Service Manual

&RQWUROOHU
PowerCommand 3200





English Original Instructions 92010 A034T571 (Issue 1)

Table of Contents

SECTION TITLE PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 INTRODUCTION
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How To Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel Power On/Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Menu Display and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Menu Units Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Engine Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Alternator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Control Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
History/About Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Bus Data Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
3 CONTROL CALIBRATION AND ADJUSTMENT
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Modifying Setup/Adjust Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Adjust Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Electronics Box Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

i
SECTION TITLE PAGE




ii
 Safety Precautions
Before operating the generator set (genset), read the EXHAUST GASES ARE DEADLY
Operators Manual and become familiar with it and the
equipment. Safe and efficient operation can be Provide an adequate exhaust system to properly
achieved only if the equipment is properly operated expel discharged gases away from enclosed or
and maintained. Many accidents are caused by failure sheltered areas and areas where individuals are
to follow fundamental rules and precautions. likely to congregate. Visually and audibly inspect
the exhaust daily for leaks per the maintenance
The following symbols, found throughout this manual, schedule. Make sure that exhaust manifolds are se-
alert you to potentially dangerous conditions to the oper- cured and not warped. Do not use exhaust gases to
ator, service personnel, or the equipment. heat a compartment.
Be sure the unit is well ventilated.
This symbol warns of immediate Engine exhaust and some of its constituents are
hazards which will result in severe personal in- known to the state of California to cause cancer,
jury or death. birth defects, and other reproductive harm.
MOVING PARTS CAN CAUSE SEVERE
WARNING This symbol refers to a hazard or un- PERSONAL INJURY OR DEATH
safe practice which can result in severe person-
al injury or death. Keep your hands, clothing, and jewelry away from
moving parts.
CAUTION This symbol refers to a hazard or un- Before starting work on the generator set, discon-
safe practice which can result in personal injury nect battery charger from its AC source, then dis-
or product or property damage. connect starting batteries, negative (-) cable first.
This will prevent accidental starting.
Make sure that fasteners on the generator set are
FUEL AND FUMES ARE FLAMMABLE secure. Tighten supports and clamps, keep guards
in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result
from improper practices. Do not wear loose clothing or jewelry in the vicinity of
moving parts, or while working on electrical equip-
DO NOT fill fuel tanks while engine is running, un- ment. Loose clothing and jewelry can become
less tanks are outside the engine compartment. caught in moving parts. Jewelry can short out elec-
Fuel contact with hot engine or exhaust is a potential trical contacts and cause shock or burning.
fire hazard. If adjustment must be made while the unit is run-
ning, use extreme caution around hot manifolds,
DO NOT permit any flame, cigarette, pilot light, moving parts, etc.
spark, arcing equipment, or other ignition source
near the generator set or fuel tank. DO NOT OPERATE IN FLAMMABLE AND
Fuel lines must be adequately secured and free of EXPLOSIVE ENVIRONMENTS
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed and
made with an approved flexible line. Do not use zinc become difficult to stop, resulting in possible fire, explo-
coated or copper fuel lines with diesel fuel. sion, severe personal injury and death. Do not operate a
Be sure all fuel supplies have a positive shutoff genset where a flammable vapor environment can be
valve. created by fuel spill, leak, etc., unless the genset is
equipped with an automatic safety device to block the air
Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to servicing near it. Lead-acid batteries emit a highly the genset are solely responsible for operating the gen-
explosive hydrogen gas that can be ignited by arc- set safely. Contact your authorized Onan/Cummins deal-
ing, sparking, smoking, etc. er or distributor for more information.

LS-13
iii
ELECTRICAL SHOCK CAN CAUSE take care not to ingest, breathe the fumes, or con-
SEVERE PERSONAL INJURY OR DEATH tact used oil.
Provide appropriate fire extinguishers and install
Remove electric power before removing protective them in convenient locations. Consult the local fire
shields or touching electrical equipment. Use rub-
department for the correct type of extinguisher to
ber insulative mats placed on dry wood platforms
use. Do not use foam on electrical fires. Use extin-
over floors that are metal or concrete when around
guishers rated ABC by NFPA.
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surface to be Make sure that rags are not left on or near the en-
damp when handling electrical equipment. gine.
Use extreme caution when working on electrical Remove all unnecessary grease and oil from the
components. High voltages can cause injury or unit. Accumulated grease and oil can cause over-
death. DO NOT tamper with interlocks. heating and engine damage which present a poten-
tial fire hazard.
Follow all applicable state and local electrical
codes. Have all electrical installations performed by Keep the generator set and the surrounding area
a qualified licensed electrician. Tag and lock open clean and free from obstructions. Remove any de-
switches to avoid accidental closure. bris from the set and keep the floor clean and dry.
DO NOT CONNECT GENERATOR SET DIRECT- Do not work on this equipment when mentally or
LY TO ANY BUILDING ELECTRICAL SYSTEM. physically fatigued, or after consuming any alcohol
Hazardous voltages can flow from the generator set or drug that makes the operation of equipment un-
into the utility line. This creates a potential for elec- safe.
trocution or property damage. Connect only Substances in exhaust gases have been identified
through an approved isolation switch or an ap-
by some state or federal agencies as causing can-
proved paralleling device.
cer or reproductive toxicity. Take care not to breath
GENERAL SAFETY PRECAUTIONS or ingest or come into contact with exhaust gases.

Coolants under pressure have a higher boiling point

Do not store any flammable liquids, such as fuel,
cleaners, oil, etc., near the generator set. A fire or
than water. DO NOT open a radiator or heat ex-
explosion could result.
changer pressure cap while the engine is running.
Allow the generator set to cool and bleed the system Wear hearing protection when going near an oper-
pressure first. ating generator set.
Used engine oils have been identified by some state To prevent serious burns, avoid contact with hot
or federal agencies as causing cancer or reproduc- metal parts such as radiator, exhaust manifold, muf-
tive toxicity. When checking or changing engine oil, fler and exhaust pipe.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv
1. Introduction
ABOUT THIS MANUAL True RMS meter for accurate measurement of
small AC and DC voltages. Fluke models 87 or
This manual provides PowerCommand Control 8060A are good choices.
(PCC) calibration and adjustment procedures, Battery Hydrometer
control operation, alternator test and repair
Jumper Leads
procedures.
Tachometer or Frequency Meter
Operating and maintenance instructions are in the Wheatstone Bridge or Digital Ohmmeter
applicable Operators Manual.
Variac
Read Safety Precautions and carefully observe all Load Test Panel
instructions and precautions in this manual.
Megger or Insulation Resistance Meter
TEST EQUIPMENT HOW TO OBTAIN SERVICE
To perform the test procedures in this manual, the Always give the complete Model, Specification and
following test equipment must be available: Serial number of the generator set as shown on the
 nameplate when seeking additional service
information or replacement parts. The nameplate is
 located on the side of the generator output box.

WARNING Incorrect service or replacement of

parts can result in severe personal injury or

death, and/or equipment damage. Service per-
 sonnel must be qualified to perform electrical
 and mechanical service. Read and follow Safety
 Precautions, on pages iii and iv.

1-1
THIS PAGE LEFT INTENTIONALLY BLANK

1-2
 2. Control Operation
GENERAL present, it will wait for a pulse from a remote Master
First Start Sensor. On receiving that pulse, the con-
The following describes the function and operation
trol will signal the paralleling breaker to close.
of the PowerCommand generator set control. All in-
dicators, control switches/buttons and graphical If bus voltage is present, the control will check for
display are located on the face of the control panel proper phase rotation, adjust the generator set to
as illustrated in Figure 2-1. the bus voltage and frequency level, and then syn-
Normally, generator set configuration options are chronize the generator set to the system bus. When
set at the factory. When a new control is installed on a synchronous condition is achieved, the control will
a generator set or when parts are replaced, the con- send a signal to close the paralleling breaker.
trol must be configured for that generator set. Setup
and calibration procedures are described in Sec- When the paralleling breaker is closed, the genera-
tion 3. tor set will assume its proportional share of the total
load on the system bus.
SEQUENCE OF OPERATION
CONTROL PANEL POWER ON/OFF
When the PowerCommand control is in the AUTO
mode, it will cause the generator set to start on re- MODES
ceiving a signal from a remote device. The control
will initiate a starter cranking signal and verify that The power on/off modes of the control panel and op-
the engine is rotating. The control will provide suffi- erating software are Power On, Screen Saver and
cient fuel to the engine to accelerate to start discon- Sleep/Awake.
nect speed. On reaching that speed, the control will
ramp the generator set to idle (warm-up) or rated Power On Mode: In this mode, power is continu-
speed and voltage. ously supplied to the control panel. The controls
operating software and control panel LEDs/graphi-
On reaching rated speed and voltage, the control cal display will remain active until the Screen Saver
checks the system bus voltage. If no bus voltage is mode is activated.

2-1
Screen Saver Mode: Power to the graphical dis- If these conditions are not met, Sleep mode is dis-
play will be removed after 10 minutes (generator set abled in Auto mode.
not running or running). The 10 minute timer resets
and begins after each control panel action (any but- The graphical display can enter Screen Saver mode
ton or switch selection) or signal received by the op- even if Sleep mode is disabled.
erating software. The bottom LEDs of the Analog
AC Metering Panel (bar graphs) may remain on dur- If Sleep mode is enabled in Auto mode, Sleep mode
ing Screen Saver mode, indicating that the operat- is activated when there are no unacknowledged
ing software is active (Awake mode). faults and Screen Saver mode is active.
When a Warning signal is sensed by the PCC (for
example, low coolant temp), the control will display The operating software is initialized and the control
the warning message. The control will remain active panel LEDs and graphical display are turned on in
until the Fault Acknowledge button is pressed to response to one of the following:
clear the warning message and start the 10 minute
timer. Moving/pressing any control panel switch/but-
ton. (If Sleep mode is enabled in Auto mode,
Sleep/Awake Mode: In the Sleep mode, the con- the control will remain asleep if Sleep mode
trols operating software is inactive and the LEDs was previously active in Off mode.)
and the graphical display on the control panel are all Receiving a remote start input signal (genera-
off. Sleep mode is a feature that is used to reduce tor set in Auto mode)
battery power consumption when the control is not
being used. Receiving an active DCD signal on the RS-232
port.
In Off mode, Sleep mode is activated when there
are no unacknowledged faults and Screen Saver Modem RI latch becoming active.
mode is active. Digital display waking up.
In Auto mode, Sleep mode can be enabled or dis- Lonworks (backplane) wakeup becoming ac-
abled. When shipped from the factory, it is disabled. tive.
You can enable Sleep mode by making these
changes: Customer fault 2 or 3 only (shutdown or warn-
ing indicator is on).
Use InPower service tool to set Auto Sleep En-
able to Sleep in Auto. Dial Out process becoming active.
Set switch S1 on the Genset/Paralleling Card To activate the control and view the menu display
to Sleep/Off. This switch is located next to con- without starting the generator set, press any button
nector J8 and relay K9. on the control panel.

2-2
 OPERATOR PANEL SWITCH PANEL

REMOTE START,
NOT IN AUTO,
SHUTDOWN,
WARNING
STATUS INDICATORS
ANALOG AC PANEL LAMP/ FAULT EMERGENCY
METERING LAMP TEST ACKNOWLEDGE STOP PUSH
PANEL BUTTON BUTTON BUTTON

DISPLAY MENU EXERCISE MANUAL RUN/

SELECTION BUTTONS BUTTON & STOP BUTTON
(1 of 6) INDICATOR & INDICATOR

GRAPHICAL 0/MANUAL/AUTO
DISPLAY SWITCH

FIGURE 2-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)

2-3
 CONTROL PANEL ASSEMBLY normal range values, amber for warning levels and
red for shutdown conditions.
The control panel assembly (Figure 2-1) consist of
two panels, the Operator Panel and the Switch Pan- Scales for each function are in % of nominal values.
el. The control panel assembly can be mounted on Resolution is 1% for values close to nominal, and in-
the genset or in a freestanding cabinet located near creases at values further from nominal.
the genset. In either location, the function of the Graphical Display: The graphical display is capa-
control panel assembly switches and indicators re- ble of displaying up to 9-lines of data with approxi-
main the same. mately 27 characters per line. The display is used to
Dependent on site requirements, the Operator Pan- view the menus of the menu-driven operating sys-
el is either mounted on the control panel assembly tem.
(full-featured) as shown in Figure 2-1 or is con- The top three lines of the graphical display contain
tained in a separate enclosure and mounted re- the following control information in the order de-
motely of the control panel assembly. scribed:
The function of several buttons on the operator pan- State Line modes of operation, such as
el will vary dependent on the location of the operator Stopped, Time Delay To Start, Warm Up At
panel (remote or local of the control panel assem- Idle, etc. (see Figure 2-2), and paralleling op-
bly). If the function differs, it is noted as either re-
erations, such as Standby, Dead BUS Close,
mote or local operator panel in the button de-
scription. Synchronize, Load Share and Load Govern.
Action Line system actions, such as Warning,
Operator Panel Derate, Shutdown Cool-down and Shutdown,
and fault codes.
The operator panel contains the following compo-
nents: Description Line Fault code messages.
Analog AC Metering Panel: This panel simulta- Display Menu Selection Buttons: Six momentary
neously displays 3-phase line to line AC volts and buttonsthree on each side of the graphical dis-
current, kW, power factor and frequency. play windoware used to navigate through the sys-
tem control menus and to adjust generator set pa-
The meter panel is composed of a series of LEDs, rameters. The button is active when the message
that are configured in bar graphs for each function. adjacent to the button is highlighted (displayed in
The LEDs are color coded, with green indicating inverse video).

2-4
Switch Panel Fault Acknowledge: Press this button to acknowl-
edge warning and shutdown messages after the
The switch panel contains the following compo- fault has been corrected.
nents:
To acknowledge a Warning message, the 0/Manu-
Emergency Stop Button: Push the button in for al/Auto switch can be in any position. (It is not nec-
emergency shutdown of the engine. If the engine is essary to stop the generator set to acknowledge an
not running, pushing the button in will prevent the inactive Warning condition.) To acknowledge a
starting of the engine, regardless of the start signal shutdown message with this button, the 0/Manual/
source (local or remote). Auto switch must be in the 0 (Off) position.

To reset: This button is also used to blink a fault code if the

1. Pull the button out. Shutdown or Warning Status Indicator is lit. (This
2. Move the 0/Manual/Auto switch to 0. function is used when the control does not contain a
3. Press the front panel Fault Acknowledge graphical display.) Refer to Reading Fault Codes in
button. this section, which describes how to use this button
4. Select Manual or Auto, as required. for interpreting fault codes.

Remote Start Indicator: This green lamp is lit Panel Lamp/Lamp Test Button: Press this button
whenever the control is receiving a remote run sig- to turn on or off the panel lamp. Press and hold
nal. When flashing, it indicates a load demand stop down this button for three seconds or more to turn
mode. all control panel LEDs on to make sure all lamps illu-
minate. The illumination will shut off after releasing
Not in Auto Indicator: This red lamp flashes con- the button.
tinuously when the 0/Manual/Auto switch is not in Exercise Button: Press this button to initiate a pre-
the Auto position. (If in Auto position and lamp is programmed exercise sequence. To start the exer-
flashing, service is required.) cise sequence, press and hold down the Exercise
button and move the O/Manual/Auto switch from
Shutdown Status Indicator: This red lamp is lit
Auto to Manual and back to Auto or from Manual to
whenever the control detects a shutdown condition.
Auto.
The generator set can not be started when this lamp
is on. After the condition is corrected, shutdown in- Manual Run/Stop Button: This button starts and
dicators can be reset by turning the 0/Manual/Auto stops the set locally and will bypass Time Delay to
switch to the 0 position, and pressing the Fault Ac- Start and Stop sequences. The 0/Manual/Auto
knowledge button. switch must be in the Manual position to enable this
button.
Dependent upon the specific fault that occurs, the
engine may or may not shut down immediately. A 0/Manual/Auto Switch: Manual position enables
fault that could cause engine damage, causes an the use of the switch panel Manual Run/Stop but-
immediate engine shutdown (bypasses engine ton.
cool-down sequence). All other faults would allow Auto position enables start/stop control of the en-
the engine to run during the cool-down sequence gine from a remote location. (Disables the use of the
before engine shutdown. switch panel Manual Run/Stop button.)
Warning Status Indicator: This yellow lamp is lit 0 (Off) position prevents the starting of the set (local
whenever the control detects a warning condition. or remote). If moved to 0 during set operation, will
After the condition is corrected, warning indicators cause an immediate engine shutdown (bypasses
can be reset by pressing the Fault Acknowledge cool-down timers). This hot shutdown should be
button. (It is not necessary to stop the generator set avoided, if possible, to help prolong the life of the
if the fault becomes inactive during genset opera- engine. Hot shutdowns are logged by the system
tion.) software.

2-5
 READING FAULT CODES A three digit fault code is indicated by three sets of
blinks separated by a two second pause. The first
If the genset contains the optional graphical display set corresponds to the hundreds position, the sec-
and a fault occurs, the fault code/message will be ond to the tens position and the third to the ones dig-
displayed in the display Description Line (Figure it. Example for Code No. 213:
2-2). If the control does not contain the graphical
display, the fault code is read from the Warning and Shutdown LED:
Shutdown status indicators. blink-blink-pause-blink-pause-blink-blink-blink

Reading Fault codes Using Warning/Shutdown Warning LED:

Indicators: If the Warning or Shutdown status indi- blink (2 seconds)
cator is lit, press and hold the Fault Acknowledge The light will display the fault codes (active or inac-
button and release after one second or more. After tive) in succession, starting with the most recent. Up
one second, the Shutdown lamp will begin to blink to 32 (unacknowledged) fault codes can be stored
the active fault code(s) as follows. in control panel memory.
The Warning lamp is used to indicate the start of a To return the control to the most recent fault code,
new code. The Warning lamp will remain on for 2 press and release the Fault Acknowledge button
seconds, followed by the Shutdown lamp blinking (less than one second) and repeat procedure.
the fault code. This sequence occurs three times for
each code. The fourth flash of the Warning lamp in- When the fault code is acknowledged and cor-
dicates the beginning of the second fault code. rected, the recorded fault will be deleted from the
LED fault log, but will remain in a data log that main-
There are distinct pauses between repetitions of the tains a fault code history. (The InPower service tool
code blink transmissions of the Shutdown lamp. is required to view this data log.)

2-6
 MENU DISPLAY AND SWITCHES Menu Buttons: Six momentary buttonsthree on
each side of the graphical display windoware
Figure 2-2 shows the graphical display and the used to navigate through the system control menus
menu selection buttons. and to adjust generator set parameters. The button
Graphical Display: The graphical display is capa- is active when the message or symbol adjacent to
ble of displaying up to 9-lines of data with approxi- the switch is highlighted (displayed in inverse vid-
mately 27 characters per line. The display is used to eo). The displayed message or symbol indicates
view the menus of the menu-driven operating sys- the function of the button.
tem. Refer to the menu trees later in this section.
The display is also used to show the following sys- In the graphical display, the B symbol indicates
tem information: that selecting the adjacent button causes the operat-
ing program to go to the next menu displayas
State Line modes of operation, such as shown in the menu diagrams.
Stopped, Time Delay To Start, Warm Up At
Idle, etc., and paralleling operations, such as
Standby, Dead BUS Close, Synchronize, etc. In the graphical display, the Y symbol indicates
that selecting the adjacent button causes the operat-
Action Line system actions, such as Warning, ing program to go back to the previous menu display.
Derate, Shutdown Cool-down and Shutdown,
and fault codes.
In the graphical display, the symbol indicates
Description Line Fault code/status mes- that selecting the adjacent button causes the operat-
sages. ing program to go back to Main Menu A (Figure 2-4).

STATE LINE
ACTION LINE
DESCRIPTION LINE

MENU DISPLAY
AREA

GRAPHICAL
DISPLAY

MENU MENU
BUTTONS BUTTONS

FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

2-7
 MENU UNITS SELECTION
During any control panel operation, you can change
how units are displayed by pressing the two lower
menu buttons (one on each side of display). When LOCATION LOCAL
pressing these two buttons simultaneously, the + TEMP F
PRESS FLD PSI
units submenu will appear (Figure 2-3). After PRESS GAS INHG ENTER
selecting the desired units, press the ENTER button FLOW AIR CFM
in this submenu to change and save the selections.
Use the + button to select the desired option for each
field. Use the arrow () button to move to the next
field. Selected field is highlighted.
FIGURE 2-3. UNITS SUBMENU
Local/Remote Field: This selection must be set to
Local when the graphical display is mounted on the
generator set front control panel or Remote when
mounted remotely from the generator set.
The Local/Remote selection determines which but-
tons in the Control submenu (page 2-13) are active
(displayed).
Temp Field: Used to select F or C for temperature
readings.
Pressure Fluid: Used to select PSI, KPA, BAR or
IN for pressure readings.
Pressure Gas: Used to select INHG or MMHG for
pressure readings.
Flow Air: Used to select CFM or CMM for air flow
readings.

2-8
 MAIN MENU _\_ Button: (Paralleling applications only). Used to
open and close the generator set circuit breaker
Figure 2-4 shows the main menus (Menu A and (CB). The symbol indicates if the CB is opened or
Menu B) of the system control. The two main menus closed. Opened _\_, push to close. Closed __,
are used to divide the system submenus into major push to open.
categories, such as, Engine Data, Alternator Data,
Control, etc. With the control panel 0/Manual/Auto switch in the
Manual position, the CB can only be closed by us-
To view system data, simply press the appropriate ing this button. When manually closed and the CB
menu button to select the category. After pressing opens, it must be closed again by using this button.
the desired menu button, refer to the page number To close the CB, press and hold the button until the
shown in Figure 2-4 for detailed information related symbol indicates a closed CB. (CB close will occur
to the selected category. only when setup conditions allow dead bus or
Adjust Button: The Adjust submenu is intended for generator synchronized with bus.)
qualified site personnel only. Note that a password
may be assigned to allow only authorized operators In the Auto position, the opening and closing of the
to modify this data. (Password is not required if not CB is controlled by the control system software. The
assigned.) CB symbol will indicate an open or closed CB, but
the button will be inactive when the control is in
Setup Button: The Setup submenu is described in Auto.
Section 3.
In the following figures, the boxed/highlighted field
The Adjust and Setup submenus can be viewed, indicates that the adjacent menu button is active.
but not modified without entering the correct pass- Also, the submenus are shown in the order in which
words. they are displayed when scrolling up Y or down B.

MENU A
MENU MENU
BUTTONS PAGE MENU BUTTONS
2-10 B

ENGINE MORE>>
PAGE ALTERNATOR _\_ See
2-11 CONTROL HISTORY/ABOUT Above

PAGE PAGE
2-12 2-13

MENU B

Section
3

ADJUST
BUS DATA PAGE
SETUP BACK<< 2-15

GRAPHICAL
Section DISPLAY MENU
3 A

FIGURE 2-4. SYSTEM CONTROL MAIN MENUS A AND B

2-9
 ENGINE SUBMENUS

If you press the ENGINE button in Menu A, the En-

gine submenus will appear (Figure 2-5). ENGINE DATA
The first submenu displays general information that
applies to all gensets (coolant temp, oil pressure,
etc.) The data in the remaining submenu(s) will vary
according to the type and number of sensors pro- COOLANT TEMP 180 F
vided with the engine. ENGINE SPEED 1800 RPM Y
BATTERY 29.1 VDC
OIL PRESSURE 75 PSI B
OIL TEMP 210 F

MANF TEMP 75 F
MANF PRESS ABS 180 IINHG Y
OUT PRESS ABS 180 PSI
AMBIENT PRESS 88 INHG

FIGURE 2-5. ENGINE DATA SUBMENUS

2-10
 ALTERNATOR SUBMENUS

If you press the ALTERNATOR button in Menu A,

the Alternator Data submenus will appear (Figure ALTERNATOR
2-6).
Voltage L-L and L-N: Indicates voltage Line-to
Line and Line-to-Neutral. Note that the Line-to-Neu-
tral column will not be displayed for a 3 phase/3 wire V L-L L-N AMPS
system. Accuracy 1%. L1 480 277 1340 Y
L2 480 277 1290
The voltage Line-to-Line (L1, L2 and L3) are mea- L3 480 277 1260 B
sured between L1 to L2, L2 to L3 and L3 to L1, re- FREQUENCY 60.0 HZ
spectively. AVR DUTY CYCLE 10.3 %

Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency.
AVR DUTY CYCLE: Displays voltage regulator kW kVA PF
(drive) level in percentage of maximum. L1 350 500 .80 Y
L2 350 500 .80
kW, kVA and PF: Displays generator set kW and L3 350 500 .80
kVA output (average and individual phase, and di- TOT 1050 1500 .80
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
The PF reading will contain an asterisk if the power
factor is leading (for example, *.30). FIGURE 2-6. ALTERNATOR SUBMENUS

2-11
 CONTROL SUBMENU

If you press the CONTROL button in Menu A, the the control is configured for a single unit (not in par-
Control submenu will appear (Figure 2-7). allel). The generator set continues to operate until it
runs out of fuel, the Estop button is used, or the
Local CONTROL Submenu Function load is removed.
When the operator panel is mounted on the control
Local/Remote CONTROL Submenu
panel assembly, the Run Mode Idle/Rated button is
active (displayed). Note in Figure 2-7 that this but-
Function
ton is not displayed in remote applications. Bargraph Test: The function of this button remains
The shaded area in Figure 2-7 displays the se- the same and is not dependent on operator panel
lected/active mode of operation, either IDLE or location. This button sequentially lights the LEDs to
RATED. test the bar graph display.

Run Mode Idle/Run At Rated Button: Refer to

Page 3-7 for a complete description of the Run At CONTROL
Idle mode. (Local)

Remote CONTROL Submenu Functions

When the operator panel (Figure 2-1) is mounted
remotely of the control panel assembly, the menu
buttons in the Control submenu are used to perform + RUN MODE IDLE Y
the following remote operations. (To activate these BARGRAPH TEST
menu buttons for remote/local use, refer to page
2-8.)
The 0/Manual/Auto switch must be in the Auto posi-
tion to activate the Remote Menu Buttons of the Con-
trol submenu.
CONTROL
Remote START or STOP Button: This button is (Remote)
used to start and stop the generator set when the
operator panel is mounted in a remote location.
When the generator set is operating, Stop will be
displayed for this button and Start will be displayed
START GENSET Y
when not operating.
BARGRAPH TEST
Fault Acknowledge Button: Used to reset inactive FAULT ACKNOWLEDGE
Warning messages, not Shutdown messages.
When the generator set is operating in the Remote
Start mode, removing the Remote Start command FIGURE 2-7. CONTROL SUBMENU
does not shut off the engine if the load is more than
10 per cent, the cooldown timer is set to zero, and

2-12
 HISTORY/ABOUT SUBMENUS

If you press the HISTORY/ABOUT button in Menu

A, the History/About submenus will appear (Figure HISTORY/ABOUT
2-8).
HISTORY: The control maintains a data log of the
number of engine starts and number of operating
hours for the engine and control, and the megawatt STARTS 533
and maximum torque hours of the generator set. ENGINE HOURS 1236 Y
This information is stored in non-volatile memory CONTROL HOURS 7879
KWHRS 890 B
and will not be deleted due to loss of battery power.
ABOUT: The About submenus provide the follow-
ing generator set information.
Genset model and wattage (kW/MW)
Output voltage and WYE, DELTA or SINGLE
HOURS@ % MAX TORQUE:
Frequency 50 or 60 Hz 12345@0-9 23455@50-59 Y
Rating: Standby, Prime or Base 12345@10-19 12345@60-69
12345@20-29 12345@70-79 B
Version level of the controller and panel operat- 12345@30-39 12345@80-89
ing software.

MODEL 1750DQKB Y
VOLTAGE 416 WYE
FREQUENCY 60 B
RATING STANDBY

CONTROLLER VERSION
RTOP DN30008.DFA Y
BATS APR 23 1999
OP PANEL VERSION B
RTOP 1.12
BATS 1.04

CONTINUED TO NEXT PAGE

FIGURE 2-8. HISTORY/ABOUT SUBMENUS

2-13
 HISTORY/ABOUT SUBMENUS (CONT.)

FAULT HISTORY: The control maintains a data log

of all fault conditions as they occur, and time stamps HISTORY/ABOUT (CONT.)
them with the control and engine operating hours.
Up to 32 (unacknowledged) fault codes can be
stored in control panel memory. After the fault is ac-
knowledged and corrected, the recorded fault will
be deleted from the control panel memory, but will FAULT HISTORY: 1 OF 24
+ CNTL HOURS 459 Y
remain in a data log that maintains a fault code his- OCCURRENCES 5
tory. (The InPower service tool is required to view ENGINE HOURS 334
this data log.) FAULT CODE 1437
(FAULT DESCRIPTION)
The Fault History display line: 1 of 24 indicates that
24 faults are recorded and that the most recent fault
(1) detected by the controller is displayed.
The Occurrences display line: In this example, 5 in- FIGURE 2-8. HISTORY/ABOUT SUBMENUS (CONT.)
dicates that this is the fifth occurrence of this fault.
(The InPower service tool is required to review the
last four faults of this code.)
The Occurrences number is incremented for each
new occurrence of the same fault. The controller
must detect that the original sensed fault is cor-
rected before it will increment the occurrence num-
ber for that fault.
For example, when a Low Oil Pressure fault is de-
tected, the controller will increment the Occurrences
number by 1. This fault will remain active until the
fault is acknowledged and the controller detects that
the fault is corrected. An active fault will prevent the
controller from incrementing the Occurrences num-
ber each time the engine is started. When the con-
troller detects that the oil pressure is normal the fault
will become inactive, allowing the occurrences num-
ber to be incremented for the next detected Low Oil
Pressure fault.

2-14
 BUS DATA SUBMENU
If you press the BUS DATA button in Menu B, the
Bus Data submenu will appear (Figure 2-9) (paral- BUS DATA
leling applications only).
BUS DATA STATUS LINE: The top line of the
graphical display is used to indicate the following LOAD GOVERN
BUS DATA status:
V BUS GEN
STANDBY L1 480 480 Y
DEAD BUS CLOSE: Indicates first genset in L2 480 480
_\_
system to close to bus. L3 480 480
HZ 60.1 60.1
SYNCHRONIZE: Genset is synchronizing to DEG 122 NOT SYNCHRONIZING
bus.
LOAD SHARE: Genset has closed to bus and
is sharing load with other gensets in system.
LOAD GOVERN: Genset closed to bus in par-
allel with utility (mains). FIGURE 2-9. BUS DATA SUBMENU
BUS Voltage L-L: The BUS voltage Line-to-Line
(L1, L2 and L3) are measured between L1 to L2, L2
to L3 and L3 to L1, respectively.
BUS/GEN HZ: BUS and genset frequency.
BUS/GEN SYNC STATUS: The bottom line of the
graphical display is used to indicate the following
BUS/GEN Sync status:
NOT SYNCHRONIZING: Genset is in service
mode that does not allow auto sync feature.
(Selected via InPower service tool deactivate
to allow synchronization.)
SYNCHRONIZING: Genset is synchronizing to
bus.
READY TO CLOSE: In manual mode, push cir-
cuit breaker close button to close breaker.
_\_ Button: Used to open and close the genset cir-
cuit breaker (CB) when the 0/Manual/Auto switch
is in Manual position. The symbol indicates if the CB
is opened or closed. Opened _\_, push to close.
Closed __, push to open.
In the Manual position, the CB must be closed by
this button. When manually closed and the CB
opens, it must be closed again by using this button.
To close the CB, press and hold the button until the
symbol indicates a closed CB. (CB close will occur
only when setup conditions allow dead bus or
generator synchronized with bus.)
In the Auto position, the opening and closing of the
CB is controlled by the control system software. The
CB symbol will indicate an open or closed CB, but
the button will be inactive when the control is in
Auto.

2-15
THIS PAGE LEFT INTENTIONALLY BLANK

2-16
 3. Control Calibration and Adjustment
GENERAL CAUTION If the base card has software as-
sembly A026 F566 v1.0 on the U33 flash memory
This section contains calibration and adjustment chip, you must use the latest software calibra-
procedures for the generator set control. tion for the control, or the board will lock up per-
manently.
SOFTWARE CALIBRATIONS
If the base card has software assembly A026 F566 MODIFYING SETUP/ADJUST SUBMENUS
v1.0 on the U33 flash memory chip, you must use
the latest software calibration for the control. If you The Setup and Adjust submenus allow you to cali-
load an earlier software calibration onto a base card brate the graphical display meters and to adjust
with software assembly A026 F566 v1.0, the soft- system parameters, customer defined faults, gen-
ware calibration will fail, and the board will lock up erator set voltage/frequency and paralleling ap-
permanently. plications.

CAUTION Improper calibration or adjustment

of the control can cause equipment malfunction
or damage. Calibration and adjustment must be
performed by technically qualified personnel
only.

The Setup submenus are intended for qualified ser-

vice personnel only. The Adjust submenu is in-
tended for qualified service and site personnel only.
For this reason, a password must be entered before
this data can be modified. The Setup and Adjust
submenus can be viewed, but not modified without
entering the correct password.

Saving Menu Changes

Changes are automatically saved when the menu is

FIGURE 3-1. U33 FLASH MEMORY CHIP exited.

3-1
PASSWORD Menu When viewing a Setup menu, pressing the + or
button will always display the Application Password
To allow the site personnel to modify only the Adjust menu.
submenu and not the Setup submenus, two pass-
After entering the correct password, the system will
words are assigned within the system software. An
allow you to modify the submenus. To help prevent
Application password is used for the Setup sub-
unauthorized adjustment, the entered password is
menus and a User password is used for the Adjust
valid for only 10 minutes after the last button is
submenu.
pressed.
The two passwords are assigned during the initial Entering Password
installation of the generator set (via InPower) and
will vary between sites. The installer must make To enter the password:
sure that the passwords are available to the ap- 1. Display submenu to modify.
propriate personnel.
2. Press either the + or button within the dis-
played submenu. The Password menu ap-
When the generator set is first installed, the Applica- pears.
tion password is set to GENSET to allow initial modi-
fication of the Setup submenus. The User password 3. Press the + and button to select the first char-
is initially left blank and does not require a password acter of the password (AZ or 09). (Enter Ap-
to modify the Adjust submenu. The entering of the plication password for Setup submenus; En-
User password is not required unless a password is ter User password for Adjust submenu.)
assigned to this field. (User password is site depen- 4. Press the button to select the next character
dent.) Assign the password(s) when site installation
field. Selected character field is highlighted.
is complete.
5. Repeat steps 3 and 4 to enter remaining pass-
word characters.
When viewing the Adjust menu, pressing the + or
button will display the User Password menu if a user 6. Press the Enter button after entering the pass-
password has been installed with InPower soft- word. The submenu selected in step 1 will re-
ware. If a password is not assigned to the Adjust appear.
menu, changes can be made without entering a 7. After making desired changes to submenu, exit
password. submenu to save changes.

+ OR BUTTON + OR BUTTON

ENTER APPLICATION PASSWORD ENTER USER PASSWORD

+ ENTER + ENTER

XXXXXXXX XXXXXXXX

SETUP SUBMENU PASSWORD MENU ADJUST SUBMENU PASSWORD MENU

FIGURE 3-2. PASSWORD MENUS

3-2
 SETUP MENUS To display the two Setup menus, press the
MORE>> button in Menu A and then the SETUP
button in Menu B.
Figure 3-4 shows the main menus (Menu A and
Menu B) of the system control and the two Setup To view system data or to adjust system parame-
menus. ters, press the appropriate Setup menu button to
display the desired Setup submenu(s). Refer to the
page number shown in Figure 3-3 for detailed infor-
The Setup procedure is intended for qualified ser- mation related to the selected submenu(s).
vice personnel only. The APPLICATION password CAUTION Improper calibration or adjustment
must be entered to modify the Setup submenu of the control can cause equipment malfunction
fields. Refer to Modifying Setup/Adjust Submenus or damage. Calibration and adjustment must be
in this section to enter password and to save/contin- performed by technically qualified personnel
ue menu changes. only.

MENU A MENU B

MENU
ENGINE MORE>> B ADJUST
ALTERNATOR _\_ BUS DATA
MENU
CONTROL HISTORY/ABOUT SETUP BACK<<
A

PAGE MENU
3-4 B

GOVERNING/VOLT REG Y
PAGE CUSTOMER FAULTS B NEXT
3-5 MENU
CALIBRATION

PAGE MENU
3-6 A

ABOVE
MENU

Y
PAGE ISOLATED BUS
3-7 UTILITY

PAGE MENU
3-7 A

FIGURE 3-3. SETUP SUBMENUS

3-3
GOVERNING/VOLT REG Submenu
If you press the GOVERNING/VOLT REG button GOVERNING/VOLT REG
in the Setup menu, the Governing/Volt Regulator
submenu will appear (Figure 3-4).
Use the + and buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next + GOV GAIN 80 Y
field. Exit menu to safe changes. AVR GAIN 100

GOV GAIN: If the gain adjustment is set too high,
engine speed will hunt or oscillate. If gain is set too
low, the engine will respond too slowly to changes in
load and overspeed may result. (Gain should be re-
duced to 80% for paralleling installations.)
FIGURE 3-4. GOVERNING/VOLT REG SUBMENU
AVR GAIN: If the gain adjustment is set too high,
output voltage will be unstable. If gain is set too low,
the output voltage will respond sluggishly to
changes in load and overshoot may result.

3-4
CUSTOMER FAULTS Submenus
If you press the CUSTOMER FAULTS button in CUSTOMER FAULTS
the Setup menu, the Customer Faults submenus
will appear (Figure 3-5).
There are a total of four customer fault inputs.
(Faults 3 and 4 paralleling only.) The message dis-
CUSTOMER FAULT1:
played at the bottom of the menu can be modified + ENABLE ON Y
for each of these faults in addition to selecting the ACTIVE CLOSED B
following operating parameters for each fault. RESPONSE WARNING

Enable On or Off ***CUSTOMER FAULT1 ******************
Active Closed or Open
Response Shutdown, Cooldown, Derate or
Warning
Shutdown: Genset will immediately shut
down. Normally used for engine faults. CUSTOMER FAULT2:
+ Y
Cooldown: Cooldown sequence will be initi-
B
ated before shutdown. Should not be used for RESPONSE WARNING

engine faults.
***CUSTOMER FAULT2 ******************
Derate: Used to lower kW output of genset for
warnings such as pre-high coolant tempera-
ture, etc. Paralleling application controller will
CONTINUES THROUGH TWO
reduce percentage of kW load sharing on the ADDITIONAL MENUS FOR A
set. Non-paralleling application controller will TOTAL OF FOUR POSSIBLE
lower percentage of kW load by operating load CUSTOMER FAULT MESSAGES
shed relay contacts.
Warning: Display message, genset continues
to operate. FIGURE 3-5. CUSTOMER FAULTS SUBMENUS
The Enable and the Active fields apply to the Fault 1
and 4 submenus only.
With the Active field selected, pressing the + or
buttons will toggle the selection between CLOSED
and OPEN. Use same operation for remaining field
selections.
To enter the desired customer fault message, press
the B or Y button to display the submenu that con-
tains the customer fault message (1 through 4) to be
changed. Use the button to scroll down through
the menu selections to the editable fault message
(bottom menu line).
Use the button to move to each character posi-
tion within the fault message line.
With the desired character position selected, use +
or buttons to select the appropriate character.
If these messages are changed, you should note
these changes in the Troubleshooting section of the
Operators manual for this generator set.

3-5
CALIBRATION Submenus
If you press the CALIBRATION button in the Setup CALIBRATION
menu, the Calibration submenus will appear (Fig-
ure 3-6).
Use the + and buttons to increase or decrease the
values in the following fields. Use the arrow () but- VOLTAGE CALIBRATION
ton to move the cursor within a field or to the next + L1 480 -X.X% Y
L2 480 -X.X%
field. Exit menu to safe changes. L3 480 -X.X% B

The Calibration submenus allow you to calibrate the
control with the reading from a calibrated meter.
Calibration is accomplished by using this section of
the menu software to adjust the display so that it
matches the reading taken on an accurate, recently
calibrated meter.
CURRENT CALIBRATION
Calibration is normally only required when replac- + L1 234 -X.X% Y
L2 123 -X.X%
ing certain circuit cards. Refer to the Calibration L3 562 -X.X% B
Procedure in this section which contains a list of the
cards that require control calibration.
When performing Bus Voltage Calibration from the
graphical display, the genset must be off and the Bus
live. If the genset is running, it will synchronize to the
Bus.
BUS VOLTAGE CALIBRATION
+ L1 480 -X.X% Y
L2 480 -X.X%
L3 480 -X.X%

FIGURE 3-6. CALIBRATION SUBMENUS

3-6
ISO BUS / UTILITY Submenus (Paralleling and frequency in a range of minus 40% to plus 10%
Application) of normal bus conditions. When the paralleling
breaker has closed, the control will bring the gener-
The Isolated BUS submenus (Figure 3-7) and the ator set back to normal voltage and frequency.
Utility submenus (Figure 3-8) adjust the control pa-
rameters for generator set protection, synchroniz- When the generator set is paralleled to another
ing and load sharing for both isolated bus and utility generator set, the control provides automatic load
(mains) paralleling applications. Utility (mains) par- sharing functions for both real (kW) and reactive
allel applications may require adjustment of both (kVAR) loads. Load sharing is proportional between
the Isolated BUS and Utility submenus. generator sets based on their standby ratings. If two
generator sets of different sizes are paralleled, they
Always perform ISO BUS calibration before Utility will assume the same percentage of the system
BUS calibration.
load automatically. This can easily be verified on the
The sync check (permissive) function is operational kW Load LED bar graph on the front of the control
in both automatic and manual (RUN) modes. The panel.
control will make sure that the generator set is at
When the utility paralleling mode is enabled and the
proper voltage, within the defined sync check win-
generator set paralleling breaker is closed, the gen-
dow for the defined period of time and that phase
rotation is correct. When all criteria are met, the par- erator set will assume load based on external ana-
alleling breaker is closed automatically by the con- log input signal. The input signal must be calibrated
trol (auto mode), or by operation of the breaker from 05 VDC. When the signal is at 0.5 to 1 VDC,
close switch by the operator (manual mode). the control will operate the generator at no load in
parallel with the utility (mains) source. At 4.5 VDC
The synchronizing function of the control is enabled and greater, the control will operate the generator
when the control has brought the generator set to set at 110% of the generator set base load setting.
90% of rated speed and voltage, and has sensed When the load govern signal is between 1 VDC and
that bus voltage is available. The control automati- 4.5 VDC the control will operate the generator set at
cally adjusts the generator set speed and voltage to a load level which is determined by a linear relation-
match the bus frequency and voltage. The control ship between the kW reference and the load govern
can force the generator set to match bus voltage signal.

3-7
ISO BUS Submenus
If you press the ISO BUS button in the Setup ISOLATED BUS
menu, the Isolated BUS submenus will appear (Fig-
ure 3-7).
Use the + and buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ISOLATED BUS:
ton to move the cursor within a field or to the next SYNC TIME LIMIT 120 SEC
+ Y
field. Exit menu to safe changes. REV PWR LMT 10 %
REV PWR TIME 3 SEC B
SYNC TIME LIMIT: This parameter adjusts the time
PERM WIN-PH 20 DEG
delay in seconds before the Fail To Synchronize PERM WIN-TIME .5 SEC
alarm will operate.
REVERSE PWR LMT: Adjusts the reverse power
set point. For PowerCommand generator sets, a CONTINUED TO NEXT PAGE
typical set point is 10-15%.
REVERSE PWR TIME: Adjusts the reverse power
function time delay. A typical time delay which is
suitable for PowerCommand generator sets is 3 se- FIGURE 3-7. ISO BUS SUBMENUS
conds.
Lower reverse power set points can result in nui-
sance reverse power shutdown faults.
PERM WIN-PHASE: Adjusts the width of the per-
missive (sync-check) acceptance window. The ad-
justment range is from five to twenty electrical de-
grees. Recommended set point is 20 degrees for
isolated bus applications, and 15 degrees for utility
(mains) paralleling applications.
PERM WIN-TIME: Adjusts the time period (in se-
conds) for which the generator set must be synchro-
nized with the system bus, before a breaker close
signal is issued by the PowerCommand control.
Available range is 0.5 to 5 seconds. Recommended
value for PowerCommand generator sets is 0.5 se-
conds for isolated bus applications.

3-8
Adjusting the control for a smaller sync-check win-
dow or longer time delay will cause synchronizing
ISOLATED BUS (CONT.)
time to be extended.
SYNC GAIN: The sync gain adjustment controls
how quickly the governor will respond to try to mini-
mize the bus/generator phase difference. Increas-
ing the gain speeds up the response. If the gain is ISOLATED BUS:
too high instability can result. + SYNC GAIN 1.0 Y
KW BALANCE 0.3
KW Balance and KVAR Balance changes should be KVAR BALANCE 1.2 B
equally shared among all generator sets. KW GAIN 1.0
KVAR GAIN 1.0
KW BALANCE: This function adjusts the kW load
sharing function of the generator set. Before adjust-
ing this value, all generator set calibrations should
be performed. If the total load on the system is not CONTINUED TO NEXT PAGE
shared proportionately, the kW Balance can be
used to adjust the generator set for more precise
load sharing. Increasing the kW Balance value will
cause the generator set to reduce the percentage of FIGURE 3-7. ISO BUS SUBMENUS (CONT.)
the total kW load on that set.
KVAR BALANCE: This function adjusts the kVAR
load sharing function of the generator set. Before
adjusting this value, all generator set calibrations
should be performed. If the total load on the system
is not shared proportionately, the kVAR balance can
be used to adjust the generator set for more precise
load sharing. Increasing the kVAR balance value
will cause the generator set to reduce the percent-
age of the total kVAR load on that set.
KW GAIN: Adjusts the rate of change of kW load on
the generator set. With a constant load on the sys-
tem, if the generator set load is constantly chang-
ing, reduce the gain adjustment on the generator
set. This also allows modification of the rate of load
assumption on transient load change.
KVAR GAIN: Adjusts the rate of change of kVAR
load on the generator set. With a constant load on
the system, if the generator set load is constantly
changing, reduce the gain adjustment on the gener-
ator set. This also allows modification of the rate of
load assumption on transient load change.

3-9
1ST FAIL TIME: Time delay in seconds after a sig-
nal from the first start master is not sensed by the ISOLATED BUS (CONT.)
PCC that a FIRST START FAIL warning is dis-
played.
RAMP UNLOAD TIME: When a load demand stop
input is sensed the load is ramped down from the
present load level on the set to the ramp unload lev- ISOLATED BUS:
+ 1ST FAIL TIME 12 SEC Y
el in the time specified in seconds. RAMP UNLD 20 SEC
RAMP UNLD LEVEL 10 %
RAMP UNLOAD LEVEL: The load demand ramp
RAMP LOAD TIME 3 SEC
unload function will ramp the load down from the LOSS FIELD 20 SEC
present level on the set to this level before opening
the set circuit breaker. Value shown is in % of genset
standby rating.
FIGURE 3-7. ISO BUS SUBMENUS (CONT.)
RAMP LOAD TIME: When the load demand stop
signal is removed the load is ramped from 0kW to
the load share level in the specified time after the
circuit breaker closes.
LOSS FIELD TIME: Adjusts the loss of field func-
tion time delay. A typical delay which is suitable for
PowerCommand generator sets is 2 seconds.

3-10
UTILITY Submenus
If you press the UTILITY button in the Setup UTILITY
menu, the Utility submenus will appear (Figure 3-8).
Use the + and buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
UTILITY:
field. Exit menu to safe changes.
+ BASE LOAD 80% Y
BASE LOAD (%): This controls the maximum kW
PF LEVEL 1.00
B
load level that the generator set will operate at when RAMP LOAD 3
RAMP UNLD 20
paralleled with the utility (mains). The value shown MODE MULTIPLE
indicates the steady state load on the generator as
a percent of the generator set standby rating.
Check generator set ratings for maximum load level
at which the generator set should operate when
paralleled with the utility (mains). Extended opera- UTILITY:
tion at load levels in excess of the generator set rat- + KW GOVERN GAIN 1.00 Y
ing can cause abnormal engine wear or premature KVAR GOVERN GAIN 1.00

engine failure.
PF LEVEL: Adjusts the power factor that the gener-
ator set will run at when paralleled to the utility
(mains). Recommended setting is 1.0.
RAMP LOAD TIME: This is the ramp time from
FIGURE 3-8. UTILITY SUBMENUS
present set load to level determined by the load set
analog input. This is active when the control first en-
ters the load govern mode.
RAMP UNLOAD TIME: This is the ramp time from
present set load to 0 kW. This ramp is active when
the load set analog input is less than 0.5 volts.
MODE MULTIPLE/SINGLE: This controls wheth-
er the set is to operate as part of a multiple set or
single set (PLTE or PLTF) system. (Refer to LOAD
DEMAND SHUTDOWN and SINGLE MODE
VERIFY function descriptions in wiring diagram,
page 5-8.)
KW GOVERN GAIN: This controls the rate that the
generator set kW load is increased after the genera-
tor set has closed to the system bus when utility
(mains) paralleled. Decreasing this value will result
in slower loading of the generator set.
KVAR GOVERN GAIN: This controls the rate that
the generator set kVAR load is increased after the
generator set has closed to the system bus when
utility (mains) paralleled. Decreasing this value will
result in slower loading of the generator set.

3-11
 ADJUST SUBMENU are disabled to prevent inadvertent misadjustment
of the paralleling load sharing functions.
Figure 3-9 shows the main menus (Menu A and
Menu B) of the system control and the Adjust sub- Use the + and buttons to increase or decrease the
values in the following fields. Use the arrow () but-
menu. ton to move the cursor within a field or to the next
field. Exit menu to safe changes.
To display the Adjust submenu, press the MORE>>
button in Menu A and then the ADJUST button in VOLTAGE: Used to adjust the output voltage 5%.
Menu B.
FREQUENCY: Used to adjust the frequency 3 Hz.
The Adjust procedure is intended for qualified ser- START DELAY: This delay applies only to remote
vice personnel and site personnel only. The USER starting in the Auto mode (0/Manual/Auto switch in
password must be entered to modify the Adjust sub- Auto). The Start Delay adjustment range is 0 to 300
menu fields. Refer to Modifying Setup/Adjust Sub- seconds.
menus in this section to enter password and to save
menu changes. STOP DELAY: This delay applies only to remote
stopping in the Auto mode (0/Manual/Auto switch in
If the generator set is operating in parallel with a Auto). The Stop Delay adjustment range is 0 to 600
system bus, the voltage and frequency adjustments seconds.

MENU A

MENU
ENGINE MORE>> B
ALTERNATOR _\_
CONTROL HISTORY/ABOUT

MENU B

ADJUST
BUS DATA
MENU
SETUP BACK<<
A

ADJUST:
+ VOLTAGE 208 1.2 % Y
FREQ 60.0 HZ -0.0 HZ
START DELAY 5 SEC
STOP DELAY 11 SEC

FIGURE 3-9. ADJUST SUBMENU

3-12
 CALIBRATION PROCEDURE able and the genset is running. Consequently, it is
not possible to calibrate the genset output voltage
There are several circuit cards/modules that, when display of the genset that is running when the bus is
removed and replaced, require you to recalibrate energized. If it is necessary to adjust the output volt-
the control panel display for genset voltage and cur- age display of the genset that is running, the InPower
rent and bus voltage. service tool must be used to switch off the synchro-
nizer function of the control.
Note that the type of calibration to perform varies for
each card. The letters A, B and C are used to desig- 1. Display the Voltage Calibration submenu
nate which of the following three calibration proce- (Page 3-6).
dures are required for each card/module. 2. With the genset OFF, attach a calibrated volt-
meter to the AC output from L1 to L2. (L1 to
Genset board (A, B & C) No adjustments re- Neutral for single phase alternators.)
quired for Genset board if controller contains
the Parallel board. 3. Start the genset and allow it to reach normal
operating speed.
Parallel board (A, B & C)
4. Calibrate voltage reading for L1 so that the
PT/CT board (A & B) reading on the display agrees with the cali-
Bus PT (C) brated voltmeter.
5. Shut the generator set OFF.
CTs (B)
6. Repeat steps 2 through 5 for L2 and L3. (In step
2 attach meter to the AC output from L2 to L3 to
calibrate L2 and L3 to L1 to calibrate L3.)
WARNING Contacting hazardous voltage com-
ponents can cause electrocution, resulting in 7. Exit menu to Save changes.
severe personal injury or death. Calibration and (B) Genset Ammeter Display Calibration
adjustment must be performed by technically
qualified personnel only. Read and observe all 1. Display the Current Calibration submenu
WARNINGS and CAUTIONS in your generator (Page 3-6).
set manuals. 2. With the genset OFF, attach a calibrated
CAUTION Improper calibration or adjustment ammeter to L1.
of the PowerCommand control can cause 3. Start the genset and allow it to reach normal
equipment malfunction or damage. Calibration operating speed.
and adjustment must be performed by techni- 4. Load the genset to maximum rated kVA at
cally qualified personnel only. rated voltage.
Use a calibrated RMS multimeter for accurate 5. Calibrate the reading for L1 current so that the
measurements. Fluke models 87 or 8060A are reading on the display agrees with calibrated
good choices. ammeter.
6. Repeat steps 2 through 5 for L2 and L3. (In step
(A) Genset Voltage Display Calibration 2, attach meter to L2 to calibrate L2 current and
The PowerCommand control automatically synchro- L3 to calibrate L3 current.)
nizes to the system bus when bus voltage is avail- 7. Exit menu to Save changes.

3-13
(C) Bus Voltage Calibration
The PowerCommand control automatically synchro-
nizes to the system bus when bus voltage is avail-
able and the genset is running. Consequently, it is
not possible to calibrate the genset bus voltage dis-
play of the genset that is running when the bus is en-
ergized. If it is necessary to adjust the bus voltage
display of the genset that is running, the InPower
service tool must be used to switch off the synchro-
nizer function of the control.
1. Display the Bus Voltage Calibration submenu
(Page 3-6).
2. With all gensets OFF, attach a calibrated volt-
meter to TB1-A (L1) and TB1-B (L2) of the bus
PT module (Figure 3-10).
3. Start another genset and allow it to reach nor-
mal operating speed and voltage. Connect op-
erating genset to the bus.
4. Calibrate the voltage reading for Bus Volts L1
so that the reading on the display matches the
reading on the calibrated meter.
TB1-A L1
5. Shut the generator set OFF. TB1-B L2
6. Repeat steps 2 through 5 for Bus Volts L2 and TB1-C L3
L3. (In step 2 attach meter to the AC output
from L2 to L3 to calibrate L2; L3 to L1 to cali-
FIGURE 3-10. BUS PT MODULE
brate L3.)
7. Exit menu to Save changes.

3-14
 ELECTRONICS BOX CONTROL WIRING (see Figure 3-12). Optional equipment such as a re-
mote annunciator panel, sensing devices used to
The generator set control box assembly (Figure monitor genset operation, remote start/stop
3-11), which is located on the rear or optionally on switches, control box heater, and etc. are also at-
either side of the control housing, contains connec- tached to these terminal blocks. Driver signals for
tion points for remote control and monitor options. customer supplied relays are also provided for sev-
CAUTION Do not attach conduit to the control eral alarm and shut down conditions.
box assembly for any reason. All conduit must CAUTION When removing terminal block con-
be attached to the control housing. Attaching
nectors (TB4, TB5, or TB8) from cards in card
conduit to the control box assembly will com-
cage, note orientation of connector. These ter-
press the control box vibration isolators, caus-
minal block connectors are not keyed and can
ing the box to vibrate and damage the electronic
be installed incorrectly, which will cause con-
circuitry.
trol failures.
A sealable pass-through is provided on the back of
the control box for customer monitor/control wiring TB3, TB4, TB5, and TB8 Customer
(Figure 3-12). Connections
Customer monitor/control connections are at- Refer to pages 5-8 and 5-9 for typical connections
tached to terminal blocks TB3, TB4 TB5 and TB8 to TB3, TB4, TB5, and TB8.

CONTROL BOX CONTROL

ASSEMBLY HOUSING
(REAR MOUNT) ASSEMBLY

DO NOT ATTACH
CONDUIT TO CONTROL
BOX ASSEMBLY FOR
ANY REASON

VIBRATION
ISOLATORS
(QTY 4)

FIGURE 3-11. CONTROL BOX REAR MOUNT

3-15
 ENGINE/GENERATOR
CUSTOMER HARNESS (FACTORY SEALED)
CONTROL WIRING
ACCESS/BOOT LONWORKS/PARALLELING
WIRING ACCESS (OPTIONAL)

CONTROL BOX
(TOP VIEW)

CONTROL BOX

TB3
CARD
CAGE

OPTIONAL
RUN RELAYS
K11, K12 & K13

OPTIONAL
SHUTDOWN
ALARM RELAY K16

VOLTAGE
REGULATOR
MODULE
TB5
PT/CT
MODULE BUS PT
TB4
MODULE

TOP VIEW OF
CARD CAGE

OPTIONAL
TB8

FIGURE 3-12. CONTROL BOX ASSEMBLY

3-16
 RUN RELAYS (K11, K12, K13) as fans, pumps and motorized air dampers. The run
relays are energized when the generator set reach-
The optional run relays are rail mounted inside the es operating speed.
control box (Figure 3-12). The rail mount allows you
to easily remove and replace the snap-on relays. The contacts are rated:
The generator set can be equipped with one, two or
three run relays. 10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw run relays (Figure 6 amps at 240 VAC, 80%PF
3-13) are used to control auxiliary equipment such 3 amps at 480/600 VAC, 80%PF

K11, K12, K13

CUSTOMER
K11, K12, K13
CONNECTIONS

K11, K12, K13

K11 K12 K13

RUN RELAY RUN RELAY RUN RELAY

NO NO NO
NC NC NC

COIL TB3-7
TB3-5
(SWITCHED B+) COM (GND)

FIGURE 3-13. OPTIONAL RUN RELAYS (K11, K12, K13)

3-17
 ALARM RELAY (K16) such as audible alarms. Any generator set shut-
down will energize the alarm relay.
The optional alarm relay is rail mounted inside the
control box (Figure 3-12). The rail mount allows you The contacts are rated:
to easily remove and replace the snap-on relay. 10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw alarm relay (Figure 6 amps at 240 VAC, 80%PF
3-14) is often used to energize warning devices 3 amps at 480/600 VAC, 80%PF

K16

CUSTOMER
K16
CONNECTIONS

K16

K16
SHUTDOWN ALARM

NO
NC

COIL TB3-18
TB3-17
(COM ALARM) COM (GND)

FIGURE 3-14. OPTIONAL ALARM RELAY (K16)

3-18
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email [email protected]
www.cumminspower.com
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are trademarks of Cummins Inc.
E2010 Cummins Power Generation, Inc. All rights reserved.