PowerCommand® 3201

digital generator set

control

Description Features
®
The PowerCommand 3201 Control is a microprocessor- Digital full authority electronic engine controls -
based generator set monitoring, metering and control Provide engine monitoring, protection and governing.
system. The control provides an operator interface to the These functions are integrated with voltage regulation and
genset, digital voltage regulation, digital governing and paralleling functions for optimum system performance.
generator set protective functions. It may incorporate
Digital voltage regulation - Provides fast, controlled
optional automatic digital paralleling controls and/or power
response to load changes and high levels of immunity to
transfer controls. The integration of all the functions into a
the effects of non-linear loads.
single control system provides enhanced reliability and
performance compared to conventional control systems. AmpSentry™ protective relay - UL Listed, true
alternator overcurrent protection.
The PowerCommand control is designed for mounting on
the generator set and is suitable for use on generator sets AC output metering - Includes analog and digital
ranging in size from 20 kW to 4000 kW. It will directly read display.
AC voltages up to 600 VAC and can be configured for any
Battery monitoring system - Senses and warns
frequency, voltage and power connection configuration
against weak battery condition that is not detected by
from 120 to 13,800 VAC. The operator panel may be
conventional DC over and undervoltage monitoring.
remote-mounted from the generator set and connected via
an RS485 network connection. Message display - Digital alarm and status.
The control offers a wide range of standard control and Generator set monitoring - Displays status of all
digital display features so custom control configurations critical engine and alternator generator set functions.
are not needed to meet application requirements and
Smart starting control system - Integrated fuel
system reliability is not compromised by use of untested
ramping to limit black smoke and frequency overshoot, in
special components.
addition to optimized cold weather starting.
Power for PowerCommand Control is usually derived from
Advanced serviceability - Utilizes InPower™, a PC-
the generator set starting batteries. It functions over a
based software service tool.
voltage range from 8 VDC to 35 VDC.
Digital power transfer control - Optional control
functions that allow operation in open transition, closed
transition or soft (ramping) transfer modes.
®
PowerCommand LonWorks network - Optional
network interface providing expanded input/output
capability, remote monitoring and control by annunciators
and other equipment, and easier installation.
Warranty - Backed by a comprehensive warranty and
worldwide distributor service network.

©2008|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch 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.
S-1444h (4/08) Page 1 of 10
Operator panel Operator adjustments - The control includes provisions
for many set up and adjustment functions via raise/lower
The operator panel provides the user with a complete switches on the operator panel. Functions that can be
package of easy to view and use information. It includes adjusted by the operator include:
an enhanced graphical operator panel that allows the user
- Time delay start (0-300 seconds)
to view up to 9 lines of information, as well as graphical
- Time delay stop (0-600 seconds)
displays of system data. Connections to the operator
- Alternator voltage (+5%)
panel are sealed, locking plug interfaces for reliable,
- Alternator frequency (+3 Hz)
vibration-resistant interconnection to the generator set
wiring harness. The operator panel can be configured to require an access
code prior to adjusting these values. A second access
Control switches and functions 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.

Analog AC metering panel

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 generator set can be started The PowerCommand control is equipped with an analog
using the exercise push-button or with a start signal from a AC metering panel that simultaneously displays 3-phase
remote device, such as automatic transfer switches. line-to-line AC volts and current, kW, power factor and
Manual run/stop control switch and indicating frequency.
LED - When the mode control switch is in the manual The meter panel is composed of a series of LEDs
position and the manual run/stop switch is pressed, the configured in bar graphs for each function. The LEDs are
generator set will start, bypassing all time delay starts. color coded with green indicating normal range values,
(Time delay idle can also be bypassed with another control amber for warning levels and red for shutdown conditions.
action.) If the generator set is running in the manual mode, Scales for each function are in % of nominal rated values.
pressing the run/stop switch will cause the generator set to
shut down. An LED (light emitting diode) lamp adjacent to Graphical display panel
the switch will light to indicate the generator set is in
manual mode.
Exercise control switch and indicating LED - When
the mode control switch is in the auto position 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.
Panel lamp/lamp test control switch. The PowerCommand control is provided with a graphical
display capable of displaying up to 9 lines of data with
Fault acknowledge/reset switch - The control approximately 27 characters per line. The graphical
includes a fault acknowledge function to allow the operator display is accompanied by a set of six tactile-feel
to reset the fault condition. If the fault condition is not membrane switches that are used by the operator to
corrected, the fault will reappear, but will not be logged as navigate through control menus and to make control
a separate event. Multiple faults can be logged and adjustments. Display is configurable for multiple
displayed at one time. languages. It is configurable for units of measurement.
Emergency stop control switch. The display incorporates three levels of operation and
adjustability. All data on the control can be viewed by
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©2008|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch 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.
S-1444h (4/08) Page 2 of 10
scrolling through screens with the navigation keys. The Digital synchroscope - Bus voltage and frequency,
top three lines of the display are allocated to mode and generator set bus voltage and frequency, the phase angle
status messages that continuously display the operating displacement and a signal indicating “ready to close”. A
mode of the control system, as well as any faults or breaker control switch is included on this panel for
warning conditions that may be present on the controller. convenient operation of the equipment without switching
If more than one fault or warning message is present, the between viewing screens.
messages will scroll to allow the operator to view all active
messages in the system. Engine data
Basic engine data - Engine starting battery voltage,
Screen-saver mode - The operator panel can be
engine lube oil pressure and engine coolant temperature.
programmed to automatically switch off to reduce battery
voltage drain when the control is not being used and the Engine service data - Varies with engine used, but
generator set is not running. Depressing any button on the typically includes: Engine coolant pressure, engine fuel rail
operator panel, new fault conditions or receipt of a remote temperature and pressure, engine fuel input and output
signal at the control will “wake up” the control. temperature, intake manifold temperature and pressure,
ambient air pressure, crankcase blowby flow and
Generator set data aftercooler inlet coolant temperature.
Generator set hardware data - Generator set rating in Engine fuel consumption - The fuel consumed by the
kVA, complete generator set model number and serial engine is calculated by the control based on fuel flow into
number, engine model and serial number and alternator the engine and returned by the engine, and the
model and serial number. The control also displays the temperature of the two flow streams. Accuracy is + 5%
part number of the control and the software version over 500 hours of operation. Data provided includes
present in the control. overall average fuel consumed and consumption since
Data logs - Number of start attempts and number of start reset. This information is read with InPower.
attempts since reset. Number of times generator set has Engine exhaust temperature (optional).
run and number of times since reset. Duration of
generator set running time and duration of running time Power transfer control data (optional)
since last reset. Generator set kWh produced and kWh
Utility (mains) source data - Displays line-to-line and
produced since last reset.
line-to-neutral voltage of utility (mains) source, frequency
Adjustment history - Record of adjustment and setting and estimated amps, and kW and kVA supplied by utility
changes made on the control, identifies whether (mains) source (optional when power transfer control is
adjustment was made via the operator panel or with a used).
service tool. If a service tool is used, the control provides
System status information - Provides graphical
a record of the serial number of the tool used. This
system status display showing availability of sources and
information is read with InPower.
positions of each contactor.
Fault history - Record of the most recent fault conditions
System control - Allows operator to view status of
with time stamp, along with the number of times each fault
system and manually control operation of the system.
has occurred. At least 20 events are stored in the control
Provides manual adjustment capability for time delay start,
memory.
stop, transfer and retransfer, as well as time delays for
Load profile data - Data indicating the total operating program transition (when used) and power transfer overlap
hours at percent of load in 10% increments and since time.
reset.
Internal control functions
Generator set AC data
General functions
Generator set output frequency, voltage and
current - All phases (line-to-line and line-to-neutral for System control voltage - The control operates on 24
voltage. Accuracy 1%. VDC from the generator set starting batteries. Control
functions are fully operational over a voltage range of 8
Generator set power output - PowerCommand VDC to 36 VDC.
displays generator set kW and kVA output (average phase,
individual phase and direction of flow) and power factor Emergency start mode - PowerCommand accepts a
with leading/lagging indication. Accuracy 5%. ground signal from remote devices or a network signal to
automatically start the generator set and immediately
Generator set kWh energy output - Total kWh accelerate to rated speed and voltage.
produced and total produced since last reset with time
stamp of time of last reset. PowerCommand includes a smart starting system that is
designed to quickly start the engine, minimize black
smoke, minimize voltage and frequency overshoot, and
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©2008|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch 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.
S-1444h (4/08) Page 3 of 10
oscillations on starting. The control system does this by engine protective functions are adjusted for the lower
careful simultaneous control of the engine fuel system and engine speed and alternator function is disabled.
alternator excitation system.
Time delay start and stop (cool down) - Configurable
Non-emergency start mode - The control is provided for time delay of 0-300 seconds prior to starting after
with a separate remote start input or a network signal to receiving a remote start signal in normal operation modes
start the generator set via the programmable idle control. and for time delay of 0-600 seconds prior to ramp-to-idle
Using the non-emergency mode, the generator set takes or shutdown after signal to stop in normal operation
longer to start, but there is less wear on the engine. In this modes. The generator set control will monitor the load
start mode, the generator set will start, operate at idle during operation of the generator set, and if the total load
speed for a predefined time period or until the engine on the set is less than 10% of rated it will reduce the
reaches operating temperature (whichever time is shorter), operation time for the time delay stop in order to prevent
and then ramp to rated speed and voltage. Time delay is extended operation of the engine at very light load levels.
adjustable from 0-300 seconds and default is 10 seconds. Default for both time delay periods is 0 seconds.
The control also monitors and records the source of start
signals, when that information is available. The control Engine governing
automatically exits idle mode if an emergency remote start Isochronous governing - Controls engine speed within
signal is received at the control. + 0.25% for any steady state load from no load to full load.
Data logging - The control maintains a record of manual Frequency drift will not exceed + 0.5% for a 33 °C (60 °F)
control operations, warning and shutdown conditions and change in ambient temperature over an 8 hour period.
other events. It uses the control “on” time as the time- Droop governing - Control can be adjusted to droop
stamp means when a real time clock is not included with from 0 to 10% from no load to full load, using InPower.
the control. The control also stores critical engine and
alternator data before and after a fault occurs, for use by Temperature dynamics - Modifies the engine fuel
InPower and the technician in evaluating the root causes system control parameters as a function of engine
for the fault condition. temperature. Allows engine to be more responsive when
warm and more stable when operating at lower
Fault simulation mode - PowerCommand, in temperature levels.
conjunction with InPower software, will accept commands
to allow a technician to verify the proper operation of Isochronous load sharing control - See Paralleling
critical protective functions of the control by simulating Functions/Load sharing controls.
failure modes or by forcing the control to operate outside Droop load sharing control - See Paralleling
of its normal operating ranges. InPower also provides a Functions/Load sharing controls.
complete list of faults and settings for the protective
functions of the specific generator set it is communicating Idle mode - Engine governing can be regulated at an idle
with. speed for a programmed period on start or stop of the
engine. When the engine is operating at idle speed, the
Built in test - The control system automatically tests alternator excitation is automatically switched off.
itself, and all the sensors, actuators and harnesses in the
control system, on a startup signal. The test can also be Alternator control
initiated from InPower and can be accomplished either
locally to the generator set or remotely. Digital output voltage regulation - PowerCommand
will regulate output voltage to within 0.5% for any loads
Engine control between no load and full load. Voltage drift will not exceed
+ 0.5% for a 33 °C (60 °F) change in temperature in an 8
Engine starting - The control operates a factory- hour period. On engine starting, or sudden load
supplied fuel valve that enables engine starting. acceptance, voltage is controlled to a maximum of 5%
Cycle cranking - Configurable for number of starting overshoot over nominal level.
cycles (1 to 7) and duration of crank and rest periods. Torque-matched V/Hz overload control - The voltage
Control includes starter protection algorithms to prevent roll-off set point and rate of decay (i.e., the slope of the
the operator from specifying a starting sequence that V/Hz curve) is adjustable in the control. This function is
might be damaging. Default setting is for (3) start cycles automatically disabled when the control is in a
composed of 15 seconds of cranking and 15 seconds of synchronizing mode.
rest.
Fault current regulation - PowerCommand will
Programmable idle speed control - In this mode the regulate the output current on any phase to a maximum of
generator set would start and run to idle speed. It would 3 times rated current under fault conditions for both single
operate at that speed for a programmed time period, then phase and three phase faults. In conjunction with a
ramp to rated speed. When the control gets a signal to permanent magnet generator, it will provide 3 times rated
stop, it will ramp to idle, operate for the programmed current on all phases for motor starting and short circuit
period at idle and then shut down. During idle mode, coordination purposes.
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©2008|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch 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.
S-1444h (4/08) Page 4 of 10
Isochronous (kVar) load sharing control - See auxiliary contacts and verify that the breaker has
Paralleling Functions/Load sharing controls. connected the generator set to the system bus. If the
control does not sense a breaker closure within 0.5 second
Droop (kVar) load sharing control - See Paralleling
of the close signal, the control will monitor the phase
Functions/Load sharing controls.
relationship between the generator set and the bus. If this
indicates that the generator set is not closed to the bus,
Protective functions the “breaker fail to close” alarm will be indicated, the
On a warning condition, the control will indicate a fault by breaker will be opened and the generator set shut down. If
lighting the warning LED on the control panel and the phase relationship monitor indicates that the generator
displaying the fault name and code on the operator display set is in parallel with the bus, “circuit breaker auxiliary
panel. The nature of the fault and time of occurrence are contact failure” will be indicated and the generator set will
logged in the control. The service manual and InPower continue to run in normal operation mode.
service tool provide service keys and procedures based on Breaker fail to open warning - The control system
the service codes provided. monitors the operation of breakers that have been signaled
On a shutdown condition, the control will light the to open. If the breaker does not open within 1 second of
shutdown LED on the control panel, display the fault name initiation of signal, a “breaker fail to open” warning is
and code, initiate shutdown and lock out the generator set. initiated. The control will logically allow the generator set
The shutdown sequence of the generator set includes to continue to run if shutdown of the generator set with the
programmable cooldown at idle for fault conditions that do breaker closed will cause potential damage or operating
not endanger the engine. The control maintains a data log problems.
of all fault conditions as they occur and time stamps them Bus or generator set PT input calibration error -
with the controller run time and engine operating hours The control system monitors the sensed voltage from the
data. Adjustments to most set points are made using the bus and generator set output voltage-potential
InPower service tool. transformers. When the paralleling breaker is closed, it will
The control system includes a “fault bypass” mode that indicate a warning condition when they read different
forces the system to function regardless of the status of values.
protective functions. In this mode, the only protective Emergency stop - Annunciated whenever the local or
functions that are operational are over speed, loss of both remote emergency stop signal is received. Alarm panel
speed sensors, moving the control switch to the off distinguishes between local or remote operation.
position or pressing the emergency stop switch. The
control maintains a record of the time that the mode is AmpSentry protective relay
enabled and of all warning or shutdown conditions that
have occurred while in the “fault bypass” mode. AmpSentry protective relay is a UL Listed comprehensive
monitoring and control system integral to the
Many protective functions within the control system are PowerCommand Control System that guards the electrical
configurable for warning, shutdown or both (2 levels). integrity of the alternator and power system by providing
Exceptions to this include functions such as over speed protection against a wide array of fault conditions in the
conditions, and loss of speed sensing. In addition, some generator set or in the load. It also provides single and
warning functions can incorporate control functions as a three phase fault current regulation so that downstream
consequence of a fault. protective devices have the maximum current available to
quickly clear fault conditions without subjecting the
System protective functions: alternator to potentially catastrophic failure conditions.
Ground fault warning (option - 600 VAC class See document R1053 below for a full size time over
generator sets) - Ground (earth) fault sensing is current curve. The control does not include protection
adjustable over a range of 100-1200 amps with time required for interconnection to a utility (mains) service.
delays of 0-1 second. May be configured for shutdown Over current warning - Output current on any phase at
rather than alarm. more than 110% of rating for more than 60 seconds.
Configurable alarm and status inputs - Over current shutdown (51V) - Output current on any
PowerCommand will accept up to four alarm or status phase is more than 110%, less than 175% of rating and
inputs (contact closed to ground) to indicate customer- approaching thermal damage point of alternator. Control
specified conditions. The control is programmable for includes algorithms to protect alternator from repeated
warning, shutdown or status indication and for labeling the over current conditions over a short period of time. The
input (up to 24 characters). Sixteen additional faults can control does not include instantaneous trip functions, as
be input to the control via the network. they are not necessary for alternator protection and
Breaker fail to close and breaker auxiliary contact complicate short circuit coordination (discrimination).
warning or shutdown - When the paralleling control
signals a circuit breaker to close, it will monitor the breaker
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©2008|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch 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.
S-1444h (4/08) Page 5 of 10
 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 rated kW, 0-120 second
delay. Defaults: 105%, 60 seconds.
Reverse power shutdown (32) - Adjustment range: 5-
20% of standby kW rating, delay 1-15 seconds. Defaults:
ALTERNATOR THERMAL 10%, 3 seconds.
DAMAGE CURVE
10 Sync check (25) - Verifies that the generator set is
operating in synchronism with the system bus prior to
AMPSENTRY
allowing the paralleling breaker to close. Includes dead
PROTECTION bus sensing capability.
1
Fail to synchronize warning or shutdown -
Indicates that the generator set could not be brought to
synchronization with the system bus. Configurable for
0.1
warning or shutdown and adjustable for time delay of 10-
120 seconds. Default is 120 seconds.
0.05

Phase sequence sensing shutdown - Verifies that the

generator set phase sequence matches the bus prior to
1 3 10 100
allowing the paralleling breaker to close. The generator set
AMPS (TIMES RATED) will shutdown if the generator set and bus phase sequence
do not match.
Short circuit shutdown (51) -Output current on any Reverse Var shutdown - Shutdown level is adjustable:
phase is more than 175% of rating at time of shutdown. 15-50% of rated Var output, delay 10-60 seconds.
The control replicates the function of a 51V relay by Defaults: 20%, 10 seconds.
discriminating between short circuit conditions and
High alternator temperature (option).
shutdown conditions, and shutting down the genset as
fast as is necessary on a short circuit condition while Engine protection
operating as long as is possible on an overload condition.
Control includes algorithms to protect alternator from Over speed shutdown - Default setting is 115% of
repeated over current conditions over a short time. nominal.
High AC voltage shutdown (59) - Output voltage on Low lube oil pressure shutdown - Level is preset to
any phase exceeds preset values. Time to trip is inversely match the capabilities of each engine. Control includes
proportional to amount above threshold. Values time delays to prevent nuisance shutdown signals.
adjustable from 105-125% of nominal voltage, with time Low lube oil pressure warning - Level is preset to
delay adjustable from 0.25-10 seconds. Default value is match the capabilities of each engine. Control includes
110% for 10 seconds. time delays to prevent nuisance shutdown signals.
Low AC voltage shutdown (27) - Voltage on any High coolant temperature shutdown.
phase has dropped below a preset value. Adjustable over
a range of 50-95% of reference voltage, time delay 2-10 High coolant temperature warning.
seconds. Default value is 85% for 10 seconds. Function Low coolant pressure warning/shutdown.
tracks reference voltage. Control does not nuisance trip
when voltage varies due to the control directing voltage to Low coolant level warning/shutdown.
drop, such as during a voltage roll-off during Low coolant temperature warning - Indicates that
synchronizing. engine temperature may not be high enough for a 10
Under frequency shutdown (81u) - Generator set second start or proper load pickup.
output frequency cannot be maintained. Settings are Low and high battery voltage warning - Indicates
adjustable from 0-10 Hz below nominal governor set point, battery charging system failure by continuously monitoring
for a 0-20 second time delay. Default: 6 Hz, 10 seconds. battery voltage and indicating a problem when voltage is
Under frequency protection is disabled when excitation is outside a preset acceptance band.
switched off (such as when engine is operating in idle
speed mode or the synchronizer is enabled). Discharged battery protection - When DC voltage is
below a preset threshold, the control will shut down to
Over frequency shutdown/warning (81o) - Generator avoid completely discharging the battery.
set is operating at a potentially damaging frequency level.
Defaults: Disabled.

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©2008|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch 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.
S-1444h (4/08) Page 6 of 10
Weak battery warning - The control system will test the system determines kW load on the engine and kVar load
battery bank each time the generator set is signaled to on the alternator as a percent of generator set capacity,
start and indicate a warning if the generator set battery and then regulates fuel and excitation systems to maintain
indicates impending failure. system and genset at the same percent of load without
impacting voltage or frequency regulation. The control can
Fail to start (overcrank) shutdown.
also be configured for operation in droop mode for kW or
Fail to crank shutdown - Control has signaled starter to Kvar load sharing.
crank engine but engine does not rotate.
Load govern controls - When PowerCommand receives
Redundant starter disconnect. a signal indicating that the generator set is paralleled with
an infinite source such as a utility (mains) service, the
Redundant speed sensors - Loss of one sensor results
generator set will operate in load govern mode. In this
in a mag pickup sensor warning. Loss of both sensors
mode the generator set will synchronize and close to the
results in mag pickup failure.
bus, ramp to a pre-programmed kW and kVar load level,
Low fuel day tank and low fuel main tank warning. and then operate at that point. Control is adjustable for
Cranking lockout - The control will not allow the starter kW values from 0-100% of standby rating, and 0.7-1.0
to attempt to engage or to crank the engine when the power factor (leading). Default setting is 80% of standby
engine is rotating. and 1.0 power factor. The control includes inputs to allow
independent control of kW and kVar load sharing level by a
Sensor failure indication - All analog sensors are remote device while in the load govern mode. The rate of
provided with sensor failure logic to indicate if the sensor load increase and decrease is also adjustable in the
or interconnecting wiring has failed. Separate indication is control.
provided for fail high or low.
Load demand control - The control system includes the
High crankcase blowby level warning. ability to respond to an external signal to initiate load
High fuel temperature warning. demand operation. On command, the generator set will
ramp to no load, open its paralleling breaker, cool down,
High intake manifold temperature/pressure. and shut down. On removal of the command, the
Aftercooler cooler inlet over temperature. generator set will immediately start, synchronize, connect,
and ramp to its share of the total load on the system.
Paralleling functions (optional)
Power transfer control (optional)
First Start Sensor™ System - PowerCommand
provides a unique control function that positively prevents The Power transfer control feature allows PowerCommand
multiple generator sets from simultaneously closing to an to provide integrated automatic power transfer functions
isolated bus under black start conditions. The First Start including source availability sensing and transfer device
Sensor system is a communication system between (circuit breaker) monitoring and control. The control is
generator sets that allows the generator sets to work configurable for open transition, fast transfer (100 mS), or
together to determine which generator set in a system soft (ramping) sequences of operation. Standard functions
should be the first to close to the bus. The system include:
includes an independent backup function, so that if the • 3-phase (line-to-neutral) close differential under voltage
primary system is disabled the required functions are still sensing for utility (mains) service. Sensing for pickup in
performed. an adjustable range from 85-100% of nominal, with
Synchronizer - PowerCommand incorporates a digital default at 95% of dropout setting. Dropout is
synchronizing function to force the generator set to match configurable 75-98% of pickup, with default at 85%.
the phase relationship and voltage of the generator set • 3-phase over voltage sensing for normal utility service
output with the system bus or utility grid. The adjustable for pickup at 95-105% of dropout and
synchronizer includes provisions to provide proper dropout configurable for 105-135% of nominal. Time
operation even with highly distorted bus voltage delay is adjustable in a range of 0.5-120 seconds.
waveforms. The synchronizer includes adjustments for Default is disabled and is enabled using InPower.
phase angle window (5°-20°) and time delay (0.5-5
seconds). The synchronizer is 3-phase sensing, and • Under frequency sensing for normal utility service.
includes controls to directly operate a paralleling breaker. Adjustment range is 80-95% of nominal. Default is
The breaker controls include fail to open and fail to close disabled and is enabled using InPower.
protection. • Configurable sequence of operation with or without
Load sharing controls - The generator set control adjustable program-transition capability. Adjustment
includes an integrated load sharing control system for both range is 0-60 seconds.
real (kW) and reactive (kVar) loads when the generator • Remote exercise feature accepts a remote signal to
set(s) are operating on an isolated bus. The control initiate with or without load testing, or testing can be
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©2008|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch 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.
S-1444h (4/08) Page 7 of 10
 initiated by the operator. Test sequence may include a Control interface
programmed idle period prior to acceleration to rated
voltage and frequency, and after cool down. Test may Input signals to the PowerCommand control
be configured to be performed with load or without load. include:
• Time delay start and stop as described in this document; Remote start signal - May be connected via either
®
time delay transfer adjustable in a range of 0-120 discrete signal or Lon Network or both for premium
seconds and retransfer in a range of 0-1800 seconds; all reliability. Discrete signal is normally open contact to
in 1-second increments. ground or normally closed contact that opens to indicate
start signal. Separate signal inputs available for
• Fail to disconnect timer is adjustable in a range of 0.1 to emergency start and non-emergency start.
120 seconds.
Remote emergency stop.
Environment Low main or day tank fuel level warning.
The control is designed for proper operation without Remote alarm reset.
recalibration in ambient temperatures from -40 °C to +70
Load demand stop.
°C (-40 °F to +158 °F) and for storage from -40 °C to +80
°C (-40 °F to +176 °F). Control will operate with humidity Utility parallel (load govern) mode command.
up to 95%, non-condensing and at altitudes up to 5000 m
Configurable customer inputs - Control includes
(13,000 ft).
provisions for (4) input signals from customer discrete
The operator control panel has a single membrane surface devices. (16) additional input signals can be implemented
which is impervious to the effects of dust, moisture, oil and with the use of external network modules.
exhaust fumes. The panel uses sealed membrane or oil-
tight switches to provide long reliable service life in harsh Output signals from the control include:
environments. Generator set running signal - Fused normally open
The control system is specifically designed for resistance contact rated 5 A at 30 VDC/180 VAC, closes to indicate
to RFI/EMI and to resist the effects of vibration to provide generator set is running.
a long reliable life when mounted on a generator set. The
Generator set common shutdown signal - Self-
control includes transient voltage surge suppression to
protected relay driver.
provide compliance to referenced standards.
Load shed signal - Self-protected relay driver.
The control is mounted on a vibration-isolated structure
Operation is configurable for under frequency or over kW
attached to the generator set skid and includes all
load or both. Adjustment range is 80-140% of standby
generator set wiring factory-installed.
rating with time delay of 0-120 seconds. Default settings
are overload 105%, 60 sec, and under frequency 3 Hz
below governor reference for 3 seconds.
Ready to load signal - Self-protected relay driver.
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.
Modem control signal - Self-protected relay driver.
Paralleling breaker interface - Fused normally open
relay contact (5 A, 30 VDC/180 VAC) for parallel breaker
close signal and normally open contact for parallel breaker
open signal.
Control power for auxiliary devices is available from the
controller.

Network connections include:

Serial interface - This communication port is to allow
the control to communicate with a personal computer
running InPower service and maintenance software.
Echelon® LonWorks interface (option) – System
allows for fast, effective incorporation of auxiliary I/O,
remote annunciation, redundant start commands from
Cummins transfer switches, and other control functions.
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www.cumminspower.com
©2008|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch 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.
S-1444h (4/08) Page 8 of 10
Software Options and accessories
InPower - An optional PC-based software service tool ‰ Isolated bus paralleling. Provides all automatic and
that is designed to directly communicate to manual paralleling functions for systems that operate
PowerCommand generator sets and transfer switches to isolated from the utility service.
facilitate service and monitoring of these products. ‰ Full function paralleling. Provides all paralleling
PowerCommand for Windows® - An optional functions, including automatic and manual operation,
software tool that is used to remotely monitor and control protection, and other features described in this
generator sets, transfer switches and other on-site power document.
system devices. ‰ Open transition power transfer control. Control will
operate two circuit breakers to provide power transfer
Certifications between a normal source and a generator in a “break
before make” sequence.
PowerCommand meets or exceeds the requirements of ‰ Fast closed transition power transfer control. Control
the following codes and standards: will operate two circuit breakers to provide power
NFPA110: For Level 1 systems transfer between a normal source and generator in a
“make before break” sequence between live sources,
UL508: Recognized or Listed and suitable for use on UL
and “break before make” from a failed source.
2200 Listed generator sets
Overlap between sources is 100 mS or less.
CSA C282-M: 1999 compliance
‰ Closed transition (ramping) power transfer control.
CSA 22.2 No. 14 M91: Industrial Controls Control will operate two circuit breakers to provide
ISO 8528-4: 1993 compliance, Controls and Switchgear power transfer between a normal source and
NFPA99: Standard for Health Care Facilities generator in a “make before break” sequence between
CE Mark live sources, and “break before make” from a failed
source. Overlap time between sources is
EN 50081-1: Residential, Commercial, Light Industrial
configurable, and control ramps load from source to
EN 50081-2: Industrial source to minimize disturbances on transfer.
EN 50082-1: Residential, Commercial, Light Industrial ‰ Key-type mode select switch.
EN 50082-2: Industrial ‰ Ground fault alarm module.
ISO 7637, pulses #2b, 4: DC Supply Surge Voltage
Test
‰ Exhaust temperature monitoring.

Mil Std 202C, Method 101: Salt Fog Test ‰ Alternator temperature monitoring.
ANSI C62.41: Surge Withstand ‰ Network Interface Module
IEC 801.2, 3, 4, 5 ‰ Digital remote annunciator. (See S-1343)
ISO9001: PowerCommand control systems and ‰ Digital output relay module (See S-1431)
generator sets are designed and manufactured in ISO9001 ‰ ®
Modbus interface. (See S-1471)
certified facilities.
‰ Cummins Power Generation iWatch™ remote
monitoring system (S-1518)
Warranty
‰ Cummins Power Generation iWatch Wireless™ remote
PowerCommand control systems are a part of complete monitoring system (S-1572)
power systems provided by Cummins Power Generation
and are covered by a one year limited warranty as a ‰ ILSI (isochronous load sharing interface). Allows
standard feature. PowerCommand to share real load with other load
sharing systems that incorporate analog load sharing
Extended warranty options are available for coverage up to lines. See document C604 for more information.
10 years.
‰ Utility protective relaying. Gensets can be provided
with power switching mechanisms and utility grade
protective relaying to meet local grid protection
requirements.

Our energy working for you.™

www.cumminspower.com
©2008|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch 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.
S-1444h (4/08) Page 9 of 10
See your distributor for more information

Cummins Power Generation

Americas Europe, CIS, Middle East and Africa Asia Pacific
rd
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 electrical except
through an approved device or after building main breaker is open.

Our energy working for you.™

www.cumminspower.com
©2008|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch 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.
S-1444h (4/08) Page 10 of 10