S 6476
S 6476
S 6476
PowerStart 0600
Our energy working for you.TM
Description
The PowerStart control is a microprocessor-based generator set monitoring and control system. The control
provides a simple operator interface to the generator set, manual and remote start/stop control and shutdown fault
indication and AMF (Auto Mains Failure) Functionality. The integration of all control functions into a single control
provides enhanced reliability and performance compared to conventional generator set control systems. This control
has been designed and tested to meet the harsh environment in which gensets are typically applied. The PowerStart
generator set control is suitable for use on a wide range of generator sets in non-paralleling applications. It is
suitable for use with reconnectable or non-reconnectable generators, can be configured for either 50 Hz or 60 Hz
and voltage and power connection from 190-600 VAC line-to-line. This control includes an intuitive operator
interface that allows Genset start/stop for complete genset control as well as system metering, fault annunciation,
configuration and diagnostics. The interface includes seven generator set status LED lamps with both internationally
accepted symbols and English text to comply with customer needs.
The interface also includes an LED backlit LCD display with tactile-feel soft-switches for easy operation and screen
navigation. The manual/auto/stop switch function is integrated into overlay of the controller. All data on the control
can be viewed by scrolling through Screens with the navigation keys. Screen can be viewed either by scrolling
or non scrolling mode. Forward navigation and backward navigation is also provided. The control displays the
current active fault, fault occurrences and time-ordered history of the five previous faults with respect to Real Time
Clock Stamp, Engine Running Time. Power for this control is derived from the generator set Starting batteries and
functions over a voltage from 8VDC to 32VDC.
Overvoltage sensor
T
hree phase LL and LN overvoltage sensing for dropout adjustable from 105-135% of nominal and dropout adjustable delay from
0.5-120 sec
Timers
C
ontrol provides transfer time delays including Time delay engine start (0-3600 sec), time delay normal to emergency (0-300 sec) and
programmed transition delay (0-600 sec)
C
ontrol provides retransfer time delays including time delay emergency to normal (0-1800 sec) and programmed transition delay (0-600 sec),
time delay engine cooldown (0-3600 sec)
Protective functions:
On operation of a protective function, the control will indicate a fault Alternator protection
by illuminating the appropriate status LED, as well as display the fault
code and fault description on the LCD. The nature of the fault and Battleshort Mode
time of occurrence are logged in the control. The service manual and When enabled and Battleshort switch is active, the control will
InPowerTM Service Tool provide service keys and procedures based allow non-critical shutdown faults to be bypassed. If a bypass
onthe service codes provided. In Power is used to configure settings. shutdown fault occurs, the fault code and description will still
be annunciated, but the genset will not shutdown. This will be
followed by a fail to shutdown fault. Emergency stop
Configurable alarm input
critical shutdown faults are not bypassed.
T
he control accepts maximum three alarm inputs (contact closed Please refer to control service and operator manual for list of
to ground) to cause a shutdown or warning response from the critical faults
control.
High AC voltage shutdown (59)
Output voltage on any phase exceeds preset values. Values
Emergency stop adjustable from 105-125% of nominal voltage, with time delay
A
nnunciated whenever an emergency stop signal is received from adjustable from 1-10 seconds. Default value is 110% for 5
external switch. seconds.
Low AC voltage shutdown (27)
Voltage on any phase has dropped below a preset value.
Engine protection Adjustable over a range of 50-95% of voltage, time delay 2-20
Low lube oil pressure warning/shutdown - Level is preset to seconds. Default value is 90% for 5 seconds.
match the capabilities of the engine used. Control includes time Under frequency shutdown (81 u)
delays to prevent nuisance shutdown signals. Generator set output frequency cannot be maintained. Settings are
High coolant temperature warning/shutdown - Level is preset adjustable from 2-10 Hz below nominal governor set point, for a
to match the capabilities of the engine used. Control includes time 500-2000 half cycles delay. Default: 5 Hz, 1000 half cycles.
delays to prevent nuisance shutdown signals. Over frequency shutdown/warning (81 o)
Low coolant temperature warning - Indicates that engine Generator set is operating at a potentially damaging frequency
temperature may not be high enough for 1 min. and start or proper level. Settings are adjustable from 2-10 Hz above nominal governor
load acceptance. set point for 100-2000 half cycles delay. Default: 5 Hz, 1000 half
Sensor failure indication - Logic is provided on the base control cycles.
to detect analog sensor or interconnecting wiring failures. Loss of sensing voltage shutdown
Shutdown of generator set will occur on loss of voltage sensing
General engine protection: inputs to the control.
Current Imbalance Warning Fault
Low Fuel Level Warning - Indicates that engine fuel level reached the
Issues warning when current imbalance is observed per phase
Low Fuel Level Warning Threshold (30% by default).
when genset is in running state.
Charging Alternator Failure Warning - Indicates that engine charging High Current warning/shutdown (51)
alternator voltage reached the low/high charging alternator threshold Implementation of the thermal damage curve with instantaneous
when charging alternator enable trim is enabled. trip level calculated based on current transformer ratio and
application power rating.
ow and high battery voltage warning - Indicates status of
L
battery charging system (failure) by continuously monitoring Auto Mains Failure Protections:
battery voltage.
Weak battery warning - The control will test the battery each time Breaker/ATS Switch fail to close warning - when the control
the generator set is signaled to start and indicate a warning if the signals a ATS switch to close, it will monitor the ATS switch
battery indicates impending failure. feedback contacts and verifies that switch is closed. If the control
Cranking lockout - The control will not allow the starter to does not sense ATS switch closure within an adjustable time period
attempt to engage or to crank the engine when the engine is of ter the close signal, the fail to close warning will be initiated.
running. Breaker/ATS Switch fail to open warning - when the control signals
Fail to start shutdown - The control will indicate a fault if the a ATS switch to open, it will monitor the ATS switch feedback
generator set fails to start by the completion of the engine crack contacts and verifies that switch is opened. If the control does not
sequence. sense ATS switch opened within an adjustible time period after the
open signal, the fail to open warning will be initiated.
Environment
The control is designed for proper operation without recalibration in ambient temperatures from -15 °C (5 °F) to +70° C (158 °F), and for storage
from -20 °C (-4 °F) to +80 °C (176 °F). Control will operate with humidity up to 95%, non-condensing.
The control board is conformal coated to provide resistance to dust and moisture. The single membrane surface, which is impervious to effects of
dust, moisture, oil and exhaust fumes. This panel uses a sealed membrane to provide long reliable service life in harsh environments.
The control is specifically designed and tested for resistance to RFI/EMI and to resist effects of vibration to provide a long reliable life when
mounted on a generator set. The control includes transient voltage surge suppression to provide compliance to referenced standards.
Software
InPower (beyond 11.5.2.0 version) is a PC-based software service tool that is designed to directly communicate to PowerStart generator sets and
transfer switches, to facilitate service and monitoring of these products.
Certifications
PowerStart meets or exceeds the requirements of the following codes and standards:
CE marking: The control is suitable for use on generator sets to be CE-marked.
EN 50081-1,2 residential/light industrial emissions or industrial emissions.
EN 50082-1,2 residential/light industrial or industrial susceptibility.
ISO 7637-2, level 2; DC supply surge voltage test.
PowerStart control and generator sets are designed and manufactured in ISO 9001 certified facilities.
Warranty
All components and subsystems are covered by an express limited one year warranty. Other optional and extended factory warranties and local
distributor maintenance agreements are available.
Mechanical
Cummins Power Systems Offices