PCCP Control System
PCCP Control System
Generation
PowerCommand™
Paralleling
Generator Set Control
Integrated Control
System Reliability
The PowerCommand™ Control, is a system to occupy much less physical The PowerCommand Control has been
microprocessor-based generator set space than conventional control subjected to extensive hours of
monitoring, metering, and control arrangements. prototype and quality assurance testing
system. It offers advanced levels of The control system has sophisticated at the factory and in the field. All control
functions for reliability and optimum servicing capabilities that allow system components are selected and
generator set performance. parameters to be interrogated, integrated to withstand the vibration
An extensive array of integrated monitored and adjusted with a laptop levels typical in a generator set
standard control and digital display computer. installation. The control has been
features eliminates the need for subjected to accelerated life tests to
discrete component devices such as Comprehensive verify MTBF calculations in excess of
the voltage regulator, governor control Standard Features 240,000 hours.
and protective relays. The control offers a wide range of
It also eliminates the need for separate standard control and digital display Single Source Solution
paralleling control devices such as features, so custom control All the major components of our
synchronizers and load sharing configurations are not needed to generating sets – the engine, alternator
controls, import/export controls, and meet application specifications. and control systems – are manufactured
var/power factor controls. The System reliability is not compromised within the Cummins group, providing the
consolidation of controls allows the by the use of untested special assurance of a single source
components. responsibility and servicing.
● Advanced Serviceability.
● AmpSentry™ Protection for true alternator
overcurrent protection. ● PowerCommand Network Capability (optional).
● Analogue and Digital AC Output Metering. ● CE Compliant.
● Battery Monitoring System to sense and warn ● Quality Assurance to ISO 9001.
against a weak battery condition.
● Dust, Water and Oil Resistant - Equivalent to IP54.
● Digital Alarm and Status Message Display.
Voltage Regulation Performance synchronize to the system bus, and close at no load. The
● Voltage Regulation generator set then ramps up to its proportional share of the
±0.5% from no load to full load. total load on the system.
● Voltage Drift Isochronous Reactive Load Sharing
±0.5% for 60°F (33°C) change in ambient over eight (8) ● Reactive load sharing controls allow generator sets to
hours with temperature stabilization at each point. share load to within as low as 1% of equal. Load sharing
● Random Voltage Variation controls operate directly on the excitation system, to
For constant loads from no load to full load will not exceed provide zero droop in voltage for loads from zero to 100%
±0.5% of its mean value. of rated generator set capacity.
● Reactive load sharing controls to allow the generator set to
Governing Performance share reactive load with an infinite bus. The control system
● Frequency Regulation allows a technician to adjust the operating reactive load
Isochronous under varying loads from no load to full load. level on the generator set.
● Frequency Drift Synchronizer
±0.5% drift for a 60°F (33°C) change in ambient over 8 ● Range: The synchronizer can drive generator set
hours with temperature stabilization at both points. frequency and voltage to a bus value which is –40% to
Isochronous Real Load Sharing +10% of selected voltage and frequency. Ramp speed for
● Real load sharing controls allow generator sets to share matchng is 4%/second.
load to within as low as 1% of equal. Load sharing controls ● Frequency Differential: Controls generator set to
operate directly on the engine governor actuator, to provide match bus frequency.
zero droop in frequency for loads from zero to 100% of ● Voltage Differential: Electronically controls generator
rated generator set capacity. set voltage to within 1% of system bus voltage, and
● Kilowatt import and export control, to allow the generator checks for correct phase rotation to bus.
set to share load with an infinite bus. The controls allow ● Permissive Protection: Adjustable for a phase
setting of ramping rate, and steady state operation level. difference of 5-20 degrees, with phase difference
Steady state kW load level can be based on a preset kW decreasing. Time delay is adjustable from 0.5 to 5
level, or on a signal from a remote control device which seconds.
allows loading of the generator set as a function of the load ● Control System: Automatically resets bus frequency
provided by the utility (mains) service. and voltage to preset values after the paralleling breaker
● Load demand ramping controls cause the generator set to closes.
ramp down to a low load condition prior to switching off on ● Includes “Dead Bus” Sensor: Allows closure of the
a load demand signal. On removing the load demand generator set to an inactive system bus.
signal, the generator set will automatically start,
Allows the operator to manually open or close the paralleling ● Exhaust temperature (°F or °C). Left and right bank
breaker when the control is in the “RUN” mode. The breaker temperatures are provided for V-block engines (optional).
close function is operated through a permissive function (with
dead bus logic) to prevent accidental out-of-phase paralleling of Engine Warning and Shutdown
the generator set with the system bus.
Messages
Adjustment Menu On sensing a warning or shutdown condition, the control displays
Allow the operator to set basic generator set operating the warning or shutdown message, lights the warning or
parameters. Adjustment ranges are limited to help prevent shutdown indicator lamp on the front of the control, and provides
operator error and damage to connected equipment. Critical a code number referenced to the generator set manuals. The
adjustments are possible only after entering an access code. manuals provide the operator with more information on the nature
Adjustments include: of the problem and how to get the generator set back into service.
● Voltage (±5%).
Functions provided include:
● Frequency (±5%). ● Low oil pressure (warning).
● Time Delay Start (0-300 seconds). ● Low coolant temperature (warning).
● Time Delay Stop (0-600 seconds). ● High coolant temperature (warning).
Critical service level adjustments are possible only after entering ● Low coolant level (programmable warning or shutdown).
an access code. All operators and service level control system ● Low Fuel – Daytank (warning, external input signal).
adjustments are made through digital raise/lower switches from ● Oil pressure sender (warning, indicates a sender or wiring
the front of the control panel. The adjustment level is displayed failure in the oil pressure monitoring system).
on the control panel. There are no rotary switches or pots in the ● Engine temperature sender (warning, indicates a sender or
control system. wiring failure in the engine temperature monitoring equipment).
External Control Adjustments ● Low oil pressure (shutdown).
All adjustments for automatic voltage regulation, engine speed ● High coolant temperature (shutdown).
governing, and other critical functions are performed directly on ● Fail to crank (shutdown, indicates failure of engine to rotate on
the control panel by using a security code and without entering start command).
the control enclosure. ● Overcrank (shutdown, indicates cranking time exceeds 75
Provides detailed information on all critical generator set ● Overspeed (shutdown, engine speed greater than 115% of
parameters. Detailed messages provide a clear indication of nominal).
problems with reference to the operator’s service manual for ● Emergency Stop (shutdown).
further direction. Indicator lamps are high intensity, dual-element The control has provisions for four programmable fault conditions.
LED’s for long life and easy reading in any lighting condition. These may be either warning or shutdown conditions. Labels for
A two-line, 16 character-per-line, LED alphanumeric screen customer faults can be programmed into the control.
displays alarm and status messages and information regarding The PowerCommand Control maintains an historical data log of
AC output, engine conditions, and adjustments via a menu-driven the latest alarm and status conditions on the generator set. On an
system. The operator can easily follow the logic path without the alarm or shutdown condition, the control logs the nature of the
use of an operator’s manual. fault and the engine operating time that the fault occurred. This
Status Indicators data log is useful for diagnosis of service problems on the
Three dual-element LED indicating lamps provide basic generator generator set.
set status information on the control face. Solid state indicators Control Options
on internal circuit boards provide status and diagnostic High alternator temperature alarm.
information about the generator set. Ground fault alarm.
Non-Automatic Indicator Historical Data
When the Run/Off/Auto switch is in the OFF or RUN position, the The control displays the last 20 alarm and/or shutdown messages,
red non-automatic indicator will flash on and off. along with the engine hour time that the condition occurred.
Warning Indicator Duty Cycle Data
An amber light indicates the status screen is displaying a warning The control will display the number of engine operating hours at
condition. The reset switch is used to clear the message after the 0-10% load, 10-20% load, 20-30% load...., 100-110%, and
warning condition is corrected. 110-120% of rated kW capacity.
Specifications May Change Without Notice 08/01 CPG S-1005C
Kilowatt Meter: Indicates 3-phase AC power output as a
Generator Warning and Shutdown percent of rated load. Provides a true indication of total kW load
Messages on the generator set, regardless of the load power factor. Scale is
Overload - When total kW load exceeds 100% of the standby 0-125%. Accuracy is ±5%.
rating of the generator set (110% of prime rating) for 5 seconds, a Frequency Meter: Indicates generator set output frequency
load shed signal is issued and a warning alarm is activated. in hertz. Calculated frequency is based on engine speed and
Overcurrent - When the current on any phase exceeds 110% alternator voltage zero-crossing and is not affected by voltage
of the generator set rated current for more than 60 seconds, a waveform distortion caused by non-linear loads. Scale is
warning alarm is activated. 45-65 Hz. Accuracy is ±0.5 Hz.
Overcurrent - The generator set is shut down when the current AC Voltmeter: Dual scale AC voltmeter indicates alternator
on any phase is between 110-175% of rated and the time/current output voltage. Accuracy: ±2%. Scales: 0-300 VAC, 0-400 VAC,
integral approaches alternator thermal limits. 0-600 VAC; 0-750 VAC; 0-5260 VAC; or 0-15,000 VAC.
Short Circuit - The generator set is shut down when the AC Ammeter: Indicates current output in percent of maximum
current on any phase exceeds 175% of rated and the time/current rated standby current. Accuracy: ±2%. Scale: 0-125%.
integral approaches alternator thermal limits. Phase Select Switch: Allows the operator to select the phase
Fail to Synchronize - The control system monitors the monitored by the analogue voltmeter and ammeter. LED
generator set as it is attempting to synchronize with a live bus, indicators display which phase is being monitored and which
and initiates a fault signal if synchronizing is not achieved within voltage scale is applicable.
an adjustable time delay period (10-120 seconds). The control
system can be configured for warning, shutdown, or switching off Digital Metering
this function. The digital metering display provides access to alternator
Failure to Close - The control system monitors the paralleling performance data and a more accurate readout of the AC output
breaker auxiliary contacts, and initiates a fault signal if the information displayed on the analogue meters. The following
breaker fails to close within an adjustable time delay period after outputs are included on the display:
● Generator set output voltage (3-phase, line-to-line, or line-to-
the control has signalled it to close (0.5-15 seconds). The control
system can be configured for warning, shutdown, or switching off neutral).
● Parallel bus voltage (3-phase, line-to-line).
this function.
● Generator set output current (3-phase).
High AC Voltage - Generator set is shut down when AC
● Power Factor (0 to 1, leading or lagging).
voltage exceeds 110% for 10 seconds, or with no delay when
● AC Kilowatts.
voltage exceeds 130% of nominal.
● AC Kilowatt-hours.
Low AC Voltage - Generator set is shut down when AC voltage
● Alternator exciter duty and governor duty (%).
falls below 85% of rated voltage for more than 10 seconds.
● Generator set output frequency (Hz).
Reverse Power - Generator set is shut down when kW flow
● Parallel bus frequency (Hz).
into the generator set exceeds an adjustable set point (5-15% of
generator set rating) for an adjustable time period (1-15 seconds). The voltage and current data for all three phases is displayed
Under Frequency - Generator set is shut down when AC simultaneously on a single screen so load and voltage balance is
frequency falls below 90% of rated frequency for more than 20 readily apparent.
seconds. Digital Synchroscope
Loss of Excitation - Generator set is shut down when kVAR is The digital display includes a synchroscope function for
less than 0.16-0.41 per unit kVAR (adjustable) for more than 2-10 monitoring the phase difference (in degrees, faster or slower than
seconds (adjustable). bus) between the generator set and the system bus. An indicator
Phase Rotation - Prohibits paralleling when generator set is provided to advise the operator when the generator set is within
phase rotation does not match system bus. specified paralleling parameters.
AC Output Metering
Combines digital and analogue metering to provide accurate digital
readout plus analogue indication of trends and operating conditions.
Analogue Meters
Analogue metering on the control panel provides clear indication
of generator set stability, including the magnitude of displacement
and rate of change during load transients, which cannot be
viewed as clearly with digital metering equipment. These meters
are also ideal for “walk-by” status checks by the operator. All
meters are 2.5 inch (63.5mm), 90 degree scale. Meter faces UV
protected against discoloration from exposure to sunlight. The
kilowatt meter and ammeter are scaled in percent of AC output for
easy recognition of generator set status and load level (0-90% of
rating: green; 90-100% of rating: amber; >100% of rating: red).
● Weak Battery (battery voltage less than 14.4 VDC for more
System Control
Status Indicators: Selection Switches
• Warning
• Shutdown
• Non-Automatic Voltage Meter Scale
Indicator Lamp
Digital Display
and Status Panel Phase Selector Switch
2 Line/32 Character with Indicators
LED Display
Reset Switch
Breaker Control
Switch
Emergency Stop Switch
Run/Off/AutoSwitch
Self Test Switch Menu “Home” Switch
(Key Switch Optional)
Panel Light Switch
Environmentally sealed
single-membrane face panel
Exhaust Opacity Customer interface provides protection against a
Control helps to reduce enclosure gives easy wide range of environmental
Automatic black smoke during access to PowerCommand conditions
Overload alarm engine start-up Control terminal blocks and
and load shed connections
protects critical
system loads
Combined analogue
and digital display
gives clear indication
of generator set
system parameters
UL 508 Listed
Advanced service
diagnostic system
for faster problem
analysis and
repair