CUMMINS PowerCommand 3201 Service Manual

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CUMMINS PowerCommand 3201 Service Manual | Manualzz

Service Manual

Controller

PowerCommand

3201

English − Original Instructions − 2010 $7 (Issue )

Table of Contents

SECTION TITLE PAGE

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ABOUT THIS MANUAL

TEST EQUIPMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO OBTAIN SERVICE

2. Control Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PANEL POWER ON/OFF MODES

CONTROL PANEL ASSEMBLY

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

READING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MENU DISPLAY AND SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LANGUAGE/UNITS SELECTION MENU

MAIN MENU

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALTERNATOR SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HISTORY/ABOUT SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HISTORY/ABOUT SUBMENUS (CONT.)

PARALLEL DATA SUBMENU

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER TRANSFER MAIN/SUBMENUS

UTILITY (PWR TRAN) SUBMENUS

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STATUS (PWR TRAN) SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSFER CONTROL (PWR TRAN) SUBMENU . . . . . . . . . . . . . . . . .

GENSET (PWR TRAN) SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-11

2-12

2-13

2-14

2-15

2-16

2-17

2-19

2-20

2-21

2-22

2-6

2-7

2-8

2-9

2-1

2-1

2-1

2-4

3. Control Calibration and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARALLELING and NON − PARALLELING . . . . . . . . . . . . . . . . . . . . . . . . .

SOFTWARE CALIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MODIFYING SETUP/ADJUST SUBMENUS

SETUP MENUS

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GOVERNING/VOLT REG SUBMENU

CUSTOMER FAULTS SUBMENUS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4

3-6

CALIBRATION SUBMENUS

ISOLATED BUS SUBMENUS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8

3-11

UTILITY SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER TRANSFER CONTROL MAIN MENUS . . . . . . . . . . . . . . . . . . .

UTILITY SENSORS SUBMENUS

GENSET SENSORS SUBMENUS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-17

3-19

3-20

3-22

TIMERS SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TEST/EXERCISE SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUST SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-24

3-26

3-28

3-29

3-1

3-1

3-1

3-1

3-3

1-1

1-1

1-1

1-1

2-1

i

SECTION TITLE PAGE

CONTROL BOX WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RUN RELAYS (K11, K12, K13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALARM RELAY (K16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAGNETIC SPEED PICKUP UNIT (MPU) INSTALLATION . . . . . . . . .

3-31

3-33

3-34

3-35

ii

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 operator, service personnel, or the equipment.

This symbol warns of immediate hazards which will result in severe personal injury or death.

WARNING

This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.

CAUTION

This symbol refers to a hazard or unsafe 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, unless 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 arcing, 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 secured 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, disconnect battery charger from its AC source, then disconnect 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 equipment. Loose clothing and jewelry can become caught in moving parts.

 If adjustment must be made while the unit is running, 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, explosion, 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 genset safely. Contact your authorized Cummins Power

Generation distributor for more information.

v

ELECTRICAL SHOCK CAN CAUSE

SEVERE PERSONAL INJURY OR DEATH

 Remove electric power before removing protective shields or touching electrical equipment. Use rubber 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 contacts 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 electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device.

GENERAL SAFETY PRECAUTIONS

 Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat exchanger 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 reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact 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 overheating and engine damage which present a potential fire hazard.

 Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris 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 unsafe.

 Substances in exhaust gases have been identified by some state or federal agencies as causing cancer 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

vi

1. Introduction

ABOUT THIS MANUAL

This manual provides PowerCommand  Control

3201 (PCC) calibration and adjustment procedures, 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 service 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 information or replacement parts. The nameplate is located 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 personnel must be trained and experienced to perform electrical and mechanical service. Read and follow Important Safety Instructions, on pages iii and iv.

1-1

THIS PAGE LEFT INTENTIONALLY BLANK

1-2

2.

Control Operation

GENERAL

The following describes the function and operation of the PowerCommand  Control 3200 (PCC). All indicators, 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 control must be configured for that generator set. Setup and calibration procedures are described in Section 3 .

SEQUENCE OF OPERATION

When the PowerCommand control is in the AUTO mode, it will cause the generator set to start on receiving 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 sufficient fuel to the engine to accelerate to start disconnect 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 control 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 synchronize 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 generator 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 operating software are Power On, Screen Saver and

Sleep/Awake.

Power On Mode: In this mode, power is continuously supplied to the control panel. The control’s operating software and control panel LEDs/graphical display will remain active until the Screen Saver mode is activated.

2-1

Screen Saver Mode: Power to the graphical display 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 button or switch selection) or signal received by the operating software. The bottom LEDs of the Analog

AC Metering Panel (bar graphs) may remain on during Screen Saver mode, indicating that the operating 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 control’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 disabled. 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 Enable to Sleep in Auto.

 Set switch S1 on the Genset/Paralleling Card to Sleep/Off. This switch is located next to connector J8 and relay K9.

If these conditions are not met, Sleep mode is disabled 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/button. (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 (generator 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 active.

 Customer fault 2 or 3 only (shutdown or warning 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.

2-2

OPERATOR PANEL

ANALOG AC

METERING

PANEL

SWITCH PANEL

PANEL LAMP/

LAMP TEST

BUTTON

FAULT

ACKNOWLEDGE

BUTTON

REMOTE START,

NOT IN AUTO,

SHUTDOWN,

WARNING

STATUS INDICATORS

EMERGENCY

STOP PUSH

BUTTON

0

GRAPHICAL

DISPLAY

DISPLAY MENU

SELECTION BUTTONS

(1 of 6)

EXERCISE

BUTTON &

INDICATOR

MANUAL RUN/

STOP BUTTON

& INDICATOR

0/MANUAL/AUTO

SWITCH

FIGURE 2-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)

2-3

CONTROL PANEL ASSEMBLY

The control panel assembly (Figure 2-1) consist of two panels, the Operator Panel and the Switch Panel .

Dependent on site requirements, the Operator Panel 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 assembly). If the function differs, it is noted as either “remote” or “local operator panel” in the button description.

Operator Panel

The operator panel contains the following components:

Analog AC Metering Panel: This panel simultaneously 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 increases at values further from nominal.

Graphical Display: The graphical display is capable of displaying up to 9-lines of data with approximately 27 characters per line. The display is used to view the menus of the menu-driven operating system.

The top three lines of the graphical display contain the following control information in the order described:

 State Line − modes of operation, such as

Stopped, Time Delay To Start, Warm Up At

Idle, etc. (see Figure 2-2), and paralleling operations, 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 display window—are used to navigate through the system control menus and to adjust generator set parameters. The button is active when the message adjacent to the button is highlighted (displayed in inverse video).

2-4

Switch 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, 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 signal. When flashing, it indicates a load demand stop mode.

Not in Auto Indicator: This red lamp flashes continuously 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 indicators can be reset by turning the 0/Manual/Auto switch to the 0 position, and pressing the Fault Acknowledge 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 operation.)

Fault Acknowledge: Press this button to acknowledge warning and shutdown messages after the fault has been corrected.

To acknowledge a Warning message, the 0/Manual/Auto switch can be in any position. (It is not necessary 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 illuminate. The illumination will shut off after releasing the button.

Exercise Button: Press this button to initiate a preprogrammed exercise sequence. To start the exercise 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 button.

Auto position enables start/stop control of the engine 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.

2-5

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 indicator 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 indicates 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 second to the tens position and the third to the ones digit. 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 inactive) 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 corrected, the recorded fault will be deleted from the

LED fault log, but will remain in a data log that maintains a fault code history. (The InPower service tool is required to view this data log.)

2-6

MENU DISPLAY AND SWITCHES

Figure 2-2 shows the graphical display and the menu selection buttons.

Graphical Display: The graphical display is capable of displaying up to 9-lines of data with approximately 27 characters 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 following system 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 messages.

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 video). 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 operating 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 operating program to go back to the previous menu display.

In the graphical display, the “ ” symbol indicates that selecting the adjacent button causes the operating program to go back to Main Menu A (Figure 2-4).

STATE LINE

ACTION LINE

DESCRIPTION LINE

MENU DISPLAY

AREA

GRAPHICAL

DISPLAY

MENU

BUTTONS

MENU

BUTTONS

FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

2-7

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 (default = 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 remotely from the generator set.

The Local/Remote selection determines which buttons in the Control submenu (page 2-13) are active

(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 air flow readings.

+

ENGLISH

LOCATION

TEMP  F

PSI

INHG

FLOW AIR

ENTER

FIGURE 2-3. LANGUAGE/UNITS MENU

2-8

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 assigned 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 passwords.

_\_ Button (Paralleling Applications Only)

When displayed, indicates that the feature for generator 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 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.)

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.

2-9

MENU A

MENU

BUTTONS

PAGE

2-11

PAGE

2-12

PAGE

2-13

ENGINE

ALTERNATOR

CONTROL

MORE>>

POWER TRAN or _\_

HISTORY/ABOUT

MENU B

Section

3

SETUP

ADJUST

PARALLEL DATA

BACK<<

GRAPHICAL

DISPLAY

Section

3

PAGE

2-16

MENU

A

FIGURE 2-4. SYSTEM CONTROL MAIN MENUS A AND B

MENU

B

MENU

BUTTONS

Page

2-9

PAGE

2-14

2-10

ENGINE SUBMENUS

If you press the “ENGINE” button in Menu A, the Engine 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 provided with the engine.

ENGINE

ENGINE SPEED 1800

BATTERY

 F

OIL PRESSURE

RPM

VDC

75

29.1

Y

B

MANF TEMP  F

MANF PRESS ABS

RAIL PRESS ABS

PUMP PRESS ABS

FUEL INLET TEMP

PSI

75

180

180

291

 F 172

COOLANT PRESSURE 59

Y

B

CFM

TIMING PRESS

 F

AMBIENT PRESS

25

50

AFTERCOOLER TEMP 76

INHG 88

Y

FIGURE 2-5. ENGINE SUBMENUS

2-11

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-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 to L1, respectively.

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 direction of flow) and power factor with leading/lagging indication. Accuracy 5%.

The PF reading will contain an asterisk if the power factor is leading (for example,

*.30).

ALTERNATOR

V L-L

L1 480

L2 480

L3 480

1340

277

277

60.0 HZ

AVR DUTY CYCLE kW

L1 350

L2 350

L3 350 kVA

500

500

500

TOT1050 1500

PF

.80

.80

.80

.80

FIGURE 2-6. ALTERNATOR SUBMENUS

Y

B

Y

2-12

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 button is not displayed in remote applications.

The shaded area in Figure 2-7 displays the selected/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 position to activate the Remote Menu Buttons of the Control 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 generator set continues to operate until it runs out of fuel, the E − stop button is used, or the load is removed.

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.

2-13

Enable Sync: Displayed in paralleling applications only. Intended for service personnel to turn off the synchronizer for troubleshooting/testing purposes.

CONTROL

(Local)

+ RUN MODE IDLE

ENABLE SYNC

BARGRAPH TEST

CONTROL

(Remote)

START GENSET

FAULT ACKNOWLEDGE

ENABLE SYNC

BARGRAPH TEST

FIGURE 2-7. CONTROL SUBMENU

B

Y

Y

B

Y

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 following 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 operating software.

HISTORY/ABOUT

STARTS 533

ENGINE HOURS

7879

KWHRS 890

Y

B

HISTORY-HRS@ %MAX TORQUE

12345@0-9

12345@60-69

12345@20-29

12345@80-89

Y

B

MODEL 1750DQKB

VOLTAGE416 WYE

60

RATINGSTANDBY

Y

B

CONTROLLER VERSION

RTOP

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

2-14

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 acknowledged 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 history. (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 indicates 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 corrected before it will increment the occurrence number for that fault.

For example, when a Low Oil Pressure fault is detected, 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 number each time the engine is started. When the controller detects that the oil pressure is normal the fault will become inactive, allowing the occurrences number to be incremented for the next detected Low Oil

Pressure fault.

HISTORY/ABOUT (CONT.)

+

FAULT HISTORY: 1 OF 24

CNTL HOURS

OCCURRENCES

ENGINE HOURS

1437

( FAULT DESCRIPTION )

Y

FIGURE 2-8. HISTORY/ABOUT SUBMENUS (CONT.)

2-15

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 applications only.

_\_ 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.

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 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 parallel 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.

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.)

PARALLEL DATA

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 circuit breaker close button to close breaker.

LOAD GOVERN

V BUS

L1 480

L2 480

L3 480

GEN

480

480

480

HZ60.1

60.1

DEG − 122 NOT SYNCHRONIZING

FIGURE 2-9. BUS DATA SUBMENU

Y

_\_

2-16

POWER TRANSFER MAIN/SUBMENUS

If you press the “POWER TRANS” button in Menu

A, the Power Transfer main menu will appear (Figure 2-10). The Power Transfer Control (PTC) feature 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 (circuit breakers) for the utility (S1) and the genset

(S2).

If utility fails, the control will initiate the genset starting 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 Power 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.

2-17

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 genset start/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 genset fault (e.g., warning, derate, or shutdown w/cooldown fault). The retransfer timer is ignored as is the retransfer inhibit.

− EMERG TEST: Emergency Test sequence initiated through Remote Start switch with emergency 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 performed 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.)

MENU

BUTTONS

PAGE

2-19

PAGE

2-20

PAGE

2-21

PTC STATUS LINE

B UTILITY

STATUS

TRANSFER CONTROL

DEG − 123 SYNCHRONIZING

GENSET B

PAGE

2-22

MENU

BUTTONS

FIGURE 2-10. POWER TRANSFER MAIN MENU

MENU

A

2-18

UTILITY (PWR TRAN) SUBMENUS

If you press the “Utility” button in the Power Transfer

Main menu, the Utility submenus will appear (Figure 2-11).

Voltage L-L and L-N: Indicates utility voltage Lineto 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 measured between L1 to L2, L2 to L3 and L3 to L1, 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%.

The PF reading will contain an asterisk if the power factor is leading (for example, *.30).

UTILITY

V L-L

L1480

L2 480

L3480

UTILITY:

FREQUENCY

L-N

277

277

60.0 HZ kW

L1

L2 125

L3

TOT

UTILITY: kVA

175

PF

.96

FIGURE 2-11. UTILITY SUBMENUS

Y

B

Y

2-19

STATUS (PWR TRAN) SUBMENUS

If you press the “Status” button in the Power Transfer Main menu, the Status submenus will appear

(Figure 2-12).

Connected: Indicates which source(s) is connected to the load.

Available: Indicates when the corresponding sources have acceptable output voltage and frequency. 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 contact disables it. When enabled, the event is displayed 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 remote contact between TB3-64 and TB3-65. Closing the contact enables the feature and opening the contact disables it. When enabled, the event is displayed on the graphical display.

STATUS

GEN

CONNECTED

AVAILABLEYES

VOLT L12 480

HZ

KW L2

NO

0.0

456

TRAN INHOFF

ON

FIGURE 2-12. STATUS SUBMENUS

Y

B

Y

2-20

TRANSFER CONTROL (PWR TRAN) SUBMENU

If you press the “TRANSFER CONTROL” button in the Power Transfer Main menu, the Transfer Control 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 appropriate CB ENABLE button (Utility or Genset).

Example (Figure 2-13)

In the example in Figure 2-13, the CB ENABLE button for “ Utility ” was pressed. (If the CB ENABLE button for the “ Genset ” was pressed, ENABLE

GEN CB would be displayed in the second submenu, 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 return 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 submenu.

TRANSFER CONTROL

UTILITY

CB ENABLE

<< BACK

ENABLE UTIL CB

CANCEL

UTILITY

OPEN UTIL

<< BACK

UTILITY

CLOSE UTIL

<< BACK

GENSET

CB ENABLE

GENSET

CB ENABLE

GENSET

CB ENABLE

FIGURE 2-13. TRANSFER CONTROL SUBME-

NUS

2-21

GENSET (PWR TRAN) SUBMENUS

If you press the “Genset” button in the Power Transfer 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-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 to L1, respectively.

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 direction of flow) and power factor with leading/lagging indication. Accuracy 5%.

The PF reading will contain an asterisk if the power factor is leading (for example,

*.30).

GENSET

V L-L

L1 480

L2 480

L3 480

GENSET:

FREQUENCY

L-N

277

277

1320

60.0 HZ kW

L1 100

L2 125

L3 150

GENSET: kVA

150

175

200

TOT375 525

PF

.97

.96

.95

.96

FIGURE 2-14. GENSET SUBMENUS

Y

B

Y

2-22

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 application, entering the checksum data into the Dataplate Checksum dialog in InPower t is not required. 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 software calibration will fail, and the board will lock up permanently.

CAUTION

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, or the board will lock up permanently.

MODIFYING SETUP/ADJUST SUBMENUS

The Setup and Adjust submenus allow you to calibrate the graphical display meters and to adjust system parameters, customer defined faults, generator set voltage/frequency and paralleling applications.

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 service personnel only. The Adjust submenu is intended 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.

FIGURE 3-1. U33 FLASH MEMORY CHIP

3-1

PASSWORD Menu

To allow the site personnel to modify only the Adjust submenu and not the Setup submenus, two passwords are assigned within the system software. An

Application password is used for the Setup submenus 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 appropriate personnel.

When the generator set is first installed, the Application and User password are both set to GENSET to allow initial modification of the Setup and Adjust submenus. Assign new passwords when site installation 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 displayed submenu. The Password menu appears.

3. Press the + and − button to select the first character of the password (A − Z or 0 − 9). (Enter Application password for Setup submenus; Enter 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 password characters.

6. Press the Enter button after entering the password. The submenu selected in step 1 will reappear.

7. After making desired changes to submenu, exit submenu to save changes.

+ OR − BUTTON + OR − BUTTON

+

ENTER APPLICATION PASSWORD

ENTER

XXXXXXXX

+

ENTER USER PASSWORD

ENTER

XXXXXXXX

SETUP SUBMENU PASSWORD MENU ADJUST SUBMENU PASSWORD MENU

FIGURE 3-2. PASSWORD MENUS

3-2

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 service 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 parameters, 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 information 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.

MENU A MENU B

ENGINE

ALTERNATOR

CONTROL

MORE>>

POWER TRAN or _\_

HISTORY/ABOUT

MENU

B

SETUP

SETUP MENU 1

PAGE

3-4

PAGE

3-5

PAGE

3-6

GOVERNING/VOLT REG

CUSTOMER FAULTS

CALIBRATION

Y

B

SETUP MENU 2

PAGE

3-12

PAGE

3-7

PAGE

3-11

POWER TRANSFER SETUP

ISOLATED BUS

UTILITY

Y

ADJUST

PARALLEL DATA

BACK<<

MENU

A

MENU

B

NEXT

MENU

MENU

A

ABOVE

MENU

MENU

A

FIGURE 3-3. SETUP SUBMENUS

3-3

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 (  ) button 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 reduced 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.

3-4

+

GOVERNING/VOLT REG

80%

100%

Y

FIGURE 3-4. GOVERNING/VOLT REG SUBMENU

3-5

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 displayed 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 initiated before shutdown. Should not be used for engine faults.

Derate: Used to lower kW output of genset for warnings such as pre-high coolant temperature, etc. Paralleling application − controller will reduce precentage of kW load sharing on the set. Non-paralleling application − controller will

CUSTOMER FAULTS SUBMENUS

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 contains 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 position 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.

3-6

CUSTOMER FAULTS

+

CUSTOMER FAULT1:

ENABLE ON

ACTIVE CLOSED

Y

B

***CUSTOMER FAULT1 ******************

+

CUSTOMER FAULT2:

Y

B

***CUSTOMER FAULT2 ******************

CONTINUES THROUGH TWO

ADDITIONAL MENUS FOR A

TOTAL OF FOUR POSSIBLE

CUSTOMER FAULT MESSAGES

FIGURE 3-5. CUSTOMER FAULTS SUBMENUS

3-7

CALIBRATION SUBMENUS

If you press the “CALIBRATION” button in the Setup menu, the Calibration submenus will appear (Figure 3-6).

Use the + and − buttons to increase or decrease the values in the following fields. Use the arrow (  ) button 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 replacing 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.

3-8

CALIBRATION

+

VOLTAGE CALIBRATION

L1 480-X.X%

L2 480-X.X%

L3 480-X.X%

Y

B

+

CURRENT CALIBRATION

L1 234-X.X%

L2 123-X.X%

L3 562-X.X%

Y

B

+

BUS VOLTAGE CALIBRATION

L1 480 -X.X%

L2 480 -X.X%

L3 480 -X.X%

Y

FIGURE 3-6. CALIBRATION SUBMENUS

3-9

ISOLATED BUS / UTILITY Submenus

(Paralleling Application)

The Isolated BUS submenus (Figure 3-7) and the

Utility submenus (Figure 3-8) adjust the control parameters for generator set protection, synchronizing and load sharing for both isolated bus and utility

(mains) paralleling applications. Utility (mains) parallel 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 window for the defined period of time and that phase rotation is correct. When all criteria are met, the paralleling breaker is closed automatically by the control (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 automatically 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 generator 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 generator set will assume load based on external analog 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 relationship between the kW reference and the load govern signal.

3-10

If you press the “ISOLATED BUS” button in the Setup 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 (  ) button 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

ISOLATED BUS SUBMENUS

suitable for PowerCommand generator sets is 3 seconds.

Lower reverse power set points can result in nuisance reverse power shutdown faults.

PERM WIN-PHASE: Adjusts the width of the permissive (sync-check) acceptance window. The adjustment range is from five to twenty electrical degrees. 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 seconds) for which the generator set must be synchronized 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.

3-11

ISOLATED BUS

+

ISOLATED BUS:

SYNC TIME LIMIT 120

REV PWR LMT

SEC

DEG

SEC

10

3

20

PERM WIN-TIME .5

Y

B

CONTINUED TO NEXT PAGE

FIGURE 3-7. ISO BUS SUBMENUS

3-12

Adjusting the control for a smaller sync-check window 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 minimize the bus/generator phase difference. Increasing 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 adjusting 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 percentage 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 system, if the generator set load is constantly changing, 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 generator set. This also allows modification of the rate of load assumption on transient load change.

3-13

ISOLATED BUS (CONT.)

+

ISOLATED BUS:

SYNC GAIN

KW BALANCE

KVAR BALANCE

KW GAIN

KVAR GAIN

1.0

0.3

1.2

1.0

1.0

Y

B

CONTINUED TO NEXT PAGE

FIGURE 3-7. ISO BUS SUBMENUS (CONT.)

3-14

1ST FAIL TIME: Time delay in seconds after a signal from the first start master is not sensed by the

PCC that a FIRST START FAIL warning is displayed.

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 level 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 function time delay. A typical delay which is suitable for

PowerCommand generator sets is 2 seconds.

3-15

ISOLATED BUS (CONT.)

+

ISOLATED BUS:

1ST FAIL TIME

RAMP UNLD

%

RAMP LOAD TIME

LOSS FIELD

SEC

RAMP UNLD LEVEL 10

SEC

SEC

12

20

3

20

Y

FIGURE 3-7. ISO BUS SUBMENUS (CONT.)

3-16

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 (  ) button 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 operation at load levels in excess of the generator set rating can cause abnormal engine wear or premature engine failure.

PF LEVEL: Adjusts the power factor that the generator set will run at when paralleled to the utility

(mains). Recommended setting is 1.0.

UTILITY SUBMENUS

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 enters 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 whether 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 generator 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.

3-17

UTILITY

+

UTILITY:

BASE LOAD

PF LEVEL

RAMP LOAD

RAMP UNLD

MODE

80%

1.00

3

20

MULTIPLE

Y

B

+

UTILITY:

KW GOVERN GAIN 1.00

KVAR GOVERN GAIN1.00

Y

FIGURE 3-8. UTILITY SUBMENUS

3-18

POWER TRANSFER CONTROL MAIN

MENUS

If you press the “POWER TRANSFER SETUP” button 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 appropriate PTC main menu button and refer to the page number shown in Figure 3-9 for detailed information related to the submenu selected.

PAGE

3-13

PAGE

3-15

PAGE

3-17

PAGE

3-18

UTILITY SENSORS

GENSET SENSORS

TIMERS

TEST/EXERCISE

Y

B

PTC MAIN MENU 1

NEXT

MENU

Y

PTC MAIN MENU 2

FIGURE 3-9. PTC SETUP MAIN MENUS

3-19

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 (

) button 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-toline voltage which yields 100% voltage at the terminals 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 utility (bus) PT modules are as follows, based on module 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 primary stage transformer with a ratio of 4200/240 is used. This means that utility (bus) PT module number − 01 should be used. The voltage which will yield the 100% volts (208V from above table) is calculated as follows:

208 x (4200/240) = 3640. Thus enter 3640V.

U NOM VOLT LL: Enter the nominal utility line-toline 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 applies to both the utility undervoltage and overvoltage 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 seconds (0.5 seconds).

UV MIN PHASE: Displays the lowest line voltage of the three utility phases.

3-20

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 seconds (3 seconds).

OV MAX PHASE: Displays the highest line voltage of the three utility phases.

UTILITY SENSORS

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.

+

PT VOLT LL

U

CT RATIO: 1

U

416

480

1000

L − L

U KW

Y

B

+

PICK UP

DROP OUT

ENABLED

%

95

85

DELAY 0.5 S

MIN PHASE 470

Y

B

+

PICK UP

DISABLED

%

95

DROP OUT 110

DELAY 3.0 S

MAX PHASE485

Y

B

+

UTILITY FREQ:

CENTER

PICK UP

DROP OUT

DELAY

HZ

FREQUENCY

10

%

S

1

1.0

Y

3-21

FIGURE 3-10. UTILITY 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 (

) button 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 Adjust 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 applies to both the genset undervoltage and overvoltage sensors. Range: L − L, L − N (L − N).

G BASE LOAD: Enter the maximum load the genset 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).

GENSET SENSORS SUBMENUS

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 unloaded. This is the %kW level at which a closed transition soft retransfer will disconnect from the genset. Range: 0 − 100% (5%).

GEN UNDERVOLTAGE: Non-adjustable field, always enabled.

GEN 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 seconds (4 seconds).

UV MIN PHASE: Displays the lowest line voltage of the three genset phases.

3-22

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 seconds (3 seconds).

OV MAX PHASE: Displays the highest line voltage of the three genset phases.

GENSET SENSORS

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 frequency.

+

NOM VOLT LL

G

G

G

RAMP UNLOAD

G

480

L − L

80.0%

20 S

20 S

5 %

Y

B

+

GEN UV: ENABLED

PICK UP

DROP OUT

%

95

85

DELAY 1.0 S

MIN PHASE 470

Y

B

+

GEN OV: DISABLED

PICK UP

%

95

DROP OUT 110

DELAY 8.0 S

MAX PHASE485

Y

B

+

GEN FREQ:DISABLED

CENTER

PICK UP

DROP OUT

DELAY

HZ

FREQUENCY

12

%

S

2

5.0

Y

3-23

FIGURE 3-11. GENSET SENSORS SUBMENUS

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 (

) button 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 cooldown 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 seconds (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 Programmed 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 paralleled.

Enter a time from 0 to 1800 seconds (20 seconds).

3-24

TIMERS

+

S

STOP DELAY60

TRANSFER 10

RETRANSFER900

S

MAX PARALLEL30

Y

FIGURE 3-12. TIMERS SUBMENU

3-25

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 (  ) button 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 sequence, which is initiated through the Remote Start

(TEST) switch, to operate with or without load. Default: OFF

EXER WITH LOAD: Feature allows genset Exercise sequence, which is initiated through control panel Exercise button to operate with or without load. Default: OFF

3-26

TEST/EXERCISE

+

MODE CT-SOFT

TEST WITH LOADOFF

EXER WITH LOADOFF

Y

FIGURE 3-13. TIMERS SUBMENU

3-27

ADJUST SUBMENU

Figure 3-14 shows the main menus (Menu A and

Menu B) of the system control and the Adjust submenu.

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 required, the USER password menu will appear when you try to modify the Adjust submenus. (Refer to

PASSWORD Menu in this section to enter password.

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

MENU A 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 (  ) button 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 adjustment range is 0 to 300 seconds.

STOP DELAY: This delay applies only to remote stopping in the Auto mode. The Stop Delay adjustment 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

MENU

B

+

ADJUST:

START DELAY

SEC

%

5

11

VOLTAGE 208 1.2

HZ

Y

B

MENU B

SETUP

ADJUST

BUS DATA

BACK<<

MENU

A

+

BUS L1

ADJUST:

STANDBY

VOLTAGE DROOPOFF

V

POWER FACTOR0.80

VOLT

B

+

FIGURE 3-14. ADJUST SUBMENU

3-28

ADJUST:

STANDBY

SPEED DROOPOFF

BUS FREQ60.0HZ

TOTAL KW300

60.0

0.40HZ

Y

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 current and bus voltage.

Note that the type of calibration to perform varies for each card. The letters A, B and C are used to designate which of the following three calibration procedures 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 components can cause electrocution, resulting in severe 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 technically qualified personnel only.

Use a calibrated RMS multimeter for accurate measurements.

(A) Genset Voltage Display Calibration

The PowerCommand control automatically synchronizes to the system bus when bus voltage is available 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 voltage display of the genset that is running, the InPower service tool must be used to switch off the synchronizer function of the control.

1. Display the Voltage Calibration submenu

(Page 3-6).

2. With the genset OFF, attach a calibrated voltmeter 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 calibrated 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 ammeter 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.

3-29

(C) Bus Voltage Calibration

The PowerCommand control automatically synchronizes to the system bus when bus voltage is available and the genset is running. Consequently, it is not possible to calibrate the genset bus voltage display of the genset that is running when the bus is energized. 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 synchronizer function of the control.

1. Display the Bus Voltage Calibration submenu

(Page 3-6).

2. With all gensets OFF, attach a calibrated voltmeter 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 normal operating speed and voltage. Connect operating 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 calibrate L3 .)

7. Exit menu to safe changes.

CONTROL

BOX DOOR

TB1-A (L1)

TB1-B (L2)

TB1-C (L3)

FIGURE 3-15. BUS PT MODULE

3-30

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 attached to terminal blocks TB3 and TB8 (see Figure

3-16). Optional equipment such as a remote annunciator panel, sensing devices used to monitor genset operation, remote start/stop switches, control box heater, and etc. are also attached to these terminal 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.

3-31

OPTIONAL

RUN RELAYS

K11, K12 & K13

OPTIONAL

SHUTDOWN

ALARM RELAY K16

CONTROL WIRING

ACCESS

TB8

FIGURE 3-16. CONTROL BOX ASSEMBLY INTERIOR

3-32

CARD

CAGE

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 reaches 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

TB3-5

(SWITCHED B+)

K11, K12, K13

K11, K12, K13

K11, K12, K13

K11

RUN RELAY

NO

NC

COIL

COM

TB3-7

(GND)

CUSTOMER

CONNECTIONS

K12

RUN RELAY

NO

NC

K13

RUN RELAY

NO

NC

FIGURE 3-17. OPTIONAL RUN RELAYS (K11, K12, K13)

3-33

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

K16

K16

K16

CUSTOMER

CONNECTIONS

K16

SHUTDOWN ALARM

NO

NC

TB3-17

(COM ALARM)

COIL

COM

TB3-18

(GND)

FIGURE 3-18. OPTIONAL ALARM RELAY (K16)

3-34

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 engine. That can damage blades and cause property damage and personal injury.

3-35

MAGNETIC

PICKUP

SENSOR

ENGINE

FLYWHEEL

RING GEAR

FIGURE 3-19. MPU SENSOR

3-36

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.

E 2010 Cummins Power Generation, Inc. All rights reserved.

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Key Features

  • Comprehensive fault and alarm monitoring
  • Automatic start/stop and load shedding
  • Remote monitoring and control
  • User-friendly interface
  • Multiple language support
  • Comprehensive documentation

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Frequently Answers and Questions

What is the CUMMINS PowerCommand 3201?
The CUMMINS PowerCommand 3201 is a generator controller that provides advanced control and protection for your generator set.
What are the benefits of using the CUMMINS PowerCommand 3201?
The CUMMINS PowerCommand 3201 offers a wide range of benefits, including: - Comprehensive fault and alarm monitoring - Automatic start/stop and load shedding - Remote monitoring and control - User-friendly interface - Multiple language support - Comprehensive documentation
What are some of the applications for the CUMMINS PowerCommand 3201?
The CUMMINS PowerCommand 3201 is ideal for a wide range of applications, including: - Emergency backup power - Prime power - Peak shaving - Grid support - Islanding - Paralleling
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