Trainer’s Guide

CMT0642ĆENĆTG
04/2004
PowerCommand Control 3200 Introduction

Revision History

v1.6 (04/2004)
1. Updated from trainer’s comments/changes January 2004 USAF class

v1.5 (07/2003)
1 Updated TG to match PG 07/03 updates

v1.4 (01/2003)
1. Updated lesson 2 to match PG additions in November 2002.
2. Updated lesson 3 to get visuals to match PG.
3. Updated lesson 4 to get visuals to match PG.
4. Updated lessons 5–8 to match visuals in PG.

v1.3 (11/2002)
1. Updated lesson 7 to remove need for 5K Ohm resistor in Droop Paralleling and Reactive
Droop Compensation
2. Changed Instructor’s Guide at bottom of pages to Trainer’s Guide and removed all
Cummins/Onan logos in footers.
3. Removed Lesson: on first page of lesson sections and in headers.

v1.2 (02/2002)
1. Updated InPower section due to update to InPower v 2.80

v1.1 (02/2000)
1. Numerous revisions found in first QTQ session. Many sections involved in this revision,
subtle changes to text and diagrams.

v1.00 (02/1999)
1. Initial draft for first QTQ session in 1999

Cummins, Onan, and PowerCommand are registered trademarks of Cummins Inc.

Copyright E 1999–2004 by Cummins Power Generation

Trainer’s Guide i-1

Introduction PowerCommand Control 3200

PowerCommand) Control 3200 Module

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
The introduction describes the audience, the purpose, and the structure of
the training module.

Introduction to the PowerCommand Control 3200 . . . . . . . . . . . . . . . . . . . . 1-1

This lesson presents an overview of the PowerCommand Control. The
participant will learn to identify the main features of the PowerCom-
mand Control.

Introduction to the PowerCommand Control 3200 Hardware . . . . . . . . . . . 2-1

This lesson presents an introduction to the PowerCommand Control
3200 on a generator set

PowerCommand Control 3200 Operator Menus . . . . . . . . . . . . . . . . . . . . . . . 3-1

This lesson presents the menu system used in the PowerCommand Con-
trol.

PowerCommand Control 3200 Sequence of Operation . . . . . . . . . . . . . . . . 4-1

This lesson covers the sequence of operation for local and remote opera-
tion of the GenSet control from initiation of the run signal to completion
of cooldown period and stopping of the set.

PowerCommand Control 3200 Service Menus . . . . . . . . . . . . . . . . . . . . . . . . 5-1

This lesson presents an overview of the PowerCommand Control Ser-
vice Manual.

PowerCommand Control 3200 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 6-1

This lesson presents the troubleshooting steps and job aids for the Power-
Command Control. It will cover the use of the troubleshooting sections
of the Service Manual, reading wiring diagrams, and the use of the break-
out box for troubleshooting common problems on a generator set.

PowerCommand Control 3200 GenSet Installation . . . . . . . . . . . . . . . . . . . . 7-1

This lesson presents the steps required to properly install a GenSet with a
PowerCommand Control 3200.

i-2 Trainer’s Guide

PowerCommand Control 3200 Introduction

PowerCommand Control 3200 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

This lesson presents an overview of the PowerCommand Control 3200
Service Manual.

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
This section lists the most common terms used throughout this training
module pertaining to the PowerCommand Control 3200 first used on the
QSK45/60 generator sets.

Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Participant In-class and Homework Activities.

Activity Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-1

Answers to Participant In-class and Homework Activities.

Module Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Final exam and answer key for the PCC-3200 class.

Comment Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Evaluation of class material and instruction.

Trainer’s Guide i-3

Introduction PowerCommand Control 3200

Introduction

Welcome! Welcome to the Instructor’s Guide for the

PowerCommand Control 3200 module! This guide was
written by Cummins Power Generation’s Sales and
Technical Training department to make your job as a
instructor easier.

We suggest you read through the entire Introduction to

become familiar with the guide’s structure. Then, just
follow the step-by-step instructions for each lesson.

Module Purpose The purpose of the PowerCommand Control 3200 module

is to help Cummins Power Generation distributor service
technicians better understand the PowerCommand Control
3200 which is going to be used on paralleling and standby
Gensets with Full Authority Electronic (FAE) engines.

With this information, our technical force will be better

prepared to meet our customers’ varying needs.

Module Audience This module was written for Cummins Power Generation
distributor trainers who have previous experience with or
knowledge of electrical, engine, and generator basics.

Module Structure This module contains lessons on related topics. Each lesson
follows a carefully designed training format, including a
warm up, presentation, and activity (or exercise).

Lesson Format

Warm ups help you focus and begin thinking about the
lesson topic. The presentation portion of the lesson is
where you receive new information. The activity follows
the presentation; it gives you the chance to practice new
skills or work with new ideas.

This module covers PowerCommand Networks theory at

an overview level, hardware, and software.

The second half of the course is mainly hands–on for the

participants.

i-4 Trainer’s Guide

PowerCommand Control 3200 Introduction

Module Assessment

After completing all the lessons in this module, you will

have the participants complete a written module
assessment. The module assessment (section 9 of the
Trainer’s Guide) lets us evaluate the level of knowledge
you have on the topic after completing the module.

After reviewing the written assessment, we expect you to

have the participants also complete the performance
assessment (section 10 of the Trainer’s Guide). This lets the
participants know if they have understood the materials
well enough to use the instruction they received in the field
and commission customers’ networks.

Module Comment Form

You will also have the participants complete a module

comment form. This form gives you the chance to comment
on the usefulness and effectiveness of the training module
and make suggestions for improvements.

We will use the results from the module assessment and

module comment form to help us determine if there is a
need to modify the module.

Please mail the module assessments and comment forms to

the Cummins Power Generation Sales and Technical
Training department as soon as possible after the training
session. The address is:

Cummins Power Generation

Sales and Technical Training
OF282
1400 73rd Avenue N.E.
Minneapolis, MN. 55432

Preparing for the To simplify your preparations for the training session,
Training Session we’ve broken out your major tasks.

1. Coordinate the session—Arrange for a location, date,

and time convenient for the session participants. Plan
the session as far in advance as possible.

Trainer’s Guide i-5

Introduction PowerCommand Control 3200

Try to arrange for a quiet, seminar-type meeting place,

away from the participants’ regular work area.
Do as much as possible to help make participants
comfortable. Arrange for refreshments and meals, if
appropriate.
2. Preview the lessons—Review the lesson objectives and
read through the trainer’s instructions. Use the Notes
column to write any comments or additional
information you want to include.
3. Practice your presentation—You’ll feel more at ease
if you practice the presentation portion of each lesson at
least once before the session. The participants will also
be more attentive if you appear organized and prepared.
4. Organize and prepare the module training
materials—Make copies of the written examination,
the module assessment, and the module comment forms
(found at the back of this trainer’s guide) for each
participant to complete at the end of the module.
Review the Materials Needed section at the beginning
of each lesson and order the appropriate number of
participant’s guides, service literature, and materials in
advance from Onan’s Literature department using a
copy of the form found at the end of this section.
Note: We recommend you order materials two to
three weeks in advance of your session.
5. Arrange for training equipment—For this training
course you will need an overhead projector and screen,
a flipchart stand with paper and markers or a
whiteboard and markers, and PowerCommand
Networks hardware and software for the module.
6. Confirm attendance—A few days before the session,
verify who will be attending. We recommend
conducting the session with four to twelve participants.
7. Set up the room—Plan to arrive at least 30 minutes
before the session begins. Check the lighting, acoustics,
and temperature of the room. Find out how to adjust the
lighting and temperature.

i-6 Trainer’s Guide

PowerCommand Control 3200 Introduction

Make sure all equipment (such as overhead projector,

extra bulbs, flipchart stands) are in place and in
working order before the session begins.

The Training Session Training Session Hours

This training session is designed as a 24-hour course. When
this course is presented at the factory we have delivered the
course from 8:00 to 4:00 Monday through Wednesday, and
have completed all sections and qualification testing.

Conducting the Introductions

Training Session
At the beginning of the session, have each person introduce
himself or herself and say a few words about his or her
experience on the subject to be covered.

As an alternative, you might want to let participants

interview each other and introduce the person they
interviewed to the group.

If participants do not know each other, make name tags and

table top name tents and ask participants to use them
throughout the session.

Expectations

After introductions, label a flipchart page with the word

Expectations. Ask the participants what expectations they
have for the session, then explain which of their
expectations you will be able to address.

If you will not be able to address all of the participants’

expectations, arrange to follow up on their concerns at a
later date.

Lessons

The first time you conduct the training for this module,
follow the step-by-step lesson instructions. Feel free to add
comments from your own experience, but follow the
structure of the module. Once you are familiar with the
module you can modify the session for the specific needs
of the group.

Trainer’s Guide i-7

Introduction PowerCommand Control 3200

Trainer’s Checklist

Use this check list to help you prepare for the training session.

Before You Begin

Review lesson objectives and read through step-by-step instructions.

Scheduling

• Set session date and time

• Reserve meeting room

• Arrange for refreshments / meals

Participants

• Send session announcements to participants

• Verify number of participants attending

Materials
See Materials Needed section at the beginning of each lesson

• Download latest Trainer’s Guide and Visuals from PowerGen U

• Download and print Participant Guides, Print sets, etc. from

PowerGen U

• Order additional lesson materials (see included list)

• Make copies of the Module qualification exam and comment sheet

Equipment

• LCD projector, screen, and extra bulbs

• Flipchart stand, paper, markers, and masking tape

• Training versions of PowerCommand Controls 3200 and

simulators

i-8 Trainer’s Guide

PowerCommand Control 3200 Introduction

• PowerCommand Tool Kits and Wrist Straps for participants

• PCC 3200 Tool Kit for breakout practice in troubleshooting lesson.

• One Universal Simulator for each workstation

• Extension cords
• Screwdrivers and flashlights for each workstation.

Practice

• Review the lesson instructions and practice the presentation

portion of the module at least once before the session; be sure to
use all of the training materials in your review.

Room Setup

• Arrive at least 30 minutes before session start time

• Locate lighting and temperature control switches

• Arrange tables and equipment

Trainer’s Guide i-9

Introduction PowerCommand Control 3200

HOW TO ORDER MATERIAL

REMEMBER...

Order the following material through Western Graphics

- Participant’s Guides

- Service Manuals

- Installation and Operator’s Manuals

- Specification Sheets

Materials Needed for the PCC 3200 class

Description Order/Part Number Quantity

PowerCommand Control 3200 Participant’s Guide 1) 932-0367

PowerCommand Control 3200 Operator Manual 1) 960-0153

PowerCommand Control 3200 Installation Manual 1) 960-0620

PowerCommand Control 3200 Service Manual 1) 625-3422

GenSet T&R Manual 2) 3666394 * One set

per table

GenSet Wiring Diagram 2) 3666465

Module Assessment Form from Trainer’s Guide 3) B/W copier

PCC 3200 Customer Information 1) 900–0298

Module Comment Form In Participant’s Guide

1) Required - Order these through Western Graphics

2) Optional - Order these through Gannet
3) Required - Copy locally

* Genset T&R Manuals can be used over and over for classes.

i-10 Trainer’s Guide

PowerCommand Control 3200 Introduction

Introduction to the PowerCommand) Control 3200

Estimated Time: 2 hours

Equipment Needed

Overhead projector and screen or PC with LCD Projector and screen

Materials Needed

Module overhead set or slide set

One for each participant:

PowerCommand Control Participant’s Guide Guide (CMT0642-EN-PG)

One for each table:

PowerCommand Control 3200 Control Panel and Card Cage

One for the class:

PowerCommand Control 3200 Control Box

Trainer’s note: This is an overview of the new PowerCommand

Control 3200 system. The location of the hardware on the gener-
ator set will be covered in the next lesson.

Trainer’s Guide 1-1

Introduction PowerCommand Control 3200

Warm Up
In this lesson we are going to introduce ourselves to the PowerCommand Control 3200.

We are going to look at the control panels for the new control.

Finally, we are going to look at a the circuit cards which make up the actual control which
operates the generator set.

First, let’s look at the objectives for this lesson:

Objectives

After completing this lesson, participants should be able to:

• Identify the New PowerCommand Control 3200.

• Locate and identify the New PowerCommand Control 3200 switch panel components.

• Locate and identify the New PowerCommand Control 3200 operator panel components.

• Identify the PowerCommand Control 3200 circuit cards.

• Identify the PowerCommand Control 3200 external modules.

• Identify the PowerCommand Control 3200 “wakeup” signals

1-2 Trainer’s Guide

PowerCommand Control 3200 Introduction

Introduction to the PCC 3200

What is the PCC 3200

New Features:
Smart Starting Plus
Enhanced Fault Logging
Multiple Paralleling Configurations
WakeĆup Signals

OH1Ć1 S&TT 01/03

Slide 1-1 Introduction to the PCC 3200

Participant's Text Trainer's Text

Prior to PowerCommand Control being Have the Participants turn to Page 1-2 in
available, virtually all generator set their Participant’s Guide. Show Visual 1-1
controls were discrete logic or elec- and explain:
tromechanical relay based controls. The PCC 3200 is based on the original Pow-
Communications with these products erCommand Control released in 1995.
occurred using dry contact relay in- The PCC 3200 has more electronics than
terfaces to external facility manage- previous controls. This allows the PCC
ment or alarm systems, indicating 3200 to provide more information to the
generator set status with no additional operator, the technician, and the genset.
information.
The PowerCommand Control changed that The network option is required to use the
equation. Being a microprocessor- remote Operator Panel.
based control with (optional) full in-
formation generator set access (local
and remote), a richer set of generator
set monitoring and protection func-
tions became available.

Trainer’s Guide 1-3

Introduction PowerCommand Control 3200

Participant's Text Trainer's Text

In addition to the many control, annunci- The network card is an option that can be
ation, automatic voltage regulator and purchased while ordering the genset, or
governor functions, the PowerCom- added later in the field.
mand Control can easily be upgraded
to communicate over a PowerCom- When adding the network card in the field,
mand Network, or work as part of a the technician must also download a new
paralleling system. calibration file into the control to run the
network card.
Besides operating the engine, the PCC also
monitors and displays the generator The limits listed here are also used in all oth-
voltage, current, power factor, and er PowerCommand Controls.
load level. If the active or reactive
load goes over 95% of the limit for
the selected generator set, a warning
message will be displayed on the
graphical display panel on the PCC
operator panel. If the current or load
goes over 100% of the limit, the PCC
will shut down the generator set well
before the generator is damaged.

Now the new PowerCommand Control, with The options are available when purchasing
its modular hardware and software the genset or can be added later in the
bundling, allows Onan to better field.
serve customers and allow them to
match generator set controls to their
exact application – while staying two
steps ahead of the competition.

New Power Command Features Smart Starting Plus allows the customer to
have their genset control modified to fit
Smart Starting Plus
their needs, using InPower service tool
software.

• Programmable Idle Function on Start Engine temp must be 100 F or lower to start
at idle.

• Cooldown at Idle When the Remote Start signal is removed,

the genset runs at rated, then idle to
cool down before stopping.

1-4 Trainer’s Guide

PowerCommand Control 3200 Introduction

Participant's Text Trainer's Text

• Shutdown after Cooldown with If there is an alternator fault the control turns
Alternator Faults off the regulator section of the control and let
the engine cool down as it normally does.

Enhanced Fault Logging in Control: The All faults are stored in the control with the
control maintains a record of manual first and latest times listed,along with how
control operations, warning and shut- many total faults of this type.
down conditions. It uses the control There are over 149 faults for the engine
“ON” time as the time stamp means alone in the PCC 3200 control system.
when a real time clock is not in-
cluded in the control. It also stores
critical engine and alternator data be-
fore and after a fault occurs for use
by a technician using the InPower
service software in evaluating the
problem.

Multiple Paralleling Configurations

• Integral Master Control Functions The PCC 3200 can operate a stand-alone
including Load Demand and Load genset, be part of a CPG paralleling system,
Adding/Shedding. or be used with any Cummins engine with
any type of electronic governor.
• Integral Power Transfer Configurations

• Paralleling Interface to Woodward and

Barber-Colman equipment.
Wake Up Signals

The PowerCommand control will “go to

sleep” after a pre-determined time delay, set
with InPower software. These signals will
wake up the control:
• Manual Start switch pressed when the
mode switch is in the Manual position. Manual Operation

• Exercise switch is pressed when the Exercise Operation

mode switch is moved from Manual to
Auto.

• Remote Start signal input. Automatic start Operation

Trainer’s Guide 1-5

Introduction PowerCommand Control 3200

Participant's Text Trainer's Text

• Connecting the Service tool to the InPower software connected to
control (in the software). • Connector 12 Operator Panel

• Connector 13 Genset Control

• Panel Lamp/ Lamp Test switch pressed.

• Digital display button pressed.

• LonWorks wake up signal input.

• Customer switches 2 or 3 active. As with the original PowerCommand Con-

trol, only customer inputs 2 and 3 are wake-
up signals.

Trainer's Personal Comments

1-6 Trainer’s Guide

PowerCommand Control 3200 Introduction

PowerCommand Control 3200 Panels

Operator Panel Switch Panel

OH1Ć2 S&TT 10/00

Slide 1-2 Generator Set Control Panels

Participant's Text Trainer's Text

Generator Set Control Panels Both of these control panels have their own
internal microprocessors.
This graphic shows the operator panel on the
In the original control panel setup, these pan-
left and the switch panel on the right. els had an RFI/EMI gasket, and a NEMA 3R
outer covering on the back of the panels.
The operator panel may be remotely mounted
RFI – Radio Frequency Interference
up to 4,000 feet away from the set.
EMI – Electromagnetic Interference
The switch panel must be mounted on the
set.

Both panels have a NEMA 3R raintight

housing. This will keep dust and oth-
er foreign particles out of the control
housing.

Trainer’s Guide 1-7

Introduction PowerCommand Control 3200

Switch Panel
REMOTE START,
NOT IN AUTO, EMERGENCY STOP
SHUTDOWN, PUSH BUTTON
WARNING
STATUS INDICATORS

FAULT
ACKNOWLEDGE
BUTTON

PANEL LAMP/ LAMP

TEST BUTTON

EXERCISE BUT-
TON & INDICATOR 0/MANUAL/AUTO
SWITCH
MANUAL RUN/STOP
BUTTON & INDICATOR

OH1Ć3 S&TT 10/00

Slide 1-3 PowerCommand Switch Panel

Participant's Text Trainer's Text

Switch Panel – Standard The red-colored portion on the visual is re-
movable to change the language used on the
The Switch panel is mounted on the genera- front of the switch panel.
tor set. This is the minimum control
required to operate a generator set.

There are two physical switches and four

membrane switches on the switch
panel.

All writing, except the “0” position indicator,

is on a removable panel. The legend
panel may be removed and replaced
with another panel in a different lan-
guage.

1-8 Trainer’s Guide

PowerCommand Control 3200 Introduction

Participant's Text Trainer's Text

Physical Switches Describe the operation of the Switch Panel
physical switches:
• Emergency Stop Switch. Pressing the
• Emergency Stop Switch
Emergency Stop Switch will cause the
generator set to immediately shutdown,
and it will not start until the control
switch is reset and the fault is reset. If
the generator set is not running, pressing
the emergency stop button will prevent it
from attempting to start.

• 0/Manual/Auto switch. This switch has • 0/Manual/Auto switch

several uses in controlling the generator
set.

• When placed in the “0” position while

the generator set is running, the set will
shut down immediately. If the engine
temperature is above 160° F a “Hot
Shutdown” will be logged.

• In the MANUAL position, the control

will not complete any automatic
sequences, except those that involve
engine or alternator protection.

• In the AUTO mode, the generator set

can be started by pressing the exercise
pushbutton, or on receipt of a start signal
from a remote device. The control
maintains an internal record of manual
control activities performed on the
generator set.

Membrane Switches Describe the operation of the Switch Panel

membrane switches:
• RUN switch. Toggles generator set to
• Run Switch
run/stop mode when the 0/Manual/Auto
switch is in the MANUAL position.

Trainer’s Guide 1-9

Introduction PowerCommand Control 3200

Participant's Text Trainer's Text

• When the mode control switch is in
the MANUAL position and the
Manual Run switch is pressed, the
generator set will start and go to Idle
speed if the Coolant Temperature is
below 100° F (37.7° C) bypassing
time delay start. The generator set
will run at Idle speed until the Cool-
ant temp has reached the temperature
stated above, or for a maximum of 10
minutes. An LED lamp adjacent to
the switch will light to indicate the
generator set is in manual mode.

• If the generator set is running in the

MANUAL mode, pressing the Manu-
al Run switch again will cause the
generator set to shut down after the
cooldown time delays.

• Fault Acknowledge Switch. Allows the • Fault Acknowledge Switch

operator to acknowledge warnings and
shutdowns from the switch panel. The
0/Run/Auto switch must be in the “0”
position to acknowledge shutdown
faults.

• Panel Lamp/Lamp Test Switch. • Panel Lamp/Lamp Test Switch

Allows the operator to switch on LED
lamps to illuminate the control. Holding
the switch down allows the lamps on the
panel to be illuminated, so that it can
verified that they are operating properly.
Holding the switch down for 5 seconds
while a fault is in the control will enable
a fault flashout on the LED next to the
switch.

1-10 Trainer’s Guide

PowerCommand Control 3200 Introduction

Participant's Text Trainer's Text

• Exercise Switch and Indicating Lamp. • Fault Acknowledge Switch
When the mode control switch is moved
from the Manual to the Auto positions
while the EXERCISE control switch is
pressed, the generator set will complete
a pre-programmed exercise sequence.
The exercise sequence is set with the
InPower Service Tool software.

• Exercise functions are disabled when

a remote start command is received
by the control. An LED adjacent to
the switch will light to indicate the
generator set is in exercise mode.

• When the exercise period is comple-

ted, the control will indicate that the
generator set is in cooldown mode by
flashing the exercise LED.
There are four LEDs on the top of
this panel
LEDs Describe the operation of the LEDs:

• Remote Start • Remote Start

The control sees a remote start signal.

• Not in Auto • Not in Auto

The 0/Run/Auto switch is not in the
AUTO position

• Shutdown, • Shutdown
There is a shutdown condition

• Warning • Warning
There is a non-shutdown condition

Trainer's Personal Comments

Trainer’s Guide 1-11

Introduction PowerCommand Control 3200

Operator Panel

ANALOG AC
METERING
PANEL

DISPLAY MENU
SELECTION BUTTON
(1 of 6)

GRAPHICAL
DISPLAY
OH1Ć4 S&TT 10/00

Slide 1-4 Operator Panel

Participant's Text Trainer's Text

Operator Panel – Optional. May be re- The Operator Panel is not required for opera-
motely mounted from GenSet. tion of the factory gensets.
However, it makes operation easier as you do
The Operator panel may be mounted remote- not need a PC and InPower software to moni-
ly from the generator set. The maxi- tor or adjust the genset.
mum distance for remote mounting is
4,000 feet.

Analog AC metering panel displays simulta-

neously 3-phase AC line current, kW,
power factor, frequency, and line-to-
line voltage.

• LED’s are color coded, Make sure the participants understand these
green indicates normal range of values display LEDs and what they indicate.
amber indicates warning levels,
red indicates shutdown condition

1-12 Trainer’s Guide

PowerCommand Control 3200 Introduction

Participant's Text Trainer's Text

• Amps and kW are displayed from
0–125% of nominal value.

• Power Factor is displayed from –.6

(lagging) to +.9 (leading)

• Frequency and Voltage are displayed

from <70% to 110% of nominal value.

This panel can be configured for peak

capture

The graphical display panel includes provi- Make sure the participants understand the
sions for set up and adjustment func- Graphical Display and that it can display
tions. Changes to some of these graphic images, such as Chinese and other
similar languages.
functions are protected by the two
passwords which can be set with the
InPower service software.

The graphical display panel incorporates 3 There are three security levels included in the
level of operation and adjustability. PCC 3200 control.

• Monitoring level. • No password required

• Operator level (user) password allows • Password is normally not set at the
adjustment of time delay start and stop, factory
voltage, and frequency.

• Service level (application) password • Password is factory set to GENSET at

allows setup and calibration of the the factory. When the password is
control. cleared, it resets to GENSET.
The graphical display panel is capable of
displaying up to 9 lines of data with
approximately 27 characters per line.
It is capable of multiple languages,
including character-based languages.
It is configurable for units of mea-
surement.

Trainer’s Guide 1-13

Introduction PowerCommand Control 3200

Participant's Text Trainer's Text

The graphic display on the Operator panel The graphical display is an LCD panel like
turns off after 10 minutes if no but- on the older Master Controls used in parallel-
tons around it are pressed. This hap- ing systems. It “goes to sleep” to prevent the
graphical display panel from having an
pens to save the screen from burn-in. image burned into it.
The display will wake up from the
“screen saver” mode when any of the
six buttons around it are pressed.

This version of the PowerCommand Control

offers a more compact system with
selectable options for customers who
do not need all of the features.

The graphical display panel has extensive

language capabilities and has the po-
tential for graphics

Trainer's Personal Comments

1-14 Trainer’s Guide

PowerCommand Control 3200 Introduction

First Control Box – Inside View

PT/CT
Module

Fuel Control
Regulator Card Heatsink
Output
Module

Card Cage

OH1Ć5 S&TT 10/00

Slide 1-5 PowerCommand Control Box

Participant's Text Trainer's Text

Early GenSet Control Box. The early PCC 3200 controls (used on the
DQKB and DQKC gensets) had the control
The early Control Box looks like a large panel at the end of the alternator, and a con-
green box. It does not have a control trol box with the rest of the hardware by the
panel mounted with it. engine.

The Control Box is mounted on the front of The same Regulator Output Module, PT/CT
the alternator reconnection box. Module and BUS PT Module are used in this
control as in the older PowerCommand Con-
The control box of the PowerCommand Con- trol.
trol contains the operating hardware
which controls the generator set.

On the left are the PT/CT Module and the

Regulator Output Module.

Trainer’s Guide 1-15

Introduction PowerCommand Control 3200

Participant's Text Trainer's Text

On the bottom at the right is the card cage
holding the circuit cards which allow
the control to operate the generator
set.

On the right end of the control box is the heat

sink for the fuel control card.

Trainer's Personal Comments

1-16 Trainer’s Guide

PowerCommand Control 3200 Introduction

PT/CT Module

OH1Ć6 S&TT 10/00

Slide 1-6 Potential Transformer / Current Transformer Module

Participant's Text Trainer's Text

The Potential Transformer (PT) and Current The output of the PT/CT module is 18 VAC
Transformer (CT) Module is the first that is fed into the Generator Interface Mod-
step in measuring the generator set ule GIF card) in standby sets, or the Parallel-
ing card in paralleling sets.
output voltage and current.

There are four PT/CT Modules available:

• 347/600 Volts Used with 600

Volt generator sets.

• 240/416 Volts Used with

Non-Reconnectable generator sets.

• 120/208 Volts Used with

Reconnectable generator sets.

• 69/120 Volts Used with

Medium & High voltage generator sets.

Trainer’s Guide 1-17

Introduction PowerCommand Control 3200

Participant's Text Trainer's Text

PT/CT Module Voltage Sensing The voltage is sensed from each phase to the
return for that phase out of the transformers
The input voltage is reduced through a on the P””T/CT Module.
set of transformers to a nominal value of
18 VAC (measured from each phase to
its own common terminal).

Neutral is connected to the PT/CT Mod-

ule, but it is not carried through to the
PowerCommand Control. Neutral is as-
sumed in the control.

When you set up the control for a Wye

or Star connection you will see Phase-to-
Neutral and Phase-to-Phase voltages in
the menus.

When you set up the control for a Delta

configuration the display shows only
Phase-to-Phase voltages in the menus.

PT/CT Module Current Sensing

PowerCommand Sets use 0.55 Amp. The output current from the CTs is applied to
burden resistors in the PT/CT Module. Full
CTs instead of the industry-standard 5.0
load current from the genset will produce a
Amp. CTs.. voltage output of 1.65 VAC to the GIF card.

Each phase of current input is applied to

a burden resistor in the PT/CT Module.
This is a safety measure to prevent dam-
age to the CTs if the connection between
the PT/CT Module and the generator in-
terface card or paralleling interface card
is accidentally opened.

The nominal output from the PT/CT

Module when the current input is at its
rated maximum is 1.65 VAC.
Trainer's Personal Comments

1-18 Trainer’s Guide

PowerCommand Control 3200 Introduction

Regulator Output Module

OH1Ć7 S&TT 10/00

Slide 1-7 Regulator Output Module Inputs

Participant's Text Trainer's Text

The Regulator Output Module is a “power The Regulator Output Module receives a 12
amplifier” for the excitation signal. Volt Pulse-Width Modulated (PWM) signal
from the GIF card and sends a 300 Volt 3
The Regulator Output Module receives a kHz PWM signal to the exciter stator.
low-level excitation signal from the
Generator Interface Module and am-
plifies it to a high enough level to
control the alternator.

This module has two inputs and one output:

Input Signals

• “Run” signal from the Base Card.

• 3-Phase AC voltage from the Permanent

Magnet Generator (PMG).

Trainer’s Guide 1-19

Introduction PowerCommand Control 3200

Participant's Text Trainer's Text

Output Signals

• Pulse-Width Modulated (PWM) AVR Output PWM is a 3 kHz signal.

excitation signal. The output to the F1
terminal of the exciter stator is +300
Volts DC (rectified from the PMG AC
input). The output to the F2 terminal of
the exciter is a PWM Ground Signal.

• When the ground-potential pulse to the

F2 terminal of the exciter is wider
(higher duty cycle) more power is sent to
the exciter, and the output voltage of the
alternator goes up.

There are three LEDs on this module. These LEDs can be used to troubleshoot the
genset AC Output system.
• DS1 Green
Module has “Run” signal from the Base
Card.

• DS2 Amber
Brightness is relative to Excitation Duty
Cycle.

• DS3 Green
PMG Voltage is 105 VAC or higher (850
RPM). This LED indicates that the
secondary start disconnect contacts in
the Regulator Output Module are open.

Trainer's Personal Comments

1-20 Trainer’s Guide

PowerCommand Control 3200 Introduction

First PowerCommand Card Cage

Backplane Paralleling Card Base Card

Connector
Heat Sink

CARD
CAGE

LonWorks Generator Fuel Control Card

Top View
Interface Interface
Card Card

OH1Ć8 S&TT 10/00

Slide 1-8 Card cage assembly

Participant's Text Trainer's Text

Required circuit cards This graphic shows the Card Cage that holds
the circuit cards that make up the control.
Fuel System I/O Card: This is the interface The Fuel card takes the place of the Engine
module between the base board and Interface card and the Governor Output Mod-
the fuel control actuator(s). This ule of the PCC 3100 control.
Board has a large heat–sink which
will protrude from the end of the con-
trol assembly.

Base Card: This is the board which has the The Base card takes the place of the Digital
microprocessor and memory chips. Board and the Display Board in the PCC
This card only deals with digital sig- 3100 control.
nals and pulse-width modulated sig- TB8 has 5 terminals that are used when
nals. installing the genset.
Base card Green LED flashes:
> Steady – Normal
> 50/50 – Not Programmed
> Less than 50% on = Bad card or program

Trainer’s Guide 1-21

Introduction PowerCommand Control 3200

Participant's Text Trainer's Text

Generator Interface Card: This is the inter- The GIF card takes the place of the Customer
face module between the base card Input card and the Analog card in the PCC
and the alternator. Voltage and current 3100 control.
signals from the alternator enter the TB4 has terminals for the genset and paral-
generator interface card from the PT/ leling breaker, and two customer inputs.
CT Module. The excitation signal
goes through the generator interface
card on its way to the Regulator Out-
put Module.

Optional circuit cards

Paralleling Card: This is the interface mod- The Paralleling card as all paralleling con-
ule between the base card and the nections on it and four customer inputs that
generator and Bus signals. This card are only available when the paralleling card
is installed.
performs all of the calculations need-
ed to synchronize the generator fre-
quency and voltage levels to the bus.

Network Card: This is the interface module

between PCC and the Network. It al-
lows the PowerCommand Control to
become a node on the LonWorks net-
work.

Trainer's Personal Comments

1-22 Trainer’s Guide

PowerCommand Control 3200 Introduction

Old Style Customer Connections

Control Panel update

connection (C12)

OPTIONAL RUN RELAYS

Modem or PC
connector (C13)

OH1Ć9 S&TT 10/00

Slide 1-9 Customer Connection Terminal Block

Participant's Text Trainer's Text

PowerCommand Control Box Customer This is where most of the customer connec-
Connections. tions are landed to the control.

The customer connection terminal block is

located at the left end of the control
box housing. Most customer connec-
tions are made at the terminal blocks
on the individual circuit cards.

There is room for the three optional relays

(shown above) which can be used to
control devices outside of the Power-
Command Control.

The connector to the right of TB3 is used to Connector 12 is used to update the Operator
download updated software into the panel software (menus).
control panel.

Trainer’s Guide 1-23

Introduction PowerCommand Control 3200

Participant's Text Trainer's Text

The connector to the left of the terminal Connector 13 is used to update the software
block can be used for two functions: in the genset control and make changes to the
control trims or adjustments with “InPower
software.
• To connect a modem to the control for
remote access.

• To connect a PC using InPower service

software to the control.

Trainer's Personal Comments

1-24 Trainer’s Guide

PowerCommand Control 3200 Introduction

Interim Control Box – Front View

OH1Ć10 S&TT 10/00

Slide 1-10 Interim Control Box – Front View

Participant's Text Trainer's Text

This control box was designed for the This control box was introduced on The
QSX15 generator sets, but replaces QSX-powered gensets. It is expected that
the earlier control box on the QSK- eventually all Q-Series gensets will have this
control box.
series generator sets built after April
2000.

This control box includes the Switch and Op-

erator panels and is hinged on its left
side.

Note that the Operator and Switch Panels

now have a one-piece front panel.
Trainer's Personal Comments

Trainer’s Guide 1-25

Introduction PowerCommand Control 3200

Interim Control Box – Open View

Control Panels

Card Cage
OH1Ć11 S&TT 10/00

Slide 1-11 Interim PowerCommand Control Box

Participant's Text Trainer's Text

PowerCommand Control Box introduced This genset control has a NEMA 3R box. It
in September 2000 is a rain-tight box with a seal on the edge of
the door.
This control box is a NEMA 3R enclosure
and is raintight. Because of this, the The wiring enters the control box through the
raintight enclosures for the Switch heat-shrink tubing shells seen at the top of
Panel and Operator Panel used in this the box at the back.
control box are scheduled to be re-
moved. The door has an internal-wrenching hex bolt
to open the door.
The interior of the control box has all of the
components in the earlier control box
plus more terminals on TB3 for cus-
tomer connections.

1-26 Trainer’s Guide

PowerCommand Control 3200 Introduction

Participant's Text Trainer's Text

This control box is located at the alternator
end of the generator set where the
control panels were originally
installed on the QSK60 generator
sets.

Trainer's Personal Comments

Trainer’s Guide 1-27

Introduction PowerCommand Control 3200

Inside the Interim Control Box

C12
Control Panel

C13 InPower
& Calibrations

PT/CT Bus PT
Module Module
Regulator
Output
Module

OH1Ć12 S&TT 10/00

Slide 1-12 Inside the Interim PowerCommand Control Box

Participant's Text Trainer's Text

PowerCommand Control Box introduced In this control box the terminal block for
in September 2000 most of the customer connections is on the
left of the control box.
The C12 and C13 connectors are both on the
left side of this Control Box. C12 is
The blue rectangular box at the top near the
on the top, and C13 is on the bottom. center of the box is where the DC voltage is
connected to the two-pin connectors for the
There are two DIN rails for installation of re- circuit cards in the card cage.
lays and other devices.

The Card Cage is on a shelf on the right side

of the box with the heat sink out of
the right side of the enclosure.

1-28 Trainer’s Guide

PowerCommand Control 3200 Introduction

Participant's Text Trainer's Text

The modules are at the bottom of the enclo- These are the same modules used in the PCC
sure: 3100 control system.

• Regulator Output Module on the left

• PT/CT Module in the center

• Bus PT module at the right

• There is a spare attachment point for

another Bus PT Module for Automatic
Mains Failure installations.

Trainer's Personal Comments

Trainer’s Guide 1-29

Introduction PowerCommand Control 3200

PCC 3201 Control Box – Front View

OH1Ć13 S&TT 10/00

Slide 1-13 Interim Control Box – Front View

Participant's Text Trainer's Text

PowerCommand Control Box introduced This control box was introduced on The
in September 2000 QSX-powered gensets. It is expected that
eventually all Q-Series gensets will have this
This control box was designed for the control box.
QSX15 generator sets, and replaces
the earlier control box on the QSK-
series generator sets.

This control box includes the Switch and Op-

erator panels and is hinged on its left
side.

Trainer's Personal Comments

1-30 Trainer’s Guide

PowerCommand Control 3200 Introduction

PCC 3201 Control Box – Open View

Control Panels

Regulator
Output Module Card Cage
OH1Ć14 S&TT 10/00

Slide 1-14 Current PowerCommand Control Box

Participant's Text Trainer's Text

PowerCommand Control Box introduced This genset control has a NEMA 3R box. It
in September 2000 is a rain-tight box with a seal on the edge of
the door.
This control box is a NEMA 3R enclosure
and is raintight. Because of this, the The wiring enters the control box through the
raintight enclosures for the Switch heat-shrink tubing shells seen at the top of
Panel and Operator Panel used in this the box at the back.
control box are scheduled to be re-
moved. The door has an internal-wrenching hex bolt
to open the door.
The interior of the control box has all of the
components in the earlier control box
plus more terminals on TB3 for cus-
tomer connections.

Trainer’s Guide 1-31

Introduction PowerCommand Control 3200

Participant's Text Trainer's Text

This control box is located at the alternator
end of the generator set where the
control panels were originally
installed on the QSK60 generator
sets.

Trainer's Personal Comments

1-32 Trainer’s Guide

PowerCommand Control 3200 Introduction

Inside the PCC 3201 Control Box

4-Slot
OH1Ć15 Card Cage S&TT 10/00

Slide 1-15

Participant's Text Trainer's Text

PowerCommand Control Box introduced In this control box the terminal block for
in September 2000 most of the customer connections is on the
left of the control box.
The C12 and C13 connectors are both on the
left side of this Control Box. C12 is
The blue rectangular box at the top near the
on the top, and C13 is on the bottom. center of the box is where the DC voltage is
connected to the two-pin connectors for the
There are two DIN rails for installation of re- circuit cards in the card cage.
lays and other devices.

The Card Cage is on a shelf on the right side

of the box with the heat sink out of
the right side of the enclosure.

Trainer’s Guide 1-33

Introduction PowerCommand Control 3200

Participant's Text Trainer's Text

The modules are at the bottom of the enclo- These are the same modules used in the PCC
sure: 3100 control system.

• Regulator Output Module on the left

• PT/CT Module in the center

• Bus PT module at the right

• There is a spare attachment point for

another Bus PT Module for Automatic
Mains Failure installations.

Trainer's Personal Comments

1-34 Trainer’s Guide

PowerCommand Control 3200 Introduction

PCC 3201 Card Cage – Top View

OH1Ć16 S&TT 01/03

Slide 1-16 New Card Cage – Top View

Participant's Text Trainer's Text

The newest card cage has only slots for four This card cage will be used until the Control
cards: Area Network (CAN) link is built into
the control.
• Fuel Card
After that, the Fuel card will be removed and
• Base Card the control will talk directly to the
ECM on the engine.
• Genset/Paralleling Card

• Network Card The Genset/Paralleling card is used for stand-

by and paralleling gensets.

The network card allows the genset to com-

municate on the FTT-10 network.

Trainer’s Guide 1-35

Introduction PowerCommand Control 3200

PCC 3201 Card Cage – Side View

Network Card Base Card

Heat Sink

Fuel Card
Parallel/GIF Card
OH1Ć17 S&TT 01/03

Slide 1-17 New Card Cage – Side View

Participant's Text Trainer's Text

The Fuel card is always next to the Heat Sink The fuel card has drivers for the solenoids
when Quantum engines with a Full and valves in the fuel system and it
Authority Electronic fuel system. creates a high amount of heat.

The Base card has the microprocessor and The Base card does all the calculations re-
memory that we change values in quired to make the genset operate prop-
when setting trims for control param- erly.
eters.

The GIF/Parallel card brings the Voltage and The GIF/Parallel card is the input to the con-
Current values into the control, and trol from the PT/CT and Bus PT mod-
send the excitation signal out to the ules.
Regulator Output Module.

The Network card allows the PCC 3200 to The network card can be used in a self-install
communicate on the FTT-10 network. of a technician-installed network.

1-36 Trainer’s Guide

PowerCommand Control 3200 Introduction

PCC 3200 Introduction Activity

1Ć1 Introduction quiz

OH1Ć18 S&TT 01/03

Participant's Text Trainer's Text

Match the functions and components /
switches; use the demonstrator or Participants’
Guide.
The Trainer’s key to this activity is lo-
cated in the Activities tab as Activity
1-1.

Trainer’s Guide 1-37

Introduction PowerCommand Control 3200

Wrap-Up
In this lesson we have looked at the major components in the new PowerCommand Control.

We learned about the two control panels:

Operator Panel and
Switch Panel.

We learned about the Control Box and what it contains.

We learned about the separate modules in the Control Box which are used with a standby
generator set.

We learned about the circuit cards in the card cage located in the Control Box.

We learned about the Customer Terminal Block located on the left end of the Control Box.

Homework Activity
For homework read the operation and menu sections of the Operator Manual.

1-38 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Introduction to the PCC 3200 Hardware

Estimated Time: 4 hours

Equipment Needed

Overhead projector and screen or PC with LCD Projector and screen

Materials Needed

Module overhead set or slide set

QSK45/60 Cummins Breakout Tool Kit Tool Kit 3163768

GCS Module to show “keying” of Fuel and Base card connectors

One for each participant:

PowerCommand Control Participant’s Guide Guide (CMT0642-EN-PG)

QSK45/60 G-Drive Control Wiring Diagram Diagram 3666467

QSK45/60 Genset Control Wiring Diagram Diagram 3666465

Five-Color highlighters set

Trainer’s note: This is a more in-depth introduction to the new

PowerCommand Control 3200. The location of the hardware, the
InPower software, and the block diagram of the control operation
are covered here.

Trainer’s Note: There is a colored copy of the GCS Module diagram on PGU for the
Participant’s Guide. This diagram can be downloaded with the Participant’s Guide, but must
be printed as an 11x17” page in landscape mode. This diagram is numbered to be placed at
the back of section 2 of the PG.

Trainer’s Guide 2-1

PCC 3200 Hardware PowerCommand Control 3200

Warm Up
In this lesson we are going to introduce ourselves more deeply to the New PowerCommand
Control 3200 by starting with the G-Drive Control connection and operation, and then
looking at the standby control on a generator set and how that control operates.
We are going to look at the standby control circuit cards and how they communicate to the
engine, alternator, and each other.
Finally, we are going to look at a the paralleling control circuit cards and how they communicate
to the engine, alternator, and each other.
First, let’s look at the objectives for this lesson:

Objectives

After completing this lesson, participants should be able to:

• Identify the PowerCommand Control 3200 panel on a generator set from the factory.

• Locate the PowerCommand Control 3200 on a generator set.

• Identify the wiring harness connections used with a PowerCommand Control 3200.

• Locate the modules used with the PowerCommand Control 3200.

• Identify the modules used with the PowerCommand Control 3200.

• Identify the LEDs on the modules used with the PowerCommand Control 3200.

• Locate the customer terminal blocks used with the PowerCommand Control 3200.

2-2 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

PowerCommand Generator Set

Newer GenSets
(starting with QSX 15)

First GenSets

CONTROL BOX CONTROL PANEL

OH2Ć1 S&TT 10/00

Slide 2-1 Components on a generator set with a PowerCommand Control 3200

Participant's Text Trainer's Text

The PowerCommand Control is a new con- Have the Participants turn to page 2-2 in
trol that will be used as the standard con- their Participant’s Guide. Show visual 2-1
trol on all generator sets with electronic and explain:
fuel systems, starting with the QSK60 Please notice that there are two locations on
generator sets in April, 1999. this diagram for the control box and one
location for the control panels.
This control has a microprocessor and stored
information for each generator set kW The initial QSK45/60 generator set control
and frequency selection. This customized box is located:
setup of the control is done at the time
• on the front of the alternator
the generator set is run in the test cell.
reconnection box – on vibration
isolators.

Trainer’s Guide 2-3

PCC 3200 Hardware PowerCommand Control 3200

Participant's Text Trainer's Text

All of the associated hardware used with the The control panels can be located:
PowerCommand Control is located inside
• on the end of the set – as in the past
the Control Box which is mounted on the
front side of the generator set output box. • off of the set – the medium voltage
The control box is shown shock-mounted to generator sets have the Control
the front of the alternator reconnection Panels mounted on a stand-alone
box on this page. The control box may pedestal like with the older
also be mounted on the frame rail of the PowerCommand Control Medium
generator set to help reduce the amount Voltage sets.
of vibration at the control box.
• A second operator panel may be
The Control Panel can be mounted on the remotely mounted. This operator
end of the generator set (normal posi- panel communicates with the
tion), or on the side of the generator set. PowerCommand Control box via the
PowerCommand Network.
The Control Panel consists of two separate
sections. The Switch Panel and the Oper- After the QSX15 sets are released, a new con-
ator Panel. trol box will be used. The new control
box includes the control panels and is
mounted at the alternator end of the gen-
erator set where the older PowerCom-
mand Control was located.

Trainer's Personal Comments

2-4 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

G-Drive GCS Module

C03

Fuel Card
Warning &
Base Card Shutdown
LEDs

25-Pin
Connectors
50-Pin
Connectors

OH2Ć2 S&TT 10/00

Slide 2-2 GCS Module

Participant's Text Trainer's Text

Generator-Drive Control System (GCS) The G-Drive control is the most basic control
Module using the PowerCommand Control 3200
technology. This control is designed to
The GCS Module monitors and controls the
be sold with a G-Drive engine and skid-
engine systems.
base to a G-Drive assembler, like Agrek-
In the small window on the side of the mod- ko or Katolite.
ule you can see the Warning and Shut-
down LEDs. This module is known as the Generator-
Drive Control System or GCS module.
• LOP Shutdown
• HET Shutdown • NEMA 3R raintight housing
(connectors are on the bottom)
• Overspeed Shutdown
• Common Warning • Contains two circuit cards:
Base card – microprocessor and
• Common Alarm Shutdown
memory chips
The specific fault LED on the OEM control Fuel card – different calibration for
panel tells the operator what fault has oc- each fuel system and load setting.
curred.

Trainer’s Guide 2-5

PCC 3200 Hardware PowerCommand Control 3200

Participant's Text Trainer's Text

The 50-pin connectors on the module con- • 50-pin polarized connectors are part
nect to the extension harness supplied of the extension harness.
with the engine and module. Fuel card connector will not fit on
Base card
Base card connector will not fit on
Fuel card

The 25-pin connectors connect to the opera- • A separate control panel must be
tor panel. designed and built by the G-Drive
assembler.
The GCS Module does not control the alter-
nator. The GOEM assembler must select • 25-pin connectors are shipped with
and install an Automatic Voltage Regu- the GCS module
lator (AVR) to control the output voltage The assembler makes up the harness
from the generator set. from the 25-pin connectors to the
control panel.

Trainer's Personal Comments

2-6 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

G-Drive Control

Operator panel and wiring

harness not supplied Exciter G21
Operator Field
Panel

Connector 03 is only
used on G-Drive Fuel Regulator
Control cards. L1
L2

ÇÇÇÇÇ ÇÇÇÇÇ
C03 C06 L3

ÇÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇ
Fuel L1 L2 N L3

ÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇ
Control Base
Card Card Voltage Regulator and Alternator not supplied

ÇÇÇÇÇ Ribbon

ÉÉÉÉÉ ÉÉÉ
Cable

ÉÉÉÉÉ ÉÉÉ
C02 C05 GCS Module
On the Engine

ÉÉÉÉÉ ÉÉÉÉÉÉÉÉ
Fuel
System G-Drive Control

ÉÉÉÉÉ ÉÉÉÉÉÉÉÉ
Wiring Harness
Engine Senders

ÉÉÉÉÉÉÉÉ
and Sensors Wiring Harness Connection

OH2Ć3 S&TT 10/00

Slide 2-3 Generator Drive System (GCS) Architecture

Participant's Text Trainer's Text

This diagram is designed to help the techni- Here is the block diagram of the G-Drive
cian: control

S understand how the Control components Notice that there are two cards in the dotted-
connect in the GCS Module, and line box which defines the GCS module:

S help the technician determine where a • Fuel card

problem might be in the control system.
• Base card
The components inside the dashed line are in
the GCS Module.
The components outside the dashed line are
mounted and located elsewhere on the
G-Drive mule sold to assemblers.

Trainer’s Guide 2-7

PCC 3200 Hardware PowerCommand Control 3200

Participant's Text Trainer's Text

The small boxes indicate where the techni- The small blue boxes indicate where the
cian can disconnect a cable connector and technician can disconnect a cable con-
test for signals entering or leaving the nector and test for signals entering or
control modules or circuit cards. leaving the control modules or circuit
cards using the breakout tool.
The filled arrow indicates connections inside
the GCS module. These signals can only Connector 03 is only used in the GCS
be checked with the InPower software Module.
tool.
There is a copy of the G-Drive Wiring Dia-
gram at the back of this section.

2-8 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Wiring Diagram 3666347

OH2Ć4 S&TT 10/00

Slide 2-4 Wiring Diagram 3666347

Participant's Text Trainer's Text

This diagram should be at the back of section Have the participants refer to the G-Drive
2 of the Participant’s Guide. Wiring Diagram (3666347) for the Op-
erator Interface harness connections.
Trainers can also order this print from Gan-
Remind the participants that the interconnec-
net and hand it out in class.
tion link between the Fuel and Base
cards (inside the module) is not shown
on the G-Drive Wiring Diagram.
Connector 03 – Fuel Card – 25 pins
Connector 03 on the Fuel card in the
GCS module has drivers for meters and
lights which are not on the fuel card
used in the generator set Fuel card.
These drivers are for components which
are not needed on the generator set con-
trol fuel card.

Trainer’s Guide 2-9

PCC 3200 Hardware PowerCommand Control 3200

Participant's Text Trainer's Text

• Meter and Lamp drivers are on the
GCS Fuel card

• Alternate Frequency is for 50/60 Hz

engines.

• Droop and Frequency adjust are for

operator interface to change the
no-load and full-load engine speeds.
Connector 06 – Base Card – 25 pins

• Local Emergency Stop switch

• Run/Stop switch

• Alarm Reset switch

• Idle/Rated selector switch

• Diagnostic Mode switch – ( This also

can be accomplished by connecting
the Diagnostic Mode Enable
connectors from Inline A together)

• Remote Emergency Stop switch

• Backup Starter Disconnect relay

contacts

• Crank Coil

• RS-485 Modbus Interface for remote

monitoring of the engine parameters.
On the GenSet this is used to
communicate with the Operator
panel.
The engine harness also has a Deutch 9-pin
connector used for communicating with
the control from a PC running InPower
service software.
Trainer's Personal Comments

2-10 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Participant's Text Trainer's Text

There is a new breakout kit for the G-Drive
and Generator Set controls, which is
available from Cummins Service Tools,

PART NUMBER: 3163768, available

from Cummins Service Tools, Colum-
bus, IN.

Show the participants the breakout tool

and its cables

• This tool has the 25-pin and 50-pin

cable connectors needed for this
engine and generator set control
wiring harness.

• You can only measure values for one

connector at a time.

• Remember to disconnect the battery

before removing or installing
connectors to prevent sparking and
damage to connector pins.

• The tool is designed so you an open

the circuit for a specific signal and
inject the proper signal to verify
control operation or failure to operate.
Trainer's Personal Comments

Trainer’s Guide 2-11

PCC 3200 Hardware PowerCommand Control 3200

Early GenSet Control Box

Control Panel
update connection
C12
Terminal Block PT/CT
Module

Fuel Control
Card
Heat
Sink

Base Card
Generator Card

Left End View

Modem or PC connector
C13 Regulator
Output
OH2Ć5 S&TT 10/00
Module

Slide 2-5 Components inside the PowerCommand Control 3200 Control Box

Participant's Text Trainer's Text

After removing the control cover, the techni- The original PowerCommand Control Box is
cian will find that the box has several divided into two sections:
modules inside, and a card cage to hold
• Customer Connections (TB3) are on
the new circuit cards.
the end of the box.
Most of the customer connections go directly
Most of the customer connections are made
to the connectors or terminal blocks on
here, but some essential ones are made at
the cards in the card cage. However, there
terminal boards on the circuit cards.
are some customer connections made to
the terminal blocks in the smaller box ac- • Control card cage and Modules.
cessible by removing the cover on the left
end of the control box. Each circuit card is assigned a specific slot in
the card cage.
There are three circuit cards which are re-
quired in the card cage for a generator If the cards are inserted into different slots
set. These cards are: the control will give you a specific fault
telling you which card is in the wrong
slot, and the control will not operate.

2-12 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Participant's Text Trainer's Text

There are three circuit cards which are Fuel System Card
required in the card cage for a
The fuel systems card must be at the right
generator set. These cards are:
end of the card cage next to the heatsink
Fuel Control card for all HPI-PT Quantum engines.

• contains the circuits needed to operate It scales its engine input signals to a 0-5 volt
the generator set fuel system range and converts them to a digital sig-
components. nal form for the microprocessor.

Base card It converts the time-based signals from the

base card to Pulse-Width Modulated
• contains the processor and the operating (PWM) signals for the fuel system ac-
software. tuators.
Generator Interface card It provides a DC output signal for the Fuel
Shutoff Valve and Pump Priming supply
• contains the circuits needed to monitor
valves.
and control the alternator.
This fuel card does not have the meter and
lamp drivers which are needed on the
GCS module Fuel card. Those compo-
nents are only on the G-Drive fuel card.
Base Card

Trainer's Personal Comments Next to the fuel systems card is the base card.
This card contains the Motorola micro-
processor which runs the control.
This card only receives digital signals.
The base card sends out both digital and
time-based signals. The time-based sig-
nals are converted into PWM signals by
the output cards to operate the engine
and alternator.
GenSet Interface (GIF) Card
Next to the base card is the GenSet Interface
card which has several uses.
• In all generator sets it connects to the
Regulator Output Module to provide
a PWM drive signal for the excitation
of the alternator.

Trainer’s Guide 2-13

PCC 3200 Hardware PowerCommand Control 3200

Participant's Text Trainer's Text

• In standby sets is receives the voltage
and current information from the
PT/CT Module. In this case it scales
the voltage and current input signals
to a 0-5 volt range and converts them
to a digital signal for the
microprocessor.

• When using PT fuel systems like on

the DGMB sets powered by the K50
engine, the GenSet card provides the
fuel actuator drive signal. In this case,
the GenSet card would be next to the
heatsink.
Trainer's Personal Comments

2-14 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Interim Control Box

Control Panels

Card Cage
OH2Ć6 S&TT 10/00

Slide 2-6 Current PowerCommand Control Box

Participant's Text Trainer's Text

Control Box introduced on QSX-15 gen- This control box was first used on the
sets in September of 2000 QSX15-powered gensets.
It is expected that all gensets using the PCC
This control box is a NEMA 3R enclosure 3200 controls will have this control by 2004.
and is raintight. Because of this, the rain-
You need metric Hex wrench (approximately
tight enclosures for the Switch Panel and 10 mm) to open the door.
Operator Panel used in this control box
are scheduled to be removed.
The interior of the control box has all of the
components in the earlier control box
plus more terminals on TB3 for customer
connections.
This control box is located at the alternator
end of the generator set where the control
panels were originally installed on the
QSK60 generator sets.

Trainer’s Guide 2-15

PCC 3200 Hardware PowerCommand Control 3200

Standby Generator Set Control

ÉÉÉ
ÉÉ ÉÉÉÉÉÉ ÉÉÉ
PMG
Card Cage

ÇÇ
ÉÉ ÉÉÉ
ÉÉÉÉÉÉ ÉÉÉ
Exciter
On the Engine Field
Operator Regulator
G-Drive Control Panel Switch

ÇÇ ÉÉÉ ÉÉÉ
Panel Output
Module
GenSet Control

ÉÉÉÉÉ ÇÇÇ ÇÇÇ

ÉÉÉÉÉ ÇÇÇ ÇÇÇ
C06 C06 C01 C01
CT1

ÉÉÉÉÉ ÇÇÇ ÇÇÇ

Generator
Interface

ÉÉÉÉÉ ÇÇÇ ÇÇÇ

Card CT2
C01

ÉÉÉ ÉÉÉÉÉ ÇÇÇ

Base PT/CT
CT3
Card Module

ÉÉÉ ÉÉÉÉÉ
ÉÉÉ ÉÉÉÉÉ
Fuel
Control
Card ÇÇÇ
ÇÇÇ
L1
L2

ÉÉÉÉ ÇÇÇ
L3
N

ÉÉÉÉ ÉÉÉÉÉ
C02 C05
Fuel

ÉÉÉÉ ÉÉÉÉÉ
System Wiring Harness
L1 L2 N L3

ÉÉÉÉÉ
Engine Senders Wiring Harness Connection
and Sensors
Backplane Connection

OH2Ć7 S&TT 10/00

Slide 2-7 PowerCommand Standby System Architecture

Participant's Text Trainer's Text

This diagram is designed to help the techni- The small blue boxes indicate where the
cian: technician can disconnect a cable con-
nector and test for signals entering or
S understand how the PowerCommand leaving the control modules or circuit
Control components connect in the cards using the breakout tool.
standby control, and
The filled arrows inside the dashed box indi-
S help the technician determine where a cate connections inside the control card
problem might be in the cage. These signals can only be checked
PowerCommand System. with the InPower software tool.
The components inside the dashed line are in The green-filled boxes are added to make the
the control housing card cage mounted on Genset Control for factory gensets.
the generator set.

2-16 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Participant's Text Trainer's Text

The components outside the dashed line are
mounted inside the control box, or are
located elsewhere on the generator set.
The components outside the dashed line are
mounted inside the control box, or are
located elsewhere on the generator set.

The small boxes indicate where the techni-

cian can disconnect a cable connector and
test for signals entering or leaving the
control modules or circuit cards.

The filled arrows indicate connections inside

the control card cage. These signals can
only be checked with the InPower soft-
ware tool.

Trainer's Personal Comments

Trainer’s Guide 2-17

PCC 3200 Hardware PowerCommand Control 3200

Wiring Diagram 3666465

OH2Ć8 S&TT 10/00

Slide 2-8 Wiring Diagram 3666465 (QSK456/60 Genset)

Participant's Text Trainer's Text

Pass out 3666465 Wiring Diagrams to the Have participants look at Fuel card connec-
participants. tions on this diagram, and compare them to
Have them look at both sides: the G-Drive Diagram.

• Wiring Diagram If the participants have access to permanent

colored pens, have them color the edge of the
• Fault Codes card in the card cage and the associated con-
nectors & terminal blocks the same color:
• Base Card – Green

• GIF Card – Blue

• Fuel Card – Orange

• Paralleling Card – Purple

NOTE: These colors may wear off with time.
but they help the participants learn what
card has the specific connectors on it in
class.

2-18 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Participant's Text Trainer's Text

Fuel System Card Connector 02 is the 50-pin connector on the
Fuel card. The signals entering connec-
The fuel systems card bolts to the heatsink tor 02 from the engine are:
for all HPI-PT Quantum engines.
• Fuel Rail Pressure
It scales its engine input signals to a 0-5 volt
range and converts them to a digital sig- • Timing Rail Pressure (1 & 2)
nal form for the microprocessor on the
• Fuel Pump Pressure
base card.
It converts the time-based signals from the • Blowby Pressure
base card to Pulse-Width Modulated
• Coolant Pressure
(PWM) signals for the fuel system ac-
tuators. • Ambient Air Pressure
It provides a DC output signal for the Fuel • Oil Level
Shutoff Valve and Pump Priming supply
valves. • Coolant Level

• Fuel Temperature
The signals going to the engine from the Fuel
card are:

• Fuel Rail Actuator signal

• Timing Rail Actuator signals 1 & 2

• Fuel Pump actuator

• Fuel Shutoff Valve signal

• Fuel Priming Pump signal

These signals are used on both G-Drive and
Generator Set Fuel cards.

Trainer's Personal Comments

Trainer’s Guide 2-19

PCC 3200 Hardware PowerCommand Control 3200

Participant's Text Trainer's Text

Base Card Connector 05 is the 50-pin connector on the
Base card. The signals entering connec-
Next to the fuel systems card is the base card. tor 05 from the engine are:
This card contains the Motorola micro-
processor which runs the control. • Engine speed (1 & 2)
This card receives digital signals from the • Coolant Temperature
Fuel card, and several analog signals
from the engine. • Intake Manifold Temperature
The base card connectors we saw used in the • Oil Pressure
GCS module are used for the same pur-
poses in the GenSet control. However, • Intake Manifold Pressure
we have added a Terminal Block — TB8
• Aftercooler Water Temperature
— for remote start and Emergency Stop
signal input. Base Card
(connectors 05, 06, and TB8)
Connector 05 is used for engine monitoring, • Connector 05 right side – top
cranking, and also to connect B+ and • Connector 06 center of diagram
Ground to TB3, the main customer con- • TB8 left center
nection TB.
The Base card also has a Deutch 9-pin con-
Connector 06 is used to monitor and control
nector used for communicating with the
cranking and running of the engine, and
control from a PC running InPower ser-
is in the Emergency Stop circuit.
vice software.
The Base card also has a 5-pin terminal
board (TB8) which is used for the re- The base card sends out both digital and
mote start and Local Emergency Stop time-based signals. The time-based sig-
signals into the control. nals are converted into PWM signals by
the output cards to operate the engine
and alternator.
Trainer's Personal Comments

2-20 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Participant's Text Trainer's Text

Generator Interface (GIF) card (to left
of C 05)

The GIF card has a 50-pin connector 01

which connects the GenSet card to the
control panels, the PT/CT module, TB3,
the Paralleling Card, and the Regulator
output module.
The GIF card also has a 15-pin terminal
block (TB4) which is used to connect the
generator set and utility breakers to the
generator set. Customer connection
switch #1 (customer fault #1) is also on
TB4.
The GIF card also has a terminal on TB4 to
control the modem relay. This relay is
used to reset power to the modem if the
modem locks up.
Terminal Block TB3 (left center bottom half
of dwg.)
TB3 is the main customer connection termi-
nal block in the PowerCommand Control
3200.

Trainer's Personal Comments

Trainer’s Guide 2-21

PCC 3200 Hardware PowerCommand Control 3200

Participant's Text Trainer's Text

PT/CT Module

The PT/CT module monitors the alternator

output voltage and current and provides
a sample of the output to the GIF card.

• When the output voltage is at its

nominal value the output of the
PT/CT module is 18 VAC.

• When the alternator is putting out

100% of the 0.8 lagging Power Factor
current it can produce the PC/CT
output is 1.65 VAC.

Regulator Output Module

The Regulator Output module creates the

excitation signal from the rectified PMG
AC voltage.

• The Regulator Output Module PWM

signal has the same duty cycle as the
TPU signal received from the GIF card.

• The rectified DC level from the PMG is

applied to the F1 or X terminal of the
exciter stator.

• A negative-going PWM signal is

applied to the F2 or XX terminal of the
exciter stator.

• The difference between the X and XX

terminals of the exciter stator
determines the output voltage and
current from the alternator.
Trainer's Personal Comments

2-22 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

InPower Service Tool Software

OH2Ć9 S&TT 10/00

Slide 2-9 In-Power service software1. Common tool for all new Power generation applications

Participant's Text Trainer's Text

Common tool for all new Power generation This is a the basic display of the InPower ser-
applications vice software.
Windows NT, 2000, ME, and XP 32–bit ap- This software is used to perform adjustments
plication and testing of the:
Required for service and troubleshooting of • G-Drive controls.
the engine and control systems.
• PowerCommand Generator Set
Will also be used in servicing and trouble- controls.
shooting new PowerCommand transfer
switches. • OTPC switches.
InPower service software will be covered lat- • New generator sets and switches
er in this course. released in the future by Cummins
Power Generation.
The InPower software will be used with the
PowerCommand Control 3200 later in
this course.

Trainer’s Guide 2-23

PCC 3200 Hardware PowerCommand Control 3200

PowerCommand Control Options

Bus PT
Module

Network Module

Paralleling Module
OH2Ć10 S&TT 10/00

Slide 2-10 PowerCommand Control 3200 modules and cards

Participant's Text Trainer's Text

When the PowerCommand GenSet is fitted There are options for the PowerCommand
with a Paralleling Interface board, a Bus Control 3200 available from the factory
PT Module is added to bring in the volt- or as field kits.
age and phase rotation on the load side of
Two options are the:
the paralleling breaker.
• Paralleling Card and Bus PT Module,
Another option is the PowerCommand Net-
and the
work card. This card allows the Power-
Command Control to communicate over • Network card
the PowerCommand Network with other
devices in the network.
In addition to these options, there are three
open slots in the card cage for future op-
tions.

2-24 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Participant's Text Trainer's Text

Paralleling Card

2. The Paralleling option allows the gener-

ator set to parallel to an isolated or infi-
nite bus.

3. It also is used with the new PLTE

switchgear when paralleling one genera-
tor set to the utility grid.

Network Card

4. The Network card allows the generator

set control to communicate on a Power-
Command Network. It performs the
same functions as the GCM did in the
PowerCommand Control 3100.

Trainer's Personal Comments

Trainer’s Guide 2-25

PCC 3200 Hardware PowerCommand Control 3200

Paralleling Control with Network

ÉÉ
ÉÉ ÉÉÉ
ÉÉÉ ÉÉÉ ÉÉÉ
Card Cage PMG
On the Engine G21

ÇÇ
ÈÈ ÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉ ÉÉÉ
Exciter
G-Drive Control Operator Field
Switch Regulator
Panel

ÈÈ
ÍÍ ÉÉÉ
GenSet Control Panel Output
Module
Network Option

ÈÈÈÉÉÉÉÉÉÍÍÍ ÇÇ
Paralleling Option

ÈÈÈ ÉÉÉÉÉÉ ÍÍÍ ÇÇ

C06 C06 C01 C01
CT1

ÈÈÈ ÉÉÉÉÉÉ ÍÍÍ ÇÇ

Network Cable Network
C11 Card

ÈÈÈÉÉÉÉÉÉ ÍÍÍ ÇÇ
TB6 CT2

ÉÉÉ ÉÉÉÉÉÉ ÍÍÍ ÇÇ

Base PT/CT CT3
Card Generator Module

ÉÉÉ ÉÉÉÉÉÉÍÍÍ ÇÇ
Interface
Fuel Paralleling
Card L1

ÉÉÉÉÉÉÉÉÉÍÍÍ ÇÇ
Control C04 L2
Card

ÉÉÉ ÇÇÍÍÍÍÍ
L3
N

ÉÉÉ ÉÉÉÉÉÉ ÍÍ ÍÍÍÍÍ

C02 C05 C04 Paralleling
Circuit Breaker
Fuel

ÉÉÉ ÉÉÉÉÉÉ ÍÍ
System L1

ÉÉÉÉÉÉ ÍÍ
L2
Engine Senders L3
and Sensors Bus

ÍÍ
Wiring Harness N
PT
Mod.
Backplane Connection L1 L2 N L3
OH2Ć11 S&TT 10/00
Wiring Harness Connection

Slide 2-11 PowerCommand Paralleling System Architecture

Participant's Text Trainer's Text

This diagram is designed to help the techni- This diagram helps explain the operation of
cian: paralleled generator sets with the Power-
Command Control and the LonWorks
S understand how the PowerCommand card option.
System components connect in the
paralleling version of the control, and This diagram is designed to help the
technician:
S help determine where a problem might
be in the PowerCommand System. • understand how the PowerCommand
Control components connect in the
Notice that in this diagram the PT/CT and paralleled control, and
Bus PT modules both connect to the Par-
alleling Interface card, not the Generator • help the technician determine where a
Interface Card as in the standby version problem might be in the
of the control. PowerCommand System.

2-26 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Participant's Text Trainer's Text

The filled arrows inside the dashed box indi-
cate connections inside the control card
cage. These signals can only be checked
with the InPower software tool.
Bus PT Module

The Bus PT Module samples the Bus voltage

on the downstream side of the generator
set paralleling breaker and provides that
sampled voltage the Paralleling card.

• When the Bus voltage is at its

nominal level the Bus PT module
output voltage will be 18 VAC.

• The Bus PT Module also sends the

Bus frequency to the Paralleling
Card.
Paralleling Card

The Paralleling card uses both the alternator

output voltage and the Bus voltage to tell
the Base card if the alternator output
voltage is slower or faster than the Bus
voltage.

• Note that the Bus PT and the PT/CT

Modules both connect to the
Paralleling card in this configuration.

• The Paralleling card will tell the Base

card if the engine has to speed up or
slow down to match the Bus
frequency.

• The “synchronizer” display comes

form this information provided to the
Base card from the Paralleling card.
Trainer's Personal Comments

Trainer’s Guide 2-27

PCC 3200 Hardware PowerCommand Control 3200

Wiring Diagram 3666465

OH2Ć12 S&TT 10/00

Slide 2-12 Wiring Diagram 3666465 (QSK456/60 Genset)

Participant's Text Trainer's Text

Have participants refer back to the 3666465 Bus PT Module (lower left corner)
Genset Wiring Diagram handed out previous-
ly in this lesson. The Bus PT Module connects the Bus volt-
age to the Paralleling card.

• TB1 connects to the Bus side of the

paralleling breaker. Nominal Line
voltage input.

• TB2 connects to Connector 04 on the

Paralleling card. 18 VAC output.
Paralleling card (bottom center)

The Paralleling card tells the Base card how

far the alternator is out of synchronism
with the Bus voltage and frequency.

2-28 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Trainer's Guide

TB5 connects the load share lines (kW and kVAR) to the other generator sets.
TB5 also connects several other inputs to the Paralleling card.

• Ground Fault switch input

• Customer Switch #3

• Customer Switch #4
Connector 04 connects to TB3 for paralleling inputs:

• 22 – Sync Enable

• 25 – First Start Enable

• 21 – Load Demand Shutdown

• 23 – Single Mode Enable

• 24 – Ramp Load / Unload

If you look at the wiring diagram you will see that the PT/CT Module and the Bus PT
Module both connect to the Paralleling card and the GIF card.

In a future control (Automatic Mains Failure (AMF)) the Paralleling card will per-
form the paralleling functions as it does now.

• Synchronizing to the Bus

• Voltage matching to the Bus.

The GIF card will actually look at the Utility source voltage and work with the Auto-
matic Transfer Switch to perform a closed transition (if the customer has pur-
chased that ATS option):

• Back to the utility when the utility returns after a power outage, or

• When the generator set is running in Peak Shave, Base Load, or Interruptible
modes.
Trainer's Personal Comments

Trainer’s Guide 2-29

PCC 3200 Hardware PowerCommand Control 3200

Early Bus PT Module

18 VAC

18 VAC

18 VAC

Out to Paralleling
Interface Card

In from Emergency Bus

OH2Ć13 S&TT 10/00

Slide 2-13 Early Bus PT Module

Participant's Text Trainer's Text

Each phase of output voltage is sensed and This is the older Bus PT module initially
the output of the generator is stepped used with the PowerCommand Control
down in a transformer on the Bus PT 3200.
module to a nominal value of 18 VAC to
The input voltage on TB1 is going to be line-
represent the output voltage.
to-Line voltage (up to 600 VAC). If the
This 18 VAC output is read from that phase alternator output voltage is over 600
to its own “common” terminal as shown VAC a transformer package will reduce
in the above graphic. the output voltage to a 120/208 or
277/480 voltage for the Bus PT module.
The neutral leg of the generator is connected
to the Bus PT module when the generator The nominal output voltage from this module
output is a Wye connection. is 18 VAC.
The input is Phase-to-Phase with a neutral
connection for Wye or Star wired alter-
nators.

2-30 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Participant's Text Trainer's Text

Neutral is not carried through to the Parallel- The output is a separate output pair for each
ing Interface Module. If you have prob- phase:
lems synchronizing the Wye/Star con-
• A and A return
nected alternator to a Delta load, discon-
nect and isolate the wire from the neutral • B and B return
terminal of the Bus PT Module.
• C and C return

Trainer's Personal Comments

Trainer’s Guide 2-31

PCC 3200 Hardware PowerCommand Control 3200

Later Bus PT Module

In from Emergency Bus

Inter-GenSet
“First-On-Line”
connections.

18 VAC

18 VAC Out to Paralleling

Interface Card
18 VAC

OH2Ć14 S&TT 10/00

Slide 2-14 Later Bus PT Module

Participant's Text Trainer's Text

Each phase of output voltage is sensed and This is the new Bus PT module which will be
the output of the generator is stepped used with the PowerCommand Control
down in a transformer on the Bus PT 3200. Its design eliminates the Master
module to a nominal value of 18 VAC First Start Sensor in the Master Parallel-
to represent the output voltage. ing Control.
The terminals on the module perform the
This 18 VAC output is read from that phase
same functions as the terminals on the
to its own “common” terminal as
older Bus PT module.
shown in the above graphic.
• Four input terminals
The neutral leg of the generator is connected
to the Bus PT module when the gen- • Six output terminals
erator output is a Wye connection.
• A set of terminals for the “ready to
close” function which replaces the
Master First Start control and wiring
in PowerCommand Control 3200
generator sets with this module.

2-32 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Participant's Text Trainer's Text

Neutral is not carried through to the Parallel- • In the case where two generator sets
ing Interface Module. If you have are at the Ready-to-Load state at the
problems synchronizing the Wye/Star same time, the Bus PT Modules
connected alternator to a Delta load, perform an arbitration process to
disconnect and isolate the wire from determine which module (and
the neutral terminal of the Bus PT generator set) will close to the bus
Module. first (an electronic version of “Rock,
Scissors, Paper”).
The new Bus PT Module eliminates the need
for the Master First Start Sensor which
was used with the PowerCommand Con-
trol 3100 generator sets to determine
which generator set would close to the
dead bus first.
This Bus PT Module has a circuit which al-
lows the generator sets to determine if
another generator set is about to close its
paralleling breaker to the dead bus.
This new circuit brings the functionality of
the “inhibit” circuit in the SSPS and
OSPS paralleling systems to PowerCom-
mand Paralleling. This circuit absolutely
prevents two generator sets paralleling to
a dead bus out of phase.
This Bus PT Module requires a pair of wires
be connected between all of the Bus PT
modules. This wire pair is checked to see
if the voltage level is “high” or “low.” If
the level is “low,” another generator set is
ready to close its paralleling breaker to
the dead bus.

Trainer's Personal Comments

Trainer’s Guide 2-33

PCC 3200 Hardware PowerCommand Control 3200

Shop Introduction Activities

Control & Control Panel Parts

Card Cage and Cards
Switch Panel Parts
Operator Panel Parts

OH2Ć15 S&TT 01/03

Slide 2-15 Section 5 Activities

Participant's Text Trainer's Text

Match the functions and components /
switches; use the demonstrator or Partici-
pants’ Guide.
Trainer’s answers to this activity are
located in the Activities tab.

2-34 Trainer’s Guide

PowerCommand Control 3200 PCC 3200 Hardware

Wrap-Up
In this lesson we have looked at the standard and optional components in the PowerCommand
Control 3200.

We learned about the two control panels:

Operator Panel and
Switch Panel.
We learned about the Control Box and what it contains:
Card cage which includes:
Fuel Card
Base Card
Generator Interface (GIF) Card
Paralleling Card
LonWorks Card
PT/CT Module
Regulator Output Module
Bus PT Module
We learned about the Customer Terminal Block (TB3) located on the left end of the Control Box.
We learned about the terminal blocks on the circuit cards in the card cage.
We looked at the old and new Bus PT modules.

Homework Activity
For homework read the Operator Manual and answer the questions in Activity #2.

The answers to the homework activities are in the Homework Tab in the Trainer’s
Guide.

Trainer’s Guide 2-35

PCC 3200 Hardware PowerCommand Control 3200

This page intentionally left blank

2-36 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

PowerCommand Control 3200 Operator Menus

Estimated Time: 1.5 hours

Equipment Needed

Overhead projector and screen or PC with LCD Projector and screen

Materials Needed

Module overhead set or slide set

One for each participant:

PowerCommand Control Participant’s Guide Guide (CMT0642-EN-PG)

Menu handout copied from Instructor’s Guide handouts

Five-Color highlighters set

Trainer’s note: In this lesson the participants will use the simula-
tors for the first time. They will navigate around the Operator-
Level menus.

Trainer’s Guide 3-1

Operator Menus PowerCommand Control 3200

Warm Up
In this lesson we are going to introduce ourselves to the menu system on the
PowerCommand Control 3200.

We are going to look at the menu sections which the operator would use to monitor and
control a generator set with a PowerCommand Control 3200.

First, let’s look at the objectives for this lesson:

Objectives

After completing this lesson, participants should be able to:

• Locate and identify the front panel buttons used in navigating the PowerCommand Control
3200 menus.

• Identify the menu choices accessible without using the User password.

• Use the Engine Menu to determine engine parameters when the genset is running and
stopped.

• Use the Adjust Menu to change engine and generator parameters when the genset is running.

• Use the Alternator Menu to determine alternator parameters when the genset is running.

• Determine PowerCommand Control 3200 genset setup parameters, and what software
version is installed in the PowerCommand Control 3200.

3-2 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

PowerCommand Menu Display

STATE LINE
ACTION LINE
DESCRIPTION LINE

MENU DISPLAY AREA

GRAPHICAL DISPLAY

MENU MENU
BUTTONS BUTTONS
”Two Finger Salute” Buttons

OH3Ć1 S&TT 10/00

Slide 3-1 PowerCommand Control 3200 Menu structure

Participant's Text Trainer's Text

The new PowerCommand Control 3200 has a Have the Participants turn to Page 3-2 in
much different menu system than the their Participant’s Guide. Show Visual 3-1
original PowerCommand Control had. and explain:

The menu screen is an electro-luminescent The electroluminescent display (ELD) on the

screen similar to the screen on a portable PowerCommand Control 3200 can dis-
computer. This means that the screen can play much more than the PowerCom-
have more than two lines of information. mand Control 3100 could.

Some menus can have as many as six lines of Here are some differences:
information.
PowerCommand Control 3100
The new graphical display allows us to have
menus in many languages including Chi- • Two lines of text
nese and Arabic.
• 16 characters per line

• letters, numbers, and punctuation marks

only.

Trainer’s Guide 3-3

Operator Menus PowerCommand Control 3200

Participant's Text Trainer's Text

The six buttons on the left and right sides of PowerCommand Control 3200
the display are used to move through the
menu system. • Nine lines of text
The menu system has two “main” menu • Up to 27 characters per line
screens which will assist you in navigat-
ing the menu system. • Letters, numbers, and punctuation in any
language
Later in this course we will find which Oper-
ator screen is password protected. • Graphical displays (waveforms)

• Graphical languages can be used

(Chinese, Japanese, Arabic).
The graphic on page 3-2 of your partici-
pants’ guide shows the name of the areas
of the ElectroLuminescent Display
(ELD) screen.

State Line
Action Line
Description Line
Menu Display Area

• The “State” line shows the state of the

generator set (stopped, cooling down,
etc.)

• The “Action” line shows what action the

generator set is taking at that time.
(warning, shutdown, etc.)

• The “Description” line shows an

enhancement of the Action line (warning
legend, etc.)

• The “Menu Display Area” shows the

menus we will navigate in this lesson and
the next one, Service Menus.

3-4 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

Participant's Text Trainer's Text

There are six buttons around the Display
Screen used to navigate through the me-
nus.

• The bottom two buttons can be pressed at

any time to change the display for a
specific operator. We will see this later
when we go through the menu system.

Trainer's Personal Comments

Trainer’s Guide 3-5

Operator Menus PowerCommand Control 3200

PowerCommand Menu Symbols

Toggle a selection
Go on to the next choice
ENTER Save selections into EEPROM memory
Go down one level in the menu
Go up one level in the menu
Open or Close the paralleling breaker
Go back to the top-level menu

Select previous or next item

OH3Ć2 S&TT 10/00

Slide 3-2 PowerCommand Menu symbols

Participant's Text Trainer's Text

These are the main symbols you will see in These symbols are used to navigate through
the menus for the PowerCommand Con- the menus in the PCC 3200 control menus.
trol 3200.
The symbols in the top half of the graphic are
used to navigate within a menu box.
The symbols in the bottom half are used to
navigate between menu levels.
The graphical symbols were chosen to make
the selection process as simple as
There is one more symbol which we will
cover later when it shows up on the menu
screen.

3-6 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

Language/Units Menu

Highlighted item is changed

TIME DELAY STOP

LANGUAGE ENGLISH
LOCATION LOCAL
ENTER
TEMP °F
PRES FLD PSI
PRESS GAS INHG

Language pick not present in this menu. When languages

are available, Language will be the top choice.

OH3Ć3 S&TT 10/00

Slide 3-3 Language / Units SubMenu

Participant's Text Trainer's Text

The Language selection and Units selection Language / Units menu frame
menus are reached by pressing the two
lowest menu buttons at the same time These menu frames are reached by
(Two-finger salute). pressing the two bottom buttons on the
Operator Panel at the same time. With
The menu selections will be: the PowerCommand Control 3100 you
NOTE: Language selection may not be available on had to be in the “Setup 4” menu to make
the Operator Panel at your workstation these choices.

On the PowerCommand Control 3200

NOTE: you can make these changes at any time.

Participants have a table on their

page here that is on the next page in
the TG.

Trainer’s Guide 3-7

Operator Menus PowerCommand Control 3200

SELECTION CHOICES
Language English Francais Español Portuguesa
Temperature °F °C
Pressure Fluid PSI kPa Bar
Pressure Gas Inches H2O Inches HG
Location Local Remote

NOTE: Language selection may not be available on the Operator Panel at your workstation

Participant's Text Trainer's Text

Local operation is selected when the Opera- There are four sections to this menu:
tor panel is mounted on the generator set.
• Language (when enabled in the Operator
Remote operation is selected when the Oper-
Panel calibration)
ator panel is mounted remotely from the
English and three other languages can be
generator set. The Operator panel may be
selected. The three other languages will
mounted up to 4,000 feet from the gener-
depend on the software loaded into the
ator set. Distance / wire sizes are listed in
Operator Panel.
the Installation Manual.
• Temperature
Celsius or Fahrenheit can be selected.

• Pressure (Fluid and Gas pressure are

separate measurements)
Pounds per Square Inch (PSI)
kilo Pascals (kPa)
Atmospheres of pressure (Bar)
Inches (inches of Hg or Water will show
up in the pressure menus)

• Operator Panel Location

Local (at the generator set)
Remote (Remotely mounted – up to
4,000 ft. from the set).
Trainer's Personal Comments

3-8 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

Main Menu A (Home Menu)

MENU A

TIME DELAY STOP MENU

WARNING 112 B
ACTUATOR NOT RESPONDING
ENGINE MORE>>
ALTERNATOR _\_
CONTROL HISTORY/ABOUT

STOPPED WARNING
TIME DELAY TO START DERATE
WARMUP AT IDLE SHUTDOWN COOLDOWN
RATED FREQ AND VOLTAGE SHUTDOWN
COOLDOWN/STOP DELAY
COOLDOWN AT IDLE

OH3Ć4 S&TT 10/00

Slide 3-4 Main Menu “A”

Participant's Text Trainer's Text

This menu screen helps you to find engine, Main Menu A
alternator, history, and control data.
This is the top-level menu in the Power-
The “MORE” button takes you to the second Command Control 3200 menu system.
“main” menu on the next page. When you press the lower right-hand
The circuit breaker symbol allows the opera- button by the ELD the menu display will
tor to open and close the paralleling change to this menu frame.
breaker only when running the generator
set in the Manual mode. Have partricipants pull out menu
foldout at the end of this section.
Next we will see the menus you can reach
from the Main Menu “A” screen: The three left-hand buttons take you to spe-
cific menu trees.
• Engine Data submenu • Engine Data

• Alternator Data submenu • Alternator Data

• Control submenu • Control data for Local or Remote control

of the generator set.

Trainer’s Guide 3-9

Operator Menus PowerCommand Control 3200

Participant's Text Trainer's Text

The three right-hand buttons take you to oth-
er menu levels or functions.

• Main Menu B – The next main level of

the menu system

• 52Gn Paralleling Circuit Breaker

Close/Open (manual mode only)

• About / History
These menu frames will show you the
data that you used to find in the
“Version” and “History” menus of the
PowerCommand Control 3100.
Trainer's Personal Comments

3-10 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

Engine Data Menu

TIME DELAY STOP

COOLANT TEMP 180 °F

ENGINE SPEED 1800 RPM
BATTERY 29.1 VDC
OIL PRESSURE 75 PSI

TIME DELAY STOP

MANF TEMP 75 ° F
MANF PRESS ABS 180 INHG
RAIL PRESS ABS 180 PSI
PUMP PRESS ABS 291 PSI
FUEL INLET TEMP 172 ° F
COOLANT PRESSURE 59 PSI

OH3Ć5 S&TT 10/00

Slide 3-5 Engine Data submenus

Participant's Text Trainer's Text

The Engine menus give you information on The menus in the Operator Panel may be
the operation of the engine in a simple different than the menus in the training
way. package. The menus in the training
package are designed to show how the
The units displayed will be in the units
menus system operates, not what is dis-
which the operator chose in the Lan-
played.
guage/Units menu.
The information displayed in the Operator The Engine menu frames show you all
Panel menus depends on the calibration of the engine data you found in the Pow-
downloaded into the Operator Panel. erCommand Control 3100 – and more.
The menus shown here are in version
1.04 for the QSK 45/60-powered genera- • Coolant Temperature
tor sets.
• Oil Pressure

• Engine Speed

Trainer’s Guide 3-11

Operator Menus PowerCommand Control 3200

Participant's Text Trainer's Text

• Battery Voltage

• Intake Manifold Temperature

• Intake Manifold Pressure

• Fuel Rail Pressure

• Fuel Pump Pressure

• Fuel Inlet Temperature

The pressure and temperature are dis-
played in the units selected by the opera-
tor.

The menus displayed for the QSX 15-pow- The Engine Menus shown on the menu
ered generator sets will be slightly dif- handout for the QSX15 engine are the
ferent than the menus for the QSK bottom two sections, under the
45/60-powered generator sets. QSK45/60 menus.

Trainer's Personal Comments

3-12 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

Alternator Data Menu

TIME DELAY STOP

VOLTAGE
V L-L L-N AMPS
L1 480 277 .1340
L2 480 277 .1290
L3 480 277 .1260
FREQUENCY 60.0 HZ
AVR 10.3%

TIME DELAY STOP

kW kVA PF
L1 500 350 .80
L2 500 350 .80
L3 500 350 .80
TOT 1500 1050 .80

OH3Ć6 S&TT 10/00

Slide 3-6 Alternator Data submenus

Participant's Text Trainer's Text

The Alternator Data menus give you infor- The Alternator menu frames show you
mation on the operation of the alternator all of the generator data you found in the
in a simple way. PowerCommand Control (I) – and more.
The units displayed will be in the units which
• Line-To-Line Voltage
the operator chose in the Language/Units
menu. • Line-To-Neutral Voltage
The Line to Neutral voltage column will not (Wye or Star only)
be displayed for Delta connected alterna- • Frequency out of the alternator
tors.
• AVR Duty Cycle
The %AVR menu indication shows the regu-
lator drive signal duty cycle. • Current per phase

• kW load per phase

Trainer’s Guide 3-13

Operator Menus PowerCommand Control 3200

Participant's Text Trainer's Text

• kVA load per phase

• Power Factor per phase

• Total kW Load

• Total kVA Load

• Calculated Power Factor for each phase

• Average Power Factor

If the Power Factor number has an aster-
If an asterisk is displayed in front of the isk * in front of it, the Power Factor is
Power Factor number, that indicates a for a leading load.
leading power factor (e.g., *0.95 indi-
cates a leading power factor with a value
of 0.95).
Trainer's Personal Comments

3-14 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

Control Menu

REMOTE LOCAL

START GENSET RUN MODE IDLE

BARGRAPH TEST BARGRAPH TEST
FAULT ACKNOWLEDGE

START GENSET RATED

STOP GENSET IDLE

OH3Ć7 S&TT 10/00

Slide 3-7 Power Command Control submenu

Participant's Text Trainer's Text

The Control submenu has two different func- The Control menu frames show you what
tions depending on whether the control is choices are available when the control is
mounted on the generator set or remotely. selected in the Local or the Remote con-
figuration.
Both choices can test the Bargraph LEDs.
The 0/Manual/Auto switch on the switch Local
panel must be in the “Auto” position to
activate the Start/Stop and Fault Ac- The generator set must be started at the
knowledge buttons on the Operator panel. Switch panel. When the generator set is
running in the Manual mode the operator
When the control is in the “local” position has a choice of:
(on the set), the operator can select Idle
or Rated operating speed. In “local” • Run at Idle
mode the operator has to acknowledge
faults at the switch panel. • Run at Rated

Trainer’s Guide 3-15

Operator Menus PowerCommand Control 3200

Participant's Text Trainer's Text

For Remote operation the following selec- Cummins Power Generation does not
tions must be made: want the engine run at Idle speed for
more than ten minutes, so after ten min-
• Language/Units menu utes the engine speed will automatically
Remote operation change to Rated speed.
• 0/Run/Auto switch
If the Operator wants to continue run-
Auto position
ning at Idle speed, the Operator must
• Control button again select “Run at Idle”).
Start/Stop
• Bargraph Test
When the operator presses the “START
GENSET” button, the engine will operate This button allows the operator to check
in the “non-emergency remote start” the bargraph display and make sure all
mode. The engine will warm up and cool of the LEDs are working properly.
down at idle for the preset time periods.
Warnings and Shutdowns must be ac-
knowledged at the Switch Panel when
the Operator Panel is configured as Lo-
cal.

Remote

The 0/Manual/Auto switch must be in

the “Auto” position for the Remote Op-
erator panel to start the generator set.

When the Operator selects “Start” the

generator set will start and run in a
“Non-Emergency Remote” mode.

When the Operator selects “Stop” the

generator set will go through its pre-pro-
grammed cooldown and stop time de-
lays.

Trainer's Personal Comments

3-16 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

History/About Menu

RATED FREQ AND VOLTAGE

STARTS 8733
ENGINE HOURS 1236
CONTROL HOURS 7879
KWHRS 890

RATED FREQ AND VOLTAGE

HISTORY – HRS@%MAX TORQUE

12345 @0–9 12345 @50–59
12345 @10–19 12345 @60–69
12345 @20–29 12345 @70–79
12345 @30–39 12345 @80–89
12345 @40–49 12345 @90–100

OH3Ć8 S&TT 10/00

Slide 3-8 History/About submenus

Participant's Text Trainer's Text

The History/About submenus contain a run- The History/About menu frames show
ning history of generator set operation you what the generator set has done, the
and faults experienced by the generator load on the set, the setup of the generator
set. set, the programs downloaded into the
Base Card and the Operator Panel, and
History 1 contains Starts, engine and control
the active and inactive faults.
hours, and kilowatt–hours produced by
the set. History 1
History 2 contains load profile data detailing
the number of hours the set has run in • Number of Starts
each load percentage range.
• Number of engine run hours

• Number of Control hours

• MegaWatt Hours of power produced

Trainer’s Guide 3-17

Operator Menus PowerCommand Control 3200

Participant's Text Trainer's Text

About 1 contains History 2

• Model number • Number of hours at each of ten power

• Output voltage and connection type ratings. This allows you to see if the set is
being run with too low a load, too much
• Base Frequency load, or if the load is just right.

• Rating (Standby, Prime, Base) About 1

• Model Number
About 2 contains
• Voltage and connection type
• RTOP = Calibration loaded into the Base
card • Frequency

• BATS = Base card basic software • Rating Standby / Prime / Base

revision
• Application Rating
• Main = Operator Panel menu software
About 2
• Boot = Operator Panel basic software
revision • Controller RTOP Calibration

History 3 contains • Controller BATS Bootloader

• Fault history – Number of faults in • Operator Panel RTOP Menus

memory
• Operator Panel BATS Bootloader
• Data on a specific fault
History 3
(in this case fault #112)

• Control Hours at last occurrence 54452 Fault History of the Control

• Number of occurrences 5 • How many faults in the control

• Engine hours at latest occurrence 32412 • Control Hours at the last Occurrence

• Numeric code for this fault 112 • How many of this fault

• Fault Name: Actuator Not Responding • Engine Hours at the last Occurrence

• Fault Code

Trainer's Personal Comments

3-18 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

Main Menu B

MENU B

ADJUST

BUS DATA

SETUP BACK<<

BACK TO
GRAPHICAL DISPLAY MENU A

MENU MENU
BUTTONS BUTTONS

OH3Ć9 S&TT 10/00

Slide 3-9 Main Menu “B”

Participant's Text Trainer's Text

This menu gives you choices which do not Main Menu B allows you to see the data
concern operation of the engine or alter- which cannot fit on Main Menu A. Most
nator. of the information on Main Menu B is
Operator-Level menus.
The pages indicated on this screen are refer-
enced to the Operator’s Manual.
• Adjust Takes you to the Adjust Menu
The menus you can reach from the Main frame
Menu “B” screen are:
• Bus Data Takes you to the Bus Volts
• Adjust submenu This menu is menu
password protected to prevent
tampering. • Back Takes you back to Main Menu A

• Bus Data submenu • Setup Takes you to the Technician Menus

• Setup submenus
The Back button will take you back to Main
menu “A.”

Trainer’s Guide 3-19

Operator Menus PowerCommand Control 3200

Participant's Text Trainer's Text

A big difference between the PCC 3200
and the PCC 3100 is that with the new
control you don’t have to know the pass-
word to see how the control is config-
ured and calibrated.

You do need the password to change

the calibration unless you are using In-
Power software.

Trainer's Personal Comments

3-20 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

Adjust Menu

MAIN MENU B
TIME DELAY STOP
WARNING – 112
ACTUATOR NOT RESPONDING
ADJUST

BUS DATA

SETUP BACK<<

TIME DELAY STOP

WARNING – 112
ACTUATOR NOT RESPONDING
User Password protects ADJUST:
Voltage, Frequency, and VOLTAGE 480 1.2 %
Time Delay Adjustments. FREQ 60.0 HZ –0.0 HZ
START DELAY 5 SEC
STOP DELAY 300 SEC

OH3Ć10 Application Password protects Stop Delay S&TT 10/00

Slide 3-10 Adjust submenu

Participant's Text Trainer's Text

The ADJUST menu is password protected. Adjust Menu
The Adjust menu allows the operator to The Adjust Menu has several items
change the the following parameters: which are password protected. In the be-
• Generator Set Voltage ± 5% ginning, only the Stop Time Delay was
protected, but in later versions of the
• Generator Set Frequency ± 3 Hz Operator Panel RTOP both the Start and
Stop delays were password protected.
• Start Delay 0 – 300 seconds

• Stop Delay 0 – 600 seconds • Voltage Adjust

Allows the operator to change the voltage
Up or Down 5%.

• Frequency Adjust
Allows the operator to change the engine
speed Up or Down 3 Hz.

Trainer’s Guide 3-21

Operator Menus PowerCommand Control 3200

Participant's Text Trainer's Text

• Start Delay
Allows the operator to change the Start
Delay period.

• Stop Delay
Allows the operator to change the Stop
Delay period.
Depending on the RTOP in your Opera-
tor panel, one or both of the time delays
may be password protected.

Trainer's Personal Comments

3-22 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

User Password Menu

+ OR – BUTTON IN ADJUST MENU SENDS YOU HERE

ENTER USER PASSWORD

ENTER

XXXXXXX
X

OH3Ć11 S&TT 10/00

Slide 3-11 Password submenu

Participant's Text Trainer's Text

This menu is used to input the password, or If you “CLEAR” the User Password in
to change the password. InPower and do not “SET” a new pass-
word, the password defaults to “GEN-
• + & – keys move through number and SET.”
letter keys.
Enter Password Menu
• → key moves to next spot in password

• <Enter> key puts password into The Password entry screen only appears
memory. when the operator or technician tries to
adjust some parameter which is pro-
If you clear this password with InPower soft- tected by a password.
ware, the password defaults to GENSET.
When you are in the Adjust Menu and
try to change the Stop Delay in a “stan-
dard production” set you will be sent to
the User Password screen

Trainer’s Guide 3-23

Operator Menus PowerCommand Control 3200

Participant's Text Trainer's Text

When you are in the Setup menus and
you try to change any setup parameter
you will be sent to the Application Pass-
word screen.

The default password for the Application

Password is “GENSET.”

In early sets the User Password was set

to “NULL” and it was ignored until
someone cleared the password in the In-
Power software.

Trainer's Personal Comments

3-24 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

Save/Continue Menu

SAVE

CONTINUE

OH3Ć12 S&TT 10/00

Slide 3-12 Save/Continue Menu

Participant's Text Trainer's Text

After you change something in the Adjust Save / Continue Menu
Menu and try to move to another menu,
the “Save/Continue” screen pops up. Press the “Home” button to get to the
Save/Restore menu.
• You can choose to save your changes, or
• Save Keeps the changes you have made
• Continue without saving the data.
and writes them to the EEPROM or Flash
If you choose to save, you will go to the Memory as appropriate.
menu you pointed toward out of the pre-
vious menu:
If you picked the “go down” arrow you will
be taken down to the next level.
If you picked the “go up” arrow you will be
taken up to the previous level.
If you picked the “home” arrow you will be
taken up to Main Menu A.

Trainer’s Guide 3-25

Operator Menus PowerCommand Control 3200

Participant's Text Trainer's Text

If you choose to continue, the change will • Continue Returns the changes to their
not be saved. When the generator set is previous value and does not make any
turned off and restarted, it will operate changes to the EEPROM or Flash
off tee data which was previously stored. Memory.

Trainer's Personal Comments

3-26 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

Bus Data Menu

STANDBY
DEAD BUS CLOSE
SYNCHRONIZE
LOAD SHARE
LOAD GOVERN

LOAD GOVERN

V BUS GEN
L1 480 480
L2 480 480
L3 480 480
Hz 60.1 60.0
DEG –122 NOT SYNCHRONIZING

NOT SYNCHRONIZING
SYNCHRONIZING
READY TO CLOSE

OH3Ć13 S&TT 10/00

Slide 3-13 Bus Data submenu

Participant's Text Trainer's Text

The Bus Data menu gives the operator the Bus Data
following information when the Power-
Command Control 3200 is set up for par- The “State Line” of the Bus Data menu
alleling: tells about the state of the generator set
in relation to the Emergency Bus:
• Line-to-Line Bus Voltage
• Standby (Not working in relation to the
• Bus Frequency.
Bus)
• Phase difference between the Bus and
• Dead Bus Close (Loss of Master First
the generator set (reference is the Bus).
Start Pulse)

• Synchronize (Synchronize mode

available)

• Load Share (Paralleled in an Isolated Bus

system)

Trainer’s Guide 3-27

Operator Menus PowerCommand Control 3200

Participant's Text Trainer's Text

• Whether the Permissive Relay function • Load Govern (paralleled in an Infinite
is ready to close the Utility breaker, and Bus system)
the position of the Utility (Mains)
The Bus Data Menu tells the voltage of
breaker.
the Emergency Bus and the generator
• The circuit breaker symbol shows the set, and tells what the control is doing at
position of the paralleling breaker. The that time.
operator cannot control the breaker from
this screen. • Bus Voltage by phase

• Generator Set Voltage by phase

• Bus Frequency

• Generator Set Frequency

• Degrees between the Generator Set and

the Bus (reference)

• What the control is doing:

Synchronizing
Not Synchronizing
Ready To Close (synchronized)

Trainer's Personal Comments

3-28 Trainer’s Guide

PowerCommand Control 3200 Operator Menus

Operator Menu Activities

3Ć1 Operator Menus

3Ć2 Operator Menu Quiz

OH3Ć14 S&TT 01/03

Slide 3-14 Operator Menu Activities

Participant's Text Trainer's Text

This activity is designed to familiarize the
participants with the Operator-Level me-
nus for the PCC 3200 control.

The Quiz can be used as an in-class or home-

work activity. Some of the questions are
designed to create controversy between
the students.

Trainer’s answers to this activity are

located in the Activities tab.

Trainer’s Guide 3-29

Operator Menus PowerCommand Control 3200

Wrap-Up
In this lesson we have looked at the Operator-Level menus in the PowerCommand Control
3200.

We learned about the two main menus:

Main Menu A
Main Menu B

We learned about the Engine Menus

We learned about the Alternator Menus

We learned about the Local and Remote Control Menus

We learned about the History and About Menus

We learned about the Adjust Menus

We learned about the Bus Data Menus

We learned about the Password Menu

We learned about the Save/Continue Menu

We learned about the “Two Finger Salute” Menu which can be used at any place in the menu
system.

In the PCC(I) we had a “Three-Finger Salute” where we reset the control and told it what
engine and alternator it was controlling. Each of the generator sets the PCC(I) could control
had the same type of fuel system. The program for the fuel system was located in the
EPROM which we changed when we wanted to go from a Single to a Paralleling generator
set.

In the PCC 3200 we don’t have that kind of setup menu for the control because the PCC
3200 normally operates a different kind of engine. Each engine it controls has a different
calibration program which has to be downloaded into the control to make the engine work
properly.

In the next lesson we will learn about operating the PCC 3200 and the sequence of operation
of the PCC 3200.

3-30 Trainer’s Guide

PowerCommand Control 3200 Operation

PowerCommand Control 3200 Operation

Estimated Time: 4.0 hours

Equipment Needed

Overhead projector and screen or PC with LCD Projector and screen

PowerCommand Control Simulator Kit (1 for each 2 participants)

PC with SimMon4 software and “Black Box” to control up to eight simulators at one time or
PowerCommand 2100 simulators for individual control operation.

Materials Needed

Module overhead set or slide set

One for each participant:

PowerCommand Control Participant’s Guide Guide (CMT0642-EN-PG)

PowerCommand Control 3200 Operator’s Manual Manual (960–0153)

PowerCommand Control 3200 Sequence of Operation print set

Trainer’s Guide 4-1

Operation PowerCommand Control 3200

Warm Up
In this lesson we are going to introduce ourselves to the PowerCommand Control 3200 sequence
of operation.

We are going to look at what the control does for the generator set, and how the operator can
interpret the operation as OK or not OK.

We are going to review the operation of the 0-Manual-Auto switch and how it is used with the
pushbuttons on the Switch panel to operate the generator set in the Manual, Exercise, and
Non-Emergency Auto modes.

We will look at the flowchart of the control operation for the different modes, and find where the
signals are present on the generator set wiring diagram.

First, let’s look at the objectives for this lesson:

Objectives
After completing this lesson, you should be able to:
• List the main signals used by the PowerCommand Control for operation cues.

• State two uses by the PowerCommand Control for the Magnetic Pickup signal.

• State two uses by the PowerCommand Control for the PMG signal.

• Select from a list, the eight signals that will wake-up the PowerCommand Control when it is
in the Standby mode.

• Describe the Inputs and Outputs for the 0-Manual-Auto and Emergency Stop switches.

• Show where to check for specific operation signals during the Start and Run modes of
operation.

• Describe the sequence of operation of the PowerCommand Control and what signals are
present at any point in the sequence.

• Operate a generator set with a PowerCommand Control 3200.

• Determine operating parameters for Idle and Rated speeds.

4-2 Trainer’s Guide

PowerCommand Control 3200 Operation

PCC 3200 Operation

Tells Operator what is happening

Start and run genset
Two Starter Disconnects
Switched B+ output
Monitor Frequency
Monitor Voltage & Current
Exercise Functionality
Idle mode operation
OH4Ć1 S&TT 01/03

Slide 4-1 PCC 3200 Operation

Participant's Text Trainer's Text

PowerCommand Control 3200 Have the Participants turn to Page 4-2 in
their Participant’s Guide. Show Visual 4-1
System Operation and explain:
Be able to tell the Operator what position the
Off/Run/Auto switch is in, and what in- The PowerCommand Control 3200 Sys-
puts and outputs should be available. tem does these things in its Operation
sequence.
Display an LED on the front panel when the
Off/Run/Auto switch is not in the Auto
• Tells position of the 0-Manual-Auto
position, and send a steady signal out as a
switch, and if a Remote Start input is
“Not In Auto” signal to an annunciator.
available.
Start the engine when commanded.
• Display the “Not in Auto” LED when the
0-Manual-Auto switch is not in the Auto
position.

• Start the engine when commanded.

Trainer’s Guide 4-3

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

Provide power to the Fuel Solenoid Valve, • Provide power to the FSV, DC Alternator,
DC Alternator, and the Regulator Output and the Regulator Output module.
Module.
• Monitor MPU signal to see if the engine
Monitor Mag Pickup signal for use as a Pri- is turning over, and for primary starter
mary Start Disconnect signal and to see if disconnect.
the starter turned the flywheel.
• Send a “RUN” signal to the FSV when
Send the Switched B+ (Run) signal to the the MPU signal is received at the Base
Fuel Solenoid when the Mag Pickup sig- card.
nal is received at the Base card.
Disconnect the starter when the engine (MPU
signal) reaches a certain speed. • Disconnect the starter when the MPU
signal gets to the proper frequency.
Monitor PMG voltage as secondary method
of start disconnect. • Monitor PMG voltage and frequency as
a secondary starter disconnect.
Compare the MPU signal against the genera-
tor output frequency. If the relationship is • Compare MPU and Alternator
not correct, shut the set down on Mag frequencies for MPU failure fault.
Pickup Failure.
Monitor Over and Under Voltage and Fre-
quency conditions.
Monitor Overcurrent, Overload, and Short • Monitor over and under voltage
Circuit conditions. conditions.

Monitor phasing of CTs, and shut down on • Monitor over current, overload, and
Reverse Power if connected improperly. short circuit conditions.

Monitor and display Customer-selected

• Monitor phasing of CTs and shut down
Warnings or Shutdowns.
on reverse power if they CTs are
connected improperly.

• Monitor and display customer selected

warnings or shutdowns.

Trainer's Personal Comments

4-4 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

Offer a standardized “Exercise” function for PowerCommand Control 3200 additions over
the generator set. the initial PowerCommand Control.
Run the generator set in Idle mode with the
• Offer a standardized “exercise” function
regulator disconnected to warm up and
for the generator set.
cool down the engine when required.
• Run the engine in Idle mode with the
regulator disconnected to warm up and
cool down the engine when required.

Trainer's Personal Comments

Trainer’s Guide 4-5

Operation PowerCommand Control 3200

MPU Uses

Crankshaft rotation
Primary start disconnect speed
Speed regulation
Mag Pickup Failure fault

OH4Ć2 S&TT 01/03

Slide 4-2 MPU Uses in the PCC 3200

Participant's Text Trainer's Text

This input signal tells the PCC 3200 if the The PowerCommand Control 3200 uses the
flywheel is turning. Magnetic Pickup (MPU) signal to:
When the START signal is sent to the gener-
• see if the engine is turning when the
ator set, the PCC 3200 waits for the MPU
starter is engaged.
input before energizing the RUN relay.
The MPU input signal is also used by the • tell the control when the engine is
PCC 3200 as: running fast enough to disconnect the
starter.
• the primary starter disconnect signal,
• regulate the idle and rated speeds.
• the Idle and running speed regulation
signal, • measure against the output frequency for
a Mag Pickup Failure fault.
• Fail to Crank Fault input.

4-6 Trainer’s Guide

PowerCommand Control 3200 Operation

PMG Uses

Secondary Starter Disconnect

Prevent Fault
Excitation supply

OH4Ć3 S&TT 01/03

Slide 4-3 PMG uses in the PCC 3200

Participant's Text Trainer's Text

This three-phase signal is used to: The PowerCommand Control 3200 uses the
Permanent Magnetic Generator signal
• open a set of contacts in the Regulator to:
Output Stage that act as the AC (backup)
Starter Disconnect circuit. This happens • provide a secondary starter disconnect at
when the genset is running at 850 rpm 850 RPM when the PMG output is 105
(105 VAC rms output from the PMG). VAC.
• develop the pulsating DC excitation • Provide the AC power for rectification
voltage. into the PWM DC voltage sent to the
exciter stator, which produces the output
voltage from the main alternator.

Trainer’s Guide 4-7

Operation PowerCommand Control 3200

Switch Panel

REMOTE START
LED

EXERCISE SWITCH
AND LED

MANUAL SWITCH
AND LED

(OFF/MANUAL/AUTO)
MODE SWITCH
0

OH4Ć4 S&TT 10/00

Slide 4-4 Switch Panel

Participant's Text Trainer's Text

Mode (Off/Run/Auto) Switch
Position
This input tells the PowerCommand Control
what the generator set should be doing: Mode Switch Position

• 0 Not Available for operation • 0 Not available for operation

• MANUAL Manual operation • Manual Manual operation

• AUTO Remote operation (Normal, • Auto Automatic Emergency,

Exercise, or Emergency) Automatic Non-Emergency, or Exercise
operation
Manual Operation can be from the Switch
Panel or the Operator Panel Manual mode Operator panel must be in
LOCAL location to change between
• Operator panel must be on the genset. “Idle” and “Rated” speeds.

4-8 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

Exercise Mode is run in Auto position so if a Exercise mode
remote start signal comes in the set will 0-Manual-Auto switch is in the “AUTO”
change to the emergency run mode. position so the set can run in Emergency
operation if needed.

Auto mode can be in Emergency Start or Auto Mode

Non-Emergency Start. Auto start is from Can be Emergency or Non-emergency
an automatic transfer switch or the Oper- operation.
ator Panel (in remote mode).

Trainer's Personal Comments

Trainer’s Guide 4-9

Operation PowerCommand Control 3200

Manual Operation

LOCAL START
(Manual Mode)

CONTROL
RUN BUTTON

WARM-UP
@
IDLE
Engine Temperature
1 or 2 greater than 100°F to
switch from Idle to Rated
RATED SPEED
&
VOLTAGE

CONTROL STOP EMERGENCY

BUTTON STOP BUTTON

COOL-DOWN
@ Engine Temperature
RATED/IDLE3 greater than 160°F gives
Cooldown at Rated = 3 min. “Hot Shutdown” Fault
Cooldown at Idle = 2 min. 3

STOP

NOTES:
1. Timer expires.
2. Coolant temperature reaches operating level.
3. Cool-down can be at rated speed and/or idle with
different time-outs for each.

OH4-5 S&TT 83/99

Slide 4-5 Manual Start sequence of operation

4-10 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

Manual Start from Switch Panel Manual Operation

• When the Off/Run/Auto switch is in the • The “Manual” pushbutton is used with
Manual position, the operator presses the the 0–Manual–Auto switch to start the set
“Manual Run/Stop” pushbutton to start in Manual mode. Engineering wanted a
the generator set. two-step procedure to keep nuisance
• The operator can select to “Run at Idle” starting by vandals to a minimum.
or Run at Rated” from the Control menu • If the engine temperature is less than
of the Local Operator Panel. 100° F the engine will start and run at
NOTE: Do Not run the set at idle for more Idle to warm up the engine.
than ten minutes. Long idling periods The factory setting on the Idle timer
can promote engine damage from (Note #1) is Ten minutes. After this tim-
lowered combustion chamber er expires the engine will ramp up to
temperatures. rated speed.
• The set will start and run at idle to warm If the coolant temperature goes above
up the engine. 100° F the engine will ramp up to rated
• When the engine is warm (100° F or speed.
higher) the set will ramp up to normal
If the Operator selects “Run at Idled”
speed.
from the “local” Operator Panel control
menu the engine will ramp down to idle
speed and remain there until the coolant
temperature exceeds 100° F or the ten
minute timer expires.

• If the Operator selects “Run at Rated”

from the “local” Operator Panel control
menu the engine will ramp up to rated
speed.

• When the operator again presses the

• The set will run until the operator again Manual pushbutton on the Switch panel,
presses the “Manual Run/Stop” the set will go into its cooldown mode.
pushbutton on the switch panel.

Trainer’s Guide 4-11

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

• The set will continue to run at rated Cooldown time depends on generator set
speed for the Stop Time Delay. The load and the timers set with InPower
Manual LED will flash when the set is software.
cooling down. Cooldown at rated speed
is factory set to 3 minutes. If the generator set carried more than
10% load in the past ten minutes, the
• After the set has cooled down at rated cooldown time will be extended to pro-
speed it will ramp down to idle and cool vide a longer cooldown at rated speed.
down at idle for 2 minutes.
Once the cooldown at rated speed is
• To be ready for the next power outage completed, the set will ramp down to
the Operator must turn the idle and run at idle for ten minutes to
0–MAnual–Auto switch back to the complete the cooldown period.
“Auto” position.
• After the cooldown period is completed,
the set will stop.

• The Operator must place the

0–Manual–Auto switch back in the Auto
position so the set will start when the
utility power fails.
Ask participants:

How long does the timer let the engine run at idle when warming up from a cold start?

10 minutes maximum.

When does the engine ramp from idle to rated speed automatically?

When the engine coolant reaches 100° F or the ten minute timer expires.

Why does the engine run at idle for only ten minutes?

If the engine runs at idle for longer than ten minutes the combustion chamber temperatures
can drop low for complete combustion of the fuel. The unburned fuel can allow deposits to
form on the injectors, piston rings, and valves. Unburned fuel can wash lubricating oil
from the cylinder walls and dilute the crankcase oil.
Trainer's Personal Comments

4-12 Trainer’s Guide

PowerCommand Control 3200 Operation

Cooldown at Rated Speed

100

90
80
70
60
50 Cooldown at Rated depends on % load
40 180 seconds at less than 10% load
30
20
10

0
0 10 30 50 70 90 110 130 150 170 190 210 230
LOAD
TIME
OH4Ć6 S&TT 10/00

Slide 4-6 Rated Cooldown Time Delay

Participant's Text Trainer's Text

The Cooldown time delay is determined by When the generator set control no longer
the load on the generator set during the sees a “Run” signal, the cooldown mode
run time. starts timing. There are two separate
cooldown mode sections:
The generator set will run at rated speed for
180 seconds after the load goes below
• Cooldown at Rated, and
10% of rated load.
Cooldown at Rated time is determined
In the example above, the generator set is
by the summing of two numbers:
running at approximately 80% to the ten
second mark, then the load ramps down
• The Cooldown at Rated Trim (changed
to 8% at the 35 second mark. At that time
with InPower) is factory set at 3 minutes.
the Remote Start signal was removed and
the breaker opened removing the load • The load factor on the generator set
completely. within the last ten minutes.

Trainer’s Guide 4-13

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

The set starts cooling down for the Stop If the load on the set was more than 10%
Time Delay and the Cooldown Timer at the load factor time delay is added to the
the same time. If there is no Stop Time Cooldown at Rated Time Delay to make
Delay, the set will run until the 215 sec- a total cooldown at rated time delay of 6
ond mark with no load. This allows the minutes.
engine and alternator to cool down.
If the load on the set was 10% or less in
At the 215 second mark the set ramps down the last 10 minutes, the load factor Time
to Idle for the Idle cooldown period. Delay is set to zero. That makes the
Idle cooldown is dependent upon the trim cooldown at rated time delay 3 minutes.
setting saved in the Base card. The facto-
ry default Idle cooldown is 2 minutes. • Cooldown at Idle.

NOTE: if the Time Delay Stop (set in at the Cooldown at Idle trim is factory set to
Operator panel) is longer than the Cooldown ten minutes.
delay (set with InPower), the set will run
with no load for the longer time delay. • All modes of operation use both of these
cooldown timers.

Trainer's Personal Comments

4-14 Trainer’s Guide

PowerCommand Control 3200 Operation

Exercise Operation

LOCAL START
(Auto Mode)

CTRL EXERCISE
BUTTON
REMOTE START from Op Panel
(Remote Location) (Auto Mode)
TIME DELAY TO
START
1

WARM-UP
@
IDLE
Engine Temperature
1 or 2 greater than 100°F to
switch from Idle to Rated
RATED SPEED
&
VOLTAGE

EXERCISE TIME
EXPIRES

TIME DELAY TO EMERGENCY

STOP STOP BUTTON
Time Delay To Stop runs at 1
the same time as
Cooldown at Rated = 3 min. COOL-DOWN
Engine Temperature
@
greater than 160°F gives
RATED/IDLE3
Cooldown at Idle = 2 min. “Hot Shutdown” Fault
1

STOP

NOTES:
1. Timer expires.
2. Coolant temperature reaches operating level.
3. Cool-down can be at rated speed and/or idle with
different time-outs for each.

OH4-7 S&TT 83/99

Slide 4-7 Exercise sequence of operation

Trainer’s Guide 4-15

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

Exercise Mode Exercise Operation

The exercise mode start consists of two coor- • The Exercise pushbutton on the Switch
dinated switch operations: panel must be held in as the
The Exercise pushbutton on the Switch panel 0–Manual–Auto switch is moved from
must be held in while the 0–Manual– Manual to Auto. This starts the exercise
Auto switch is rotated: timer.

• The Emergency Start Time Delay will

• from Auto to Manual and back to Auto,
count down on the ElectroLuminescent
or
Display (ELD) on the Operator Panel.
• from Manual to Auto.
• After the start time delay has completed,
The generator set will time for start using the the engine will start and run at idle.
pre-programmed start delay.

Ask participants:

When would the engine not start and run at idle speed?

When the engine coolant temperature is above 100° F.

After the generator set starts the engine will • After the idle time delay is completed
run at idle unless the engine coolant ex- the engine will ramp up to rated speed
ceeds 100° F. and remain there until the end of the
exercise period.
When the engine coolant exceeds the thresh-
old temperature the set will ramp up to
rated speed.
The generator set will continue to run for the
pre-programmed Exercise time delay.
At the end of the exercise period the set will
cool down.

4-16 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

• The set will continue to run at rated • The set will cooldown at rated speed for
speed for the Stop Time Delay. The a period of time determined by the load
Exercise LED will flash when the set is carried by the set in this last exercise
cooling down. period. The higher the load, the longer
the cooldown at rated speed.

• If the generator set has run at over 10% • When the Cooldown period has expired,
load in the past ten minutes the the set will ramp down to Idle and
cooldown period at rated speed will be cooldown at idle for 10 minutes.
extended by the control software.
• At the end of the idle cooldown period
• Once the cooldown at rated speed has the engine will stop. Since the switch is
been completed, the engine will ramp in the Auto position, the set is ready for
down to idle speed and complete its the next power outage.
cooldown period.

Trainer's Personal Comments

Trainer’s Guide 4-17

Operation PowerCommand Control 3200

Automatic Non-Emergency Operation

0/Manual/Auto
Switch in AUTO

NON-EMERGENCY REMOTE START

REMOTE START from Remote Op Panel
from OTPC ATS

TIME DELAY TO
START
1

WARM-UP
@
IDLE
1 or 2 Engine Temperature
greater than 100°F to
RATED SPEED switch from Idle to Rated
&
VOLTAGE

REMOTE
STOP

TIME DELAY TO EMERGENCY

STOP STOP BUTTON
1
Time Delay To Stop runs at
the same time as
Cooldown at Rated = 3 min. COOL-DOWN
@ Engine Temperature
RATED/IDLE3 greater than 160°F gives
Cooldown at Idle = 2 min. “Hot Shutdown” Fault
1

STOP

NOTES:
1. Timer expires.
2. Coolant temperature reaches operating level.
3. Cool-down can be at rated speed and/or idle with
different time-outs for each.

OH4-8 S&TT 83/99

Slide 4-8 Automatic Start sequence – Non-Emergency mode

4-18 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

Non-Emergency Start Inputs Automatic Non-Emergency Opera-
tion
There are two Non-Emergency Start Inputs
• The 0–Manual–Auto switch stays in the
• Remote non-emergency start from a
Auto position. The difference between
PowerCommand OT ATS.
this mode of operation and the
• Remote start signal from the Emergency Auto mode is the signal the
remote-mounted Operator Panel. control receives to start the generator set.

Non-Emergency Remote start sequence • The control needs to receive a Remote

Start signal from a transfer switch along
• The set will start after the Start Time
with a “start type” signal. The
Delay (0–300 seconds).
PowerCommand OTPC ATS can send
both of these signals to the control.

• Another way to start the generator set in

the Non-Emergency mode is to start the
set by using the remote Operator Panel
control menu pick “Start GenSet.”

• Either of these will start the set in the

Non-Emergency mode.

• The set will start and run at idle to • First, if the engine coolant temperature is
warm up the engine. less than 100° F, the engine will idle for
a maximum of ten minutes or until the
• When the engine is warm or the idle coolant temperature exceeds 100° F.
timer has expired the set will ramp up to
normal speed. • Once the Idle Warmup time delay is
completed, the set will ramp up to rated
• The set will run for the preset exercise speed. The set will continue to run at
time period at normal speed. rated speed until the Remote Start signal
is removed.

Trainer’s Guide 4-19

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

• The set will continue to run at rated • When the Remote Start signal is
speed for the Stop Time Delay. The removed, the set will start the Cooldown
Remote Start LED will flash when the Timer. This timer responds to the load
set is cooling down. carried by the set in this run. The higher
the load, the longer the cooldown at rated
• After the Stop Delay time period the set speed.
will ramp down to idle and cool down at
idle for the Idle Cooldown Time Delay. • When the Cooldown Timer expires the
set will ramp down to idle for the Idle
• After completion of the idle cooldown Cooldown period. This period is factory
period the set will stop. set to ten minutes.

• At the end of the idle cooldown period

the set will shut down. Since the switch is
in the Auto position, the set is ready for
the next power outage.
Trainer's Personal Comments

4-20 Trainer’s Guide

PowerCommand Control 3200 Operation

Automatic Emergency Operation

REMOTE START
(Auto Mode)

EMERGENCY
REMOTE START

TIME DELAY TO
START
1

RATED SPEED
&
VOLTAGE

REMOTE
STOP

TIME DELAY TO EMERGENCY

STOP STOP BUTTON
1
Time Delay To Stop runs at
the same time as
Cooldown at Rated = 3 min. COOL-DOWN
@ Engine Temperature
RATED/IDLE3 greater than 160°F gives
Cooldown at Idle = 2 min. “Hot Shutdown” Fault
1

STOP
NOTES:
1. Timer expires.
2. Coolant temperature reaches operating level.
3. Cool-down can be at rated speed and/or idle with
different time-outs for each.

OH4-9 S&TT 83/99

Slide 4-9 Automatic Start sequence – Emergency mode

Trainer’s Guide 4-21

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

Emergency Start Input Automatic Emergency Operation

Remote Start Input from ATS or Paralleling • The 0–Manual–Auto switch stays in the
Master Control Auto position. The difference between
• A Remote Run input with the this mode of operation and the
Off/Run/Auto switch in the Auto Non-Emergency Auto mode is the signal
position starts the generator set. the control receives to start the generator
set.
• The set will start after the Start Time
Delay (0–300 seconds). • The control needs to receive a Remote
Start signal from a transfer switch. Any
transfer switch Remote Start signal will
start the generator set in the Emergency
mode.

• The set will start and run at rated speed • Once the starter has disconnected, the set
after the time delay. will ramp up to rated speed. The set will
continue to run at rated speed until the
Remote Start signal is removed.

• When the Remote Start signal is

• When the remote start input is removed removed, the set will start the Cooldown
the set will run at normal speed for the Timer. This timer responds to the load
Stop Time Delay period. carried by the set in this run. The higher
the load, the longer the cooldown at rated
• The set will continue to run at rated speed.
speed for the Stop Time Delay. The
Remote Start LED will flash when the • When the Cooldown Timer expires the
set is cooling down. set will ramp down to idle for the Idle
Cooldown period. This period is factory
• After cooling down at rated speed the set to ten minutes.
engine will run at idle to complete the
cooldown of the engine. • At the end of the idle cooldown period
the set will shut down. Since the switch is
• After completion of the idle cooldown in the Auto position, the set is ready for
period the set will stop. the next power outage.

Trainer's Personal Comments

4-22 Trainer’s Guide

PowerCommand Control 3200 Operation

Crank & Run Relay Effective Circuits

20Amps
MPU
Battery Positive

REMOTE
E-STOP
SWITCH

LOCAL
E-STOP
SWITCH

REG OUTPUT
MODULE
BACKUP
START
DISCONNECT

BASE CARD CRANK CRANK

Monitor RELAY

RUN
CRANK RELAY
SIGNAL

AMS

Inline F
B
To Block
STARTER
Heaters

RUN Monitor

RUN SIGNAL

OH4-10 S&TT 83/99

Slide 4-10 Crank and Run Relay effective circuits

Trainer’s Guide 4-23

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

Crank Relay Crank and Run Effective circuits

Crank Relay Coil B+ comes through the in- • The lines colored RED on the screen are
harness 20 Amp. fuse. always B+ as long as the battery is
• Crank relay receives a ground signal connected, and the Local and Remote
from the Base card to energize the relay Emergency Stop switches are in the “out”
coil. position.

• Current through the relay coil is sensed • Notice that the position of each switch
by the Base card. and most of the relay contacts are sensed
by the Base card. This allows the
Emergency Stop Switches PowerCommand Control 3200 to be
more precise in measuring if relay coils
• If either Emergency Stop switch is open, and contacts are doing what they are
the Crank Relay cannot energize. commanded to do.
• Both switches are “push to open,” and • When the Base card sees a signal to start
Pull to close.” the engine, it sends a ground signal
(dashed arrow) to the bottom of the
• Position of the contacts is sensed by the
Crank Relay.
Base card.
Backup Start Disconnect • The Base card monitors the ground signal
to the Crank Relay coil and the current
• This is included to satisfy NFPA-110 through the relay driver circuit. This lets
requirements. the Base card know if the Crank Relay
coil has energized or not.
• Position of the contacts is sensed by the
Base card.

Crank Relay Contacts If the Crank Relay coil does not energize,
the fault is 1478
Receive unfused B+ from the generator set Crank Relay Driver Error
battery.
• Because the Crank Relay has B+ on the
“Position” of these relay contacts is sensed other side, it energizes.
by checking AMS contact position.
• The Crank Relay contacts now close and
deliver unfused B+ to the AMS. The
AMS energizes and its contacts close
also.

4-24 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

• The Base card monitors the state of the
AMS contacts to see if a “crank” signal
was really sent to the starter.

If the AMS Relay contacts do not close, the

fault is 1477
Crank Relay Contact Error

• Once the starter turns the engine over, the

MPU will send a signal to the Base card
to show that the flywheel did turn over.

If the MPU does not send a signal, the fault

is 115
No Engine Speed Signal Detected

If the engine does not turn over, the fault is

1438
Engine Failed to Crank
You can see from the listing of these
faults that the PowerCommand Control
3200 is going to be much easier to trou-
bleshoot. It tells you exactly what it is
doing or not doing at all times.

• Once the Base card sees the MPU signal,

it sends a ground signal (dashed arrow) to
the bottom of the Run Relay.

Run Relay
• The Base card monitors the ground
Emergency Stop Switches signal to the Run Relay coil and the
current through the relay driver circuit.
• If either Emergency Stop switch is open, This lets the Base card know if the Run
the Run Relay cannot energize. Relay coil has energized or not.

• Run Relay receives a ground signal from If the Run Relay coil does not energize, the
the Base card to energize the relay coil. fault is 1415
Run Relay Driver Error
• Current through the relay coil is sensed
by the Base card.

Trainer’s Guide 4-25

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

Run Relay Contacts • The Base card monitors the ground signal
to the Run Relay coil and the current
Receive unfused B+ from the generator set through the relay driver circuit. This lets
battery. the Base card know if the Run Relay coil
Position of these relay contacts is sensed di- has energized.
rectly by the Base card. If the Run Relay coil does not energize, the
fault is 1415
Run Relay Driver Error

• The Run Relay contacts now close.

• The Base card monitors the state of the

Run Relay contacts to see if a “run”
signal was really sent to the set.

If the Run Relay contacts do not close, the

fault is 1414
Run Relay Contact Error
I wanted to go through this diagram —
which simplifies the operation of the
crank and run circuits — so you could
see how the control tells us what it sees
or does not see at each checkpoint in its
logic.

Notice that this diagram shows the fused B+

passing through the two Emergency
Stop switch contacts before getting to
the crank disconnect contacts and the
run relay.

The actual contacts are not connected in se-

ries like this. However, the logic of the
control makes them operate as if they
were connected like this.

If either of the Emergency Stop switch con-

tacts are open, the generator set will not
crank if it is stopped, or stop if it is run-
ning.

4-26 Trainer’s Guide

PowerCommand Control 3200 Operation

Switch Panel Circuits

Lamp

OH4Ć11 S&TT 10/00

Slide 4-11 Switch Panel Circuits

Participant's Text Trainer's Text

This diagram shows the bidirectional use of
the circuits for the Manual and Exercise
switches and LEDs.

It also shows how to check the Mode Switch

to see if it is working properly.

Walk through testing of the Mode switch to

see if the contacts are working.
Trainer's Personal Comments

Trainer’s Guide 4-27

Operation PowerCommand Control 3200

PCC 3200 Operation Activities

4Ć1 PCC 3200 Operation Quiz

4Ć2 Operation Exercises
Manual Mode
Exercise Mode
NonĆEmergency Auto Operation
Emergency Auto Operation
4Ć3 Wiring Diagram Questions

OH4Ć12 S&TT 01/03

Slide 4-12 Operation Activities

Participant's Text Trainer's Text

Activity 1 is a quick quiz on the sequence of
operation of the PowerCommand Control
3200.

Activity 2 is answering questions on the op-

eration of the control from the Operator’s
Manual.

Activity 3 will require you to look at the wir-

ing diagram and determine where certain sig-
nals enter and leave the control.
When you are finished with activities 1
through 3, we will go through the se-
quence of operation of the control on a
separate set of diagrams.

Trainer’s answers to this activity

are located in the Activities tab.

4-28 Trainer’s Guide

PowerCommand Control 3200 Operation

Wrap-Up
In this lesson we have looked at the different modes of operation of the PowerCommand Control
3200.

We learned about four modes:

Manual
Exercise
Non-Emergency Automatic
Emergency Automatic

We learned about the effective crank and run relay diagram.

We learned about the sequence of operation in Manual and Auto modes.

Next we will go through a 5- page print set that shows where to check the sequence of operation
in Manual mode.

Trainer’s Guide 4-29

Operation PowerCommand Control 3200

PCC 3200 Sequence of Operation

Participant's Text Trainer's Text
In this lesson we are going to work through Trainer’s note: In this lesson the participants
the sequence of operation for the Power- will use the Sequence of Operation
Command Control 3200. prints and the overall Wiring Diagram to
see what is happening in the control as it
We are going to look at a specialized dia-
starts, runs, and stops.
gram, the overall wiring diagram, and the
wiring diagram in the Service Manual to Pass out the colored 11 X 17 5-page
determine what signals are present at any sets Sequence of Operation (SOP)
point of the operational sequence. prints to the participants.

Have the participants turn to Page 2 of the

5-page print set.

Make sure to have extra copies of the SOP

prints available in case a participant needs
another.

Orientation to the print

The Sequence of Operation print has only a

few of the PowerCommand Control 3200
components which are shown on the full
wiring diagram.

• There is a “Key” to the color codes used

on this diagram

• Red Battery B+

• Purple Signals out of the ECM

• Black ECM returns, Grounds, OEM

wiring

• Blue Signals into the ECM

Trainer's Personal Comments
Green Data Link Signals (not used on this
print)

4-30 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

While we are using this print, you will find The diagram of the Control card cage shows
that the color code we are using will ap- how the cards are colored. The connec-
pear on the side of the print as we need tors on this print are colored the same
it. way as the cards.

Orange Manual position We only show three cards on this print:

Base Card, Fuel Card, and
Red Manual Crank and pushbutton Generator Interface Card
because those are all we need to make
Blue Crank Status the engine start and run (in the class-
room).
Dark Orange MPU signal
The inline connectors and the Switch panel
Light Green Run Signal
and the Operator panel connectors are
Green Run Status shown filled with white.

Brown MPU Starter Disconnect The Voltage Regulator Output Module has
had the secondary start disconnect con-
Dark PinkPMG Starter Disconnect tacts added on this print. They are not on
the Wiring Diagram.

We will first go through the Manual op-

eration of the control, then the Automat-
ic mode.
Trainer's Personal Comments

Trainer’s Guide 4-31

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

Manual Operation Have the participants turn to Page 2 of the
5-page print set.

Ask the following questions

Q. What has to happen for the set to start in

Manual mode?

The 0/Manual/Auto switch has to be

moved to the Manual position
The Manual pushbutton must be pressed
to start the control sequence.

Q. Which signal going out of the Switch

Panel is a “Manual Position” signal?

C23 pin 18, and it goes to C06 pin 05 on

the Base Card.

So the wire between C23-18 and C05-05 is the

Mode Switch in Manual signal. Its color
is Orange.

OK, we’ve got the switch in the Manual posi-

tion.

Q. How do we get the Not In Auto LED to

flash?

The Not In Auto LED gets its signal from

connector 01 pin 42 on the GIF card. This
signal tells the Switch Panel to flash the
LED. Color the line between C01–42 and
C23–21 Orange.

That means that the Base card and

the GIF card must be communicating.
I don’t see any wires on this print be-
tween the two cards.

4-32 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

Q. How do they communicate?

Through the Backplane connections in

the card cage.
This is the red line between the two
cards to remind us of that link.

OK, now let’s get the engine started.

Q. What’s next?

Press the Manual pushbutton to start the

Manual operation sequence.

Q. Where does the Manual pushbutton

signal come out of the Switch Panel, and
to where does it go?

C23–22 to C01–44

Q. When we press the Manual pushbutton,

does the Manual LED come on right
then or later?

It comes on at the same time.

That means that this signal line is a two-way

line. The Manual pushbutton signal goes
to the GIF card, and the “Turn on the
LED” signal comes back — on the same
RED line.

Trainer's Personal Comments

Trainer’s Guide 4-33

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

Now we have to get the starter relay series
energized to turn the starter. If we work
backwards from the starter, we find this
sequence:

• Starter

• AMS contacts

• AMS coil

• Crank Relay contacts

• Crank Relay coil

Q. Where does the signal to energize the
crank relay originate?

06–02 on the Base card.

That means that when we press the Manual

pushbutton on the Switch panel a signal
goes to the GIF card, and the GIF card
must tell the Base card it’s time to crank
the engine.

Q. Is the signal from 06–02 one-way or

two-way?

Two way. The Base card energizes the

crank relay coil and measures the cur-
rent through the relay driver circuit to
make sure the relay coil is good.

Q. If we applied a ground at 06–02 and the

relay coil was open, what voltage drop
would we measure across the crank
relay coil?

24 Volts (B+ to Ground) — same as if

the relay coil was energizing. That’s
why the control monitors the current
through the relay coil!

4-34 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

Ok, the crank coil is energized.

Q. What’s next?

We have to close the Crank Relay con-

tacts.

Ok, the relay energizes and the Crank Relay

contacts close.
That means we are going to send a RED
COLORED +24 Volts (Run Supply)
from

• Inline D–2 through the crank relay

contacts to

• Inline D–1 and on to Inline C–08

• and on to Inline E–C to the right-hand

contact of the Crank Slave Coil.
Have the participants turn to Page 3 of the
5-page print set.

• The slave coil will energize and its

contacts will close (Blue Slash) carrying
unfused B+ to the starter switch
terminals. The engine is cranking over
now.

Q. How do we know the crank slave relay

contacts closed?

We have the Crank Status signal which

returns to the Base card.
Trainer's Personal Comments

Trainer’s Guide 4-35

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

The MPU signal goes from Q. How does the Crank Status signal get to
the Base card?
• the MPU connector pins B–C and D–A to
• Crank Slave relay contacts close.
• Inline A 01–02 and 03–04 to
• Inline E–D to
• C 05 pins 30–29 and 36–37.
• Inline A–30 to

• C 06–01 on the Base card this sequence

is colored Blue.
This signal tells the control the crank slave
relay contacts did close. So if the MPU
signal does not appear at the Base card
we know the fault 1477 Crank Relay
Contact Error will not show up on the
Operator panel.

Next is the MPU signal to the Base card —

we made this a Dark Orange line to in-
dicate a pulsating signal.

The MPU signal goes from

• the MPU connector pins A–B and A–B to

• Inline A 01–02 and 03–04 to

• 06 pins 39–38 and 36–37.

Q. What are all of those lines and dots by

the MPU cable?

Shielded cable (outside “box”)

Twisted pairs (inside ovals)

Notice that the shield is carried through the

Inline A connector to the MPU connec-
tor, but the shield is only grounded at the
Base card.

4-36 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

OK, we’ve got flywheel rotation and a
Magnetic Pickup signal to tell us the
flywheel speed. What’s next?

Now we have to energize the Run relay.

Have the participants turn to Page 4 of the

5-page print set.

Q. Where does the signal originate to

energize the Run relay?

Base card.

OK we have to send a signal from the Base

card to the Run relay to energize the
relay.

Q. What polarity is this signal?

Ground because the relay has B+ on its

right side from the Local Emergency
Stop switch on the Switch panel.

The signal to the Run relay comes from This signal tells us the Run relay energized.
06–03 and it again is a two–way signal On this print the Run relay contacts only
path. We colored it Light Green. The go to the Base card. In reality this signal
Base card sends an energization signal to also goes to the block heaters.
the relay and then monitors the current
though the relay driver on the Base card On the PowerCommand Control 3100 we
to make sure the coil is energizing. had to send the “Switched B+” signal to
the Fuel, Ignition, and Governor circuits
Next the Run relay contacts close, sending because they were separate from the
the Run Status signal (Dark Green) to main control.
the Base card
In the PowerCommand Control 3200 the
• through Inline D–4 Fuel Solenoid Valve signal comes from
the Fuel card, as do the signals to the
fuel and timing rail actuators.

Trainer’s Guide 4-37

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

We aren’t worried about ignition circuits yet,
but when the PowerCommand Control
3200 is ported to gaseous powered en-
gines the Run Relay contacts will send a
signal to the ignition circuits.

We don’t have to worry about the Governor

Output Module used in the PowerCom-
mand Control 3100 as that circuitry is
in the Fuel card.

Have the participants turn to Page 5 of the

5-page print set.

Q. How do we disconnect the starter?

MPU signal goes up to 475 RPM for pri-

mary disconnect.

PMG signal goes to 105 VAC at 850

RPM for secondary disconnect.

When the MPU signal reaches 475 RPM the

Vase card removes the ground signal
from 06–02 and the Crank relay deener-
gizes. That makes the Crank Slave relay
drop out and the starter disconnects.

When the engine gets to approximately 850

RPM the PMG is putting out 105 VAC
which energizes the secondary start dis-
connect relay in the Regulator output
Module. When this relay energizes, the
N/C contacts shown between 07–05 and
07–06 open removing B+ from the
Crank relay.

4-38 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

When the secondary start disconnect relay
contacts open they remove B+ from
C06–06 which tells the control the sec-
ondary starter disconnect contacts have
opened. That way we will not see fault
1326 Backup Start Disconnect Con-
tacts have failed.

OK, we’ve run the set long enough, let’s stop

it.

Q. What does the operator do to stop the set

in Manual mode?

Press the Manual pushbutton.

When you press the Manual pushbutton a

second time, the control goes into the
cooldown mode of Manual operation.

The signal line from C23–22 to C01–44 tells

the GIF card to start timing for cool-
down at rated and idle speeds.

The GIF card then tells the Switch panel to

start flashing the Manual LED to show
the operator it heard the request to stop.

The cooldown time delay is determined by a

10 minute minimum delay and the
amount of load on the set in the present
operation.

• If the load is less than 10% it is

considered No Load.

• If the load is 11 to 100% the time delay is

extended by 10 minutes.
Have participants refer to visual 4-6 to
see the chart on cooldown.

Trainer’s Guide 4-39

Operation PowerCommand Control 3200

Participant's Text Trainer's Text

Once the Cooldown Time delay has finished
timing out the engine will be ramped
down to Idle and the engine will cool-
down at Idle for 3 minutes.

When the engine is at Idle the Voltage Regu-

lation circuits are turned off.

After completion of the Idle cooldown time

delay the set will stop.

Q. If the set is running at Idle in cooldown

or warmup mode and you see the
Remote Start LED light on the Switch
panel, what should you do?

Turn the Mode switch to Auto and the

set will run in Automatic mode. When
you turn the switch from Manual to Auto
or from Auto to Manual there is no
“OFF” position between them.
Trainer's Personal Comments

4-40 Trainer’s Guide

PowerCommand Control 3200 Operation

Participant's Text Trainer's Text

Automatic Operation Q. What is different in Automatic
operation?
In Automatic mode of operation, the start
signal is a closing set of contacts between The Mode switch stays in the Auto posi-
TB8–5 (Control Ground) and TB8–4 tion.
(Remote Start). In this case the Base card
just listens to itself – there are no inputs The “start” signal comes from a transfer
from the GIF card, but the Base card does switch.
have to get the GIF card to light the Re-
mote start LED on the switch panel. The rest of the operation — from C06–02 on-
ward is just the same.

Trainer's Personal Comments

Trainer’s Guide 4-41

Operation PowerCommand Control 3200

Wrap-Up
In this lesson we have looked at the Manual operation sequence for the PowerCommand Control
3200.

We learned about the Switch Panel and how it communicates to the Base card and the GIF
card to start the engine.

We learned about the Crank relay and its contacts, the Crank Slave relay, and its contacts,
and the Crank Signal line.

We learned about the Run Relay and its contacts, and the Run Signal line.

We learned about the primary and secondary starter disconnects, the MPU signals and the
PMG signal.

You should now be able to troubleshoot a failed control which does not crank, or cranks but
will not run.

4-42 Trainer’s Guide

PowerCommand Control 3200 Service Menus

PowerCommand Control 3200 Service Menus

Estimated Time: 1.5 hours

Equipment Needed

Overhead projector and screen or PC with LCD Projector and screen

PowerCommand Control Simulator Kit (1 for each 2 participants)

PC with SimMon4 software and “Black Box” to control up to eight simulators at one time or
individual PowerCommand 2100 simulators for each table.

Materials Needed

Module overhead set or slide set

One for each participant:

PowerCommand Control Participant’s Guide Guide (CMT0642-EN-PG)

PowerCommand Control 3200 Service Manual Manual (960–0512)

Menu handout used in lesson three

Five-Color highlighters set

Trainer’s note: In this lesson the participants will use the simula-
tors again. They will navigate around and make changes in the
Setup menus.

Trainer’s Guide 5-1

Service Menus PowerCommand Control 3200

Warm Up
In this lesson we are going to introduce ourselves to the Setup menus in the PowerCommand
Control 3200.

We are going to look at the menu sections which the technician would use to monitor and
calibrate a generator set with a PowerCommand Control 3200.

First, let’s look at the objectives for this lesson:

Objectives

After completing this lesson, participants should be able to:

• Locate and identify the front panel buttons used in navigating the PCC menus.

• Identify the menu choices accessible without using the Application password.

• Use the Governing/Voltage Reg menu to change governor parameters and monitor AVR gain.

• Use the Customer Fault menu to monitor and change customer faults.

• Use the Calibration menu to monitor and change Voltage and Current calibration.

• Use the Paralleling menus to monitor and change paralleling parameters.

5-2 Trainer’s Guide

PowerCommand Control 3200 Service Menus

Setup Menu
MENU B

TIME DELAY STOP

WARNING – 112
ACTUATOR NOT RESPONDING
ADJUST

BUS DATA
SETUP BACK<<

PARALLELING
TIME DELAY STOP SETS ONLY
WARNING – 112
ACTUATOR NOT RESPONDING
GOVERNING/VOLT REG

CUSTOMER FAULTS
ISO BUS
CALIBRATION
UTILITY

OH5Ć1 S&TT 10/00

Slide 5-1 Setup Menu

Participant's Text Trainer's Text

These menus are used by technicians in set- Have the Participants turn to page 5-2 in their
ting up and calibrating the Power- Participant’s Guide. Show visual 5-1 and
Command Controls on generator sets. explain:
When you select the “Setup” button you are
We will work through these menus from top presented with the first setup menu.
to bottom.
When you select the “Page-down” button
you see the paralleling menus is the
paralleling option and calibration are
installed in the control.

Trainer's Personal Comments

Trainer’s Guide 5-3

Service Menus PowerCommand Control 3200

Special Menus

TIME DELAY STOP

APPLICATION PASSWORD

ENTER
XXXXXXXX

SAVE

CONTINUE

OH5Ć2 S&TT 10/00

Slide 5-2 Application Password and Save/Continue menus

Participant's Text Trainer's Text

When you try to enter the application section When you start to change anything in the set-
of the PowerCommand Control me- up menus, you must input the Application
nus, you will be asked to supply the password.
“application” password.

The default password for all controls is You also have to input this password in the
“GENSET”. InPower software password parameter fold-
er before you can change any password pro-
tected parameter in the control.
When the installation and commissioning are
complete it is suggested that this
password be changed to keep unau-
thorized people from making changes
to the application data.

This password can be cleared with InPower

software in case the password has
been forgotten.

5-4 Trainer’s Guide

PowerCommand Control 3200 Service Menus

Participant's Text Trainer's Text

When technicians are done making changes You have to press the “Home” button to get
to a menu section and try to go to the to the Save/Restore menu pick.
next section of the menu they will be You must select the “Save” option to save the
asked if they want to save the changes changes to the control’s EEPROM memory.
they made or go back to the previous-
ly saved data.

If they choose “save” the changes will be

written to the EEPROM memory on
the Base Card.

If they choose “continue” the changes will be

valid until the generator set is stopped
and re-started.

Trainer's Personal Comments

Trainer’s Guide 5-5

Service Menus PowerCommand Control 3200

Governing/Volt Reg Menu

GOV GAIN 80 %
AVR GAIN 75 %

OH5Ć3 S&TT 10/00

Slide 5-3 Governing and voltage regulator menu

Participant's Text Trainer's Text

The technician can adjust the governor gain
and ramping time, and the regulator
gain on this menu.

• Governor gain <1 to 10 maximum

• Governor ramp 0 to 30 seconds

• AVR gain <1 to 10 maximum

When you press the + or – button, the pass-
word screen will appear.

The default password is __ __ __ __ __ __ The default password is GENSET

5-6 Trainer’s Guide

PowerCommand Control 3200 Service Menus

Standard Customer Fault Menu

CUSTOMER FAULT 1:
ENABLE ON
ACTIVE CLOSED
RESPONSE WARNING
***CUSTOMER FAULT1 ******************

CUSTOMER FAULT 2:

RESPONSE WARNING
***CUSTOMER FAULT2 ******************

OH5Ć4 S&TT 10/00

Slide 5-4 Standard Customer Fault screens

Participant's Text Trainer's Text

The two Standard Customer Faults can be There are four Customer Fault inputs avail-
setup with the customer fault screens. able if you have the Paralleling card and cal-
The technician can change these pa- ibration installed.
rameters: The standard inputs are on the GIF card.

• Customer Fault text display

• Select Warning or Shutdown

The +/– keys cycle through the alphanumeric
choices.

The → key moves to the next position to the

right.

When you leave the customer fault screens

you will be asked to “save or restore.”

Trainer’s Guide 5-7

Service Menus PowerCommand Control 3200

Participant's Text Trainer's Text

Customer Fault 1 has selections of

• “Enable/Disable” and

• “Active Closed/Active Open”.

Customer Fault 2 can only be selected as

• Warning or Shutdown.

Trainer's Personal Comments

5-8 Trainer’s Guide

PowerCommand Control 3200 Service Menus

Optional Customer Fault Menu

CUSTOMER FAULT 3:

RESPONSE WARNING
***CUSTOMER FAULT3 ******************

CUSTOMER FAULT 4:
ENABLE ON
ACTIVE CLOSED
RESPONSE WARNING
***CUSTOMER FAULT4 ******************

OH5Ć5 Available with LonWorks card only S&TT 10/00

Slide 5-5 Optional Customer Fault screens

Participant's Text Trainer's Text

Customer Faults 3 & 4 are only available There are four Customer Fault inputs avail-
when the Paralleling option and calibra- able if you have the Paralleling card and cal-
tion are downloaded into the control. ibration installed.
The optional inputs are on the Paralleling
These two Customer Faults can be setup with card.
the customer fault screens.
These two menu screens are only available
when the Paralleling card is installed in
the card cage and enabled with the proper
calibration.
The technician can change these parameters:
• Customer Fault text display
• Select Warning or Shutdown

Trainer’s Guide 5-9

Service Menus PowerCommand Control 3200

Participant's Text Trainer's Text

The +/– keys cycle through the alphanumeric
choices.
The → key moves to the next position to the
right.
When you leave the customer fault screens
you will be asked to “save or restore.”
Customer Faults 1 & 4 have selections of
“Enable/Disable” and “Active Closed/
Active Open”. Customer Faults 2 & 3 can
only be selected as Warning or Shut-
down.

Trainer's Personal Comments

5-10 Trainer’s Guide

PowerCommand Control 3200 Service Menus

Calibration Menus

VOLTAGE CALIBRATION
L1 480 X.X %
L2 480 -X.X %
L3 480 -X.X %

PARALLELING SETS ONLY

CURRENT CALIBRATION
L1 234 -X.X % BUS VOLTAGE CALIBRATION
L2 123 -X.X % L1 480 -X.X %
L3 562 -X.X % L2 480 -X.X %
L3 480 -X.X %

OH5Ć6 S&TT 10/00

Slide 5-6 Voltage and Current calibration menus

Participant's Text Trainer's Text

When you calibrate a PowerCommand Con- You need to measure the output voltage with
trol, you have to tell the control what the a calibrated meter to successfully cali-
value of the input is, and also what per- brate the PCC 3200 control.
cent of the maximum this value is.
These calibrations are like the Displays (val-
ue) and Meters (percent) calibrations in
the PowerCommand Control 3100.
The Bus Volts must be calibrated with the With the newer PCC 3200 calibrations you
generator set shut down and the bus live. can turn off the synchronizer with In-
Power to calibrate the control to itself
as the bus voltage where there is no
mains voltage available.

Trainer’s Guide 5-11

Service Menus PowerCommand Control 3200

Isolated Bus Paralleling Menu

ISOLATED BUS:
SYNC TIME LIMIT
120 SEC
REVERSE PWR LMT % 10 %
REVERSE PWR TIME 3 SEC
PERM WIN-PHASE 20 DEG
PERM WIN-TIME . 5 SEC

ISOLATED BUS:
SYNC GAIN 1.0 ISOLATED BUS:
KW BALANCE 0.3 1ST FAIL TIME 12 SEC
KVAR BALANCE 1.2 RAMP UNLOAD TIME 120 SEC
KW GAIN 1.0 RAMP UNLOAD LEVEL 10 %
KVAR GAIN 1.0 RAMP LOAD TIME 3 SEC
LOSS FIELD TIME 20 SEC

OH5Ć7 S&TT 10/00

Slide 5-7 Isolated Bus paralleling menus

Participant's Text Trainer's Text

These calibrations must be performed before These menus are only available if the paral-
the infinite bus calibrations. leling option is installed.
The calibrations are used to set up the paral-
leling control functions of the Power-
Command Control which are use in par- Descriptions of these calibrations are on the
alleling to other generator sets, but not to following pages.
a utility or mains source.
The default settings are shown in the menus.
The calibration procedures are shown in Sec-
tion 3 of the Service Manual.
Trainer's Personal Comments

5-12 Trainer’s Guide

PowerCommand Control 3200 Service Menus

Trainer's Text
Trainer’s note: If the participants have questions on these adjustments, talk about the specific
adjustments for which they have questions. Otherwise skip the explanation for these adjust-
ments.
Fail to Synchronize fault time delay

This is a time delay from the time the set starts in an Emergency mode. The time
delay is normally 120 seconds. After 120 seconds in an Emergency start the parallel-
ing breaker should be closed. This alarm tells the operator that the paralleling break-
er has not yet closed after the set has run long enough for the breaker to close.

Reverse Power limit

This is the maximum reverse kW the alternator can accept from the Bus. This is fac-
tory set to 10% of the kW rating of the alternator.

Reverse Power time delay

This is the time delay for the Reverse Power shutdown. After this time delay has
timed out the control enables the “Alternator Kill” section of the logic.

Alternator Kill

When the PowerCommand Control 3200 sees an alternator shutdown fault, the con-
trol does not kill the generator set, it just kills the alternator. This allows the engine
to cool down before it is stopped.

The Alternator Kill section of the control logic will

• Trip the paralleling breaker open

• Disable the Voltage Regulator

With the alternator input turned off (excitation) the alternator cannot produce volt-
age and will cool down as the engine runs at rated and idle speeds to cool down.

Permissive Window phase angle

This is the plus-or-minus degree window the generator-to-Bus relationship must stay
in for the Permissive Window time delay for the “Permissive Relay” function of the
control to be set to “ON”

Trainer’s Guide 5-13

Service Menus PowerCommand Control 3200

Trainer's Text
Permissive Window Time Delay

This is the time delay for the “Permissive Relay” function of the con-
trol to be set to “ON.” This time delay starts after the Phase Angle is
less than the phase angle set in control.

Synchronizer Gain

This adjustment adjusts how much signal is sent to the governor

when the set is synchronizing to a live Bus. If this gain is too high,
the set can be unstable when synchronizing to a live Bus.

kW Balance

This adjustment allows the technician to adjust kW load hunting

when there is a steady kW load applied to the set.

kVAR Balance

This adjustment allows the technician to adjust kVAR load hunting

when there is a steady kVAR load applied to the set.

kW Gain

This adjustment allows the technician to control how fast the generator set assumes a
kW load after closing of the 52G paralleling breaker — Isolated Bus load only.
There is another kW gain for the Infinite Bus kW load assumption in the Utility
menu.

kVAR Gain

This adjustment allows the technician to control how fast the generator set assumes a
kVAR load after closing of the 52G paralleling breaker — Isolated Bus load only.
There is another kVAR gain for the Infinite Bus kVAR load assumption in the Utility
menu.

First Start Sensor failure time delay

This is the time delay which must be completed before the control will go into its
“Dead Bus” mode of operation. This time delay starts at the end of each Master First
Start Sensor pulse, and resets upon receipt of each new pulse.

5-14 Trainer’s Guide

PowerCommand Control 3200 Service Menus

Trainer's Text
Ramp Unload Time Delay

This is the ramp time that the control can take to unload the generator set upon re-
ceiving a Load Demand Shutdown signal.

Ramp Unload Setpoint

This is the load percentage at which the control will enable the Alternator Kill sec-
tion of the control logic.

Ramp Load Time

This is the time delay after the set restarts where it ramps up to its percentage of total
Bus load on removal of the Load Demand Shutdown signal .

Loss of Field Time Delay

This si the time delay when the control sees a leading power factor at 0.9 Leading
before it enables the Alternator Kill section of the control logic.

Trainer’s Guide 5-15

Service Menus PowerCommand Control 3200

Infinite Bus Paralleling Menu

UTILITY:
BASE LOAD 80 %
PF LEVEL 1.00
RAMP LOAD TIME 3 SEC
PARALLELING RAMP UNLOAD TIME 20 SEC
SETS ONLY MODE MULTIPLE

SINGLE
SYNC ONLY
ISO MANUAL
ISO AUTO
UTILITY: UTIL SINGLE
KW GOVERN GAIN 120 UTIL MULTIPLE
KVAR GOVERN GAIN 3

PARALLELING
SETS ONLY

OH5Ć8 S&TT 10/00

Slide 5-8 Utility (Infinite Bus) calibration menus

Participant's Text Trainer's Text

These menus set up the infinite bus parame- These menus are only available if the paral-
ters for the PowerCommand Control. leling option is installed.
These calibrations must be performed after
the Isolated Bus calibration.
The default settings are shown in the menus. Descriptions of these calibrations are on the
following pages.
The calibration procedures are shown in Sec-
tion 3 of the Service Manual.

Trainer's Personal Comments

5-16 Trainer’s Guide

PowerCommand Control 3200 Service Menus

Trainer's Text
Base Load

This is the maximum load the set can carry when the Utility or Mains breaker is
closed and the set is operating in parallel with the utility source.

Power Factor Level

The power factor the generator set will be excited to when the Utility breaker is
closed. The factory recommended setting is 1.00.

Ramp Load Time

The time delay after closing the Utility Breaker that the set can take to ramp up to
the Base Load setting. This time delay is used in taking part or all of the load from
the utility source.

Ramp Unload Time Delay

The time delay after closing the Utility Breaker that the set can take to ramp down to
the Unload Level where the paralleling breaker will be tripped open. This time delay
is used in returning the load to the utility source.

Multiple/Single

Is this set operating by itself or is it part of a paralleling system with other generator
sets?

kW Governor Gain

This gain setting adjusts how fast the generator set kW load will be increased after
closing the paralleling breaker when accepting load from a utility source.

kW Integral Gain

This gain setting determines how fast the generator set will respond to large kW load
changes when paralleled to a utility source.

kVAR Governor Gain

This gain setting adjusts how fast the generator set kVAR load will be increased after
closing the paralleling breaker when accepting load from a utility source.

Trainer’s Guide 5-17

Service Menus PowerCommand Control 3200

Trainer's Text
kVAR Integral Gain

This gain setting determines how fast the generator set will respond
to large kVAR load changes when paralleled to a utility source.

5-18 Trainer’s Guide

PowerCommand Control 3200 Service Menus

Adjust Menu

MAIN MENU B
TIME DELAY STOP
WARNING – 112
ACTUATOR NOT RESPONDING
ADJUST

BUS DATA

SETUP BACK<<

TIME DELAY STOP

WARNING – 112
ACTUATOR NOT RESPONDING
User Password protects ADJUST:
Voltage, Frequency, and VOLTAGE 480 1.2 %
Time Delay Adjustments. FREQ 60.0 HZ –0.0 HZ
START DELAY 5 SEC
STOP DELAY 300 SEC

OH5Ć9 S&TT 10/00

Slide 5-9 Adjust menu

Participant's Text Trainer's Text

When setting up a paralleling set, remember The Adjust menu allows you to set the gener-
that the voltage and current must be the ator set Voltage and Frequency before
same on both sets before you attempt to you start making paralleling menu ad-
close the paralleling breakers. justments.
If you have reverse power or cross-current It is very important to have the generator sets
problems, use the Adjust menu to set the adjusted to the same output voltage and
voltage and frequency to the proper value frequency before attempting to parallel
before you start changing the paralleling them.
calibrations.
Use the “Relative” button on your meter to
create a differential meter when calibrat-
ing voltage and frequency on two or
more sets.

This way, the readings will be as close as

your meter can make them.

Trainer’s Guide 5-19

Service Menus PowerCommand Control 3200

Service Menu Activities

Service Menus
Gov/Reg Menu
Customer Faults
Calibration Menu
Isolated Bus Paralleling Menu
Infinite Bus Paralleling Menu
TechnicianĆLevel Menu Quiz

OH5Ć10 S&TT 01/03

Slide 5-10 Section 5 Activities

Participant's Text Trainer's Text

Go through the setup menus and fill in the
blanks:
Trainer’s answers to this activity
are located in the Activities tab.

5-20 Trainer’s Guide

PowerCommand Control 3200 Service Menus

Wrap-Up
In this lesson we have looked at the menus used by the technician to calibrate and adjust the
PowerCommand Control 3200.

We learned about the five menus:

Governor/Reg menu
Customer Faults menu
Calibration menu
Isolated Bus paralleling menu
Utility Bus paralleling menu

We learned it is important to make sure the voltage and frequency for

all generator sets are the same before starting to adjust the paralleling
menus.

Homework Activity
For homework read Chapter 5 in the Service Manual and answer the questions in the Quiz at the
end of this lesson.

Trainer’s Guide 5-21

Service Menus PowerCommand Control 3200

This page intentionally left blank

5-22 Trainer’s Guide

PowerCommand Control 3200 Troubleshooting

Troubleshooting the PowerCommand Control 3200

Estimated Time: 2.5 hours

Equipment Needed

Overhead projector and screen or PC with LCD Projector and screen

PowerCommand Control Simulator Kit (1 for each 2 participants)

PC with SimMon4 software and “Black Box” to control up to eight simulators at one time or
PowerCommand Control 2100 simulators and controls for each table.

PowerCommand Control Tool Kit Tool Kit 3824746

PowerCommand Control 3200 Tool Kit Tool Kit 3163768

True RMS meters (one per two participants)

Materials Needed

Module overhead set or slide set

One for each participant:

PowerCommand Control Participant’s Guide Guide (CMT0642-EN-PG)

PowerCommand Control Service Manual Manual (960-0512)

Cummins Generator set wiring diagram Diagram (3666465)

Trainer’s note: In this lesson the participants will use the simula-
tors to troubleshoot problems with the control panel/card cage/
simulator setup.
Installation of problems is at the back of this section.

Trainer’s Guide 6-1

Troubleshooting PowerCommand Control 3200

Warm Up
In this lesson we are going to learn about troubleshooting problems with the PowerCommand
Control 3200.
We are going to use the Cummins/Onan Service Manual, the Fault Information System, the
Generator Set Wiring Diagram, and the InPower service tool to isolate and solve problems
with the engine, control, and alternator.
First, let’s look at the objectives for this lesson:

Objectives

After completing this lesson, you should be able to:

• Locate the troubleshooting information in the Service Manual.

• Locate and follow the procedures for installing the PowerCommand Control 3200 breakout
tool.

• Locate and identify the LEDs on the circuit boards in the card cage and those on the
modules inside the Control Box.

• Use the InPower service tool to isolate problems on a generator set to the failed component.

6-2 Trainer’s Guide

PowerCommand Control 3200 Troubleshooting

Key Troubleshooting Points

Good “Look and Listen” inspection

Interpret data and LEDs
Proper meter use
Read and interpret Wiring Diagrams
Static protection – wrist strap
Use troubleshooting charts and other data
Write down your readings

OH6Ć1 S&TT 10/00

Slide 6-1 Key Troubleshooting Points

Participant's Text Trainer's Text

Have the Participants turn to Page 6-2 in
their Participant’s Guide. Show Visual 6-1
and explain:
Key Troubleshooting Points

The basic steps of troubleshooting must

still be used when troubleshooting an ad-
vanced electronic control system like the
PowerCommand Control 3200.

One of the most important troubleshooting The first step in the visual inspection should
points is to make a good visual inspection be of the Operator Panel and its display
of the generator set – see what looks bad. of the fault. If a fault is not displayed,
go to the History/About menu and find
the latest fault listed there.
• Remember, if the fault has been
acknowledged, it will not show up in the
History/About listing.

Trainer’s Guide 6-3

Troubleshooting PowerCommand Control 3200

Participant's Text Trainer's Text

• Only unacknowledged faults are listed
there.
• If you have exhaust temperature senders,
checking the EGT can help troubleshoot
a problem to a bank, or group, of
cylinders.
• Discoloration of the alternator wrapper
can point to output current over the
indicated maximum level.
Another key troubleshooting point is to listen Listen to the customer and the generator set.
to the set as it starts, runs, and stops. You Does it sound different than a normal
know what a good-running set sounds generator set? Some audible indications
like, and you know what doesn’t sound are:
right.
• Shorted output leads – the set lugs after
Look at the LEDs on the Switch panel and in it starts to generate voltage.
the Control Box. Look at the graphical • Exhaust leaks
display on the Operator panel. Write
• Excessive noise from one or more
down what you see before you change
cylinders
the indications.
• What does the customer say about the
problem and when it started to occur.

Proper meter use is still, if not more, impor-

tant.
• True RMS meters indicate proper value
with a signal containing harmonics.
• Digital meters are usually more accurate
than analog meters.
• Knowing in advance what voltage or
current or resistance reading you expect
to measure is good troubleshooting
practice.

6-4 Trainer’s Guide

PowerCommand Control 3200 Troubleshooting

Participant's Text Trainer's Text

Static Protection
• Own and use a wrist strap.
• Check your wrist strap for proper
resistance.
• The strap cannot help dissipate static
charges if it has too much resistance or is
not working properly.
What is the proper resistance for a wrist
strap?
1 MegOhm
In troubleshooting you will need to read and Use the troubleshooting charts in the Cum-
interpret wiring diagrams. It helps to mins 3666465 manual and the Fault In-
have your wiring diagrams pre-marked formation System troubleshooting pro-
with some of the data you will need in cedures to find the problem location.
troubleshooting the PowerCommand
Troubleshooting charts in Cummins
Control 3200.
manuals are written in the Easy-Likely
Use the troubleshooting charts and other fashion.
troubleshooting data you receive in
school and from other technicians. Some • The easiest problems to check which are
of the troubleshooting tips you receive in the most likely to occur are listed first.
the field are worth more than anything • The hardest problems to check which are
you will get in school. the least likely to occur are listed last.
For example if the set shut down on low
oil pressure, you would check the oil
level before tearing the engine down to
see if the oil bypass valve was stuck in
the open position.

Trainer’s Guide 6-5

Troubleshooting PowerCommand Control 3200

Participant's Text Trainer's Text

Write down what you see, hear, and measure. Write down what your measurements show.
When you start taking the same measure-
• Find out what the proper values are and
ment for the third or fourth time – you
write them on your wiring diagram or
know you’re stuck. Call someone and
schematic diagram.
talk over what you wrote down. It helps!
• Know what value you expect the meter to
display when you take a reading.
• When you see yourself taking the same
measurement for the third time, stop and
regroup.

Trainer's Personal Comments

6-6 Trainer’s Guide

PowerCommand Control 3200 Troubleshooting

Troubleshooting Tools

PowerCommand Service Tool Kit

InPower service software
Fault Listing (Active/Inactive)
Strip Chart
Test Function
PowerCommand Control 3200 Breakout Tool
True RMS meter

OH6Ć2 S&TT 10/00

Slide 6-2 Troubleshooting tools

Participant's Text Trainer's Text

Troubleshooting tools for the Power-
Command Control 3200 include:

Some of the modules in the PowerCommand The initial PowerCommand Control service
Control 3200 use the same AMP Wea- tool kit (3824746)
therpack connectors used in the Power-
• This kit is used for all of the AMP
Command Control (I). The PowerCom-
Weatherpack connectors on the modules.
mand Service Tool Kit (3824746) is
made to test the AMP Weatherpack con-
nections – use it.

InPower service software has several nice InPower service tool software.
features which can be very useful in
• Fault Listing (Active and Inactive faults
troubleshooting a PowerCommand Con-
are listed)
trol 3200 generator set.
• Strip chart to check performance.

Trainer’s Guide 6-7

Troubleshooting PowerCommand Control 3200

Participant's Text Trainer's Text

• List of Active and Inactive faults by time • Test Function – Replace the reading from
and date of occurrence. a sender or sensor with an electronic
value created by the InPower software.
• Strip chart to look at parameters over a
period of time.

• InPower has a test function with which

you can tell the control to ignore the
reading from the sensor and use a
parameter value you input.

There is a new breakout tool kit designed PowerCommand Control 3200 Breakout
specifically for the PowerCommand Tool Kit.
Control 3200 and the GCS module used
• Checking inputs to the control cards at
on G-Drive generator sets. It has the
25-pin and 50-pin connectors.
25-pin and 50-pin connectors you see on
the control cage cards. • Checking outputs from the control cards
at 25-pin and 50-pin connectors.
One of the most important troubleshooting
True RMS meter
tools you can have is a True RMS meter.
Fluke and Tektronix both make excellent • Fluke 87, 8040A, 43 (Power Factor
meters which are available for much less Meter)
than a good digital camera. That’s anoth- • Tektronix also has excellent True RMS
er nice thing to have to send pictures meters.
with warranty claims.

Trainer's Personal Comments

6-8 Trainer’s Guide

PowerCommand Control 3200 Troubleshooting

Similarities in Troubleshooting

Interpret data
Good meter use
Wiring & Schematic Diagrams

OH6Ć3 S&TT 01/03

Slide 6-3 Troubleshooting Similarities & Differences

Participant's Text Trainer's Text

The technician still has to interpret the data The technician still interprets data:
given by the customer, operator, and the
generator set. • From the Generator Set
• From the Customer
The technician still uses a good meter to test
voltages, currents, and resistances. Technician still uses a meter

The technician still uses wiring diagrams to • to check for B+ and

determine if the harness is connected
• to check for some signals.
properly.

Trainer's Personal Comments

Trainer’s Guide 6-9

Troubleshooting PowerCommand Control 3200

Differences in Troubleshooting

Static Damage
Ground signals
Test kit needed for senders
Must crank set for O/C testing
Breakout tool needed
LED, ELD, InPower indications

OH6Ć4 S&TT 01/03

Slide 6-4 Troubleshooting Similarities & Differences

Participant's Text Trainer's Text

The technician can be a cause of more dam- The technician can cause damage
age to the control than the original prob-
• Static charges can damage the circuit
lem due to static electricity.
board components
• Small pieces can get stuck easier – it’s
really hard to turn a generator set upside
down and shake it to get a small screw
dislodged.

The technician is generally looking for The control signals are mainly Ground
ground signals. potential

• Ground in – Ground out

• Most signals are digitally coded and
must be checked with InPower software

6-10 Trainer’s Guide

PowerCommand Control 3200 Troubleshooting

Participant's Text Trainer's Text

The technician cannot ground out the HCT The technician cannot ground senders to
and LOP senders to simulate a warning simulate Low oil pressure or high engine
or shutdown. A software tool is needed to temperature any more.
check the engine sensors.
• Senders and sensors are two-wire or
three-wire devices.
• Disconnecting the connector from a
sender causes a different fault than
having a shorted sender.
The technician cannot just remove a fuse to The technician cannot just disable the
check overcrank problems. starter to check the Overcrank timer.

• If the engine does not crank over the set

shuts down on “Fail to Crank”
• If the engine cranks but fails to start the
set shuts down on “Fail to start” or
“Overcrank”
• If the engine cranks but there is no
magnetic pickup signal there is a
different fault.
The technician cannot check the voltage or Special Breakout tools are needed to
ground on connections without a special troubleshoot the control.
breakout tool.
• You cannot just disconnect a connector
from the control and expect the rest of
the control to operate properly.
• All wires must be connected for the set
to operate properly.
• The Cummins Breakout tool allows you
to open one specific signal line and
inject a signal to troubleshoot down to a
known failed part.
• The PowerCommand Control Tool Kit
(3824746) allows the technician to check
the connectors that are common to the
PowerCommand Controls 3100 and
3200.

Trainer’s Guide 6-11

Troubleshooting PowerCommand Control 3200

Participant's Text Trainer's Text

The technician has to deduce the proper trou- Many visual cues need to be checked to
bleshooting procedure from the Switch determine what the real problem is with
panel LEDs, the Operator panel Electro- the control.
luminescent Display, the LEDs on circuit
boards and modules, and the InPower • LED bargraph
service tool. • ELD display
• Switch Panel LEDs
• LEDs on circuit cards
The technician needs a PC and InPower
software

• InPower software allows technician to

change and save trims
• InPower Pro software allows technician
to download calibrations as well as
change and save trims.

Trainer's Personal Comments

6-12 Trainer’s Guide

PowerCommand Control 3200 Troubleshooting

Troubleshooting Aids

FIS Codes
Breakout Tool
InPower Software
LOP Warnings/Shutdowns
Menus

OH6Ć5 S&TT 01/03

Slide 6-5

Participant's Text Trainer's Text

The Cummins Service Manual includes a
Fault Information System (FIS) which
lists all fault codes and troubleshooting
procedures for each fault.

The Operator panel shows the FIS code for

that specific fault and gives a short de-
scription of the nature of the fault.

The technician uses the FIS section of the

manual to determine where to check for
proper and improper indications. The FIS
section starts at the engine end of the har-
ness and proceeds through each connec-
tor to the control.

Trainer’s Guide 6-13

Troubleshooting PowerCommand Control 3200

Participant's Text Trainer's Text

The technician uses the breakout tool to
check for proper signals into and out of
the card cage. The wiring connections are
shown on the wiring diagram for that
generator set family.

The technician uses the PowerCommand Ser-

vice Tool kit (Part Number 3824746) to
check for signals out of the PT/CT Mod-
ule and into or out of the Switch Panel.
An adapter is needed to use this tool kit
with the Deutsche connector on the Op-
erator Panel.

The technician uses the InPower service

software tool to check signals inside the
card cage.

The InPower service tool can also be used to

troubleshoot problems by replacing a real
signal with a test signal.

A table of Low Oil Pressure warning and

shutdown limits for normal and idle op-
eration is shown in the InPower manual.

Page 2-7 in the Service Manual shows the

Main Menus and what is available from
the Operator panel menu display.

6-14 Trainer’s Guide

PowerCommand Control 3200 Troubleshooting

Participant's Text Trainer's Text

Remember, just because you have a certain
shutdown does not mean that the engine
or generator information is not available
for troubleshooting. The PCC has an
RMS-type metering system built in
which can display many different volt-
ages, currents, and pressures to assist you
in its troubleshooting.

Section 6 in the Service Manual has Onan

prints that might help you in trouble-
shooting some problems. Remember, the
PowerCommand Control 3200 does the
same things as the PowerCommand Con-
trol 3100, just on different boards.

Trainer's Personal Comments

Trainer’s Guide 6-15

Troubleshooting PowerCommand Control 3200

Troubleshooting Activities

InĆClass practice
Breakout Tool Familiarization
Simulator Problems
Genset Problems if available

OH6Ć6 S&TT 01/03

Slide 6-6 Troubleshooting Activities

Participant's Text Trainer's Text

We will be doing some pencil and paper trou-
bleshooting first.
Then we will look at and learn to use the new
PCC 3200 troubleshooting breakout tool
kit.
Then you will use the breakout kit in trouble-
shooting problems on the simulators.
Trainer’s Note:

If you have a running genset, you can also

have on-genset troubleshooting with In-
Power and the breakout kits.
Trainer's Personal Comments

6-16 Trainer’s Guide

PowerCommand Control 3200 Troubleshooting

Trainer's Text
Activity 6-1 – Group Troubleshooting Exercises
In this exercise you want to set up all simulator/control installations with the same prob-
lem and have all of the groups work together to learn to solve the problems.
Trainer’s answers to this activity are located in the Activities tab.

Problem #1
Change the Oil Pressure slider on the SimMon4 Analog Outputs screen to
give an oil pressure reading of 10 PSI.

On the new simulators, turn the pot down during a break and cover the simulator with a
cloth to hide the change.
Problem #2
Change the Coolant Temperature slider on the SimMon4 Analog Outputs
screen to give a Coolant Temperature reading of 235 5F.

On the new simulators, turn the pot up during a break and cover the simulator with a cloth
to hide the change.
Trainer’s Note: These two last problems cannot be applied without the old
simulators or InPower software use on the new simulators.

Problem #3
Change the Intake Manifold Pressure slider on the SimMon4 Analog Outputs
screen to give an Intake Manifold pressure reading of 53 PSI.

Problem #4
Change the Timing Rail Pressure slider on the SimMon4 Fuel screen to give
a Timing Rail pressure reading of 153 PSI.

Now how do we get InPower to indicate 253 PSI? Is there a pressure over-
ride that we can apply on the parameter?

Trainer’s Guide 6-17

Troubleshooting PowerCommand Control 3200

This page intentionally left blank

6-18 Trainer’s Guide

PowerCommand Control 3200 Troubleshooting

Trainer's Text
Activity 6-2 – Individual Troubleshooting Exercises
In this exercise you want to set up all simulator/control installations with different prob-
lems and have all of the groups work around the room and solve all of the problems.
Trainer’s answers to this activity are located in the Activities tab.

You need six to eight different problems for trainers to use in troubleshooting practice.
If you are using the old simulators, you can have the participants stay at
their location while you change parameter values with the PC.

If you are using the Universal Simulators, have the participants take a break
then they will have to circulate among the simulators to see all the prob-
lems.

Trainer’s Guide 6-19

Troubleshooting PowerCommand Control 3200

Wrap-Up
In this lesson we have looked about troubleshooting the PowerCommand Control 3200. We
learned that troubleshooting the PowerCommand Control 3200 is the same as
troubleshooting any other control in some ways.

We learned about and practiced troubleshooting the PCC 3200; how it is similar to and different
from troubleshooting other CPG controls:
• Visual and aural inspections are the same
• Finding out what the customer knows is the same
• Using a meter is the same
• Reading diagrams is the same
We learned that troubleshooting the PowerCommand Control 3200 is different than
troubleshooting any other control in some ways.

• Different Tools needed

• Software program needed
• PC needed
We learned that it is important to use a wrist strap when removing and replacing circuit
cards in the PowerCommand Control.

We learned it is important to make sure you know the approximate voltage, resistance, or
current reading you expect when preparing to make measurements.

Homework Activity
For homework study the troubleshooting charts in the genset service manual and the FIS tables
that are supplied with InPower software.

6-20 Trainer’s Guide

PowerCommand Control 3200 Options

PowerCommand Control 3200 Options

Estimated Time: 1.5 hours

Equipment Needed

Overhead projector and screen or PC with LCD Projector and screen

PowerCommand Control Simulator Kit (1 for each 2 participants) and PC with SimMon4
software and “Black Box” to control up to eight simulators at one time or PowerCommand
Control 2100 simulators and controls for each table.

Static Wrist Straps (one per two participants)

Materials Needed

Module overhead set or slide set

One for each participant:

PowerCommand Control Participant’s Guide Guide (CMT0642-EN-PG)

PowerCommand Control Service Manual Manual (960–0512)

Cummins Generator Set Wiring Diagram Diagram (3666465)

Trainer’s note: In this lesson the participants will install option

circuit cards and check them out with the simulators.

Trainer’s Guide 7-1

Options PowerCommand Control 3200

Warm Up
In this lesson we are going to install and check out options for the PowerCommand Control
3200.
We are going to also look at the wiring diagram to determine how to check the operation of these
modules to make sure they are operating properly.
First, let’s look at the objectives for this lesson:

Objectives

After completing this lesson, participants should be able to:

• Install options for the PowerCommand Control 3200.

• Check out options for the PowerCommand Control 3200.

7-2 Trainer’s Guide

PowerCommand Control 3200 Options

Installing Options

Battery Disconnected
Static Wrist Strap
Install Option Card, etc.
Install Wiring Harness
Battery Connected
Download Proper Calibration
Test Generator Set

OH 7Ć1 S&TT 10/00

Slide 7-1 Installation Steps for PowerCommand Control 3200 Options

Participant's Text Trainer's Text

Have the Participants turn to Page 7-2 in
their Participant’s Guide. Show Visual 7-1
and explain:
Installation Steps
The installation steps listed here are safe
working practices for electronic circuit cards
and the extra steps you must perform for the
PowerCommand Control 3200 so the control
will recognize the new card(s).

Battery Disconnected

Disable the battery charger then disconnect • Disable or turn off the battery charger(s)
the battery – Negative cable first. before disconnecting the battery cable(s).
• Negative cable first
• Disconnect from the engine grounding bolt
to prevent sparking at the battery

Trainer’s Guide 7-3

Options PowerCommand Control 3200

Participant's Text Trainer's Text

Connect your wrist strap and remove cov-
er(s). Static Wrist Strap
• Prevents you from “zapping” the circuit
cards with static electricity you
accumulate.
• 1 Meg Ohm resistance between you and
the grounding point to slowly remove
static electricity.

Install the new card in the proper slot of the Install option card and its associated
card cage. Install other modules, etc. modules(s)
• Put on your wrist strap first.
• Static-free packaging on new card
should not be opened until at the
installation location.
• Remove old card and lay it on a clean
static-free surface.
• Install new card.
• Put old card in static-free packaging
from new card for return to RECON.
• Install any other modules which go with
the card (Bus PT module for paralleling
card).

Install wiring harness.

Install the wiring harness for the option. • Connect wires from TB on circuit card
to other wiring needed for this option.
• You may have to have an electrician
install tube and wire for this option.
• NFPA37 (Gaseous Fuel Code) 1998
edition specifically requires stranded
wire for generator set installations.

Trainer's Personal Comments

7-4 Trainer’s Guide

PowerCommand Control 3200 Options

Participant's Text Trainer's Text

Reconnect battery cables and enable
the battery charger.
Reconnect battery and enable the battery • Negative cable at the engine block should
charger. be the last cable installed to prevent
sparking at the battery.
• You may want to place the battery
charger on “Equalize” charge after this
installation if the customer does not have
a PM Program for equalizing cell
voltages.

Download proper calibration into the

Base card.

Using InPower service software download • Determine proper calibration part

the proper calibration into the Base number from the installation paperwork.
Card. • Using InPower Service Tool v 3.0A or
later, download the calibration into the
Base card.

Test the generator set to make sure

the option is working properly.

Test the generator set with the new option to • You may have to install options in other
verify proper operation. generator sets to test the option fully:
Paralleling option for multiple sets
LonWorks card needs a network for
operational check

Trainer's Personal Comments

Trainer’s Guide 7-5

Options PowerCommand Control 3200

PowerCommand GenSet Options

Paralleling Card

LonWorks Card

OH 7Ć2 S&TT 10/00

Slide 7-2 PowerCommand Control Options

Participant's Text Trainer's Text

The Paralleling card is used to parallel a Option Card Locations
PowerCommand GenSet to another Pow-
Paralleling card goes in slot 4.
erCommand GenSet or to a utility source
of power. • Paralleling card goes between GIF card
and LonWorks card.
The LonWorks card is used to allow this
GenSet to operate as a node on the Pow- LonWorks card goes in slot 5.
erCommand Network. • LonWorks card goes in slot to the left of
Each of these options requires the installation the Paralleling card.
technician to add wiring and download a
calibration to the Base card with InPower
software.

Trainer's Personal Comments

7-6 Trainer’s Guide

PowerCommand Control 3200 Options

New Bus PT Module

TB-14
TO GENSET
CONTROL

TB-13
TO OTHER
BUS PT
MODULES

OH 7Ć3 S&TT 10/00

Slide 7-3 New Bus PT Module

Participant's Text Trainer's Text

The new Bus PT Module eliminates the need One of the problems with the older Bus PT
for the Master First Start Sensor which Module and First Start Sensor was that there
was used with the PowerCommand Con- was no interconnect between the gensets so
they could sense when another genset was
trol 3100 generator sets to determine closing to the bus.
which generator set would close to the
dead bus first.
This Bus PT Module has a circuit which al-
lows the generator sets to determine if
another generator set is about to close its
paralleling breaker to the dead bus.

Trainer’s Guide 7-7

Options PowerCommand Control 3200

Participant's Text Trainer's Text

The new Bus PT Module requires two wires The new Bus PT Module includes this con-
be connected between all of the Bus PT nection between the gensets to make sure
modules. These wires are checked to see that only one genset can close to a dead bus.
if the voltage level is “high” or “low.” If
the level is “low,” another generator set is This connection is specified on the intercon-
ready to close its paralleling breaker to nect diagram as a twisted-pair connection.
the dead bus.
If two or more modules have asked to close
their breakers to the bus as “First-on-
line” the modules go through an arbitra-
tion process to determine which module
will have the First-on-line closure.
When a module pulls the high side of the pair
of terminals to ground, it then looks to
see if any other module has pulled the
high side to ground.
The module that wins closes its breaker to
the dead bus, and the rest of the PCC
3200 controls synchronize to the live bus.

Additional Trainer Comments

This Bus PT Module is available as an option at the time the genset is ordered, or as
an aftermarket option installed in the field.
The part number for the module is 0300Ć4985

Trainer's Personal Comments

7-8 Trainer’s Guide

PowerCommand Control 3200 Options

Connecting Bus PT Modules

OH 7Ć4 S&TT 10/00

Slide 7-4 Connecting Multiple Bus PT Modules for Inhibit functionality

Participant's Text Trainer's Text

The 1-2 terminals and the 3-4 terminals on You connect terminals 1 and 2 on one mod-
TB13 are the same points electrically. ule to terminals 3 and 4 on the next module.
This allows each module to communicate
They are connected in a series configuration with all other modules.
so all modules can see what each individ-
ual module is doing to close its breaker to
the bus.
Trainer's Personal Comments

Trainer’s Guide 7-9

Options PowerCommand Control 3200

Master First Start Input

OH 7Ć5 S&TT 10/00

Slide 7-5 Master First Start Input from the new Bus PT Module

Participant's Text Trainer's Text

TB14-3 on the Bus PT Module connects to These connections are shown on the new
TB3-25 in the PCC 3200 controls. Master Control installation diagrams.
A representative diagram is provided as the
TB3-25 connects to C4-01 on the Paralleling last page (foldout) of section 7 of the Partici-
Module in the card cage as shown in the pant’s Guide.
partial diagram on the next page and on
print 366465 for the QSK45/60 gensets.

Trainer's Personal Comments

7-10 Trainer’s Guide

PowerCommand Control 3200 Options

Paralleling Option Connectors

From PT/CT and Bus PT modules

To GIF card

OH 7-6 S&TT 03/99

Slide 7-6 Paralleling Option Connections

Participant's Text Trainer's Text

Paralleling Card Inputs Paralleling card Connections

• Current Transformer (CT) Input 1.65 This diagram shows the connections into and
VAC with full standby current load on out of the paralleling card.
genset. • Connector 04 wiring will connect to TB3
as shown.
• Voltage input 18 VAC with nominal
input to PT/CT or Bus PT module.

Trainer’s Guide 7-11

Options PowerCommand Control 3200

Participant's Text Trainer's Text

• External kW load share 5 VDC for • Connector 04 also connects to:
100% load PT/CT Module
Bus PT Module
• External kVAR load share 5 VDC for 0.0 GIF card
PF Inductive load
• TB5 wiring connects to Ground Fault
• Ground Fault switch = closed contact for equipment and two Customer Fault
Ground Fault inputs.
• TB5 also connects to the other generator
• Customer Switch #3 and #4 = closed
sets’ TB5 at the same terminals for kW
contact for Customer Switch Input
and kVAR load sharing.
• First Start Enable + 24 VDC pulse =
True

• Sync Enable + 24 VDC = True (Single

Mode)

• Load Demand Shutdown = closed

contact for shutdown

• Single Mode Enable = closed contact for

Single Mode

• Ramp Load/Unload = closed contact for

Ramp Load, open contact for Ramp
Unload

Paralleling Card Outputs

• External kW load share 5 VDC for

100% load

• External kVAR load share 5 VDC for 0.0

PF Inductive load

• Ground Fault Meter = 0 – 1.0 mA

Trainer's Personal Comments

7-12 Trainer’s Guide

PowerCommand Control 3200 Options

Network Option Connections

Backplane

To Base
through
RJ-45 connector

card
OH 7Ć7 S&TT 10/00

Slide 7-7 Network Card Connections

Participant's Text Trainer's Text

Network Card Inputs LonWorks card Connections
• Connector 14-01 = 24 VDC B+ The older Network cards (TP/XF-78) had a
• Connector 14-02 = Ground three-terminal blue connector that could
be used as a network power supply for
other network modules.
Network Card Outputs – not normally used
for power source The newer network modules (FT-10) do not
have that network power connector.
• TB6-4 = 24 VDC B+
• TB6-6 = Ground Connector 06 is the 6-pin black network
connector that all network modules use
to connect to the network through pins
1 and 2.
Trainer's Personal Comments

Trainer’s Guide 7-13

Options PowerCommand Control 3200

Participant's Text Trainer's Text

Network Card Data Terminals (Input & Out- The Twisted pair (LonTalk cable) can be con-
put) nected at one of two places:

• TB6-1 and -2 for network data wiring • C 11 LonTalk cable only

• TB6 LonTalk cable and Power
• C11 (RJ-45) for installation PC
connections
connection

Additional Trainer Comments

Several other differences between the older and newer network modules:

OLD Service Toggle switch

Terminator switch on top of module.

NEW Service Pushbutton

Terminator switch on board, can see it through the slot on the side of the card cage.

Trainer's Personal Comments

7-14 Trainer’s Guide

PowerCommand Control 3200 Options

Installation Activities

7Ć1 Remove & Replace Cards

Power Off
Swap LonWorks & Parallel cards
Check results with InPower
Power Off
Replace cards in proper slots
7Ć2 Options Quiz

OH 7Ć8 S&TT 01/03

Slide 7-8 Installation Activities

Participant's Text Trainer's Text

This is just like having to tell your PC what
card is in which slot with an IBM with Mi-
croChannel architecture, or setting interrupts
when installing options in a “normal” PC.

If the cards are in the wrong slots, the Base

card tells you that, and wants you to fix the
problem before operating the control.
Trainer’s answers to this activity are
located in the Activities tab.

Go through the removal and installation of

the Paralleling and LonWorks cards.

When the workstations are started with the

Paralleling and LonWorks cards in the wrong
slots, the participants should see faults telling
them the cards in slots 4 and 5 are incorrect.

Trainer’s Guide 7-15

Options PowerCommand Control 3200

Participant's Text Trainer's Text

The Base card looks for a “signature” for
each card in a specific slot of the backplane.

This is just like having to tell your PC what

card is in which slot with an IBM with Mi-
croChannel architecture, or setting interrupts
when installing options in a “normal” PC.

If the cards are in the wrong slots, the Base

card tells you that, and wants you to fix the
problem before operating the control.
Trainer’s answers to this activity are
located in the Activities tab.
Trainer's Personal Comments

7-16 Trainer’s Guide

PowerCommand Control 3200 Options

Wrap-Up

Wrap-Up
In this lesson we have installed optional cards into the PowerCommand Control 3200.
We learned about the dedicated slots for specific cards.
The only time you will not have the five cards in these slots (with the older PCC 3200
Control) is if you have a K50 engine with an EFC actuator.
Then you will have the GIF card next to the heat sink, and the Fuel card in slot #3.
We learned it is important to make sure the circuit cards are properly seated and in the right
slot before running the generator set.

Homework Activity
For homework read Chapter 5 in the Service Manual and answer the questions in the Quiz at the
end of this lesson.

Trainer’s Guide 7-17

Options PowerCommand Control 3200

This page intentionally left blank

7-18 Trainer’s Guide

PowerCommand Control 3200 Installation

PowerCommand Control 3200 GenSet Installation

Estimated Time: 1.5 hours

Equipment Needed

Overhead projector and screen or PC with LCD Projector and screen

Materials Needed

Module overhead set or slide set

One for each participant:

PowerCommand Control Participant’s Guide Guide (CMT0642-EN-PG)

PowerCommand Control Installation Manual Manual (960–0153)

Cummins Generator Set Wiring Diagram Diagram (3666465)

Five-Color highlighters set

Trainer’s note: In this lesson the participants will use the simula-
tors again. They will navigate around and make changes in the
Setup menus.

Trainer’s Guide 8-1

Installation PowerCommand Control 3200

Warm Up
In this lesson we are going to learn about installation of generator sets with the PowerCommand
Control 3200.
We are going to look at the standard installation problems for a generator set, and specific
installation problems for the generator sets with the PowerCommand Control 3200.
First, let’s look at the objectives for this lesson:

Objectives

After completing this lesson, participants should be able to:

• Locate the sections in the Installation Manual as needed.
• Locate and interpret the connections on the Generator Set Wiring Diagram.
• Describe proper wiring for a generator set & transfer switch installation.
• Determine if a generator set is connected properly after reviewing a problem statement.

8-2 Trainer’s Guide

PowerCommand Control 3200 Installation

SWEEPING ELBOW
MUFFLER
THIMBLE DC CONTROL
WIRING

AC POWER
CONDENSATION
WIRING
DRAIN TRAP

FLEXIBLE
SECTION

AIR
IN
AIR OUTLET DUCT

CONCRETE BASE VIBRATION ISOLATORS

OH 8Ć1 S&TT 10/00

Slide 8-1 Sample Genset Installation

Participant's Text Trainer's Text

The 1750 and 2000 kW generator sets are GenSet Installation
installed following standard installation
This illustration shows a proper installation
practices shown in the Installation Manu-
of a 2,000 kilowatt generator set.
al and in T-030.
One of the most important concepts of cor-
The main difference in installing one of these rect generator set installation is that more
new sets is the size of the cooling sys- air goes in then comes out through the
tem. radiator.

With these sets, the customer can order the • The air intake must be 1.5 to two times as
generator set without a cooling system large as the radiator outlet.
and design their own cooling system.

The installed cooling system must be capable

of proper cooling of the generator set.

Trainer’s Guide 8-3

Installation PowerCommand Control 3200

Participant's Text Trainer's Text

The generator set moves as it operates. • All piping to the generator set must have
a flexible section to allow the generator
set to move as it operates.

• Notice that both exhaust pipes and the

AC and the DC wiring have flexible
sections.
The thimbles in the wall must meet local
code.

Condensation drain traps are used wher-

ever an exhaust system has a rising sec-
tion to where water could get into the
exhaust system.

All generator set above 500 kW are re-

quired to have spring type vibration iso-
lators.

Except for the size of the generator set

and its cooling system, this installation is
like any other generator set installation.

The cooling system for these generator

sets is designed as a drop-shipped kit
from the kit assembler.

• The SRT for assembling the cooling

system is 16 hours with two people.

• The cooling system lines are mainly

metal tubes with flexible sections at the
end of each tube section.

• The radiator assembly consists of four

engine cooling cores, a Low Temp
Aftercooler core, and a fuel cooler core.

Trainer's Personal Comments

8-4 Trainer’s Guide

PowerCommand Control 3200 Installation

First GenSet Control Box

Control Panel
update connection
C12
Terminal Block

Fuel Control
Card

Heat
Sink

Base Card
Generator Card
Paralleling Card
Right end view
LonWorks Card
Modem or PC connector
C13

OH 8Ć2 S&TT 10/00

Slide 8-2 Components inside the First PowerCommand Control Box

Participant's Text Trainer's Text

Customer connections must be made follow- All connections for the PowerCommand
ing the diagrams in the Installation Control 3200 are made in the GenSet
Manual. control box. Some connections are
made on TB3, but others are made at the
Some customer connections are made to the terminal blocks on the circuit cards
circuit cards in the card cage. themselves.

Some customer connections are made to TB3 You will have to refer to the wiring dia-
in the left end of the Control Box. gram for that generator set when doing
the installation.

Trainer’s Guide 8-5

Installation PowerCommand Control 3200

QSX15 Genset Control Box

Terminal Block

Control Panels

Heat
Sink

Card Cage
OH 8Ć3 S&TT 10/00

Slide 8-3 QSX15 Genset PowerCommand Control 3200 Control Box

Participant's Text Trainer's Text

PowerCommand Control Box introduced This is the new PCC 3200 control box, first
in September 2000 used on the QSX15-powered gensets. Ev-
erything is in one box now, and this
Customer connections must be made follow-
makes it easier to service the control.
ing the diagrams in the Installation
Manual. Cover the following points:

Some customer connections are made to the • Customer connections must be made
circuit cards in the card cage. following the diagrams in the Installation
Manual.
Some customer connections are made to TB3
• Some customer connections are made to
in the left end of the Control Box.
the circuit cards in the card cage.
This control box is designed as a NEMA 3R
• Some customer connections are made to
raintight enclosure. Because of this, the
TB3 on the left side of the Control Box.
raintight enclosures for the Switch Panel
and Operator Panel used in this control
box have been removed.

8-6 Trainer’s Guide

PowerCommand Control 3200 Installation

Participant's Text Trainer's Text

Since the box is raintight, there are heat- • This control box is a NEMA 3R
shrinkable boots for all wires entering the enclosure and is raintight. Because of
enclosure. These boots MUST be used to this, the raintight enclosures for the
maintain the NEMA 3R rating. Switch Panel and Operator Panel used in
this control box are scheduled to be
The interior of the control box has all of the removed.
components in the earlier control box
plus more terminals on TB3 for customer • Since the box is raintight, there are
connections. heat-shrinkable boots for all wires
entering the enclosure. These boots
This control box is located at the alternator MUST be used to maintain the NEMA
end of the generator set where the control 3R rating.
panels were originally installed on the
QSK60 generator sets.
• The interior of the control box has all of
the components in the earlier control box
plus more terminals on TB3 for
customer connections.

• This control box is located at the

alternator end of the generator set where
the control panels were originally
installed on the QSK60 generator sets.

Trainer's Personal Comments

Trainer’s Guide 8-7

Installation PowerCommand Control 3200

PowerCommand Connections

TB3 In Control Box

TB4 On Generator Card
TB8 On Base Card
TB8

1
Remote Emergency Stop
2 Start Type
3

4
Remote Start
5

USE TB8-5 – NOT GROUND !!

OH 8Ć4 S&TT 10/00

Slide 8-4 PowerCommand Control 3200 Standard Installation Connection Points

Participant's Text Trainer's Text

TB3 Here are some of the connections which are
B+ and Ground to the ATS made up on TB3, TB4, and TB8.
Customer Fault #2 Input
Connections on TB3 are:
Local Low Fuel Level
Ready to Load Output • B + and Ground to the transfer switch
Load Dump Output
Common Shutdown Output • Customer fault # two input

• Local low fuel level

• Ready to load output

• Load dump output

• Common shut down output

8-8 Trainer’s Guide

PowerCommand Control 3200 Installation

Participant's Text Trainer's Text

TB4 Connections on TB4 are:
GenSet and Utility Breaker connections
• GenSet and utility breaker connections
Customer Fault #1 Input
Modem Control Output • Customer fault number one input

• Modem control output to line

TB8 Connections on TB8 are:

Remote E-Stop
Remote Start • Remote emergency stop
Start Type • Remote start

• Start type

Additional Trainer Comments

Make sure you cover that the connections on TB8 for Remote Start and Start Type are refer-
enced to Control Ground and not Battery Ground. If the installation uses Battery Ground the
Base Board can fail.

Trainer's Personal Comments

Trainer’s Guide 8-9

Installation PowerCommand Control 3200

PowerCommand Control Options

Network Module
Paralleling Module

Bus PT Module

OH 8Ć5 S&TT 10/00

Slide 8-5 PowerCommand Control optional circuit cards

Participant's Text Trainer's Text

Bus PT Module There are several options for the PowerCom-
Allows PowerCommand Control 3200 to mand Control 3200.
monitor voltage and frequency of another
• The Bus PT module allows the control to
power source which is on the other side
measure the voltage and frequency of the
of the generator set paralleling breaker.
source to which the generator set is being
paralleled.
• Tells Paralleling card the voltage on
other side of paralleling breaker.

• Tells Paralleling card the frequency on

the other side of the paralleling breaker.

8-10 Trainer’s Guide

PowerCommand Control 3200 Installation

Participant's Text Trainer's Text

LonWorks card • The LonWorks card allows
Allows PowerCommand Control 3200 to PowerCommand Control 3200 to be a
communicate on the PowerCommand node on the PowerCommand Network. to
Network. of the LonWorks card is the only card in
the control which communicates on the
• Acts as a translator between parallel parallel bus at a 115 kilo baud speed.
communications protocol in
PowerCommand

• Communication speed with other circuit

cards is 115,000 baud.

Paralleling card • The paralleling card works with the Bus

Allows PowerCommand Control 3200 to PT module and sends the difference
match voltage and frequency of another between the bus and the generator set so
power source and share both kW and the base card can synchronize the
kVAR load. generator set with the bus and close the
paralleling breaker.
• Will be expanded in later phase of
development to do more.
(RTD and Thermocouple input device
for actual alternator temp., etc.)

Trainer's Personal Comments

Trainer’s Guide 8-11

Installation PowerCommand Control 3200

Optional Paralleling Connections

TB1 Input to Bus PT Module

TB2 Output from Bus PT Module
TB3 In Control Box
TB5 On Paralleling Card
TB6 On Network Card
TB8 On Base Card

OH 8Ć6 S&TT 10/00

Slide 8-6 PowerCommand Control 3200 Standard and Optional Installation Connection Points

Participant's Text Trainer's Text

Describe each of these connections to
the participants.

TB1 TB1 - Bus Voltage Input to the PCC 3200

Bus Voltage Input from the line side of the paralleling
E1 E2 E3 EN breaker.
Maximum input is 600 VAC

TB2
Bus Voltage Representation to the Paral- TB2 - Output from the Bus PT Module. This
leling Card and the Generator Card output is a nominal 18 VAC when the
E1 & E1 Return proper voltage is present on terminals on
E2 & E2 Return TB1. Each phase is measured across the
E3 & E3 Return two terminals associated with that phase.
Nominal Output is 18 VAC Neutral is not carried through this
module to the PCC 3200.

8-12 Trainer’s Guide

PowerCommand Control 3200 Installation

Participant's Text Trainer's Text

TB3 TB3 Connections:
Sync Enable
• Sync Enable
First Start Enable
Load Demand Shutdown • First Start Enable
Single Mode Enable
Ramp Load/Unload • Load Demand Shutdown
External kW Input (+/–)
• Single Mode Enable
External kVAR Input (+/–)
Common Warning Output • Ramp Load/Unload

External kW Input (+/–)

• External kVAR Input (+/–)

• Common Warning Output

TB5 TB5 Connection:

Customer Fault #3 Input
Customer Fault #4 Input • Customer Fault #3 Input
kW Load Share Lines • Customer Fault #4 Input
kVAR LoadParticipant's
Share Lines Text Trainer's Text
Ground Fault switch Input • kW Load Share Lines
Ground Fault Meter Output
• kVAR Load Share Lines

• Ground Fault switch Input

• Ground Fault Meter Output

Trainer's Personal Comments

Trainer’s Guide 8-13

Installation PowerCommand Control 3200

Optional Network Connections

C11 On LonWorks Card

C14 On LonWorks Card

TB6 On LonWorks Card

OH 8Ć7 S&TT 10/00

Slide 8-7 Optional Network Connections

Participant's Text Trainer's Text

Network Connections
C11 C11 - RJ45 connector
Twisted Pair Connection
C14 - B+ / B– connector on older TP/XF-78 cards. This conne
been removed on the FT-10 network cards.
C14
Power (B+ / B–) Connection TB6 Connections:

• LonWorks twisted pair Input/Output

TB6
Twisted pair and Power Input/Output ter-
minal board

8-14 Trainer’s Guide

PowerCommand Control 3200 Installation

ATS Connections

TB3 In Control Box

TB8 On Base Card

OH 8Ć8 S&TT 10/00

Slide 8-8 PowerCommand Control 3200 Standard Installation Connection Points

Participant's Text Trainer's Text

Transfer switch to generator set con-
nections.
TB3 TB3 connections
B+ to the ATS for Battery Charger
Ground to the ATS for Battery Charger • B + for the battery charger.
Ground Reference • Ground for the battery charger

TB8
TB8 connections
Ground Ref. for Remote Start Signal
Remote Start Input • Ground reference for the remote start
Start Type Input signal

• Remote start signal

alone = Emergency Start

• Start type signal

with Remote = Non-Emergency start

Trainer’s Guide 8-15

Installation PowerCommand Control 3200

Data Connections

C13 In Control Box

RS232 Connector on Engine

C12 In Control Box

OH 8Ć9 S&TT 10/00

Slide 8-9 Data connection points

Participant's Text Trainer's Text

The Generator-Drive and Generator Set en- Data connections
gines used with the PowerCommand
There are three different data connections for
Control and the Generator Drive Control
the PowerCommand Control 3200:
System (GCS) module communicate us-
ing the RS232 serial protocol. • One way to talk to the base card is to use
The only requirement is that a “null-modem” the RS 232 connector on the engine.
cable must be used to communicate be- This is the Deutsch 9–pin connector
tween the PC running InPower Service used to talk to industrial engines.
Software and the control Base Card.

The RS232 connector on the engine and • C13 in the control box near TB3 is one
Connector 13 are electrically the same. It way to talk to the base card.
may be easier to connect to the RS232
connector on the engine as you don’t
have to remove a panel.

8-16 Trainer’s Guide

PowerCommand Control 3200 Installation

Participant's Text Trainer's Text

Connector 12 is used to download a new • C12 is the other connector in the end of
menu system to the Operator panel. This the control box. This connector is used
would be used if upgrading a standby set to load new menus into the operator
to a paralleling configuration. panel. You would use C12 to load
paralleling menus into a control on a
generator set onto which you had just
added the Bus PT and paralleling card.

Trainer's Personal Comments

Trainer’s Guide 8-17

Installation PowerCommand Control 3200

Installation Activities

8Ć1 Interconnect Wiring Diagram

Installation Quiz

OH 8Ć10 S&TT 01/03

Slide 8-10 Installation Activity

Participant's Text Trainer's Text

Using your DQKC Generator Set Service
Manual, the Generator Set Wiring Diagram,
and the worksheet that follows, fill in the pin
used for each of the signals listed in the first
blank, and whether this is an Input or an Out-
put pin.

Activity 1 is an exercise designed to familiar-

ize you with the installation manual and the
wiring diagram as it applies to installation of
generator sets with the PowerCommand Con-
trol 3200.

Fill in all the blanks as you go through the

worksheet so you can discuss any differences
between your answers and the Trainer’s an-
swers.

8-18 Trainer’s Guide

PowerCommand Control 3200 Installation

Participant's Text Trainer's Text

Activity 2 is a quick quiz on the installation
of PowerCommand Control 3200 generator
sets.
When you are finished with activities 1 and
2, we will go through the sequence of op-
eration of the control on a separate small-
er diagram.
Trainer’s answers to this activity are
located in the Activities tab.

Trainer's Personal Comments

Trainer’s Guide 8-19

Installation PowerCommand Control 3200

Wrap-Up
In this lesson we have looked at the installation of generator sets which have the
PowerCommand Control 3200 control system.
In this lesson we talked about installing generator sets properly. If you use the new generator set
wiring diagram and the older transfer switch installation diagram you can get by.
There are new installation diagrams for the transfer switches in the OTPC Installation Manual.
You have to remember to replace TB1 on the old generator set with TB3, TB4, and TB8 on the
new generator set.
You may also have to make connections to TB5 and TB6 on the paralleling card and on the
LonWorks Card.

8-20 Trainer’s Guide

PowerCommand Control 3200 Glossary

Alarm
Used generically to indicate either a warning or a shutdown fault.

Alternator Rating Effect

Some of the alternator protections are inherently related to the alternator capabilities rather
than GenSet power rating. For example, Reverse VARs (Loss of Field), is inherently a
function of alternator capability. Overcurrent is inherently a function of alternator capability.
If data to an alternator’s capability in these areas is not available, the PowerCommand
Control will default to basing the limits on the on the GenSet rating — as the previous
version of the PowerCommand Control did. (GenSet rating is either engine limited or
alternator limited — normally engine limited.)

Annunciation
Any means of communicating to a user or operator the status of the power system. Especially
important in the event of an alarm. Includes audible alarms, LEDs, visual displays, PC
software notification, and pagers.

Base Card
The main processor board of the PowerCommand Control for gensets or the G-Drive control
for Quantum engines. This board contains the main power supply for the control,
microprocessor, flash memory for updates to the operating system (calibration download),
backplane interface, and inputs for engine coolant and intake manifold temperature, and oil
pressure.

Calibration
Non-volatile adjustment made on the factory floor. A data set downloaded to a G-Drive or
GenSet control to update the operation of the control.

EEPROM
Electrically Erasable Programmable Read Only Memory. This memory holds data after the
power has been removed, but can be changed by writing new data on top of old data. This is
where the PowerCommand Control stores its calibration data. The service InPower software
can write a new calibration into the control flash memory.

Fault
A condition occurred which caused a warning or shutdown alarm.

Trainer’s Guide 9-1

Glossary PowerCommand Control 3200

Fuel System Card

The output interface between the base card and the fuel system components on the engine.
This board comes in G-Drive and GenSet versions. Common to both versions are the fuel
system drivers, pump priming drivers, analog-to-digital conversion circuits for engine sensor
data, and engine fluid level switches. The G-Drive board also has LED and relay drivers for
engine warnings and shutdowns, and drivers for engine monitoring meters (OP, CT, ES).
This card does not support the EFC actuator, that driver circuit is on the generator interface
card.

Generator Interface Card

The generator I/O card provides the interface between the PT/CT module and the base card
for monitoring alternator output voltage and current for non-paralleling generator sets. It also
provides the interface between the base card and the Regulator Output Module for the
excitation drive signal. This board contains the analog-to-digital conversion circuits for the
voltage and current measuring inputs, the drive circuit for the EFC actuator, the AVR output
module, and the generator and utility breaker open and close circuits. Customer faults 1 & 2 ,
generator and utility breaker position, and both remote and local low fuel inputs are on this
card.

Load Shed
Signal which directly operates a load device (breaker or transfer switch), causing it to
disconnect a load from the genset(s) when activated. This signal is usually generated because
of an overloaded system. In today’s systems, this signal is usually driven from a Master
Control.

Load Dump
Signal output from a genset which is activated by the genset when it enters an overload
and/or underfrequency condition. In today’s systems, this tells the master control that it needs
to shed some load.

LonWorks Card
The LonWorks card allows the PowerCommand Control to be an active node on the
LonWorks network. It contains the network circuitry needed to interface between RS232 and
LonTalk protocols. The service pin, reset switch and termination switch are on this card.

Nominal Value
A value which has not been trimmed. An example would be normal line frequency of 60.0
Hz. The nominal value is 60.0 Hz.

9-2 Trainer’s Guide

PowerCommand Control 3200 Glossary

Paralleling Interface Card

The paralleling I/O card provides the interface between the PT/CT module and the base card
for monitoring alternator output voltage and current and bus voltage for paralleling generator
sets. It also contains the circuitry for these paralleling functions: ground fault, load demand,
load/unload ramp, first start enable, and customer faults 3 & 4.

Per Unit (PU)

Definition #1: A unitless quantity that is the ratio of the current operating value to the
rated/nominal value. For example, a standby rated genset of 250 kW, 0.8 power factor with a
load of +260 kW, –50 kVAR would have +1.04pu kW, –0.26pu kVAR.

Definition #2: Alternator capability curves calculate per unit kW as the ratio of kW to rated
kVA. Per unit kVAR is calculated as the ratio of rated kVAR to rated kVA.

PETS
Acronym for Production Engine Test System.

PowerCommand Control
The newest control developed by Onan which will be used on generator sets with Cummins
Quantum engines, starting with the QSK45 and QSK60 generator sets in March, 1999.

The PowerCommand Control panel can be remotely mounted up to 2,000 feet from the
generator set.

PowerCommand Network
A communication network for moving information electrically among various Onan on-site
power generation modules. The PowerCommand Network will utilize Echelon LonWorks for
system module interconnection.

Potential Transformer / Current Transformer (PT/CT) Module

This module is located in the control box. The PT/CT module reduces the generator output
voltage from the output voltage level to 18 Volts AC.

The PT/CT module also receives inputs from the 0.55 Amp current transformers and
contains burden resistors for the CTs. When the generator is developing 100% current output
the output from the PT/CT module will be 1.65 Volts AC.

Trainer’s Guide 9-3

Glossary PowerCommand Control 3200

The PT/CT module connects to the generator interface card on standby sets, and to the
paralleling interface card on paralleling sets.

Power Transfer Control (PTC) Module

The PTC Module is a transfer switch control module that monitors Source 1 voltage to see if
the genset should be powering the load. When the Source 1 voltage goes out of the over or
under voltage limits the PTC Module tells the PCC 3200 which then starts in an emergency
automatic mode. Once the genset is up to proper voltage and frequency the PTC Module
opens the Source 1 contactor and closes the Genset contactor after the Programmed
Transition time delay has completed timing. When the Source 1 voltage returns to the normal
range, the Source 2 contactor opens, and after the TDPT delay, the Source 1 contactor is
closed again.

RAM
Random-Access Memory. This is the memory that the PowerCommand Control uses to
actually operate the generator set. This memory requires power to maintain its content.

Rated Current
To be calculated based on rated power (kW) and nominal voltage.

Rated kW
This is set by the end application — standby, limited time prime, unlimited time prime, or
continuous.

Reference Value
A value in a control loop which determines what the control loop is attempting to drive the
output to. An example situation would be when a synchronizing control loop is attempting to
drive the genset frequency to match the bus frequency. Perhaps the genset nominal frequency
is 60.0 Hz, the genset setpoint frequency is 61.5 Hz, but the bus frequency is 59.0 Hz
because it is overloaded. Prior to closing the circuit breaker, the genset will set its reference
frequency to 59.0 to allow it to match the bus. At this time, the reference value is 59.0 Hz.

Regulator Output Module

This module is located in the control box. The actual regulation is done on the base card by
the microprocessor, and this module is a power amplifier for the exciter stator.

9-4 Trainer’s Guide

PowerCommand Control 3200 Glossary

The Permanent Magnet Generator (PMG) is an input to this module, and serves two
functions. The PMG provides the power for the regulator output module to create the
excitation drive for the generator; and the PMG input controls a relay which acts as a
secondary start disconnect circuit when the PMg output reaches 105 Volts AC at
approximately 850 RPM.

This module contains three LEDs:

DS1 lights when the RUN signal is received from the engine interface board.
DS2 lights to show the relative intensity of the regulator drive signal. As the duty cycle
increases, this LED will get brighter.
DS3 lights to show that the secondary starter disconnect contacts are open.

Setpoint Value
A value which is the result of a trim made to a nominal value. An example would be if the
operator adjusted a nominal frequency of 60.0 Hz to 61.5 Hz. The setpoint value is 61.5 Hz.

Shutdown
A type of fault which causes the G-Drive engine or GenSet to shut down immediately or
prevents it from starting.

Status
An indication of state used for informative purposes only — not a warning or shutdown
alarm. Typically a status indication does not require any action to be taken.

Trim
Non-volatile adjustment made in the field by an operator, user, or service technician.

Utility
The primary producer/distributor of electric power. In some countries it’s called the utility
source, in some others it is called the mains or “hydro.”

Warning
A type of fault which does not shut down the engine or generator set, but is meant to warn
the user or operator of an out of normal condition which could eventually adversely affect
operation of the G-Drive engine or GenSet (i.e. could shut it down or prevent it from starting
or operating properly).

Trainer’s Guide 9-5

Glossary PowerCommand Control 3200

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9-6 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

PowerCommand Control 3200 Activity Answers

1 PCC 3200 Introduction Lesson Activities . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-3

2 Hardware Introduction Lesson Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-5

3 Operator Menu Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-9

4 Sequence of Operation Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-15

5 Technician Menu Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-23

6 Troubleshooting Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-29

7 Options Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-41

8 Installation Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-47

Trainer’s Guide 10A-1

Activity Answers PowerCommand Control 3200

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10A-2 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 1-1: Introduction to the PCC 3200 Quiz

Quiz found in Participant’s Guide page 1-16

F 1. Operator Panel A. Acknowledge Shutdowns here

O 2. Graphical Display B. Load current output is 1.65 V

D 3. Shutdown LED C. LonWorks Interface card

P 4. Warning LED D. Overspeed condition light

A 5. “0” position E. Power Amp for exciter signal

H 6. Switch Panel F. Has LED Bargraphs

N 7. Fuel Control Card G. Holds circuit cards

G 8. Card Cage H. Must be on GenSet

E 9. Regulator Output Module I. On Base card

B 10. PT/CT Module J. On Switch Panel

C 11. Has three switches K. Warmup at Idle

Q 12. Generator Interface card L. TB3 terminals

I 13. Microprocessor M. PowerCommand Control

T 14. Emergency Stop switch N. Has large heatsink

S 15. Remotely mountable O. Shows Chinese language

J 16. 0/Manual/Auto Switch P. Pre-LOP light

K 17. Exercise Switch k Q. Receives PT/CT output

R 18. DS3 shows PMG “OK” R. Regulator Output Module

M 19. Used first on QSK60 S. Operator Panel

L 20. Some customer connections T. Stops set NOW!

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Activity Answers PowerCommand Control 3200

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10A-4 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 2-1: Identify PowerCommand Control 3200

components:

7
5 6
2 3 4

Identify the components in this drawing:

7 Fuel Control Card

5 Generator Interface Card

6 Base Card

3 LonWorks Interface Card

4 Paralleling Interface Card

2 Regulator Output Module

1 PT/CT Module

Trainer’s Guide 10A-5

Activity Answers PowerCommand Control 3200

Name of this panel: Switch Panel

9
8

6
5
4
1
3

7 FAULT ACKNOWLEDGE BUTTON

6 PANEL LAMP/ LAMP TEST BUTTON

9 EMERGENCY STOP PUSH BUTTON

4 EXERCISE PUSH BUTTON

1 0/MANUAL/AUTO SWITCH

2 MANUAL RUN/STOP BUTTON

3 MANUAL RUN/STOP INDICATOR

5 EXERCISE INDICATOR

8 REMOTE START, NOT IN AUTO, SHUTDOWN,

WARNING STATUS INDICATORS

10A-6 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Name of this panel: Operator Panel

3

1 2

1 AMPERE DISPLAY

2 VOLTAGE DISPLAY

3 FREQUENCY DISPLAY

4 GRAPHICAL DISPLAY PANEL

5 MENU BUTTON

Trainer’s Guide 10A-7

Activity Answers PowerCommand Control 3200

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10A-8 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

ACTIVITY 3-1
Using your DQKC Generator Set Operator Manual and the worksheet that
follows, work through the Operator-level menus on the PowerCommand Control and
simulator at your work station.

Fill in all the blanks as you go through the worksheet so you can discuss any
differences between your answers and the Trainer’s answers.

Main Menu “A”

ENGINE MENU
1. Coolant Temperature ______

2. Engine Speed ______

3. Battery ______

4. Oil Pressure ______

5. Intake Manifold Temperature ______

6. Intake Manifold Pressure ______ What is the “Gauge” pressure? ______

7. Fuel Rail Pressure ______ What is the “Gauge” pressure? ______

8. Fuel Pump Pressure ______ What is the “Gauge” pressure? ______

9. Fuel Inlet Temperature ______

10. Coolant Pressure ______

11. Blowby Flow ______

12. Timing Rail Pressure ______

13. Aftercooler Temperature ______

14. Ambient Air Pressure ______

Trainer’s Guide 10A-9

Activity Answers PowerCommand Control 3200

ALTERNATOR DATA MENUS

VOLTAGE
L–L L–N AMPS
15. L1 ______ ______ ______

16. L2 ______ ______ ______

17. L3 ______ ______ ______

18. FREQUENCY ______

19. AVR Duty Cycle ______ %

kW kVA PF
20. L1 ______ ______ ______

21. L2 ______ ______ ______

22. L3 ______ ______ ______

23. TOT ______ ______ ______

CONTROL MENU – REMOTE

24. Remote Start or Stop? ______

25. Bargraph Test ______

26. Fault Acknowledge (where is this done?) ______

CONTROL MENU – LOCAL

27. Run Mode Rated or Idle? ______

28. Bargraph Test ______

29. Fault Acknowledge (where is this done?) ______

10A-10 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

HISTORY MENU 1
30. Number of Starts ______

31. Engine Hours ______

32. Control Hours ______

33. KWHRS ______

HISTORY MENU 2 HOURS AT % OF MAX TORQUE

34. 0–10% ______ 35. 51–60% ______

36. 11–20% ______ 37. 61–70% ______

38. 21–30% ______ 39. 71–80% ______

40. 31–40% ______ 41. 81–90% ______

42. 41–50% ______ 43. 91–100% ______

ABOUT MENU 1
44. Model ______

45. Voltage ______ Output Connection ______

46. Frequency ______

47. Rating ______

ABOUT MENU 2
48. RTOP ____________________

Single or Parallel ______

Isolated Bus or Utility? ______
49. BATS ______ Date ______

50. Op Panel RTOP ____________

51. Op Panel BATS ____________

Trainer’s Guide 10A-11

Activity Answers PowerCommand Control 3200

HISTORY 3
52. Number of faults in memory ______

53. Control Hours ______

54. Occurrences ______

55. Engine Hours ______

56. Fault Code ______

Main Menu “B”

ADJUST MENU
57. Output Voltage ______ Voltage Adjust % ______

58. Frequency ______ Frequency Adjust % ______

59. Start Delay ______

60. Stop Delay ______

BUS DATA MENU

Volts Bus Gen
61. L1 ______ ______

62. L2 ______ ______

63. L3 ______ ______

64. Hz ______ ______

65. Bus/Gen. Phase ______

10A-12 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Operator-Level Menu Quiz

Directions: Using the 960-0153 Operator’s Manual, complete the following worksheet.

1. Which menu pick will get the operator to the Oil Pressure indication?

a. Engine Data
b. Alternator Data
c. Control
d. More
2. Which menu pick will get the operator to the Percent of AVR Duty Cycle indication?

a. Engine Data
b. Alternator Data
c. Control
d. More
3. Which menu pick will get the operator to the “Run At Idle” menu pick?

a. Engine Data
b. Alternator Data
c. Control – Local
d. Control – Remote
4. Which Menu pick will get the operator to the History indications?

a. Engine Data
b. Alternator Data
c. Control
d. History/About
5. Which menu pick will get the operator to the Voltage Connection indication?

a. Alternator Data
b. History/About
c. Setup
d. Adjust

Trainer’s Guide 10A-13

Activity Answers PowerCommand Control 3200

6. Which menu pick will get the operator to where the output voltage can be changed?

a. History/About
b. More
c. Setup/Adjust
d. Adjust
7. Which menu pick will get the operator to the information on the emergency Bus?

a. History
b. About
c. Bus Data
d. Adjust
8. From Main Menu “A” what is the sequence of selections to get to the AVR Duty Cycle
indication?

a. Engine Data
b. Alternator Data
c. Control
d. History/About
9. From the Fault History display what is the fastest sequence to get to Main Menu “A”?

a.
b.
–
– – BACK<<
c. BACK<< –
–

d. –
–
– BACK<<
10. From the Engine Oil Pressure display what is the fastest sequence to get to the Stop
Delay adjustment?

a.
– BACK<< – → – →
b. MORE>> –
–PASSWORD – → – →
c.
– MORE>> – ADJUST – PASSWORD
d. – MORE>> – ADJUST – PASSWORD – " – " – "

10A-14 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 4-1: PCC 3200 Operation Quiz

Take approximately five minutes to answer the following questions.

1. What are the main signals used by the PCC as operation cues?

Mode (0 / Manual / Auto) Switch Position

Remote Start Input
Start Type Input
MPU signal
PMG Signal
Emergency Stop Inputs (Local and Remote)
2. What are two uses of the MPU signal in the PCC (II)?

Ready To Start" - Engine is turning over

Speed Regulation Signal
Primary Start Disconnect
3. What are two uses of the PMG signal by the PCC (II)?

Secondary Start Disconnect

Excitation DC source
4. When the 0/Manual/Auto switch is in the Manual or 0 position, what signal is sent to
the Switch Panel by the Generator Iinterface (GIF) card?

Flash the Not In Auto" LED

5. Why does the Red LED on the front panel flash when S12 is in the Manual or 0
position?

The switch is not in the Auto Position

6. When the Local E-Stop switch is“in,” what circuit is open?

Local EĆStop
7. When the Remote E-Stop switch is“in,” what circuit is open?

Remote EĆStop
8. When do the secondary start disconnect contacts open?

850 RPM or 105 VAC from the PMG

Trainer’s Guide 10A-15

Activity Answers PowerCommand Control 3200

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10A-16 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 4-2: PCC 3200 Operation Modes

Using the Operator’s Manual (960-0153) Operate the simulator set at your workstation.

Manual Mode
1. What position does the 0/Manual/Auto switch start at for this mode?

Manual
2. What position does the 0/Manual/Auto switch end at for this mode?

Manual
3. How does the operator start the Manual mode of operation?

Press Manual Start/Stop" Pushbutton

4. When does the control switch from Idle mode to Rated mode?

1005 F or when the Idle timer expires

5. How does the operator stop the Manual mode of operation?

Press Manual Start/Stop" Pushbutton

6. How does the control indicate cooldown timing?

Manual LED flashes

7. How long is the Cooldown time delay?

3 minutes (factory setting)

8. How long is the cooldown at Idle time delay?

2 minutes (factory setting)

Trainer’s Guide 10A-17

Activity Answers PowerCommand Control 3200

Exercise Mode
9. What position does the 0/Manual/Auto switch start at for this mode?

Manual or Auto
10. What position does the 0/Manual/Auto switch end at for this mode?

Auto
11. How does the operator start the Exercise mode of operation?

Press Exercise" Pushbutton while turning 0/Manual/Auto to Auto

12. When does the control switch from Idle mode to Rated mode?

1005 F or when the Idle timer expires

13. How does the operator stop the Exercise mode of operation?

The control stops itself automatically

14. How does the control indicate cooldown timing?

Exercise LED flashes

15. How long is the Cooldown time delay?

3 minutes (factory setting)

16. How long is the cooldown at Idle time delay?

2 minutes (factory setting)

10A-18 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Non-Emergency Automatic Mode

17. What position does the 0/Manual/Auto switch start at for this mode?

Auto
18. What position does the 0/Manual/Auto switch end at for this mode?

Auto
19. How does the operator start the Non-Emergency Automatic mode of operation?

Press Start Genset" pushbutton (Control Menu) on Op. Panel

20. When does the control switch from Idle mode to Rated mode?

1005 F or when the Idle timer expires

21. How does the operator stop the Non-Emergency Automatic mode of operation?

Press Stop Genset" pushbutton (Control Menu) on Op. Panel

22. How does the control indicate cooldown timing?

Remote Start LED flashes

23. How long is the Cooldown time delay?

3 minutes (factory setting)

24. How long is the cooldown at Idle time delay?

2 minutes (factory setting)

Trainer’s Guide 10A-19

Activity Answers PowerCommand Control 3200

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10A-20 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 4-3: Wiring Diagram Questions

Using the GenSet wiring diagram answer the following questions:
1. Where does the MPU signal enter the control?

05Ć38/39 and 05Ć36/37

2. Where does the B+ signal come from for the Crank Relay?

Battery +through 20ĆAmp. Fuse, Remote EĆStop, Local EĆStop

and Regulator Output Module (07Ć05)
3. Where does the B+ signal come from for the Run Relay?

Battery +through 20ĆAmp. Fuse, Remote EĆStop and Local EĆ

Stop
4. What connectors and pins provide a signal to flash the Manual LED when the set is cool-
ing down?

01Ć09 to 23Ć12
5. Where does the Manual position signal go from the Switch Panel?

05Ć05
6. Where does the Not In Auto LED signal come from to the Switch panel?

01Ć42
7. How does the “Manual Position” signal make the “Not In Auto” signal appear?

23Ć18 to 05Ć05 through the backplane to the GIF card, from 01Ć42
to 23Ć21.
8. How does the Manual Start signal get from the Switch Panel to the Starter?

This is the sequence used in the first three pages of the Sequence
Of Operation prints.

Trainer’s Guide 10A-21

Activity Answers PowerCommand Control 3200

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10A-22 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 5-1 Service Menus

Using your DQKC Generator Set Service Manual and the worksheet that
follows, work through the Technician-level menus on the PowerCommand Control and simulator
at your work station.

Fill in all the blanks as you go through the worksheet so you can discuss any
differences between your answers and the Trainer’s answers.

Main Menu “B”

GOV/REG MENU
1. Gov Gain ______

2. AVR Gain ______

CUST FAULT MENU

Customer Fault 1
3. Enable/Disable ______

4. Active Closed/Open ______

5. Response Change to “SHUTDOWN”

6. Customer Fault Name Change to “GENERATOR SET PAYMENT LATE”

Customer Fault 2
7. Response ______

8. Customer Fault Name

Customer Fault 3
9. Response ______

10. Customer Fault Name

Customer Fault 4
11. Enable/Disable ______

12. Active Closed/Open ______

Trainer’s Guide 10A-23

Activity Answers PowerCommand Control 3200

13. Response ______

14. Customer Fault Name

CALIBRATION MENU
15. L1 Voltage ______

16. L2 Voltage ______

17. L3 Voltage ______

18. L1 Current ______

19. L2 Current ______

20. L3 Current ______

21. BUS L1 Voltage ______

22. BUS L2 Voltage ______

23. BUS L3 Voltage ______

ISOLATED BUS PARALLELING MENU

24. Sync Time Limit ______

25. Reverse Pwr Limit ______

26. Reverse Pwr Time ______

27. Perm Win Phase ______

28. Perm Win Time ______

29. Sync Gain ______

30. kW Balance ______

31. kVAR Balance ______

32. kW Gain ______

33. kVAR Gain ______

10A-24 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

34. 1st Fail Time ______

35. Ramp Unload Time ______

36. Ramp Unload Level ______

37. Ramp Load Time ______

38. Loss Field Time ______

UTILITY BUS PARALLELING MENU

39. Base Load ______

40. PF Level ______

41. Ramp Load Time ______

42. Ramp Unload Time ______

43. Mode ______

44. kW Govern Gain ______

45. kVAR Govern Gain ______

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Activity Answers PowerCommand Control 3200

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10A-26 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Service Menu Quiz

Directions: Using the 960-0153 Operator’s Manual, complete the following worksheet.

1. Which menu pick will get the operator to the Oil Pressure indication?

a. Engine Data
b. Alternator Data
c. Control
d. More
2. Which menu pick will get to the Customer Faults Menu?

a. More – Setup – Governing/Volt Reg

b. More – Setup – 
c. More – Setup – Customer Faults
d. More – Setup – Calibration
3. Which menu pick will get to the Isolated Bus Paralleling Menu?

a. More – Setup – Governing/Volt Reg

b. More – Setup – B
c. More – Setup – Customer Faults
d. More – Setup – Calibration
4. What is the maximum value for Governor Gain?

a. 1
b. 5
c. 10
d. 40
5. What is the factory setting for Governor Gain?

a. 1
b. 5
c. 10
d. 40

Trainer’s Guide 10A-27

Activity Answers PowerCommand Control 3200

6. How many key presses does it take to get from the Utility Bus menu to Main Menu B?

a. 1
b. 2
c. 4
d. 6
7. What are the key presses needed to complete the movement in question 6?

a.
b. More
c.


More
d.
⇒
More
⇒

8. When the Operator Panel is mounted remotely, how do you start the generator set from
the remote Operator panel?

a. Control Run at Idle

b. Engine Start
c. Control Start
d. More Start
9. What is the key sequence to input the first letter of the Application Password when cali-
brating the Bus Voltage?

a. + to G
b. ⇒ to G
c.
to G
d. to G
10. What indication WILL NOT be shown when the engine is powering a Delta-connected
alternator?

a. Amps
b. Frequency
c. Volts Line–Line
d. Volts Line–Neutral

10A-28 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 6-1: Classroom Troubleshooting exercises

Using the Service Manual (960-0512) and the Cummins Generator Set wiring diagram determine
where you would check with the breakout tools to solve the problems shown below.

You should be able to determine what voltage or resistance would be a good value at the test
point you select for each problem.

Problem #1
What is the problem on this unit?

The generator set shuts down on low oil pressure. InPower shows the same pressure as the
Engine menu – 10 PSI.
Where should you check for this problem?

Oil Level; Actual oil pressure when cranking/running

Oil Pressure enabled at 10 PSI with InPower.
On what page of the FIS did you find a procedure for troubleshooting this problem?

What did you check to solve the problem?

What should the voltage be at the points you checked – with good oil pressure?

What would the voltage be at the points you checked – with 10 PSI of oil pressure?

Trainer’s Guide 10A-29

Activity Answers PowerCommand Control 3200

Problem #2
What is the problem on this unit?

The generator set shuts down on high coolant temperature. InPower shows 235° F, the En-
gine menu shows 235° F also. Checking the coolant temperature with a direct-reading gauge
shows 185° F actual temperature.
Where should you check for this problem?

Coolant Temperature set to 235° F with InPower.

On what page of the FIS did you find a procedure for troubleshooting this problem?

What did you check to solve the problem?

What should the voltage be at the points you checked – with good coolant temperature?

What would the voltage be at the points you checked – with 235° F coolant temperature?

10A-30 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Problem #3
What is the problem on this unit?

The generator set shuts down on high intake manifold pressure. InPower shows 53 PSIA, as
does the engine menu. Checking the intake manifold pressure manually shows 53 PSIA at
1800 RPM.
Where should you check for this problem?

Manifold Pressure is actually high in this case.

On what page of the FIS did you find a procedure for troubleshooting this problem?

What did you check to solve the problem?

What should the voltage be at the points you checked – with good manifold pressure?

What would the voltage be at the points you checked – with 53 PSIA manifold pressure?

Trainer’s Guide 10A-31

Activity Answers PowerCommand Control 3200

Problem #4
What is the problem on this unit?

The generator set shuts down on high timing rail pressure. InPower shows 253 PSIA. Check-
ing the timing rail pressure manually shows 153 PSIA at 1800 RPM.
Where should you check for this problem?

Timing Rail pressure enabled at 253 PSIA with InPower.

On what page of the FIS did you find a procedure for troubleshooting this problem?

What did you check to solve the problem?

What should the voltage be at the points you checked – with good timing rail pressure?

What would the voltage be at the points you checked – with 253 PSIA timing rail pressure?

10A-32 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 6-2: Troubleshooting PCC 3200 systems.

Using the Service Manual (960-0512) solve the problems on as many demonstrator units as you
can. The instructor will be able to change the problems on the demonstrator units as the
troubleshooting continues.

Problem #1
What is the problem on this unit?

On what page of the Service Manual did you find an explanation of what could cause this prob-
lem?

On what page of the Service Manual did you find a procedure for troubleshooting this problem?

What did you check to solve the problem?

What diagrams did you use to help determine how to troubleshoot the problem if there was no
procedure in the Service Manual?

Trainer’s Guide 10A-33

Activity Answers PowerCommand Control 3200

Problem #2
What is the problem on this unit?

On what page of the Service Manual did you find an explanation of what could cause this prob-
lem?

On what page of the Service Manual did you find a procedure for troubleshooting this problem?

What did you check to solve the problem?

What diagrams did you use to help determine how to troubleshoot the problem if there was no
procedure in the Service Manual?

10A-34 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Problem #3
What is the problem on this unit?

On what page of the Service Manual did you find an explanation of what could cause this prob-
lem?

On what page of the Service Manual did you find a procedure for troubleshooting this problem?

What did you check to solve the problem?

What diagrams did you use to help determine how to troubleshoot the problem if there was no
procedure in the Service Manual?

Trainer’s Guide 10A-35

Activity Answers PowerCommand Control 3200

Problem #4
What is the problem on this unit?

On what page of the Service Manual did you find an explanation of what could cause this prob-
lem?

On what page of the Service Manual did you find a procedure for troubleshooting this problem?

What did you check to solve the problem?

What diagrams did you use to help determine how to troubleshoot the problem if there was no
procedure in the Service Manual?

10A-36 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Problem #5
What is the problem on this unit?

On what page of the Service Manual did you find an explanation of what could cause this prob-
lem?

On what page of the Service Manual did you find a procedure for troubleshooting this problem?

What did you check to solve the problem?

What diagrams did you use to help determine how to troubleshoot the problem if there was no
procedure in the Service Manual?

Trainer’s Guide 10A-37

Activity Answers PowerCommand Control 3200

Problem #6
What is the problem on this unit?

On what page of the Service Manual did you find an explanation of what could cause this prob-
lem?

On what page of the Service Manual did you find a procedure for troubleshooting this problem?

What did you check to solve the problem?

What diagrams did you use to help determine how to troubleshoot the problem if there was no
procedure in the Service Manual?

10A-38 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Repairing PowerCommand) Control Harnesses with

AMP Weatherpack connectors

Trainer’s Guide 10A-39

Activity Answers PowerCommand Control 3200

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10A-40 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 7-1 Circuit Card Replacement

Using your DQKC Generator Set Service Manual and the worksheet that
follows, work through the installation of the Paralleling and LonWorks cards for your worksta-
tion.

Fill in all the blanks as you go through the worksheet so you can discuss any
differences between your answers and the Trainer’s answers.

Power Off
The Instructor will turn off all of the simulators electronically, either from his workstation, or he
will come around to each workstation individually.
When your workstation has been powered down, turn off the power switch on the simulator.

CARD REMOVAL & REPLACEMENT –1

• Put on your wrist strap.
• Using your screwdriver, remove the connectors from the Paralleling and Networks modules.
• Remove the Terminal Blocks from the Paralleling and LonWorks modules.
• Inspect the keying for TB5 on the Paralleling card. Notice that the terminal block cannot be
installed backwards like the older PowerCommand Networks Modules (DIM and CCM).
• Using your screwdriver, loosen the screws holding the Paralleling and LonWorks cards into
the card cage.
• Carefully remove the LonWorks card from the card cage and place it on your closed laptop
PC.
• Carefully remove the Paralleling card and install it into the LonWorks card slot in the card
cage.
• Install the LonWorks card into the Paralleling card slot in the card cage.
• Reconnect all of the cables and terminal blocks to the Paralleling and LonWorks cards.
• Turn on the power switch on your simulator and place your green flag on top of the card
cage.
When all groups are done with this activity, the instructor will electronically turn on the worksta-
tions again.

Trainer’s Guide 10A-41

Activity Answers PowerCommand Control 3200

When your workstation is live, start the generator set in the Manual mode.
What Faults do you see?

Why do you see these faults?

Acknowledge these faults.

Power Off
After some discussion, the Instructor will turn off all of the simulators electronically, either from
his workstation, or he will come around to each workstation individually.
When your workstation has been powered down, turn off the power switch on the simulator.

CARD REMOVAL & REPLACEMENT –2

• Put on your wrist strap.
• Using your screwdriver, remove the connectors from the Paralleling and Networks modules.
• Remove the Terminal Blocks from the Paralleling and LonWorks modules.
• Using your screwdriver, loosen the screws holding the Paralleling and LonWorks cards into
the card cage.
• Carefully remove the LonWorks card from the card cage and place it on your closed laptop
PC.
• Carefully remove the Paralleling card and install it into its own slot in the card cage.
• Install the LonWorks card into its own slot in the card cage.
• Reconnect all of the cables and terminal blocks to the Paralleling and LonWork cards.
• Turn on the power switch on your simulator and place your green flag on top of the card
cage.
When all groups are done with this activity, the instructor will electronically turn on the worksta-
tions again.

When your workstation is live, start the generator set in the Manual mode.

10A-42 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

What Faults do you see?

Trainer’s Guide 10A-43

Activity Answers PowerCommand Control 3200

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10A-44 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 7-2 PCC 3200 Options Quiz

Directions: Using the 960-0620 Installation Manual and the Generator Set Wiring Diagram,
complete the following worksheet.

1. Where does the Paralleling card go in the card cage?

a. slot 1
b. slot 2
c. slot 3
d. slot 4
2. Why do you have to connect the PT/CT module output to the Paralleling card?

a. to measure the alternator output voltage

b. to measure the alternator frequency
c. to measure the bus voltage
d. both A and B are correct

3. You would set the speed droop percentage for a PCC 3200 control in the _______ folder of
InPower.

a. Adjustments
b. Adjustments / Governor
c. Adjustments / Governor / Frequency
d. Adjustments / Governor / Gain and Droop
4. You would set the Voltage Droop percentage for a PCC 3200 control in the _______ fold-
er of InPower.

a. Adjustments
b. Adjustments / Governor / Gain and Droop
c. Adjustments / Paralleling / Speed Droop
d. Adjustments / Paralleling / Voltage Droop

Trainer’s Guide 10A-45

Activity Answers PowerCommand Control 3200

5. When the signal voltage at TB3-25 or Connector 04-29 goes positive, the generator set is
at 90% of voltage and frequency, and the bus is dead

a. the utility breaker will close.

b. the utility breaker will open.
c. the paralleling breaker will close. (First Start)
d. the paralleling breaker will open.
6. When connecting the network data cable to the LonWorks card you must put the solid
colored wire in terminal 1 of TB6 or Connector 11.

a. True
b. False
7. When TB6 is disconnected from the LonWorks card, the voltage between TB6-3 and
TB6-5 will be

a. 12 VDC.
b. 24 VDC.
c. 0 VDC.
d. 0 VAC.
8. When the network is operating properly the voltage between the two wires in the network
twisted pair will be

a. 0.52 VDC.
b. 5.2 VDC.
c. 12.52 VDC.
d. negligible.
9. The preferred power source for the LonWorks card is through

a. Connector TB6.
b. Connector 11.
c. Connector 14.
d. None of the above.
10. When installing the LonWorks card, you must use

a. InPower software.
b. LonWorks software.
c. LonMaker for Windows software.
d. Both A and C.

10A-46 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 8-1 Wiring Diagram Exercise

Using your DQKC Generator Set Service Manual, the Generator Set Wiring Diagram, and the
worksheet that follows, fill in the pin used for each of the signals listed in the first blank, and
whether this is an Input or an Output pin.

Fill in all the blanks as you go through the worksheet so you can discuss any
differences between your answers and the Trainer’s answers.

TB1 (Bus PT)

1. E1 Phase ___1___  Input

2. E2 Phase ___2___  Input

3. E3 Phase ___3___  Input

4. Neutral ___4___  Input

TB2
5. Bus L1 ___6___  Output

6. Bus L1 COM ___5___  Output

7. Bus L2 ___4___  Output

8. Bus L2 COM ___3___  Output

9. Bus L3 ___2___  Output

10. Bus L3 COM ___1___  Output

TB3
11. B+ __1–4__  Output

12. Switched B+ __5, 6__  Output

13. Ground __7–10_  Output

14. Customer Switch #2 __11___  Input

Trainer’s Guide 10A-47

Activity Answers PowerCommand Control 3200

15. Local Low Fuel Level ___13___  Input

16. Ready to Load ___15___  Output

17. Load Dump ___16___  Output

18. Common Shutdown ___17___  Output

19. Relay Driver Supply ___18___  Output

20. Control Heater __19, 20__  Input

21. Sync Enable ___22___  Input

22. First Start Enable ___25___  Input

23. Load Demand Shutdown ___21___  Input

24. Single Mode Enable ___23___  Input

25. Ramp Load/Unload ___24___  Input

26. External kVAR + ___27___  Input  Output

27. External kVAR – ___28___  Input  Output

28. External kW + ___29___  Input  Output

29. External kW – ___30___  Input  Output

30. Common Warning ___32___  Output

TB4
31. CB1 Close A ___12___  Input

32. CB1 Close B ___13__  Output

33. CB1 Position ___7___  Input

34. CB1 Inhibit ___6___  Input

35. CB2 Close A ___14___  Input

36. CB2 Close B ___15___  Output

10A-48 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

37. CB2 Position ___4___  Input

38. CB2 Inhibit ___3___  Input

39. Customer Switch #1 ___9___  Input

40. Remote Low Fuel Level ___1___  Input

41. Auto Mode ___11___  Output

42. Modem Control ___2___  Output

TB5
43. Ground Fault Switch ___7___  Input

44. Ground _8 & 9__  Output

45. Customer Switch #3 ___10___  Input

46. Customer Switch #4 ___11___  Input

47. Ground Fault Meter + ____5__  Input

48. Ground Fault Meter – ____6__  Input

49. Load Share kW + ___14___  Output

50. Load Share kW – ___15___  Output

51. Load Share kVAR + ___12___  Output

52. Load Share kVAR – ___13___  Output

53. Shield ___16___  Input

TB6
54. Data 1 ___1___  Input  Output

55. Data 2 ___2___  Input  Output

56. 24 VDC ___3___  Input  Output

Trainer’s Guide 10A-49

Activity Answers PowerCommand Control 3200

57. 24 VDC ___4___  Input  Output

58. Ground ___5___  Input  Output

59. Ground ___6___  Input  Output

TB8
60. Remote E-Stop __1&2___  Input  Output

61. Start Type ___3___  Input  Output

62. Remote Start ___4___  Input  Output

10A-50 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Activity 8-2: Installation Wiring Diagram Quiz

Directions: Using the 960-0620 Installation Manual and the Generator Set Wiring Diagram,
complete the following worksheet.

1. Where does the Start Type signal connect to the generator set control?

a. TB3-07 and TB3-11

b. TB4-07 and TB4-08
c. TB5-07 and TB5-08
d. TB8-03 and TB8-05
2. Where does the Customer Switch #4 connect to the generator set control?

a. TB3-11 and TB3-12

b. TB4-09 and TB4-10
c. TB5-09 and TB5-10
d. TB5-09 and TB5-11
3. What voltage is present between pins 20 and 21 on Connector 04 when a generator set
with an output voltage of 277/480 is paralleled to the Emergency Bus?

a. 0 Volts
b. 18 VAC
c. 120 VAC
d. 240 VAC
4. What voltage is present on pins 22 and 23 of Connector 01 when the alternator is at
100% nominal load?

a. 24 VAC
b. 18 VAC
c. 5.0 VAC
d. 1.65 VAC

Trainer’s Guide 10A-51

Activity Answers PowerCommand Control 3200

5. What voltage will be available between pins 12 and 13 of TB4 when the Utility breaker is
open?

a. 12 VDC
b. 18 VDC
c. 24 VDC
d. 120 VAC AC to close breaker
6. What voltage will be available between terminals 16 and 17 of TB4 when the Utility
breaker is closed?

a. 12 VDC
b. 18 VDC
c. 24 VDC Battery voltage to open breaker
d. 120 VAC
7. What voltage will be available between terminals 15 and 18 of TB3 when a 60 Hz gener-
ator set is at or above 1620 RPM?

a. 12 VDC
b. 18 VDC
c. 24 VDC Battery voltage
d. 120 VAC
8. To drive a paralleled generator set to 50% load, you would apply ______ to terminals 29
and 30 on TB3.

a. 9.0 VDC
b. 6.0 VDC
c. 3.0 VDC
d. 1.5 VDC 1/2 of 3.0 VDC
9. A generator set has a paralleling card properly installed and connected. It will not share
kW load properly with the other generator set at the installation. To test whether the kW
load share lines are connected properly you could

a. swap all load share lines and apply a load bank to both sets.
b. swap the kW load lines and apply a load bank to only this set.
c. swap the kW load lines and apply a load bank to both sets.
d. swap the kVAR load lines and apply a load bank to only this set.

10A-52 Trainer’s Guide

PowerCommand Control 3200 Activity Answers

Answer Key – Do not hand out to participants with the test!

1. A
2. B
3. A
4. B
5. B
6. B
7. B
8. B
9. B
10. A
11. B
12. C
13. D
14. B
15. C
16. D
17. C
18. C
19. A
20. C
21. C
22. A
23. A
24. B
25. D
26. A
27. C
28. B
29. B
30. D

Trainer’s Guide 10A-53

Activity Answers PowerCommand Control 3200

31. A
32. D
33. C
34. C
35. C
36. D
37. D
38. A
39. D
40. C
41. D
42. B
43. C
44. D
45. A
46. C
47. B
48. B
49. C
50. D

10A-54 Trainer’s Guide

PowerCommand Control 3200 Module Assessment

Module Assessment
Now that you’ve completed the PowerCommand Control 3200 module, we’d like to find out
how well it’s working. Please take up to 90 minutes to answer these questions on the module
content. You must achieve a score of 84% or higher to successfully complete the examination.

Instructions: Fill in the appropriate answer choice on the answer sheet. Completely erase any
answers you want to change. DO NOT write on the test.

1. The switch panel must be connected to the generator set and cannot be remotely mounted.

a. True
b. False

2. The Operator panel must be connected to the generator set and cannot be remotely mounted.

a. True
b. False

3. The control must have a new calibration downloaded to the base card when a new option is
installed.

a. True
b. False

4. Customer Fault #2 can be set for a Normally Closed or a Normally Open input.

a. True
b. False

5. The Cooldown at Idle is factory set for 5 minutes.

a. True
b. False

6. Only G-Drive engines have the Deutsch 9-pin data connector.

a. True
b. False

Trainer’s Guide 11-1

Module Assessment PowerCommand Control 3200

7. To change the language of the Operator panel you would remove and replace the front panel
insert.

a. True
b. False

8. Customer Fault #2 is the only one which can be set as a warning.

a. True
b. False

9. You want to connect a PC running InPower software to the PowerCommand Control (II). In
the control box you would use

a. C12
b. C13

For the next four questions match the correct answer on the right to the question on the left.

10. Early production card cage A. Four or Eight slots

11. Microprocessor B. On Base Card

12. Operator Panel C. Can be mounted remotely

13. Exercise Mode D. Warm–up at Idle

E. Has large heatsink

14. The current indication on the Operator panel goes to a maximum of

a. 135%
b. 125%
c. 110%
d. 100%

11-2 Trainer’s Guide

PowerCommand Control 3200 Module Assessment

15. The wakeup signals for the PowerCommand Control (II) include:

a. Pressing the Exercise switch with the 0/Manual/Auto switch in

the Manual position.
b. Start type input.
c. Pressing any switch when in the Auto position.
d. Both B and C are correct.

16. The PT/CT module has an output voltage of ____ VAC when the input voltage is at its nom-
inal level.

a. 36
b. 24
c. 20
d. 18

17. TB4 is on the ____ card.

a. Fuel
b. Base
c. Generator
d. Paralleling

18. Which connector in the Control Box is used to update the control calibration?

a. C10
b. C11
c. C13
d. C15

Trainer’s Guide 11-3

Module Assessment PowerCommand Control 3200

19. The PT/CT module has an output voltage of ____ VAC when the generator set load current
is at its standby rated level.

a. 1.65
b. 1.84
c. 2.41
d. 3.64

20. Which LED lights when the PMG output is 105 VAC?

a. DS1
b. DS2
c. DS3
d. DS4

21. How many gallons of coolant are used in the DQKC cooling systems?

a. 154
b. 144
c. 134
d. 124

22. Which connector is not used in the GenSet version of the control?

a. C3
b. C5
c. C6
d. C7

11-4 Trainer’s Guide

PowerCommand Control 3200 Module Assessment

23. Which pin would you check to see if the Run Relay had energized?

a. Inline F-B
b. Inline F-C
c. Inline D-1
d. Inline D-5

24. Which terminal block on the Bus PT module connects to the Paralleling card?

a. TB1
b. TB2
c. TB3
d. TB4

25. Which symbol takes you to the next choice in the menu system?

a.

b.

c.

d.

26. How far up can you adjust the generator set frequency on the Adjust menu for 60 Hz sets?

a. 3 Hz
b. 4 Hz
c. 5 Hz
d. 6 Hz

Trainer’s Guide 11-5

Module Assessment PowerCommand Control 3200

27. One of the most basic steps used when troubleshooting the PowerCommand Control (II) is

a. good meter use.

b. proper meter use.
c. good visual inspection.
d. test the meters.

28. When checking for proper operation of the Crank Relay your best test point is

a. 04-02.
b. 05-01.
c. 05-03.
d. 06-02.

29. The generator set cranks but will not run. A good check point to locate the trouble is

a. 06-06.
b. Inline D-03.
c. Inline E-C.
d. 05-05.

30. The generator set will not crank. A good checkpoint to locate the trouble is

a. Inline A-17.
b. Inline B-19.
c. Inline C-18.
d. Inline D-1.

31. The generator set will not run. A good checkpoint to locate the trouble is

a. Inline D-3.
b. Inline D-5.
c. Inline E-B.
d. Inline F-C.

11-6 Trainer’s Guide

PowerCommand Control 3200 Module Assessment

32. Generator set #1 always carries more kW load than generator set #2. You suspect crossed
kW load share wires. To troubleshoot this problem you could check the wires at

a. TB3-13/-35.
b. TB3-30/-31.
c. TB5-12/-13.
d. TB5-14/-15.

33. The generator set operates properly in Exercise or Automatic modes, but not in Manual. A
good check to locate the problem is

a. 23-03.
b. 23-12.
c. 23-18.
d. 23-22.

34. When using the Master First Start Sensor the signal at TB3-25 or Connector 04-01 goes pos-
itive and the generator is at 90% voltage and frequency, the

a. Utility breaker will close.

b. Utility breaker will open.
c. Paralleling breaker will close.
d. Paralleling breaker will open.

35. With nominal level input the BUS PT module output voltage should be ____ VAC.

a. 0.55
b. 1.65
c. 18
d. 24

Trainer’s Guide 11-7

Module Assessment PowerCommand Control 3200

36. A customer wants to use a 24 VDC signal through an NC relay contact as Customer Switch
#1. You should tell the customer

a. OK, no extra wiring is needed.

b. B+ is not acceptable as a Customer Switch input.
c. you can add a relay to change the signal from B+ to Ground.
d. both B and C are correct.

37. When connecting a PowerCommand Control (II) to an Onan OTIII ATS, connect ______ to
the remote start terminals on the ATS.

a. TB8-1/-2
b. TB8-3/-4
c. TB8-3/-5
d. TB8-4/-5

38. When using InPower to troubleshoot a PowerCommand Control (II) generator set, the tech-
nician sets the test function value for Oil Pressure to 45 PSI. When will the control again see
actual oil pressure?

a. after the set is stopped and restarted

b. When the PC running InPower is disconnected from the control
c. When the Oil Pressure sensor is disconnected and reconnected
to the engine harness
d. when the actual oil pressure goes above 45 PSI

39. In a PCC (II) 8 card rack w/no options, how many backplane slots are used for expansion?

a. 0
b. 4
c. 6
d. none of the above

11-8 Trainer’s Guide

PowerCommand Control 3200 Module Assessment

40. To start the generator set in the Manual mode with InPower the 0/Manual/Auto switch must
be in the ____ position on the switch panel.

a. 0
b. Manual
c. Auto
d. any position is OK

41. The factory setting for HOT Warning Threshold in the DQKC generator sets is ____ Deg F.

a. 150
b. 160
c. 170
d. 190

42. The DQKC LCL shutdown threshold ____ seconds.

a. 5
b. 10
c. 12
d. 16

43. The type of software version in the DQKC controller Capture File is

a. D_xxxxxx.dfa.
b. DNxxxxxx.dfa.
c. DIxxxxxx.dfa.
d. DOxxxxxx.dfa.

44. DQKC generator set Load Dump Threshold is factory set at _____ %.

a. 101.99
b. 102.99
c. 103.99
d. 104.99

Trainer’s Guide 11-9

Module Assessment PowerCommand Control 3200

45. When checking signals at the output of the PT/CT module you would use

a. the PowerCommand Control (I) tool kit.

b. the PowerCommand Control (II) tool kit.
c. InPower software.
d. both A and B are correct.

46. 24 Volt Weak battery threshold for a DQKC generator set is ____ VDC.

a. 10.931
b. 12.193
c. 14.391
d. 14.913

47. The Idle Warm–up Time in the DQKC capture file is set to _____.

a. 9.96 minutes
b. 5.0 minutes
c. 9.96 seconds
d. 5.0 seconds

48. The factory setting for overfrequency threshold in the DQKC generator sets is ____ Hz.

a. 3
b. 6
c. 9
d. 12

49. You would set the speed droop percentage for a PCC 3200 control in the _______ folder of
InPower.

a. Adjustments
b. Adjustments / Governor
c. Adjustments / Governor / Frequency
d. Adjustments / Governor / Gain and Droop

11-10 Trainer’s Guide

PowerCommand Control 3200 Module Assessment

50. You would set the Voltage Droop percentage for a PCC 3200 control in the _______ folder
of InPower.

a. Adjustments
b. Adjustments / Governor / Gain and Droop
c. Adjustments / Paralleling / Speed Droop
d. Adjustments / Paralleling / Voltage Droop

Trainer’s Guide 11-11

Module Assessment PowerCommand Control 3200

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11-12 Trainer’s Guide

PowerCommand Control 3200 Module Assessment

Answer Key – Do not hand out to participants with the test!

1. A 26. D
2. B 27. C
3. A 28. B
4. B 29. B
5. B 30. D
6. B 31. A
7. B 32. D
8. B 33. C
9. B 34. C
10. A 35. C
11. B 36. D
12. C 37. D
13. D 38. A
14. B 39. D
15. C 40. C
16. D 41. D
17. C 42. B
18. C 43. B
19. A 44. D
20. C 45. A
21. C or D 46. C
22. A 47. B
23. A 48. B
24. B 49. D
25. D 50. D

Trainer’s Guide 11-13

Module Assessment PowerCommand Control 3200

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11-14 Trainer’s Guide

PowerCommand Control 3200 Module Comment Form

Module Evaluation Form

Your feedback is very important to us. Help us evaluate the training you just completed by answering
each of the following questions. Place an ”x” in the box that most closely reflects your opinion. Your writ-
ten comments and recommendations for improving this training are also welcome. There are spaces and
extra room on the back for comments/

Date: ______________________ Trainer’s Name:____________________________________

Your name (optional): _______________________________Company____________________

No Yes
Did the Trainer state the objectives before each lesson?
Did the Trainer provide constructive and adequate answers to your questions?
Was the content presented in a logical manner?
Did the Trainer perform safe practices in the Shop?
In your opinion, was the Trainer qualified to teach this class?
Was the length of the training adequate? If no, circle one (too short/too long)
Were there enough exercises in the Classroom/Shop Activities?
Will you apply what you learned to your job?
Do you think this training was worth your time?
Would you recommend this course to your peers?

Below Ave Average Excellent

How would you rate the quality of the training material
(Participant Guide, handouts, etc.).
How would you rate the Shop Activities?
How would your rate the Classroom Activities?
How would you rate your Trainer?
How would you rate the classroom accommodations?
(space to work, restrooms, snacks)

Additional comments about your Trainer:

Additional comments about the training material/activities:

Additional comments in general:

Trainer’s Guide 12-1

Module Comment Form PowerCommand Control 3200

12-2 Trainer’s Guide

Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6266
763-574-5000 International Use
Fax: 763-574-8087
Cummins is a registered trademark of Cummins Inc.