PowerCommand®

1.2 control system

Control system description Features

• 128 x 128 pixels graphic LED backlight LCD.
®
The PowerCommand control system is a
microprocessor-based generator set monitoring, • Digital voltage regulation. Single phase full wave
metering and control system designed to meet the SCR type regulator compatible with either shunt or
demands of today’s engine driven generator sets. The PMG systems.
integration of all control functions into a single control
• Digital engine speed governing (where applicable).
system provides enhanced reliability and performance
compared to conventional generator set control • Generator set monitoring and protection.
systems. These control systems have been designed • Advanced overcurrent protection.
and tested to meet the harsh environment in which •
®
Modbus interface for interconnecting to customer
gensets are typically applied. equipment.
• 12 and 24 VDC battery operation.
• Warranty and service. Backed by a comprehensive
warranty and worldwide distributor service network.
• Certification. Suitable for use on generator sets that
are designed, manufactured, tested and certified to
relevant UL, NFPA, ISO, IEC Mil Std., CE and CSA
standards.

©2008|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power
Generation and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower and “Our energy working for you.” are
trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
S-1567b (4/08) Page 1 of 6
 designed for reliable operation in harsh
PowerCommand digital environments. The main control board is a fully
generator set control encapsulated module that is protected from the
elements.
PCC 1302 • Modbus interface - for interconnecting to customer
equipment.
• Configurable inputs and outputs - Four discrete
inputs and two dry contact relay outputs.
• Warranty and service - Backed by a comprehensive
warranty and worldwide distributor service network.
• Certifications - Suitable for use on generator sets
that are designed, manufactured, tested and certified
to relevant UL, NFPA, ISO, IEC, Mil Std., CE and
CSA standards.

Description Base control functions

The PowerCommand generator set control is suitable HMI capability
for use on a wide range of generator sets in non- Operator adjustments - The HMI includes provisions
paralleling applications. The PowerCommand control is for many set up and adjustment functions.
compatible with shunt or PMG excitation style. It is
Generator set hardware data - Access to the control
suitable for use with reconnectable or non-
and software part number, generator set rating in KVA
reconnectable generators, and it can be configured for
and generator set model number is provided from the
any frequency, voltage and power connection from 120-
600 VAC line-to-line. HMI or InPower.
Data logs - Includes engine run time, controller on
Power for this control system is derived from the time, number of start attempts.
generator set starting batteries. The control functions
over a voltage range from 8 VDC to 30 VDC. Fault history - Provides a record of the most recent
fault conditions with control hours time stamp. Up to
Features 10 events are stored in the control non-volatile
memory.
• 12 and 24 VDC battery operation. Alternator data
• Digital voltage regulation - Single phase full wave SCR
- Voltage (single or three phase line-to-line and
type regulator compatible with either shunt or PMG
line-to-neutral)
systems. Sensing is single phase.
- Current (single or three phase)
• Digital engine speed governing (where applicable) - - KVA (three phase and total)
Provides isochronous frequency regulation. - Frequency
• Full authority engine communications (where Engine data
applicable) - Provides communication and control
with the Engine Control Module (ECM). - Starting battery voltage
• Common harnessing - with higher feature Cummins - Engine speed
Power Generation controls allows for easy field - Engine temperature
upgrades. - Engine oil pressure
- Partial Full Authority Engine (FAE) data (where
• Generator set monitoring - Monitors status of all applicable)
critical engine and alternator functions.
Service adjustments - The HMI includes provisions for
• Digital genset metering (AC and DC).
adjustment and calibration of generator set control
• Genset battery monitoring system - to sense and functions. Adjustments are protected by a password.
warn against a weak battery condition. Functions include:
• Engine starting - Includes relay drivers for starter, fuel - Engine speed governor adjustments
shut off (FSO), glow plug/spark ignition power and - Voltage regulation adjustments
switch B+ applications. - Cycle cranking
• Generator set protection - Protects engine and - Configurable fault set up
alternator. - Configurable output set up
• Advanced serviceability - using InPower™, a PC- - Meter calibration
based software service tool. - Units of measurement
• Environmental protection - The control system is
Our energy working for you.™
www.cumminspower.com
©2007|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power
Generation and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower and “Our energy working for you.” are
trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
S-1567b (4/08) Page 2 of 6
Engine control Time delay start and stop (cooldown) - Configurable for
time delay of 0-300 seconds prior to starting after
SAE-J1939 CAN interface to full authority ECMs (where
receiving a remote start signal and for time delay of
applicable) - Provides data swapping between genset
0-600 seconds prior to shut down after signal to stop in
and engine controller for control, metering and
normal operation modes. Default for both time delay
diagnostics.
periods is 0 seconds.
12 VDC/24 VDC battery operations - PowerCommand
will operate either on 12 VDC or 24 VDC batteries. Alternator control
Isochronous governing (where applicable) - Capable of The control includes an integrated line-to-line sensing
controlling engine speed within +/-0.25% for any voltage regulation system that is compatible with shunt
steady state load from no load to full load. Frequency or PMG excitation systems. The voltage regulation
drift will not exceed +/-0.5% for a 33 °C (60 °F) change system is full wave rectified and has an SCR output for
in ambient temperature over an 8 hour period. good motor starting capability. Major system features
include:
Temperature dependent governing dynamics (with
electronic governing) - Modifies the engine governing Digital output voltage regulation - Capable of regulating
control parameters as a function of engine temperature. output voltage to within +/-1.0% for any loads between
This allows the engine to be more responsive when no load and full load. Voltage drift will not exceed
warm and more stable when operating at lower +/-1.5% for a 40 ºC (104 ºF) change in temperature in
temperature levels. an eight hour period. On engine starting or sudden
load acceptance, voltage is controlled to a maximum of
Remote start mode - Accepts a ground signal from
5% overshoot over nominal level.
remote devices to automatically start the generator set
and immediately accelerate to rated speed and voltage. The automatic voltage regulator feature can be
The remote start signal will also wake up the control disabled to allow the use of an external voltage
from sleep mode. The control can incorporate a time regulator.
delay start and stop.
Torque-matched V/Hz overload control - The voltage
Remote and local emergency stop - The control roll-off set point and rate of decay (i.e. the slope of the
accepts a ground signal from a local (genset mounted) V/Hz curve) is adjustable in the control.
or remote (facility mounted) emergency stop switch to
cause the generator set to immediately shut down. The Protective functions
generator set is prevented from running or cranking
with the switch engaged. If in sleep mode, activation of On operation of a protective function the control will
either emergency stop switch will wake up the control. indicate a fault by illuminating the appropriate status
LED on the HMI, as well as display the fault code and
Sleep mode - The control includes a configurable low fault description on the LCD. The nature of the fault
current draw state to minimize starting battery current and time of occurrence are logged in the control. The
draw when the genset is not operating. The control service manual and InPower service tool provide
can also be configured to go into a low current state service keys and procedures based on the service
while in auto for prime applications or applications codes provided. Protective functions include:
without a battery charger.
Configurable alarm and status inputs
Engine starting - The control system supports
automatic engine starting. Primary and backup start The control accepts up to four alarm or status inputs
disconnects are achieved by one of three methods: (configurable contact closed to ground or open) to
magnetic pickup, battery charging alternator feedback indicate a configurable (customer-specified) condition.
or main alternator output frequency. The control also The control is programmable for warning, shutdown or
supports configurable glow plug control when status indication and for labeling the input.
applicable. Emergency stop
Cycle cranking - Configurable for the number of Annunciated whenever either emergency stop signal is
starting cycles (1 to 7) and duration of crank and rest received from external switch.
periods. Control includes starter protection algorithms
to prevent the operator from specifying a starting
sequence that might be damaging.

Our energy working for you.™

www.cumminspower.com
©2007|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power
Generation and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower and “Our energy working for you.” are
trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
S-1567b (4/08) Page 3 of 6
Hydro mechanical fuel system engine Low AC voltage shutdown (27) - Voltage on any phase
protection has dropped below a preset value. Adjustable over a
range of 50-95% of reference voltage, time delay 2-20
Overspeed shutdown - Default setting is 115% of seconds. Default value is 85% for 10 seconds.
nominal.
Overcurrent warning/shutdown - Implementation of the
Low lube oil pressure warning/shutdown - Level is thermal damage curve with instantaneous trip level
preset (configurable with InPower) to match the calculated based on current transformer ratio and
capabilities of the engine used. Control includes time application power rating.
delays to prevent nuisance shutdown signals.
High lube oil temperature warning/shutdown - Level is
preset (configurable with InPower) to match the
capabilities of the engine used. Control includes time
delays to prevent nuisance shutdown signals.
High engine temperature warning/shutdown - Level is
preset (configurable with InPower) to match the
capabilities of the engine used. Control includes time
delays to prevent nuisance shutdown signals.
Low coolant temperature warning – Indicates that
engine temperature may not be high enough for a 10
second start or proper load acceptance.
Sensor failure indication - Logic is provided on the base
control to detect analog sensor or interconnecting
wiring failures.

Full authority electronic engine protection

Engine fault detection is handled inside the engine
ECM. Fault information is communicated via the SAE- Under frequency shutdown (81 u) - Generator set
J1939 data link for annunciation in the HMI. output frequency cannot be maintained. Settings are
adjustable from 2-10 Hz below nominal governor set
point, for a 5-20 second time delay. Default: 6
General engine protection
Hz, 10 seconds.
Low and high battery voltage warning - Indicates status
of battery charging system (failure) by continuously Over frequency shutdown/warning (81o) - Generator
monitoring battery voltage. set is operating at a potentially damaging frequency
level. Settings are adjustable from 2-10 Hz above
Weak battery warning - The control system will test the nominal governor set point for a 1-20 second time
battery each time the generator set is signaled to start delay. Default: 6 Hz, 10 seconds, enabled.
and indicate a warning if the battery indicates
impending failure. Loss of sensing voltage shutdown - Shutdown of
generator set will occur on loss of voltage sensing
Fail to start (overcrank) shutdown - The control system inputs to the control.
will indicate a fault if the generator set fails to start by
the completion of the engine crack sequence. Field overload shutdown - Uses field voltage to
shutdown generator set when a field overload condition
Fail to crank shutdown - Control has signaled starter to occurs.
crank engine but engine does not rotate.
Cranking lockout - The control will not allow the starter Field control interface
to attempt to engage or to crank the engine when the
Input signals to the base control include:
engine is rotating.
- Remote start
Alternator protection - Local and emergency stop
- Configurable inputs: Control includes (4) input
High AC voltage shutdown (59) - Output voltage on any
signals from customer discrete devices that are
phase exceeds preset values. Time to trip is inversely
configurable for warning, shutdown or status
proportional to amount above threshold. Values
indication, as well as message displayed
adjustable from 105-130% of nominal voltage, with
time delay adjustable from 0.1-10 seconds. Default
value is 110% for 10 seconds.

Our energy working for you.™

www.cumminspower.com
©2007|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power
Generation and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower and “Our energy working for you.” are
trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
S-1567b (4/08) Page 4 of 6
Output signals from the PowerCommand
control include:
PowerCommand human
- Configurable relay outputs: Control includes (2) relay machine interface
output contacts rated at 2 A. These outputs can be
configured to activate on any control warning or
HMI220
shutdown fault as well as ready to load, not in auto,
common alarm, common warning and common
shutdown.
- Ready to load (generator set running) signal:
Operates when the generator set has reached 90% of
rated speed and voltage and latches until generator
set is switched to off or idle mode.
Communications connections include:
- PC tool interface: This RS-485 communication port Description
allows the control to communicate with a personal
This control system includes an intuitive operator
computer running InPower or PowerCommand for
interface panel that allows for complete genset control
Windows® software.
as well as system metering, fault annunciation,
- Modbus RS-485 port: Allows the control to configuration and diagnostics. The interface includes
communicate with external devices such as PLCs five generator set status LED lamps with both
using Modbus protocol. internationally accepted symbols and English text to
Note - An RS-232 or USB to RS-485 converter is comply with customers needs. The interface also
required for communication between PC and control. includes an LED backlit LCD display with tactile feel
soft-switches for easy operation and screen navigation.
- Networking: This RS-485 communication port allows It is configurable for units of measurement and has
connection from the control to the other Cummins adjustable screen contrast and brightness.
Power Generation products.
The run/off/auto switch function is integrated into the
Mechanical drawings interface panel.
All data on the control can be viewed by scrolling
through screens with the navigation keys. The control
displays the current active fault and a time-ordered
history of the five previous faults.

Features:
• LED indicating lamps
- genset running
- remote start
- not in auto
- shutdown
- warning
- auto
- manual and stop
• 128 x 128 pixels graphic LED backlight LCD.
• Two tactile feel membrane switches for LCD defined
operation. The functions of these switches are
defined dynamically on the LCD.
• Seven tactile feel membrane switches dedicated
screen navigation buttons for up, down, left, right, ok,
home and cancel.
• Six tactile feel membrane switches dedicated to
control for auto, stop, manual, manual start, fault
reset and lamp test/panel lamps.
• Two tactile feel membrane switches dedicated to
control of circuit breaker (where applicable).
• Allows for complete genset control setup.
Our energy working for you.™
www.cumminspower.com
©2007|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power
Generation and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower and “Our energy working for you.” are
trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
S-1567b (4/08) Page 5 of 6
• Certifications: Suitable for use on generator sets that The HMI is designed for proper operation in ambient
are designed, manufactured, tested and certified to temperatures from -20 ºC (-4 ºF) to +70 ºC (158 ºF), and
relevant UL, NFPA, ISO, IEC, Mil Std., CE and CSA for storage from -30 ºC (-22 ºF) to +80 ºC (176 ºF).
standards.
The control board is fully encapsulated to provide
LCD languages supported: English, Spanish, French, superior resistance to dust and moisture. Display panel
German, Italian, Greek, Dutch, Portuguese, Finish, has a single membrane surface, which is impervious to
Norwegian, Danish, Russian, Czech and Chinese effects of dust, moisture, oil and exhaust fumes. This
Characters. panel uses a sealed membrane to provide long reliable
Communications connections include: service life in harsh environments.
- PC tool interface - This RS-485 communication port The control system is specifically designed and tested
allows the HMI to communicate with a personal for resistance to RFI/EMI and to resist effects of
computer running InPower. vibration to provide a long reliable life when mounted
- This RS-485 communication port allows the HMI to on a generator set. The control includes transient
communicate with the main control board. voltage surge suppression to provide compliance to
referenced standards.
Mechanical drawing
Certifications
PowerCommand meets or exceeds the requirements of
the following codes and standards:
- NFPA 110 for level 1 and 2 systems.
- ISO 8528-4: 1993 compliance, controls and
switchgear.
- CE marking: The control system is suitable for use on
generator sets to be CE-marked.
- EN 50081-1,2 residential/light industrial emissions or
industrial emissions.
- EN 50082-1,2 residential/light industrial or industrial
susceptibility.
- ISO 7637-2, level 2; DC supply surge voltage test.
Software - Mil Std 202C, Method 101 and ASTM B117: Salt fog
InPower (beyond 6.0 version) is a PC-based software test.
service tool that is designed to directly communicate to - PowerCommand control systems and generator sets
PowerCommand generator sets and transfer switches, are designed and manufactured in ISO 9001 certified
to facilitate service and monitoring of these products. facilities.
- UL 508 recognized or Listed and suitable for use on
Environment UL 2200 Listed generator sets.
- CSA C282-M1999 compliance.
The control is designed for proper operation without - CSA 22.2 No. 14 M91 industrial controls.
recalibration in ambient temperatures from -40 ºC
(104 ºF) to +70º C (158 ºF), and for storage from -55 ºC Warranty
(131 ºF) to +80 ºC (176 ºF). Control will operate with
All components and subsystems are covered by an
humidity up to 95%, non-condensing.
express limited one year warranty. Other optional and
extended factory warranties and local distributor
maintenance agreements are available.

See your distributor for more information

Cummins Power Generation
Americas Europe, CIS, Middle East and Africa Asia Pacific
rd
1400 73 Avenue N.E. Manston Park Columbus Ave. 10 Toh Guan Road #07-01
Minneapolis, MN 55432 USA Manston Ramsgate TT International Tradepark
Phone: 763 574 5000 Kent CT 12 5BF United Kingdom Singapore 608838
Fax: 763 574 5298 Phone 44 1843 255000 Phone 65 6417 2388
Fax 44 1843 255902 Fax 65 6417 2399
Warning: Back feed to a utility system can cause electrocution and/or property damage. Do not connect to any building’s electrical system
except through an approved device or after building main switch is open.

Our energy working for you.™

www.cumminspower.com
©2007|Cummins Power Generation Inc.|All rights reserved|Specifications subject to change without notice|Cummins Power
Generation and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower and “Our energy working for you.” are
trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
S-1567b (4/08) Page 6 of 6