remote start not in auto shutdown warning auto run 128 x 64 pixels graphic LED backlight LCD Four tactile feel membrane switches for LCD defined operation The functions of these switches are defined dynamically on the LCD Two tactile feel membrane switches dedicated for off and back e Allows for complete genset control setup Certifications Suitable for use on generator sets that are designed manufactured tested and certified to relevant UL NFPA ISO IEC Mil Std CE and CSA standards e HMI 211RS provides convenience for residential use Our energy working for you www cumminspower com 2014 Cummins Power Generation Inc All rights reserved Cummins Power Generation and Cummins are registered trademarks of Cummins Inc PowerCommand InPower and Our energy working for you are trademarks of Cummins Power
13. ive functions Advanced Overcurrent Protection Generator set monitoring amp protection Digital voltage regulation Single phase full wave SCR type regulator compatible with either shunt or PMSG systems Digital engine speed governing Provides isochronous frequency regulation 12 and 24 VDC battery operation Automatic mains failure Smooth amp automatic transfer and re transfer of load from utility to generator set amp vice versa Exerciser clock Runs generator set exerciser routines for dependability of operation Warranty and service Backed by a comprehensive warranty and worldwide distributor service network Certification Suitable for us on generator sets that are designed manufactured tested and certified to relevant UL NFPA ISO IEC Mil Std CE and CSA standards Power Generation PowerCommand digital generator set control PCC 1302 ep Ep bt Eg p Y 33 pp Ep FF 43 EF Pp aa aa PE FF Description The PowerCommand generator set control is suitable for use on a wide range of generator sets in non paralleling applications The PowerCommand control is compatible with shunt or PMG excitation style It is suitable for use with reconnectable or non reconnectable generators and it can be configured for any frequency voltage and power connection from 120 600 VAC line to line Power for this control system is derived from the generator set starting batteries The control functions o
14. l Frequency Engine data Starting battery voltage Engine speed Engine temperature Engine oil pressure Partial Full Authority Engine FAE data where applicable Service adjustments The HMI includes provisions for adjustment and calibration of generator set control functions Adjustments are protected by a password Functions include Engine speed governor adjustments Voltage regulation adjustments Cycle cranking Configurable fault set up Configurable output set up Meter calibration Units of measurement Power Generation Engine control SAE J1939 CAN interface to full authority ECMs where applicable Provides data swapping between genset and engine controller for control metering and diagnostics 12 VDC 24 VDC battery operations PowerCommand will operate either on 12 VDC or 24 VDC batteries lsochronous governing where applicable Capable of controlling engine speed within 0 25 for any steady state load from no load to full load Frequency drift will not exceed 0 5 for a 33 C 60 F change in ambient temperature over an 8 hour period Temperature dependent governing dynamics with electronic governing Modifies the engine governing control parameters as a function of engine temperature This allows the engine to be more responsive when warm and more stable when operating at lower temperature levels Remote start mode Accepts a ground signal from re
15. mote devices to automatically start the generator set and immediately accelerate to rated speed and voltage The remote start signal will also wake up the control from sleep mode The control can incorporate a time delay start and stop Remote and local emergency stop The control accepts a ground signal from a local genset mounted or remote facility mounted emergency stop switch to cause the generator set to immediately shut down The generator set is prevented from running or cranking with the switch engaged If in sleep mode activation of either emergency stop switch will wake up the control Sleep mode The control includes a configurable low current draw state to minimize starting battery current draw when the genset is not operating The control can also be configured to go into a low current state while in auto for prime applications or applications without a battery charger Engine starting The control system supports automatic engine starting Primary and backup start disconnects are achieved by one of three methods magnetic pickup battery charging alternator feedback or main alternator output frequency The control also supports configurable glow plug control when applicable Cycle cranking Configurable for the number of starting cycles 1 to 7 and duration of crank and rest periods Control includes starter protection algorithms to prevent the operator from specifying a starting sequence that might be damaging
16. neration Emergency stop Annunciated whenever either emergency stop signal is received from external switch General engine protection Low and high battery voltage warning Indicates status of battery charging system failure by continuously monitoring battery voltage Weak battery warning The control system will test the battery each time the generator set is signaled to start and indicate a warning if the battery indicates impending failure Fail to start overcrank shutdown The control system will indicate a fault if the generator set fails to start by the completion of the engine crack sequence Fail to crank shutdown Control has signaled starter to crank engine but engine does not rotate Cranking lockout The control will not allow the starter to attempt to engage or to crank the engine when the engine is rotating Hydro mechanical fuel system engine protection Overspeed shutdown Default setting is 115 of nominal Low lube oil pressure warning shutdown Level is preset configurable with InPower to match the capabilities of the engine used Control includes time delays to prevent nuisance alarms High lube oil temperature warning shutdown Level is preset configurable with InPower to match the capabilities of the engine used Control includes time delays to prevent nuisance alarms High engine temperature warning shutdown Level is preset configurable with InPower to match the capa
17. ut Heater 0300 6014 a HMI 211 with Heater A026G237 UL 508 recognized or Listed and suitable for use on UL 2200 Listed generator sets CSA C282 M1999 compliance CSA 22 2 No 14 M91 industrial controls Additional resources Warranty Resource Where to Find All components and subsystems are covered by an 1302 Service Manual QSOL express limited one year warranty Other optional and Accessories Catalog cumminspower com extended factory warranties and local distributor Additional Controls Information PowerSuite Library maintenance agreements are available PC CNet AAR a AK EAL COMPATIELE See your distributor for more information Cummins Power Generation Americas Europe CIS Middle East and Africa Asia Pacific 1400 73 Avenue N E Manston Park Columbus Ave 10 Toh Guan Road 07 01 Minneapolis MN 55432 USA Manston Ramsgate TT International Tradepark Phone 763 574 5000 Kent CT 12 5BF United Kingdom Singapore 608838 Fax 763 574 5298 Phone 44 1843 255000 Phone 65 6417 2388 Fax 44 1843 255902 Fax 65 6417 2399 Warning Back feed 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 Our energy working for you www cumminspower com 2014 Cummins Power Generation Inc All rights reserved Cummins Power Generation and Cummins are registered trademarks of Power Cummins Inc PowerComman
18. ver a voltage range from 8 VDC to 30 VDC Features e 12 and 24 VDC battery operation e Digital voltage regulation e Digital engine speed governing where applicable Provides isochronous frequency regulation e Full authority engine communications where applicable Provides communication and control with the Engine Control Module ECM Common harnessing with higher feature Cummins Power Generation controls allows for easy field upgrades Generator set monitoring Monitors status of all critical engine and alternator functions Digital genset metering AC and DC Genset battery monitoring system to sense and warn against a weak battery condition Engine starting Includes relay drivers for starter fuel shut off FSO glow plug spark ignition power and switch B applications Generator set protection Protects engine and alternator e Advanced serviceability using InPower a PC based software service tool Environmental protection The control system is designed for reliable operation in harsh environments The main control board is a fully encapsulated module that is protected from the elements e Exerciser function Routine exercising of generator set Our energy working for you www cumminspower com 2014 Cummins Power Generation Inc All rights reserved Cummins Power Generation and Cummins are registered trademarks of Cummins Inc PowerCommand InPower and Our energy working
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