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®
PowerCommand Model 200
paralleling equipment
Digital MasterControl

Description Features
®
The PowerCommand Digital MasterControl is a The control offers a wide range of standard control and
microprocessor-based paralleling system component digital display features so custom control configurations
designed to directly interface with Cummins Power can be achieved with minimum custom design work.
Generation PowerCommand paralleling generator sets.
The Digital MasterControl is designed for use in low or Major control features include:
medium voltage isolated bus (not utility paralleled)
• Full function master control for isolated bus paralleling
applications. The control system provides flexibility to
systems. System master control provides for use of the
meet specific application requirements, ease of operator
on-site power system for emergency/standby (isolated
use, advanced functionality and optimum system reliability
bus) operation.
and serviceability. The MasterControl may be either
separately installed at a convenient location or integrated • High resolution color touchscreen with graphical
into the system power sections when required. information displays, comprehensive system and
generator data, strip charting capability, integral
The PowerCommand genset control is a microprocessor-
manuals, and many other features.
based generator set monitoring, metering and control
system. The control provides an operator interface to the • Automatic load adding and shedding (optional). System
genset, digital voltage regulation, digital governing and includes “smart” load sequencing to automatically add
generator set protective functions. The integration of all load and remove load as system capacity changes due
the functions into a single control system provides to generator set availability and changes in system load
enhanced reliability and performance compared to level.
conventional control systems.
• PowerCommand Network provides detailed operational
The PowerCommand control is designed for mounting on data on all components in the system and allows direct
the generator set. operator control of the system.
Control power for PowerCommand and the Digital • Warranty. PowerCommand systems are supported by a
MasterControl is usually derived from the generator set worldwide network of independent distributors who
starting batteries and is backed up by an independent provide parts, service and warranty support.
battery backup system.
• Remote user interface (optional). The control system is
configured to allow use of a remote PC-based operator
panel, running the same software as the master control
panel.

©2008|Cummins Power Generation Inc. |All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch and “Our energy working for you.”
are trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
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Operator panel • Bus condition (energized or de-energized) Clicking on

the bus icon provides access to a bus AC data screen
The operator panel provides the user with a complete
package of easy to view and use information. System control
Touchscreen operator panel
A full color high-resolution 15 inch (diagonal) touchscreen
operator interface panel (HMI) is provided to allow the
operator to monitor and control the on site power system.
All data is configurable for display in either U.S. standard
or metric indications. Screens are configured in a typical
Windows® format with a pop-up menu in the lower left
corner of the screen providing access to various screens.
There is a context sensitive help button on each screen.
Other system control and monitoring functions accessible
through a menu button with pop-up option display.

The system control screen provides the operator with the

ability to enable or disable load demand operation, view
timer values and view the load demand sequence; initiate
test (with or without load); control the shutdown sequence

for
loadthe generator
demand timesets in the
delays; load
set thedemand mode;operation
load demand set the
set points; and display and modify the automatic load add
and shed sequence.

The HMI includes the following screens and/or functions:

One line diagram

The one-line diagram screen displays system status by a

combination
messages, andof animation, changingConditions
pop-up indicators. screen color, texton
visible
the screen include:
• Generator set(s) and bus configuration with generator
set, parallel breaker and bus energized/de-energized
indication (red indicating energized, green indicating de-
energized).
• Generator set designation. Control, data, and
performance summary screens is accessible through System data logging
hot keys (links) located on or adjacent to the genset The master control touchscreen records the date, time
icon. and nature of all alarm and shutdown conditions reported
• Generator set mode (run/off/auto). on the system. This log includes all alarms reported on
• Generator set status (normal/warning/shutdown/load the generator set and all master control and network-

demand
access tostop). A windows-like
all system popup
functions from themenu provides
one-line connected functions.
diagram screen.
• Paralleling breaker status (open/closed/tripped). (Status
and condition of other breakers and devices is optional
when supplied or required by the project.)

Our energy working for you.™

www.cumminspower.com
©2008|Cummins Power Generation Inc. |All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch and “Our energy working for you.”
are trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
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Genset status summary Trending

The genset status summary provides an analog and The Touchscreen provides real time trend charts for any
graphical display of critical generator set operating monitored value in the system, with up to 8 monitored
parameters. The screen includes generator set state points at any time. Historical trend charts using a data log
display (stopped, time delay start, idle speed state, rated function in the control may also be provided (optional).
volts/hertz, synchronizing, load share or load govern); The historical charts are configurable for functions
analog AC metering for generator set (3-phase, AC volts displayed, time frame displayed and allow comparison of
and current, frequency, kW and power factor); and 3-
phase AC bus voltage and frequency. The screen historical data from multiple time periods simultaneously.
provides a complete display of all engine and alternator Alarms
data present in the generator set control. The screen also
Any alarm on any generator set or in the system will cause
shows status of the bus and generator set breaker. Hot
an alarm bar and warning condition display to appear on
buttons are provided for quick access to similar data on
the touchscreen. A click on the bar will cause a pop-up
all machines.
screen display that describes the equipment where the
fault has occurred, and the name of the fault. The screen
allows the operator to attempt to reset the fault from the
HMI.

Service manuals
The HMI includes the ability to display the entire content

of all operating
including and service
generator manuals
sets (engine, for the and
alternator entire system,
control
system), paralleling controls, master controls, and transfer
control equipment.

Service information
The service information pop-up screen includes the name,
address and phone number for the local service point for
the equipment.

Load control
The load control screen provides an analog display of
system load as a percent of available capacity of the
generator sets that is operating in parallel on the bus. The
screen provides an alphanumeric display of this data. It
also displays the name, status and priority of each load
block (whether on or off) and the total load of that block.
The screen allows the operator to manually add and shed
loads in any sequence desired.

Our energy working for you.™

www.cumminspower.com
©2008|Cummins Power Generation Inc. |All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch and “Our energy working for you.”
are trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
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AC metering screens

The touchscreen is configurable to AC data in analog

“needle type” meter displays.

Internal components

System PLC
Paralleling control functions (synchronizing, load sharing,
etc.) are provided by the PowerCommand Generator set
paralleling controls. System control logic such as load
add and shed sequence is performed by a programmable
logic controller (PLC). The PLC is a DIN-rail mounted
device to allow easy servicing of components. Other
features of the PLC include:
• On-line changes. The PLC may be interconnected to a
personal computer and control sequences may be On a warning condition the control system indicates a
modified without shutting down the system. fault by displaying the fault name and code. The nature of
the fault and time of occurrence is logged in the genset
• EEPROM program storage. The PLC program is stored
control (based on engine operating hours) and in the
in non-volatile EEPROM memory with additional battery
master control based on a system real time clock. The
backup of the PLC RAM for storing system
service manual and InPower service tool provide service
configuration settings.
keys and procedures based on the service codes
• LED status indicators. The PLC and input/output (I/O)
provided.
blocks include LED status indicators for use in viewing
system status and diagnosis of failures.
• I/O block surge suppressors. Inputs and outputs to the
Control power system
PLC are connected via integral surge suppressors to Control power for the system is derived from the
provide protection against over voltage damage to the generator set 24 VDC starting batteries. A solid state no
system and provide greater reliability. break "best battery" selector system is provided so that
control voltage is available as long as any battery bank in
Protective functions the system is available. All battery banks are isolated to
prevent the failure of one battery from disabling the entire
Protective functions in the Digital MasterControl are system. A station battery and charger back up the
provided by the PowerCommand generator set controls. generator set control power systems so that the master
These functions include over and under bus voltage, control has multiple redundant control power.
under frequency, over load and phase sequence
protection. Since these functions are resident in the The PowerCommand control (on each generator set in the
genset controls, they are effectively redundant so that system) continually monitors the battery charging system
whenever a generator set is closed to the bus the for low and high DC voltage, and runs a battery load test
protective functions are available. The use of InPower
™
every time the engine is started. Functions and messages
software allows fast, consistent settings for all system on the generator paralleling control include:
protective functions, and they can also be adjusted • Low DC voltage (battery voltage less than 24 VDC,
through the system operator panels. except during engine cranking)
• High DC voltage (battery voltage greater than 32 VDC).

Our energy working for you.™

www.cumminspower.com
©2008|Cummins Power Generation Inc. |All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch and “Our energy working for you.”
are trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
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• Weak Battery (battery voltage less than 14.4 VDC for Loads that are shed due to overload require manual reset
more than 2 seconds during engine cranking). via the HMI.
The master control station battery also includes battery
Load demand mode
and charger failure testing and indication.
When the system is running in the emergency mode with
the "load demand" switch on and the HMI in the "on"
Sequence of operation (typical)
position, controls shall continuously monitor the total load
on the bus. If the total load on the bus falls below preset
Loss of normal power
limits for a period of 15 minutes, the controller will
System is given signal to start by receipt of start signal automatically shut down generator sets in an operator
from the power transfer equipment or other remote predetermined order until the minimum number of
device. On receipt of this signal, all generator sets generators required to operate the load remain on the
automatically and independently start, accelerate to rated bus. The purpose of this function is to allow the generator
frequency and build up to rated voltage. The first start sets to operate closer to their rated capacity, thereby
system monitors this process, and on finding a generator decreasing fuel consumption and reducing wear on the
set at 90% of rated voltage and frequency, automatically system.
disables all other units from closing to the bus and closes
the ready unit to the bus. On sensing that the available bus capacity is being
approached, the standby units will automatically be
After the first unit is closed to the bus, the control of all restarted (in the reverse order of which they were shut
remaining units is switched to the synchronizer in each down) and paralleled with the bus to assume their
generator paralleling control. The synchronizer causes the proportional share of system load. As each load parallels
generator set to synchronize with the system bus and to the bus, load ramps to load share level.
then close it at the proper time. As each unit closes to the
The system automatically compensates for generator sets
bus, the unit assumes it's proportional share of the total of different sizes.
load on the bus, and the control system automatically
adds loads to the generator bus by closing feeder
breakers. Return of normal power
When all of the system start signals are removed from the
The load control system monitors the total capacity of the
generator sets, the system will begin a retransfer process.
bus and the load demand for each load step, and
automatically manages load adding and shedding based All automatic transfer equipment (if used) will disconnect
on priority and genset capacity available to serve the load. from the generator bus, and then reconnect to the utility
source. When all loads have been transferred back to the
Failure of a unit to start or synchronize utility, the generator set paralleling breakers shall all open,
and the generator sets shall operate at no load for a
If a genset fails to start, after the fail to start time delay (in
cooldown period. When the cooldown period has been
the generator set control) has expired, the unit will be shut
completed, the generator sets shall shut down.
down and an alarm will sound. The priority control system
manages loads in the system to maintain service in priority If a system start signal is received during the cooldown
order to loads based on available generator set capacity. period, one generator set will immediately close to the
The priority override controls on the HMI may be used by system bus and all other units will synchronize to it, as
an operator to manually add low priority loads to the bus, described in “Loss of normal power” above.
if he determines that generator capacity is available to
serve the loads. Bus overload monitoring protects the Generator set exercise (test) without load
first priority loads in the event that the bus is inadvertently The system allows testing of the generator sets at no load.
overloaded due to operator error. In this operation mode the generator sets will start, build
If a unit fails to synchronize, after a preset time delay, an up to rated speed and voltage, synchronize and close to
alarm will sound, but the unit will continue to attempt to the generator bus, but system loads will not automatically
synchronize until signaled to stop by manual operation of transfer to the generator system.
the control switches on the generator set.
Exercise (test) with load mode

Bus overload The system will allow the generator sets to be tested by
transfer of the system loads to the generator sets.
If a bus overload occurs for any reason, a load shed signal
will be generated to initiate load shedding in the system. Sequence of operation in this mode shall be similar to that
If the bus does not return to proper frequency within a described for a power failure condition.
predetermined period of time (adjustable via the HMI),
additional load shed signals will be generated until the
generator set bus returns to normal frequency.

Our energy working for you.™

www.cumminspower.com
©2008|Cummins Power Generation Inc. |All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch and “Our energy working for you.”
are trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
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Control interface • Mil Std 461: Electromagnetic Emission and

Susceptibility Requirements
All control interconnections in the MasterControl are
• NFPA 70: U.S. National Electrical Code.
provided on standardized terminal block assemblies.
PowerCommand controls are suitable for use in
Interconnections to external equipment include:
emergency, critical and standby applications, as defined
• Load add and load shed relays (optional). Each relay in articles 700, 701, and 702.
includes “form C” contacts (a normally open and a • NFPA99: Standard for Health Care Facilities
normally closed contact with common return) rated 10 A • NFPA110 for level 1 systems.
@ 600 VAC. • UL508 Listed, Category NIWT7 for U.S. and Canada.
• Paralleling breaker control relays (optional). Relays is • PowerCommand control systems and generator sets
directly driven by the PowerCommand generator set are designed and manufactured in ISO9001 certified
control and mounted in the master control for facilities.
interconnection convenience.
• Bus voltage connection. Control includes fused 3- Environment
phase 4-wire connections up to 600 VAC. It provides a
bus voltage reference signal to the PowerCommand The control is designed for proper operation without
generator set control, if desired. recalibration in ambient temperatures from 0 C to +46 C
° °

• System remote start command. Provided to allow for (32 °F to 115 °F) and for storage from -20 C to +70 C
° °

remote (with load) system test. (-4 °F to 158 °F). Control will operate with humidity up to
95%, non-condensing, and at altitudes up to 10,000 feet
(5000 meters).
Construction
The control system is housed in a rigid, freestanding, Network
NEMA1/IP40, metal enclosed structure designed to
require front access only. Framework is constructed of The MasterControl includes network communications over
minimum 2.5 mm (12 ga) steel sheet metal. The a Cummins Power Generation PowerCommand Network.
® ®
framework, and all other sheet metal components of the The network utilizes the widely used Echelon Lonworks
system, is primed with a rust-inhibiting primer and finished technology as a basis. The network is suitable for local or
with satin finish ANSI 61 gray enamel. (optional) remote control and monitoring functions.

Control components are totally isolated from power-

carrying components by metal or insulating barriers. All
Options and accessories
components and surfaces operating at more than 50 volts  Load add relays (4 levels) .
are shielded to prevent inadvertent contact.  Load add relays (8 levels).
All control wiring is 105° C (221 °F), 600 volt rated and  Load shed relays (4 levels).
sized as required for safe, reliable operation. Each wire,  Load shed relays (8 levels).
device and functional component is identified by
 Breaker control relays
silk-screen or similar permanent identification.
Fuses are installed in DIN-rail mounted safety-type fuse Warranty
holders with integral “fuse blown” indicating lamps.
PowerCommand systems are part of a complete power
Terminal blocks are provided for all field connections on system provided by Cummins Power Generation and are
DIN-rail mounted devices. covered by a one-year limited warranty as a standard
feature.
Certifications Extended warranty options are available for coverage up
PowerCommand meets or exceeds the requirements of to 10 years. Contact your Cummins Power Generation
the following codes and standards: distributor for more information.
• CSA C282-M1999 Compliance
• CSA 22.2 No. 14 M91 Industrial Controls.
• IEC 801.2: Electrostatic Discharge Test
• IEC 801.3: Radiated Susceptibility
• IEC 801.4: Electrically Fast Transient
• IEC 801.5: Radiated Emissions
• IEEE 587: Surge Immunity
• ISO 8528-4: 1993 Compliance, Control Systems for
Reciprocating Engine-driven Generator Sets

Our energy working for you.™

www.cumminspower.com
©2008|Cummins Power Generation Inc. |All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch and “Our energy working for you.”
are trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
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See your distributor for more information

Cummins Power Generation

1400 73rd Avenue N.E.
Minneapolis, MN 55432
763.574.5000
Fax: 763.574.5298

Cummins Power Generation is a subsidiary of Cummins Inc.

PowerCommand is a registered trademark of Cummins Inc.
AmpSentry is a trademark of Cummins Inc.
Windows is a registered trademark of Microsoft.
LONWORKS AND LONMARK are registered trademarks of Echelon

Warning: Backfeed 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
©2008|Cummins Power Generation Inc. |All rights reserved|Specifications subject to change without notice|Cummins Power Generation
and Cummins are registered trademarks of Cummins Inc. PowerCommand, InPower, AmpSentry, iWatch and “Our energy working for you.”
are trademarks of Cummins Power Generation. Other company, product, or service names may be trademarks or service marks of others.
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