powercom_3242756

�� Registered Office : Kothrud, Pune 411 038 (India)

SPT 3242756 of 8

Subject : Introduction of PowerCom (Genset Controls) for 320KVA to 625 KVA Nodes.

Ref. No. :

FESN : Effective from June 2007.

Application Group : G-drive

Date : March, 2007

No. : 3242756

File Group : 13

Engine Family : NT 855 / N14 / K19 / V28

Service Parts Topic

Background :

Power Com controller will be introduced on NT 855, N 14,K19 & V28 genset applications on 320 to 625 KVA nodesfrom June ’07. ECPG (Electronic Control Panel + Governing) was used on the above nodes. Power Com controlis an integrated Genset controller which has two board architecture (Engine Control Board & the Alternator controlModule). The engine control board consists of engine protection & governing functions. The AC Module consistsof AC protection & AC metering functions. External Cummins Generator Technologies AVR is used to regulate theexcitation voltage of the Genset.

PowerComDescription

The PowerCom Control is a microprocessor-basedEngine Governor, monitoring, metering, and controlsystem. The control provides an operator interface tothe alternator metering & protective functions. TheVoltage regulation is done by the CGT (Newage AVR).

PowerCom controls are suitable for use on a wide rangeof generator sets from 320 KVA to 625 KVA.

Control power for PowerCom is usually derived fromthe generator set starting batteries. The controlfunctions over a voltage range from 8VDC to 35VDC.

The control offers a wide range of standard controland digital display features so user customizedcontrol is not needed to meet applicationspecifications. The system reliability is improvedby using reliable and inspected components.


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Features

Major Control Features Include:

• Non Metallic Enclosure: Housed in a plastic NEMA 3R / IP53 having a single membrane surface whichis impervious to the effects of dust, oil and exhaust fumes..

• Digital Engine Speed Governing Controls to provide isochronous / Droop frequency regulation.

• Digital parameter display for Engine & AC Output Metering.

• Digital Alarm and Status Message Display

• Generator set Monitoring: Displays status of all critical engine and alternator generator set functions.

• Smart Starting Control System: Integrated fuel ramping to limit black smoke and frequency overshoot, inaddition to optimized cold weather starting.

• Advanced Serviceability: The C-View, a PC-based software service tool for advanced diagnostics &trimming.

• User friendly front panel engine model selection: Uses one standard Base Calibration, which gives theuser to configure the engine specific calibration from the front panel without the use of C-View to down-load.

• Discrete (digital/On-Off Type) Inputs & Outputs: Control provides six configurable discrete outputs & twoconfigurable inputs.

• Alarm Indication: Easy to read LED indicators for remote start, Engine running, common alarm & commonshutdown conditions.

• BMS Compatible: PowerCom is compatible for the SCADA Software such as BMS (Building ManagementSystem) which supports Modbus Protocol with an additional Hardware (Modbus Converter). Please Referto SPT No: 3242729

• Warranty and Service - Backed by a Standard Cummins warranty and Country wide CS&S servicenetwork.

Alphanumeric Display Panel

The PowerCom control is provided with an alphanumeric LCD backlit display of 128 X 64, capable of displayingengine, alternator & fault codes with description. The display is accompanied by a set of eight tactile feelmembrane switches that are used by the operator to navigate through control menus, and to make controladjustments. (There are no rotary potentiometers in the control. All adjustments are made via the display panelor C-View)

All data on the control can be viewed by scrolling through screens with the navigation keys.

The control displays all fault codes & its status (Active /Inactive).


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The display panel includes a power down timer that will turn off the display after 10 minutes of inactivity, this isalso known as sleep mode function of the controller. Toggling the key switch from off to on or a remote start input(with Key position in ON) will wake up the control.

Generator Set Data – This data plate has following information

1. Engine Model

2. Base Calibration Version Information

3. Controller Serial Number

4. Boot loader Version

5. Engine Serial Number

The control stores the serial number of the control and the software version present in the control.

Generator Set Output Voltage - All phases, line to line and line to neutral, accuracy 1%. Data for all phases isdisplayed simultaneously to allow viewing of voltage balance.

Generator Set Output Current - All phases, accuracy 1%. Data for all phases is displayed simultaneously toallow viewing of load balance.

Generator Set Power Output - PowerCom displays generator set kW and Kva output (average and individualphase, and direction of flow), and power factor with leading/lagging indication. Accuracy 5%.

Engine Parameter Display

1. Engine Starting Battery Voltage

2. Engine Lube Oil Pressure

3. Coolant Temperature

4. Lube Oil Temperature.

5. Intake manifold Temperature (Only on NTA14 G3)

Service Adjustments – The operator panel includes provisions for adjustment and set up of all control functionsin the generator set. The operator panel includes an “Two finger Salute” access code that is used to protect thecontrol from unauthorized service level adjustments.

Internal Control Functions

Remote Start Mode - PowerCom accepts a +24 V signal from remote devices to automatically start the generatorset and immediately accelerate to rated speed and voltage.

PowerCom includes a Smart Starting system that is designed to quickly start the engine, minimize black smoke,and minimize voltage and frequency overshoot and oscillations on starting. The control system does this bycareful control of the engine fuel system.

Power down Mode – PowerCom can be configured to include a sleep mode. When enabled, and when the modeselect switch is in the ON position( on the ECB), the control will revert to a low power consumption mode until akey switch on the operator panel is toggled from off to on position.

Fault Simulation Mode - PowerCom in conjunction with C-View software will accept commands to allow atechnician to verify the proper operation of all protective functions of the control, by simulating failure modes orby forcing the control to operate outside of its normal operating ranges.

Engine Starting – The control system automatically controls the engine starter, and provides proper enginefueling and to provide fast and efficient starting.

Cycle Cranking – Pre-Configured Cyclic cranking for number of starting cycles and duration of crank and restperiods. Control includes starter protection algorithms to prevent the operator from specifying a starting se-quence that might be damaging.


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Engine Governing

The PowerCom control includes integrated digital governing capability, to directly drive an engine fuel controlvalve. Features of the governing system include:

Isochronous Governing - Controls engine speed within plus or minus 0.25% for any steady state load from noload to full load with no drifts.

Temperature Dynamics - Modifies the engine fuel system (governing) control parameters as a function of enginetemperature. Allows engine to be more responsive when warm, and more stable when operating at lower tem-perature levels.

Alternator Display & Protection

PowerCom on its own does not includes an integrated voltage regulation system. The alternator voltage regulationis done by an external CGT AVR that is compatible with either shunt or PMG type excitation systems; howeverPowerCom does have the capability to protect the alternator from Over Voltage, Under voltage, Under frequency,Over current faults.

Protective Functions

On a warning condition the control will indicate a fault by lighting the warning LED on the control panel, anddisplaying the fault name and code on the operator display panel. The nature of the fault and time of occurrenceare logged in the control. The service manual and C-View service tool provide service keys and proceduresbased on the service codes provided.

On a shutdown condition, the control will light the shutdown LED on the control panel, display the fault name andcode, and initiate shut down and lock out the generator set. The control maintains a data log of all fault conditionsas they occur, and time stamps them with the controller run time and engine operating hour’s data. Adjustmentsto most set points are made using the C-View service tool.


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PowerCom provides the following system protective functions:

• Configurable Alarm and Status Inputs - PowerCom will accept up to two alarm or status inputs (configurablecontact closed to ground or open) to indicate customer-specified conditions. The control is programmablefor warning, shutdown or status indication, and for labeling the input.

Engine Protection

• Over speed Shutdown - Default setting is 110% of nominal speed for 5 seconds.

• Low Lube Oil Pressure Shutdown - Level is preset to match the capabilities of each engine model. Controlincludes a time delay of 5 seconds to prevent nuisance shutdown signals. Please refer to the O&M Manualfor further details.

• Low Lube Oil Pressure Warning - Level is preset to match the capabilities of each engine Model. Controlincludes a time delay of 5 seconds to prevent nuisance Warning signals. Please refer to the O&M Manual forfurther details.

• High Coolant Temperature Shutdown- Default setting is 96 Degrees C. (Adjustable threshold - 95 – 100),control includes a time delay of 5 seconds to prevent nuisance shutdown signals. Please refer to the O&MManual for further details.

• High Coolant Temperature Warning - Default setting is 93 Degrees C. (Adjustable threshold - 90 – 95),control includes a time delay of 5 seconds to prevent nuisance warning signals. Please refer to the O&MManual for further details.

• Battery Charging Failure Warning - Indicates battery charging system failure by continuously monitoringbattery voltage & lighting up an LED on the front panel.

• Fail to Start (Over crank) Shutdown: Fault indicates that the Generator has failed to start after a pre-setcrank period.

• Fail to Crank Shutdown - Control has signaled starter to crank engine but engine does not rotate.

• Cranking Lockout - The control will not allow the starter to attempt to engage or to crank the engine whenthe engine is rotating.

• Sensor Failure Indication - All analog sensors are provided with sensor failure logic to indicate if the sensoror interconnecting wiring has failed. Separate indication is provided for fail high or low.

Alternator Protections included:

• Over Current Shutdown - Output current on any phase at more than 120% of rating for more than 5seconds.

• Over Voltage Shutdown (59) - Output voltage on any phase exceeds 115% of Nominal Voltage for more than5 seconds.

• Under Voltage Warning (27) - Voltage on any phase has dropped below 85% of nominal voltage for morethan 5 seconds.

• Under Frequency Warning (81u) - Generator set output frequency drops below 85% of nominal frequencyfor more than 10 seconds.

• Over Frequency Shutdown - Generator set output frequency rises above 110% of nominal frequency formore than 5 seconds.

Environment

The control is designed for proper operation without recalibration in ambient temperatures from –40C to +70C,and for storage from –55C to +80C. Control will operate with humidity up to 95%, non-condensing. Controloperation is not restricted by altitude.


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The control system is housed in a NEMA 3R/IP53 enclosure. The operator control panel has a single membranesurface, which is impervious to the effects of dust, moisture, oil, and exhaust fumes. The panel uses sealedmembrane or oil-tight switches to provide long reliable service life in harsh environments.

The control system is specifically designed and tested for resistance to RFI/EMI, and to resist the effects ofvibration to provide a long reliable life when mounted on a generator set. The control includes transient voltagesurge suppression to provide compliance to referenced standards.

PowerCom control systems and generator sets are designed and manufactured in ISO9001 certified facilities.

Software

C-View

C-View is a PC-based software service tool that is designed to directly communicate to PowerCom generatorsets to facilitate service and monitoring of these products.

Diesitel

Diesitel is a software tool that is used primarily by operators to remotely monitor and ECPG / ECP & PowerCom.

BMS Compatible: PowerCom can be made Modbus compatible by adding a Modbus Converter. For Details referto SPT No.3242729.

Control Interface

Input signals to the PowerCom control include:

• Remote Start signal. May be connected via either discrete signal

• Configurable Customer Inputs. Control includes (2) input signals from customer discrete devices that areconfigurable for warning, shutdown, or status indication, as well as message displayed.

Output signals: Control include six configurable relay drivers. Defaults for these are:

• Generator Set Common Warning signal. Operates when unit set is running under alarm conditions.

• Generator Set Common Shutdown signal.

• Engine running (generator set running) signal. Operates when the generators set has reached 90% ofrated speed and voltage and latches until generator set is switched to off or idle mode.

• Engine Not Ready to Start: Operates when the key switch is in the off position and / or if the Idle/Ratedswitch is in the idle position.

Special Instructions

PowerCom will be supplied with a mounting bracket & will be mounted by the GOEM’s appropriately in theacoustic enclosures.


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Part Availability

All the parts are available for service on twelve digit part number which is printed on the part itself

Sl.No. Part Description Part No.

1 Plastic enclosure Rear 0319-4487

2 Plastic Enclosure Front 0319-4488

3 Isolator Vibration 0402-0764

4 Pin Hinge for Box (Clip) 0406-0845

5 Three position key switch 504975

6 Mounting hardware for grounding 0819-1144

7 Coolant temperature sensor 3865346

8 Oil pressure sensor 3408497

9 Magnetic pick up 3875360

10 Coolant level sensor 3331472

11 Intake manifold temperature sensor (optional) 3865345

12 Adapter for Coolant Temp. Sensor 4053490

13 Adapter for IMT Sensor 4053490

14 Rexroth Actuator 3330601

15 Fuel Actuator Housing 4071944

16 Fuel Tube 4084238

17 LOT Sensor 3465346

18 PowerCom (Panel Control) 0319-6104

19 Mounting stand alone panel 0319-6105

20 PowerCom engine control board 0300-6085

21 AC Module board 0300-6086

22 Membrane PCB with layout 0300-6087

23 LED Board 0300-6088

24 Harness between Key switch to engine control board 0338-4728

25 Cable between AC Module to engine control board 0338-4729

26 k6 harness 0338-4735

27 N14 Harness 0338-4736

28 V28 Harness 0338-4737

29 855 Harness 0338-4738

30 PT CT Harness 0338-4739

31 Current transformers 380 Kva Note :CT's are in CGT's scope of supply.

0315-1688-0432 Current transformers 450 Kva

33 Current transformers 500 Kva

34 Current transformers 625 Kva

35 Diagram Wiring for OEM (14 Pin Connector) 0620-0286

36 Diagram Wiring Optional (6 Pin Connector) 0620-0287

37 Diagram Wiring (19 Pin Connector) 0620-0288

38 Clamp for engine harness 0332-4171

39 Heat Sink 0305-1026

40 Sticker 0098-8446


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Field Conversion

Retrofitting on the field is possible in consultation with CS&S Electronics Cell.

Note: For Further Detailed information on PowerCom please refer to the PowerCom O& M Manual Part No: 09140101 00.

Service Tool / Diesitel / Modbus Converter Part Nos.

C - View Kit 4104294

Adapter Electronic Communication 4071717

Power Com to Adapter cable 4071852 & 4071853

Adapter to PC cable 4071851

Calibration CD 4105287

ECPG Service Tool CD 4084236

Diesitel Kit 4072075

Modbus Converter Kit 4968489

Note: This is product improvement and not subject to campaign

powercom_3242756

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