25303394 CUmmins 350 Kva and 640 Kva DG Manual

Models

DGBB

DGBC

DGCA

DGCB

DGCC

DGDA

DGDB

DGEA

DGFA

DGFC

Printed U.S.A. 9000524 1297

iTable of Contents

SECTION TITLE PAGESAFETY PRECAUTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 INTRODUCTIONAbout this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How To Obtain Service 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Overview 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Control Function 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 CONTROL OPERATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of Operation 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Power On/Standby Mode 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Display and Switches 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Menu 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gen Menu 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CIRCUIT BOARDS AND MODULESGeneral 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Board (A32) 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Interface Board (A31) 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Board (A33) 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Display Board (A35) 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Interface Board (A34) 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PT/CT Board (A36) 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bus PT Board (A39) 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Communications Module (A41) 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Regulator Output Module (A37) 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Output Module (A38) 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master First Start Sensor 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 TROUBLESHOOTINGGeneral 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Indicators 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting the Control 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning and Shutdown Codes 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Oil Pressure Warning and Shutdown Limits 4-13. . . . . . . . . . . . . . . . . . . Troubleshooting Procedure 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Fuses 4-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Sharing Controls Troubleshooting Procedure 4-55. . . . . . . . . . . . . . . . . .

ii

5 CONTROL SERVICE AND CALIBRATIONGeneral 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Board Removal/Replacement 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Start Setup Menu 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Menu 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup and Calibration Menus 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Procedure 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessory Box Control Components 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Sensors 5-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Speed Pickup Unit (MPU) Installation 5-40. . . . . . . . . . . . . . . . . . . . . Current Transformer (CT) Installation 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 SERVICING THE GENERATORTesting the Generator 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Disassembly 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Reassembly 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the PMG 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 DAY TANK FUEL TRANSFER PUMP AND CONTROLOperation 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Connections 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Transfer Pump Motor Connections 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Float Switch Assembly 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 INITIAL SYSTEM STARTUPGeneral 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Startup Process 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Application Review 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Individual Generator Set Startup 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual System Operation 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic System Operation 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black Start Testing 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Reports and Acceptance 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On Site Power System Application Review (Diesel/600VAC and Lower) 8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 WIRING DIAGRAMSGeneral 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LS-12iii

Safety Precautions

Before operating the generator set, read the Opera-tors Manual and become familiar with it and the equip-ment. Safe and efficient operation can be achievedonly if the equipment is properly operated and main-tained. Many accidents are caused by failure to followfundamental rules and precautions.

The following symbols, found throughout this manual,alert you to potentially dangerous conditions to the op-erator, service personnel, or the equipment.

This symbol warns of immediatehazards which will result in severe personal in-jury or death.

WARNING This symbol refers to a hazard or un-safe practice which can result in severe per-sonal injury or death.

CAUTION This symbol refers to a hazard or un-safe practice which can result in personal injuryor product or property damage.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can resultfrom improper practices.

DO NOT fill fuel tanks while engine is running, un-less tanks are outside the engine compartment.Fuel contact with hot engine or exhaust is a potentialfire hazard.

DO NOT permit any flame, cigarette, pilot light,spark, arcing equipment, or other ignition sourcenear the generator set or fuel tank.

Fuel lines must be adequately secured and free ofleaks. Fuel connection at the engine should bemade with an approved flexible line. Do not usecopper piping on flexible lines as copper will be-come brittle if continuously vibrated or repeatedlybent.

Be sure all fuel supplies have a positive shutoffvalve.

Be sure battery area has been well-ventilated priorto servicing near it. Lead-acid batteries emit a highlyexplosive hydrogen gas that can be ignited by arc-ing, sparking, smoking, etc.

EXHAUST GASES ARE DEADLY Provide an adequate exhaust system to properly

expel discharged gases away from enclosed orsheltered areas and areas where individuals arelikely to congregate. Visually and audibly inspectthe exhaust daily for leaks per the maintenanceschedule. Make sure that exhaust manifolds are se-cured and not warped. Do not use exhaust gases toheat a compartment.

Be sure the unit is well ventilated. Engine exhaust and some of its constituents are

known to the state of California to cause cancer,birth defects, and other reproductive harm.

MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATH Keep your hands, clothing, and jewelry away from

moving parts. Before starting work on the generator set, discon-

nect battery charger from its AC source, then dis-connect starting batteries, negative (-) cable first.This will prevent accidental starting.

Make sure that fasteners on the generator set aresecure. Tighten supports and clamps, keep guardsin position over fans, drive belts, etc.

Do not wear loose clothing or jewelry in the vicinity ofmoving parts, or while working on electrical equip-ment. Loose clothing and jewelry can becomecaught in moving parts. Jewelry can short out elec-trical contacts and cause shock or burning.

If adjustment must be made while the unit is run-ning, use extreme caution around hot manifolds,moving parts, etc.

DO NOT OPERATE IN FLAMMABLE ANDEXPLOSIVE ENVIRONMENTS

Flammable vapor can cause a diesel engine to over-speed and become difficult to stop, resulting in possiblefire, explosion, severe personal injury and death. Do notoperate a diesel-powered genset where a flammable va-por environment can be created by fuel spill, leak, etc.,unless the genset is equipped with an automatic safetydevice to block the air intake and stop the engine. Theowners and operators of the genset are solely responsi-ble for operating the genset safely. Contact your autho-rized Onan/Cummins dealer or distributor for more in-formation.

iv

ELECTRICAL SHOCK CAN CAUSESEVERE PERSONAL INJURY OR DEATH Remove electric power before removing protective

shields or touching electrical equipment. Use rub-ber insulative mats placed on dry wood platformsover floors that are metal or concrete when aroundelectrical equipment. Do not wear damp clothing(particularly wet shoes) or allow skin surface to bedamp when handling electrical equipment.

Use extreme caution when working on electricalcomponents. High voltages can cause injury ordeath. DO NOT tamper with interlocks.

Follow all applicable state and local electricalcodes. Have all electrical installations performed bya qualified licensed electrician. Tag and lock openswitches to avoid accidental closure.

DO NOT CONNECT GENERATOR SET DI-RECTLY TO ANY BUILDING ELECTRICAL SYS-TEM. Hazardous voltages can flow from the gen-erator set into the utility line. This creates a potentialfor electrocution or property damage. Connect onlythrough an approved isolation switch or an ap-proved paralleling device.

MEDIUM VOLTAGE GENERATOR SETS(601V to 15kV) Medium voltage acts differently than low voltage.

Special equipment and training is required to workon or around medium voltage equipment. Operationand maintenance must be done only by personstrained and qualified to work on such devices. Im-proper use or procedures will result in severe per-sonal injury or death.

Do not work on energized equipment. Unauthorizedpersonnel must not be permitted near energizedequipment. Due to the nature of medium voltageelectrical equipment, induced voltage remains evenafter the equipment is disconnected from the powersource. Plan the time for maintenance with author-ized personnel so that the equipment can be de-en-ergized and safely grounded.

GENERAL SAFETY PRECAUTIONS

Coolants under pressure have a higher boiling pointthan water. DO NOT open a radiator or heat ex-changer pressure cap while the engine is running.Allow the generator set to cool and bleed the systempressure first.

Benzene and lead, found in some gasoline, havebeen identified by some state and federal agenciesas causing cancer or reproductive toxicity. Whenchecking, draining or adding gasoline, take care notto ingest, breathe the fumes, or contact gasoline.

Used engine oils have been identified by some stateor federal agencies as causing cancer or reproduc-tive toxicity. When checking or changing engine oil,take care not to ingest, breathe the fumes, or con-tact used oil.

Provide appropriate fire extinguishers and installthem in convenient locations. Consult the local firedepartment for the correct type of extinguisher touse. Do not use foam on electrical fires. Use extin-guishers rated ABC by NFPA.

Make sure that rags are not left on or near the en-gine.

Remove all unnecessary grease and oil from theunit. Accumulated grease and oil can cause over-heating and engine damage which present a poten-tial fire hazard.

Keep the generator set and the surrounding areaclean and free from obstructions. Remove any de-bris from the set and keep the floor clean and dry.

Do not work on this equipment when mentally orphysically fatigued, or after consuming any alcoholor drug that makes the operation of equipment un-safe.

Substances in exhaust gases have been identifiedby some state or federal agencies as causing can-cer or reproductive toxicity. Take care not to breathor ingest or come into contact with exhaust gases.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

1-1

1. Introduction

ABOUT THIS MANUALThis manual provides troubleshooting and repairinformation regarding the PowerCommandControl (PCC) and generators used on the DGSeries generator sets. Engine service instructionsare in the applicable engine service manual.Operating and maintenance instructions are in theapplicable Operators Manual.This manual does not have instructions forservicing printed circuit board assemblies. Afterdetermining that a printed circuit board assembly isfaulty, replace it. Do not repair it. Attempts to repair aprinted circuit board can lead to costly damage tothe equipment.This manual contains basic (generic) wiringdiagrams and schematics that are included to helpin troubleshooting. Service personnel must use theactual wiring diagram and schematic shipped witheach unit. The wiring diagrams and schematics thatare maintained with the unit should be updatedwhen modifications are made to the unit.Read Safety Precautions and carefully observe allinstructions and precautions in this manual.

TEST EQUIPMENTTo perform the test procedures in this manual, thefollowing test equipment must be available True RMS meter for accurate measurement of

small AC and DC voltages. Fluke models 87 or8060A are good choices.

Grounding wrist strap to prevent circuit boarddamage due to electrostatic discharge (ESD).

Battery Hydrometer Jumper Leads Tachometer or Frequency Meter Wheatstone Bridge or Digital Ohmmeter Variac Load Test Panel Megger or Insulation Resistance Meter PCC Service Tool Kit (Harness Tool and Sen-

sor Tool)HOW TO OBTAIN SERVICE

Always give the complete Model, Specification andSerial number of the generator set as shown on thenameplate when seeking additional serviceinformation or replacement parts. The nameplate islocated on the side of the generator output box.

WARNING Incorrect service or replacement ofparts can result in severe personal injury ordeath, and/or equipment damage. Service per-sonnel must be qualified to perform electricaland mechanical service. Read and follow SafetyPrecautions, on pages iii and iv.

1-2

SYSTEM OVERVIEWThe PCC is a microprocessor-based control forOnan generator sets. It provides fuel control andengine speed governing, main alternator voltageoutput regulation, and complete generator setcontrol and monitoring. It also provides controls forautomatic and semi-automatic synchronizing andautomatic load sharing controls for both isolatedbus or utility (mains) paralleling applications.The operating software provides control of thegenerator set and its performance characteristics,and displays performance information on a digitaldisplay panel. It accepts menu-driven control andsetup input from the push button switches on thefront panel.

GENERATOR SET CONTROL FUNCTIONFigure1-1 shows some of the control functions. Amore complete block diagram is provided in Section3. A system schematic is provided in Section 9.

The PCC monitors frequency from both themagnetic pick-up (MPU) and the main stator inputs.The control sends a low power pulse-widthmodulated (PWM) signal to the governor outputmodule, which then sends an amplified signal to theengine fuel control.The Bus PT module reduces the bus voltage toapproximately 18 VAC and provides a signal to thecontrol for reference in synchronizing the generatorset to the system bus.The external PT/CT module reduces generatorvoltage to approximately 18 VAC, and produces arepresentative AC voltage from CT output current.The voltage regulation function sends a low powerPWM signal to the voltage regulator output module,which then sends an amplified signal to the exciterstator.Oil, coolant, and exhaust temperatures are sensedby variable resistance element sensors. Oilpressure is sensed by a capacitive element activesensor.

Sensors

GovernorOutput

Output

MPU

NS

PMG

BatteryBT1

FuelControl

Bus PTModule

Regulator

LoadTo

1

1

2 3 4

234

FIGURE 1-1. GENERATOR SET CONTROL FUNCTIONS

2-1

2. Control Operation

GENERAL

The following describes the function and operationof the PowerCommand generator set control. All in-dicators, displays, meters and control switches arelocated on the face of the control panel as illustratedin Figure 2-1.

The PCC control cabinet must be opened only bytechnically qualified personnel.

Normally, generator set configuration options areset at the factory. When a new control is installed ona generator set or when parts are replaced, the con-trol must be configured for that generator set withthe use of the Initial Start Setup portion of the inter-nal software. Setup and calibration procedures aredescribed in Section 5.

The automatic voltage regulator (AVR) and gover-nor operation characteristic adjustments are alsodescribed in Section 5.

SAFETY CONSIDERATIONS

AC power is present when the set is running. Do notopen the generator output box while the set is run-ning.

WARNING Contacting high voltage compo-nents can cause electrocution, resulting in se-vere personal injury or death. Do not open thegenerator output box while the set is running.Read and observe all WARNINGS and CAU-TIONS in your generator set manuals.

CAUTION The PCC control cabinet must beopened only by technically qualified personnel.Lower level voltages (18 VAC to 24 VDC) arepresent in PCC control cabinet. These voltagescan cause electrical shock, resulting in per-sonal injury.Even with power removed, improper handlingof components can cause electrostatic dis-charge and damage to circuit components.

2-2

SEQUENCE OF OPERATION

When the PowerCommand control is in the AUTOmode, it will cause the generator set to start on re-ceiving a signal from a remote device. The Power-Command control will initiate a starter cranking sig-nal and verify that the engine is rotating. The Power-Command control will provide sufficient fuel to theengine to accelerate to start disconnect speed. Onreaching that speed, the control will ramp the gener-ator set to rated speed and voltage.

On reaching rated speed and voltage, the Power-Command control checks the system bus voltage. Ifno bus voltage is present, it will wait for a pulse froma remote Master First Start Sensor. On receivingthat pulse, the control will signal the parallelingbreaker to close.

If bus voltage is present, the PowerCommand con-trol will check for proper phase rotation, adjust thegenerator set to the bus voltage and frequency lev-el, and then synchronize the generator set to thesystem bus. When a synchronous condition isachieved, the control will send a signal to close theparalleling breaker.

When the paralleling breaker is closed, the genera-tor set will assume its proportional share of the totalload on the system bus.

PCC POWER ON / STANDBY MODE

Standby Mode

In the Standby (sleep) mode (selector switch S5 onthe Digital Board is set to the right and the generatorset is not running), the controls operating softwareis inactive and the LEDs and displays on front panelare all off.

The operating software is initialized and the frontpanel is turned on in response to a run signal or any

one of eight wake up inputs from remote sensingswitches.

The wake up signals are:

Emergency Stop Low Coolant Level Low Coolant Temperature Low Fuel Customer Fault Inputs 2 and 3 Run Selected on Run/Off/Auto Switch Remote Start Signal in Auto Mode Self Test switch

To activate and view the menu displays, press andrelease the Self Test switch. The PCC will initializethe operating software and permit operation of themenu display panel. If no menu selections aremade, the power to the control panel will shut downafter 30 seconds.

Power On Mode

In the Power On (awake) mode (selector switch S5on the Digital Board is set to the left), the PCC willinitialize the operating software and permit opera-tion of the menu display panel. (See Figure 3-1 forS5 location.) Power will stay on until switch (S5) isset to the Standby mode. It is recommended thatswitch S5 be left in the Power On mode in all ap-plications, except those where auxiliary batterycharging is not available.

CAUTION Electrostatic discharge will damagecircuit boards. Always wear a grounding wriststrap when touching or handling circuit boardsor socket-mounted ICs and when disconnect-ing or connecting harness connectors.

2-3

ACTIVE SWITCHINDICATOR

(1 of 6)

UPPER AND LOWERSCALE INDICATOR

FREQUENCYMETER

KILOWATTMETER

(PERCENT LOAD)

PHASE SELECTORSWITCH ANDINDICATORS

RESETSWITCH

NON-AUTOMATICWARNING

SHUTDOWNSTATUS INDICATORS

EMERGENCYSTOP PUSH

BUTTON(Turn CW to reset)

PANEL LAMPSWITCH

SELF TESTSWITCH

MENUSWITCH

ACVOLTMETER

(DUAL SCALE)

AC AMMETER(PERCENT AMPS)

ALPHANUMERICDISPLAY

MENUSELECTION

SWITCH(1 of 4)

RUN/OFF/AUTOSWITCH

PARALLELINGBREAKER

SWITCHES ANDINDICATORS

FIGURE 2-1. FRONT PANEL

2-4

FRONT PANEL

Figure 2-1 shows the features of the front panel.

AC Voltmeter: Dual scale instrument indicates ACvoltage. Measurement scale in use is shown onscale indicator lamp.

AC Ammeter: Indicates current output in percent ofmaximum rated current. (Percent current is basedon .8 PF.)

Kilowatt Meter: Indicates 3-phase AC power out-put as percent of rated load.

Frequency Meter: Indicates generator output fre-quency in hertz.

Upper and Lower Scale Indicator Lamps: Indi-cate AC voltmeter scale.

Digital Display: This two-line, 16-character per linealphanumeric display is used in the menu-drivenoperating system, in conjunction with the displaymenu selection switches and the Menu switch. Re-fer to the menu trees later in this section. The dis-play is also used to show warning and shutdownmessages.

Display Menu Selection Switches: Four momen-tary switchestwo on each side of the digital dis-play windoware used to step through the variousmenu options and to adjust generator set parame-ters. The green arrow adjacent to the switch is litwhen the switch can be used (switch is active).

Menu Switch: Press this switch to return the digitaldisplay to the MAIN MENU. Refer to the menu treeslater in this section.

Reset Switch: Press this switch to reset warningand shutdown messages after the condition hasbeen corrected. To reset a shutdown message withthe Reset switch, the Run/Off/Auto switch must bein the Off position.

With the Run/Off/Auto switch in the Auto mode,shutdown faults can be reset by removing the re-mote start input and then cycling the remote resetinput.

Self Test Switch: Press and hold this switch to lightall front panel LEDs and cycle through all shutdownand warning messages.

In the Standby (sleep) mode, with the generator setnot running, the controls operating software is inac-tive and the LEDs and displays on front panel are alloff.

To activate and view the menu displays withoutstarting the generator set, press and hold the SelfTest switch until the front panel LEDs light. ThePCC will initialize the operating software and permitoperation of the menu display panel. If no menu se-lections are made, a software timer will shut downthe power after 30 seconds.

Panel Lights Switch: Press this switch to turn con-trol panel illumination on and off. The illuminationwill shut off after about eight minutes.

Phase Selector Switch and Indicators: Press thismomentary switch to select phases of generatoroutput to be measured by the analog AC voltmeterand ammeter. LEDs indicate the selected phase.

Run/Off/Auto Switch: This switch starts and stopsthe set locally, or enables start/stop control of theengine from a remote location. (Ground to start.)

2-5

Emergency Stop Button: Push the switch in foremergency shutdown of the engine.

Remote Reset switch will not reset emergency stop.Can only be reset at the PCC front panel.

To reset:1. Turn the switch clockwise and allow it to pop

out.2. Move the Run/Off/Auto switch to Off.3. Press the front panel Reset switch.4. Select Run or Auto, as required.

Non-Automatic Status Indicator: This red lampflashes continuously when the Run/Off/Auto switchis not in the Auto position.

Warning Status Indicator: This yellow lamp is litwhenever the control detects a warning condition.After the condition is corrected, warning indicatorscan be reset by pressing the Reset switch. (It is notnecessary to stop the generator set.)

With the Run/Off/Auto switch in the Auto mode,warnings can also be reset by cycling the remote re-set input after the condition is corrected.

Shutdown Status Indicator: This red lamp is litwhenever the control detects a shutdown condition.After the condition is corrected, shutdown indica-tors can be reset by turning the Run/Off/Auto switchto the Off position, and pressing the Reset switch.In Auto mode, shutdowns can be reset by removingthe remote start input and then cycling the remotereset input.

Emergency Stop shutdown status (Code 102) can bereset only at the PCC front panel.

Paralleling Breaker Switches and Indicators:These two switches are used to manually open orclose the paralleling breaker of the generator set.The lamps are used to indicate the opened orclosed position of the paralleling breaker.

The Breaker Operation switches are operational onlywhen the Run/Off/Auto switch is in the Run position.The breaker will close when the generator set is syn-chronized with the system bus, or if the system busis de-energized.

2-6

FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES

MENU DISPLAY AND SWITCHES

Figure 2-2 shows the digital display and the menuselection switches. Refer to heading Front Panelwhich describes the menu display and switches.

In the Standby Mode, to activate and view the menudisplays without starting the generator set, pressand release the Self Test switch. This will initializethe PCC operating software and permit operation ofthe menu display panel. If no menu selections aremade, a software timer will shut down the power af-ter 30 seconds. In the Power On Mode, power iscontinuously supplied to the control panel. Displaywill always remain on.

In the digital display, the >> symbol indicates thatselecting the adjacent button causes the operatingprogram to branch to the next menu displayasshown in the menu diagrams.

In the digital display, the in the display. Refer to VERSION & DIS-PLAYS MENUS in Section 5.

2-7

DISPLAYS >

VOLTAGE _______ >>

< >

< >

ENGINE GEN

ADJUST >>

< ACTIVE BUTTON

< ACTIVE BUTTON SELECTED

INACTIVE BUTTON

RESET MENU >

RETURN TOMAIN MENU

CLEAR WARNING ANDSHUTDOWN MESSAGES

PAGES 2-8 & 2-9

MAIN MENU

VERSIONSETUP / CALHISTORY

(ACCESS CODE)

PAGES 2-10 & 2-11

OIL >

BATTERY >

RPM >

START DELAY _______ SEC >>

STOP DELAY _______SEC >>

VOLTS >

POWER >

%GOV / REG >

GOV / REG

2-8

ENGINE MENU

The facing page shows a block representation ofthe ENGINE menu. If you press the button next tothe word ENGINE in the display, the first ENGINEsubmenu will appear.

As shown in the diagram, the ENGINE menu hasthree submenus.

OIL/COOLANT submenu: This is the first sub-menu. Select OIL for a display of oil pressure and oiltemperature. Select COOLANT for a display ofcoolant temperature. When oil or coolant parame-ters are displayed, pressing the button next to the in the display to move to the BATTERY/HOURS submenu. Select BATTERY for a displayof battery voltage. Select HOURS for a display ofthe number of starts and the running hours. Whenbattery or hours parameters are displayed, press-ing the button next to the in the display to move to the RPM/EXHAUST sub-menu. Select RPM for a display of engine RPM.Select EXHAUST for a display of the (optional) ex-haust temperature. When RPM or exhaust pa-rameters are displayed, pressing the button next tothe

2-9

BATTERY

< >

< >

< >

>L___F / C

>

>

< >

< >

< >< >

BATTERY >

>

< >

< >

< >ENGINE GENADJUST >>

< >< >

OIL >

< > ___PSI / KPA >

< >< >

< >OIL >

< >

< >OIL >

OIL >

< >

>

< >BATTERY >

STARTS ___

< >BATTERY >

< >BATTERY >

L___F/C (or n/a)

Indicates OR Condition

2-10

GEN MENU

The facing page shows a block representation ofthe GEN menu. If you press the button next to theword GEN in the display, the first GEN submenuwill appear.

As shown in the diagram, the GEN menu has threesubmenus.

VOLTS/AMPS submenu: This is the first sub-menu. Select VOLTS for a display of a line-to-line orline-to-neutral selection, or for viewing of the sys-tem bus line-to-line voltage. Select line-line or line-neutral for the desired voltage display. SelectAMPS for a display of L1, L2, and L3 current inamps. When voltage or current parameters are dis-played, pressing the button next to the in the display to move to the POWER/KWHOURS submenu. Select POWER for a display ofpower output in kilowatts and a power factor value.Select KW HOURS for a display of kilowatt hours.When power or kW hours parameters are dis-played, pressing the button next to the in the display to move to the %GOV/REG/FREQUENCY submenu. Select %GOV/REGfor a display of voltage regulator and governor dutycycle (drive) levels in percentage of maximum. Se-lect FREQUENCY for a display of the generatoroutput frequency the bus frequency, or the digitalsynchroscope. When voltage regulator and gover-nor or frequency parameters are displayed, press-ing the button next to the

2-11

< >< > < >

< >

< >< >

< >

< >

< > < >

< >

< >

< >

>< >

ENGINE GENADJUST >>< >

VOLTS >

L --- L

L12 L23 L31

VOLTS >

>L1 L2 L3

ENGINE GENADJUST >>< >

VOLTS >

POWER >

>___ KW < >POWER >>KW HRS POWER >

POWER >

%GOV / REG in the displayto move to the model select submenu.

MODEL select submenu: Use the buttons next tothe and symbols to select the correct genera-tor set model number, frequency and power rating.

VOLTAGE SELECT submenu: Use the buttonsnext to the and symbols to select the correctgenerator set nominal line-to-line output voltage.

DELTA / WYE submenu: Use the buttons next tothe and symbols to select the delta or wyeoption.

SAVE submenu: From themodel select submenu,press the button next to the >> in the display tomove to the SAVE submenu. Select SAVE to saveyour changes. The MAIN MENU will then be dis-played.

5-5

< >

< >

< >

< >

>

MODEL (kw mod# freq) >>

SAVE >> < >< >

INITIAL START SETUP(It can be invoked by simultaneously pressing

the Reset, Menu, and Phase Select keys.)

ENGINE GENADJUST >>

SAVE >> < >STANDBY/PRIME

_______ >>

TO LOOP BACK & CHECK:

< >< VOLTAGE SELECT

(vac) L-L VAC >>

< >DELTA / WYE

_______ >>


5-6

ADJUST MENU

The ADJUST submenus permit adjustment of theoutput voltage and frequency and the start and stopdelay times of the generator set.

The complete calibration procedure is described inthe Calibration Procedure in this section.

The facing page shows a block representation ofthe ADJUST menu. If you press the button next tothe word ADJUST in the Main menu, the VOLT-AGE ADJUST submenu will appear.

As shown in the diagram, the ADJUST menu hasfive submenus, including a save/exit procedure.

Voltage and frequency can be adjusted only whenthe generator set is running under normal operatingparameters (not in idle mode). For example, if volt-age adjustment is selected when the set is in Idlemode or not running, the digital display will be:

VOLTAGE N/A >>

VOLTAGE submenu: This is the first submenu.Use the buttons next to the and symbols toadjust output voltage 5%.

FREQUENCYsubmenu:From theVOLTAGEsub-menu, press the button next to the >> in the dis-play to move to the FREQUENCY submenu. Usethe buttons next to the and symbols to adjustoutput frequency 5%.

START DELAY submenu: This delay applies onlyto remote starting in the Automode. From the FRE-QUENCY submenu, press the button next to the>> in the display to move to the START DELAYsubmenu. Use the buttons next to the and symbols to set the start delay. The start delay ad-justment range is 0 to 300 seconds.

STOP DELAY submenu: This delay applies onlyto remote stopping in the Auto mode. From theSTART DELAY submenu, press the button next tothe >> in the display to move to the STOP DELAYsubmenu. Use the buttons next to the and symbols to set the stop delay. The stop delay ad-justment range is 0 to 600 seconds.

IDLE SPEED submenu: From the STOP DELAYsubmenu, press the button next to the >> in thedisplay tomove to the IDLESPEED submenu. Usethe buttons next to the and symbols to set theidle speed. The idle speed adjustment range is 800RPM 100 RPM. (Default value is 800 RPM.)The idle speed can be adjusted only when the gener-ator set is running in the idle mode.When not in idlemode, N/A is displayed in RPM field.

SAVE/EXIT submenu: From the STOP DELAYsubmenu, press the button next to the >> in thedisplay tomove to theSAVE/EXITsubmenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the mainmenu.If you select SAVE, the adjustments will be retainedafter shutdown, and will be in effect when the set isrestarted. If you select EXIT without saving first, theadjustments will remain in effect until the genset isshut down, but will be reset (and will not be in effect)when the set is restarted.

5-7

< >< >

< >

< >

< >

< >>

< >< >

VOLTAGE _______ >>

>

START DELAY _______ SEC >>

STOP DELAY _______SEC >>

< SAVEEXIT >>

< SAVEEXIT >>

< >< SAVEEXIT >>

< >CHANGES SAVEDEXIT >>

CHANGES SAVEDEXIT >>

< VOLTAGE _______ >>

ENGINE GENADJUST >>

< >< >

< >< VOLTAGE

_______ >>

ENGINE GENADJUST >>

< >< >

ADJUST


< >< IDLE SPEED

_______RPM >>

5-8

SETUP AND CALIBRATION MENUS

The setup and calibration menus allow you to cali-brate the PCC with the reading from a calibratedmeter. There are four setup and calibration menusthat are selectable from the SETUP/CAL menu:

VERSION AND DISPLAYS

METERS

GOVERNOR/REGULATOR

SETUP

These fourmenus are intended for qualified servicepersonnel only. For this reason, a three-digit accesscode must be entered before you can proceed tothose menus.

ENTER CODE submenu:

The access code for your PCC is: 5 7 4.

To enter the code:1. Press the button next to the to increment the

first digit.

2. Press the button next to the >> to select thesecond digit.

3. Press the button next to the to increment thesecond digit.

4. Press the button next to the >> to select thethird digit.

5. Press the button next to the to increment thethird digit.

6. Press the button next to the >> to proceed tothe DISPLAYS/METERS submenu. (Pro-vided, of course, that you have correctly en-tered the access code.)

The following sub-sections describe how to selectandmake changes to the setup and calibrationme-nus and save the changes made to these menus.

Version Menu

The VERSIONmenu allows you to verify the modelnumber and frequency of the generator set, thedate and version of the operating software and gen-erator set configuration options. From the VER-SION menu you can also review a History file, thatcan contain up to 20 error messages.


The facing page shows a block representation ofthe VERSION submenus. If you press the buttonnext to the >> in the Main menu display, the VER-SION/SETUP/CAL menu will appear.

CAUTION Improper calibration or adjustmentof the PowerCommand control can causeequipment malfunction or damage. Calibrationand adjustment must be performed by techni-cally qualified personnel only.

VERSION submenu: If you select VERSION, thedisplay will show the generator set model number,frequency, and kW rating, and the date and versionof the operating software.

To display the generator set configuration options,press thebuttonnext to the >> in the submenu thatdisplays themodel number, frequency and etc. Thismenu provides the following information:

Generator set voltage

WYE or DELTA

Standby or Prime

Parallel or Single

HISTORY: From the VERSION, SETUP/CALmenu, press the button next to the >> in the dis-play to move to the HISTORY submenu. Press thebutton next to HISTORY to display the last (latest)recorded error message.

The software will record (save) up to 20 error mes-sages. The last error detected will always be dis-played first. As each new error is detected, the old-est error recorded after 20 will be deleted.

To view the generator set runtime at which the erroroccurred and to scroll through the remaining re-corded errors, press the button next to the >> inthe error message menu to display the RUNTIME,NEWER/OLDER menu.

The buttons next to NEWER and OLDER are usedto scroll up and down through the error messages.For example, pressing OLDER will display the nextoldest recorded error message. When pressingNEWERand the last (newest) errormessage is dis-played, or OLDERand oldest error is displayed, thedisplay will return to the HISTORY menu.

5-9

< >

< >ENGINE GENADJUST >>

< >

< ENTER CODE __ __ __ >>

VERSION MENUS

< >< >VERSION >

< >

>>

(kW) (model) (hz) >

BACK

ENGINE GENADJUST >>

< >< >< >VERSION >

< >< >VERSION >

>>

(kW) (model) (hz) >

_______ V ______BACK

< >< >VERSION >

< >HISTORY HISTORY

__________________________________ >>

< >RUNTIME _________NEWER OLDER

REFER TO FOLLOWINGMENUS IN THIS SECTION

DISPLAYS ERRORMESSAGE AND CODE

DISPLAYS VOLTAGE & GENSET CONFIGURATION


5-10

Displays Menu

The DISPLAYS submenus permit calibration of thedigital voltage, current, power factor (PF) and cool-ant temperature displays. Calibration is accom-plishedby using this sectionof themenu software toadjust the display so that it matches the readingtaken on an accurate, recently calibrated meter.


The facing page shows a block representation ofthe DISPLAYS submenus, which is the first of fourSETUP/CAL menus. If you press the button next tothe >> in the Main menu display, the VERSION/SETUP/CAL menu will appear.


DISPLAYSsubmenus: TheDISPLAYSsubmenusare intended for qualified service personnel only.For this reason, a three-digit access code must beentered before you can proceed to those menus.

Select SETUP/CAL. The display will show the EN-TER CODE submenu. Enter access code (574) aspreviously described in this section.SelectDISPLAYS toproceed to theDISPLAYSsub-menus. Use the buttons next to the and sym-

bols to calibrate the selected voltage, current, PF orcoolant temperature reading. Press the button nextto the >> in the display to move to the next adjust-ment.VOLTSL12, VOLTSL23, and VOLTSL31 referto voltages measured from L1 to L2, L2 to L3, andL3 toL1, respectively.Note that the system includesbus voltage reading provisions (BUS VOLTS L12,BUS VOLTS L23, and BUS VOLTS L31), whichmust be calibrated separately from the generatorset voltage settings.PF1, PF2 and PF3 will display N/A when the gen-erator set is not running.COOLANTTEMPRwill display N/A if the gensethas only one sensor. To calibrate coolant tempera-ture display, a precision resistor (provided in the en-gine sensor tool) must be temporally substituted forthe temperature sender. Refer toCalibrationProce-dure in this section.SAVE/EXIT submenu: From the AMPS L3 sub-menu, press the button next to the >> in the dis-play to move to the SAVE/EXIT submenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the DIS-PLAYS/METERS submenu.If you select SAVE, the adjustments will be retainedafter shutdown, and will be in effect when the set isrestarted. If you select EXIT without saving first, theadjustments will remain in effect until the genset isshut down, but will be reset (and will not be in effect)when the set is restarted.

5-11

DISPLAYS MENU

PF3 _______ >>

COOLANT TEMP R _______ >>

COOLANT TEMP L _______ >>

< >

< >

< >

< >DISPLAYS >

VOLTS L12 _______ >>

VOLTS L23 _______ >>

VOLTS L31 _______ >>

AMPS L1 _______ >>

AMPS L2 _______ >>

< >< SAVEEXIT >> < >

CHANGES SAVEDEXIT >>

< >< >CHANGES SAVEDEXIT >>

< VOLTS L12 _______ >>

< SAVEEXIT >> < >

< VOLTS L12 _______ >>

< SAVEEXIT >> < >

< >DISPLAYS >

< >< >DISPLAYS >

PF1 _______ >>

PF2 _______ >>

AMPS L3 _______ >>

< >< ENTER CODE

__ __ __ >>

< >< >VERSION >

BUS VOLTS L31 _______ >>

BUS VOLTS L23 _______ >>

BUS VOLTS L12 _______ >>


5-12

Meters Menu

The METERS submenus permit calibration of thecontrols analogmeters tomatch the calibrated digi-tal values. (Calibrate the digital display before cali-brating the analog meters.) This calibration is ac-complished by using this section of the menu soft-ware to adjust the selected meter reading so that itmatches the reading provided on the digital display.


The facing page shows a block representation ofthe METERS submenus, which is the second offour SETUP/CAL menus. If you press the buttonnext to the >> in theMain menu display, the VER-SION/SETUP/CAL submenu will appear.


METERS submenu: The METERS submenus areintended for qualified service personnel only. Forthis reason, a three-digit access code must be en-tered before you can proceed to those menus.

Select SETUP/CAL. The display will show the EN-TER CODE submenu. Enter access code (574) aspreviously described in this section.

Select METERS to proceed to the METERS sub-menus. Use the buttons next to the and sym-bols to calibrate the selected meter to match theCAL TO: value provided on the digital display.Press the button next to the >> in the display tomove to the next calibration.

VOLTMETER and % AMPERES calibration ref-erence the phase that is indicated on the phaseselection LEDs.

NOTE: The%AMPERESmeter scale is basedona0.8power factor. (100% of rated current is full load cur-rent at 0.8 PF.)

SAVE/EXIT submenu: From the HERTZ sub-menu, press the button next to the >> in the dis-play to move to the SAVE/EXIT submenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the DIS-PLAYS/METERS submenu.

If you select SAVE, the adjustments will be retainedafter shutdown, and will be in effect when the set isrestarted. If you select EXIT without saving first, theadjustments will remain in effect until the genset isshut down, but will be reset (and will not be in effect)when the set is restarted.

5-13

< >

< >

< >

< >

< >

DISPLAYS >

METERS MENU

< >< >VERSION >

A---C VOLTS CAL TO: ___ >>

% AMPERES CAL TO: ___ >>

% LOAD CAL TO: ___ >>

HERTZ CAL TO: ___ >>


CHANGES SAVEDEXIT >> < >

< >DISPLAYS >


> < >

> < >

< >DISPLAYS >

< >DISPLAYS > < >

ENTER CODE __ __ __ >>


A---C VOLTS ADJ TO: ___ >>

A---C VOLTS ADJ TO: ___ >>


5-14

Governor / Regulator Menu

The GOV/REG submenus permit adjustment ofvoltage regulator and governor parameters.

All GOV/REG menu values, except for REG VHZ andGOV RAMP, will display 100%. The expression100% represents the factory setting (default value)for the selected set. When increasing or decreasingthe value, you are increasing or decreasing from thefactory default value. (For example, entering 200%will double the value; 50% will decrease the valueby one half.)

Default values are preset by the factory. Due to sitevariables, thedefault valuesmayneed to beadjustedto attain peak performance.

The facing page shows a block representation ofthe GOV/REG submenus, which is the third of fourSETUP/CALmenus. If you press the button next tothe >> in the Main menu display, the VERSION/SETUP/CAL submenu will appear.


GOV/REG submenu: The GOV/REG submenusare intended for qualified service personnel only.For this reason, a three-digit access code must beentered before you can proceed to those menus.

Select SETUP/CAL. The display will show the EN-TERCODE submenu. Enter the access code (574)as previously described in this section.

From theDISPLAYS/METERSsubmenu, press thebutton next to the >> in the display to move to theGOV/REG/SETUP submenu. Select GOV/REG toproceed to the GOV/REG submenus.

Use the buttons next to the and symbols toadjust the selected governor and regulator parame-ters. Press the button next to the >> in the displayto move to the next adjustment.

GOV GAIN: If the gain adjustment is set too high,enginespeedwill hunt or oscillate. If gain is set toolow, the enginewill respond too slowly to changes inloadoverspeed may result.

Forparalleling applications the default value for gov-ernor gain is 70.

GOV INTEGRAL: If this adjustment is set too low,the engine will respond too slowly to changes inload. If it is set too high, engine responsewill be un-stable.

GOV RAMP: This adjustment sets the time for theengine to ramp to full operating speed. This adjust-ment applies only to set start up and does not affectthe transient response. (Adjustable range: 0through 10 seconds.)

REG GAIN: If the gain adjustment is set too high,output voltagewill be unstable. If gain is set too low,the output voltage will respond sluggishly tochanges in loadovershoot may result.

REG INTEGRAL: If this adjustment is set too low,the output voltage will respond sluggishly tochanges in load, resulting in a droop-type responseIf it is set too high, output voltage will be unstable.

REG VHZ: This underfrequency roll-off adjustmentcontrols how much excitation is reduced in re-sponse to underfrequency. If the value is set toolow, excitation will be cut too fast, and the voltagewill drop toomuch. If set too high, the generator setmay not be able to pick up rated load in one step.(Adjustable range: 1 through 50; normal range 7through 21.)

SAVE/EXIT submenu: From the REG VHZ sub-menu, press the button next to the >> in the dis-play to move to the SAVE/EXIT submenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the DIS-PLAYS/METERS submenu.


5-15

< >< >

>

< >

< >

< >

< >DISPLAYS >

GOVERNOR/REGULATOR MENU

< >GOV / REG

GOV GAIN _______% >>

GOV INTEGRAL _______% >>

GOV RAMP _______ >>



< >DISPLAYS >


> < >

> < >

< >DISPLAYS >

REG GAIN _______% >>

REG INTEGRAL _______% >>

REG VHZ _______ >>

GOV GAIN _______% >>

GOV GAIN _______% >>

>GOV / REG DISPLAYS >

< >< >VERSION >



5-16

Setup Menu

The SETUP submenus permit selection of severalconfiguration and operation options. Setup optiondefaults are listed in Table 5-2.

TABLE 5-2. SETUP DEFAULTS

SELECTION DEFAULT

CYCLE CRANK ONSYSTEM OF UNITS IMPERIAL*CUSTOMER FAULT 1 WARN*GRND FAULT WARN*DAY TANK WARN*HIGH GEN TEMP WARNEGT L NOEGT R NOLOW COOLANT SHTDLANGUAGE ENGLISH

* Default display messages for customer faults 1through 4. To change the customer fault mes-sage(s), to display the desired fault condition, referto heading Edit Customer Fault Messages.

The facing page shows a block representation ofthe SETUP submenus, which is the fourth of fourSETUP/CALmenus. If you press the button next tothe >> in the Main menu display, the VERSION/SETUP/CAL submenu will appear.


SETUP submenu: The SETUP submenus are in-tended for qualified service personnel only. For thisreason, a three-digit access code must be enteredbefore you can proceed to those menus.

Select SETUP/CAL. The display will show the EN-TERCODE submenu. Enter the access code (574)as previously described in this section.

From theDISPLAYS/METERSsubmenu, press thebutton next to the >> in the display to move to theGOV/REG/SETUP submenu. Select SETUP toproceed to the SETUP submenus.

Use the buttons next to the symbols to togglethe setup options. Press the button next to the >>in the display to move to the next adjustment.

If the cycle crankingoption is selected, themenuwillprompt for the selection of cycle number (3, 4, or 5)and crank and rest times (7 to 20 seconds).

An in-line engine that has the EGT (exhaust gastemp.) option, select YES for EGT L and NO forEGT R.

Edit Customer Fault Message(s): The four cus-tomer fault messages shown in Table 2-1 are edit-able. To enter the desired customer fault message,press the button next to the >> in the display todis-play the customer fault message to be changed.

Press the upper-left button by the display to selectthe desired character. Press the upper-right buttonto move the cursor to the next character to bechanged. (Holding this button down will return thecursor to the first position.) Themessage can be upto 16 characters. The fault code number will remainthe same, this code cannot be edited.

If these messages are changed, you should notethese changes in the Troubleshooting section of theOperators manual for this generator set.

SAVE/EXIT submenu: From the LANGUAGE sub-menu, press the button next to the >> in the dis-play to move to the SAVE/EXIT submenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the DIS-PLAYS/METERS submenu.


5-17

< >

< >

< >

< >

< >< >

< >>

>

LANGUAGE _______________>>

< >

< >

< >

< >

SETUP MENU

< >GOV / REG CYCLE CRANK

ON / OFF >>

< >SYSTEM OF UNITS

MET/ IMP >>



< >DISPLAYS >


< SAVEEXIT >> < >

< SAVEEXIT >> < >

< >DISPLAYS >

< >LOW COOLANT

SHTD / WARN >>

< >CUSTOMER FAULT1 SHTD / WARN >>

< >

< >EGT L

YES / NO >>

< >EGT R

YES / NO >>

CYCLE CRANK ON / OFF >>

CYCLE CRANK ON / OFF >>

< >

< >< >VERSION >

< > # OF CYCLE S (3, 4, or 6) >>

RESET MENU >

< >CYCLE CRANK

ON / OFF >>

RESET MENU >

< > CRANK TIME --- SEC (7 to 20) >>

RESET MENU >

IF CYCLE CRANK ON :

RESET MENU >RESET MENU >

< >

< >DAY TANK SHTD / WARN >>

< >HIGH GEN TEMP SHTD / WARN >>

GRND FAULT SHTD / WARN >>


5-18

Paralleling Setup Menu

The PARALLELING SETUP submenus adjust thecontrol parameters for generator set protection,synchronizing and load sharing for both isolatedbus and utility (mains) paralleling applications. Util-ity (mains) parallel applications may require adjust-ment of both the isolated bus and utility branchsubmenus.

The sync check (permissive) function is operationalin both automatic and manual (RUN) modes. Thecontrol will make sure that the generator set is atproper voltage, within the defined sync check win-dow for the defined period of time and that phaserotation is correct.When all criteria aremet, the par-alleling breaker is closed automatically by the con-trol (auto mode), or by operation of the breakerclose switch by the operator (run mode).

The synchronizing function of the PowerCommandcontrol is enabled when the control has brought thegenerator set to rated speed and voltage, and hassensed that bus voltage is available. The control au-tomatically adjusts the generator set speed andvoltage to match the bus frequency and voltage.The control can force the generator set to match abus voltage and frequency in a range of minus 40%to plus 10% of normal bus conditions. When theparalleling breaker has closed, the control will bringthe generator set back to normal voltage and fre-quency.

When the generator set is paralleled to anothergenerator set, the control provides automatic loadsharing functions for both real (kW) and reactive(kVAR) loads. Load sharing is proportional betweengenerator sets basedon their standby ratings. If twogenerator sets of different sizes are paralleled, theywill assume the same percentage of the systemloadautomatically. This caneasily be verified on theanalog % Load meters on the front of the Power-Command control panel.

When the utility parallelingmode is enabled and thegenerator set paralleling breaker is closed, the gen-erator set will assume load based on external ana-log input signal. The input signal must be calibratedfrom 0--5 VDC. When the signal is at 0.5 to 1 VDC,the control will operate the generator at no load inparallel with the utility (mains) source. At 4.5 VDCand greater, the control will operate the generator

set at 110% of the generator set base load setting.When the load govern signal is between 1 VDCand4.5VDC (seeFigure 5-4) the controlwill operate thegenerator set at a load level which is determined bya linear relationship between the kW reference andthe load govern signal.

ISOLATED BUS ADJUSTMENTS

SYNCTIMELIMIT:This parameter adjusts the timedelay in seconds before the Fail To Synchronizealarm will operate.

- PWR LIMIT (%): Adjusts the reverse power setpoint. ForPowerCommandgenerator sets, a typicalset point is 10-15%.

- PWR LIMIT (TIME): Adjusts the reverse powerfunction time delay. A typical time delay which issuitable for PowerCommand generator sets is 3 se-conds.

Lower reverse power set points can result in nui-sance reverse power shutdown faults.

PERM WIN-PHASE: Adjusts the width of the per-missive (sync-check) acceptance window. The ad-justment range is from five to twenty electrical de-grees. Recommended set point is 20 degrees forisolated bus applications, and 15 degrees for utility(mains) paralleling applications.

PERM WIN-TIME: Adjusts the time period (in se-conds) forwhich thegenerator setmust besynchro-nized with the system bus, before a breaker closesignal is issued by the PowerCommand control.Available range is 0.5 to 5 seconds. Recommendedvalue for PowerCommand generator sets is 0.5 se-conds for isolated bus applications.

Adjusting the control for a smaller sync-check win-dow or longer time delay will cause synchronizingtime to be extended.

SYNC GAIN: The sync gain adjustment controlshow quickly the governor will respond to try to mini-mize the bus/generator phase difference. Increas-ing the gain speeds up the response. If the gain istoo high instability can result.

SYNC INTEGRAL: The sync integral adjustmentcontrols the rate at which the governor will be ad-justed to try to minimize the bus/generator phasedifference. The lower the number the slower the re-sponse.

5-19

< >

< >DISPLAYS >

< ENTER CODE __ __ __ >>

< >

< >

PARALLELING SETUP MENU

< >GOV / REG VERSION >

< >

>< >

< -PWR LMT (%) 10 >>< >

< -PWR LMT (TIME) 3 >>< >

< PERM WIN-PHASE 20 >>< >

< PERM WIN-TIME .5 >>< >

< SYNC GAIN 95 >>< >

B (CONTINUED)

< SYNC INTEGRAL 12 >>< >

A (CONTINUED)


5-20

ISOLATED BUS ADJUSTMENTS (Cont.) (A)

KW BALANCE: This function adjusts the kW loadsharing function of the generator set. Before adjust-ing this value, all generator set calibrations shouldbe performed. If the total load on the system is notshared proportionately, the kW Balance can beused to adjust the generator set for more preciseload sharing. Increasing the kW Balance value willcause the generator set to reduce thepercentageofthe total kW load on that set.

KVAR BALANCE: This function adjusts the kVARload sharing function of the generator set. Beforeadjusting this value, all generator set calibrationsshould be performed. If the total load on the systemis not sharedproportionately, the kVARbalance canbe used to adjust the generator set for more preciseload sharing. Increasing the kVAR balance valuewill cause the generator set to reduce the percent-age of the total kVAR load on that set.

KWGAIN:Adjusts the rate of change of kW load onthe generator set. With a constant load on the sys-tem, if the generator set load is constantly chang-ing, reduce the gain adjustment on the generatorset. This also allows modification of the rate of loadassumption on transient load change.

KVAR GAIN: Adjusts the rate of change of kVARload on the generator set. With a constant load onthe system, if the generator set load is constantlychanging, reduce thegain adjustment on the gener-ator set. This also allows modification of the rate ofload assumption on transient load change.1ST START FAIL: Time delay in seconds after asignal from the first start master is not sensed by thePCC that a FIRST START FAIL warning is dis-played.RAMP UNLD TIME:When a load demand stop in-put is sensed the load is ramped down from thepresent load level on the set to the ramp unload lev-el in the time specified in seconds.RAMP UNLD LEVEL: The load demand ramp un-load function will ramp the load down from the pres-ent level on the set to this level before opening theset circuit breaker. Value shown is in % of gensetstandby rating.RAMP LOAD TIME: When the load demand stopsignal is removed the load is ramped from 0kW tothe load share level in the specified time after thecircuit breaker closes.LOSS FIELD TIME: Adjusts the loss of field func-tion time delay. A typical delay which is suitable forPowerCommand generator sets is 2 seconds. (Ver-sion 1.06, beginning 9-26-96 only.)

5-21

< >

< >

PARALLELING SETUP MENU (Cont.)

< SAVEEXIT >>

< SAVEEXIT >> < >

< >DISPLAYS >

< KW BALANCE 165 >>< >

< KVAR BALANCE 0 >>< >

< KW GAIN 6 >>< >

< KVAR GAIN 300 >>< >

>< >

< RAMP UNLD TIME 10 >>< >

< RAMP UNLD LEVEL 20 >>< >

< RAMP LOAD TIME 10 >>< >


< LOSS FIELD TIME 2 >>< >

5-22

UTILITY (MAINS) ADJUSTMENTS (B)BASE LOAD (%): Controls the maximum kW loadlevel that the generator set will operate at when par-alleledwith the utility (mains). The value shown indi-cates the steady state load on the generator as apercent of the generator set standby rating.Check generator set ratings formaximum load levelat which the generator set should operate whenparalleled with the utility (mains). Extended opera-tion at load levels in excess of the generator set rat-ing can cause abnormal engine wear or prematureengine failure.PFLEVEL:Adjusts the power factor that the gener-ator set will run at when paralleled to the utility(mains). Recommended setting is 1.0.KWGOVERNGAIN:Controls the rate that the gen-erator set kW load is increased after the generatorset has closed to the system bus when utility(mains) paralleled. Decreasing this value will resultin slower loading of the generator set.KW INTEGRAL: The kW integral adjustment isused to control the response of the generator set tolarge load changes when utility (mains) paralleled.Use of a higher integral valuewill result in slower re-sponse, and reduced kW overshoot on load as-sumption or rejection, especially on large systemload changes. Decreased integral values will alsoresult in slower load acquisition and rejection.

KVAR GOVERN GAIN: Controls the rate that thegenerator set kVAR load is increased after the gen-erator set has closed to the system bus when utility(mains) paralleled. Decreasing this value will resultin slower loading of the generator set.KVAR INTEGRAL: The kVAR integral adjustmentis used to control the response of the generator setto large load changes when utility (mains) paral-leled. Use of a higher integral value will result inslower response and reduced kVAR overshoot onload assumption or rejection, especially on largesystem load changes. Decreased integral valueswill also result in slower load acquisition and rejec-tion.RAMP LOAD TIME: This is the ramp time frompresent set load to level determined by the load setanalog input. This is activewhen the control first en-ters the load govern mode.RAMP UNLD TIME: This is the ramp time frompresent set load to the 0 kW. This ramp is activewhen the load set analog input is less than 0.5 volts.MULTIPLE/SINGLE: This controls whether the setis to operate as part of a multiple set or single set(PLTE of PLTF) system. (Refer to LOAD DE-MAND and UTILITY SINGLE VERIFY functiondescriptions in Table 5-3 for additional informationregarding Multiple/Single menu selection.)

5-23

< >

PARALLELING SETUP MENU (Cont.)

< SAVEEXIT >>

< >< >DISPLAYS >

< BASE LOAD % 80 >>< >

< PF LEVEL 1.00 >>< >

< KW GOVERN GAIN 100 >>< >

< KW INTEGRAL 4 >>< >

< KVAR GOVERN GAIN 300 >>< >

< KVAR INTEGRAL 200 >>< >

>< >

< RAMP UNLD TIME 10 >>< >

< MULTIPLE/SINGLE SINGLE>>< >


< >< SAVEEXIT >>

5-24

CALIBRATION PROCEDUREWARNING Contacting high voltage compo-

nents can cause electrocution, resulting in se-vere personal injury or death. Calibration andadjustment must be performed by technicallyqualified personnel only. Read and observe allWARNINGS and CAUTIONS in your generatorset manuals.


The calibration procedure is divided into 7 subsec-tions, with the subsections arranged in a specifiedorder. If twoormoreof the following subsectionsarerequired to calibrate the PCC, they must be com-pleted in the order shown.

When removing and replacing a defective circuitboard, you may have to perform one or more of thefollowing subsections. Table 5-1 (Control Panel Re-calibration) provides a list of the circuit boards thatrequire calibration when replaced and the calibra-tion procedure(s) that must be performed.

Use a calibrated RMS multimeter for accuratemeasurements. Fluke models 87 or 8060A aregood choices.

Initial Start Setup1. Refer to Page 5-4, which describes how and

when you should perform this procedure.To verify if the PCC is set to operate with aspecific generator set, refer to the VERSIONmenu (Page 5-9). Thismenuwill show the gen-erator set model number, frequency, and kWrating. If any of these values are incorrect, youmust perform the Initial Start Setup procedure.

Voltage and Frequency Adjustment2. With the generator set OFF, attach a calibrated

frequency/voltmeter to the AC output from L1to L2.

3. SelectADJUST from theMainMenu (page5-7)to display the VOLTAGE adjust menu.

4. Start the genset by moving the Run-Stop-Re-mote switch to the RUN position and allow thegenset to reach normal operating speed.

5. Adjust VOLTAGE (genset output voltage) sothat the calibrated voltmeter reads the desiredvoltage. (Use a calibrated voltmeter becausethe value displayed on the PCC digital displaymay not be calibrated at this time; therefore, itsaccuracy is unknown.)

6 Select the Frequency adjust menu.7. Verify that the frequency displayed on the cali-

brated meter is the desired frequency. If not,adjust to the desired frequency. (Note: If thefrequency reading on the digital display is notthe same as frequency shown on calibratedmeter, there is an equipment malfunction.)

8. If no frequency or voltage adjustment wasmade, select EXIT. If anadjustmentwasmade,SAVE, then EXIT.

Digital Voltage Display Calibration

The paralleling bus must be de-energized whilevoltage calibrations are performed. If this is notpossible, disconnect and isolate bus voltage in-puts to the Bus PTModule (A39) before attempt-ing voltage calibration.

9. Select >> from the Main Menu (Page 5-9).From this menu proceed to the VOLTS L12menu (Page 5-11).

10. With the genset OFF, attach a calibrated fre-quency/voltmeter to the AC output from L1 toL2.

11. Start the genset and allow it to reach normaloperating speed.

12. Calibrate voltage reading for VOLTS L12 sothat the reading on the digital display agreeswith the calibrated voltmeter.

13. Shut the generator set OFF.14. Repeat steps 10 through 13 for L23 and L31.

(In step 10 attach meter to the AC output fromL2 to L3 to calibrateVOLTS L23 and L3 to L1 tocalibrate VOLTS L31.)

15. If no calibration was made, select EXIT. If acalibration was made, SAVE, then EXIT.

5-25

Digital Ammeter Display Calibration16. Select >> from the Main Menu (Page 5-9).

From thismenu proceed to theAMPSL1menu(Page 5-11).

17. With the genset OFF, attach a calibratedammeter to L1.


19. Load the genset to maximum rated kVA atrated voltage.

20. Calibrate the reading for AMPS L1 so that thereading on the digital display agrees with cali-brated ammeter.

21. Repeat steps 17 through 20 for L2 and L3. (Instep 17, attach meter to L2 to calibrate AMPSL2 and L3 to calibrate AMPS L3.)


Digital Power Factor Display Calibration

Power factor calibration is not requiredexcept in ap-plications requiring a higher accuracy than 5%. Ifthe 5%accuracy is not acceptable, further calibra-tion will require reactive load sufficient to reach 0.8PF at rated load, and calibrated instruments with1% accuracy or better. Typical load rack instru-ments are not accurate enough to perform this pro-cedure.

23. Select >> from the Main Menu (Page 5-9).From this menu proceed to the PF1 menu(Page 5-11).

24. With the genset OFF, attach the power factormeter to L1.


26. Load the genset to maximum rated kVA atrated voltage.

27. Calibrate the reading for PF1 so that the read-ing on the digital display agrees with powerfactor meter.

28. Repeat steps 24 through 27 for L2 and L3. (Instep 24, attachmeter to L2 to calibratePF2andL3 to calibrate PF3.)

29. If no calibrationwasmade, select EXIT. If a cal-ibration was made, SAVE, then EXIT.

Digital Bus Voltage Calibration

30. Select >> from the Main Menu (Page 5-9).From this menu proceed to the Bus Volts L12menu (Page 5-11).

31. With the genset OFF, attach a calibrated fre-quency/voltmeter to the alternator AC outputfrom L1 to L2.

The paralleling bus must be de-energized whilevoltage calibrations are performed. If this is notpossible, disconnect and isolate bus voltage in-puts to the Bus PTModule (A39) before attempt-ing voltage calibration.

32. Start the genset and allow it to reach normaloperating speed and voltage.

33. Push the breaker close switch on the front ofthe PowerCommand control and verify that theparallelingbreaker has closedby observing theclosed lamp on the control panel and physicalcheck of the breaker.

34. Calibrate the voltage reading for Bus Volts L12so that the reading on the digital displaymatches the reading on the calibrated meter.

35. Shut the generator set OFF.

36. Repeat steps 31 through 35 for Bus Volts L23and Bus Volts L31.

37. If no calibrationwasmade, select EXIT. If a cal-ibration was made, SAVE, then EXIT.

5-26

Digital Coolant Temperature DisplayCalibration

A engine sensor calibration tool is required to per-form this procedure.

30. With the genset OFF, replace the coolanttemperature sender with the precision resistorprovided in the calibration tool.

31. Select >> from the Main Menu (Page 5-9).From this menu proceed to the COOLANTTEMP L menu (5-11).

32. Calibrate the temperature reading tomatch thetemperature indicated on the calibration tool.

33. Repeat step 32 for COOLANT TEMP R if theengine uses two sensors.


Analog meter calibration

35. Select >> from the Main Menu (Page 5-9).From this menu proceed to the A--C VOLTSCAL TO: menu (Page 5-13).

36. Start the genset and allow the genset to reachnormal operating speed.

37. Calibrate the analog Voltmeter to the digitallydisplayed value.

38. Calibrate the analog% Ampsmeter to the digi-tally displayed value.

39. Calibrate the analog % Load meter to the digi-tally displayed value.

40. Calibrate the analog Frequency meter to thedigitally displayed value.

41. SAVE, then EXIT.

5-27

ACCESSORY BOX CONTROLCOMPONENTS

Thegenerator set accessory box (Figure 5-3)whichis located on the backside of the control housing,

contains components that provide connectionpoints for remote control and monitor options. Theset can be equipped with one or more of the follow-ing components (customer terminal block TB1 isstandard).

OPTIONAL COMMONALARM RELAY K14

OPTIONAL RUN RELAYSK11, K12 & K13

CUSTOMER TERMINALBLOCK (TB1)

FIGURE 5-3. ACCESSORY BOX COMPONENTS

5-28

TB1 Customer Inputs

Refer to Page 9-9 for typical connections to TB1.

1, 2, 3, 4

TABLE 5-3. A39/A40 TB1 CUSTOMER INPUTS

A39/A40 TB1TERMINAL # FUNCTION DESCRIPTION

Bus PT Input (OnBus PT Module)

Phase to Neutral input voltages from system bus (load side of parallelingbreaker.

5 Remote Start Close to ground to start generator set. (RUN/OFF AUTO switch must bein AUTO position.)

41, 42 Common AlarmWarning

Form C output contact for remote indication of warning condition ongenerator set.

50 Master FirstStart/SynchronizerEnable

For isolated bus or multiple generator set utility (mains) applications, aB+ signal from a remote Master First Start Sensor is applied on thisterminal. For single generator set utility (mains) parallel applications,apply 24VDC to this terminal to enable synchronizer function in control.

16 -- 19 Customer Fault Grounding these terminals initiates an alarm or shutdown condition inthe control.

20 Fault Reset Applying a momentary ground signal to this terminal clears warning orshutdown faults in the control. (Except Emergency Stop.)

21 Engine Idle Grounding this input activates the Low Fuel warning.

35 Rupture BasinAlarm

Applying a ground signal to this point will cause the generator set toannunciate a Rupture Basin Alarm.

46 Utility ParallelSignal

Apply a 24VDC signal to terminal 46 to indicate to the control that it isoperating in parallel with a utility (mains) service.

47 Utility ParallelSignal

Apply a ground signal to terminal 47 to indicate to the control that it isoperating in parallel with a utility (mains) service.

A39

A40

CONTINUED

6 RemoteEmergency Stop

Grounding this input causes an immediate shutdown.

22 Low Fuel Applying a ground signal at this terminal will cause engine to run atrecommended idle speed. Voltage will be disabled.

5-29

TABLE 5-3. A39/A40 TB1 CUSTOMER INPUTS (Cont.)

A39/A40 TB1TERMINAL # FUNCTION DESCRIPTION

51 Load Demand Close to ground to initiate load demand mode in PowerCommandcontrol. (Select Multiple in Paralleling Setup Menu to enable loaddemand mode.)

52 Breaker Open /Inhibit

Close to ground to manually open the paralleling breaker or inhibitbreaker closure.

53 Breaker Position Close to ground to indicate breaker closed.

54, 55 kVAR LoadShare

Load Sharing Lines. Connect to load sharing lines in other generatorsets in the system.

56, 57 kW Load Share Load Sharing Lines. Connect to load sharing lines in other generatorsets in the system.

59, 60 External LoadSet

Analog 0 -- 5 VDC input to control kW load level on generator set whenthe generator set is paralleled to utility.

51 Utility SingleVerify

For single generator set utility (mains) applications (SINGLE selectedin the Paralleling Setup Menu), this terminal must be connected[strapped] to ground to enable breaker closure. (Version 1.06, beginning9-26-96 only.)

A40

Remote Start:When the Run/Off/Auto switch is inthe Auto position, grounding this input initiates theengine cranking and start sequence. This circuitmust beopened topermit resettinga shutdowncon-dition with the Reset input.

Low Fuel: Grounding this input actuates the LowFuelwarning. This input canbe connected to a localday tank or to amain fuel tank that is located on site.When the switch grounds this designated input, theinput will wake up the control, if it is not operating,and then initiate the fault.

Customer Fault Inputs 1 through 4: Groundingany one of these inputs activates the correspondingwarning or shutdown sequence. Warning or shut-down status is selected in the setup menu.

External sensing equipment must be connected tothe designated digital input.

The four customer faultmessagescanbeseparate-ly edited in the setup menu to display any desired

message. This allows each customer default faultmessage to be customized to represent the type ofdevice that is attached the the fault input.

The default message that is displayed, whenground is applied to the input, is as follows:

Fault 1 = CUSTOMER FAULT1Fault 2 = GRND FAULTFault 3 = DAY TANKFault 4 = HIGH GEN TEMP

If Fault 2 or 3 input is grounded, the control willwake up if it is not operating, and then initiate thefault.

Fault Reset: When the Run/Off/Auto switch is inthe Auto position and the remote start switch isopen, grounding this input resets any warning andlatched shutdown fault (except Emergency Stop,which must be reset at the front panel.)

5-30

Engine Idle:When the set is operating in the RUNmode, grounding this input causes generator buildup to be inhibited and the engine to be governed at800RPM. When ground is removed from this input,the set returns to normal speed and voltage.Engine idle operation is applicable only in the RUNmode. The PCC operating program does not permitengine idle operation when the set is operating inAUTO mode.

When the engine idle function is enabled, the con-trol automatically sets lower oil pressure warningand shutdown trip points to reflect the lower operat-ing speed. When the engine idle function is re-moved and the set reverts to normal operatingspeed, the control automatically resets oil pressurewarning and shutdown trip points to the normal set-tings.

Remote Emergency Stop: Grounding this inputcauses an immediate shutdown. Emergency stopmust be reset at the front panel.

Master First Start/Synchronizer Enable: This in-put is received from a Master First Start Sensor,which is mounted remotely from the PowerCom-mand control. The input is a pulsed signal which isused by the PowerCommand control to enable safeclosing of the paralleling breaker when the systembus is de-energized. the control will receive a pulsefrom the Master First Start Sensor approximatelyonce per second. If the PowerCommand controldoes not receive a pulse within the programmabletime delay (default is 10 seconds), the FIRSTSTART warning is displayed by the control and abackup system is enabled by the control.

When the system is set up for paralleling a singlegenerator set with a utility (mains) bus, this input is

used to enable the synchronizer in the PowerCom-mand control. (See Paralleling Setup Menu, pathB.) A 24VDC signal applied to the terminal willcause the generator set to synchronize with thevoltage reference signal applied to the bus PTmod-ule (A39).

All PCCs in a systemshould be programmed to adif-ferent first start fail time. Thiswill help prevent simul-taneous closure of breakers in the event of a failureof the master first start module

Load Demand: On receipt of a signal on the LoadDemand terminals (normally open, close toground), the generator set will ramp down to amini-mum load level and the paralleling breaker willopen. The generator set will run for a cool-down pe-riod and shut down. LOAD DEMANDSHUTDOWNwill be displayed on the PowerCommand panel.

When the Load Demand input is removed, the gen-erator set will start, synchronize and close to thesystem bus and accept its proportional share of thetotal load on the bus.

The Load Demand function of the PowerCommandcontrol is only active when the RUN/OFF/AUTOswitch is in the AUTO position and PARALLEL isselected in the Paralleling Setup Menu.

Utility SingleVerify:For single generator set utility(mains) applications, this input must be strapped toground before the generator set breaker will closewhen the utility breaker is opened.

The Load Demand function of the PowerCommandcontrol is only active when the RUN/OFF/AUTOswitch is in the AUTO position and SINGLE is se-lected in the Paralleling Setup Menu.

5-31

Utility (Mains) Parallel Input:Closure of a normal-ly open contact to ground on terminal 47 and apply-ing a 24VDC signal to terminal 46 will cause thePowerCommand control to begin operation in a util-ity (mains) paralleling mode. The ground signal isusually applied by operation of auxiliary contacts inthe utility paralleling breaker. In this operationmode, the control will ignore inputs from the loadsharing lines and operate at the load level which isdetermined by the magnitude of the Load Governsignal and the base load adjustment in the controlsetup.

Load Govern: This input is enabled when the con-trol has receivedaUtility (Mains) Parallel indication.A 0--5 VDC signal applied to these terminals will di-rect the control to operate at a specific load level,rather than being controlled by the load sharinglines (Figure 5-4). Operating load level is deter-mined by the following parameters:

0 -- 0.5 VDC: Ramp from present load tono load

0.5 -- 1.0 VDC: No load1.0 -- 4.5 VDC: 0 -- 100%of base loadsetting4.5 -- 5.0 VDC: 110% of base load setting

Rate of load ramp and base load setting are con-trolled by adjustments in the Paralleling Setupmenu of the control.

When the PCC first senses a utility breaker closurethe control will ramp up to the load govern input lev-el.

Parallel Breaker Open/Close Inhibit: This func-tion is operational only when the RUN/OFF/AUTOswitch is in the AUTO position. Closing a normallyopen contact to ground on this contact will causethe paralleling breaker to open if it is closed, or pre-vent it from closing if it is open. Removing theground signal will cause the PowerCommand con-trol to return to normal operation.

70

60

50

100

90

80

30

20

10

0

40

10 2 3 4 5

LOAD GOVERN SIGNAL (VDC)

LOAD LEVEL % OFBASE LOAD

.5 4.5

110

FIGURE 5-4. LOAD GOVERN SIGNAL VERSUS LOAD LEVEL

5-32

Operating PowerCommand in Droop Mode

ThePowerCommandcontrol is designed tooperateisochronously (with no intended droop) so thatvoltage and frequency are as constant as possiblewhen the generator set is paralleled to otherPowerCommand generator sets. In certainsituations, however, such as paralleling with othergenerators that are operating in droopmode, it maybenecessary tooperate thecontrol in a droopmodefor frequency, voltage, or both.

Note that when the generator set is paralleled to autility (mains) service it is recommended that thecontrol be operated in its utility parallelmode, ratherthan in droop, even if other generator sets in thesystemoperate in droop for that function. Thedroopmode inPowerCommandwill onlyworkwhenall theother generator sets in the system are operating indroop and the system bus voltage and frequencychange with load.

PowerCommand controls that are set up to operatein droop mode must include the paralleling option(H532). The generator set should be set up formultiple unit paralleling, but load sharinginterconnecting wiring is not used. Connect a 5Kresistor across terminal A40-TB1-54 and 55(KVAR) to cause voltage to droop. A 5K resistoracross terminal A40-TB1-56and57 (KW)will causefrequency to droop. Resistors can be used on oneor both of the load sharing terminal connections,depending on the needs of the application.

Complete all start up procedures as described inSection 8 of this manual up to the point that you areready to make load sharing adjustments. To set the

governor and voltage regulation system drooplevel:

1. Set the no load speed and voltage at thedesired level. Bus must be de-energized whenthis

25303394 CUmmins 350 Kva and 640 Kva DG Manual

Documents

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