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English – Original Instructions 11-2009 0908-0104 (Issue 4)
Operator Manual
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Generator Set Control System Publication
0908-0104PowerCommand™Control 3201 Issue 4 – 11-2009
FOREWORD
The purpose of this manual is to provide the users with sound,
general information. It is for guidance andassistance with
recommendations for correct and safe procedures. Cummins Power
Generation Limitedcannot accept any liability whatsoever for problems arising as a
result of following recommendations in thismanual.The information contained within the manual is based on
information available at the time of going to print. Inline with
Cummins Power Generation Limited policy of continuous development
and improvement,information may change at any time without notice.
The users should therefore ensure that beforecommencing any work,
they have the latest information available.Users are respectfully advised that it is their responsibility
to employ competent persons to carry out anyinstallation work in
the interests of good practice and safety. Consult your Authorised
Distributor for furtherinstallation information. It is essential
that the utmost care is taken with the application, installation
andoperation of any diesel engine due to their potentially
dangerous nature. Careful reference should also bemade to other
Cummins Power Generation Limited literature, in particular the
Health and Safety Manual(0908-0110-00) and the Engine Manual.Should you require further assistance contact: —
Cummins Power Generation1400 73
rd Avenue NE
MinneapolisMN 55432USA
Tel:+1 (763) 574-5000
Fax:+1 (763) 574-5298
e-mail:[email protected]
Cummins Power GenerationColumbus AvenueManston
ParkManstonRamsgateKent CT12 5BFUnited KingdomTel:+44 (0) 1843 255000
Fax:+44 (0) 1843 255902
e-mail:[email protected]
Cummins Power Generation10 Toh Guan Road #07-01TT International
TradeparkSingapore 608838Tel: (65) 6417 2388
Fax:(65) 6417 2399
e-mail: [email protected]
Web: www.cumminspower.com
Web: www.cumminspower.com
Web: www.cumminspower.comCummins Power Generation35A/1/2, ErandawanaPune 411 038India
Tel.: (91 020) 3024 8600Fax: (91 020) 6602 8090
e-mail:[email protected]
Cummins Power GenerationRua Jati, 310 — CumbicaGuarulhos
–SPBrazilCEP: 07180-900Tel.: (55 11) 2186 4195Fax: (55 11) 2186 4729
e-mail: [email protected]
Web: www.cumminspower.com
Web: www.cumminspower.commailto:[email protected]:[email protected]:[email protected]://www.cumminspower.com/http://www.cumminspower.com/http://www.cumminspower.com/http://www.cumminspower.com/http://www.cumminspower.com/mailto:[email protected]:[email protected]://www.cumminspower.com/http://www.cumminspower.com/http://www.cumminspower.com/http://www.cumminspower.com/http://www.cumminspower.com/mailto:[email protected]:[email protected]://www.cumminspower.com/http://www.cumminspower.com/http://www.cumminspower.com/mailto:cpg.apmktg@cummins.commailto:[email protected]:[email protected]
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Contents Page i
CONTENTS
Section Title Page
Schedule of Abbreviations
……………………………………………………………………………………………………………….i1 Safety 1-1 1.1 Warning, Caution and Note
Styles Used In This
Manual……………………………………………………
1-1 1.2
Warnings…………………………………………………………………………………………………………………….
1-1 1.3 General Information
……………………………………………………………………………………………………..
1-1 1.4 Generator Plant Safety
Code…………………………………………………………………………………………
1-12
Introduction……………………………………………………………………………………………………………………..2-1 2.1
General 2-1 2.2 Generating Set
Identification………………………………………………………………………………………….
2-1 2.3 After Sales
Services……………………………………………………………………………………………………..
2-2 2.3.1 Maintenance
………………………………………………………………………………………………………….
2-2 2.3.2Warranty
……………………………………………………………………………………………………………….
2-22.3.3 Spares
………………………………………………………………………………………………………………….
2-2 2.3.4 Overseas
………………………………………………………………………………………………………………
2-2 2.3.5 Additional
Literature………………………………………………………………………………………………..
2-23 System
Overview……………………………………………………………………………………………………………..
3-1 3.1 Generator Components – Typical Generator Set
……………………………………………………………..
3-1 3.1.1 AC Supply and Isolation
………………………………………………………………………………………….
3-2 3.1.2 Control
System………………………………………………………………………………………………………
3-2 3.1.3
Engine…………………………………………………………………………………………………………………..3-2 3.1.4
Alternator
………………………………………………………………………………………………………………
3-2 3.1.5 Generator Rating
……………………………………………………………………………………………………
3-2 3.1.6 Generator Set
Construction……………………………………………………………………………………..3-2 3.1.7Fuel
System…………………………………………………………………………………………………………..
3-33.1.8 Cooling
System………………………………………………………………………………………………………
3-3 3.1.9 Engine Exhaust (Option)
…………………………………………………………………………………………
3-3 3.1.10 DC Electrical
System………………………………………………………………………………………………
3-3 3.1.11 Alarm Module
(Option)…………………………………………………………………………………………….
3-4 3.1.12 Sensors/Senders
……………………………………………………………………………………………………
3-4 3.2 Heaters 3-5 3.2.1 Heater Supply
and Isolation
…………………………………………………………………………………….
3-5 3.2.2 Engine Heater
(Option)……………………………………………………………………………………………
3-5 3.2.3 Alternator Heater (Option)
……………………………………………………………………………………….
3-5 3.2.4 Control Panel Heater
(Option)………………………………………………………………………………….
3-5 3.3 Mains Powered Battery Charger
(Option)………………………………………………………………………..
3-63.3.1
Operation………………………………………………………………………………………………………………
3-63.3.2
Boost Charge
(Option)…………………………………………………………………………………………….
3-64 Control
System………………………………………………………………………………………………………………..
4-1 4.1 Control System
Description……………………………………………………………………………………………
4-1 4.1.1 Control Panel Power ON/OFF Modes
……………………………………………………………………….4-2 4.1.2
Control Panel — Front Panel
……………………………………………………………………………………..
4-3 4.1.3 Control Panel — Operator Panel
………………………………………………………………………………..
4-4 4.1.4 Control Panel — Switch
Panel……………………………………………………………………………………
4-4 4.2 Menu Display and
Switches…………………………………………………………………………………………..
4-6 4.2.1 Graphical
Display……………………………………………………………………………………………………
4-6 4.2.2 Menu
Buttons…………………………………………………………………………………………………………
4-6 4.3 Menu Units Selection
……………………………………………………………………………………………………
4-74.3.1
Local/Remote
Field…………………………………………………………………………………………………
4-74.4
Main
Menu…………………………………………………………………………………………………………………..
4-84.4.1 Adjust Button
…………………………………………………………………………………………………………
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4.4.2 Set-up Button
…………………………………………………………………………………………………………4-8 4.4.3
_\_ Button (Paralleling applications
only)……………………………………………………………………4-9 4.4.4
Power Trans Button (PTC applications
only)………………………………………………………………4-9 4.5
Engine Data Submenus
………………………………………………………………………………………………4-10 4.6
Alternator Data
Submenus…………………………………………………………………………………………..4-11 4.6.1
Voltage L–L and
L–N…………………………………………………………………………………………….4-11 4.6.2Amps…………………………………………………………………………………………………………………..4-11
4.6.3 Frequency
……………………………………………………………………………………………………………4-11 4.6.4
AVR Duty Cycle
……………………………………………………………………………………………………4-11 4.6.5
kW, kVA and
PF……………………………………………………………………………………………………4-11 4.7
Control Submenu
……………………………………………………………………………………………………….4-12 4.7.1
Local Control Submenu Function
……………………………………………………………………………4-12 4.7.2
Remote Control Submenu
Functions……………………………………………………………………….4-13 4.7.3
Local/Remote Control Submenu
Function………………………………………………………………..
4-13 4.8 History/About
Submenus……………………………………………………………………………………………..
4-14 4.8.1
History…………………………………………………………………………………………………………………4-14 4.8.2
About…………………………………………………………………………………………………………………..4-14 4.8.3
Fault
History…………………………………………………………………………………………………………
4-144.9
Adjust
Sub-menu………………………………………………………………………………………………………..4-164.10
Parallel Data Submenu
……………………………………………………………………………………………….4-174.10.1 Parallel Data Status Line
……………………………………………………………………………………….4-17 4.11
Password
Menu………………………………………………………………………………………………………….4-18 4.12
Power Transfer Main
Menu………………………………………………………………………………………….4-19 4.12.1
PTC Status
Line……………………………………………………………………………………………………4-20 4.12.2
Utility (PWR TRAN) Submenus
………………………………………………………………………………4-21 4.12.3
Status (PWR TRAN)
Submenus……………………………………………………………………………..
4-22 4.12.4 Transfer Control (PWR TRAN)
Submenu…………………………………………………………………
4-23 4.12.5 Generator Set (PWR TRAN) Submenus
………………………………………………………………….4-245 Operation 5-1 5.1 Safety 5-1
5.2
Introduction………………………………………………………………………………………………………………….5-1
5.3
Maintenance………………………………………………………………………………………………………………..5-1
5.4 Operating
Recommendations…………………………………………………………………………………………5-2 5.4.1
Running-in……………………………………………………………………………………………………………..5-2 5.4.2
No Load
Operation………………………………………………………………………………………………….5-2 5.4.3
Exercise
Period………………………………………………………………………………………………………
5-2 5.4.4 Low Operating
Temperatures…………………………………………………………………………………..5-2 5.4.5
High Operating Temperatures
………………………………………………………………………………….
5-2 5.4.6 Operating Conditions for Prime, Standby and
Continuous Power Ratings.
…………………….5-3 5.4.7 De-Rating
Factors…………………………………………………………………………………………………..
5-4 5.5 Generator Set Operation
……………………………………………………………………………………………….5-5 5.5.1
Sequence of
Operation……………………………………………………………………………………………5-5 5.6
Starting 5-55.6.1
Pre-start
Checks…………………………………………………………………………………………………….5-6 5.6.2
Starting at Switch Panel (Manual Mode)
……………………………………………………………………
5-85.6.3 Starting at Remote Operator Panel (Auto Mode)
………………………………………………………5-10 5.6.4
Starting from Remote Location (Switch or Device) (Auto
Mode)…………………………………. 5-10 5.6.5
Exercise
Start……………………………………………………………………………………………………….5-11 5.6.6
Cold Starting with
Loads………………………………………………………………………………………..5-11 5.7
Running at Idle (Manual)
……………………………………………………………………………………………..5-12 5.8
Stopping
……………………………………………………………………………………………………………………5-13 5.8.1
Emergency Stop (Code 1434)
………………………………………………………………………………..
5-13 5.8.2 Stopping at Switch Panel (Manual
Mode)…………………………………………………………………5-13 5.8.3
Stopping at Remote Operator Panel (Auto
Mode)……………………………………………………..
5-13 5.8.4 Stopping from Remote Location (Switch or
Device) (Auto
Mode)………………………………..5-14 5.9
Optional Power Transfer Control (PTC)
Operation………………………………………………………….5-155.9.1
PCC3201/PTC – Normal Operation Sequences
……………………………………………………….5-15 5.9.2
Test Switch
………………………………………………………………………………………………………….5-15 -
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6
Maintenance…………………………………………………………………………………………………………………….
6-1 6.1 Locking the Generator Set Out of Service
……………………………………………………………………….6-2 6.1.1
Introduction……………………………………………………………………………………………………………
6-2 6.1.2 Immobilising the Generator Set for Safe
Working……………………………………………………….
6-3 6.2 General
………………………………………………………………………………………………………………………
6-3 6.3 Daily or Refuelling Maintenance
Procedures……………………………………………………………………
6-6 6.3.1General
Information………………………………………………………………………………………………..
6-66.3.2 Engine Operation
Report…………………………………………………………………………………………
6-6 6.4 Cooling
System……………………………………………………………………………………………………………
6-6 6.4.1 Coolant Level — Check
…………………………………………………………………………………………….
6-7 6.4.2 Cooling Fan —
Inspect………………………………………………………………………………………………
6-8 6.4.3 Drive Belt — Inspect
…………………………………………………………………………………………………
6-8 6.4.4 Radiator —
Check…………………………………………………………………………………………………….
6-8 6.5 Engine
Oil……………………………………………………………………………………………………………………
6-9 6.5.1 Engine Oil Level – Check
………………………………………………………………………………………..
6-9 6.6 Fuel System
………………………………………………………………………………………………………………
6-10 6.6.1 Fuel Level
……………………………………………………………………………………………………………
6-10 6.6.2 Fuel/Water Separator — Drain
…………………………………………………………………………………
6-106.7
Fluid Containment
………………………………………………………………………………………………………
6-116.8
Hoses and Fuel Lines —
Check……………………………………………………………………………………..
6-116.9 Exhaust
System…………………………………………………………………………………………………………
6-12 6.10 Generator Set Output — AC Electric
System……………………………………………………………………
6-12 6.11 DC Electrical System
………………………………………………………………………………………………….
6-127 Troubleshooting
………………………………………………………………………………………………………………
7-1 7.1
Introduction………………………………………………………………………………………………………………….
7-1 7.2 Control Unit DC Power
Supply……………………………………………………………………………………….
7-1 7.3 Safety
Considerations…………………………………………………………………………………………………..
7-2 7.4 Fault
Finding………………………………………………………………………………………………………………..
7-3 7.5 Status Indicators
………………………………………………………………………………………………………….
7-3 7.5.1 Not In Auto Indicator
……………………………………………………………………………………………….
7-37.5.2
Shutdown Status
Indicator……………………………………………………………………………………….
7-37.5.3
Warning Status Indicator
…………………………………………………………………………………………
7-37.6 Reading Fault Codes
……………………………………………………………………………………………………
7-4 7.6.1 Reading Fault Codes Using Graphical Display
(Optional) ……………………………………………
7-4 7.6.2 Reading Fault Codes Using Warning/Shutdown
Indicators ………………………………………….
7-4 7.7 Line Circuit Breaker
(Optional)……………………………………………………………………………………….
7-6 7.8 Control and Diagnostics Via Network or PC
(Laptop)………………………………………………………..
7-6 7.9 Fault Codes
…………………………………………………………………………………………………………………
7-6 7.9.1 Category A Fault Codes
………………………………………………………………………………………….
7-6 7.9.2 Category B Fault Codes
………………………………………………………………………………………….
7-6 7.9.3 Category C Fault
Codes………………………………………………………………………………………….
7-6 7.9.4 Category D Fault
Codes………………………………………………………………………………………….
7-6 7.9.5 Category E Fault Codes
………………………………………………………………………………………….
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CONTENTS (continued)
Illustrations
Figure Title Page
Figure 2-1 Typical Generator Set Rating
Plate…………………………………………………………………….
2-1 Figure 3-1 Typical Generator Set (C450 to
C550)………………………………………………………………..
3-1 Figure 3-2 Alarm Module Front
Panel…………………………………………………………………………………3-4 Figure
4-1 Control Panel Assembly (Full Featured)
……………………………………………………………..
4-3 Figure 4-2 Graphical Display and Menu Selection
Buttons……………………………………………………
4-6 Figure 4-3 Units
Submenu………………………………………………………………………………………………..4-7 Figure
4-4 System Control Main Menus A and B
…………………………………………………………………
4-8 Figure 4-5 Engine Data Sub-menus
…………………………………………………………………………………4-10 Figure
4-6 Alternator Data
Sub-menus……………………………………………………………………………..4-11 Figure
4-7 Local Control
Sub-menu………………………………………………………………………………….
4-12Figure 4-8
Control
Sub-menu………………………………………………………………………………………….4-13 Figure
4-9 History/About Sub-menus
……………………………………………………………………………….4-15Figure 4-10 Adjust
Sub-menu……………………………………………………………………………………………4-16 Figure
4-11 Bus Data
Sub-menu……………………………………………………………………………………….4-17 Figure
4-12 Password
Menu……………………………………………………………………………………………..4-18 Figure
4-13 Power Transfer Main
Menu……………………………………………………………………………..4-19 Figure
4-14 Utility
Sub-menu…………………………………………………………………………………………….4-21 Figure
4-15 Status (PWR TRANS)
Submenus…………………………………………………………………….
4-22 Figure 4-16 Transfer Control Submenus
…………………………………………………………………………….4-23 Figure
4-17 Genset
Submenus………………………………………………………………………………………….4-24 Figure
5-1 Normal Start/Run/Stop
Sequences…………………………………………………………………….
5-9 Figure 7-1 Front Control Panel (Full-Featured)
……………………………………………………………………
7-5Tables
Table No. Title Page
Table 5-1 Manual
Run…………………………………………………………………………………………………..
5-16 Table 5-2 Utility Power
Fail…………………………………………………………………………………………….
5-17 Table 5-3 Exercise with load
………………………………………………………………………………………….
5-18 Table 7-1 Warning and Shutdown Fault Codes
………………………………………………………………….
7-7 Table 7-2 Troubleshooting Procedures for Fault Codes
……………………………………………………
7-10Supplementary Publications
The Supplementary Publications appropriate to your system will
also be supplied with the system. Whereappropriate the
corresponding Instruction Manual(s) will also be supplied with any
accessory that you order.Title Publication No
Lead Acid Battery
………………………………………………………………………………………………………..0908-0101-00Battery
Charger
………………………………………………………………………………………………………..0908-0102-00Radiator
Information
……………………………………………………………………………………………………….0908-0107-00Health
and Safety (Diesel Generator
sets)…………………………………………………………………………0908-0110-00 -
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Schedule of Abbreviations Page i
Schedule of Abbreviations AC Alternating Current MCB
Miniature Circuit BreakerACB Air Circuit Breaker MCCB Moulded Case Circuit
BreakerACH Anti-Condensation Heaters MF Mains Failed ATS
Automatic Transfer Switch MFSS Master First Start SensorAVR Automatic Voltage Regulator MR Mains Returned
MST Mains Sensing Transformer
BHP Brake Horsepower MSU Mains Sensing Unit
BMS Building Management System MV Medium Voltage
BST Busbar Sensing Transformer
NEC Neutral Earthing Contact
CB Circuit Breaker
CCA Cold Cranking Amps PCC3201 PowerCommand™
Control System
CHP Combined Heat and Power PF Power Factor
COP Continuous Power Rating PFC Power Factor Controller
CT Current Transformer PLC Programmable Logic
ControllerPMG Permanent Magnet Generator
dB(A) Unit of noise level PRP Prime Power Rating
DC Direct Current PSU Power Supply Unit
DIP Dual In-line Package PT/CT Potential Transformer /Current
TransformerDMC Digital Master Control PTC Power Transfer Control
DMSU Demand Load Standby Unit
EMCU Engine Monitoring and Control Unit QCC Quadrature Current
ControlEMF Electromotive ForceEPU Engine Protection Unit RFI Radio
Frequency InterferenceRMS Root Mean Square
FSS First Start Sensor RPM Revolutions Per Minute
RTD Resistance Temperature Detector
GCP Generator Control Panel
Genset Generator Set V Volts
GKWT Global Kilowatt Transducer VAC Volts, Alternating
CurrentVCB Vacuum Circuit Breaker
HV High Voltage VDC Volts, Direct Current
VF Volt-freeIC Integrated Circuit VT Voltage Transformer
I/O Input / Output
kVA Apparent Power
kVAR Reactive Power
kW Active / Real Power
kWh Unit of electrical energy or work
LED Light-Emitting Diode
LTA Low Temperature Aftercooling
LTP Limited Time Power RatingLV Low Voltage
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Section 1 – Preliminary and Safety Page 1-1
SECTION 1 – PRELIMINARY AND SAFETY
1 Safety
1.1 Warning, Caution and Note Styles Used In This ManualThe
following safety styles found throughout this manual indicate
potentially hazardous conditionsto the operator, service personnel
or the equipment.WARNING: WARNS OF A HAZARD THAT MAY RESULT IN SEVERE
PERSONALINJURY OR DEATH.Caution: Warns of a hazard or an unsafe practice that can result
in product or propertydamage.Note: A short piece of text giving information that
augments the current text.1.2 Warnings
WARNING: IT IS IMPORTANT TO READ AND UNDERSTAND ALL SAFETY
NOTICESPROVIDED IN THIS MANUAL. IMPROPER OPERATION OR
MAINTENANCECOULD RESULT IN A SERIOUS ACCIDENT OR DAMAGE TO
THEEQUIPMENT, CAUSING INJURY OR DEATH.1.3 General Information
This manual should form part of the documentation package
supplied by Cummins PowerGeneration Limited with specific generator
sets. In the event that this manual has been supplied inisolation please refer to the other Cummins Power Generation
Limited literature, in particular theHealth and Safety Manual
(0908-0110-00) and the engine manual relevant to your generator
set.Note: It is in the user’s interest to read and understand all
Health and Safety informationtogether with all Warnings and
Cautions contained within the documentation relevant tothe
generator set and its operation and maintenance.1.4 Generator Plant Safety Code
Before operating the generator set, read this manual and become
familiar with it and theequipment. Safe and efficient operation can
be achieved only if the equipment is properly operatedand
maintained. Many accidents are caused by failure to follow
fundamental rules andprecautions.WARNING: LIFTING AND REPOSITIONING ON THE GENERATOR SET MUST
ONLY BECARRIED OUT USING SUITABLE LIFTING EQUIPMENT, SHACKLES
ANDSPREADER BARS IN ACCORDANCE WITH LOCAL GUIDELINES ANDLEGISLATION
BY SUITABLY TRAINED AND EXPERIENCED PERSONNEL.INCORRECT LIFTING CAN
RESULT IN SEVERE PERSONAL INJURY,DEATH AND/OR EQUIPMENT DAMAGE. FOR
MORE INFORMATIONCONTACT YOUR AUTHORISED DISTRIBUTOR. -
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Section 2 – Introduction Page 2-1
SECTION 2 — INTRODUCTION
2 Introduction
2.1 GeneralBefore any attempt is made to operate the generator
set, the user should take time to read thismanual and to
familiarise him or herself with the Warnings and Operating
Procedures.A generator set must be operated and maintained properly
if you are to expect safe and reliableoperation. The manual
includes a maintenance schedule and a troubleshooting guide.The engine manual is included with the set. Where there is
conflicting information, this manualtakes precedence over the
engine manual.2.2 Generating Set Identification
Each generating set is provided with a Generating Set Rating
Plate similar to that shown below.This provides information unique
to the set.Figure 2-1 Typical Generator Set Rating Plate
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2.3 After Sales Services
We offer a full range of after sales services as follows:
2.3.1 Maintenance
WARNING: INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT
INSEVERE PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE.SERVICE
PERSONNEL MUST BE TRAINED AND EXPERIENCED TOPERFORM ELECTRICAL
AND/OR MECHANICAL SERVICE.For customers who wish to have their generator sets expertly
serviced at regular intervals theCustomer Service Department offers
a complete maintenance contract package. This covers allitems
subject to routine maintenance and includes a detailed report on
the condition of thegenerator set. In addition, this can be linked
to a 24-hour call-out arrangement, providingassistance 365 days a
year if necessary. Specialist engineers are available to maintain
optimumperformance levels from customer’s generator sets, and it is
recommended that maintenancetasks are only undertaken by trained and experienced engineers
provided by the CustomerService Department2.3.2 Warranty
All generator sets have a twelve months warranty from the
commissioning date as standard.Extended warranty coverage is also
available. In the event of a breakdown prompt assistance
cannormally be given by factory trained service engineers with
facilities to undertake all minor andmany major repairs to
equipment on site.For further warranty details contact your authorised
distributor.2.3.3 Spares
An extensive Spare Parts Department is available for any
emergency breakdown and for theengineer who carries out his own
routine maintenance. Please contact your authorised
CumminsDistributor.Please quote Plant Nos., Serial Nos., and Part Nos. when
ordering spares.2.3.4 Overseas
Agents and representatives in almost 100 countries
throughout the world offer installation and aftersales service for
the equipment provided. Your authorised distributor can provide the
name andaddress of the agent for your specific location.2.3.5 Additional LiteratureShould you require further, more
detailed information regarding the engine or alternator
pleasecontact your authorised distributor.Please quote Plant Nos. and Serial Nos.
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Section 3 – System Overview Page 3-1
SECTION 3 – SYSTEM OVERVIEW
3 System Overview
3.1 Generator Components – Typical Generator SetThe main
components of a Typical Generator Set are shown below and referred
to within thissection. Refer to the Engine Manual for location of
other components, e.g. oil filler, dipstick, etc.Data sheets are also available if additional, specific
information is required. Contact yourauthorised distributor.Various options are listed although they may not be available
for all models.Figure 3-1 Typical Generator Set (C450 to C550)
KEY OPTIONS
1. Alternator Batteries and Tray
2. Control Housing Circuit Breaker Entrance Box
3. Control Panel Electric Fuel Transfer Pump
4. Air Cleaner Engine Coolant Heater
5. Engine Sump Drain Pump
6. Radiator
7. Bed Frame
1
2
3
45
6
7
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3.1.1 AC Supply and Isolation
It is the sole responsibility of the customer to provide the AC
power supply and the means toisolate the AC input to the terminal
box. Refer to the wiring diagram supplied with the
generatorset.Note: A separate disconnecting device is required by BS EN
12601:2001.WARNING: THE DISCONNECTING DEVICE IS NOT PROVIDED AS PART OF
THEGENERATOR SET AND CUMMINS POWER GENERATION LIMITEDACCEPTS NO
RESPONSIBILITY FOR PROVIDING THE MEANS OFISOLATION.3.1.2 Control System
The control system is a micro-processor based control unit for
monitoring and protecting thegenerator set (see Section 4) and can
provide automatic paralleling. All indicators,
controlswitches/buttons and the digital display are on the face of
the control panel as illustrated inFigure 4-1.The control system provides fuel control and engine speed
governing, main alternator voltageoutput regulation, and complete
generator set control and monitoring. The control also monitorsthe
health of the engine, alternator and auxiliary systems
continuously, via an array of sensors andsenders located on the
generator set, and will affect an Automatic Shutdown if a serious
faultoccurs.3.1.3 Engine
All generator sets employ a 4-stroke, water-cooled engine
and incorporate a governor control andfull engine protection
system. Refer to the Generating Set Rating Plate for engine type
and ratingdetails.For further information refer to the engine manual supplied with
this manual.3.1.4 Alternator
All generator sets use AC alternators of a brushless,
rotating field design, which eliminates themaintenance associated
with slip rings and brushes. Refer to the Generating Set Rating
Plate foralternator type and rating details.3.1.5 Generator Rating
For details of your generator rating refer to the Generating Set
Rating Plate.3.1.6 Generator Set ConstructionMost generator sets are
constructed as a single module with the engine and alternator
connectedthrough a coupling chamber with resilient mountings to
form one unit. The engine and alternatorare mounted on a bedframe
on resilient mounts. This results in one unit of immense
strength andrigidity, with accurate alignment between the engine
and alternator, and effective damping ofengine vibration. -
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3.1.7 Fuel System
A fuel tank incorporated into the base frame can be
provided. Alternately free standing main tankswith stands providing
450, 900 and 1350 litre capacity are available as options.Note: Where spillage containment is not part of Cummins supply,
it is the responsibility of theinstaller to provide the necessary
containment to prevent contamination of theenvironment, especially
water courses/sources.3.1.7.1 Fuel Transfer Pumps (Option)
Free standing fuel tanks can be filled manually using an
optional hand fuel transfer pump.Alternatively, fuel tanks can be filled automatically
using an electrical fuel transfer pump. Thispump, which is supplied
complete with starter, operates under the control of Low and High
FuelLevel switches fitted to the tank.On automatically filled systems, the tank filler cap is replaced
with an overflow/breather connectionto allow piping to a safe area
or return to a bulk tank.3.1.7.2 Fuel / Water SeparatorsSet-mounted fuel/water separators
are fitted as standard to provide protection for the engine
fuelinjection system as water-free fuel supplies cannot be
guaranteed.3.1.8 Cooling System
The engine cooling system consists of a radiator and pusher fan,
mechanically driven water pumpand a thermostat. The fan drives air
through the radiator and removes surface heat from theengine and
alternator.The alternator has its own internal cooling fan.
3.1.9 Engine Exhaust (Option)WARNING: EXHAUST PIPES AND CHARGE
AIR PIPES ARE VERY HOT AND THEYCAN CAUSE SEVERE PERSONAL INJURY OR DEATH FROM DIRECTCONTACT OR
FROM FIRE HAZARD.Exhaust systems, which are optional and supplied in loose form,
reduce engine noise toacceptable levels and pipe exhaust gases to
an area where they will not present a hazard.Industrial and
residential types are available as options. Flexible bellows are
also available as anoption.3.1.10 DC Electrical System
A 24 volt battery system provides multi-attempt engine
starting and DC power for the generator setcontrol system.3.1.10.1 Battery System
Battery type, size and voltage are selected to suit the
generator set capacity and application onordering.3.1.10.2 Charge Alternator
An engine driven charge alternator is provided as standard
to maintain the battery in a chargedcondition when the engine is
running.3.1.10.3 Mains Powered Battery Charger (Option)
Optional single phase, mains powered battery chargers, which can
be panel or wall mounted, areavailable to maintain the battery in a
charged condition when the generator set is not running. -
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Red Lens
Amber Lens
Green Lens
Horn
Toggle Switch
3.1.11 Alarm Module (Option)
The front panel comprises a warning horn, three indicator
lights, and one toggle-switch, and hasthe ability to provide
warnings audibly and/or visually.Figure 3-2 Alarm Module Front Panel
The toggle-switch provides the user with the ability to enable
or silence the horn. The green or theamber LED will illuminate to
indicate the active mode of the toggle-switch, whilst the red LED
willilluminate if the alarm has been activated.
The three indicator lights provide the following
information:LED Label Text English
Red Alarm Actuated Alarm Actuated
Green Enabled Enabled
Amber Silenced Silenced
3.1.12 Sensors/Senders
Various generator set parameters are measured by sensors,
senders, RTDs etc. and the resultingsignals are received by the
control.Engine mounted sensors are able to monitor the following
systems:• Cooling system
• Fuel
• Lube oil
• Miscellaneous areas
Optional alternator mounted sensors are able to monitor the
following parameter:• Winding temps
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3.2 Heaters
Caution: Heater(s) must not be energised if the coolant system
has been drained.3.2.1 Heater Supply and Isolation
A heater supply is required for the operation of the
engine and alternator heaters. See Section3.1.1.A separate disconnecting device is required by BS EN
12601:2001.Note: This disconnecting device is not provided as part of the
generator set.Note: It is the sole responsibility of the customer to provide
the power supply and the meansto isolate the AC input to the
terminal box. Cummins Power Generation Limited acceptsno
responsibility for providing the means of isolation.WARNING: THE AC SUPPLY TO THE TERMINAL BOX MUST BE ISOLATED
BEFOREATTEMPTING TO GAIN ACCESS TO THE TERMINAL BOX.
Caution: Remove AC power to the heater before disconnecting
battery leads. Heater willrun continuously without DC power and can
overheat and damage heater.3.2.2 Engine Heater (Option)
The engine heater is designed to keep the engine coolant warm
when the engine is shut down. Itheats and circulates the coolant
within the engine, reducing start-up time and engine wear causedby
cold starts. The heater is controlled by an associated thermostat,
but is locked out at enginestart.WARNING: ALWAYS ISOLATE THE SUPPLY TO THE ENGINE HEATER /
THERMOSTATBEFORE CARRYING OUT ANY MAINTENANCE ON THE ENGINE.
ALWAYSISOLATE THE GENERATOR SET PRIOR TO ANY MAINTENANCE.Caution: The engine heater is in no way intended to protect the
engine and coolingsystem from freezing in sub zero conditions. If
there is any danger from freezing,then a suitable antifreeze agent
must be added to the cooling system.3.2.3 Alternator Heater (Option)
The alternator heater is designed to keep the alternator free of
condensation when the generatorset is not running. During cool and
humid conditions, condensation can form within the alternator,which
can result in insulation degradation, leading to failure, and a
possible shock hazard. Theheater is locked out at engine start.
WARNING: ALWAYS ISOLATE THE ALTERNATOR HEATER FROM THE AC
SUPPLYBEFORE WORKING ON THE ALTERNATOR OR HEATER.3.2.4 Control Panel Heater (Option)
The control panel heater provides a means of
humidity/temperature control within the control boxinterior. It
protects the components and ensures their effectiveness when the
generator set issubjected to varying ambient air conditions during
extended periods of non-use. The heater islocked out at engine
start.WARNING: ALWAYS ISOLATE THE CONTROL PANEL HEATER FROM THE
ACSUPPLY BEFORE WORKING ON THE CONTROL PANEL OR HEATER. -
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3.3 Mains Powered Battery Charger (Option)
Caution: Isolate the charger before disconnecting the
battery3.3.1 Operation
This unit maintains the battery in a fully charged condition
without over-charging. The unit alsoprovides rapid charging, when
necessary, at a current up to the rated output.The charger’s electronic control circuit allows the charger to
be left in circuit during engine crankingand to operate in parallel
with the charge alternator.The charger will supply current to the battery system when the
battery terminal voltage is equal tothe set float voltage, at which
point only a trickle charge current is present. When the
batterybecomes discharged due to a load being present and the
terminal voltage falls, the charger willagain supply current to
restore the voltage of the battery to the float voltage.Should a charge fail condition occur for longer than ten seconds
then the charge fail relay willenergise, and its contact close. Charger operation is indicated
by a red LED.Note: The LED will light even if the charger output fuse is
blown.3.3.2 Boost Charge (Option)
During trickle charging, not all cells in the battery receive
the same charge and over a period ofseveral months this may affect
battery performance. It is therefore normal to give batteries
aregular charge at their full rate to return all cells to
full capacity. This is referred to as BoostCharging (also known as
equalise charging).If the charger is fitted with a Boost Charge switch, the Boost
position should be selected atintervals detailed by the battery
manufacturer (normally around every six months).Caution: Batteries should not be left on Boost Charge for
extended periods as this willresult in excessive water consumption
and gassing and may impair battery performance. -
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SECTION 4 – CONTROL SYSTEM
4 Control System
4.1 Control System Description
The main control panel consists of two panels, the Operator
Panel and the Switch Panel. Theseand their associated equipment are
located in the Control Housing, which is mounted at the rear ofthe
generator set.Dependent on site requirements the Operator Panel may be mounted
in the control panelassembly (full-featured) as shown in Figure
4-1, or it may be contained in a separate enclosureand mounted
remotely of the control panel assembly. In this latter case, the
panel may be situatedup to 1.2km (4,000ft) away from the generator
set.Note: The function of several buttons on the Operator Panel will
vary dependent on thelocation of the Operator Panel (remote or
local of the Control Panel assembly). If thefunction differs, it is noted as either Remote or Local Operator
Panel in the description.The control system is a micro-processor
based control unit for monitoring and protecting thegenerator set
and can provide automatic paralleling. All indicators, control
switches/buttons andthe digital display are on the face of the
control panel as illustrated in Figure 4-1.The control system provides fuel control and engine speed
governing, main alternator voltageoutput regulation, and complete
generator set control and monitoring. The control also monitorsthe
health of the engine, alternator and auxiliary systems
continuously, via an array of sensors andsenders located on the
generator set, and will affect an Automatic Shutdown if a serious
faultoccurs.There are two fault level signals generated by the control
system as follows:1. Warning: signals an imminent or non-fatal fault for the
engine. The control providesan indication only for this condition.2. Shutdown: signals
a potentially fatal fault for the engine. The control will
automaticallytake the engine off-load and shut it down immediately, without a
cooling down run.The control system operates on 24V DC battery power. The
auxiliary equipment operates on LV AC power. The history data
is stored in non-volatile memory and will not be deleted due to
loss ofbattery power.In addition to the many control and annunciation functions, the
PCC 3201 can be easily upgradedto communicate over a
PowerCommand™ Network, or to work as part of a paralleling system.
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4.1.1 Control Panel Power ON/OFF Modes
The power on/off modes of the control panel and operating
software are Power On, Screen Saverand Sleep/Awake.Power On ModeIn this mode, power is continuously supplied to the
control panel. The control’s operating softwareand control panel
LEDs/graphical display will remain active until the Screen Saver
mode isactivated.Screen Saver Mode
Power to the graphical display will be removed after ten minutes
(generator set not running orrunning). The ten minute timer resets
and begins after each control panel action (any button orswitch
selection) or signal received by the operating software. The bottom
LEDs of the Analogue AC Metering Panel (bar graphs) may remain
on during Screen Saver mode, indicating that theoperating software
is active (Awake mode).When a Warning signal is sensed by the control, (for example,
Low Coolant Temp), a warningmessage will be displayed. The control
will remain active until the Fault Acknowledge button ispressed to
clear the warning message and start the ten minute timer.Sleep/Awake Mode
In the Sleep mode, the control’s operating software is inactive
and the LEDs and the graphicaldisplay on the control panel are all
off. Sleep mode is a feature that is used to reduce batterypower
consumption when the control is in the Auto mode and is not being
used.When all conditions are met (i.e., no unacknowledged faults,
Screen Saver Mode is active, andOff/Manual/Auto switch is in the
Auto position) the Sleep mode will be activated.The operating software is initialised and the control panel LEDs
and graphical display are turnedon in response to one of the
following:• Moving/pressing any control panel switch/button
• A remote start input signal (generator set in Auto
mode)• Customer fault 2 or 3 only (Shutdown or Warning
indicator is on)To activate the control and view the menu display without
starting the generator set, press anybutton on the control
panel.The InPower service tool is required to enable or disable the
Sleep mode. When shipped from thefactory, the Sleep mode is
disabled. When disabled, the operating software will always
remainactive (Awake mode) when the control is in Auto mode.Note: The InPower service tool is required in order to select
the desired mode.Contact your authorised distributor for
assistance. -
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4.1.2 Control Panel — Front Panel
Figure 4-1 Control Panel Assembly (Full Featured)
1. Analogue AC metering panel 7. Off/Manual/Auto switch (mode
switch)2. Emergency stop push switch (This is a Key Switch)
3. Status indicators 8. Manual Run/Stop button &
indicator4. Fault acknowledge button 9. Graphical display
5. Panel lamp/lamp test button 10. Display menu selection
buttons (1 of 6)6. Exercise button & indicator
SWITCH PANEL
0
OPERATOR PANEL
1 2
3
4
5
6
78910
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4.1.3 Control Panel — Operator Panel
The operator panel contains the following components:
Analogue AC Metering Panel:
This panel simultaneously displays 3–phase line-to-line AC volts
and current, kW, power factorand frequency.The meter panel is composed of a series of LEDs that are
configured in bar graphs for eachfunction. The LEDs are colour
coded, with green indicating normal range values, amber forWarning
levels and red for Shutdown conditions.Scales for each function are in % of nominal values. Resolution
is 1% for values close to nominal,and increases for values further
from nominal.Graphical Display:
The graphical display is capable of displaying up to nine lines
of data with approximately 27characters per line. The display is
used to view the menus of the menu–driven operating system.(Refer to the menu trees later in this section). The display is
also used to show Warning andShutdown messages/error codes, modes
of operation (Figure 4-2) and system actions, such asWarning,
De-rate, Shutdown, etc.Display Menu Selection Buttons:
Six momentary buttons—three on each side of the graphical
display window—are used to navigatethrough the system control menus
and to adjust generator set parameters. The button is activewhen
the message adjacent to the button is highlighted (displayed in
inverse video).4.1.4 Control Panel — Switch Panel
WARNING: SOME PANEL INTERNAL COMPONENTS MAY HAVE LIVE
EXPOSEDTERMINATIONS EVEN IF THE GENERATOR SET IS NOT RUNNING.ISOLATE
ALL EXTERNAL ELECTRICAL SUPPLIES PRIOR TO ACCESS OFTHE CONTROL
PANEL.The switch panel contains the following components:
Emergency Stop Button:
Push the button in for Emergency Shutdown of the engine. If the
engine is not running, pushingthe button in will prevent the
starting of the engine, regardless of the start signal source
(local orremote).To reset:
• Pull, or twist and pull, the button out.
• Turn the Off/Manual/Auto switch to Off (O).
• Press the front panel Fault Acknowledge button.
• Select Manual or Auto, as required.
Caution: Ensure that the cause of the emergency is fully
investigated and remediedbefore an emergency stop Reset, and
generator set Start are attempted.Note: Emergency Stop shutdown status can be reset only at the
operator control panel. -
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Remote Start Indicator:
This green lamp is lit whenever the control is receiving a
Remote Run signal. When this lamp isflashing, it indicates a load
demand stop mode.Not in Auto Indicator:
This red lamp flashes continuously when the Off/Manual/Auto
switch is not in the Auto position.(If it is in the Auto position
and the lamp is flashing, this indicates that a service is
required).Shutdown Status Indicator:
This red lamp is lit whenever the control detects a Shutdown
condition. The generator set cannotbe started when this lamp is on.
After the condition is corrected, Shutdown indicators can be
resetby turning the Off/Manual/Auto switch to the Off (O) position,
and pressing the Fault Acknowledgebutton.Dependent upon the specific fault that occurs, the engine may or
may not shut down immediately. A fault that could cause engine
damage causes an immediate engine shutdown (bypasses
enginecool–down sequence). All other faults would allow the engine
to run during the cool–downsequence before engine shutdown. In this case, the Shutdown
Status Indicator blinks during thecooldown period.Warning Status Indicator:
This yellow lamp is lit whenever the control detects a Warning
condition. After the condition iscorrected, warning indicators can
be reset by pressing the Fault Acknowledge button. (It is
notnecessary to stop the generator set if the fault becomes
inactive during generator set operation).Fault Acknowledge:
Press this button to acknowledge Warning and Shutdown messages
after the fault has beencorrected.To acknowledge a Warning message, the Off/Manual/Auto switch can
be in any position. (It is notnecessary to stop the generator set to acknowledge an inactive
Warning condition). Toacknowledge a Shutdown message with this
button, the Off/Manual/Auto switch must be in the Off(O)
position.This button is also used to blink a fault code if the Shutdown
or Warning Status Indicator is lit.(This function is used when the
control does not contain a graphical display). Refer to
ReadingFault Codes in Section 7 -Troubleshooting, which describes
how to use this button for interpretingfault codes.Panel Lamp/Lamp Test Button:
Press this button to turn the panel lamp on or off.
Press and hold down this button for a minimum of three seconds
to turn all control panel LEDs on,to make sure all lamps
illuminate. The illumination will shut off after releasing the
button.Exercise Button:
Press this button to initiate a pre-programmed exercise
sequence. The Off/Manual/Auto switch isused in conjunction with
this button to enable this function (refer to Section 5.6.5
Exercise Start).Manual Run/Stop Button:
This button starts and stops the set locally and will bypass
Time Delay to Start and Stopsequences. The Off/Manual/Auto switch
must be in the Manual position to enable this button. -
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Off/Manual/Auto Switch:
Manual position enables the use of the switch panel Manual
Run/Stop button.Auto position enables start/stop control of the engine from
a remote location. (Disables the use ofthe switch panel Manual
Run/Stop button).Off (O) position prevents the starting of the generator set
(local or remote). If moved to Off (O) during set operation,
an immediate engine shutdown will be initiated (bypasses cool–down
timers).This hot shutdown should be avoided, if possible, to help
reduce unnecessary engine wear. Hotshutdowns are logged by the
system software.A key function is provided to prevent unauthorised
operation of the switch.4.2 Menu Display and Switches
Figure 4-2 shows the graphical display and the menu selection
buttons.4.2.1 Graphical Display
The graphical display is capable of displaying up to nine lines
of data with approximately 27characters per line. The display is
used to view the menus of the menu–driven operating system.(Refer
to the menu trees later in this section). The display is also used
to show the followingsystem information:• State Line — modes of operation, such as Stopped,
Time Delay to Start, Warm Up at Idle, etc.(see Figure 4-1), and
paralleling operations, such as Standby, Dead BUS Close,
Synchronise,etc.• Action Line — system actions, such as Warning,
De-rate, Shutdown Cool–down andShutdown, and fault codes.• Description Line — Fault code/status messages.
Figure 4-2 Graphical Display and Menu Selection Buttons
4.2.2 Menu Buttons
Six momentary buttons — three on each side of the graphical
display window — are used to navigatethrough the system control
menus and to adjust generator set parameters. The button is
activewhen the message or symbol adjacent to the switch is
highlighted (displayed in inverse video). Thedisplayed message or
symbol indicates the function of the button.Note: In the graphical display, the symbol indicates that
selecting the adjacent buttoncauses the operating program to go to
the next menu display—as shown in the menudiagrams.In the graphical display, the symbol indicates that selecting
the adjacent buttoncauses the operating program to go back to the previous menu
display.STATE LINE
ACTION LINE
DESCRIPTION LINE
MENU DISPLAY AREA
GRAPHICALDISPLAY
MENUBUTTONS
MENUBUTTONS
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In the graphical display, the symbol indicates that selecting
the adjacent buttoncauses the operating program to go back to Main
Menu A (Figure 4-4).4.3 Menu Units Selection
During any control panel operation, you can change how units are
displayed by pressing the twolower menu buttons (one on each side
of display). When pressing these two buttonssimultaneously, the
unit’s submenus will appear (Figure 4-3). After selecting the
desired units,press the ENTER button in this submenu to change
and save the selections.Note: Use the + button to select the desired option for
each field. Use the arrow ( → ) button tomove to the next
field. Selected field is highlighted.Figure 4-3 Units Submenu
4.3.1 Local/Remote Field
This selection must be set to Local, when the graphical display
is mounted on the generator setfront control panel, or Remote when
mounted remotely from the generator set.The Local/Remote selection determines which buttons in the
Control submenu (Section 4.7) areactive (displayed).Temp: Used to select °F or °C for temperature readings.
Pressure Fluid: Used to select PSI, KPa, BAR or IN for pressure
readings.Pressure Gas: Used to select INHG or MMHG for pressure
readings.Flow Air: Used to select CFM or CMM for airflow readings.
LOCATION LOCAL
TEMPΕF
PRESS FLD PSIPRESS GAS INHG
ENTER
+
→
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4.4 Main Menu
Figure 4-4 shows the main menus (Menu A and Menu B) of the
system control. The two mainmenus are used to divide the system
submenus into major categories, such as, Engine Data,Alternator Data, Control, etc.To view system data, simply
press the appropriate menu button to select the category.
Afterpressing the desired menu button, refer to the following pages
for detailed information related tothe selected category.Note: The numerical information shown in the following figures
is for example only. They donot necessarily reflect the information
for your specific generator set.Figure 4-4 System Control Main Menus A and B
Note: In the following figures, the boxed/highlighted field
indicates that the adjacent menubutton is active. Also, the
submenus are shown in the order in which they are displayedwhen
scrolling up , or down .4.4.1 Adjust Button
The Adjust submenu is intended for competent site personnel
only. Note that a password may beassigned to allow only authorised
operators to modify this data.4.4.2 Set-up Button
The Set-up submenu is described in the Service manual and is
intended for competent servicepersonnel only. For this reason, a
password must be entered before this data can be
modified.Note: PTC – The PTC Setup submenu is intended for qualified
service and site personnelonly. Password is provided, but can be
changed after installation to prevent un-authorised
modifications,Note: The Adjust and Set-up submenus can be viewed, but not
modified without entering thecorrect passwords.MENUBUTTONS
MENUBUTTONS
MENU A
ENGINE
HISTORY/ABOUT
MENUB
ALTERNATORCONTROL
MORE>
POWER TRAN or_\_
MENU B
BACK
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4.4.3 _\_ Button (Paralleling applications only)
When displayed, indicates that the feature for generator set
paralleling applications is enabled.This button is used to open and
close the generator set circuit breaker (CB). The symbol
indicatesif the CB is opened or closed.Opened _\_, push
to close.Closed _-_, push to open.With the control panel Off/Manual/Auto switch in the Auto
position, the opening and closing of theCB is controlled by the
control system software. The CB symbol will indicate an open or
closedCB, but the button will be inactive when the control is in
Auto.In the Manual position, the CB can only be closed by using this
button. When manually closed andthe CB opens, it must be closed
again by using this button. To close the CB, press and hold
thebutton until the symbol indicates a closed CB. (CB close will
occur only when set-up conditionsallow — dead bus or generator set
synchronised with bus).4.4.4 Power Trans Button (PTC applications only)
When displayed, indicates that the Power Transfer Control
feature is enabled.Refer to Section 4-12 for submenu description.
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4.5 Engine Data Submenus
If you press the Engine Data button in Menu A, the Engine Data
submenus will appear(Figure 4-5).The first submenu displays general information that applies to
all generator sets (coolant temp, oilpressure, etc.) The data in
the remaining submenu(s) will vary according to the type and number
ofsensors provided with the engine.Figure 4-5 Engine Data Sub-menus
COOLANT TEMP 180ΕF
ENGINE SPEED 1800 RPMBATTERY 29.1 VDCOIL PRESSURE 75 PSI
OIL TEMP 210Ε
F
MANF TEMP 75ΕFMANF PRESS ABS 180 INHGOUT PRESS ABS 180
PSIAMBIENT PRESS 88 INHGENGINE DATA
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4.6 Alternator Data Submenus
If the Alternator Data button in Menu A is pressed, the
Alternator Data submenus will appear(Figure 4-6).4.6.1 Voltage L–L and L–N
Indicates voltage Line–to–Line, and Line–to–Neutral. Note that
the Line–to–Neutral column will notbe displayed for a
3-phase/3-wire system. Accuracy 1%.The voltages Line–to–Line (L1, L2 and L3) are measured between
L1 to L2, L2 to L3 and L3 to L1,respectively.Figure 4-6 Alternator Data Sub-menus
4.6.2 Amps
All phases. Accuracy 1%.
4.6.3 Frequency
Generator set output frequency.
4.6.4 AVR Duty Cycle
Displays voltage regulator (drive) level in percentage of
maximum.4.6.5 kW, kVA and PF
Displays generator set kW and kVA output (average and individual
phase, and direction of flow)and power factor with leading/lagging
indication. Accuracy 5%.Note: The PF reading will contain an asterisk if the power
factor is leading (e.g., *.30).kW kVA PF
L1 350 500 .80L2 350 500 .80L3 350 500 .80TOT 1050 1500 .80
V L-L L-N AMPSL1 480 277 1340L2 480 277 1290L3 480 277
1260FREQUENCY 60.0HZAVR DUTY CYCLE 10.3%ALTERNATOR DATA
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4.7 Control Submenu
If the Control button in Menu A is pressed, the Control submenu
will appear(Figure 4-7).4.7.1 Local Control Submenu Function
When the Operator panel (Figure 4-1) is mounted on the control
panel assembly, the Run ModeIdle/Rated button is active
(displayed).Note: In remote applications (Figure 4-8) this button is not
displayed.The shaded area in Figure 4-7 displays the selected/active mode
of operation, (Idle or Rated).Note: Run Mode Idle/Run at Rated Button: Refer to Section 5.7
for a complete description ofthe Run at Idle mode.Figure 4-7 Local Control Sub-menu
+ RUN MODE IDLE
CONTROL(Local)
ENABLE SYNC
BARGRAPH TEST
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4.8 History/About Submenus
Pressing the History/About button in Menu A will reveal the
History/About submenus (Figure 4-9).4.8.1 HistoryThe control maintains a data log of the number of
engine starts and number of operating hours forthe engine and
control, and the megawatt and maximum torque hours of the generator
set. Thisinformation is stored in non-volatile memory and will not
be deleted due to loss of battery power.4.8.2 About
The About submenus provide the following generator set
information:• Generator set model and wattage (kW/MW)
• Output voltage and WYE, DELTA or SINGLE
• Frequency 50 or 60 Hz
• Rating: Standby, Prime or Base
• Version level of the controller and panel operating
software4.8.3 Fault History
The control maintains a data log of all fault conditions as they
occur, and time stamps them withthe control and engine operating
hours.Up to 32 (unacknowledged) fault codes can be stored in control
panel memory. Following Faultacknowledgement and correction, it is
deleted from the control panel memory. However, it remainsin a data
log that maintains the fault code history. (The InPower service
tool is required to view thisdata log).The Fault History display line: 1 of 24 indicates that 24 faults
are recorded and that the mostrecent fault (1) detected by the
controller is displayed.The Occurrences display line: In this example, 5 indicates
that this is the fifth occurrence of thisfault. (The InPower
service tool is required to review the last four faults of this
code).Note: The Occurrences number is incremented for each new
occurrence of the same fault.The controller must detect that the
original sensed fault is corrected before it willincrement the
occurrence number for that fault.For example, when a Low Oil Pressure fault is detected, the
controller will incrementthe Occurrences number by 1. This fault
will remain active until the controller detectsthat the fault is
corrected. An active fault will prevent the controller from
incrementingthe Occurrences number each time the engine is started.
When the controller detectsthat the oil pressure is normal the fault will become inactive,
allowing the occurrencesnumber to be incremented for the next
detected Low Oil Pressure fault. -
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Section 4 – Control System Page 4-15
Figure 4-9 History/About Sub-menus
STARTS533
ENGINE HOURS 1236CONTROL HOURS 7879KWHRS
890
HRS@%MAX TORQUE
12345@0-9 23455@50-5912345@10-19 12345@60-6912345@20-29
12345@70-7912345@30-39 12345@80-89MODEL 1750DQKBVOLTAGE 416 WYEFREQUENCY 60RATING STANDBY
CONTROLLER VERSIONRTOP DN30008.DFABATS FEB 15 1999OT PANEL
VERSIONRTOP 1.12BATS 1.04FAULT HISTORY 1 OF 24
CNTL HOURS 459
OCCURRENCES 5ENGINE HOURS 334FAULT CODE 1437
(FAULT DESCRIPTION)
HISTORY/ABOUT
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4.9 Adjust Sub-menu
If the Adjust button in Menu B is pressed, the Adjust submenu
will appear(Figure 4-10).The Adjust submenu is intended for qualified service personnel
and site personnel only and mayrequire a USER password.
If a password is required, the USER password menu will
appear whenyou try to modify the Adjust submenu. (Refer to Password
Menu in Section 4.11 to enterpassword).Changes are automatically saved when you exit this menu.
Note: Use the + and — buttons to increase or
decrease the values in the following fields. Usethe arrow
( → ) button to move the cursor within a field or to the
next field. Selected fieldis highlighted.• START DELAY: This delay applies only to remote starting
in the Auto mode.The Start Delay adjustment range is 0 to 300
seconds.• STOP DELAY: This delay applies only to remote
stopping in the Automode. The Stop Delay adjustment range is 0 to
600seconds.• VOLTAGE: Used to adjust the output voltage
±5%.• FREQUENCY: Used to adjust the frequency ±3 Hz.
• VOLTAGE/SPEED DROOP: These two sub-menus apply to
a generator set that has theparalleling option enabled and is
configured to operate indroop mode. These adjustments must be
performed bytechnically qualified personnel only.Figure 4-10 Adjust Sub-menu
ADJUST:START DELAY 5 SECSTOP DELAY 11 SECVOLTAGE 208 1.2 %FREQ
60.0 HZ -0.0 HZ+
6
—
ADJUST:STANDBY
VOLTAGE DROOP OFFBUS L1 480 VPOWER FACTOR 0.80VOLT 4.99 %
+
6
—
ADJUST:STANDBYSPEED DROOP OFFBUS FREQ 60.0 HZTOTAL KW 300 HZFRE
60.0 0.40 HZ+
6
—
ADJUST
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4.10 Parallel Data Submenu
If the Parallel Data button in Menu B is pressed, the Parallel
Data submenu will appear(Figure 4-11). This menu is displayed in
paralleling applications only.4.10.1 Parallel Data Status Line
The top line of the graphical display is used to indicate the
following Parallel Data status:• STANDBY: Indicates no paralleling activity is
occurring.• DEAD BUS CLOSE: Indicates first generator set in system
to close to bus.• SYNCHRONISE: Generator set is synchronising to
bus.• LOAD SHARE: Generator set has closed to bus and is
sharing load with othergenerator sets in system.• LOAD GOVERN: Generator set closed to bus in parallel
with utility (mains).Figure 4-11 Bus Data Sub-menu
BUS Voltage L–L: The BUS voltage Line–to–Line (L1, L2 and
L3) is measured between L1 to L2,L2 to L3 and L3 to L1,
respectively.BUS/GEN HZ: BUS/GEN hertz.
BUS/GEN SYNC STATUS: The bottom line of the graphical
display is used to indicate thefollowing BUS/GEN Sync status:• NOT SYNCHRONIZING: Generator set is in service
mode that does not allow auto syncfeature.• SYNCHRONIZING: Generator set is synchronising to
bus.• READY TO CLOSE: In manual mode, push circuit breaker
close button to closebreaker.• _\_ Button: (Paralleling applications only). Used
to open and close thegenerator set circuit breaker (CB). The symbol
indicates if theCB is opened or closed.Opened _\_ , push
to close.Closed _-_ , push to open.With the control panel Off/Manual/Auto switch in the Auto
position, the opening and closing of theCB is controlled by the
control system software. The CB symbol will indicate an open or
closedCB, but the button will be inactive when the control is in
Auto.In the Manual position, the CB must be closed by this button.
When manually closed and the CBopens, it must be closed again by using this button. To close
the CB, press and hold the buttonuntil the symbol indicates a
closed CB. (CB close will occur only when set-up conditions allow
-dead bus or generator synchronised with bus).LOAD GOVERNV BUS GENL1 480 480L2 480 480L3 480 480HZ 60.1
60.1DEG – 122 NOT SYNCHRONIZING_\_
PARALLEL DATA
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4.11 Password Menu
When viewing the Adjust submenu, pressing either the + or
— button will display the Passwordmenu (Figure 4-12) if a
User password is assigned to this field. After entering the
correctpassword, the system will allow you to modify the submenu. To
prevent unauthorised adjustment,the entered password is valid for
only ten minutes after the last button is pressed.Note: Application Password is intended only for competent
service personnel to allowadjustment of Set-up submenu
parameters.To enter the password:
1. Display Adjust submenu.
2. Press either the + or — button within the
displayed submenu. The Password menu appears.(Adjustment is allowed
if Password menu does not appear).3. Press the + and — button to select the first
character of the User password (A-Z or 0-9).4. Press the → button to select the next character field.
Selected character field is highlighted.5. Repeat steps 3 and 4 to enter remaining password
characters.6. Press the Enter button after entering the password.
The Adjust submenu will re-appear.7. Exit Adjust submenu to save changes.
Figure 4-12 Password Menu
ENTER USER PASSWORD(OR)
ENTER APPLICATIONPASSWORD
xxxxxxxx
ENTER+
→
+ OR — BUTTON
—
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Section 4 – Control System Page 4-19
4.12 Power Transfer Main Menu
If you press the Power Trans button in Menu A, the Power
Transfer main menu will appear(Figure 4–13).Note: The Power Transfer Control (PTC) feature must be enabled
to display this menu.The PTC feature enables the PCC3201 to monitor the utility
voltage (mains) and frequency forfailure, and control the opening
and closing of the contacts (circuit breakers) for the utility (S1)
andthe generator set (S2).If utility fails, the control will initiate the starting
sequence (Figure 5–1), open S1 and close S2 tothe load. When
utility returns, the load is retransferred to the utility (S1
closes and S2 opens) andthe control initiates the generator set
shutdown sequence.The symbol displayed in the middle of the Power Transfer main
menu indicates whichbreaker (utility or generator set) is
closed/opened to the load. The symbol shown inFigure 4-13 indicates that the utility breaker is closed and
supplying power to the load.The Power Transfer main menu also indicates if the utility and
the generator set are available toaccept load. When the control
detects that either source is ready to accept load, Utility
and/orGenset will be displayed in inverse video.The Power Transfer main menu has four submenu groups:
• Utility
• Status
• Transfer Control
• Genset
To view system data, simply press the appropriate menu button to
select the category. Afterpressing the desired menu button, refer
to the following pages for detailed information related tothe
selected category.Figure 4-13 Power Transfer Main Menu
MENUBUTTONS
MENUBUTTONS
PTC STATUS LINE
DEG – 123 SYNCHRONIZING
STATUS
TRANSFER CONTROL
UTILITY
GENSET
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4.12.1 PTC Status Line
The top line of the graphical display is used to indicate the
following PTC status:• NOT ENABLED: PTC is not enabled. Control panel
switch in O (Off) position.• MANUAL: Control panel switch is in Manual
position. All PTC actions or generator setstart/stop actions are
manually controlled.• NORMAL UTIL: Load is connected to the utility.
• RETRAN: Retransfer of load to utility.
• RETRAN OVRD: Immediate retransfer of load to
utility due to generator set fault (e.g.,warning, derate, or
shutdown with cooldown fault). The retransfer timer is ignored as
is theretransfer inhibit.• EMERG TEST: Emergency Test sequence initiated
through Remote Start switch withemergency start sequence enabled
(TB8–3 terminal opened). Emergency test mode meansthat the
generator set will continue to run even if a generator set warning
or derate faultoccurs. This test can be performed with or without
load (refer to Section 5.9). See Table 5–3for sequence of operation.• TEST: Test sequence
initiated through Remote Start switch with emergency start
sequencedisabled (TB8–3 terminal closed). Test mode is non–emergency,
which means that aretransfer to utility will occur if any problems
occur with the generator set while testing withload. This test can
be performed with or without load (refer to Section 5.9). See Table
5–3 forsequence of operation.• EXERCISE: Exercise sequence initiated through
control panel. This test can be performedwith or without load
(refer to Section 5.9). A retransfer to utility will occur if any
problemsoccur with the generator set during the exercise sequence.
See Table 5–3 for sequence ofoperation.• UTILITY FAIL: Utility has failed. (Initiates
transfer of load to generator set if Off/Manual/Autoswitch is in
Auto.) -
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Section 4 – Control System Page 4-21
4.12.2 Utility (PWR TRAN) Submenus
If the Utility button in the Power Transfer Main menu is
pressed, the Utility submenu will appear(Figure 4–14).• Voltage L–L and L–N: Indicates utility voltage
Line–to–Line and Line–to–Neutral. Note thatthe Line–to–Neutral
column will not be displayed for a 3 phase/3 wire system. Accuracy
1%.The voltage Line–to–Line (L1, L2 and L3) are measured between L1
to L2, L2 to L3 and L3 toL1, respectively.• Amps: L2 only. Accuracy 1%.
• Frequency: Utility frequency.
• kW, kVA and PF: Displays (L2 only) utility kW and
kVA output (average and direction of flow)and power factor with
leading/lagging indication. Accuracy 5%.Note: The PF reading will contain an asterisk if the power
factor is leading(for example, *.30).Figure 4-14 Utility Sub-menu
UTILITY:V L-L L-N AMPSL1 480 277L2 480 277 1320L3 480
277FREQUENCY 60.0HZUTILITY
UTILITY:kWL kVA PF
L1L2 125 175 .96L3TOT
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4.12.3 Status (PWR TRAN) Submenus
If the St
File Specifications:951/951506-powercommand_3201.pdf file (14 Aug 2023) |
Accompanying Data:
CUMMINS PowerCommand 3201 Controller PDF Service Manual (Updated: Monday 14th of August 2023 06:46:11 AM)
Rating: 4.1 (rated by 64 users)
Compatible devices: PowerComand 1301, PS0500, PowerCommand 3100, AvK MA330, Stamford MX322, PowerCommand FT-10, PowerCommand 3.3, PowerCommand 2.2.
Recommended Documentation:
Service Manual (Text Version):
(Ocr-Read Summary of Contents of some pages of the CUMMINS PowerCommand 3201 Document (Main Content), UPD: 14 August 2023)
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CUMMINS PowerCommand 3201 User Manual
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CUMMINS PowerCommand 3201 User Guide
-
CUMMINS PowerCommand 3201 PDF Manual
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CUMMINS PowerCommand 3201 Owner’s Manuals
Recommended: 18H0500 — Z 54 Color Jetprinter Inkjet Printer, BE-32, CX 10, PL36PC50EC
Links & Tools
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Metron, Inc. Date: 09/22/04 Approved: MH DOC#: 605 Revision: B Date: 06/14/06 Approved: MH Page: 1 of 24 MANUAL FOR MODEL MP300 to MP700 ELECTRIC MOTOR DRIVEN FIRE PUMP CONTROLLERS Starting Serial No. «MA» T …
MP300 24
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Operator: Save these instructions for future use!FAILURE TO READ AND FOLLOW ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLING OR OPERATING THIS CONTROL COULD CAUSE PERSONAL INJURY AND/OR PROPERTY DAMAGE.INSTALLATION INSTRUCTIONSTYPE 1127 HOT WATER CONTROL Surface Type — S.P.D.T.THESE CONTROLS MUST BE INSTALLE …
1127 8
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PBlack Red White [S[Specificationpecification]]MC-9200H/AFunction Auto recognition of cellPeak current 200 ASize 105 x 50x 36 mmWeight 325 gCell LiPo 6-14 cells 22.2 〜 51.8 VBEC 5 〜 8 V / 10 ABrushless motor MC-9200H/AReceiverLEDTo CH3To free port Not useTo free port To drive battery Throt …
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Operating Impressions, Questions and Answers:
-
Service Manual
Controller PowerCommand 3201
English Original Instructions2010$7 (Issue )
-
iTable of Contents
SECTION TITLE PAGE
1. Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .ABOUT THIS MANUAL 1-1. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . TEST EQUIPMENT 1-1. . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOW TO OBTAIN SERVICE 1-1. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .2. Control Operation 2-1. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.GENERAL 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . SEQUENCE OF
OPERATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . CONTROL PANEL POWER ON/OFF MODES 2-1. . . . . . .
. . . . . . . . . . . . . . CONTROL PANEL ASSEMBLY 2-4. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . READING FAULT
CODES 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . MENU DISPLAY AND SWITCHES 2-7. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . LANGUAGE/UNITS
SELECTION MENU 2-8. . . . . . . . . . . . . . . . . . . . . . . . .
. MAIN MENU 2-9. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SUBMENUS
2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . ALTERNATOR SUBMENUS 2-12. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . CONTROL SUBMENU
2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . HISTORY/ABOUT SUBMENUS 2-14. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . HISTORY/ABOUT SUBMENUS
(CONT.) 2-15. . . . . . . . . . . . . . . . . . . . . . . . .
PARALLEL DATA SUBMENU 2-16. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . POWER TRANSFER MAIN/SUBMENUS 2-17. . .
. . . . . . . . . . . . . . . . . . . . . . UTILITY (PWR TRAN)
SUBMENUS 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATUS (PWR TRAN) SUBMENUS 2-20. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . TRANSFER CONTROL (PWR TRAN) SUBMENU 2-21.
. . . . . . . . . . . . . . . . GENSET (PWR TRAN) SUBMENUS 2-22. .
. . . . . . . . . . . . . . . . . . . . . . . . . . .3. Control Calibration and Adjustment 3-1. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .GENERAL 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . PARALLELING and
NONPARALLELING 3-1. . . . . . . . . . . . . . . . . . . . . . . . .
SOFTWARE CALIBRATIONS 3-1. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . MODIFYING SETUP/ADJUST SUBMENUS 3-1.
. . . . . . . . . . . . . . . . . . . . . . . SETUP MENUS 3-3. . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . GOVERNING/VOLT REG SUBMENU 3-4. . . . . . . .
. . . . . . . . . . . . . . . . . . . . . CUSTOMER FAULTS SUBMENUS
3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIBRATION SUBMENUS 3-8. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . ISOLATED BUS SUBMENUS 3-11. . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . UTILITY
SUBMENUS 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . POWER TRANSFER CONTROL MAIN MENUS
3-19. . . . . . . . . . . . . . . . . . . UTILITY SENSORS SUBMENUS
3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENSET SENSORS SUBMENUS 3-22. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . TIMERS SUBMENU 3-24. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST/EXERCISE SUBMENU 3-26. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . ADJUST SUBMENU 3-28. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIBRATION PROCEDURE 3-29. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . -
ii
SECTION TITLE PAGECONTROL BOX WIRING 3-31. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . RUN RELAYS
(K11, K12, K13) 3-33. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . ALARM RELAY (K16) 3-34. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAGNETIC
SPEED PICKUP UNIT (MPU) INSTALLATION 3-35. . . . . . . . . -
vIMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS This manual containsimportant
instructions that should be followed duringinstallation and
maintenance of the generator set andbatteries.Before operating the generator set (genset), read theOperators
Manual and become familiar with it and theequipment. Safe and
efficient operation can beachieved only if the equipment is
properly operatedand maintained. Many accidents are caused by
failureto follow fundamental rules and precautions.The following symbols, found throughout this manual,alert you to
potentially dangerous conditions to the oper-ator, service
personnel, or the equipment.This symbol warns of immediatehazards which will result in
severe personal in-jury or death.WARNING This symbol refers to a hazard or un-safe practice which
can result in severe person-al injury or death.CAUTION This symbol refers to a hazard or un-safe practice which
can result in personal injuryor product or property damage.FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can resultfrom
improper practices.DO NOT fill fuel tanks while engine is running, un-less tanks
are outside the engine compartment.Fuel contact with hot engine or
exhaust is a potentialfire hazard.DO NOT permit any flame, cigarette, pilot light,spark, arcing
equipment, or other ignition sourcenear the generator set or fuel
tank.Fuel lines must be adequately secured and free ofleaks. Fuel
connection at the engine should bemade with an approved flexible
line. Do not use zinccoated or copper fuel lines with diesel
fuel.Be sure all fuel supplies have a positive shutoffvalve.
Be sure battery area has been well-ventilated priorto servicing
near it. Lead-acid batteries emit a highlyexplosive hydrogen gas
that can be ignited by arc-ing, sparking, smoking, etc.EXHAUST GASES ARE DEADLY
Provide an adequate exhaust system to properlyexpel discharged
gases away from enclosed orsheltered areas and areas where
individuals arelikely to congregate. Visually and audibly
inspectthe exhaust daily for leaks per the maintenanceschedule.
Make sure that exhaust manifolds are se-cured and not warped. Do
not use exhaust gases toheat a compartment.Be sure the unit is well ventilated. Engine exhaust and some of
its constituents areknown to the state of California to cause cancer,birth defects,
and other reproductive harm.MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATH
Keep your hands, clothing, and jewelry away frommoving
parts.Before starting work on the generator set, discon-nect battery
charger from its AC source, then dis-connect starting batteries,
negative () cable first.This will prevent accidental starting.Make sure that fasteners on the generator set aresecure. Tighten
supports and clamps, keep guardsin position over fans, drive belts,
etc.Do not wear loose clothing or jewelry in the vicinity ofmoving
parts, or while working on electrical equip-ment. Loose clothing
and jewelry can becomecaught in moving parts.If adjustment must be made while the unit is run-ning, use
extreme caution around hot manifolds,moving parts, etc.DO NOT OPERATE IN FLAMMABLE ANDEXPLOSIVE ENVIRONMENTS
Flammable vapor can cause an engine to overspeed andbecome
difficult to stop, resulting in possible fire, explo-sion, severe
personal injury and death. Do not operate agenset where a flammable
vapor environment can becreated by fuel spill, leak, etc., unless
the genset isequipped with an automatic safety device to block the
airintake and stop the engine. The owners and operators ofthe
genset are solely responsible for operating the gen-set safely.
Contact your authorized Cummins PowerGeneration distributor for
more information. -
vi
ELECTRICAL SHOCK CAN CAUSESEVERE PERSONAL INJURY OR DEATH
Remove electric power before removing protectiveshields or
touching electrical equipment. Use rub-ber insulative mats placed
on dry wood platformsover floors that are metal or concrete when
aroundelectrical equipment. Do not wear damp clothing(particularly
wet shoes) or allow skin surface to bedamp when handling electrical
equipment. Do notwear jewelry. Jewelry can short out electrical
con-tacts and cause shock or burning.Use extreme caution when working on electricalcomponents. High
voltages can cause injury ordeath. DO NOT tamper with
interlocks.Follow all applicable state and local electricalcodes. Have all
electrical installations performed bya qualified licensed
electrician. Tag and lock openswitches to avoid accidental
closure.DO NOT CONNECT GENERATOR SET DIRECT-LY TO ANY BUILDING
ELECTRICAL SYSTEM.Hazardous voltages can flow from the generator
setinto the utility line. This creates a potential for
elec-trocution or property damage. Connect onlythrough an approved
isolation switch or an ap-proved paralleling device.GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a higher boiling pointthan water.
DO NOT open a radiator or heat ex-changer pressure cap while the
engine is running.To prevent severe scalding, let engine cool
downbefore removing coolant pressure cap. Turn capslowly, and do
not open it fully until the pressure hasbeen relieved.Used engine oils have been identified by some stateor federal
agencies as causing cancer or reproduc-tive toxicity. When checking
or changing engine oil,take care not to ingest, breathe the fumes,
or con-tact used oil.Keep multi-class ABC fire extinguishers handy.Class A fires
involve ordinary combustible materialssuch as wood and cloth; Class
B fires, combustibleand flammable liquid fuels and gaseous fuels;
ClassC fires, live electrical equipment. (ref. NFPA No. 10).Make sure that rags or combustible material are notleft on or
near the generator set.Make sure generator set is mounted in a manner toprevent
combustible materials from accumulatingunder or near the unit.Remove all unnecessary grease and oil from theunit. Accumulated
grease and oil can cause over-heating and engine damage which
present a poten-tial fire hazard.Keep the generator set and the surrounding areaclean and free
from obstructions. Remove any de-bris from the set and keep the
floor clean and dry.Do not work on this equipment when mentally orphysically
fatigued, or after consuming any alcoholor drug that makes the
operation of equipment un-safe.Substances in exhaust gases have been identifiedby some state or
federal agencies as causing can-cer or reproductive toxicity. Take
care not to breathor ingest or come into contact with exhaust
gases.Do not store any flammable liquids, such as fuel,cleaners, oil,
etc., near the generator set. A fire orexplosion could result.Wear hearing protection when near an operatinggenerator set.
To prevent serious burns, avoid contact with hotmetal parts such
as radiator system, turbo chargersystem and exhaust system.KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
-
1-1
1. Introduction
ABOUT THIS MANUAL
This manual provides PowerCommand Control3201 (PCC) calibration
and adjustment proce-dures, control operation, alternator test and
repairprocedures.Operating and maintenance instructions are in theapplicable
Operators Manual.Read Important Safety Instructions and carefullyobserve all
instructions and precautions in thismanual.TEST EQUIPMENTTo perform the test procedures in this manual,
thefollowing test equipment must be available True RMS meter for
accurate measurement ofsmall AC and DC voltages. Battery Hydrometer Jumper Leads
Tachometer or Frequency Meter Wheatstone Bridge or Digital Ohmmeter
Variac Load Test Panel Megger or Insulation Resistance Meter
InPower Service Tool (PC based genset ser-vice tool)
HOW TO OBTAIN SERVICEAlways give the complete Model,
Specification andSerial number of the generator set as shown on
thenameplate when seeking additional service infor-mation or
replacement parts. The nameplate is lo-cated on the side of the
generator output box.WARNING Incorrect service or replacement ofparts can result in
severe personal injury ordeath, and/or equipment damage. Service
per-sonnel must be trained and experienced to per-form electrical
and mechanical service. Readand follow Important Safety
Instructions, onpages iii and iv. -
1-2
THIS PAGE LEFT INTENTIONALLY BLANK
-
2-1
2. Control Operation
GENERAL
The following describes the function and operationof the
PowerCommand Control 3200 (PCC). All in-dicators, control
switches/buttons and graphicaldisplay are located on the face of
the control panelas illustrated in Figure 2-1.Normally, generator set configuration options areset at the
factory. When a new control is installed ona generator set or when
parts are replaced, the con-trol must be configured for that
generator set. Setupand calibration procedures are described in
Sec-tion 3.SEQUENCE OF OPERATION
When the PowerCommand control is in the AUTOmode, it will cause
the generator set to start on re-ceiving a signal from a remote
device. The controlwill initiate a starter cranking signal and
verify thatthe engine is rotating. The control will provide
suffi-cient fuel to the engine to accelerate to start discon-nect
speed. On reaching that speed, the control willramp the generator
set to idle (warm-up) or ratedspeed and voltage.On reaching rated speed and voltage, the controlchecks the
system bus voltage. If no bus voltage ispresent, it will wait for a pulse from a remote MasterFirst
Start Sensor. On receiving that pulse, the con-trol will signal the
paralleling breaker to close.If bus voltage is present, the control will check forproper
phase rotation, adjust the generator set tothe bus voltage and
frequency level, and then syn-chronize the generator set to the
system bus. Whena synchronous condition is achieved, the control
willsend a signal to close the paralleling breaker.When the paralleling breaker is closed, the genera-tor set will
assume its proportional share of the totalload on the system
bus.CONTROL PANEL POWER ON/OFFMODES
The power on/off modes of the control panel and op-erating
software are Power On, Screen Saver andSleep/Awake.Power On Mode: In this mode, power is continu-ously supplied to
the control panel. The controlsoperating software and control panel
LEDs/graphi-cal display will remain active until the Screen
Savermode is activated. -
2-2
Screen Saver Mode: Power to the graphical dis-play will be
removed after 10 minutes (generator setnot running or running). The
10 minute timer resetsand begins after each control panel action
(any but-ton or switch selection) or signal received by the
op-erating software. The bottom LEDs of the AnalogAC Metering Panel
(bar graphs) may remain on dur-ing Screen Saver mode, indicating
that the operat-ing software is active (Awake mode).When a Warning signal is sensed by the PCC (forexample, low
coolant temp), the control will displaythe warning message. The
control will remain activeuntil the Fault Acknowledge button is
pressed toclear the warning message and start the 10
minutetimer.Sleep/Awake Mode: In the Sleep mode, the con-trols operating
software is inactive and the LEDsand the graphical display on the
control panel are alloff. Sleep mode is a feature that is used to
reducebattery power consumption when the control is notbeing
used.In Off mode, Sleep mode is activated when thereare no
unacknowledged faults and Screen Savermode is active.In Auto mode, Sleep mode can be enabled or dis-abled. When
shipped from the factory, it is disabled.You can enable Sleep mode
by making thesechanges:Use InPower service tool to set Auto Sleep En-able to Sleep in
Auto.Set switch S1 on the Genset/Paralleling Cardto Sleep/Off. This
switch is located next to con-nector J8 and relay K9.If these conditions are not met, Sleep mode is dis-abled in Auto
mode.The graphical display can enter Screen Saver modeeven if Sleep
mode is disabled.If Sleep mode is enabled in Auto mode, Sleep modeis activated
when there are no unacknowledgedfaults and Screen Saver mode is
active.The operating software is initialized and the controlpanel LEDs
and graphical display are turned on inresponse to one of the
following:Moving/pressing any control panel switch/but-ton. (If Sleep mode
is enabled in Auto mode,the control will remain asleep if Sleep
modewas previously active in Off mode.)Receiving a remote start input signal (genera-tor set in Auto
mode)Receiving an active DCD signal on the RS-232port.
Modem RI latch becoming active. Digital display waking up.
Lonworks (backplane) wakeup becoming ac-tive.
Customer fault 2 or 3 only (shutdown or warn-ing indicator is
on).Dial Out process becoming active.To activate the control and
view the menu displaywithout starting the generator set, press any
buttonon the control panel. -
2-3
DISPLAY MENUSELECTION BUTTONS
(1 of 6)
0/MANUAL/AUTOSWITCH
REMOTE START,NOT IN AUTO,SHUTDOWN,
WARNINGSTATUS INDICATORS
GRAPHICALDISPLAY
ANALOG ACMETERING
PANEL
OPERATOR PANEL SWITCH PANEL
MANUAL RUN/STOP BUTTON& INDICATOR
EXERCISEBUTTON &INDICATOR
FAULTACKNOWLEDGE
BUTTON
PANEL LAMP/LAMP TEST
BUTTON
EMERGENCYSTOP PUSH
BUTTON
0
FIGURE 2-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)
-
2-4
CONTROL PANEL ASSEMBLY
The control panel assembly (Figure 2-1) consist oftwo panels,
the Operator Panel and the Switch Pan-el.Dependent on site requirements, the Operator Pan-el is either
mounted on the control panel assembly(full-featured) as shown in
Figure 2-1 or containedin a separate enclosure and mounted remotely
ofthe control panel assembly.The function of several buttons on the control panelwill vary
dependent on the location of the controlpanel (remote or local of
the control panel assem-bly). If the function differs, it is noted
as either re-mote or local operator panel in the button
de-scription.Operator Panel
The operator panel contains the following compo-nents:
Analog AC Metering Panel: This panel simulta-neously displays
3-phase line to line AC volts andcurrent, kW, power factor and
frequency.The meter panel is composed of a series of LEDs,that are
configured in bar graphs for each function.The LEDs are color
coded, with green indicatingnormal range values, amber for warning
levels andred for shutdown conditions.Scales for each function are in % of nominal values.Resolution
is 1% for values close to nominal, and in-creases at values further
from nominal.Graphical Display: The graphical display is capa-ble of
displaying up to 9-lines of data with approxi-mately 27 characters
per line. The display is used toview the menus of the menu-driven
operating sys-tem.The top three lines of the graphical display containthe
following control information in the order de-scribed:State Line modes of operation, such asStopped, Time Delay To
Start, Warm Up AtIdle, etc. (see Figure 2-2), and paralleling
op-erations, such as Standby, Dead BUS Close,Synchronize, Load
Share and Load Govern.Action Line system actions, such as Warning,Derate, Shutdown
Cool-down and Shutdown,and fault codes.Description Line Fault code messages.Display Menu Selection
Buttons: Six momentarybuttonsthree on each side of the graphical
dis-play windoware used to navigate through the sys-tem control
menus and to adjust generator set pa-rameters. The button is active
when the messageadjacent to the button is highlighted (displayed in
in-verse video). -
2-5
Switch Panel
The switch panel contains the following compo-nents:
Emergency Stop Button: Push the button in foremergency shutdown
of the engine. If the engine isnot running, pushing the button in
will prevent thestarting of the engine, regardless of the start
signalsource (local or remote).To reset:1. Pull the button out.2. Move the 0/Manual/Auto switch
to 0. 3. Press the front panel Fault Acknowledgebutton.4. Select Manual or Auto, as required.
Remote Start Indicator: This green lamp is litwhenever the
control is receiving a remote run sig-nal. When flashing, it
indicates a load demand stopmode.Not in Auto Indicator: This red lamp flashes con-tinuously when
the 0/Manual/Auto switch is not inthe Auto position. (If in Auto
position and lamp isflashing, service is required.)Shutdown Status Indicator: This red lamp is litwhenever the
control detects a shutdown condition.The generator set can not be
started when this lampis on. After the condition is corrected,
shutdown in-dicators can be reset by turning the
0/Manual/Autoswitch to the 0 position, and pressing the Fault
Ac-knowledge button.Dependent upon the specific fault that occurs, theengine may or
may not shut down immediately. Afault that could cause engine
damage, causes animmediate engine shutdown (bypasses
enginecool-down sequence). All other faults would allowthe engine
to run during the cool-down sequencebefore engine shutdown. In this
case, the ShutdownStatus Indicator blinks during the cooldown
period.Warning Status Indicator: This yellow lamp is litwhenever the
control detects a warning condition.After the condition is
corrected, warning indicatorscan be reset by pressing the Fault
Acknowledgebutton. (It is not necessary to stop the generator setif
the fault becomes inactive during genset opera-tion.)Fault Acknowledge: Press this button to acknowl-edge warning and
shutdown messages after thefault has been corrected.To acknowledge a Warning message, the 0/Manu-al/Auto switch can
be in any position. (It is not nec-essary to stop the generator set
to acknowledge aninactive Warning condition.) To acknowledge
ashutdown message with this button, the 0/Manual/Auto switch must
be in the 0 (Off) position.This button is also used to blink a fault code if theShutdown or
Warning Status Indicator is lit. (Thisfunction is used when the
control does not contain agraphical display.) Refer to Reading
Fault Codes inthis section, which describes how to use this
buttonfor interpreting fault codes.Panel Lamp/Lamp Test Button: Press this buttonto turn on or off
the panel lamp. Press and holddown this button for three seconds or
more to turnall control panel LEDs on to make sure all lamps
illu-minate. The illumination will shut off after releasingthe
button.Exercise Button: Press this button to initiate a pre-programmed
exercise sequence. To start the exer-cise sequence, press and hold
down the Exercisebutton and move the O/Manual/Auto switch fromAuto
to Manual and back to Auto or from Manual toAuto.Manual Run/Stop Button: This button starts andstops the set
locally and will bypass Time Delay toStart and Stop sequences. The
0/Manual/Autoswitch must be in the Manual position to enable
thisbutton.0/Manual/Auto Switch: Manual position enablesthe use of the
switch panel Manual Run/Stop but-ton.Auto position enables start/stop control of the en-gine from a
remote location. (Disables the use of theswitch panel Manual
Run/Stop button.)0 (Off) position prevents the starting of the set (localor
remote). If moved to 0 during set operation, willcause an immediate
engine shutdown (bypassescool-down timers). This hot shutdown
should beavoided, if possible, to help prolong the life of
theengine. Hot shutdowns are logged by the systemsoftware. -
2-6
READING FAULT CODES
If the genset contains the optional graphical displayand a fault
occurs, the fault code/message will bedisplayed in the display
Description Line (Figure2-2). If the control does not contain the
graphicaldisplay, the fault code is read from the Warning
andShutdown status indicators.Reading Fault codes Using Warning/ShutdownIndicators: If the
Warning or Shutdown status indi-cator is lit, press and hold the
Fault Acknowledgebutton and release after one second or more.
Afterone second, the Shutdown lamp will begin to blinkthe active
fault code(s) as follows.The Warning lamp is used to indicate the start of anew code. The
Warning lamp will remain on for 2seconds, followed by the Shutdown
lamp blinkingthe fault code. This sequence occurs three times
foreach code. The fourth flash of the Warning lamp in-dicates the
beginning of the second fault code.There are distinct pauses between repetitions of thecode blink
transmissions of the Shutdown lamp.A three digit fault code is indicated by three sets ofblinks
separated by a two second pause. The firstset corresponds to the
hundreds position, the sec-ond to the tens position and the third
to the ones dig-it. Example for Code No. 213:Shutdown LED:blink-blink-pause-blink-pause-blink-blink-blink
Warning LED:blink (2 seconds)
The light will display the fault codes (active or inac-tive) in
succession, starting with the most recent. Upto 32 (unacknowledged)
fault codes can be storedin control panel memory.To return the control to the most recent fault code,press and
release the Fault Acknowledge button(less than one second) and
repeat procedure.When the fault code is acknowledged and cor-rected, the recorded
fault will be deleted from theLED fault log, but will remain in a
data log that main-tains a fault code history. (The InPower service
toolis required to view this data log.) -
2-7
MENU DISPLAY AND SWITCHES
Figure 2-2 shows the graphical display and themenu selection
buttons.Graphical Display: The graphical display is capa-ble of
displaying up to 9-lines of data with approxi-mately 27 characters
per line. The display is used toview the menus of the menu-driven
operating sys-tem. Refer to the menu trees later in this
section.The display is also used to show the following sys-tem
information:State Line modes of operation, such asStopped, Time Delay To
Start, Warm Up AtIdle, etc., and paralleling operations, such
asStandby, Dead BUS Close, Synchronize, etc.Action Line system actions, such as Warning,Derate, Shutdown
Cool-down and Shutdown,and fault codes.Description Line Fault code/status mes-sages.
Menu Buttons: Six momentary buttonsthree oneach side of the
graphical display windowareused to navigate through the system
control menusand to adjust generator set parameters. The buttonis
active when the message or symbol adjacent tothe switch is
highlighted (displayed in inverse vid-eo). The displayed message or
symbol indicatesthe function of the button.In the graphical display, the symbol indicatesthat selecting the
adjacent button causes the operat-ing program to go to the next
menu displayasshown in the menu diagrams.In the graphical display, the symbol indicatesthat selecting the
adjacent button causes the operat-ing program to go back to the
previous menu display.In the graphical display, the symbol indicatesthat selecting the
adjacent button causes the operat-ing program to go back to Main
Menu A (Figure 2-4).STATE LINE
ACTION LINE
MENU DISPLAYAREA
GRAPHICALDISPLAY
MENUBUTTONS
DESCRIPTION LINE
MENUBUTTONS
FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS
-
2-8
LANGUAGE/UNITS SELECTION MENU
During any control panel operation, you can selectone of three
languages and change how units aredisplayed by pressing the two
lower menu buttons(one on each side of display). When pressing
thesetwo buttons simultaneously, the language/unitsmenu will appear
(Figure 2-3). After making desiredselections, press the ENTER
button in this menu tochange and save the selections.Use the + buttons to select the desired option foreach field.
Use the arrow () button to move to thenext field. Selected field is
highlighted.Language: Used to select desired language (de-fault =
English).Location: This selection must be set to Local whenthe graphical
display is mounted on the generatorset front control panel or
Remote when mounted re-motely from the generator set.The Local/Remote selection determines which but-tons in the
Control submenu (page 2-13) are active(displayed).Temp: Used to select F or C for temperature read-ings.
Pressure Fluid: Used to select PSI, KPA, BAR orIN for pressure
readings.Pressure Gas: Used to select INHG or MMHG forpressure
readings.Flow Air: Used to select CFM or CMM for air flowreadings.
ENTER
LANGUAGEENGLISHLOCATIONLOCAL
TEMP FPRESS FLDPSI
PRESS GASINHGFLOW AIRCFM
+
FIGURE 2-3. LANGUAGE/UNITS MENU
-
2-9
MAIN MENU
Figure 2-4 shows the main menus (Menu A andMenu B) of the system
control. The two main menusare used to divide the system submenus
into majorcategories, such as, Engine Data, Alternator
Data,Control, etc.To view system data, simply press the appropriatemenu button to
select the category. After pressingthe desired menu button, refer
to the page numbershown in Figure 2-4 for detailed information
relatedto the selected category.In the following figures, the boxed/highlighted fieldindicates
that the adjacent menu button is active.Also, the submenus are
shown in the order in whichthey are displayed when scrolling up or
down .Adjust Button
The Adjust submenu is intended for qualified sitepersonnel only.
Note that a password may be as-signed to allow only authorized
operators to modifythis data. (Password is not required if not
assigned.)Setup Button
The Setup submenu is described in Section 3.
The Adjust and Setup submenus can be viewed,but not modified
without entering the correct pass-words._\_ Button (Paralleling Applications Only)
When displayed, indicates that the feature for gen-erator set
paralleling applications is installed. Thisbutton is used to open
and close the generator setcircuit breaker (CB). The symbol
indicates if the CBis opened or closed. Opened _\_, push to
close.Closed __, push to open.With the control panel 0/Manual/Auto switch in theAuto position,
the opening and closing of the CB iscontrolled by the control
system software. The CBsymbol will indicate an open or closed CB,
but thebutton will be inactive when the control is in Auto.In the Manual position, the CB can only be closedby using this
button. When manually closed and theCB opens, it must be closed
again by using this but-ton. To close the CB, press and hold the
button untilthe symbol indicates a closed CB. (CB close will oc-cur
only when setup conditions allow dead bus orgenerator synchronized
with bus.)Power Trans Button (Power TransferControl Applications Only)
When displayed, indicates that the Power TransferControl (PTC)
feature is installed. Refer to page2-17 for PTC Data submenu
description. The PTCsetup submenu is described in Section 3. -
2-10
ENGINE
ALTERNATOR
CONTROL
MORE>>
POWER TRAN or _\_
HISTORY/ABOUT
PAGE2-11
PAGE2-12
PAGE2-13
PAGE2-14
Page2-9
MENUB
GRAPHICALDISPLAY
MENUBUTTONS
MENUBUTTONS
SETUP
ADJUST
PARALLEL DATA
BACK
-
2-11
ENGINE SUBMENUS
If you press the ENGINE button in Menu A, the En-gine submenus
will appear (Figure 2-5).The first submenu displays general information thatapplies to
all gensets (coolant temp, oil pressure,etc.) The data in the
remaining submenu(s) will varyaccording to the type and number of
sensors pro-vided with the engine.COOLANT TEMP 180 FOIL PRESSURE 75PSI
ENGINE SPEED 1800RPMBATTERY 29.1VDC
MANF TEMP 75 FMANF PRESS ABS 180INHGRAIL PRESS ABS 180PSIPUMP
PRESS ABS 291PSIFUEL INLET TEMP 172 FCOOLANT PRESSURE 59PSIENGINE
BLOWBY FLOW 25CFMTIMING PRESS 50PSIAFTERCOOLER TEMP 76 FAMBIENT
PRESS 88INHGFIGURE 2-5. ENGINE SUBMENUS
-
2-12
ALTERNATOR SUBMENUS
If you press the ALTERNATOR button in Menu A,the Alternator Data
submenus will appear (Figure2-6).Voltage L-L and L-N: Indicates voltage Line-toLine and
Line-to-Neutral. Note that the Line-to-Neu-tral column will not be
displayed for a 3 phase/3 wiresystem. Accuracy 1%.The voltage Line-to-Line (L1, L2 and L3) are mea-sured between
L1 to L2, L2 to L3 and L3 to L1, re-spectively.Amps: All phases. Accuracy 1%.
Frequency: Generator set output frequency.
AVR DUTY CYCLE: Displays voltage regulator(drive) level in
percentage of maximum.kW, kVA and PF: Displays generator set kW andkVA output (average
and individual phase, and di-rection of flow) and power factor with
leading/lag-ging indication. Accuracy 5%.The PF reading will contain an asterisk if the powerfactor is
leading (for example,*.30).kW kVA PFL1 350 500 .80L2 350 500 .80L3 350 500 .80TOT1050 1500
.80ALTERNATOR
V L-L L-NAMPSL1 480 2771340L2 480 2771290L3 480 2771260
FREQUENCY60.0 HZAVR DUTY CYCLE10.3 %
FIGURE 2-6. ALTERNATOR SUBMENUS
-
2-13
CONTROL SUBMENU
If you press the CONTROL button in Menu A, theControl submenu
will appear (Figure 2-7).Local CONTROL Submenu Function
When the operator panel is mounted on the controlpanel assembly,
the Run Mode Idle/Rated button isactive (displayed). Note in Figure
2-7 that this but-ton is not displayed in remote applications.The shaded area in Figure 2-7 displays the se-lected/active mode
of operation, either IDLE orRATED.Remote CONTROL Submenu Functions
When the operator panel (Figure 2-1) is mountedremotely of the
control panel assembly, the menubuttons in the Control submenu are
used to performthe following remote operations. (To activate
thesemenu buttons for remote/local use, refer to page2-8.)The 0/Manual/Auto switch must be in the Auto posi-tion to
activate the Remote Menu Buttons of the Con-trol submenu.Remote START or STOP Button: This button isused to start and
stop the generator set when theoperator panel is mounted in a
remote location.When the generator set is operating, Stop will bedisplayed for
this button and Start will be displayedwhen not operating.When the generator set is operating in the RemoteStart mode,
removing the Remote Start commanddoes not shut off the engine if
the load is 10 per cent,the cooldown timer is set to zero, and the
control isconfigured for a single unit (not in parallel). The
gen-erator set continues to operate until it runs out offuel, the
Estop button is used, or the load is re-moved.Fault Acknowledge Button: Used to reset inactiveWarning
messages, not Shutdown messages.Local/Remote CONTROL SubmenuFunction
Bargraph Test: The function of this button remainsthe same and
is not dependent on operator panellocation. This button
sequentially lights the LEDs totest the bar graph display.Enable Sync: Displayed in paralleling applicationsonly. Intended
for service personnel to turn off thesynchronizer for
troubleshooting/testing purposes.CONTROL(Remote)
START GENSET
FAULT ACKNOWLEDGE
CONTROL(Local)
+ RUN MODE IDLE
BARGRAPH TEST
BARGRAPH TEST
ENABLE SYNC
ENABLE SYNC
FIGURE 2-7. CONTROL SUBMENU
-
2-14
HISTORY/ABOUT SUBMENUS
If you press the HISTORY/ABOUT button in MenuA, the
History/About submenus will appear (Figure2-8).HISTORY: The control maintains a data log of thenumber of engine
starts and number of operatinghours for the engine and control, and
the megawattand maximum torque hours of the generator set.This
information is stored in non-volatile memoryand will not be deleted
due to loss of battery power.ABOUT: The About submenus provide the follow-ing generator set
information.Genset model and wattage (kW/MW) Output voltage and WYE, DELTA
or SINGLE Frequency 50 or 60 Hz Rating: Standby, Prime or Base
Version level of the controller and panel operat-ing software.
STARTS 533ENGINE HOURS1236CONTROL HOURS7879KWHRS 890
HISTORY/ABOUT
HISTORY-HRS@ %MAX
TORQUE12345@0-923455@50-5912345@10-1912345@60-6912345@20-2912345@70-7912345@30-3912345@80-89MODEL 1750DQKBVOLTAGE416 WYE
FREQUENCY60RATINGSTANDBY
CONTROLLER VERSIONRTOPDN30008.DFABATSAPR 23 1999
OP PANEL VERSIONRTOP1.09 AUG 17 1999
BATS1.02 MAY 6 1999
CONTINUED TO NEXT PAGE
FIGURE 2-8. HISTORY/ABOUT SUBMENUS
-
2-15
HISTORY/ABOUT SUBMENUS (CONT.)
FAULT HISTORY: The control maintains a data logof all fault
conditions as they occur, and time stampsthem with the control and
engine operating hours.Up to 32 (unacknowledged) fault codes can bestored in control
panel memory. After the fault is ac-knowledged and corrected, the
recorded fault willbe deleted from the control panel memory, but
willremain in a data log that maintains a fault code his-tory. (The
InPower service tool is required to viewthis data log.)The Fault History display line: 1 of 24 indicates that24 faults
are recorded and that the most recent fault(1) detected by the
controller is displayed.The Occurrences display line: In this example, 5 in-dicates that
this is the fifth occurrence of this fault.(The InPower service
tool is required to review thelast four faults of this code.)The Occurrences number is incremented for eachnew occurrence of
the same fault. The controllermust detect that the original sensed
fault is cor-rected before it will increment the occurrence num-ber
for that fault.For example, when a Low Oil Pressure fault is de-tected, the
controller will increment the Occurrencesnumber by 1. This fault
will remain active until thefault is acknowledged and the
controller detects thatthe fault is corrected. An active fault will
prevent thecontroller from incrementing the Occurrences num-ber
each time the engine is started. When the con-troller detects that
the oil pressure is normal the faultwill become inactive, allowing
the occurrences num-ber to be incremented for the next detected Low
OilPressurefault.FAULT HISTORY: 1 OF 24CNTL HOURS459OCCURRENCES5ENGINE
HOURS334FAULT CODE1437(FAULT DESCRIPTION)HISTORY/ABOUT (CONT.)
+
FIGURE 2-8. HISTORY/ABOUT SUBMENUS (CONT.)
-
2-16
PARALLEL DATA SUBMENUIf you press the PARALLEL DATA button in
MenuB, the Parallel Data submenu will appear (Figure2-9). This menu
is displayed in paralleling applica-tions only.PARALLEL DATA STATUS LINE: The top line ofthe graphical display
is used to indicate the follow-ing PARALLEL DATA status:STANDBY: Indicates no paralleling activity isoccurring at
present.DEAD BUS CLOSE: Indicates first genset insystem to close to
bus.SYNCHRONIZE: Genset is synchronizing tobus.
LOAD SHARE: Genset has closed to bus andis sharing load with
other gensets in system.LOAD GOVERN: Genset closed to bus in par-allel with utility
(mains).BUS Voltage L-L: The BUS voltage Line-to-Line(L1, L2 and L3) are
measured between L1 to L2, L2to L3 and L3 to L1, respectively.BUS/GEN HZ: BUS/GEN hertz.
BUS/GEN SYNC STATUS: The bottom line of thegraphical display is
used to indicate the followingBUS/GEN Sync status:NOT SYNCHRONIZING: Genset is in servicemode that does not allow
auto sync feature.(Selected via InPower service tool deactivateto
allow synchronization.)SYNCHRONIZING: Genset is synchronizing tobus.
READY TO CLOSE: In manual mode, push cir-cuit breaker close
button to close breaker._\_ Button: Used to open and close the generatorset circuit
breaker (CB). The symbol indicates if theCB is opened or closed.
Opened _\_, push to close.Closed __, push to open.With the control panel 0/Manual/Auto switch in theAuto position,
the opening and closing of the CB iscontrolled by the control
system software. The CBsymbol will indicate an open or closed CB,
but thebutton will be inactive when the control is in Auto.In the Manual position, the CB must be closed bythis button.
When manually closed and the CBopens, it must be closed again by
using this button.To close the CB, press and hold the button until
thesymbol indicates a closed CB. (CB close will occuronly when
setup conditions allow dead bus orgenerator synchronized with
bus.)_\_
V BUS GENL1 480 480L2 480 480L3 480 480HZ60.1 60.1
DEG 122 NOT SYNCHRONIZING
PARALLEL DATA
LOAD GOVERN
FIGURE 2-9. BUS DATA SUBMENU
-
2-17
POWER TRANSFER MAIN/SUBMENUS
If you press the POWER TRANS button in MenuA, the Power Transfer
main menu will appear (Fig-ure 2-10). The Power Transfer Control
(PTC) fea-ture must be installed to display this menu.The PTC feature enables the PCC to monitor theutility voltage
(mains) and frequency for failure andcontrol the opening and
closing of the contacts (cir-cuit breakers) for the utility (S1)
and the genset(S2).If utility fails, the control will initiate the genset start-ing
sequence, open S1 and close S2 to the load.When utility returns,
the load is retransferred to theutility (S1 closes/S2 opens) and
the control initiatesthe genset shutdown sequence.The symbol displayed in the middle of the Pow-er Transfer main
menu indicates which breaker(utility or genset) is closed/opened to
the load. Thesymbol presently shown indicates that the
utilitybreaker is closed and supplying power to the load.The Power Transfer main menu also indicates if theutility and
the generator set are available to acceptload. When the control
detects that either source isready to accept load, UTILITY and/or
GENSET willbe displayed in inverse video.The Power Transfer main menu has four submenugroups. Refer to
the page numbers shown in Figure2-10 for the Power Transfer submenu
descriptions. -
2-18
PTC Status Line
The top line of the graphical display is used to indi-cate the
following PTC status:NOT ENABLED: PTC is not enabled. Controlpanel switch in O (Off)
position.MANUAL: Control panel switch is in Manualposition. All PTC
actions or genset start/stopactions are manually controlled.NORMAL UTIL: Load is connected to the util-ity.
RETRAN: Retransfer of load to utility. RETRAN OVRD: Immediate
retransfer of loadto utility due to genset fault (e.g., warning, der-ate, or
shutdown w/cooldown fault). The re-transfer timer is ignored as is
the retransfer in-hibit.EMERG TEST: Emergency Test sequence ini-tiated through Remote
Start switch with emer-gency start sequence enabled (TB8-3
terminalopened). Emergency test mode means thatthe genset will continue to run even if a gensetwarning or
derate fault occurs. This test can beperformed with or without load
(refer to TEST/EXERCISE submenu in Section 3).TEST: Test sequence initiated through RemoteStart switch with
emergency start sequencedisabled (TB8-3 terminal closed). Test mode
isnon-emergency, which means that a retransferto utility will occur
if any problems occur withthe genset while testing with load. This
test canbe performed with or without load (refer toTEST/EXERCISE
submenu in Section 3).EXERCISE: Exercise sequence initiatedthrough control panel. This
test can be per-formed with or without load (refer to
TEST/EX-ERCISE submenu in Section 3). A retransfer toutility will
occur if any problems occur with thegenset during the exercise
sequence.UTILITY FAIL: Utility has failed. (Initiatestransfer of load to
genset if O/MANUAL/AUTOswitch is in AUTO.)UTILITY
STATUS
TRANSFER CONTROL
GENSET
PAGE2-19
PAGE2-20
PAGE2-21
MENUA
PAGE2-22
MENUBUTTONS
MENUBUTTONS
DEG 123 SYNCHRONIZING
PTC STATUS LINE
FIGURE 2-10. POWER TRANSFER MAIN MENU
-
2-19
UTILITY (PWR TRAN) SUBMENUS
If you press the Utility button in the Power TransferMain menu,
the Utility submenus will appear (Fig-ure 2-11).Voltage L-L and L-N: Indicates utility voltage Line-to Line and
Line-to-Neutral. Note that the Line-to-Neutral column will not be
displayed for a 3 phase/3wire system. Accuracy 1%.The voltage Line-to-Line (L1, L2 and L3) are mea-sured between
L1 to L2, L2 to L3 and L3 to L1, re-spectively.Amps: L2 only. Accuracy 1%.
Frequency: Utility frequency.
kW, kVA and PF: Displays (L2 only) utility kW andkVA output
(average and direction of flow) and pow-er factor with
leading/lagging indication. Accuracy5%.The PF reading will contain an asterisk if the powerfactor is
leading (for example, *.30).UTILITY:kW kVA PF
L1L2 125 175 .96L3TOT
UTILITY
UTILITY:V L-L L-NAMPS
L1480 277L2 480 2771320
L3480 277FREQUENCY60.0 HZ
FIGURE 2-11. UTILITY SUBMENUS
-
2-20
STATUS (PWR TRAN) SUBMENUS
If you press the Status button in the Power Trans-fer Main menu,
the Status submenus will appear(Figure 2-12).Connected: Indicates which source(s) is con-nected to the
load.Available: Indicates when the correspondingsources have
acceptable output voltage and fre-quency. Both can be available
simultaneously.Volt L12: Indicates utility and generator set Line 1 toLine 2
voltage.HZ: Utility and generator set output frequency.
KW L2: Utility and generator set Phase B (L2) kWoutput.
Transfer Inhibit: This feature is used to controlload transfer
to the genset. When activated, loadtransfer to the genset will not
take place if the utilityfails.Transfer inhibit is controlled by connecting a remotecontact
between TB3-57 and TB3-58. Closing thecontact enables the feature
and opening the con-tact disables it. When enabled, the event is
dis-played on the graphical display.Retransfer Inhibit: This feature is used to preventthe PTC from
automatically transferring the loadback to the utility. When
activated, load transfer willnot take place unless the genset fails
(RetransferInhibit is ignored if the genset fails).Retransfer inhibit is controlled by connecting a re-mote contact
between TB3-64 and TB3-65. Closingthe contact enables the feature
and opening thecontact disables it. When enabled, the event is
dis-played on the graphical display.TRAN INHOFFRETRAN INHON
STATUS
UTILGENCONNECTEDYESNOAVAILABLEYESNOVOLT L12 4800
HZ 60.00.0KW L2 4560
FIGURE 2-12. STATUS SUBMENUS
-
2-21
TRANSFER CONTROL (PWR TRAN) SUBMENU
If you press the TRANSFER CONTROL button inthe Power Transfer
Main menu, the Transfer Con-trol submenu will appear (Figure
2-13).The symbol displayed in the middle of theTRANSFER CONTROL
submenu indicates whichbreaker (utility or genset) is closed/opened
to theload. The symbol presently shown indicates that theutility
breaker is closed and supplying power to theload.During genset operation in the manual mode, youcan manually
transfer/retransfer load between theutility and the genset. To
transfer load, press the ap-propriate CB ENABLE button (Utility or
Genset).Example (Figure 2-13)
In the example in Figure 2-13, the CB ENABLE but-ton for Utility
was pressed. (If the CB ENABLEbutton for the Genset was pressed,
ENABLEGEN CB would be displayed in the second subme-nu, allowing
you to open or close the genset circuitbreaker.)After pressing the utility CB ENABLE button, thesecond submenu
will be displayed allowing you toeither CANCEL or ENABLE the
entered selection.Pressing the CANCEL button will return the displayto the
previous menu.Pressing the ENABLE button will display the thirdsubmenu. With
this submenu displayed you can re-turn to the second submenu
without opening theutility circuit breaker (press -
2-22
GENSET (PWR TRAN) SUBMENUS
If you press the Genset button in the Power Trans-fer Main menu,
the Genset submenus will appear(Figure 2-14).Voltage L-L and L-N: Indicates voltage Line-toLine and
Line-to-Neutral. Note that the Line-to-Neu-tral column will not be
displayed for a 3 phase/3 wiresystem. Accuracy 1%.The voltage Line-to-Line (L1, L2 and L3) are mea-sured between
L1 to L2, L2 to L3 and L3 to L1, re-spectively.Amps: All phases. Accuracy 1%.
Frequency: Generator set output frequency.
kW, kVA and PF: Displays generator set kW andkVA output (average
and individual phase, and di-rection of flow) and power factor with
leading/lag-ging indication. Accuracy 5%.The PF reading will contain an asterisk if the powerfactor is
leading (for example,*.30).GENSET:kW kVA PF
L1 100 150 .97L2 125 175 .96L3 150 200 .95TOT375 525 .96
GENSET
GENSET:V L-L L-NAMPSL1 480 2771320L2 480 2771320L3 480
2771320FREQUENCY60.0 HZ
FIGURE 2-14. GENSET SUBMENUS
-
3-1
3. Control Calibration and Adjustment
GENERALThis section contains calibration and
adjustmentprocedures for the generator set control.PARALLELING AND NONPARALLELINGIf the generator set was purchased
for a parallingapplication but will be used for a nonparalling
ap-plication, entering the checksum data into the Data-plate
Checksum dialog in InPower is not re-quired. However, the
Adjustments Paralleling Paralleling Level must be set to Basic.SOFTWARE CALIBRATIONSIf the base card has software assembly A026
F566v1.0 on the U33 flash memory chip, you must usethe latest
software calibration for the control. If youload an earlier
software calibration onto a base cardwith software assembly A026
F566 v1.0, the soft-ware calibration will fail, and the board will
lock uppermanent-ly.FIGURE 3-1. U33 FLASH MEMORY CHIP
CAUTION If the base card has software as-sembly A026 F566 v1.0
on the U33 flash memorychip, you must use the latest software
calibra-tion for the control, or the board will lock up
per-manently.MODIFYING SETUP/ADJUST SUBMENUS
The Setup and Adjust submenus allow you to cali-brate the
graphical display meters and to adjustsystem parameters, customer
defined faults, gen-erator set voltage/frequency and paralleling
ap-plications.CAUTION Improper calibration or adjustmentof the control can
cause equipment malfunctionor damage. Calibration and adjustment
must beperformed by technically qualified personnelonly.The Setup submenus are intended for qualified ser-vice personnel
only. The Adjust submenu is in-tended for qualified service and
site personnel only.For this reason, a password must be entered
beforethis data can be modified. The Setup and Adjustsubmenus can
be viewed, but not modified withoutentering the correct
password.Saving Menu Changes
Changes are automatically saved when the menu isexited.
-
3-2
PASSWORD Menu
To allow the site personnel to modify only the Adjustsubmenu and
not the Setup submenus, two pass-words are assigned within the
system software. AnApplication password is used for the Setup
sub-menus and a User password is used for the Adjustsubmenu.The two passwords are assigned during the initialinstallation of
the generator set (via InPower) andwill vary between sites. The
installer must makesure that the passwords are available to the
ap-propriate personnel.When the generator set is first installed, the Applica-tion and
User password are both set to GENSET toallow initial modification
of the Setup and Adjustsubmenus. Assign new passwords when site
instal-lation is complete.When viewing the Adjust menu, pressing the + or button will
display the User Password menu.When viewing a Setup menu, pressing the + or button will always
display the Application Passwordmenu.After entering the correct password, the system willallow you to
modify the submenus. To help preventunauthorized adjustment, the entered password isvalid for 10
minutes after the last button is pressed(i.e., the password will
need to be reentered afterthe ten minute timeout.Entering Password
To enter the password:
1. Display submenu to modify.
2. Press either the + or button within the dis-played submenu.
The Password menu ap-pears.3. Press the + and button to select the first char-acter of the
password (AZ or 09). (Enter Ap-plication password for Setup
submenus; En-ter User password for Adjust submenu.)4. Press the button to select the next characterfield. Selected
character field is highlighted.5. Repeat steps 3 and 4 to enter remaining pass-word
characters.6. Press the Enter button after entering the pass-word. The
submenu selected in step 1 will re-appear.7. After making desired changes to submenu, exitsubmenu to save
changes.+ OR BUTTON
ENTER
ENTER APPLICATION PASSWORD
+
XXXXXXXX
+ OR BUTTON
ENTER
ENTER USER PASSWORD
+
XXXXXXXX
SETUP SUBMENU PASSWORD MENU ADJUST SUBMENU PASSWORD MENU
FIGURE 3-2. PASSWORD MENUS
-
3-3
SETUP MENUS
Figure 3-3 shows the main menus (Menu A andMenu B) of the system
control and the two Setupmenus.The Setup procedure is intended for qualified ser-vice personnel
only. The APPLICATION passwordmust be entered to modify the Setup
submenufields. Refer to PASSWORD Menu in this section toenter
password and to save menu changes.To display the two Setup menus, press the
MORE>> button in Menu A and then the SETUPbutton in Menu
B.To view system data or to adjust system parame-ters, press the
appropriate Setup menu button todisplay the desired Setup
submenu(s). Refer to thepage number shown in Figure 3-3 for
detailed infor-mation related to the selected submenu(s).CAUTION Improper calibration or adjustmentof the control can
cause equipment malfunctionor damage. Calibration and adjustment
must beperformed by technically qualified personnelonly.GOVERNING/VOLT REG
CUSTOMER FAULTS
CALIBRATION
ISOLATED BUS
UTILITY
ENGINE
ALTERNATOR
CONTROL
MORE>>
POWER TRAN or _\_
HISTORY/ABOUT SETUP
ADJUST
PARALLEL DATA
BACK
-
3-4
GOVERNING/VOLT REG SUBMENU
If you press the GOVERNING/VOLT REG buttonin the Setup menu, the
Governing/Volt Regulatorsubmenu will appear (Figure 3-4).Use the + and buttons to increase or decrease thevalues in the
following fields. Use the arrow () but-ton to move the cursor
within a field or to the nextfield. Exit menu to safe changes.GOV GAIN: If the gain adjustment is set too high,engine speed
will hunt or oscillate. If gain is set toolow, the engine will
respond too slowly to changes inload and overspeed may result.
(Gain should be re-duced to 80% for paralleling installations.)AVR GAIN: If the gain adjustment is set too high,output voltage
will be unstable. If gain is set too low,the output voltage will
respond sluggishly tochanges in load and overshoot may result. -
3-5
GOVERNING/VOLT REG
GOV GAIN80%AVR GAIN100%
+
FIGURE 3-4. GOVERNING/VOLT REG SUBMENU
-
3-6
CUSTOMER FAULTS SUBMENUS
If you press the CUSTOMER FAULTS button inthe Setup menu, the
Customer Faults submenuswill appear (Figure 3-5).There are a total of four customer fault inputs.(Faults 3 and 4
paralleling only.) The message dis-played at the bottom of the menu
can be modifiedfor each of these faults in addition to selecting
thefollowing operating parameters for each fault.Enable On or Off Active Closed or Open Response Shutdown,
Cooldown, Derate orWarning
Shutdown: Genset will immediately shutdown. Normally used for
engine faults.Cooldown: Cooldown sequence will be initi-ated before shutdown.
Should not be used forengine faults.Derate: Used to lower kW output of genset forwarnings such as
pre-high coolant tempera-ture, etc. Paralleling application
controller willreduce precentage of kW load sharing on theset.
Non-paralleling application controller willlower percentage of kW load by operating loadshed relay
contacts.Warning: Display message, genset continuesto operate.The Enable and the Active fields apply to the Fault 1and 4
submenus only.With the Active field selected, pressing the + or buttons will
toggle the selection between CLOSEDand OPEN. Use same operation for
remaining fieldselections.To enter the desired customer fault message, pressthe or button
to display the submenu that con-tains the customer fault message (1
through 4) to bechanged. Use the button to scroll down throughthe
menu selections to the editable fault message(bottom menu
line).Use the button to move to each character posi-tion within the
fault message line.With the desired character position selected, use +or buttons to
select the appropriate character.If these messages are changed, you should notethese changes in
the Troubleshooting section of theOperators manual for this
generator set. -
3-7
CUSTOMER FAULTS
CUSTOMER FAULT1:ENABLE ONACTIVE CLOSEDRESPONSEWARNING
***CUSTOMER FAULT1 ******************
+
CONTINUES THROUGH TWOADDITIONAL MENUS FOR ATOTAL OF FOUR
POSSIBLECUSTOMER FAULT MESSAGES
+
CUSTOMER FAULT2:
RESPONSEWARNING
***CUSTOMER FAULT2 ******************
FIGURE 3-5. CUSTOMER FAULTS SUBMENUS
-
3-8
CALIBRATION SUBMENUS
If you press the CALIBRATION button in the Setupmenu, the
Calibration submenus will appear (Fig-ure 3-6).Use the + and buttons to increase or decrease thevalues in the
following fields. Use the arrow () but-ton to move the cursor
within a field or to the nextfield. Exit menu to safe changes.The Calibration submenus allow you to calibrate thecontrol with
the reading from a calibrated meter.Calibration is accomplished by
using this section ofthe menu software to adjust the display so that itmatches the
reading taken on an accurate, recentlycalibrated meter.Calibration is normally only required when replac-ing certain
circuit cards. Refer to the CalibrationProcedure in this section
which contains a list of thecards that require control
calibration.When performing Bus Voltage Calibration from thegraphical
display, the genset must be off and the Buslive. If the genset is
running, it will synchronize to theBus. -
3-9
CALIBRATION
VOLTAGE CALIBRATIONL1 480-X.X%L2 480-X.X%L3 480-X.X%
+
CURRENT CALIBRATIONL1 234-X.X%L2 123-X.X%L3 562-X.X%
+
BUS VOLTAGE CALIBRATIONL1 480 -X.X%L2 480 -X.X%L3 480 -X.X%
+
FIGURE 3-6. CALIBRATION SUBMENUS
-
3-10
ISOLATED BUS / UTILITY Submenus(Paralleling Application)
The Isolated BUS submenus (Figure 3-7) and theUtility submenus
(Figure 3-8) adjust the control pa-rameters for generator set
protection, synchroniz-ing and load sharing for both isolated bus
and utility(mains) paralleling applications. Utility (mains)
par-allel applications may require adjustment of boththe Isolated
BUS and Utility submenus.Always perform ISO BUS calibration before UtilityBUS
calibration.The sync check (permissive) function is operationalin both
automatic and manual (RUN) modes. Thecontrol will make sure that
the generator set is atproper voltage, within the defined sync
check win-dow for the defined period of time and that phaserotation
is correct. When all criteria are met, the par-alleling breaker is
closed automatically by the con-trol (auto mode), or by operation
of the breakerclose switch by the operator (manual mode).The synchronizing function of the control is enabledwhen the
control has brought the generator set to90% of rated speed and
voltage, and has sensedthat bus voltage is available. The control
automati-cally adjusts the generator set speed and voltage tomatch
the bus frequency and voltage. The controlcan force the generator
set to match bus voltageand frequency in a range of minus 40% to plus 10%of normal bus
conditions. When the parallelingbreaker has closed, the control
will bring the gener-ator set back to normal voltage and
frequency.When the generator set is paralleled to anothergenerator set,
the control provides automatic loadsharing functions for both real
(kW) and reactive(kVAR) loads. Load sharing is proportional
betweengenerator sets based on their standby ratings. If
twogenerator sets of different sizes are paralleled, theywill
assume the same percentage of the systemload automatically. This
can easily be verified on thekW Load LED bar graph on the front of
the controlpanel.When the utility paralleling mode is enabled and thegenerator
set paralleling breaker is closed, the gen-erator set will assume
load based on external ana-log input signal. The input signal must
be calibratedfrom 05 VDC. When the signal is at 0.5 to 1 VDC,the
control will operate the generator at no load inparallel with the
utility (mains) source. At 4.5 VDCand greater, the control will
operate the generatorset at 110% of the generator set base load
setting.When the load govern signal is between 1 VDC and4.5 VDC the
control will operate the generator set ata load level which is
determined by a linear relation-ship between the kW reference and
the load governsignal. -
3-11
ISOLATED BUS SUBMENUS
If you press the ISOLATED BUS button in the Set-up menu, the
Isolated BUS submenus will appear(Figure 3-7).Use the + and buttons to increase or decrease thevalues in the
following fields. Use the arrow () but-ton to move the cursor
within a field or to the nextfield. Exit menu to safe changes.SYNC TIME LIMIT: This parameter adjusts the timedelay in seconds
before the Fail To Synchronizealarm will operate.REVERSE PWR LMT: Adjusts the reverse powerset point. For
PowerCommand generator sets, atypical set point is 10-15%.REVERSE PWR TIME: Adjusts the reverse powerfunction time delay.
A typical time delay which issuitable for PowerCommand generator sets is 3seconds.
Lower reverse power set points can result in nui-sance reverse
power shutdown faults.PERM WIN-PHASE: Adjusts the width of the per-missive
(sync-check) acceptance window. The ad-justment range is from five
to twenty electrical de-grees. Recommended set point is 20 degrees
forisolated bus applications, and 15 degrees for utility(mains)
paralleling applications.PERM WIN-TIME: Adjusts the time period (in sec-onds) for which
the generator set must be synchro-nized with the system bus, before
a breaker closesignal is issued by the PowerCommand
control.Available range is 0.5 to 5 seconds. Recommendedvalue for
PowerCommand generator sets is 0.5seconds for isolated bus
applications. -
3-12
ISOLATED BUS
ISOLATED BUS:SYNC TIME LIMIT 120SEC
REV PWR LMT 10%REV PWR TIME 3SECPERM WIN-PH 20DEGPERM WIN-TIME
.5SEC+
CONTINUED TO NEXT PAGE
FIGURE 3-7. ISO BUS SUBMENUS
-
3-13
Adjusting the control for a smaller sync-check win-dow or longer
time delay will cause synchronizingtime to be extended.SYNC GAIN: The sync gain adjustment controlshow quickly the
governor will respond to try to mini-mize the bus/generator phase
difference. Increas-ing the gain speeds up the response. If the
gain istoo high instability can result.KW Balance and KVAR Balance changes should beequally shared
among all generator sets.KW BALANCE: This function adjusts the kW loadsharing function of
the generator set. Before adjust-ing this value, all generator set
calibrations shouldbe performed. If the total load on the system is
notshared proportionately, the kW Balance can beused to adjust the
generator set for more preciseload sharing. Increasing the kW
Balance value willcause the generator set to reduce the percentage
ofthe total kW load on that set.KVAR BALANCE: This function adjusts the kVARload sharing
function of the generator set. Beforeadjusting this value, all
generator set calibrationsshould be performed. If the total load on
the systemis not shared proportionately, the kVAR balance canbe
used to adjust the generator set for more preciseload sharing.
Increasing the kVAR balance valuewill cause the generator set to
reduce the percent-age of the total kVAR load on that set.KW GAIN: Adjusts the rate of change of kW load onthe generator
set. With a constant load on the sys-tem, if the generator set load
is constantly chang-ing, reduce the gain adjustment on the
generatorset. This also allows modification of the rate of
loadassumption on transient load change.KVAR GAIN: Adjusts the rate of change of kVARload on the
generator set. With a constant load onthe system, if the generator
set load is constantlychanging, reduce the gain adjustment on the
gener-ator set. This also allows modification of the rate ofload
assumption on transient load change. -
3-14
ISOLATED BUS (CONT.)
ISOLATED BUS:SYNC GAIN 1.0KW BALANCE 0.3
KVAR BALANCE 1.2KW GAIN 1.0KVAR GAIN 1.0
+
CONTINUED TO NEXT PAGE
FIGURE 3-7. ISO BUS SUBMENUS (CONT.)
-
3-15
1ST FAIL TIME: Time delay in seconds after a sig-nal from the
first start master is not sensed by thePCC that a FIRST START FAIL
warning is dis-played.RAMP UNLOAD TIME: When a load demand stopinput is sensed the
load is ramped down from thepresent load level on the set to the
ramp unload lev-el in the time specified in seconds.RAMP UNLOAD LEVEL: The load demand rampunload function will ramp
the load down from thepresent level on the set to this level before openingthe set
circuit breaker. Value shown is in % of gensetstandby rating.RAMP LOAD TIME: When the load demand stopsignal is removed the
load is ramped from 0kW tothe load share level in the specified
time after thecircuit breaker closes.LOSS FIELD TIME: Adjusts the loss of field func-tion time delay.
A typical delay which is suitable forPowerCommand generator sets is
2 seconds. -
3-16
ISOLATED BUS (CONT.)
ISOLATED BUS:1ST FAIL TIME 12SECRAMP UNLD 20SEC
RAMP UNLD LEVEL 10%RAMP LOAD TIME 3SECLOSS FIELD 20SEC
+
FIGURE 3-7. ISO BUS SUBMENUS (CONT.)
-
3-17
UTILITY SUBMENUS
If you press the UTILITY button in the Setupmenu, the Utility
submenus will appear (Figure 3-8).Use the + and buttons to increase or decrease thevalues in the
following fields. Use the arrow () but-ton to move the cursor
within a field or to the nextfield. Exit menu to safe changes.BASE LOAD (%): This controls the maximum kWload level that the
generator set will operate at whenparalleled with the utility
(mains). The value shownindicates the steady state load on the
generator asa percent of the generator set standby rating.Check generator set ratings for maximum load levelat which the
generator set should operate whenparalleled with the utility
(mains). Extended opera-tion at load levels in excess of the
generator set rat-ing can cause abnormal engine wear or
prematureengine failure.PF LEVEL: Adjusts the power factor that the gener-ator set will
run at when paralleled to the utility(mains). Recommended setting
is 1.0.RAMP LOAD TIME: This is the ramp time frompresent set load to
level determined by the load setanalog input. This is active when
the control first en-ters the load govern mode.RAMP UNLOAD TIME: This is the ramp time frompresent set load to
0 kW. This ramp is active whenthe load set analog input is less
than 0.5 volts.MODE MULTIPLE/SINGLE: This controls wheth-er the set is to
operate as part of a multiple set orsingle set (PLTE or PLTF)
system. (Refer to LOADDEMAND SHUTDOWN and SINGLE MODE EN-ABLE
function descriptions in wiring diagram,page 5-8.)KW GOVERN GAIN: This controls the rate that thegenerator set kW
load is increased after the genera-tor set has closed to the system
bus when utility(mains) paralleled. Decreasing this value will
resultin slower loading of the generator set.KVAR GOVERN GAIN: This controls the rate thatthe generator set
kVAR load is increased after thegenerator set has closed to the
system bus whenutility (mains) paralleled. Decreasing this value
willresult in slower loading of the generator set. -
3-18
UTILITY
UTILITY:BASE LOAD 80%PF LEVEL 1.00RAMP LOAD 3RAMP UNLD 20MODE
MULTIPLE+
UTILITY:KW GOVERN GAIN 1.00KVAR GOVERN GAIN1.00
+
FIGURE 3-8. UTILITY SUBMENUS
-
3-19
POWER TRANSFER CONTROL MAINMENUS
If you press the POWER TRANSFER SETUP but-ton in the Setup menu
2 in Figure 3-3, the two mainmenus of the optional Power Transfer
Control(PTC) feature will appear (Figure 3-9).To adjust PTC system parameters, press the ap-propriate PTC main
menu button and refer to thepage number shown in Figure 3-9 for
detailed infor-mation related to the submenu selected.UTILITY SENSORS
GENSET SENSORS
TIMERS
PAGE3-13
PAGE3-15
PAGE3-17
NEXTMENU
TEST/EXERCISE PAGE3-18
PTC MAIN MENU 1
PTC MAIN MENU 2
FIGURE 3-9. PTC SETUP MAIN MENUS
-
3-20
UTILITY SENSORS SUBMENUS
If you press the UTILITY SENSORS button in thePTC Main Menu 1,
the Utility Sensors submenuswill appear (Figure 3-10).The following field descriptions show the valid fieldentries and
default value (shown in parenthesis) foreach field.Use the + and buttons to increase or decrease thevalues in the
following fields. Use the arrow () but-ton to move the cursor
within a field or to the nextfield. Exit menu to save changes.U PT VOLT LL: Enter the value of the utility line-to-line
voltage which yields 100% voltage at the termi-nals of the utility
(bus) PT module.Range: 115000V, adjustable by standard nominalvoltage values,
100V, 10V and 1V increments (1V).The 100% voltages for each of the four possible util-ity (bus)
PT modules are as follows, based on mod-ule dash number:01 = 208
volts LL02 = 416 volts LL03 = 600 volts LL04 = 120 volts LLExample 1: Nominal Utility voltage is 480V. Thismeans that
utility (bus) PT module number 02should be used. The voltage which
will yield 100%volts at this PT module is 416 per the above
table.Thus enter 416V.Example 2: Nominal Utility voltage is 4160V. A pri-mary stage
transformer with a ratio of 4200/240 isused. This means that
utility (bus) PT module num-ber 01 should be used. The voltage
which will yieldthe 100% volts (208V from above table) is
calcu-lated as follows:208 x (4200/240) = 3640. Thus enter 3640V.
U NOM VOLT LL: Enter the nominal utility line-to-line voltage.
For example, 480, 4160, etc.. Range:115000 V, adjustable by
standard nominal voltagevalues, 100V, 10V and 1V increments
(1V).U CT RATIO: Enter the CT Ratio of the Utility L2 CT.This is the
Ratio to 1 Amp. Range: 118000 (1A).CAUTION This CT must be rated for 1 Ampoutput (e.g. NOT 5 Amp).
Be sure CT secondarycircuit has burden resistor or a shorting
jumperin place before putting power through the CT.Example: CT
Ratio = 2650:1. Thus enter 2650.U SENSOR TYPE: Enter the line-to-line (L-N) for 3phase
line-neutral voltage sensing or line-to-line(L-L) for 3 phase
line-line voltage sensing. This ap-plies to both the utility
undervoltage and overvol-tage sensors. Range: LL, LN (LN).U : Enter utility connection type.Range: Delta, Wye (Wye).
U UNLOADED KW: Enter the kW on utility Line 2 atwhich the
utility is considered as unloaded. This isthe L2 kW level at which
a closed transition softtransfer will disconnect from the
utility.UTILITY UNDERVOLTAGE: Non-adjustable field,always enabled.
UTILITY OVERVOLTAGE, FREQUENCY: Used toenable or disable menu
function. Choose Enabledor Disabled (Enabled).UV PICKUP: Enter a number between 85 and100% of the nominal
voltage (90%).UV DROP OUT: Enter a number between 75 and98% of the
under-voltage pick-up percentage(90%).UV DELAY: Enter a time between 0.1 and 5.0 sec-onds (0.5
seconds).UV MIN PHASE: Displays the lowest line voltage ofthe three
utility phases. -
3-21
OV PICKUP: This adjusts the over-voltage pickupas a percentage
of the over-voltage drop-out. Entera number between 95 and 99%
(95%).OV DROP OUT: Enter a percentage between 105and 135% of the
nominal voltage (110%).OV DELAY: Enter a range between 0 and 120 sec-onds (3
seconds).OV MAX PHASE: Displays the highest line voltageof the three
utility phases.CENTER (FREQ): Enter a frequency between 45and 65 Hz (60
Hz).PICK UP (FREQ): Enter a percentage between 5and 20% of the
nominal frequency (10%).DROP OUT (FREQ): Enter a percentage between1 and 5% of the
nominal frequency (1%).DELAY (FREQ): Enter a time between 0.1 and 15.0seconds (5.0
seconds).FREQUENCY: This field displays the sensed utilityline
frequency.UTILITY SENSORS
UPT VOLT LL 416UNOM VOLT LL 480UCT RATIO: 1 1000USENSOR TYPE
LLUUNLOADED KW 50 KW
+
UTILITY UV:ENABLED%VLL
PICK UP 95475DROP OUT 85465
DELAY 0.5 SMIN PHASE 470
+
UTILITY OV:DISABLED%VLL
PICK UP 95487DROP OUT 110490
DELAY 3.0 SMAX PHASE485
+
UTILITY FREQ:DISABLEDCENTER 60HZPICK UP 10%DROP OUT 1%DELAY
1.0SFREQUENCY60.5HZ
+
FIGURE 3-10. UTILITY SENSORS SUBMENUS
-
3-22
GENSET SENSORS SUBMENUS
If you press the GENSET SENSORS button in thePTC Main Menu 1,
the Genset Sensors submenuswill appear (Figure 3-11).The following field descriptions show the valid fieldentries and
default value (shown in parenthesis) foreach field.Use the + and buttons to increase or decrease thevalues in the
following fields. Use the arrow () but-ton to move the cursor
within a field or to the nextfield. Exit menu to save changes.G NOM VOLT LL: Non-adjustable field, displayscurrent setting of
genset nominal voltage. (See Ad-just submenu to adjust the output
voltage 5%.)G SENSOR TYPE: Enter the line-to-line (L-N) for 3phase
line-neutral voltage sensing or line-to-line(L-L) for 3 phase
line-line voltage sensing. This ap-plies to both the genset
undervoltage and overvol-tage sensors. Range: LL, LN (LN).G BASE LOAD: Enter the maximum load the gen-set will carry
during a closed transition. Range:0100% (80%).G RAMP LOAD: Enter the ramp time for the gensetramp load rate
during a closed transition soft loadtransfer. Ramp rate is +100%kW
divided by thistime setting. Range: 0900 seconds (20 sec).G RAMP UNLOAD: Enter the ramp time for thegenset ramp unload
rate during a closed transtionsoft load retransfer. Ramp rate is
100%kW dividedby this time setting. Range: 0900 seconds
(20sec).G UNLOADED KW: Enter the %kW (based onstandby rating) that the
genset is considered un-loaded. This is the %kW level at which a
closed tran-sition soft retransfer will disconnect from the
gen-set. Range: 0100% (5%).GEN UNDERVOLTAGE: Non-adjustable field, al-ways enabled.
GEN OVERVOLTAGE, FREQUENCY: Used to en-able or disable menu
function. Choose Enabled orDisabled (Enabled).UV PICKUP: Enter a number between 85 and100% of the nominal
voltage (90%).UV DROP OUT: Enter a number between 75 and98% of the
under-voltage pick-up percentage(90%).UV DELAY: Enter a time between 0.1 and 5.0 sec-onds (4
seconds).UV MIN PHASE: Displays the lowest line voltage ofthe three
genset phases. -
3-23
OV PICKUP: This adjusts the over-voltage pickupas a percentage
of the over-voltage drop-out. Entera number between 95 and 99%
(95%).OV DROP OUT: Enter a percentage between 105and 135% of the
nominal voltage (110%).OV DELAY: Enter a range between 0 and 120 sec-onds (3
seconds).OV MAX PHASE: Displays the highest line voltageof the three
genset phases.CENTER (FREQ): Enter a frequency between 45and 65 Hz (60
Hz).PICK UP (FREQ): Enter a percentage between 5and 20% of the
nominal frequency (10%).DROP OUT (FREQ): Enter a percentage between1 and 5% of the
nominal frequency (1%).DELAY (FREQ): Enter a time between 0.1 and 15.0seconds (5.0
seconds).FREQUENCY: Displays the sensed genset line fre-quency.
GENSET SENSORS
GNOM VOLT LL 480GSENSOR TYPE LLGBASE LOAD 80.0%GRAMP LOAD 20
SGRAMP UNLOAD 20 SGUNLOADED KW 5 %+
GEN UV: ENABLED%VLL
PICK UP 95475DROP OUT 85465
DELAY 1.0 SMIN PHASE 470
+
GEN OV: DISABLED%VLL
PICK UP 95487DROP OUT 110490
DELAY 8.0 SMAX PHASE485
+
GEN FREQ:DISABLEDCENTER 59HZPICK UP 12%DROP OUT 2%DELAY 5.0S
FREQUENCY60.0HZ
+
FIGURE 3-11. GENSET SENSORS SUBMENUS
-
3-24
TIMERS SUBMENU
If you press the TIMERS button in the PTC MainMenu 1, the Timers
submenu will appear (Figure3-12).The following field descriptions show the valid fieldentries and
default value (shown in parenthesis) foreach field.Use the + and buttons to increase or decrease thevalues in the
following fields. Use the arrow () but-ton to move the cursor
within a field or to the nextfield. Exit menu to save changes.START DELAY: Sets time delay for genset enginestart. Prevents
nuisance genset starting during briefpower interruptions.Enter a range from 0 to 300 seconds (0 seconds).
STOP DELAY: Sets the time delay for engine cool-down following a
re-transfer. This stop delay worksin conjunction with and is
activated at the same timeas the normal cooldown timer. (Will
extend normalcooldown timer if entered time is greater.)Enter a time from 0 to 600 seconds (0 seconds).
TRANSFER: In a Normal to Emergency transferthis function allows
the genset to stabilize beforethe load is applied. Enter a time
from 0 to 120 sec-onds (10 seconds).RETRANSFER: In a Emergency to Normal transferthis function
allows the utility to stabilize before theload is applied.Enter a time from 0 to 1800 seconds (600 seconds).
PGM TRANSIT: Sets the time delay for Pro-grammed Transition. A
setting of 0.0 disables theprogram.Enter a time from 0 to 60 seconds (0 seconds).
MAX PARALLEL: Sets the maximum time duringclosed transition that
utility and genset can be paral-leled.Enter a time from 0 to 1800 seconds (20 seconds).
-
3-25
TIMERS
START DELAY60SSTOP DELAY60STRANSFER 10SRETRANSFER900SPGM
TRANSIT5SMAX PARALLEL30S+
FIGURE 3-12. TIMERS SUBMENU
-
3-26
TEST/EXERCISE SUBMENU
If you press the TEST/EXERCISE button in thePTC Main Menu 2, the
Test/Exercise submenu willappear (Figure 3-13).The following field descriptions show the valid fieldentries and
default value (shown in parenthesis) foreach field.Use the + and buttons to increase or decrease thevalues in the
following fields. Use the arrow () but-ton to move the cursor
within a field or to the nextfield. Exit menu to save changes.MODE: Indicates the generator set application typefor PTC
option.OT-PGM TRAN Open transition load transfer.CT-MOMENT Closed
transition load transferwith momentary ( -
3-27
TEST/EXERCISE
MODE CT-SOFT
TEST WITH LOADOFFEXER WITH LOADOFF
+
FIGURE 3-13. TIMERS SUBMENU
-
3-28
ADJUST SUBMENU
Figure 3-14 shows the main menus (Menu A andMenu B) of the
system control and the Adjust sub-menu.To display the Adjust submenu, press the MORE>>button in
Menu A and then the ADJUST button inMenu B.The Adjust submenus are intended for qualifiedservice personnel
and site personnel only and mayrequire a USER password. If a
password is re-quired, the USER password menu will appear whenyou
try to modify the Adjust submenus. (Refer toPASSWORD Menu in this
section to enter pass-word.Changes are automatically saved when you exitthis menu.
If the generator set is operating in parallel with asystem bus,
the voltage and frequency adjustmentsare disabled to prevent inadvertent misadjustmentof the
paralleling load sharing functions.Use the + and buttons to increase or decrease thevalues in the
following fields. Use the arrow () but-ton to move the cursor
within a field or to the nextfield. Exit menu to safe changes.START DELAY: This delay applies only to remotestarting in the
Auto mode. The Start Delay adjust-ment range is 0 to 300
seconds.STOP DELAY: This delay applies only to remotestopping in the
Auto mode. The Stop Delay adjust-ment range is 0 to 600
seconds.VOLTAGE: Used to adjust the output voltage 5%.
FREQUENCY: Used to adjust the frequency 3 Hz.
VOLTAGE/SPEED DROOP: These two submenusapply to a genset that
has the paralleling option andis configured to operate in droop
mode.ENGINE
ALTERNATOR
CONTROL
MORE>>
_\_
HISTORY/ABOUT
SETUP
ADJUST
BUS DATA
BACK
-
3-29
CALIBRATION PROCEDURE
There are several circuit cards/modules that, whenremoved and
replaced, require you to recalibratethe control panel display for
genset voltage and cur-rent and bus voltage.Note that the type of calibration to perform varies foreach
card. The letters A, B and C are used to desig-nate which of the
following three calibration proce-dures are required for each
card/module.Genset/Parallel board (A, B & C) PT/CT board (A & B) Bus
PT (C) CTs (B)WARNING Contacting high voltage compo-nents can cause
electrocution, resulting in se-vere personal injury or death.
Calibration andadjustment must be performed by technicallyqualified
personnel only. Read and observe allWARNINGS and CAUTIONS in your
generatorset manuals.CAUTION Improper calibration or adjustmentof the PowerCommand
control can causeequipment malfunction or damage. Calibrationand
adjustment must be performed by techni-cally qualified personnel
only.Use a calibrated RMS multimeter for accurate mea-surements.
(A) Genset Voltage Display Calibration
The PowerCommand control automatically synchro-nizes to the
system bus when bus voltage is avail-able and the genset is
running. Consequently, it isnot possible to calibrate the genset
output voltagedisplay of the genset that is running when the bus isenergized.
If it is necessary to adjust the output volt-age display of the
genset that is running, the InPowerservice tool must be used to
switch off the synchro-nizer function of the control.1. Display the Voltage Calibration submenu(Page 3-6).
2. With the genset OFF, attach a calibrated volt-meter to the AC
output from L1 to L2. (L1 toNeutral for single phase
alternators.)3. Start the genset and allow it to reach normaloperating
speed.4. Calibrate voltage reading for L1 so that thereading on the
display agrees with the cali-brated voltmeter.5. Shut the generator set OFF.6. Repeat steps 2 through 5 for L2
and L3. (In step2 attach meter to the AC output from L2 to L3 tocalibrate L2 and
L3 to L1 to calibrate L3.)7. Exit menu to safe changes.
(B) Genset Ammeter Display Calibration
1. Display the Current Calibration submenu(Page 3-6).
2. With the genset OFF, attach a calibrated am-meter to L1.
3. Start the genset and allow it to reach normaloperating
speed.4. Load the genset to maximum rated kVA atrated voltage.
5. Calibrate the reading for L1 current so that thereading on
the display agrees with calibratedammeter.6. Repeat steps 2 through 5 for L2 and L3. (In step2, attach
meter to L2 to calibrate L2 current andL3 to calibrate L3
current.)7. Exit menu to safe changes.
-
3-30
(C) Bus Voltage Calibration
The PowerCommand control automatically synchro-nizes to the
system bus when bus voltage is avail-able and the genset is
running. Consequently, it isnot possible to calibrate the genset
bus voltage dis-play of the genset that is running when the bus is
en-ergized. If it is necessary to adjust the bus voltagedisplay of
the genset that is running, the InPowerservice tool must be used to
switch off the synchro-nizer function of the control.1. Display the Bus Voltage Calibration submenu(Page 3-6).
2. With all gensets OFF, attach a calibrated volt-
meter to TB1-A (L1) and TB1-B (L2) of the busPT module (Figure
3-15).3. Start another genset and allow it to reach nor-mal operating
speed and voltage. Connect op-erating genset to the bus.4. Calibrate the voltage reading for Bus Volts L1so that the
reading on the display matches thereading on the calibrated
meter.5. Shut the generator set OFF.6. Repeat steps 2 through 5 for
Bus Volts L2 andL3. (In step 2 attach meter to the AC outputfrom L2 to L3 to
calibrate L2; L3 to L1 to cali-brate L3.)7. Exit menu to safe changes.
TB1-A (L1)
CONTROLBOX DOOR
TB1-B (L2)
TB1-C (L3)
FIGURE 3-15. BUS PT MODULE
-
3-31
CONTROL BOX WIRING
The generator set control box assembly, which canbe located on
either side of the genset, containsconnection points for remote
control and monitoroptions.Customer monitor/control connections are at-tached to terminal
blocks TB3 and TB8 (see Figure3-16). Optional equipment such as a remote annun-ciator panel,
sensing devices used to monitor gen-set operation, remote
start/stop switches, controlbox heater, and etc. are also attached
to these ter-minal blocks. Driver signals for customer
suppliedrelays are also provided for several alarm and shutdown
conditions. Refer to Customer Connectionsdiagram in Section 7. -
3-32
TB8
CARDCAGE
OPTIONALSHUTDOWN
ALARM RELAY K16
OPTIONALRUN RELAYS
K11, K12 & K13
CONTROL WIRINGACCESS
FIGURE 3-16. CONTROL BOX ASSEMBLY INTERIOR
-
3-33
RUN RELAYS (K11, K12, K13)
The optional run relays are rail mounted inside thecontrol box
(Figure 3-16). The rail mount allows youto easily remove and
replace the snap-on relays.The generator set can be equipped with
one, two orthree run relays.The three-pole, double-throw run relays (Figure3-17) are used to
control auxiliary equipment suchas fans, pumps and motorized air dampers. The runrelays are
energized when the generator set reach-es operating speed.The contacts are rated:
10 amps at 28 VDC or 120 VAC, 80%PF 6 amps at 240 VAC, 80%PF 3
amps at 480/600 VAC, 80%PFCUSTOMERCONNECTIONS
TB3-7(GND)
TB3-5(SWITCHED B+)
NO
COIL
COM
NC
K11, K12, K13
K11RUN RELAY
K11, K12, K13
K11, K12, K13
K12RUN RELAY
K13RUN RELAY
NO
NC
NO
NC
FIGURE 3-17. OPTIONAL RUN RELAYS (K11, K12, K13)
-
3-34
ALARM RELAY (K16)
The optional alarm relay is rail mounted inside thecontrol box
(Figure 5-2). The rail mount allows youto easily remove and replace
the snap-on relay.The three-pole, double-throw alarm relay (Figure5-4) is often
used to energize warning devices suchas audible alarms. Any generator set shutdown willenergize the
alarm relay.The contacts are rated:
10 amps at 28 VDC or 120 VAC, 80%PF 6 amps at 240 VAC, 80%PF 3
amps at 480/600 VAC, 80%PFCUSTOMERCONNECTIONS
TB3-18(GND)
TB3-17(COM ALARM)
NO
COIL
COM
NC
K16
K16
K16
K16SHUTDOWN ALARM
FIGURE 3-18. OPTIONAL ALARM RELAY (K16)
-
3-35
MAGNETIC SPEED PICKUP UNIT (MPU)INSTALLATION
To install the MPU sensor, bar the engine until agear tooth on
the flywheel lines up in the center ofthe mounting hole. Thread the sensor in gently byhand until it
just touches the gear tooth. Back it outone quarter turn and set
the locknut.CAUTION Do not use fan blade to bar over en-gine. That can
damage blades and cause prop-erty damage and personal injury. -
3-36
MAGNETICPIC
Published on December 2016 | Categories: Documents | Downloads: 330 | Comments: 0 | Views: 830
Service Manual
Controller
PowerCommand
3201
English − Original Instructions 9−2010 A034T572 (Issue 1)
i
Table of Contents
SECTION TITLE PAGE
1. Introduction 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABOUT THIS MANUAL 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST EQUIPMENT 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO OBTAIN SERVICE 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Control Operation 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEQUENCE OF OPERATION 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL POWER ON/OFF MODES 2-1 . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL ASSEMBLY 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
READING FAULT CODES 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MENU DISPLAY AND SWITCHES 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LANGUAGE/UNITS SELECTION MENU 2-8 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN MENU 2-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SUBMENUS 2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR SUBMENUS 2-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL SUBMENU 2-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HISTORY/ABOUT SUBMENUS 2-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HISTORY/ABOUT SUBMENUS (CONT.) 2-15 . . . . . . . . . . . . . . . . . . . . . . . . .
PARALLEL DATA SUBMENU 2-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TRANSFER MAIN/SUBMENUS 2-17 . . . . . . . . . . . . . . . . . . . . . . . . .
UTILITY (PWR TRAN) SUBMENUS 2-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATUS (PWR TRAN) SUBMENUS 2-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFER CONTROL (PWR TRAN) SUBMENU 2-21 . . . . . . . . . . . . . . . . .
GENSET (PWR TRAN) SUBMENUS 2-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Control Calibration and Adjustment 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARALLELING and NON−PARALLELING 3-1 . . . . . . . . . . . . . . . . . . . . . . . . .
SOFTWARE CALIBRATIONS 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODIFYING SETUP/ADJUST SUBMENUS 3-1 . . . . . . . . . . . . . . . . . . . . . . . .
SETUP MENUS 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GOVERNING/VOLT REG SUBMENU 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CUSTOMER FAULTS SUBMENUS 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIBRATION SUBMENUS 3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ISOLATED BUS SUBMENUS 3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UTILITY SUBMENUS 3-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TRANSFER CONTROL MAIN MENUS 3-19 . . . . . . . . . . . . . . . . . . .
UTILITY SENSORS SUBMENUS 3-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENSET SENSORS SUBMENUS 3-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMERS SUBMENU 3-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST/EXERCISE SUBMENU 3-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUST SUBMENU 3-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIBRATION PROCEDURE 3-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
SECTION TITLE PAGE
CONTROL BOX WIRING 3-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RUN RELAYS (K11, K12, K13) 3-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALARM RELAY (K16) 3-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAGNETIC SPEED PICKUP UNIT (MPU) INSTALLATION 3-35 . . . . . . . . .
v
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains
important instructions that should be followed during
installation and maintenance of the generator set and
batteries.
Before operating the generator set (genset), read the
Operator’s Manual and become familiar with it and the
equipment. Safe and efficient operation can be
achieved only if the equipment is properly operated
and maintained. Many accidents are caused by failure
to follow fundamental rules and precautions.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper-
ator, service personnel, or the equipment.
This symbol warns of immediate
hazards which will result in severe personal in-
jury or death.
WARNING This symbol refers to a hazard or un-
safe practice which can result in severe person-
al injury or death.
CAUTION This symbol refers to a hazard or un-
safe practice which can result in personal injury
or product or property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can result
from improper practices.
DO NOT fill fuel tanks while engine is running, un-
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential
fire hazard.
DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source
near the generator set or fuel tank.
Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be
made with an approved flexible line. Do not use zinc
coated or copper fuel lines with diesel fuel.
Be sure all fuel supplies have a positive shutoff
valve.
Be sure battery area has been well-ventilated prior
to servicing near it. Lead-acid batteries emit a highly
explosive hydrogen gas that can be ignited by arc-
ing, sparking, smoking, etc.
EXHAUST GASES ARE DEADLY
Provide an adequate exhaust system to properly
expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
likely to congregate. Visually and audibly inspect
the exhaust daily for leaks per the maintenance
schedule. Make sure that exhaust manifolds are se-
cured and not warped. Do not use exhaust gases to
heat a compartment.
Be sure the unit is well ventilated.
Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
birth defects, and other reproductive harm.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
Keep your hands, clothing, and jewelry away from
moving parts.
Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
connect starting batteries, negative (−) cable first.
This will prevent accidental starting.
Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
in position over fans, drive belts, etc.
Do not wear loose clothing or jewelry in the vicinity of
moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
caught in moving parts.
If adjustment must be made while the unit is run-
ning, use extreme caution around hot manifolds,
moving parts, etc.
DO NOT OPERATE IN FLAMMABLE AND
EXPLOSIVE ENVIRONMENTS
Flammable vapor can cause an engine to overspeed and
become difficult to stop, resulting in possible fire, explo-
sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
created by fuel spill, leak, etc., unless the genset is
equipped with an automatic safety device to block the air
intake and stop the engine. The owners and operators of
the genset are solely responsible for operating the gen-
set safely. Contact your authorized Cummins Power
Generation distributor for more information.
vi
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH
Remove electric power before removing protective
shields or touching electrical equipment. Use rub-
ber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not
wear jewelry. Jewelry can short out electrical con-
tacts and cause shock or burning.
Use extreme caution when working on electrical
components. High voltages can cause injury or
death. DO NOT tamper with interlocks.
Follow all applicable state and local electrical
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open
switches to avoid accidental closure.
DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator set
into the utility line. This creates a potential for elec-
trocution or property damage. Connect only
through an approved isolation switch or an ap-
proved paralleling device.
GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex-
changer pressure cap while the engine is running.
To prevent severe scalding, let engine cool down
before removing coolant pressure cap. Turn cap
slowly, and do not open it fully until the pressure has
been relieved.
Used engine oils have been identified by some state
or federal agencies as causing cancer or reproduc-
tive toxicity. When checking or changing engine oil,
take care not to ingest, breathe the fumes, or con-
tact used oil.
Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
and flammable liquid fuels and gaseous fuels; Class
C fires, live electrical equipment. (ref. NFPA No. 10).
Make sure that rags or combustible material are not
left on or near the generator set.
Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
under or near the unit.
Remove all unnecessary grease and oil from the
unit. Accumulated grease and oil can cause over-
heating and engine damage which present a poten-
tial fire hazard.
Keep the generator set and the surrounding area
clean and free from obstructions. Remove any de-
bris from the set and keep the floor clean and dry.
Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
or drug that makes the operation of equipment un-
safe.
Substances in exhaust gases have been identified
by some state or federal agencies as causing can-
cer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases.
Do not store any flammable liquids, such as fuel,
cleaners, oil, etc., near the generator set. A fire or
explosion could result.
Wear hearing protection when near an operating
generator set.
To prevent serious burns, avoid contact with hot
metal parts such as radiator system, turbo charger
system and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
1-1
1. Introduction
ABOUT THIS MANUAL
This manual provides PowerCommand
Control
3201 (PCC) calibration and adjustment proce-
dures, control operation, alternator test and repair
procedures.
Operating and maintenance instructions are in the
applicable Operator’s Manual.
Read Important Safety Instructions and carefully
observe all instructions and precautions in this
manual.
TEST EQUIPMENT
To perform the test procedures in this manual, the
following test equipment must be available
True RMS meter for accurate measurement of
small AC and DC voltages.
Battery Hydrometer
Jumper Leads
Tachometer or Frequency Meter
Wheatstone Bridge or Digital Ohmmeter
Variac
Load Test Panel
Megger or Insulation Resistance Meter
InPower Service Tool (PC based genset ser-
vice tool)
HOW TO OBTAIN SERVICE
Always give the complete Model, Specification and
Serial number of the generator set as shown on the
nameplate when seeking additional service infor-
mation or replacement parts. The nameplate is lo-
cated on the side of the generator output box.
WARNING Incorrect service or replacement of
parts can result in severe personal injury or
death, and/or equipment damage. Service per-
sonnel must be trained and experienced to per-
form electrical and mechanical service. Read
and follow Important Safety Instructions, on
pages iii and iv.
1-2
THIS PAGE LEFT INTENTIONALLY BLANK
2-1
2. Control Operation
GENERAL
The following describes the function and operation
of the PowerCommand
Control 3200 (PCC). All in-
dicators, control switches/buttons and graphical
display are located on the face of the control panel
as illustrated in Figure 2-1.
Normally, generator set configuration options are
set at the factory. When a new control is installed on
a generator set or when parts are replaced, the con-
trol must be configured for that generator set. Setup
and calibration procedures are described in Sec-
tion 3.
SEQUENCE OF OPERATION
When the PowerCommand control is in the AUTO
mode, it will cause the generator set to start on re-
ceiving a signal from a remote device. The control
will initiate a starter cranking signal and verify that
the engine is rotating. The control will provide suffi-
cient fuel to the engine to accelerate to start discon-
nect speed. On reaching that speed, the control will
ramp the generator set to idle (warm-up) or rated
speed and voltage.
On reaching rated speed and voltage, the control
checks the system bus voltage. If no bus voltage is
present, it will wait for a pulse from a remote Master
First Start Sensor. On receiving that pulse, the con-
trol will signal the paralleling breaker to close.
If bus voltage is present, the control will check for
proper phase rotation, adjust the generator set to
the bus voltage and frequency level, and then syn-
chronize the generator set to the system bus. When
a synchronous condition is achieved, the control will
send a signal to close the paralleling breaker.
When the paralleling breaker is closed, the genera-
tor set will assume it’s proportional share of the total
load on the system bus.
CONTROL PANEL POWER ON/OFF
MODES
The power on/off modes of the control panel and op-
erating software are Power On, Screen Saver and
Sleep/Awake.
Power On Mode: In this mode, power is continu-
ously supplied to the control panel. The control’s
operating software and control panel LEDs/graphi-
cal display will remain active until the Screen Saver
mode is activated.
2-2
Screen Saver Mode: Power to the graphical dis-
play will be removed after 10 minutes (generator set
not running or running). The 10 minute timer resets
and begins after each control panel action (any but-
ton or switch selection) or signal received by the op-
erating software. The bottom LEDs of the Analog
AC Metering Panel (bar graphs) may remain on dur-
ing Screen Saver mode, indicating that the operat-
ing software is active (Awake mode).
When a “Warning” signal is sensed by the PCC (for
example, low coolant temp), the control will display
the warning message. The control will remain active
until the Fault Acknowledge button is pressed to
clear the warning message and start the 10 minute
timer.
Sleep/Awake Mode: In the Sleep mode, the con-
trol’s operating software is inactive and the LEDs
and the graphical display on the control panel are all
off. Sleep mode is a feature that is used to reduce
battery power consumption when the control is not
being used.
In Off mode, Sleep mode is activated when there
are no unacknowledged faults and Screen Saver
mode is active.
In Auto mode, Sleep mode can be enabled or dis-
abled. When shipped from the factory, it is disabled.
You can enable Sleep mode by making these
changes:
Use InPower service tool to set Auto Sleep En-
able to Sleep in Auto.
Set switch S1 on the Genset/Paralleling Card
to Sleep/Off. This switch is located next to con-
nector J8 and relay K9.
If these conditions are not met, Sleep mode is dis-
abled in Auto mode.
The graphical display can enter Screen Saver mode
even if Sleep mode is disabled.
If Sleep mode is enabled in Auto mode, Sleep mode
is activated when there are no unacknowledged
faults and Screen Saver mode is active.
The operating software is initialized and the control
panel LEDs and graphical display are turned on in
response to one of the following:
Moving/pressing any control panel switch/but-
ton. (If Sleep mode is enabled in Auto mode,
the control will remain asleep if Sleep mode
was previously active in Off mode.)
Receiving a remote start input signal (genera-
tor set in Auto mode)
Receiving an active DCD signal on the RS-232
port.
Modem RI latch becoming active.
Digital display waking up.
Lonworks (backplane) wakeup becoming ac-
tive.
Customer fault 2 or 3 only (shutdown or warn-
ing indicator is on).
Dial Out process becoming active.
To activate the control and view the menu display
without starting the generator set, press any button
on the control panel.
2-3
DISPLAY MENU
SELECTION BUTTONS
(1 of 6)
0/MANUAL/AUTO
SWITCH
REMOTE START,
NOT IN AUTO,
SHUTDOWN,
WARNING
STATUS INDICATORS
GRAPHICAL
DISPLAY
ANALOG AC
METERING
PANEL
OPERATOR PANEL SWITCH PANEL
MANUAL RUN/
STOP BUTTON
& INDICATOR
EXERCISE
BUTTON &
INDICATOR
FAULT
ACKNOWLEDGE
BUTTON
PANEL LAMP/
LAMP TEST
BUTTON
EMERGENCY
STOP PUSH
BUTTON
0
FIGURE 2-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)
2-4
CONTROL PANEL ASSEMBLY
The control panel assembly (Figure 2-1) consist of
two panels, the Operator Panel and the Switch Pan-
el.
Dependent on site requirements, the Operator Pan-
el is either mounted on the control panel assembly
(full-featured) as shown in Figure 2-1 or contained
in a separate enclosure and mounted remotely of
the control panel assembly.
The function of several buttons on the control panel
will vary dependent on the location of the control
panel (remote or local of the control panel assem-
bly). If the function differs, it is noted as either “re-
mote” or “local operator panel” in the button de-
scription.
Operator Panel
The operator panel contains the following compo-
nents:
Analog AC Metering Panel: This panel simulta-
neously displays 3-phase line to line AC volts and
current, kW, power factor and frequency.
The meter panel is composed of a series of LEDs,
that are configured in bar graphs for each function.
The LEDs are color coded, with green indicating
normal range values, amber for warning levels and
red for shutdown conditions.
Scales for each function are in % of nominal values.
Resolution is 1% for values close to nominal, and in-
creases at values further from nominal.
Graphical Display: The graphical display is capa-
ble of displaying up to 9-lines of data with approxi-
mately 27 characters per line. The display is used to
view the menus of the menu-driven operating sys-
tem.
The top three lines of the graphical display contain
the following control information in the order de-
scribed:
State Line − modes of operation, such as
Stopped, Time Delay To Start, Warm Up At
Idle, etc. (see Figure 2-2), and paralleling op-
erations, such as Standby, Dead BUS Close,
Synchronize, Load Share and Load Govern.
Action Line − system actions, such as Warning,
Derate, Shutdown Cool-down and Shutdown,
and fault codes.
Description Line − Fault code messages.
Display Menu Selection Buttons: Six momentary
buttons—three on each side of the graphical dis-
play window—are used to navigate through the sys-
tem control menus and to adjust generator set pa-
rameters. The button is active when the message
adjacent to the button is highlighted (displayed in in-
verse video).
2-5
Switch Panel
The switch panel contains the following compo-
nents:
Emergency Stop Button: Push the button in for
emergency shutdown of the engine. If the engine is
not running, pushing the button in will prevent the
starting of the engine, regardless of the start signal
source (local or remote).
To reset:
1. Pull the button out.
2. Move the 0/Manual/Auto switch to 0.
3. Press the front panel Fault Acknowledge
button.
4. Select Manual or Auto, as required.
Remote Start Indicator: This green lamp is lit
whenever the control is receiving a remote run sig-
nal. When flashing, it indicates a load demand stop
mode.
Not in Auto Indicator: This red lamp flashes con-
tinuously when the 0/Manual/Auto switch is not in
the Auto position. (If in Auto position and lamp is
flashing, service is required.)
Shutdown Status Indicator: This red lamp is lit
whenever the control detects a shutdown condition.
The generator set can not be started when this lamp
is on. After the condition is corrected, shutdown in-
dicators can be reset by turning the 0/Manual/Auto
switch to the 0 position, and pressing the Fault Ac-
knowledge button.
Dependent upon the specific fault that occurs, the
engine may or may not shut down immediately. A
fault that could cause engine damage, causes an
immediate engine shutdown (bypasses engine
cool-down sequence). All other faults would allow
the engine to run during the cool-down sequence
before engine shutdown. In this case, the Shutdown
Status Indicator blinks during the cooldown period.
Warning Status Indicator: This yellow lamp is lit
whenever the control detects a warning condition.
After the condition is corrected, warning indicators
can be reset by pressing the Fault Acknowledge
button. (It is not necessary to stop the generator set
if the fault becomes inactive during genset opera-
tion.)
Fault Acknowledge: Press this button to acknowl-
edge warning and shutdown messages after the
fault has been corrected.
To acknowledge a Warning message, the 0/Manu-
al/Auto switch can be in any position. (It is not nec-
essary to stop the generator set to acknowledge an
inactive Warning condition.) To acknowledge a
shutdown message with this button, the 0/Manual/
Auto switch must be in the 0 (Off) position.
This button is also used to blink a fault code if the
Shutdown or Warning Status Indicator is lit. (This
function is used when the control does not contain a
graphical display.) Refer to Reading Fault Codes in
this section, which describes how to use this button
for interpreting fault codes.
Panel Lamp/Lamp Test Button: Press this button
to turn on or off the panel lamp. Press and hold
down this button for three seconds or more to turn
all control panel LEDs on to make sure all lamps illu-
minate. The illumination will shut off after releasing
the button.
Exercise Button: Press this button to initiate a pre-
programmed exercise sequence. To start the exer-
cise sequence, press and hold down the Exercise
button and move the O/Manual/Auto switch from
Auto to Manual and back to Auto or from Manual to
Auto.
Manual Run/Stop Button: This button starts and
stops the set locally and will bypass Time Delay to
Start and Stop sequences. The 0/Manual/Auto
switch must be in the Manual position to enable this
button.
0/Manual/Auto Switch: Manual position enables
the use of the switch panel Manual Run/Stop but-
ton.
Auto position enables start/stop control of the en-
gine from a remote location. (Disables the use of the
switch panel Manual Run/Stop button.)
0 (Off) position prevents the starting of the set (local
or remote). If moved to 0 during set operation, will
cause an immediate engine shutdown (bypasses
cool-down timers). This hot shutdown should be
avoided, if possible, to help prolong the life of the
engine. Hot shutdowns are logged by the system
software.
2-6
READING FAULT CODES
If the genset contains the optional graphical display
and a fault occurs, the fault code/message will be
displayed in the display Description Line (Figure
2-2). If the control does not contain the graphical
display, the fault code is read from the Warning and
Shutdown status indicators.
Reading Fault codes Using Warning/Shutdown
Indicators: If the Warning or Shutdown status indi-
cator is lit, press and hold the Fault Acknowledge
button and release after one second or more. After
one second, the Shutdown lamp will begin to blink
the active fault code(s) as follows.
The Warning lamp is used to indicate the start of a
new code. The Warning lamp will remain on for 2
seconds, followed by the Shutdown lamp blinking
the fault code. This sequence occurs three times for
each code. The fourth flash of the Warning lamp in-
dicates the beginning of the second fault code.
There are distinct pauses between repetitions of the
code blink transmissions of the Shutdown lamp.
A three digit fault code is indicated by three sets of
blinks separated by a two second pause. The first
set corresponds to the hundreds position, the sec-
ond to the tens position and the third to the ones dig-
it. Example for Code No. 213:
Shutdown LED:
blink-blink-pause-blink-pause-blink-blink-blink
Warning LED:
blink (2 seconds)
The light will display the fault codes (active or inac-
tive) in succession, starting with the most recent. Up
to 32 (unacknowledged) fault codes can be stored
in control panel memory.
To return the control to the most recent fault code,
press and release the Fault Acknowledge button
(less than one second) and repeat procedure.
When the fault code is acknowledged and cor-
rected, the recorded fault will be deleted from the
LED fault log, but will remain in a data log that main-
tains a fault code history. (The InPower service tool
is required to view this data log.)
2-7
MENU DISPLAY AND SWITCHES
Figure 2-2 shows the graphical display and the
menu selection buttons.
Graphical Display: The graphical display is capa-
ble of displaying up to 9-lines of data with approxi-
mately 27 characters per line. The display is used to
view the menus of the menu-driven operating sys-
tem. Refer to the menu trees later in this section.
The display is also used to show the following sys-
tem information:
State Line − modes of operation, such as
Stopped, Time Delay To Start, Warm Up At
Idle, etc., and paralleling operations, such as
Standby, Dead BUS Close, Synchronize, etc.
Action Line − system actions, such as Warning,
Derate, Shutdown Cool-down and Shutdown,
and fault codes.
Description Line − Fault code/status mes-
sages.
Menu Buttons: Six momentary buttons—three on
each side of the graphical display window—are
used to navigate through the system control menus
and to adjust generator set parameters. The button
is active when the message or symbol adjacent to
the switch is highlighted (displayed in inverse vid-
eo). The displayed message or symbol indicates
the function of the button.
In the graphical display, the “B” symbol indicates
that selecting the adjacent button causes the operat-
ing program to go to the next menu display—as
shown in the menu diagrams.
In the graphical display, the “Y” symbol indicates
that selecting the adjacent button causes the operat-
ing program to go back to the previous menu display.
In the graphical display, the “ ” symbol indicates
that selecting the adjacent button causes the operat-
ing program to go back to Main Menu A (Figure 2-4).
STATE LINE
ACTION LINE
MENU DISPLAY
AREA
GRAPHICAL
DISPLAY
MENU
BUTTONS
DESCRIPTION LINE
MENU
BUTTONS
FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS
2-8
LANGUAGE/UNITS SELECTION MENU
During any control panel operation, you can select
one of three languages and change how units are
displayed by pressing the two lower menu buttons
(one on each side of display). When pressing these
two buttons simultaneously, the language/units
menu will appear (Figure 2-3). After making desired
selections, press the ENTER button in this menu to
change and save the selections.
Use the + buttons to select the desired option for
each field. Use the arrow () button to move to the
next field. Selected field is highlighted.
Language: Used to select desired language (de-
fault = English).
Location: This selection must be set to Local when
the graphical display is mounted on the generator
set front control panel or Remote when mounted re-
motely from the generator set.
The Local/Remote selection determines which but-
tons in the Control submenu (page 2-13) are active
(displayed).
Temp: Used to select F or C for temperature read-
ings.
Pressure Fluid: Used to select PSI, KPA, BAR or
IN for pressure readings.
Pressure Gas: Used to select INHG or MMHG for
pressure readings.
Flow Air: Used to select CFM or CMM for air flow
readings.
ENTER
LANGUAGE ENGLISH
LOCATION LOCAL
TEMP F
PRESS FLD PSI
PRESS GAS INHG
FLOW AIR CFM
+
FIGURE 2-3. LANGUAGE/UNITS MENU
2-9
MAIN MENU
Figure 2-4 shows the main menus (Menu A and
Menu B) of the system control. The two main menus
are used to divide the system submenus into major
categories, such as, Engine Data, Alternator Data,
Control, etc.
To view system data, simply press the appropriate
menu button to select the category. After pressing
the desired menu button, refer to the page number
shown in Figure 2-4 for detailed information related
to the selected category.
In the following figures, the boxed/highlighted field
indicates that the adjacent menu button is active.
Also, the submenus are shown in the order in which
they are displayed when scrolling up Y or down B.
Adjust Button
The Adjust submenu is intended for qualified site
personnel only. Note that a password may be as-
signed to allow only authorized operators to modify
this data. (Password is not required if not assigned.)
Setup Button
The Setup submenu is described in Section 3.
The “Adjust” and “Setup” submenus can be viewed,
but not modified without entering the correct pass-
words.
_\_ Button (Paralleling Applications Only)
When displayed, indicates that the feature for gen-
erator set paralleling applications is installed. This
button is used to open and close the generator set
circuit breaker (CB). The symbol indicates if the CB
is opened or closed. Opened _\_, push to close.
Closed _−_, push to open.
With the control panel 0/Manual/Auto switch in the
Auto position, the opening and closing of the CB is
controlled by the control system software. The CB
symbol will indicate an open or closed CB, but the
button will be inactive when the control is in Auto.
In the Manual position, the CB can only be closed
by using this button. When manually closed and the
CB opens, it must be closed again by using this but-
ton. To close the CB, press and hold the button until
the symbol indicates a closed CB. (CB close will oc-
cur only when setup conditions allow − dead bus or
generator synchronized with bus.)
Power Trans Button (Power Transfer
Control Applications Only)
When displayed, indicates that the Power Transfer
Control (PTC) feature is installed. Refer to page
2-17 for PTC Data submenu description. The PTC
setup submenu is described in Section 3.
2-10
ENGINE
ALTERNATOR
CONTROL
MORE>>
POWER TRAN or _\_
HISTORY/ABOUT
PAGE
2-11
PAGE
2-12
PAGE
2-13
PAGE
2-14
Page
2-9
MENU
B
GRAPHICAL
DISPLAY
MENU
BUTTONS
MENU
BUTTONS
SETUP
ADJUST
PARALLEL DATA
BACK<<
Section
3
MENU
A
PAGE
2-16
Section
3
MENU A
MENU B
FIGURE 2-4. SYSTEM CONTROL MAIN MENUS A AND B
2-11
ENGINE SUBMENUS
If you press the “ENGINE” button in Menu A, the En-
gine submenus will appear (Figure 2-5).
The first submenu displays general information that
applies to all gensets (coolant temp, oil pressure,
etc.) The data in the remaining submenu(s) will vary
according to the type and number of sensors pro-
vided with the engine.
B
COOLANT TEMP 180 F
OIL PRESSURE 75 PSI
ENGINE SPEED 1800 RPM
BATTERY 29.1 VDC
Y
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
ENGINE
Y
BLOWBY FLOW 25 CFM
TIMING PRESS 50 PSI
AFTERCOOLER TEMP 76 F
AMBIENT PRESS 88 INHG
B
Y
FIGURE 2-5. ENGINE SUBMENUS
2-12
ALTERNATOR SUBMENUS
If you press the “ALTERNATOR” button in Menu A,
the Alternator Data submenus will appear (Figure
2-6).
Voltage L-L and L-N: Indicates voltage Line-to
Line and Line-to-Neutral. Note that the Line-to-Neu-
tral column will not be displayed for a 3 phase/3 wire
system. Accuracy 1%.
The voltage Line-to-Line (L1, L2 and L3) are mea-
sured between L1 to L2, L2 to L3 and L3 to L1, re-
spectively.
Amps: All phases. Accuracy 1%.
Frequency: Generator set output frequency.
AVR DUTY CYCLE: Displays voltage regulator
(drive) level in percentage of maximum.
kW, kVA and PF: Displays generator set kW and
kVA output (average and individual phase, and di-
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
The PF reading will contain an asterisk if the power
factor is leading (for example,
*.30).
Y
kW kVA PF
L1 350 500 .80
L2 350 500 .80
L3 350 500 .80
TOT1050 1500 .80
ALTERNATOR
B
V L-L L-N AMPS
L1 480 277 1340
L2 480 277 1290
L3 480 277 1260
FREQUENCY 60.0 HZ
AVR DUTY CYCLE 10.3 %
Y
FIGURE 2-6. ALTERNATOR SUBMENUS
2-13
CONTROL SUBMENU
If you press the “CONTROL” button in Menu A, the
Control submenu will appear (Figure 2-7).
Local CONTROL Submenu Function
When the operator panel is mounted on the control
panel assembly, the Run Mode Idle/Rated button is
active (displayed). Note in Figure 2-7 that this but-
ton is not displayed in remote applications.
The shaded area in Figure 2-7 displays the se-
lected/active mode of operation, either IDLE or
RATED.
Remote CONTROL Submenu Functions
When the operator panel (Figure 2-1) is mounted
remotely of the control panel assembly, the menu
buttons in the Control submenu are used to perform
the following remote operations. (To activate these
menu buttons for remote/local use, refer to page
2-8.)
The 0/Manual/Auto switch must be in the Auto posi-
tion to activate the Remote Menu Buttons of the Con-
trol submenu.
Remote START or STOP Button: This button is
used to start and stop the generator set when the
operator panel is mounted in a remote location.
When the generator set is operating, Stop will be
displayed for this button and Start will be displayed
when not operating.
When the generator set is operating in the Remote
Start mode, removing the Remote Start command
does not shut off the engine if the load is 10 per cent,
the cooldown timer is set to zero, and the control is
configured for a single unit (not in parallel). The gen-
erator set continues to operate until it runs out of
fuel, the E−stop button is used, or the load is re-
moved.
Fault Acknowledge Button: Used to reset inactive
Warning messages, not Shutdown messages.
Local/Remote CONTROL Submenu
Function
Bargraph Test: The function of this button remains
the same and is not dependent on operator panel
location. This button sequentially lights the LEDs to
test the bar graph display.
Enable Sync: Displayed in paralleling applications
only. Intended for service personnel to turn off the
synchronizer for troubleshooting/testing purposes.
CONTROL
(Remote)
START GENSET
FAULT ACKNOWLEDGE
CONTROL
(Local)
+ RUN MODE IDLE Y
Y
Y
BARGRAPH TEST
Y
B
BARGRAPH TEST
Y
B
ENABLE SYNC
ENABLE SYNC
FIGURE 2-7. CONTROL SUBMENU
2-14
HISTORY/ABOUT SUBMENUS
If you press the “HISTORY/ABOUT” button in Menu
A, the History/About submenus will appear (Figure
2-8).
HISTORY: The control maintains a data log of the
number of engine starts and number of operating
hours for the engine and control, and the megawatt
and maximum torque hours of the generator set.
This information is stored in non-volatile memory
and will not be deleted due to loss of battery power.
ABOUT: The About submenus provide the follow-
ing generator set information.
Genset model and wattage (kW/MW)
Output voltage and WYE, DELTA or SINGLE
Frequency 50 or 60 Hz
Rating: Standby, Prime or Base
Version level of the controller and panel operat-
ing software.
Y
STARTS 533
ENGINE HOURS 1236
CONTROL HOURS 7879
KWHRS 890
HISTORY/ABOUT
B
B
HISTORY-HRS@ %MAX TORQUE
12345@0-9 23455@50-59
12345@10-19 12345@60-69
12345@20-29 12345@70-79
12345@30-39 12345@80-89
Y
Y
B
MODEL 1750DQKB
VOLTAGE416 WYE
FREQUENCY 60
RATINGSTANDBY
CONTROLLER VERSION
RTOPDN30008.DFA
BATSAPR 23 1999
OP PANEL VERSION
RTOP1.09 AUG 17 1999
BATS1.02 MAY 6 1999
Y
B
CONTINUED TO NEXT PAGE
FIGURE 2-8. HISTORY/ABOUT SUBMENUS
2-15
HISTORY/ABOUT SUBMENUS (CONT.)
FAULT HISTORY: The control maintains a data log
of all fault conditions as they occur, and time stamps
them with the control and engine operating hours.
Up to 32 (unacknowledged) fault codes can be
stored in control panel memory. After the fault is ac-
knowledged and corrected, the recorded fault will
be deleted from the control panel memory, but will
remain in a data log that maintains a fault code his-
tory. (The InPower service tool is required to view
this data log.)
The Fault History display line: 1 of 24 indicates that
24 faults are recorded and that the most recent fault
(1) detected by the controller is displayed.
The Occurrences display line: In this example, 5 in-
dicates that this is the fifth occurrence of this fault.
(The InPower service tool is required to review the
last four faults of this code.)
The Occurrences number is incremented for each
new occurrence of the same fault. The controller
must detect that the original sensed fault is cor-
rected before it will increment the occurrence num-
ber for that fault.
For example, when a Low Oil Pressure fault is de-
tected, the controller will increment the Occurrences
number by 1. This fault will remain active until the
fault is acknowledged and the controller detects that
the fault is corrected. An active fault will prevent the
controller from incrementing the Occurrences num-
ber each time the engine is started. When the con-
troller detects that the oil pressure is normal the fault
will become inactive, allowing the occurrences num-
ber to be incremented for the next detected Low Oil
Pressure
fault.
FAULT HISTORY: 1 OF 24
CNTL HOURS 459
OCCURRENCES 5
ENGINE HOURS 334
FAULT CODE 1437
(FAULT DESCRIPTION)
HISTORY/ABOUT (CONT.)
Y +
FIGURE 2-8. HISTORY/ABOUT SUBMENUS (CONT.)
2-16
PARALLEL DATA SUBMENU
If you press the “PARALLEL DATA” button in Menu
B, the Parallel Data submenu will appear (Figure
2-9). This menu is displayed in paralleling applica-
tions only.
PARALLEL DATA STATUS LINE: The top line of
the graphical display is used to indicate the follow-
ing PARALLEL DATA status:
− STANDBY: Indicates no paralleling activity is
occurring at present.
− DEAD BUS CLOSE: Indicates first genset in
system to close to bus.
− SYNCHRONIZE: Genset is synchronizing to
bus.
− LOAD SHARE: Genset has closed to bus and
is sharing load with other gensets in system.
− LOAD GOVERN: Genset closed to bus in par-
allel with utility (mains).
BUS Voltage L-L: The BUS voltage Line-to-Line
(L1, L2 and L3) are measured between L1 to L2, L2
to L3 and L3 to L1, respectively.
BUS/GEN HZ: BUS/GEN hertz.
BUS/GEN SYNC STATUS: The bottom line of the
graphical display is used to indicate the following
BUS/GEN Sync status:
− NOT SYNCHRONIZING: Genset is in service
mode that does not allow auto sync feature.
(Selected via InPower service tool − deactivate
to allow synchronization.)
− SYNCHRONIZING: Genset is synchronizing to
bus.
− READY TO CLOSE: In manual mode, push cir-
cuit breaker close button to close breaker.
_\_ Button: Used to open and close the generator
set circuit breaker (CB). The symbol indicates if the
CB is opened or closed. Opened _\_, push to close.
Closed _−_, push to open.
With the control panel 0/Manual/Auto switch in the
Auto position, the opening and closing of the CB is
controlled by the control system software. The CB
symbol will indicate an open or closed CB, but the
button will be inactive when the control is in Auto.
In the Manual position, the CB must be closed by
this button. When manually closed and the CB
opens, it must be closed again by using this button.
To close the CB, press and hold the button until the
symbol indicates a closed CB. (CB close will occur
only when setup conditions allow − dead bus or
generator synchronized with bus.)
_\_
Y
V BUS GEN
L1480 480
L2480 480
L3480 480
HZ60.1 60.1
DEG −122 NOT SYNCHRONIZING
PARALLEL DATA
LOAD GOVERN
FIGURE 2-9. BUS DATA SUBMENU
2-17
POWER TRANSFER MAIN/SUBMENUS
If you press the “POWER TRANS” button in Menu
A, the Power Transfer main menu will appear (Fig-
ure 2-10). The Power Transfer Control (PTC) fea-
ture must be installed to display this menu.
The PTC feature enables the PCC to monitor the
utility voltage (mains) and frequency for failure and
control the opening and closing of the contacts (cir-
cuit breakers) for the utility (S1) and the genset
(S2).
If utility fails, the control will initiate the genset start-
ing sequence, open S1 and close S2 to the load.
When utility returns, the load is retransferred to the
utility (S1 closes/S2 opens) and the control initiates
the genset shutdown sequence.
The symbol displayed in the middle of the Pow-
er Transfer main menu indicates which breaker
(utility or genset) is closed/opened to the load. The
symbol presently shown indicates that the utility
breaker is closed and supplying power to the load.
The Power Transfer main menu also indicates if the
utility and the generator set are available to accept
load. When the control detects that either source is
ready to accept load, UTILITY and/or GENSET will
be displayed in inverse video.
The Power Transfer main menu has four submenu
groups. Refer to the page numbers shown in Figure
2-10 for the Power Transfer submenu descriptions.
2-18
PTC Status Line
The top line of the graphical display is used to indi-
cate the following PTC status:
− NOT ENABLED: PTC is not enabled. Control
panel switch in O (Off) position.
− MANUAL: Control panel switch is in Manual
position. All PTC actions or genset start/stop
actions are manually controlled.
− NORMAL UTIL: Load is connected to the util-
ity.
− RETRAN: Retransfer of load to utility.
− RETRAN OVRD: Immediate retransfer of load
to utility due to genset fault (e.g., warning, der-
ate, or shutdown w/cooldown fault). The re-
transfer timer is ignored as is the retransfer in-
hibit.
− EMERG TEST: Emergency Test sequence ini-
tiated through Remote Start switch with emer-
gency start sequence enabled (TB8-3 terminal
opened). Emergency test mode means that
the genset will continue to run even if a genset
warning or derate fault occurs. This test can be
performed with or without load (refer to TEST/
EXERCISE submenu in Section 3).
− TEST: Test sequence initiated through Remote
Start switch with emergency start sequence
disabled (TB8-3 terminal closed). Test mode is
non-emergency, which means that a retransfer
to utility will occur if any problems occur with
the genset while testing with load. This test can
be performed with or without load (refer to
TEST/EXERCISE submenu in Section 3).
− EXERCISE: Exercise sequence initiated
through control panel. This test can be per-
formed with or without load (refer to TEST/EX-
ERCISE submenu in Section 3). A retransfer to
utility will occur if any problems occur with the
genset during the exercise sequence.
− UTILITY FAIL: Utility has failed. (Initiates
transfer of load to genset if O/MANUAL/AUTO
switch is in AUTO.)
B UTILITY
STATUS
TRANSFER CONTROL
GENSET B
PAGE
2-19
PAGE
2-20
PAGE
2-21
MENU
A
PAGE
2-22
MENU
BUTTONS
MENU
BUTTONS
DEG −123 SYNCHRONIZING
PTC STATUS LINE
FIGURE 2-10. POWER TRANSFER MAIN MENU
2-19
UTILITY (PWR TRAN) SUBMENUS
If you press the “Utility” button in the Power Transfer
Main menu, the Utility submenus will appear (Fig-
ure 2-11).
Voltage L-L and L-N: Indicates utility voltage Line-
to Line and Line-to-Neutral. Note that the Line-to-
Neutral column will not be displayed for a 3 phase/3
wire system. Accuracy 1%.
The voltage Line-to-Line (L1, L2 and L3) are mea-
sured between L1 to L2, L2 to L3 and L3 to L1, re-
spectively.
Amps: L2 only. Accuracy 1%.
Frequency: Utility frequency.
kW, kVA and PF: Displays (L2 only) utility kW and
kVA output (average and direction of flow) and pow-
er factor with leading/lagging indication. Accuracy
5%.
The PF reading will contain an asterisk if the power
factor is leading (for example, *.30).
Y
UTILITY:
kW kVA PF
L1
L2 125 175 .96
L3
TOT
UTILITY
B
UTILITY:
V L-L L-N AMPS
L1480 277
L2 480 277 1320
L3480 277
FREQUENCY 60.0 HZ
Y
FIGURE 2-11. UTILITY SUBMENUS
2-20
STATUS (PWR TRAN) SUBMENUS
If you press the “Status” button in the Power Trans-
fer Main menu, the Status submenus will appear
(Figure 2-12).
Connected: Indicates which source(s) is con-
nected to the load.
Available: Indicates when the corresponding
sources have acceptable output voltage and fre-
quency. Both can be available simultaneously.
Volt L12: Indicates utility and generator set Line 1 to
Line 2 voltage.
HZ: Utility and generator set output frequency.
KW L2: Utility and generator set Phase B (L2) kW
output.
Transfer Inhibit: This feature is used to control
load transfer to the genset. When activated, load
transfer to the genset will not take place if the utility
fails.
Transfer inhibit is controlled by connecting a remote
contact between TB3-57 and TB3-58. Closing the
contact enables the feature and opening the con-
tact disables it. When enabled, the event is dis-
played on the graphical display.
Retransfer Inhibit: This feature is used to prevent
the PTC from automatically transferring the load
back to the utility. When activated, load transfer will
not take place unless the genset fails (Retransfer
Inhibit is ignored if the genset fails).
Retransfer inhibit is controlled by connecting a re-
mote contact between TB3-64 and TB3-65. Closing
the contact enables the feature and opening the
contact disables it. When enabled, the event is dis-
played on the graphical display.
Y
TRAN INHOFF
RETRAN INH ON
STATUS
B
UTIL GEN
CONNECTED YES NO
AVAILABLEYES NO
VOLT L12 480 0
HZ 60.0 0.0
KW L2 456 0
Y
FIGURE 2-12. STATUS SUBMENUS
2-21
TRANSFER CONTROL (PWR TRAN) SUBMENU
If you press the “TRANSFER CONTROL” button in
the Power Transfer Main menu, the Transfer Con-
trol submenu will appear (Figure 2-13).
The symbol displayed in the middle of the
TRANSFER CONTROL submenu indicates which
breaker (utility or genset) is closed/opened to the
load. The symbol presently shown indicates that the
utility breaker is closed and supplying power to the
load.
During genset operation in the manual mode, you
can manually transfer/retransfer load between the
utility and the genset. To transfer load, press the ap-
propriate CB ENABLE button (Utility or Genset).
Example (Figure 2-13)
In the example in Figure 2-13, the CB ENABLE but-
ton for “Utility” was pressed. (If the CB ENABLE
button for the “Genset” was pressed, ENABLE
GEN CB would be displayed in the second subme-
nu, allowing you to open or close the genset circuit
breaker.)
After pressing the “utility” CB ENABLE button, the
second submenu will be displayed allowing you to
either CANCEL or ENABLE the entered selection.
Pressing the CANCEL button will return the display
to the previous menu.
Pressing the ENABLE button will display the third
submenu. With this submenu displayed you can re-
turn to the second submenu without opening the
utility circuit breaker (press <<BACK) or you can
press the OPEN UTIL button.
Pressing the OPEN UTIL button will display the
fourth submenu, indicating that the utility circuit
breaker is now opened.
Note that the fourth submenu displays CLOSE
UTIL. Pressing this button will close the utility circuit
breaker and redisplay the third subme-
nu.
ENABLE UTIL CB
TRANSFER CONTROL
UTILITY GENSET
CB ENABLE CB ENABLE
<< BACK
CANCEL
UTILITY GENSET
OPEN UTIL CB ENABLE
<< BACK
UTILITY GENSET
CLOSE UTIL CB ENABLE
<< BACK
FIGURE 2-13. TRANSFER CONTROL SUBME-
NUS
2-22
GENSET (PWR TRAN) SUBMENUS
If you press the “Genset” button in the Power Trans-
fer Main menu, the Genset submenus will appear
(Figure 2-14).
Voltage L-L and L-N: Indicates voltage Line-to
Line and Line-to-Neutral. Note that the Line-to-Neu-
tral column will not be displayed for a 3 phase/3 wire
system. Accuracy 1%.
The voltage Line-to-Line (L1, L2 and L3) are mea-
sured between L1 to L2, L2 to L3 and L3 to L1, re-
spectively.
Amps: All phases. Accuracy 1%.
Frequency: Generator set output frequency.
kW, kVA and PF: Displays generator set kW and
kVA output (average and individual phase, and di-
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
The PF reading will contain an asterisk if the power
factor is leading (for example,
*.30).
Y
GENSET:
kW kVA PF
L1 100 150 .97
L2 125 175 .96
L3 150 200 .95
TOT375 525 .96
GENSET
B
GENSET:
V L-L L-N AMPS
L1 480 277 1320
L2 480 277 1320
L3 480 277 1320
FREQUENCY 60.0 HZ
Y
FIGURE 2-14. GENSET SUBMENUS
3-1
3. Control Calibration and Adjustment
GENERAL
This section contains calibration and adjustment
procedures for the generator set control.
PARALLELING AND NON−PARALLELING
If the generator set was purchased for a paralling
application but will be used for a non−paralling ap-
plication, entering the checksum data into the Data-
plate Checksum dialog in InPowert is not re-
quired. However, the Adjustments Paralleling −
Paralleling Level must be set to Basic.
SOFTWARE CALIBRATIONS
If the base card has software assembly A026 F566
v1.0 on the U33 flash memory chip, you must use
the latest software calibration for the control. If you
load an earlier software calibration onto a base card
with software assembly A026 F566 v1.0, the soft-
ware calibration will fail, and the board will lock up
permanent-
ly.
FIGURE 3-1. U33 FLASH MEMORY CHIP
CAUTION If the base card has software as-
sembly A026 F566 v1.0 on the U33 flash memory
chip, you must use the latest software calibra-
tion for the control, or the board will lock up per-
manently.
MODIFYING SETUP/ADJUST SUBMENUS
The Setup and Adjust submenus allow you to cali-
brate the graphical display meters and to adjust
system parameters, customer defined faults, gen-
erator set voltage/frequency and paralleling ap-
plications.
CAUTION Improper calibration or adjustment
of the control can cause equipment malfunction
or damage. Calibration and adjustment must be
performed by technically qualified personnel
only.
The Setup submenus are intended for qualified ser-
vice personnel only. The Adjust submenu is in-
tended for qualified service and site personnel only.
For this reason, a password must be entered before
this data can be modified. The Setup and Adjust
submenus can be viewed, but not modified without
entering the correct password.
Saving Menu Changes
Changes are automatically saved when the menu is
exited.
3-2
PASSWORD Menu
To allow the site personnel to modify only the Adjust
submenu and not the Setup submenus, two pass-
words are assigned within the system software. An
Application password is used for the Setup sub-
menus and a User password is used for the Adjust
submenu.
The two passwords are assigned during the initial
installation of the generator set (via InPower) and
will vary between sites. The installer must make
sure that the passwords are available to the ap-
propriate personnel.
When the generator set is first installed, the Applica-
tion and User password are both set to GENSET to
allow initial modification of the Setup and Adjust
submenus. Assign new passwords when site instal-
lation is complete.
When viewing the Adjust menu, pressing the + or −
button will display the User Password menu.
When viewing a Setup menu, pressing the + or −
button will always display the Application Password
menu.
After entering the correct password, the system will
allow you to modify the submenus. To help prevent
unauthorized adjustment, the entered password is
valid for 10 minutes after the last button is pressed
(i.e., the password will need to be reentered after
the ten minute time−out.
Entering Password
To enter the password:
1. Display submenu to modify.
2. Press either the + or − button within the dis-
played submenu. The Password menu ap-
pears.
3. Press the + and − button to select the first char-
acter of the password (A−Z or 0−9). (Enter Ap-
plication password for Setup submenus; En-
ter User password for Adjust submenu.)
4. Press the button to select the next character
field. Selected character field is highlighted.
5. Repeat steps 3 and 4 to enter remaining pass-
word characters.
6. Press the Enter button after entering the pass-
word. The submenu selected in step 1 will re-
appear.
7. After making desired changes to submenu, exit
submenu to save changes.
+ OR − BUTTON
ENTER
ENTER APPLICATION PASSWORD
+
−
XXXXXXXX
+ OR − BUTTON
ENTER
ENTER USER PASSWORD
+
−
XXXXXXXX
SETUP SUBMENU PASSWORD MENU ADJUST SUBMENU PASSWORD MENU
FIGURE 3-2. PASSWORD MENUS
3-3
SETUP MENUS
Figure 3-3 shows the main menus (Menu A and
Menu B) of the system control and the two Setup
menus.
The Setup procedure is intended for qualified ser-
vice personnel only. The APPLICATION password
must be entered to modify the Setup submenu
fields. Refer to PASSWORD Menu in this section to
enter password and to save menu changes.
To display the two Setup menus, press the
MORE>> button in Menu A and then the SETUP
button in Menu B.
To view system data or to adjust system parame-
ters, press the appropriate Setup menu button to
display the desired Setup submenu(s). Refer to the
page number shown in Figure 3-3 for detailed infor-
mation related to the selected submenu(s).
CAUTION Improper calibration or adjustment
of the control can cause equipment malfunction
or damage. Calibration and adjustment must be
performed by technically qualified personnel
only.
GOVERNING/VOLT REG
CUSTOMER FAULTS
CALIBRATION
Y
B
ISOLATED BUS
UTILITY
ENGINE
ALTERNATOR
CONTROL
MORE>>
POWER TRAN or _\_
HISTORY/ABOUT SETUP
ADJUST
PARALLEL DATA
BACK<<
MENU A MENU B
PAGE
3-4
PAGE
3-5
PAGE
3-6
MENU
A
MENU
B
NEXT
MENU
PAGE
3-7
PAGE
3-11
MENU
A
ABOVE
MENU
MENU
B
MENU
A
Y POWER TRANSFER SETUP
SETUP MENU 1
SETUP MENU 2
PAGE
3-12
FIGURE 3-3. SETUP SUBMENUS
3-4
GOVERNING/VOLT REG SUBMENU
If you press the “GOVERNING/VOLT REG” button
in the Setup menu, the Governing/Volt Regulator
submenu will appear (Figure 3-4).
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
field. Exit menu to safe changes.
GOV GAIN: If the gain adjustment is set too high,
engine speed will “hunt” or oscillate. If gain is set too
low, the engine will respond too slowly to changes in
load and overspeed may result. (Gain should be re-
duced to 80% for paralleling installations.)
AVR GAIN: If the gain adjustment is set too high,
output voltage will be unstable. If gain is set too low,
the output voltage will respond sluggishly to
changes in load and overshoot may result.
3-5
GOVERNING/VOLT REG
Y
GOV GAIN 80%
AVR GAIN 100%
+
−
FIGURE 3-4. GOVERNING/VOLT REG SUBMENU
3-6
CUSTOMER FAULTS SUBMENUS
If you press the “CUSTOMER FAULTS” button in
the Setup menu, the Customer Faults submenus
will appear (Figure 3-5).
There are a total of four customer fault inputs.
(Faults 3 and 4 paralleling only.) The message dis-
played at the bottom of the menu can be modified
for each of these faults in addition to selecting the
following operating parameters for each fault.
Enable − On or Off
Active − Closed or Open
Response − Shutdown, Cooldown, Derate or
Warning
Shutdown: Genset will immediately shut
down. Normally used for engine faults.
Cooldown: Cooldown sequence will be initi-
ated before shutdown. Should not be used for
engine faults.
Derate: Used to lower kW output of genset for
warnings such as pre-high coolant tempera-
ture, etc. Paralleling application − controller will
reduce precentage of kW load sharing on the
set. Non-paralleling application − controller will
lower percentage of kW load by operating load
shed relay contacts.
Warning: Display message, genset continues
to operate.
The Enable and the Active fields apply to the Fault 1
and 4 submenus only.
With the Active field selected, pressing the + or −
buttons will toggle the selection between CLOSED
and OPEN. Use same operation for remaining field
selections.
To enter the desired customer fault message, press
the B or Y button to display the submenu that con-
tains the customer fault message (1 through 4) to be
changed. Use the button to scroll down through
the menu selections to the editable fault message
(bottom menu line).
Use the button to move to each character posi-
tion within the fault message line.
With the desired character position selected, use +
or − buttons to select the appropriate character.
If these messages are changed, you should note
these changes in the Troubleshooting section of the
Operator’s manual for this generator set.
3-7
CUSTOMER FAULTS
Y
B
CUSTOMER FAULT1:
ENABLE ON
ACTIVE CLOSED
RESPONSE WARNING
***CUSTOMER FAULT1 ******************
+
−
CONTINUES THROUGH TWO
ADDITIONAL MENUS FOR A
TOTAL OF FOUR POSSIBLE
CUSTOMER FAULT MESSAGES
Y
B
+
−
CUSTOMER FAULT2:
RESPONSE WARNING
***CUSTOMER FAULT2 ******************
FIGURE 3-5. CUSTOMER FAULTS SUBMENUS
3-8
CALIBRATION SUBMENUS
If you press the “CALIBRATION” button in the Setup
menu, the Calibration submenus will appear (Fig-
ure 3-6).
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
field. Exit menu to safe changes.
The Calibration submenus allow you to calibrate the
control with the reading from a calibrated meter.
Calibration is accomplished by using this section of
the menu software to adjust the display so that it
matches the reading taken on an accurate, recently
calibrated meter.
Calibration is normally only required when replac-
ing certain circuit cards. Refer to the Calibration
Procedure in this section which contains a list of the
cards that require control calibration.
When performing Bus Voltage Calibration from the
graphical display, the genset must be off and the Bus
live. If the genset is running, it will synchronize to the
Bus.
3-9
CALIBRATION
VOLTAGE CALIBRATION
L1 480-X.X%
L2 480-X.X%
L3 480-X.X%
+
−
CURRENT CALIBRATION
L1 234-X.X%
L2 123-X.X%
L3 562-X.X%
+
−
BUS VOLTAGE CALIBRATION
L1 480 -X.X%
L2 480 -X.X%
L3 480 -X.X%
+
−
Y
Y
B
Y
B
FIGURE 3-6. CALIBRATION SUBMENUS
3-10
ISOLATED BUS / UTILITY Submenus
(Paralleling Application)
The Isolated BUS submenus (Figure 3-7) and the
Utility submenus (Figure 3-8) adjust the control pa-
rameters for generator set protection, synchroniz-
ing and load sharing for both isolated bus and utility
(mains) paralleling applications. Utility (mains) par-
allel applications may require adjustment of both
the Isolated BUS and Utility submenus.
Always perform ISO BUS calibration before Utility
BUS calibration.
The sync check (permissive) function is operational
in both automatic and manual (RUN) modes. The
control will make sure that the generator set is at
proper voltage, within the defined sync check win-
dow for the defined period of time and that phase
rotation is correct. When all criteria are met, the par-
alleling breaker is closed automatically by the con-
trol (auto mode), or by operation of the breaker
close switch by the operator (manual mode).
The synchronizing function of the control is enabled
when the control has brought the generator set to
90% of rated speed and voltage, and has sensed
that bus voltage is available. The control automati-
cally adjusts the generator set speed and voltage to
match the bus frequency and voltage. The control
can force the generator set to match bus voltage
and frequency in a range of minus 40% to plus 10%
of normal bus conditions. When the paralleling
breaker has closed, the control will bring the gener-
ator set back to normal voltage and frequency.
When the generator set is paralleled to another
generator set, the control provides automatic load
sharing functions for both real (kW) and reactive
(kVAR) loads. Load sharing is proportional between
generator sets based on their standby ratings. If two
generator sets of different sizes are paralleled, they
will assume the same percentage of the system
load automatically. This can easily be verified on the
kW Load LED bar graph on the front of the control
panel.
When the utility paralleling mode is enabled and the
generator set paralleling breaker is closed, the gen-
erator set will assume load based on external ana-
log input signal. The input signal must be calibrated
from 0−5 VDC. When the signal is at 0.5 to 1 VDC,
the control will operate the generator at no load in
parallel with the utility (mains) source. At 4.5 VDC
and greater, the control will operate the generator
set at 110% of the generator set base load setting.
When the load govern signal is between 1 VDC and
4.5 VDC the control will operate the generator set at
a load level which is determined by a linear relation-
ship between the kW reference and the load govern
signal.
3-11
ISOLATED BUS SUBMENUS
If you press the “ISOLATED BUS” button in the Set-
up menu, the Isolated BUS submenus will appear
(Figure 3-7).
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
field. Exit menu to safe changes.
SYNC TIME LIMIT: This parameter adjusts the time
delay in seconds before the Fail To Synchronize
alarm will operate.
REVERSE PWR LMT: Adjusts the reverse power
set point. For PowerCommand generator sets, a
typical set point is 10-15%.
REVERSE PWR TIME: Adjusts the reverse power
function time delay. A typical time delay which is
suitable for PowerCommand generator sets is 3
seconds.
Lower reverse power set points can result in nui-
sance reverse power shutdown faults.
PERM WIN-PHASE: Adjusts the width of the per-
missive (sync-check) acceptance window. The ad-
justment range is from five to twenty electrical de-
grees. Recommended set point is 20 degrees for
isolated bus applications, and 15 degrees for utility
(mains) paralleling applications.
PERM WIN-TIME: Adjusts the time period (in sec-
onds) for which the generator set must be synchro-
nized with the system bus, before a breaker close
signal is issued by the PowerCommand control.
Available range is 0.5 to 5 seconds. Recommended
value for PowerCommand generator sets is 0.5
seconds for isolated bus applications.
3-12
ISOLATED BUS
ISOLATED BUS:
SYNC TIME LIMIT 120 SEC
REV PWR LMT 10 %
REV PWR TIME 3 SEC
PERM WIN-PH 20 DEG
PERM WIN-TIME .5 SEC
+
−
Y
B
CONTINUED TO NEXT PAGE
FIGURE 3-7. ISO BUS SUBMENUS
3-13
Adjusting the control for a smaller sync-check win-
dow or longer time delay will cause synchronizing
time to be extended.
SYNC GAIN: The sync gain adjustment controls
how quickly the governor will respond to try to mini-
mize the bus/generator phase difference. Increas-
ing the gain speeds up the response. If the gain is
too high instability can result.
KW Balance and KVAR Balance changes should be
equally shared among all generator sets.
KW BALANCE: This function adjusts the kW load
sharing function of the generator set. Before adjust-
ing this value, all generator set calibrations should
be performed. If the total load on the system is not
shared proportionately, the kW Balance can be
used to adjust the generator set for more precise
load sharing. Increasing the kW Balance value will
cause the generator set to reduce the percentage of
the total kW load on that set.
KVAR BALANCE: This function adjusts the kVAR
load sharing function of the generator set. Before
adjusting this value, all generator set calibrations
should be performed. If the total load on the system
is not shared proportionately, the kVAR balance can
be used to adjust the generator set for more precise
load sharing. Increasing the kVAR balance value
will cause the generator set to reduce the percent-
age of the total kVAR load on that set.
KW GAIN: Adjusts the rate of change of kW load on
the generator set. With a constant load on the sys-
tem, if the generator set load is constantly chang-
ing, reduce the gain adjustment on the generator
set. This also allows modification of the rate of load
assumption on transient load change.
KVAR GAIN: Adjusts the rate of change of kVAR
load on the generator set. With a constant load on
the system, if the generator set load is constantly
changing, reduce the gain adjustment on the gener-
ator set. This also allows modification of the rate of
load assumption on transient load change.
3-14
ISOLATED BUS (CONT.)
ISOLATED BUS:
SYNC GAIN 1.0
KW BALANCE 0.3
KVAR BALANCE 1.2
KW GAIN 1.0
KVAR GAIN 1.0
+
−
Y
B
CONTINUED TO NEXT PAGE
FIGURE 3-7. ISO BUS SUBMENUS (CONT.)
3-15
1ST FAIL TIME: Time delay in seconds after a sig-
nal from the first start master is not sensed by the
PCC that a FIRST START FAIL warning is dis-
played.
RAMP UNLOAD TIME: When a load demand stop
input is sensed the load is ramped down from the
present load level on the set to the ramp unload lev-
el in the time specified in seconds.
RAMP UNLOAD LEVEL: The load demand ramp
unload function will ramp the load down from the
present level on the set to this level before opening
the set circuit breaker. Value shown is in % of genset
standby rating.
RAMP LOAD TIME: When the load demand stop
signal is removed the load is ramped from 0kW to
the load share level in the specified time after the
circuit breaker closes.
LOSS FIELD TIME: Adjusts the loss of field func-
tion time delay. A typical delay which is suitable for
PowerCommand generator sets is 2 seconds.
3-16
ISOLATED BUS (CONT.)
ISOLATED BUS:
1ST FAIL TIME 12 SEC
RAMP UNLD 20 SEC
RAMP UNLD LEVEL 10 %
RAMP LOAD TIME 3 SEC
LOSS FIELD 20 SEC
+
−
Y
FIGURE 3-7. ISO BUS SUBMENUS (CONT.)
3-17
UTILITY SUBMENUS
If you press the “UTILITY” button in the Setup
menu, the Utility submenus will appear (Figure 3-8).
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
field. Exit menu to safe changes.
BASE LOAD (%): This controls the maximum kW
load level that the generator set will operate at when
paralleled with the utility (mains). The value shown
indicates the steady state load on the generator as
a percent of the generator set standby rating.
Check generator set ratings for maximum load level
at which the generator set should operate when
paralleled with the utility (mains). Extended opera-
tion at load levels in excess of the generator set rat-
ing can cause abnormal engine wear or premature
engine failure.
PF LEVEL: Adjusts the power factor that the gener-
ator set will run at when paralleled to the utility
(mains). Recommended setting is 1.0.
RAMP LOAD TIME: This is the ramp time from
present set load to level determined by the load set
analog input. This is active when the control first en-
ters the load govern mode.
RAMP UNLOAD TIME: This is the ramp time from
present set load to 0 kW. This ramp is active when
the load set analog input is less than 0.5 volts.
MODE − MULTIPLE/SINGLE: This controls wheth-
er the set is to operate as part of a multiple set or
single set (PLTE or PLTF) system. (Refer to “LOAD
DEMAND SHUTDOWN” and “SINGLE MODE EN-
ABLE” function descriptions in wiring diagram,
page 5-8.)
KW GOVERN GAIN: This controls the rate that the
generator set kW load is increased after the genera-
tor set has closed to the system bus when utility
(mains) paralleled. Decreasing this value will result
in slower loading of the generator set.
KVAR GOVERN GAIN: This controls the rate that
the generator set kVAR load is increased after the
generator set has closed to the system bus when
utility (mains) paralleled. Decreasing this value will
result in slower loading of the generator set.
3-18
UTILITY
UTILITY:
BASE LOAD 80%
PF LEVEL 1.00
RAMP LOAD 3
RAMP UNLD 20
MODE MULTIPLE
+
−
UTILITY:
KW GOVERN GAIN 1.00
KVAR GOVERN GAIN1.00
+
−
Y
B
Y
FIGURE 3-8. UTILITY SUBMENUS
3-19
POWER TRANSFER CONTROL MAIN
MENUS
If you press the “POWER TRANSFER SETUP” but-
ton in the Setup menu 2 in Figure 3-3, the two main
menus of the optional Power Transfer Control
(PTC) feature will appear (Figure 3-9).
To adjust PTC system parameters, press the ap-
propriate PTC main menu button and refer to the
page number shown in Figure 3-9 for detailed infor-
mation related to the submenu selected.
UTILITY SENSORS
GENSET SENSORS
TIMERS
Y
B
PAGE
3-13
PAGE
3-15
PAGE
3-17
NEXT
MENU
TEST/EXERCISE Y
PAGE
3-18
PTC MAIN MENU 1
PTC MAIN MENU 2
FIGURE 3-9. PTC SETUP MAIN MENUS
3-20
UTILITY SENSORS SUBMENUS
If you press the “UTILITY SENSORS” button in the
PTC Main Menu 1, the Utility Sensors submenus
will appear (Figure 3-10).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
field. Exit menu to save changes.
U PT VOLT LL: Enter the value of the utility line-to-
line voltage which yields 100% voltage at the termi-
nals of the utility (bus) PT module.
Range: 1−15000V, adjustable by standard nominal
voltage values, 100V, 10V and 1V increments (1V).
The 100% voltages for each of the four possible util-
ity (bus) PT modules are as follows, based on mod-
ule dash number:
−01 = 208 volts LL
−02 = 416 volts LL
−03 = 600 volts LL
−04 = 120 volts LL
Example 1: Nominal Utility voltage is 480V. This
means that utility (bus) PT module number −02
should be used. The voltage which will yield 100%
volts at this PT module is 416 per the above table.
Thus enter 416V.
Example 2: Nominal Utility voltage is 4160V. A pri-
mary stage transformer with a ratio of 4200/240 is
used. This means that utility (bus) PT module num-
ber −01 should be used. The voltage which will yield
the 100% volts (208V from above table) is calcu-
lated as follows:
208 x (4200/240) = 3640. Thus enter 3640V.
U NOM VOLT LL: Enter the nominal utility line-to-
line voltage. For example, 480, 4160, etc.. Range:
1−15000 V, adjustable by standard nominal voltage
values, 100V, 10V and 1V increments (1V).
U CT RATIO: Enter the CT Ratio of the Utility L2 CT.
This is the Ratio to 1 Amp. Range: 1−18000 (1A).
CAUTION This CT must be rated for 1 Amp
output (e.g. NOT 5 Amp). Be sure CT secondary
circuit has burden resistor or a shorting jumper
in place before putting power through the CT.
Example: CT Ratio = 2650:1. Thus enter 2650.
U SENSOR TYPE: Enter the line-to-line (L-N) for 3
phase line-neutral voltage sensing or line-to-line
(L-L) for 3 phase line-line voltage sensing. This ap-
plies to both the utility undervoltage and overvol-
tage sensors. Range: L−L, L−N (L−N).
U <wye> <delta>: Enter utility connection type.
Range: Delta, Wye (Wye).
U UNLOADED KW: Enter the kW on utility Line 2 at
which the utility is considered as unloaded. This is
the L2 kW level at which a closed transition soft
transfer will disconnect from the utility.
UTILITY UNDERVOLTAGE: Non-adjustable field,
always enabled.
UTILITY OVERVOLTAGE, FREQUENCY: Used to
enable or disable menu function. Choose Enabled
or Disabled (Enabled).
UV PICKUP: Enter a number between 85 and
100% of the nominal voltage (90%).
UV DROP OUT: Enter a number between 75 and
98% of the under-voltage pick-up percentage
(90%).
UV DELAY: Enter a time between 0.1 and 5.0 sec-
onds (0.5 seconds).
UV MIN PHASE: Displays the lowest line voltage of
the three utility phases.
3-21
OV PICKUP: This adjusts the over-voltage pickup
as a percentage of the over-voltage drop-out. Enter
a number between 95 and 99% (95%).
OV DROP OUT: Enter a percentage between 105
and 135% of the nominal voltage (110%).
OV DELAY: Enter a range between 0 and 120 sec-
onds (3 seconds).
OV MAX PHASE: Displays the highest line voltage
of the three utility phases.
CENTER (FREQ): Enter a frequency between 45
and 65 Hz (60 Hz).
PICK UP (FREQ): Enter a percentage between 5
and 20% of the nominal frequency (10%).
DROP OUT (FREQ): Enter a percentage between
1 and 5% of the nominal frequency (1%).
DELAY (FREQ): Enter a time between 0.1 and 15.0
seconds (5.0 seconds).
FREQUENCY: This field displays the sensed utility
line frequency.
UTILITY SENSORS
U PT VOLT LL 416
U NOM VOLT LL 480
U CT RATIO: 1 1000
U SENSOR TYPE L−L
U UNLOADED KW 50 KW
+
−
Y
UTILITY UV: ENABLED
% VLL
PICK UP 95 475
DROP OUT 85 465
DELAY 0.5 S
MIN PHASE 470
+
−
Y
B
UTILITY OV: DISABLED
% VLL
PICK UP 95 487
DROP OUT 110 490
DELAY 3.0 S
MAX PHASE485
+
−
Y
B
UTILITY FREQ: DISABLED
CENTER 60 HZ
PICK UP 10 %
DROP OUT 1 %
DELAY 1.0 S
FREQUENCY60.5 HZ
+
−
Y
B
FIGURE 3-10. UTILITY SENSORS SUBMENUS
3-22
GENSET SENSORS SUBMENUS
If you press the “GENSET SENSORS” button in the
PTC Main Menu 1, the Genset Sensors submenus
will appear (Figure 3-11).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
field. Exit menu to save changes.
G NOM VOLT LL: Non-adjustable field, displays
current setting of genset nominal voltage. (See Ad-
just submenu to adjust the output voltage 5%.)
G SENSOR TYPE: Enter the line-to-line (L-N) for 3
phase line-neutral voltage sensing or line-to-line
(L-L) for 3 phase line-line voltage sensing. This ap-
plies to both the genset undervoltage and overvol-
tage sensors. Range: L−L, L−N (L−N).
G BASE LOAD: Enter the maximum load the gen-
set will carry during a closed transition. Range:
0−100% (80%).
G RAMP LOAD: Enter the ramp time for the genset
ramp load rate during a closed transition soft load
transfer. Ramp rate is +100%kW divided by this
time setting. Range: 0−900 seconds (20 sec).
G RAMP UNLOAD: Enter the ramp time for the
genset ramp unload rate during a closed transtion
soft load retransfer. Ramp rate is −100%kW divided
by this time setting. Range: 0−900 seconds (20
sec).
G UNLOADED KW: Enter the %kW (based on
standby rating) that the genset is considered un-
loaded. This is the %kW level at which a closed tran-
sition soft retransfer will disconnect from the gen-
set. Range: 0−100% (5%).
GEN UNDERVOLTAGE: Non-adjustable field, al-
ways enabled.
GEN OVERVOLTAGE, FREQUENCY: Used to en-
able or disable menu function. Choose Enabled or
Disabled (Enabled).
UV PICKUP: Enter a number between 85 and
100% of the nominal voltage (90%).
UV DROP OUT: Enter a number between 75 and
98% of the under-voltage pick-up percentage
(90%).
UV DELAY: Enter a time between 0.1 and 5.0 sec-
onds (4 seconds).
UV MIN PHASE: Displays the lowest line voltage of
the three genset phases.
3-23
OV PICKUP: This adjusts the over-voltage pickup
as a percentage of the over-voltage drop-out. Enter
a number between 95 and 99% (95%).
OV DROP OUT: Enter a percentage between 105
and 135% of the nominal voltage (110%).
OV DELAY: Enter a range between 0 and 120 sec-
onds (3 seconds).
OV MAX PHASE: Displays the highest line voltage
of the three genset phases.
CENTER (FREQ): Enter a frequency between 45
and 65 Hz (60 Hz).
PICK UP (FREQ): Enter a percentage between 5
and 20% of the nominal frequency (10%).
DROP OUT (FREQ): Enter a percentage between
1 and 5% of the nominal frequency (1%).
DELAY (FREQ): Enter a time between 0.1 and 15.0
seconds (5.0 seconds).
FREQUENCY: Displays the sensed genset line fre-
quency.
GENSET SENSORS
G NOM VOLT LL 480
G SENSOR TYPE L−L
G BASE LOAD 80.0%
G RAMP LOAD 20 S
G RAMP UNLOAD 20 S
G UNLOADED KW 5 %
+
−
Y
GEN UV: ENABLED
% VLL
PICK UP 95 475
DROP OUT 85 465
DELAY 1.0 S
MIN PHASE 470
+
−
Y
B
GEN OV: DISABLED
% VLL
PICK UP 95 487
DROP OUT 110 490
DELAY 8.0 S
MAX PHASE485
+
−
Y
B
GEN FREQ: DISABLED
CENTER 59 HZ
PICK UP 12 %
DROP OUT 2 %
DELAY 5.0 S
FREQUENCY60.0 HZ
+
−
Y
B
FIGURE 3-11. GENSET SENSORS SUBMENUS
3-24
TIMERS SUBMENU
If you press the “TIMERS” button in the PTC Main
Menu 1, the Timers submenu will appear (Figure
3-12).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
field. Exit menu to save changes.
START DELAY: Sets time delay for genset engine
start. Prevents nuisance genset starting during brief
power interruptions.
Enter a range from 0 to 300 seconds (0 seconds).
STOP DELAY: Sets the time delay for engine cool-
down following a re-transfer. This stop delay works
in conjunction with and is activated at the same time
as the normal cooldown timer. (Will extend normal
cooldown timer if entered time is greater.)
Enter a time from 0 to 600 seconds (0 seconds).
TRANSFER: In a Normal to Emergency transfer
this function allows the genset to stabilize before
the load is applied. Enter a time from 0 to 120 sec-
onds (10 seconds).
RETRANSFER: In a Emergency to Normal transfer
this function allows the utility to stabilize before the
load is applied.
Enter a time from 0 to 1800 seconds (600 seconds).
PGM TRANSIT: Sets the time delay for Pro-
grammed Transition. A setting of 0.0 disables the
program.
Enter a time from 0 to 60 seconds (0 seconds).
MAX PARALLEL: Sets the maximum time during
closed transition that utility and genset can be paral-
leled.
Enter a time from 0 to 1800 seconds (20 seconds).
3-25
TIMERS
START DELAY60 S
STOP DELAY60 S
TRANSFER 10 S
RETRANSFER900 S
PGM TRANSIT5 S
MAX PARALLEL30 S
+
−
Y
FIGURE 3-12. TIMERS SUBMENU
3-26
TEST/EXERCISE SUBMENU
If you press the “TEST/EXERCISE” button in the
PTC Main Menu 2, the Test/Exercise submenu will
appear (Figure 3-13).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
field. Exit menu to save changes.
MODE: Indicates the generator set application type
for PTC option.
OT-PGM TRAN − Open transition load transfer.
CT-MOMENT − Closed transition load transfer
with momentary (<100ms) overlap.
CT-SOFT − Closed transition load transfer with
load ramping.
TEST WITH LOAD: Feature allows genset Test se-
quence, which is initiated through the Remote Start
(TEST) switch, to operate with or without load. De-
fault: OFF
EXER WITH LOAD: Feature allows genset Exer-
cise sequence, which is initiated through control
panel Exercise button to operate with or without
load. Default: OFF
3-27
TEST/EXERCISE
MODE CT-SOFT
TEST WITH LOADOFF
EXER WITH LOADOFF
+
−
Y
FIGURE 3-13. TIMERS SUBMENU
3-28
ADJUST SUBMENU
Figure 3-14 shows the main menus (Menu A and
Menu B) of the system control and the Adjust sub-
menu.
To display the Adjust submenu, press the MORE>>
button in Menu A and then the ADJUST button in
Menu B.
The Adjust submenus are intended for qualified
service personnel and site personnel only and may
require a USER password. If a password is re-
quired, the USER password menu will appear when
you try to modify the Adjust submenus. (Refer to
PASSWORD Menu in this section to enter pass-
word.
Changes are automatically saved when you exit
this menu.
If the generator set is operating in parallel with a
system bus, the voltage and frequency adjustments
are disabled to prevent inadvertent misadjustment
of the paralleling load sharing functions.
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next
field. Exit menu to safe changes.
START DELAY: This delay applies only to remote
starting in the Auto mode. The Start Delay adjust-
ment range is 0 to 300 seconds.
STOP DELAY: This delay applies only to remote
stopping in the Auto mode. The Stop Delay adjust-
ment range is 0 to 600 seconds.
VOLTAGE: Used to adjust the output voltage 5%.
FREQUENCY: Used to adjust the frequency 3 Hz.
VOLTAGE/SPEED DROOP: These two submenus
apply to a genset that has the paralleling option and
is configured to operate in droop mode.
ENGINE
ALTERNATOR
CONTROL
MORE>>
_\_
HISTORY/ABOUT
SETUP
ADJUST
BUS DATA
BACK<<
MENU A
MENU B
MENU
B
MENU
A
+
−
ADJUST:
START DELAY 5 SEC
STOP DELAY 11 SEC
VOLTAGE 208 1.2 %
FREQ 60.0 HZ -0.0 HZ
Y
B
+
−
ADJUST:
STANDBY
VOLTAGE DROOPOFF
BUS L1 480 V
POWER FACTOR0.80
VOLT 4.99 %
Y
B
+
−
ADJUST:
STANDBY
SPEED DROOPOFF
BUS FREQ60.0HZ
TOTAL KW300 KW
FREQ 60.0 0.40HZ
Y
FIGURE 3-14. ADJUST SUBMENU
3-29
CALIBRATION PROCEDURE
There are several circuit cards/modules that, when
removed and replaced, require you to recalibrate
the control panel display for genset voltage and cur-
rent and bus voltage.
Note that the type of calibration to perform varies for
each card. The letters A, B and C are used to desig-
nate which of the following three calibration proce-
dures are required for each card/module.
Genset/Parallel board (A, B & C)
PT/CT board (A & B)
Bus PT (C)
CT’s (B)
WARNING Contacting high voltage compo-
nents can cause electrocution, resulting in se-
vere personal injury or death. Calibration and
adjustment must be performed by technically
qualified personnel only. Read and observe all
WARNINGS and CAUTIONS in your generator
set manuals.
CAUTION Improper calibration or adjustment
of the PowerCommand control can cause
equipment malfunction or damage. Calibration
and adjustment must be performed by techni-
cally qualified personnel only.
Use a calibrated RMS multimeter for accurate mea-
surements.
(A) Genset Voltage Display Calibration
The PowerCommand control automatically synchro-
nizes to the system bus when bus voltage is avail-
able and the genset is running. Consequently, it is
not possible to calibrate the genset output voltage
display of the genset that is running when the bus is
energized. If it is necessary to adjust the output volt-
age display of the genset that is running, the InPower
service tool must be used to switch off the synchro-
nizer function of the control.
1. Display the Voltage Calibration submenu
(Page 3-6).
2. With the genset OFF, attach a calibrated volt-
meter to the AC output from L1 to L2. (L1 to
Neutral for single phase alternators.)
3. Start the genset and allow it to reach normal
operating speed.
4. Calibrate voltage reading for L1 so that the
reading on the display agrees with the cali-
brated voltmeter.
5. Shut the generator set OFF.
6. Repeat steps 2 through 5 for L2 and L3. (In step
2 attach meter to the AC output from L2 to L3 to
calibrate L2 and L3 to L1 to calibrate L3.)
7. Exit menu to safe changes.
(B) Genset Ammeter Display Calibration
1. Display the Current Calibration submenu
(Page 3-6).
2. With the genset OFF, attach a calibrated am-
meter to L1.
3. Start the genset and allow it to reach normal
operating speed.
4. Load the genset to maximum rated kVA at
rated voltage.
5. Calibrate the reading for L1 current so that the
reading on the display agrees with calibrated
ammeter.
6. Repeat steps 2 through 5 for L2 and L3. (In step
2, attach meter to L2 to calibrate L2 current and
L3 to calibrate L3 current.)
7. Exit menu to safe changes.
3-30
(C) Bus Voltage Calibration
The PowerCommand control automatically synchro-
nizes to the system bus when bus voltage is avail-
able and the genset is running. Consequently, it is
not possible to calibrate the genset bus voltage dis-
play of the genset that is running when the bus is en-
ergized. If it is necessary to adjust the bus voltage
display of the genset that is running, the InPower
service tool must be used to switch off the synchro-
nizer function of the control.
1. Display the Bus Voltage Calibration submenu
(Page 3-6).
2. With all gensets OFF, attach a calibrated volt-
meter to TB1-A (L1) and TB1-B (L2) of the bus
PT module (Figure 3-15).
3. Start another genset and allow it to reach nor-
mal operating speed and voltage. Connect op-
erating genset to the bus.
4. Calibrate the voltage reading for Bus Volts L1
so that the reading on the display matches the
reading on the calibrated meter.
5. Shut the generator set OFF.
6. Repeat steps 2 through 5 for Bus Volts L2 and
L3. (In step 2 attach meter to the AC output
from L2 to L3 to calibrate L2; L3 to L1 to cali-
brate L3.)
7. Exit menu to safe changes.
TB1-A (L1)
CONTROL
BOX DOOR
TB1-B (L2)
TB1-C (L3)
FIGURE 3-15. BUS PT MODULE
3-31
CONTROL BOX WIRING
The generator set control box assembly, which can
be located on either side of the genset, contains
connection points for remote control and monitor
options.
Customer monitor/control connections are at-
tached to terminal blocks TB3 and TB8 (see Figure
3-16). Optional equipment such as a remote annun-
ciator panel, sensing devices used to monitor gen-
set operation, remote start/stop switches, control
box heater, and etc. are also attached to these ter-
minal blocks. Driver signals for customer supplied
relays are also provided for several alarm and shut
down conditions. Refer to Customer Connections
diagram in Section 7.
3-32
TB8
CARD
CAGE
OPTIONAL
SHUTDOWN
ALARM RELAY K16
OPTIONAL
RUN RELAYS
K11, K12 & K13
CONTROL WIRING
ACCESS
FIGURE 3-16. CONTROL BOX ASSEMBLY INTERIOR
3-33
RUN RELAYS (K11, K12, K13)
The optional run relays are rail mounted inside the
control box (Figure 3-16). The rail mount allows you
to easily remove and replace the snap-on relays.
The generator set can be equipped with one, two or
three run relays.
The three-pole, double-throw run relays (Figure
3-17) are used to control auxiliary equipment such
as fans, pumps and motorized air dampers. The run
relays are energized when the generator set reach-
es operating speed.
The contacts are rated:
10 amps at 28 VDC or 120 VAC, 80%PF
6 amps at 240 VAC, 80%PF
3 amps at 480/600 VAC, 80%PF
CUSTOMER
CONNECTIONS
TB3-7
(GND)
TB3-5
(SWITCHED B+)
NO
COIL
COM
NC
K11, K12, K13
K11
RUN RELAY
K11, K12, K13
K11, K12, K13
K12
RUN RELAY
K13
RUN RELAY
NO
NC
NO
NC
FIGURE 3-17. OPTIONAL RUN RELAYS (K11, K12, K13)
3-34
ALARM RELAY (K16)
The optional alarm relay is rail mounted inside the
control box (Figure 5-2). The rail mount allows you
to easily remove and replace the snap-on relay.
The three-pole, double-throw alarm relay (Figure
5-4) is often used to energize warning devices such
as audible alarms. Any generator set shutdown will
energize the alarm relay.
The contacts are rated:
10 amps at 28 VDC or 120 VAC, 80%PF
6 amps at 240 VAC, 80%PF
3 amps at 480/600 VAC, 80%PF
CUSTOMER
CONNECTIONS
TB3-18
(GND)
TB3-17
(COM ALARM)
NO
COIL
COM
NC
K16
K16
K16
K16
SHUTDOWN ALARM
FIGURE 3-18. OPTIONAL ALARM RELAY (K16)
3-35
MAGNETIC SPEED PICKUP UNIT (MPU)
INSTALLATION
To install the MPU sensor, bar the engine until a
gear tooth on the flywheel lines up in the center of
the mounting hole. Thread the sensor in gently by
hand until it just touches the gear tooth. Back it out
one quarter turn and set the locknut.
CAUTION Do not use fan blade to bar over en-
gine. That can damage blades and cause prop-
erty damage and personal injury.
3-36
MAGNETIC
PICKUP
SENSOR
ENGINE
FLYWHEEL
RING GEAR
FIGURE 3-19. MPU SENSOR
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email [email protected]
www.cumminspower.com
Cummins
R
, the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.
E2010 Cummins Power Generation, Inc. All rights reserved.
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Екатеринбург
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г. Екатеринбург, ул. Старых большевиков, д. 2
Дизельные генераторы от компании
«РУ-Техника»
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Каталог
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- Каталог
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Дизельные генераторы 10 кВт — 100 кВт
- Назад
- Дизельные генераторы 10 кВт — 100 кВт
-
10 кВт
-
12 кВт
-
16 кВт
-
20 кВт
-
24 кВт
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30 кВт
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40 кВт
-
50 кВт
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60 кВт
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75 кВт
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80 кВт
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100 кВт
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Дизельные генераторы 120 кВт — 300 кВт
- Назад
- Дизельные генераторы 120 кВт — 300 кВт
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120 кВт
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140 кВт
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150 кВт
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160 кВт
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180 кВт
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200 кВт
-
220 кВт
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250 кВт
-
280 кВт
-
300 кВт
-
Дизельные генераторы 310 кВт — 640 кВт
- Назад
- Дизельные генераторы 310 кВт — 640 кВт
-
310 кВт
-
315 кВт
-
320 кВт
-
350 кВт
-
360 кВт
-
400 кВт
-
460 кВт
-
500 кВт
-
550 кВт
-
600 кВт
-
640 кВт
-
Дизельные генераторы 700 кВт — 1300 кВт
- Назад
- Дизельные генераторы 700 кВт — 1300 кВт
-
700 кВт
-
800 кВт
-
900 кВт
-
1000 кВт
-
1100 кВт
-
1200 кВт
-
1300 кВт
-
Дизельные электростанции 1400 кВт — 4000 кВт
- Назад
- Дизельные электростанции 1400 кВт — 4000 кВт
-
1400 кВт
-
1500 кВт
-
1600 кВт
-
1800 кВт
-
2000 кВт
-
3000 кВт
-
4000 кВт
-
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Электростанции серии АД
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Cummins (Великобритания)
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AKSA (Турция)
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Екатеринбург
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Контактная информация
г. Екатеринбург, ул. Старых большевиков, д. 2