6283 - Fundamentals of PowerCommand Controls - PG - EN - V1.1

Fundamentals of PowerCommand Controls
Classroom Training
Participant’s Guide Version 1.1
6283 – Fundamentals of PowerCommand Controls

Copyright © 2014 Cummins Inc.
This product is for TRAINING PURPOSES only. Do not use this material in place of the current
revision of controlled documents such as technical manuals, operator’s manuals or other work
instructions. The information contained herein is confidential and proprietary to Cummins Inc.
and its affiliates. No unauthorized disclosures may be made without the written permission of
Cummins Inc. or one of its affiliated entities.
Page 2 of 163 | Cummins Inc.

6283 – Fundamentals of PowerCommand Controls 10/10/2014
Table of Contents
Course Overview ........................................................................................................................................... 4
Lesson 1: Introduction .................................................................................................................................. 5
Lesson 2: PCC Controls Safety ..................................................................................................................... 15
Lesson 3: Controls Subsystems ................................................................................................................... 29
Lesson 4: PCC 1302 Hardware .................................................................................................................... 55
Lesson 5: Operator Menus .......................................................................................................................... 67
Lesson 6: Service Menus ............................................................................................................................. 77
Lesson 7: Sequence of Operations ............................................................................................................ 111
Lesson 8: InPower Service Tool................................................................................................................. 131
Lesson 9: Troubleshooting PowerCommand Controls ............................................................................. 157
Cummins Inc. | Page 3 of 163

Course Overview
Main Goal
The primary purpose of this course is to teach the basic knowledge and skills associated with operating,
configuring, commissioning, and troubleshooting Cummins Power Generation PowerCommand Controls.
Taking Notes
It is highly recommended to take notes and make sketches during the class. For most people, the act of
writing and drawing helps you remember what you’ve heard.
Making this an Active and Interactive Course

This should be an active and interactive course: the more engaged you are in this course, the more you will
take from it. Note there will be frequent stopping points for discussion, that questions are encouraged and
expected throughout the course, and that participation is key to the success of the course.
Asking Questions
One of the most important parts of this course is for you to ask any questions and for the instructor to give
you a good answer. Feel free to ask a question any time. If you have any unanswered questions at the end
of a lesson, ask them then or write them on the Question Parking Lot.

Lesson 1: Introduction
Objectives Lesson Length : 1 hour
 Introduce commercial generator set
controllers
 Describe what makes a PowerCommand
Control
 Understand how to download service
literature
A generator set is comprised of three main systems:
Genset Controls • Prime Mover
Genset Controller
• Alternator
• Genset Controller
The alternator consists of a rotor and a stator. When

the rotor is magnetized by an excitation voltage and
rotated within the stator, electricity is produced.
The prime mover is the mechanical means of
rotating the alternator.
Prime Mover
Alternator
3 7/7/2014 Cummins Confidential
The genset controller is responsible for controlling the alternator and prime mover to produce consistent,
reliable, and usable electricity for the customer. The genset controller collects numerous inputs from the
prime mover, the alternator, and the customer itself. This data tells the genset controller many things
such as the speed of the engine, the voltage of the alternator output, the coolant temperature, etc.
The genset controller uses that input data, and compares it to preconfigured setpoints and programming
and responds with outputs. Those outputs could be to increase the excitation voltage, increase the speed
of the engine, annunciate a warning message, or shutdown the genset altogether.
The genset controller is responsible for these features and many more.
Notes:

Every generator set controller has to control all of
Genset Control Features the different subsystems of the generator set.
 Interacts with a Customer’s on-site power system
A generator set is typically part of a larger power
 Starts/Stops the prime mover
generation system. It could be interacting with
 Regulates engine speed
other generator sets, automatic transfer switches,
 Regulates alternator output voltage
or other power distribution equipment. A generator
 Protects the genset
set controller must take input from other systems as
well as provide outputs for other systems to use.
A generator set must start and stop the prime

mover when necessary. This could be by manual
4 7/7/2014 Cummins Confidential operator input, or by automatic input from one of
the customer’s other systems.
Once the engine is running, the control must regulate the engine speed to a nominal RPM. Typically, the
alternator is rotated directly by the crankshaft of the engine, so RPM is tied directly to frequency output.
The generator set controller must also control the alternator output voltage to provide consistent, usable
power to the customer.
Finally, even as all of these things are happening at once, the control is responsible for protecting the
generator set. The control is monitoring many sensors and inputs from the engine, alternator, and other
systems to make sure the generator set is operating in appropriate environments. If the control begins to
detect a scenario which may be dangerous for the generator set, it may issue a warning. If the condition
persists, it may shut the generator set down completely.
What makes a generator set controller a
History of PowerCommand Controls “PowerCommand Control”? That is the inclusion of
microprocessors.
Before PowerCommand Controls, all the generator

set controls that Cummins Power Generation
Produced were analog based. That is, they took real,
scalable voltage based inputs and used hard
electrical components to return real, scalable,
voltage based outputs. All of the gauges, timers,
PCC 3100 – the first PowerCommand Control
protections, and displays were based on analog
electronics.
With the advent of the microprocessor, Cummins Power Generation was able to consolidate all of the
decision making, timing, protections, and control into a computer chip. This eliminated the need for
internal hard-wired circuitry for genset control and monitoring.
Thus, the total footprint of a PowerCommand Control was drastically reduced. A paralleling control, which
was needed for every generator set, was reduced from the size of a refrigerator to the size of a
microwave.
Notes:

Generator Set Control The PowerCommand Control is simply that, a

control. It is responsible for everything that the
generator set does, and how it does it.
It is responsible for starting and stopping the prime

mover, protecting the alternator, protecting the
generator set, and interacting with different
operators and customer’s equipment.
A PowerCommand Control is essentially a number of subsystems. These subsystems interact together to

control the generator set to produce proper electrical power for a customer. Some of these subsystems
include:
• Human Machine Interface – interacting with a local operator
• Remote Interface – interacting with a customer’s remote system such as a Building Management
System or Automatic Transfer Switch
• Engine Control – either controlling the engine by interacting with the engine’s Engine Control
Module (ECM), or controlling the governor actuator itself
• Alternator Control – controlling the excitation of the alternator by monitoring alternator voltage
and responding with the correct corresponding excitation voltage
• Alternator Protection – Determining conditions which may be harmful to the generator set’s
alternator and responding correctly
• Engine Protection – Determining conditions which may be harmful to the generator set’s engine
and responding correctly
We will be touching on all of these subsystems in this course.
PowerCommand Controls typically display a series
Menu Driven of Menus that annunciate all of the parameters
associated with the control. With this menu system,
you can search running parameters such as voltage,
current, engine speed, battery voltage, among
others.
The operator can navigate these menus by

interacting with the Human Machine Interface
(HMI) of the control. The HMI typically consists of a
graphical display, pushbuttons and LEDs. The
pushbuttons are used to navigate the menus and
7 7/7/2014 Cummins Confidential control the generator set. The LEDs display
information about the current operation state of the
generator set.
Notes:

PowerCommand Controls are configurable. Each
Configurable type of PowerCommand Control can be configured
specific to different applications.
Some PowerCommand Controls have more features

than others (such as paralleling, breaker control,
and networking), but all can be configured to
different frequencies, voltages, engine
configurations, monitoring parameters, etc.
InPower v. 10.0
There are two ways to configure a PowerCommand
Control.
One way is by using the Service Menus offered by the HMI. The HMI displays different menus, and the
operator can adjust different parameters based on which menu is being shown. The operator can scroll
through different menus until he/she finds the correct parameter they are looking for. Then, by using the
HMI pushbuttons he/she can configure the parameter to the desired value.
Another way to configure the PowerCommand Control is by using Cummins Power Generation’s
electronic service tool “InPower”. InPower is an application on a personal computer that allows the
technician to access all of the monitoring and configurable parameters associated with the
PowerCommand Controls. The operator can change the parameter using the application and save the
new parameter to the control.
The PowerCommand Control is also responsible for
Protections protecting the engine and the alternator of the
generator set. It does this by monitoring sensors
inputted into the PowerCommand Control. It
compares the data from those sensors against
PowerCommand
Auto NOT IN AUTO
SHUTDOWN
configured protection setpoints.
! WARNING
Fault
At: 123.2 Hrs REMOTE START
If one or more of those setpoints go beyond a

Fault Number: 1434 Auto AUTO
Local Emergency
Stop MANUAL RUN
threshold for a certain period of time, the generator

control may respond by issuing a warning or a
shutdown command.
Notes:

PowerCommand Controls also can operate

Customer Interaction automatically, without the intervention of a local
operator. The PowerCommand control can be left in
“Auto Mode” and have remote start and stop
connections wired to it. These can be wired to a
customer’s equipment, which can be used to start
and stop the generator set remotely.
Typical customer equipment which uses the

generator sets in Automatic Mode are Building
Management Systems (BMS) and Automatic
Transfer Switches (ATS).
A BMS is usually a central computer that controls all of the power distribution in a customer’s facility. This
system can control, monitor, start, and stop every piece of equipment including backup power
generators.
An ATS is a device that senses when utility power has been lost locally at a facility, start an emergency
generator set, and transfer electrical power automatically over to the emergency power.
Each PowerCommand Control has slightly different
Basic Genset Operation ways in which it controls a generator set through a
sequence of operations, but in general, they all
 Start Type Input (Mode Selection)
follow a similar process.
 Start Input
 Start Relay/Run Relay
Start Type Input
 Start Disconnect
A generator set control in order to know how to
 Speed Governing
operate the generator set, first must know which
 Automatic Voltage Regulation start type input it is looking for. There are several
 Protections modes of a generator set that we will expand upon
 Shutdown Sequence later on: Off, Manual, and Auto. Depending on
which mode the generator set control is in, the
11 7/7/2014 Cummins Confidential control will look for different start inputs and ignore
others.
Start Input
Once the start type is determined, the generator set is waiting for a start input. Once that start input is
active, the generator set control begins its controlled start sequence.
Start Relay Output

The generator set engages a start relay, sending battery power to the starter solenoid. The starter motor
teeth engage with the flywheel of the engine and the engine begins to crank.
Run Relay Output

Once the engine is cranking, the generator set control engages the run relay, opening up a Fuel Shutoff
Valve (FSO). This sends fuel to the engine, causing it to begin to run.

Start Disconnect
Once the engine reaches a certain speed, the starter isn’t needed anymore. Once this speed is reached,
the PCC disengages the start relay, which retracts the starter from the flywheel. The engine is now
running on its own.
Speed Governing
Either the Engine Control Module (ECM) or the PCC will now have to govern the speed of the engine to
the appropriate RPM. RPM is tied directly to frequency of the alternator output, so this is crucial. The
ECM or PCC does this by controlling the amount of fuel allowed into the fuel system by using a governor.
Voltage Regulation
The PCC (or a third party Automatic Voltage Regulator) must also control the output voltage of the
alternator to the appropriate voltage needed by the customer. It does this by controlling the excitation
voltage of the exciter stator. The more excitation voltage which is applied to the exciter stator, the more
voltage is produced by the alternator.
Protections
Part of the PCC’s job is to protect the engine and the alternator from damage. It does this by monitoring
many sensors for pressure, temperature, voltage, and current. If one of those sensors detects a value that
is above or below a certain threshold, the generator set may be shut down to protect itself from damage.
Shutdown Sequence
Once the generator set is no longer needed for power, it can be shut down. Similarly to the start input,
shutdown input will be dependent on the mode of the generator set control. In some instances the
generator set will be shut down immediately (E-stop, for example). In other instances, such as shutdown
in Auto mode, the PCC will control a shutdown to cool the engine down at rated or idle speed.
The PCC 3100 was the original PowerCommand
PCC 3100 Control. This was the first fully integrated paralleling
control that Cummins Power Generation offered.
Before the 3100, generator sets required a

Paralleling control as well as a generator set control.
By utilizing the microprocessor, the paralleling
control and the generator set were integrated into
one PowerCommand Control.
Features of the PCC 3100 control:

• Paralleling capable
12 7/7/2014 Cummins Confidential • Requires a PMG (no shunt to operate)
• Hydra-mechanical only, has governor
control for governor actuator
• 4 analog gauges
• Menu driven display
Notes:

The PCC 3201 is based on the original PCC 3100

PCC 3200/3201 released in 1995. The PCC 3201 is more powerful
than the 3100, allowing the PCC 3201 to provide
more information to the operator, the technician,
and the genset.
The PCC 3200 was the first iteration of this family of

control, using a card cage based hardware system.
Each board in the card cage was responsible for a
PCC 3200 HMI
different function/subsystem of the control. The
PCC 3201 Card Cage
PCC 3200 eventually went through an evolution to
the 3201, which is what is in current production.
Additional features of the PCC 3201

• Smart Starting Plus (to reduce smoking at start up)
• Full Authority Electronic (FAE) capabilities
• Enhanced Fault Logging
• Multiple Paralleling Configurations
• Networking capable
The PCC 2100 is a stand-alone generator set
PCC 2100 controller. It is not able to perform paralleling
functions.
The PCC 2100 can communicate with other

generator sets and networking equipment using FT-
10 networks.
PCC 2100 HMI

PCC 2100 Control (inside of box)
The PCC 2100 is able to control the engine of the
generator set by communicating with an engine’s
Electronic Control Module over a J1939 data link.
Notes:

The 1.X control is the control that we will focus
PC1.X mostly on in this course, Fundamentals of
PowerCommand Controls. It essentially consists of
one main control board, the PCC 1302, and a Human
Machine Interface (HMI).
HMI 211
OR
The selection of the HMI will determine the name of
the control as a whole.
PC1.1 = PCC 1302 control board plus the HMI 211
PCC 1302 Control Board
PC1.1R = PCC 1302 control board plus the HMI 211R
HMI 220
The PC1.X was the first in the latest generation of generator set controls, and the first control to utilize
the “Common Connector Harness”. The common connector harness allows for relatively simple upgrading
or downgrading of PCX.X controls. For example, the generator set voltage connection on the PCC 1302
control board has the same name and connection points on the PCC 2300 control board and the PCC 3300
control board.
The PC1.X can communicate with other generator sets and networking equipment using an open source
language called Modbus.
The PC2.X control can be used on either Hydra-
PC2.X mechanical or CAN connected ECM based
application.
The PC2.X also uses the common connector harness

introduced with the PC1.X control.
HMI 220
OR
The selection of the HMI also determines the name
of the control as a whole.
HMI 320
Additional features of the PC2.X control

• Non-paralleling
• Can only be used in CAN/ECM based applications
• Can easily be upgraded to the PC3.X control
Notes:

The PC3.3 control is the current “flagship” control of

PC3.3 CPG.
It uses the common connector harness used by the

1.X and the 2.X control, but only uses one display,
the HMI 320.
The PC3.3 has many of the same functions of the 1.X

HMI 320 and the 2.X, but is paralleling capable.
The PC3.3 has many paralleling functions

• First start/Dead Bus Close
• Synchronizing and Voltage Matching
• Permissive Sync Check
• Isochronous Load Share (Isolated Bus Paralleling)
• Speed and Voltage Droop
• Load Governing (Utility Paralleling)
• Breaker Control Interface
• Extended Paralleling Control (Base Load/Peak Shave)
• Many Application types (paralleling topology)
• Masterless Load Demand
The best way to find the service literature for your
Using Service Literature generator set controller is to “Search by Plant,
Model, or Spec”. Select CPG – Fridley from the Plant
dropdown menu, and then select your genset or
controller type model.
Clicking Search will bring up a list of service

literature for that model of genset which includes
Operator Manuals, Service Manuals, and Parts &
Service Bulletins. This type of literature search is
important to servicing gensets because you are able
to see important Parts & Service Bulletins that may
18 7/7/2014 Cummins Confidential aid your efforts in servicing and troubleshooting a
customer’s genset.
Notes:

Activity 1-1
Skills Exercise
Download Service Literature

Required Materials:
• Personal Computer (laptop) with internet connection
Instructions:
1. Go to www.quickserve.cummins.com
2. Login using your wwid and password (or create an account if needed)
3. Using the Generator/Alternator Content search function download the Service Manual for the
PowerCommand 1.X control.

Lesson 2: PCC Controls Safety

 Describe the Responsibility of the employee
 Identify the Authorization levels
 Determine Approach Boundaries
 Shock Hazard
 Arc Flash Hazard
 Determine Appropriate PPE for work on
energized Power Command Controls
 Identify specific Power Command Controls
electrical hazards
This module is not intended to replace a qualified
Introduction NFPA 70E safety course. This is intended to
reinforce and remind the service technician about
 This module is not intended to be a qualifying NFPA
70E safety course
the safe and required electrical practices laid out by:
 Every Cummins employee is responsible for his/her
• NFPA 70E
own safety
– Follow safe practices and procedures This document is available to all Cummins
– Work only when properly trained employees and can be accessed by going to
– De-energize, lock and tag-out
https://login.ihserc.com/login/erc? . Log-in using
your WWID and Password.
– Wear correct PPE
– Maintain training
Work on Cummins PowerCommand Controls will also fall under corporate policy:
• Cummins Procedure for Energized Electrical work on systems with rated voltage of less than 1000
VAC or 1500 VDC (CORP 09-04-06-02)
• Permit to Work and Authorization levels (CWI 09-04-06-01)
These documents can be accessed via http://mycummins.cummins.com/ and search for “Electrical
Safety”.
Every Cummins employee is responsible for his or her own safety:

• Following safe practices and procedures
• Working on or around equipment and systems only with the proper training and authorization
• Unless justified, work on equipment that has been de-energized, locked and tagged out
• Wear the correct Personal Protective Equipment
Notes:

Authorization Levels
There are three Authorization Levels for electrical

Authorized
work laid out by the Cummins policy and NFPA 70E:
• Unqualified
• Qualified
• Authorized
Qualified
Unqualified
An “Unqualified Person” is one that may work with low voltage electrical equipment and has received
training on how to recognize that electrical exposure may exists and how to avoid risk of injury.
Unqualified persons may enter electrical areas or use electrical equipment as a part of their function, but
may not perform work on electrical equipment or perform switching operations on distribution
equipment.
A “Qualified Person” is one who has been trained to recognize and avoid the hazards associated with
work on or near exposed energized electrical parts. He/she has been trained on the equipment, work
methods, precautionary techniques, PPE, and special tools to perform safe work. This training can include
a qualified NFPA 70E safety course, and continued, supervised on-the-job training.
An “Authorized Person” is one who has been Qualified as above, but has been authorized in writing by
Cummins to work on electrical equipment.
Just because a technician is Authorized on certain electrical systems does not mean that he/she is
Authorized on all systems. Training and Authorization must match the level of work to be performed (i.e.
Low Voltage and High Voltage).
Notes:

NFPA states that energized electrical conductors

Electrical Safe Work Condition and circuit parts shall be put into an electrically safe
work condition if the worker is going to enter the
limited approach boundary or arc flash hazard
exists, unless:
• The exposed voltage is less than 50V
• De-energizing introduces additional hazards
(i.e. life support equipment, prison alarms,
etc.)
An electrically safe work condition is to be

disconnected from energized parts, locked
out/tagged out, and tested to make sure the piece
of equipment is de-energized.
Typical for PC Controls, this would consist of:
• Engaging the local E-stop on the genset(s). Lock and tag-out
• Removing the remote start connection to the emergency genset(s). Lock and tag-out
• Removing the battery charging circuit, and negative connection from the genset battery
For more information and definitions about establishing an electrical safe work condition, go to NFPA 70E
section 120
If de-energizing the equipment is not feasible, an
Energized Work Permit Energized Electrical Work permit must be filled out
and authorized by the company. There will need to
be justification for not de-energizing the equipment.
An Authorized person can perform work within the

Limited Approach boundary of energized equipment
that has exposed voltage above 50V without
needing to file an Energized Electrical Work permit
only in the following situations:
• Testing
• Troubleshooting
• Voltage Measurement
For more information and definitions regarding Energized Work Permits go to NFPA 70E section 130.2(B).
The Energized Work Permit used by CPG can be found on http://mycummins.cummins.com/ on the
Electrical Safety page.
Notes:

Electrical Shock
The risk of electrical shock is one of the hazards with

working on energized equipment. Electric Shock is
the effect of the electric current passing through the
human body.
Shock Hazard Analysis is to be performed at the

time of installation or major modification of the
transfer switch, or other electrical system or
equipment.
The Shock Hazard analysis will determine:

• Voltage Level which personnel will be exposed to
• Limited Approach Boundary
• Restricted Approach Boundary
• Prohibited Approach Boundary
• PPE necessary to minimize the possibility of electric shock.
Shock Approach Boundaries exist to define the
Shock Approach Boundaries distances which a person can be from an exposed,
energized electrical conductor or circuit part, and
what work they can do within those boundaries.
Limited Approach
Limited Approach Boundary: An approach limit at a
distance from an exposed energized electrical
Exposed, Restricted Approach conductor or circuit part within which a shock
energized
conductor
hazard exists. Entered only by Authorized Persons or
Prohibited Approach Qualified/Unqualified persons escorted by an
Authorized Person
Restricted Approach Boundary: An approach limit at a distance from which there is an increased risk of
shock, due to electrical arc over combined with inadvertent movement for personnel working in close
proximity to the energized electrical conductor or circuit part. Entered only by Authorized Persons
required to use shock protection techniques and equipment
Prohibited Approach Boundary: An approach limit at a distance from exposed electrical conductor or
circuit part within which work is considered the same as making contact with the electrical conductor or
circuit part. Entered only by Authorized Persons requiring same shock protection as if in direct contact
with live parts.
Notes:

The Approach Boundary distances are defined in

Approach Boundary Distances section 130.4 of NFPA 70E
For electrical equipment (such as a PowerCommand

Voltage L-L Limited Restricted Prohibited
Approach Approach Approach
Control) with a L-L voltage of less than 300 VAC, the

Boundary Boundary Boundary
50 – 300 V 3’ – 6” Avoid Contact Avoid Contact Limited Approach boundary is 3’-6”. The Restricted
301 – 750 V 3’ – 6” 1’ – 0” 0’ – 1” and Prohibited approach boundaries are simply
listed as “Avoid Contact”.
For electrical equipment with a L-L voltage between

301 VAC and 750 VAC, the Limited Approach
boundary is 3’-6”, Restricted Approach Boundary is
1’-0”, and the Prohibited Approach Boundary is 0’-
1”.
In order for an Authorized person to break the Restricted Approach Boundary to perform electrical work,
he/she must be wearing appropriate PPE.
For more information and definitions regarding Approach Boundaries go to NFPA 70E section 130.4
Arc flash is where a flashover of electric current
Arc Flash/Blast leaves its intended path and travels through the air
from one conductor to another, or to ground.
Arc flash is caused by electrical current

uncontrollably conducting from phase to ground,
phase to neutral, or phase to ground accompanied
by the ionization of the surrounding air.
Arc Blast is the pressure wave caused by the arc

flash. This can be a very violent event, and is
potentially deadly if a person is within the path of
the arc. The pressure of the blast can reach up to
200 lb/in2, and the temperatures can reach up to
35,000 deg F.
Arc flash analysis is to be performed at the time of installation or major modification of the generator set
or other equipment in the system. The Arc Flash Hazard analysis will determine:
• Arc Flash Boundary
• Incidental energy at the working distance
• PPE that Authorized persons shall use within the Arc Flash Boundary
The Arc flash analysis is to be performed by a qualified power engineer.

Notes:

The Arc Flash Analysis will determine the Arc Flash
Arc Flash Boundary Boundary. This is different from the Shock Approach
Boundaries earlier discussed.
The Arc Flash Boundary is the approach limit where

a potential Arc Flash hazard exists. Anyone entering
this Arc Flash Boundary must wear the appropriate
Arc Flash
Exposed,
Boundary PPE as defined by NFPA 70E.
energized
conductor
For more information about the Arc Flash Boundary
go to NFPA 70E section 130.5
After the Arc Flash Hazard Analysis and Shock

Labeling of Equipment Hazard Analysis are complete, all electrical systems
and equipment are required to be labeled with the
following:
Nominal
Voltage • Unique Name
• Nominal Voltage
Hazard/Risk
Category • Arc Flash Boundary
Approach
Boundaries • Limited Approach Boundary
Flash
Boundary • Restricted Approach Boundary
• Prohibited Approach Boundary
• Hazard/Risk Category
The Authorized person will use the Hazard/Risk Category on this label to select the proper Personal
Protective Equipment.
Notes:

Any Cummins Authorized Personnel are required to

Standard Personal Protective Equipment wear the following when conducting electrical work
– no matter what the hazard category:
• Flame Retardant shirt and pants w/
minimum 8 cal/cm2 or comparable cover-
Safety Glasses alls for infrequent work
• Safety glasses w/ side shields
Hearing Protection
• Leather electrically rated footwear
• Hearing protection
8 cal/cm2 clothing
Leather Safety Wearing conductive jewelry while performing
Shoes
electrical work is strictly prohibited.
In addition to this, based on the hazard category as defined by the Arc Flash and Shock Hazard analysis,
there may be additional PPE required.
If Rubber Insulating Gloves are required when
Rubber Insulating Gloves entering the shock Restricted Approach Boundary,
they must be used properly:
• Gloves shall be rated for the proper system
voltage
• Leather Protectors shall be worn over the
gloves
• Gloves must be visually inspected and
checked for leaks prior to each use (roll-up
test)
Leather Protector
Rubber Insulating Glove
Gloves rated by voltage:
• Class 00 = 500 volts max.
• Class 0 = 1000 volts max.
• Class 1 = 10 kV max.
Notes:

The Hazard/Risk Categories are meant to simplify
Arc Flash PPE Hazard/Risk Categories the selection of PPE when working inside of an Arc
Flash Boundary.
H/R Cat 0 H/R Cat 1 H/R Cat 2
Arc Clothing Natural/Non 4 cal/cm2 8 cal/cm2

Melting When dealing with low voltage generator sets
Safety Glasses Yes Yes Yes (<1000 VAC) it is likely you will see three different
Hearing Protection Yes Yes Yes Hazard/Risk Categories defined after the Arc Flash
Leather Gloves Yes Yes Yes
Hazard Analysis.
Leather Shoes Yes Yes Yes
AR Face Shield No Yes Yes
Hard Hat No Yes Yes

The guidelines listed in NFPA are only minimums;
AR Balaclava No No Yes PPE is only meant to minimize Arc Blast injuries, so
more PPE is always better.
Category 0: The Cummins standard personal protective equipment is sufficient for work on H/R Cat 0
equipment/procedures.
Category 1: Standard Cummins required PPE plus a 4 cal/cm2 minimum rated face shield and hard hat.
Category 2: Standard Cummins required PPE plus an 8 cal/cm2 minimum rated face shield, hard hat, and
balaclava.
For more information and definitions of Arc Flash Hazard/Risk Categories and PPE recommendations go to
NFPA 70E Section 130.7 (2012 edition).
In NFPA 70E, there is a look-up table that defines
Table 130.7(C) Hazard/Risk Category is present based on the type
of equipment, nominal voltage, and the description
of work being performed.
This table will be necessary if the Arc Flash/Shock

Analysis label is missing. This table also defines
whether or not Rubber Insulating Gloves and
Insulated tools are required.
Notes:

If it is necessary for an Authorized person to cross

Boundaries the Arc Flash or Shock Limited Approach
Boundaries, protective barriers shall be set up
around the energized equipment. This is to prevent
Unqualified persons from accidentally entering the
boundary and potentially risking injury.
Barriers should be set up at least as far away as the

NFPA 70E recommended Limited Approach
Boundary or Arc Flash Boundary, whichever is
farther. Barriers can be set up farther away if
necessary to perform work.
Notes:

Typical PCC Energized Components
Bus Voltage Genset Voltage
PCC 3300 PCC 1302
AVR Power Input

CT Inputs
If the control cabinet is accessed or opened, even if the genset is not running, there are a certain electrical
hazards to be aware of.
Bus Voltage
This only applies to paralleling controls. Even when the genset is not running there could be voltage
present at the Bus Voltage sensing input to a paralleling control.
Genset Voltage
This is the sensing input for PCC Controls. When the genset is running and producing voltage (even when
the genset breaker is open) there will be rated voltage at this terminal block.
CT Inputs
This is the sensing input for the Current Transformers which the PCC control measures how much current
the load is drawing from the genset. There could be up to 5 amps of current present at this plug.
AVR Power Input

PCC controls are capable of performing their own Automatic Voltage Regulation (AVR). The input for the
AVR can be up to 230 VAC from the Permanent Magnet Generator (PMG) or special windings directly
from the alternator itself.
Any and all of these points should be used to define the Shock Hazard Approach Boundaries.
Notes:

Newer versions of PowerCommand Controls come

Lock Out Tag Out equipped with a Lock-Out-Tag-Out (LOTO) sleeve
around the Local Emergency Stop. This is meant to
be used any time service is to be performed on the
generator set.
To Lock-Out-Tag-Out the emergency stop, engage

the emergency stop switch, and then place the
LOTO lock into the holes provided in the sleeve.
This will prevent anyone from disengaging the

emergency stop when service is being performed.
If the LOTO emergency stop sleeve is not place, it is good practice to remove the battery cable from the
generator set starting batteries and place a LOTO terminal cover and lock around the battery cable
terminal. This will prevent anyone from reconnecting the generator set battery while service is being
performed.
All work on energized electrical systems and
Insulated Tools equipment performed inside the Limited Approach
Boundary shall be performed using only properly
certified insulated tools rated at a minimum of 1000
VAC. These tools should be inspected before each
use for the integrity of the electrical insulation.
Notes:

Selecting the correct multimeter to use when
Proper Meter Selection testing or troubleshooting a PowerCommand
Control on a generator set is a very important
decision. There are several different categories of
multimeters based on their intended uses.
Using an incorrect category multimeter could result

in the destruction of the multimeter or injury to the
user. The category will be printed on the front of the
multimeter. The four different categories of
multimeters are:
Category I: Electronic level. This device is intended to be used on protected electronic equipment.
Category II: Single phase-receptacle connected loads. This multimeter is intended to be used on AC
appliances, household outlets, etc.
Category III: Three phase distribution. This multimeter is intended to be used in switch gear, transfer
switches, feeder breakers, etc. This is the category of multimeter that will be required for work on most
CPG energized transfer switches.
Category IV: Three phase at utility connection. This multimeter is intended to be used in switching
stations, outside service entrances, utility main breakers, etc.
Notes:

Activity 2-1
Skills Exercise
Voltage Measurement
Required Materials
• Running genset or working generator set simulator
• Multimeter
• Proper PPE
• NFPA 70E
Select the Proper PPE for voltage measurement

1. Using NFPA 70E, select the proper HRC of PPE required for voltage measurement
PPE Required:_________________________________________________
2. Inspect and put on the required PPE
Measure Voltage
3. Select a multimeter capable of performing voltage measurements on a three phase generator set
Category of Multimeter:________________
4. Measure voltage at the PowerCommand Control using the multimeter while wearing the proper
PPE
a. L1-L2 _________
b. L2-L3 _________
c. L1-L3 _________
d. L1-N _________
e. L2-N _________
f. L3-N _________

THIS PAGE INTENTIONALLY LEFT BLANK

Lesson 3: Controls Subsystems

 Understand the Human Machine Interface
Subsystem
 Understand Basic Generator Set Operation
 Understand AVR inputs/outputs
 Understand Governor inputs/outputs
A PowerCommand generator set control can
Human Machine Interface (HMI) essentially be thought of as a number of different
subsystems all working together to produce
controlled electrical power to a customer. The
Human Machine Interface (HMI) is one of these
systems.
The HMI is a way for an operator to interact with

the PowerCommand Control. The interaction is
“two-way”. The operator can use the HMI to input
information to the PowerCommand Control, and the
PowerCommand Control can use lights and
37 7/8/2014 Cummins Confidential graphical displays to send information to the
operator.
Remember that the display is not the “control” it is
Display Connections simply the operator’s interface to the control. You
can think of it as a two way street. The operator can
configure the control, and operate the generator set
by interacting with the control. The PCC can display
monitoring parameters, annunciate faults, and
display LEDs.
The display, or HMI includes:
Display
• Graphical Display
• Soft pushbuttons
• Hard pushbuttons
• Switches
38 7/8/2014 Cummins Confidential • Bar Graph
• Emergency Stop(s)
Notes:

The PCC control can display many pieces of
HMI: Display information to the operator through the graphical
Text Only
display on the HMI. The operator can use the
Graphical
Display
Display
pushbuttons to navigate through many menus
containing monitoring parameters.
Engine Monitoring Menus

Soft Pushbuttons
Each PCC menu structure is different and may

Menu
Structure
change based on engine application, but typically

the operator can find information such as generator
Hard Pushbuttons
Genset Info
Description Lines
set battery voltage, engine temperature, oil
pressure, and engine run time. This information is
39 7/8/2014 Cummins Confidential gathered by various sensors by either the Engine
Control Module (ECM) and sent to the
PowerCommand Control through a data link, or the
sensors are wired directly to the PCC.
Alternator Monitoring Menus
Again, each PCC may show different alternator information based on application, but typically the
operator can find information such as line-to-line voltage, line-to-neutral voltage, frequency, current, kW,
kVA, and Power Factor. This information is typically gathered by voltage and current sensing inputs wired
to the PowerCommand Control
Configuration/Service Menus
The graphical display also is used to display configuration menus. The configuration menus allow the
operator to input new configuration settings to the PCC which will change the way in which the PCC
operates the generator set.
Notes:

HMI: LED Indicators

The PCC can also display information to the
operator by using colored LEDs. These LEDs will be
lit, unlit, or flashing depending on the current
condition of the PCC. These are used to readily alert
the operator of conditions present on the generator
set control.
Standard PCC Configurable

Each PowerCommand Control has different (if
LED Indicators PCC LED similar) LEDs. The most common ones are listed
Indicators
below.
Running/Manual Run LED

The running LED is typically green, and is solidly lit when the generator set is running. Some PCCs have a
Manual Run LED, this green led is only lit when the generator set has been started and is running in the
Manual Mode.
Remote Start
This green LED is only lit when there is a Remote Start signal present. The remote start is a connection
point that a customer will make to start the generator set automatically, without input from the operator.
Note that the Remote Start LED can be lit even if the generator set is not running.
Not in Auto
This red LED is flashing when the generator set is not in Auto mode. In Auto mode, the generator set can
be started remotely by the remote start input. Any time that the generator set is not in Auto (Off Mode,
Manual Mode, Shutdown condition) the light will flash.
Shutdown
This red LED is lit when there is a shutdown condition. Part of the PCCs job is to protect the engine and
alternator it is controlling, so when there is a condition that may be harmful to the generator set, the PCC
may shut down.
Warning
This amber LED is lit when there is a warning condition. Similar to the shutdown LED, this is to alert the
operator when there is a potential condition that could be harmful to the generator set. In this condition,
the PCC will keep the generator set running.
Configurable LEDs
Some PowerCommand Control’s HMIs have configurable LEDs. These LEDs can be set to light when
certain programmable events occur.
Notes:

HMI: Pushbuttons
Lamp Test
Fault Reset
Genset
Operation
Menu Breaker Emergency

Navigation Control Stop
The PCC can communicate with the operator using the graphical displays and LEDs, but the operator can
communicate to the PCC using pushbuttons on the HMI. Each PCCs HMI may be different but there are
similarities and consistencies throughout the entire product line.
Menu Navigation
These buttons are used to navigate through the menu structure of the HMI’s graphical display. Some of
these buttons may be “hard pushbuttons” and some may be “soft pushbuttons”. Hard pushbuttons have
a function that does not change (such as the Home button shown on the visual). Soft pushbuttons may
change depending on what is shown on the graphical display (such as the 4 unlabeled buttons below the
display).
Genset Operation
These buttons are used by the operator to control the generator set’s operation. These buttons are used
to select the generator set’s mode, and start and stop the generator set manually. Some PowerCommand
Control’s HMIs also have breaker operation where the generator set’s electrically operated circuit breaker
can be opened or closed in the manual mode.
Fault Reset
Some HMIs combine this button with the “Off” button, but every PCC must have a way to reset shut down
faults. When in off mode, a shutdown fault can be cleared by pushing this button.
Lamp Test
Most HMIs have this pushbutton which allows the operator to test the LEDs on the HMI for proper
functionality

Emergency Stop
The local Emergency Stop is considered part of the HMI. The Emergency Stop has several functions, the
primary one being shutting down the generator set immediately in the case of an emergency. The E-stop
can also be used to prevent the generator set from starting if service is being done on the generator set.
The E-stop also controls the Keyswitch to the ECM, and usually induces a data-save when engaged.
Therefore, do not remove battery power for at least 30 to 60 seconds after depressing the E-stop on a
genset which uses an engine with an ECM (refer to engine’s service manual for exact time). Note: The E-
stop is not to be used for usual manual stopping of the generator set. Manual stopping, when done
correctly, usually will include the proper cooldown time delays, whereas using the E-stop will shut the
engine down hot.
PowerCommand Controls also have a Remote
HMI: Emergency Stops Emergency Stop input. When either the Local or
Local E-STOP
Remote E-stops are engaged, a signal is sent to the
Remote E-STOP
generator controller to prevent operation. As
additional safety, the E-stops physically interrupt B+
from getting to the FSO and Start relay coils. In
B+
order to do this, a second e-stop contact is added in
series with B+ and the FSO and Start relay coils.
The diagram shown illustrates one possible way to

do this. Power to the fuel shutoff valve and start
To Relay Coils
relays are provided in series through one contact of

42 7/8/2014 Cummins Confidential the two contact e-stop switch.
The start and FSO relay coils will be discussed

further in depth later.
Notes:

PowerCommand Controls typically have three
HMI: Stop/Manual/Auto modes of operation: Off, Manual, and Auto. Legacy
Manual
controls typically had a physical switch to select the
modes; newer versions have individual pushbuttons
on the HMI to select the mode.
Auto
Off Mode
The Off Mode is when the generator set is not
running, and is not in standby mode. When in Off
Mode, the control does not allow the generator set
to start – either by pressing the start button or by
Stop
receiving a remote start signal. If the generator set
43 7/8/2014 Cummins Confidential is already running and the technician places the
genset into “Off” mode, the control initiates a
normal shutdown sequence.
Manual/Run Mode
The Manual Mode is the mode the operator will select if he/she would like to operate the genset
manually by input to the HMI. In Manual Mode, the remote start signal is ignored. Once in manual mode,
the operator can select Run Mode, and the generator set will start and will continue to run until the
control is put into Off mode.
Auto Mode
When the generator set is in Auto mode, the generator set can be started with a remote signal only.
When in Auto mode, the generator set can start at any time without any operator input (or warning). If
the generator set is running in Auto Mode, and the Off button is pressed or the remote start signal is
removed, the control initiates a normal shutdown sequence.
Notes:

In addition to the components which are found

HMI: Auxiliary Displays standard on PowerCommand Controls, there can
often be optional auxiliary displays which provide
additional operator-PCC interaction.
Remote HMI
Some PCCs offer a remote HMI option. A remote
Remote HMI
Annunciator HMI often has most of the functionality of a local
HMI, besides some functions which the PCC will
require to be done by an operator locally – such as
fault resets.
Bar Graph
Bar Graph
A bar graph is another optional display device. A bargraph offers a graphical LED display of common
alternator outputs such as amperage, kW, power factor, frequency and voltage. All of the information
presented by a bar graph can be found using the monitoring menus as well.
Annunciator
An annunciator displays a number of different conditions of a generator set through colorized LEDs.
Annunciators are networked devices which can be placed up to many thousand meters away from the
generator set.
Analog Gauges
Some PCC devices support analog gauges as well for monitoring parameters such as battery voltage and
oil pressure. Similar to the bar graph however, all of the information presented by the analog gauges can
also be found in the monitoring menus.
Notes:

A large portion of the roll of a PowerCommand
Alternator Interface: Voltage Control’s job is to monitor different parameters
Alternator happening on the alternator. This alternator
interface can be thought of as subsystem of the
L1 L2 L3 N PowerCommand Control.
L1 Voltage Input
L2 Voltage Input
L3 Voltage Input Each phase (and neutral depending on the
N Voltage Input
connection type of the alternator) is typically
directly inputted to the PCC. With these inputs, the
PCC can determine line to line and line to neutral
voltage for each of the phases, and compare the
values for alternator protection and voltage
Alternator
Output
45 7/8/2014 Cummins Confidential regulation.

Typically there is direct connection between the output of the alternator and the PCC to eliminate any
failure point. An exception would be an alternator that has been wired to high voltage (13,800 VAC).
Typically the sensing lines are stepped down by transformers before the PCC.
In addition to sensing voltage, many
Alternator Interface: Current PowerCommand Controls are capable of sensing the
Alternator current that is flowing out of the alternator. It does
this by utilizing Current Transformers (CTs).
Typical CT L1 L2 L3 N Current transformers work by the principle of
mutual induction. When current is being passed
through a CT, it induces a current flow through the
secondaries of the CT.
CTs are sized as a ratio between primary (the

current of the conductor passing through the hole in
the CT) amperage and the secondary (the current
Alternator
Output
46 7/8/2014 Cummins Confidential induced on the CT windings themselves) amperage.

So a 50:5 CT means that at 50 Amps maximum, the CT windings will have a secondary current flow of 5
Amps.
With this linear relationship between the primary and secondary amperage, the PCC can monitor the
secondary current, and determine the primary current.
CTs typically have a dot on them that represents the polarity of the CT. The CT should always be installed
with the dot facing the source of power (in this case the alternator). Failure to do so will result in most
PowerCommand Controls shutting down on “reverse power”.
Notes:

Automatic Voltage Regulation

Most PowerCommand Controls are capable of
providing their own Automatic Voltage Regulation.
Field Output (DC) Exciter Automatic voltage regulators are designed to
maintain a constant and consistent output voltage
Alternator from the alternator to be used by a customer. In
order to do this during load changes and other
Voltage Sensing (AC)
L1 L2 L3 N
varying conditions, the AVR must increase or
decrease DC current supplied to the exciter stator.
The exciter stator produces a magnetic field.
As the magnetic field increases (by increasing the DC current supplied by the AVR), the alternator output
voltage increases. As the magnetic field decreases (by decreasing the DC current supplied by the AVR), the
alternator output voltage decreases.
The PCC monitors the output voltage of the main alternator. It compares that input voltage against the
nominal value it has been programmed to regulate to. If there is an error between the actual voltage
output of the alternator and the desired voltage, it will have to adjust the DC current (“field”) output to
correct the error; if the PCC increases the field output the alternator voltage will increase, if the PCC
decreases the field output the alternator voltage will decrease.
So if the AVR senses AC power and responds with a
AVR Input (Self Excited) DC pulse width field output to the exciter stator,
where does the power for the DC field output come
from? That depends on the type of input to the AVR
AC
circuit.
Main Stator Output There are two types of excitation systems – self
(Auxiliary Windings)
excited and separately excited.
Main Rotor
In a self-excited system, AC voltage directly from the
alternator is sent to the AVR circuitry. This is a
separate connection from that voltage which was
48 9/10/2014 Cummins Confidential sent to the PCC for voltage sensing, this is only for
AVR Power. It is this AC power that will be
controlled and “sent back” to the excitation system
on the field windings.
Notes:

In separately excited systems, a separate generator
AVR Input (Separately Excited) is used – a permanent magnet generator (PMG) –
especially to power the AVR field. In this case, the
PMG supplies AC power which the AVR uses and
sends back to the exciter stator field windings.
AC
Main Rotor
PMG
The PCC controls the exciter stator voltage by

AVR Output Pulses
sending a DC Pulse Width signal (or similar).
By pulsing the DC signal off and on very rapidly, the

V DC
PCC can control the magnetic field of the exciter

Time On Time Off
time stator, which in turn will control the current induced
DC
on the exciter rotor, and eventually the alternator
voltage from the main stator.
Exciter Stator
Main Rotor
The more time “On” the DC pulse is in relation to
the time “Off”, the more magnetism will build up in
the exciter stator, and the more voltage from the
50 7/8/2014 Cummins Confidential main stator will increase.
The ratio of time ON to total time is called the Duty Cycle, and it is represented as a percentage value.
For example, if AVR duty cycle is 25%, that means that the time On in relation to the time ON+OFF = 25%.
Notes:

Sometimes, the PowerCommand Control does not

AVR Power Stage have enough current carrying capacity to handle the
AVR input from the PMG/shunt windings, or provide
the PWM signal to the exciter stator. In these cases,
Exciter the PCC may use a secondary board that handles the
AVR inputs and outputs.
Alternator
The operation of the AVR is essentially the same,

L1 L2 L3 N
but the PCC signal is essentially amplified by the
power stage before being sent to the exciter stator.
So the AVR circuit on a PowerCommand Control

AVR Control includes an input voltage from either a shunt
winding or a PMG, and a controlled output signal (a
PWM or similar DC signal) to the exciter stator field.
We discussed that the PCC monitors alternator

AC Voltage Sensing Varied Field DC Output
output voltage and compares it to a setpoint, and
will adjust the field voltage in response to any error
that may be present. But what determines how
much the PCC changes the DC field output? How
aggressively does the PCC respond to a difference in
Compare to setpoint
Enter into control algorithm
alternator voltage and programmed nominal

• Proportional
• Integral
voltage?
• Derivative
Most PCC use a closed-loop, PID algorithm to calculate the field output voltage. PID stands for
Proportional, Integral, and Derivative. These are three coefficients in an equation. We don’t need to know
exactly how or what the equation is, but we need to know how each coefficient changes how the PCC
reacts to voltage changes.
Proportional
The Proportional coefficient is looking at the present error – that is the current difference between the
nominal voltage and the actual alternator output.
Integral
The Integral coefficient is looking at the past errors – that is the accumulation of all the differences
between the nominal voltage and the alternator output over time.
Derivative
The Derivative coefficient is looking at the prediction of future errors – that is, as the alternator output
voltage is recovering towards the programmed nominal voltage, making sure it is not on pace to “over
correct”.
Notes:

Alternator Interface: Frequency
Alternator
The PowerCommand Control can also sense the
L1 L2 L3 N
frequency of the alternator by monitoring the
Voltage (frequency) input
voltage inputs to the control. The alternator
produces alternating current, where the current
alternates between positive and negative while still
doing work. You can think of alternating current like
a lumberjack sawing through a piece of wood by
going both forwards and backwards.
Alternator
Output
Like the lumberjack’s saw, when the current is turning directions, there will be a moment in time where
the current has zero potential. This is known as a “zero crossing” point for voltage, and monitoring these
points where voltage equals zero is how the PCC monitors frequency.
Frequency (in hertz) is directly related to the engine speed because the alternator is typically on the same
shaft as the crankshaft of the engine.
Notes:

Engine Interface
Another subsystem of Power Command Controls

the engine interface connections. The engine
interface will be dependent on whether or not the
 ECM Connection engine that the PCC is controlling has an ECM or is
 Mag Pickup
being controlled directly by the PCC. If the engine
has an ECM, most of the interaction between the
 Engine Sensors
PCC and the engine will be done over the data link.
 Governor Output
ECM Connection
If the engine that the PCC is controlling has an Electronic Control Module/Unit (ECM or ECU, respectively),
the PCC will not need electronic governing output to the governor actuator. The PCC will simply send
signals to the ECU, and the ECU will send signals back to the PCC over a data link. Typically this is a J1939,
twisted pair data link. All of the communication between the PCC and the ECU will be sent over this
communication protocol.
If the generator set is a hydra mechanical unit, then the PCC must monitor all of the engine sensors, and
monitor and govern engine speed.
Magnetic Pickup
The magnetic pickup is a device which the ECM or PCC uses to monitor engine speed.
Engine Sensors
If the PCC is controlling an engine with no ECM, the engine sensors that the PCC will need to monitor to
protect the engine (Oil Pressure, Engine Temp, etc.) will be wired directly to the PCC. If there is an ECM,
they will be connected to the ECM, and transmitted to the PCC over the CAN data link.
Electronic Governor Output

Most Power Command Controls provide electronic governing capability for a generator set when an
electronic governor option is installed on the genset. It has a field adjustment trim to enable or disable
the electronic governing feature. This output would be enabled when the generator set’s engine does not
have an Electronic Control Unit (ECU) installed to govern the speed of the engine.
Notes:

The magnetic pickup is a device which the ECM or
Engine Interface: Speed Sensing PCC uses to monitor engine speed, relying on the
principle of mutual induction. The MPU is
 Relies on magnetic
positioned near the flywheel of the engine – as the
induction – pulses of
voltage as teeth go by teeth of the flywheel go by, they induce a voltage
 PCC counts the
onto the coil of the MPU, which the PCC can
number of pulses per monitor.
minute, and divides by
the number of flywheel The PCC or ECM then “counts” the number of pulses
teeth
per minute, and divides by the number of flywheel
 Pulses per min/# of teeth. This ratio is the RPM of the engine.
teeth = RPM
The PCC can determine the engine speed from either the Hz of the alternator or the pulses of the MPU. If
the engine speeds do not match, a speed/hertz mismatch fault will occur.
Governor Output Module
On a hydra-mechanical generator set, the PCC

V DC
controls the electronic governor on the engine. The

electronic governor actuator is essentially a spring
loaded ball valve. When the PCC sends a DC voltage
to the governor actuator, the valve opens allowing
fuel to pass to the intake. When the DC voltage goes
Governor Output Governor Actuator away, a spring force closes the valve.
Module
By pulsing the DC signal off and on very rapidly, the PCC can control the fuel rate very closely, since the
short pulses of DC power trying to open the valve will balance the spring force trying to close the valve.
Most PCC main base boards do not have the current capacity to control the governor actuator directly. So
a governor output module, essentially a signal amplifier, is used to amplify the pulse width signal from the
PCC to a strong enough DC pulse to control the spring loaded governor actuator.
Notes:

The governor control circuit on a PowerCommand

Governor Control Control is similar to the AVR circuit previously
discussed. The governor control circuit includes an
input signal from the Magnetic Pickup (the current
RPM of the engine) and a controlled output signal (a
PWM DC) to the governor actuator. The PCC
Engine Speed Sensing Varied Governor PWM Output
monitors engine speed and compares it to a
nominal setpoint, and will adjust the governor
actuator output in response to any error that may
be present. But what determines how much the PCC
changes the governor actuator output? How
Compare to setpoint
Enter into control algorithm
aggressively does the PCC respond to a difference in

• Proportional
• Integral
engine speed and programmed nominal speed?

• Derivative
Again, the PCC use a closed-loop, PID algorithm to calculate the governor actuator output. PID stands for
Proportional, Integral, and Derivative. These are three coefficients in an equation. Again, we don’t need to
know exactly how or what the equation is, but we need to know how each coefficient changes how the
PCC reacts to voltage changes.
Proportional
The Proportional coefficient is looking at the present error – that is the current difference between the
nominal engine speed and the actual engine speed.
Integral
The Integral coefficient is looking at the past errors – that is the accumulation of all the differences
between the nominal engine speed and the actual engine speed over time.
Derivative
The Derivative coefficient is looking at the prediction of future errors – that is, as the actual engine speed
is recovering towards the programmed nominal speed, making sure it is not on pace to “over correct”.
Notes:

ECM Data Link
If the generator set’s prime mover is an engine with

an Engine Control Module (ECM), often the
PowerCommand Control will not need to control or
Twisted Pair
monitor the engine directly. The PCC will instead
Data Link interact with the ECM to provide the speed
governing and engine protection otherwise
Terminating Resistors provided by the PCC.
The PCC and ECM typically speak over a J1939 data communication “backbone”. This is two-way
communication between the PCC and the ECM:
• Fault annunciation from the ECM to PCC. The PCC will still display the warning/shutdown and a
fault code, but the fault itself will be coming from the ECM, not the PCC
• Engine monitoring data from the ECM to the PCC. The PCC will display engine monitoring
parameters in the operator menus, but the sensors from which the data is gathered are actually
being sent from the ECM.
• Start/Stop Commands from the PCC to the ECM.
• Speed bias from the PCC to the ECM (in some cases). Many times the RPM setpoint will be set in
the ECM only, and can only be adjusted using the ECM’s service tool.
Physically, the J1939 data link is a twisted pair, shielded data cable. On either end, where the connections
are made to the PCC and the ECM, a 120 ohm terminating resistor is used to absorb electrical noise on the
data link. If those 120 ohm resistors are removed, the connection between the PCC and ECM could be
corrupted.
Notes:

More specifically, PowerCommand Controls and

Power Generation Interface (PGI) Cummins ECMs use Power Generation Interface
(PGI) to communicate. PGI is very similar to J1939
 SAE J1939 based
data link communication, but has been modified for
 Has been modified for Cummins’ proprietary use
Cummins proprietary use.
 Two main components to the data link
– Physical (how the devices are connected together)
– Electrical (how the devices use the data link to
The PGI communication uses multiplexing: the
communicate with one another) ability to send and receive multiple messages
between two or more interconnected devices over a
single transmission medium, called a data-link.
Different types of data such as switch positions or
sensor values can be communicated over the data
63 10/1/2014 Cummins Confidential link.
The purpose of multiplexing, or using network communications in general, is to reduce the amount of
components and wires that are transmitting and receiving information.
There are two parts to the PGI Datalink:

• Physical Datalink, which defines how the two (or more) devices are physically wired together.
• Electrical Datalink, which defines how the messages are transmitted across the datalink by
the devices.
J1938 Data Link physical topology
PGI Physical Datalink • Twisted wire pair plus a shield (to reduce
interference)
• Backbone and Stub structure
• Limited to 40 meters (approximately 131 ft)
length maximum. This is a J1939 SAE
standard requirement.
• Supports up to 30 connections at a time
• Each component can be connected to the
datalink with a stub up to 1 meter in length
At each end of the backbone there needs to be a terminating resistor with a nominal resistance of
120ohms (these have a blue cap). This minimizes the reflections within the datalink.
If you need to extend the length of the backbone, you can do so by removing the terminating resistor on
the end you wish to extend, add the required length of backbone (remember this extension plus the
original backbone cannot exceed 40 meters in length) and replace the terminating resistor at the end of
the extended piece. You may need to extend the backbone if you are removing the controller pedestal
from the genset and mount it elsewhere.
If there are unused connectors to the datalink, they must have plugs put in place (these typically have an
orange cap).

The J1939 datalink carries a series of 1s and 0s in
PGI Electrical Datalink each message.
• A 1 is a high voltage differential between
the J1939 high and the J1939 low.
• A 0 is a low voltage differential between the
J1939 high and the J1939 low.
At a Baud Rate of 250k it is possible for the voltages

on the J1939 high and low wires to change from 0 to
1, 250 thousand times per second.
Since the messages are sent by a voltage differential, it is essential that all devices are on the same
ground plain.
If the grounds of two ECM’s are different, then a low voltage differential of one ECM may appear to be a
high voltage differential to another. Hence messages get corrupted and communication is lost.
Notes:

Generator Set Interface
A common connection point on a Power Command

Control is a terminal block which contains all of the
generator set interface connections. Generator set
 Start Circuit interface connections can be thought of as those
 Run Circuit
sensors, inputs, and outputs that are used by the
Power Command Control to control or monitor the
 Switched B+
generator set, but are not associated with the main
 Battery Input
alternator or prime mover directly.
 Battery Charger Input
Start Relay
The start relay output is a driver for the Start Relay. The start relay controls battery power to the starter
solenoid. When the start relay output is active, the Start Relay engages, sending battery power directly to
the starter and the starter solenoid. This will engage the starter into the flywheel of the engine causing it
to crank.
Run Relay
The run relay output is a driver for the Run Relay. The run relay controls the fuel shut off valve (FSO).
When the run relay output is active, the Run Relay engages, which opens the FSO. When the FSO is
opened, fuel can enter into the fuel system of the engine. With conditions right, and the engine is
cranking, the fuel will cause the engine to start to run.
Switched B+ Relay
The Switched B+ relay output is a driver for a Switched B+ Relay. Switched B+ is battery power that is only
available when the genset is running. When the genset reaches its start disconnect speed, the switched
B+ relay output becomes active, which activates the Switched B+ Relay. This relay then sends battery
power to various locations.
Battery Input
PowerCommand controls require battery power to operate. Unlike Switched B+, regular battery power
(B+) is available any time the generator set battery is connected and powered. This power enables the
PCC to operate in standby mode when the generator set is not running.
Battery Charging Alternator Input

PowerCommand Controls rely on a number of inputs to determine engine speed. Aside from governing
the engine at the proper RPM, PCCs also need to know when to disengage the starter motor from the
flywheel. This is known as the “Start Disconnect” speed. The PCC relies on many inputs in case one input
fails. One of the secondary start disconnect inputs is the Battery Charging Alternator Input. This input
signal can also be used to flash the field, should the excitation field collapse.
Notes:

One of the major jobs of a PowerCommand Control
Protections: Thresholds is to protect the generator set from conditions
Nominal
which may be harmful to the engine, alternator, or
other subsystems. It does this by monitoring many
different inputs and sensors and comparing the data
from those sensors to programmed (often
configurable) parameters.
Low Low Acceptable High High Each parameter that a PCC monitors is different and
has different monitoring thresholds, but in general,
Shutdown Warning Operating Warning Shutdown
Range
a parameter can be acceptable, be in a warning

condition, or a shutdown condition.
When a parameter is acceptable, it is near its “nominal” set point, and the condition is operating in a
completely normal condition. As the parameter moves away from nominal it may near a warning
threshold. Often there are both high and low warning thresholds, which warn the operator of conditions
that are both above and below normal operating conditions. The PCC typically keeps the generator set
running when the parameter enters a warning condition.
As the parameter continues to move away from nominal, it may enter a shutdown threshold. Once the
condition has wandered this far from nominal, the PCC will shut down the generator set as this is a
potentially harmful condition for the generator set to be in.
A PowerCommand Control typically handles shut
Protections: Shutdowns and Warnings down conditions and warning conditions differently.
Warning
When the PCC detects a condition that requires a
warning response, the PCC will light the warning LED
and display the fault and description on the
graphical display. This lets the operator know that
the generator set may be in a condition that may
become harmful. The generator set continues to run
Shutdown Fault Warning Condition
and produce power during warning conditions. If
the conditions were to improve out of the warning
61 7/8/2014 Cummins Confidential condition and return back to normal, the PCC would
clear the warning on its own.
Shutdown
When the PCC detects a condition that requires a shutdown response, the PCC will light the shutdown
LED and display the fault number and description on the graphical display. In addition, the PCC may
immediately shut the generator set down (if the condition could be harmful to the engine) or shutdown
with cool down time delays under no electrical load (if the condition could be harmful to the alternator).
Shutdown faults must be reset manually; they will not clear on their own. Typically this requires an
operator on site to clear the faults.
Notes:

Fault Numbers
Fault Type
Engine
A PowerCommand Control will give information
Run Time about why it has shut down or why it is displaying a
Fault Number warning condition. Each PowerCommand Control is
different in this fault annunciation, but typically a
Description PCC’s HMI will display the fault type, the run time
the fault occurred, a fault number, and a description
of the fault.
Fault Type
Typically, a PCC will display whether this is an active fault or an acknowledged fault. Acknowledged faults
will typically only be found in the fault history. Active faults will be displayed on the front screen until they
are acknowledged/reset (in the case of shut down faults) or the warning condition has been correct (in
the case of warning faults).
Engine Run Time

The engine run time of the generator set is also given as an indication of when the fault occurred. This can
be useful in troubleshooting.
Fault Number
The fault number is a very good troubleshooting tool. The fault number can be looked up in the service
manual of the generator set or the control, and likely causes can be investigated.
Fault Description
The HMI will also typically display a description of what the logic is behind the fault.
Notes:

While the generator set is running, it is the duty of
Alternator Protections the PowerCommand Control to protect the
alternator from conditions that may be harmful.
 High/Low AC Voltage
These conditions can arise from a number of
 Overcurrent different causes, such as electrical overloading and
 Over/Under Frequency short circuits.
 Loss of Sensing
 Overexcitation Because these conditions can be very damaging to
the alternator, and often affect the power output to
Main Rotor
the customer, these alternator protection faults are
often shutdown faults. In some types of
PowerCommand Controls, however, just because
63 7/8/2014 Cummins Confidential they are shutdown faults does not mean that the
generator set has to “shut down” immediately.
Often, in order to both protect the alternator and the engine, the PCC will actually open the electrically
controlled breaker and allow the engine to cool down under no load conditions. This prevents damage to
the engine and the alternator.
Here are some examples of Alternator Protection Faults.

High / Low AC Voltage Shutdown - High voltage default to 110% of the rated voltage for 10 seconds time
delays and instantaneous voltage default to 130% of the rated voltage. Low AC voltage default to 85% of
the rated voltage for 10 seconds time delays.
Over current Warning/Shutdown – Shutdown set to be below alternator damage curve up until maximal
measureable point. Currents above the maximal measureable point shutdown after the HCT Shutdown
Time Delay. Warning level set to half of the shutdown threshold.
Under/Over Frequency - Under frequency default to - 6Hz of the 50 Hz / 60 Hz frequency for 10 seconds
time delays. Over frequency default to + 6Hz of the 50 Hz / 60 Hz frequency for 10 seconds time delays.
Loss Of Sensing AC Voltage Shutdown – Loss of sensing AC voltage detects the loss of voltage sensing or
senses the loss of zero crosses. This fault will also be the primary way to detect short circuit conditions.
Over excitation Shutdown – Over excitation is used to detect short circuit alternator faults.
Notes:

AmpSentry™ is a feature of many PowerCommand

Protections – AmpSentry™ Controls that protects the generator set’s alternator
from overcurrent situations. Typically, in the past,
 Alternator thermal
damage curve
this was done by using circuit breakers.
Fails Here
– defines “how much current
10 for how long” without Circuit breakers are limited because they do not
damage
– log-log curve
precisely limit current to the exact specifications of
the alternator. With AmpSentry™, the
Seconds
– does not describe how

1
much current can be PowerCommand Control uses the manufacturer’s
produced
OK Here exact Alternator Thermal Damage curve as the
0.03
protection reference to protect the alternator.
1 10 Amps ( x rated)
The alternator thermal damage curve provides the amount of 3-phase amperage (based on a multiplier of
the rated max amperage) that the alternator can withstand for a certain period of time before significant
deterioration in life starts to occur.
Basically, if you chart the current flow with respect to time, you’re OK as long as you never pass over the
red line. Once the PCC sees the current go over that red line (3 phase amps for a certain period of time) it
will disable excitation.
Note that x axis is current in multiples of rating, and y axis is time and both are logarithmic scales.
This graph shows typical protections for a typical
Protections – AmpSentry™ molded case circuit breaker, AmpSentry protection,
and a typical alternator thermal damage curve.
Typical Alternator
Thermal Damage
As you can see, the molded case circuit breaker

Curve (red)
AmpSentry™ provides too much protection in some instances,

and not enough in other instances. It will trip
10
Protection
(black)
1
unnecessarily at high steady state current levels
TIME (SECONDS)
Typical Circuit
Breaker Protection (time greater than 10 seconds) and in instantaneous
conditions (time less than 0.05 seconds). Also, in
(blue)
0.1
0.05
between, it offers no protection; it will not trip until
1 3 10 100
the current draw is well beyond the alternator
thermal damage curve.
AMPS (TIMES RATED)
Since PCC monitors volts and amps in real time, it knows everything it needs to know to provide its own
overcurrent protection without the need of a physical circuit breaker. In addition, the PCC is not
influenced by ambient temperature conditions like a thermally operated circuit breaker would be.
The PCC with AmpSentry also provides better coordination (tripping the protection device closest to the
fault itself) because it does not have an instantaneous region (the big block regions on the curve).
Alternators do not need instantaneous regions; the reason that breakers have them is not to protect the
alternator but to protect the breaker itself.
Notes:

Engine Protections the PowerCommand Control to protect the engine
from conditions that may be harmful. These
 Low/High Oil Pressure
conditions may just be warnings to the operator
 Low/High Eng. Temp that some operating conditions are outside of an
 Overspeed acceptable threshold and maintenance/repairs must
 Battery Faults be done to mitigate them. Others may be more
 Fail to Start/Crank urgent, and will force a shutdown of the generator
set altogether.
Here are some examples of Engine Protection

Faults:
Over Speed Shutdown – Engine Over Speed default setting is 115% of the rated engine speed nominal.
Control includes time delays to prevent nuisance shutdown signals.
Low Lube Oil Pressure Warning/Shutdown - Level is preset (configurable with a PC based service tool) to
match the capabilities of the engine used. Control includes time delays to prevent nuisance
warning/shutdown signals.
High Engine Temperature Warning/Shutdown - Level is preset (configurable with PC based service tool)
to match the capabilities of the engine used. Control includes time delays to prevent nuisance
Low Coolant Temperature Warning - Indicates that engine temperature may not be high enough for a 10-
second start or proper load pickup. Level is preset (configurable with a PC based service tool) to match
the capabilities of the engine used. Control includes time delays to prevent nuisance warning signals.
Low Battery Voltage Warning - Indicates battery charging system failure by continuously monitoring
battery voltage. Control includes time delays to prevent nuisance warning signals.
High Battery Voltage Warning – Indicates battery charging system is of higher level by continuously
monitoring battery voltage. Control includes time delays to prevent nuisance warning signals.
Weak Battery Voltage Warning - Control system will test the battery bank each time the generator set is
signaled to start, and indicate a warning if the generator set battery indicates impending failure. Control
includes time delays to prevent nuisance warning signals.
Fail to Start (Overcrank) Shutdown. – Control system runs out of crank cycles before the engine starts.
Fail to Crank Shutdown - Control has signaled starter to crank the engine but engine does not rotate.
Cranking Lockout - The control will not allow the starter to attempt to engage or to crank the engine
when the engine is rotating (when control senses the valid engine RPM above the noise threshold value.)
Sensor Failure Indication – Out of range high / low diagnostic logic is provided on the base control to
detect analog sensor or interconnecting wiring failures.

Customer Connections
The PowerCommand Control also has to interact
 Data/Network
with the Customer’s equipment. Customer
 Ready to Load interconnection can be thought of as another
 Configurable Outputs subsystem of a PowerCommand Control.
 Configurable Inputs
 Remote Connections Customer Connections can be thought of as those
that are used by things that are outside of the
PCC Control Board
generator set. Often, these connections would be
needed to be made by the technician in the field
when the generator set is first installed on site.
Data/Network Connections
Often, a generator set needs to be able to communicate with other gensets, Building Management
Systems (BMS), or remote monitoring devices. This is done using network cable. This course is not going
to cover networking, but the connections for networking are made at the Customer Connection terminal
block. For example, a customer wants to know when the genset is running, and what the engine speed is.
Instead of wiring directly from the magnetic pickup and from the B+ relay, that information is broken
down by the PCC control, and sent as packets of information over the network. Depending on what
network protocol is used, there may be one or two pairs of data cable, as well as a shield wire.
Ready to Load Signal

Ready to Load is a common signal that is used by the customer’s equipment (i.e. an Automatic Transfer
Switch). The PCC control will activate this signal when the generator set is ready to assume electrical load
and power the customer’s building, etc. Ready to Load is typically activated when the generator set is
running at least 90% of Nominal Voltage and Frequency.
Configurable Inputs/Outputs
In addition to all of the Inputs and Outputs that we have been talking about that the control uses to
control and protect the generator set, there are often additional inputs and outputs that can be
configured later to customer specifications
Remote Start Connections

Remote Start connections are used to start and stop the genset in automatic mode. Remote connections
are used to start and stop the generator set remotely. The PCC control must be left in the automatic
mode in order to be operated remotely. Remote Start connections can vary by type depending on which
Power Command Control they are connected to. Some PCC uses “dry” start contacts, where the two
remote start connections simply have to be closed in order to start the genset. Others may require a
separate ground signal or a separate B+ signal.
Remote E-Stop
In addition to the local Emergency Stop that is located near the HMI of the control, there can also be a
Remote E-Stop. This E-Stop is typically wired in series w/ the Local E-Stop so that either E-stop will shut
down the genset. Also, both have to be restored in order to start the genset again. The remote E-stop can
be located on the exterior of the generator set’s container, or any other location the customer wishes.
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Configurable Inputs
Configurable Input Power Command Controls can also accept
Configurable Inputs. This input is typically an
 Customer input causes event to occur in PCC
(warning/shutdown/etc)
isolated ground (common) input. When common is
 Active Open or Closed
applied to the configurable input, then that input
becomes active. That input can be configured to
TB
cause a warning or a shutdown of the generator set.
Cust.
Input Genset Control
Typical configurable inputs that can be used are:
COM
Low Fuel in the Day Tank, Low Coolant
Temperature, etc. These inputs would typically be
used by sensors or switches that are not standard
68 7/8/2014 Cummins Confidential on the generator set, but the customer would want
to be used to control and protect the generator set.
Configurable Outputs
Configurable Outputs Typically on a Power Command Control there are
small relays that can be programmed to activate
 Event occurs in PCC causing configurable relay to
change states
when certain events are active.
Some configurable outputs will have a connection

TB point for a Common (C), a Normally Closed (NC),
Internal Event and a Normally Open (NO). When the configured
event is not active, the relay is not active. Therefore,
Customer Annunciation (Fault Code)
the connection point between C and NC is

connected, and the connection point between C and
NO is open.
Most configurable outputs will only have 2

connections, however: Common and Normally
Open.
When the configured event becomes active, the PCC energizes the configurable relay. Then, the
connection point between C and NO is connected, and the connection point between C and NC is open.
These points can be wired to control an alarm, another relay, or sent to a customer’s equipment for
monitoring.
Notes:

Lesson 4: PCC 1302 Hardware

 Define all inputs to PCC 1302 control board
 Define all outputs from PCC 1302 control
board
 Locate inputs/outputs on wiring diagram
 Locate inputs/outputs on hardware/genset
HMI 211 Front Panel

This is the common HMI display of the Power
Command 1302. The PCC 1302 control board can
Graphical
Display LED Indicators
use two types of HMIs, the HMI 211 and the HMI
220.
When the HMI 211 is used, the collective generator

set control is called the “PC1.1”. When the HMI 220
is used, the collective generator set control is called
Menu Selection
“Soft Buttons”
Previous & Off Mode
“Hard Buttons”
the “PC1.2”. This naming convention is used for the
2300 control and 3300 control as well.
The HMI 211 is the display that we will learn in the most depth here in Fundamentals of Power Command
Controls, but the principles of menu navigation, soft push buttons, hard pushbuttons and LED indicators
will carry through to most all of the Power Command Controls that Cummins has to offer.
The HMI 211 has many features that allow the technician to see what the control is doing, as well as input
information into the control to operate the generator set or change configuration.
Graphical Display
The graphical display is used to view all of the different menus of the control system, read fault codes,
and other information.
Menu Selection Buttons

These are 4 “soft” buttons. The functions of these soft pushbuttons change depending on what is
displayed above the button on the graphical display.
Previous Menu Button

This button is a “hard” pushbutton. The function of this buttons does not change based on the display.
Press this button to view the previous main menu.
Notes:

Off Button
This is also a “hard” pushbutton. Press this button to switch to the off mode. If the genset is running, the
genset will immediately begin its shut-down sequence. This button is also used to acknowledge warning
and shutdown messages after a fault has been corrected.
LED Indicators
The HMI display panel has 6 LED indicators.
• Not in Auto (Red) is lit when the control is not set in Auto Mode.
• Shutdown (Red) is lit when the control detects a shutdown condition. The genset cannot be
started when this lamp is lit. After the condition has been corrected, the lamp can be reset by
pressing the Off button.
• Warning (Amber) is lit whenever the control detects a warning condition. This lamp is
automatically shut off when the warning condition no longer exists.
• Remote Start (Green) is lit when the control is receiving a remote run signal.
• Auto (Green) is lit when the control is in Auto mode.
• Manual Run (Green) is lit when the genset is running after being started in Manual mode.
These six LED indicators are very standard, and will appear on most of the Power Command Controls to
annunciate the state of the generator sets.
The rear of the HMI 211 contains two connection
HMI 211 Rear points. These two connection points are essentially
identical. One of the connectors, typically J1,
connects to the PCC control board.
The other, typically J2, is unused. This connector can

be used to connect to the HMI with InPower, or the
display can be “daisy chained” to another remote
display.
The PCC 1302 control board is made up of a single

PCC 1302 Control Board control board in a large potting shell.
There are several connection points on the board.

TB1, at the bottom, is where all customer
connections are made.
The other connections on the board go to the

engine, alternator, current transformers, and
communications cables.
Notes:

PCC 1302 Connectors
DS1 – LED Status

J18 – Excitation Power
Indicator
J17 – Field Output

TB1 – Customer
Connections J22 – Genset Voltage
Sense
J25 – Display J12 – Genset CTs

Connection
TB15– RS485/Modbus
J20 – Genset J11 – Engine

Accessories Harness
All connectors use a tension or mechanical latch to hold the harness jack in place. All connectors are
keyed so the harness jack cannot easily be inserted incorrectly.
Connections to the PCC 1302:

• J11 - Connections to the engine harness and/or the ECM
• J12 - CT Inputs
• J17 − Exciter Field Output
• J18 − AVR Power Supply
• J20 − Genset Accessories Harness
• J22 − Genset Voltage Sense
• J25 − Operator Panel (HMI) Harness
• TB1 − Customer Connections
• TB15 − RS485 / Service Tool Connections
• DS1 − Status indicator. DS1 flashes to let you know the control board’s software is operating. The
heartbeat of the control and will blink once a second when the control is awake and operating. The
heartbeat will stop blinking when the control is asleep.
Notes:

TB1
TB1 Customer Connections Customer connections go to TB1 terminals.
TB1 Connections
TB1 - Customer Connections
PIN Signal Name Connect To
• 1 – PCCNet A signal (network)

TB1-1 PCCNet A Network Data A
TB1-2 PCCNet B Network Data B
Pin 16
• 2 – PCCNet B signal (network)
TB1-3 PCCNet Shield / B+ return
TB1-4 Ready to Load 20ma Low Side relay driver
• 3 – PCCNet Shield (network)

TB1-5 B+ Output (5A)
TB1-6 Configurable Relay 1 - A
TB1-7 Configurable Relay 1 - B
TB1-8
TB1-9
Configurable Relay 2 - A
Configurable Relay 2 - B
• 4 – Ready to load 20mA Low Side driver
TB1-10
TB1-11
Remote Start Return
Remote Start
• 5 – B+ Output (5A protected)
TB1-12 Configurable Input 1
Pull to TB1-13 to activate input. Remove
from TB1-13 to deactivate input • 6 – Configurable Relay 1 A contact
• 7 – Configurable Relay 1 B contact
TB1-13 Configurable Input - Common Common for the two fault inputs
Pull to TB1-13 to activate input. Remove
TB1-14 Configurable Input 2
from TB1-13 to deactivate input
• 8 – Configurable Relay 2 A contact

TB1-15 Remote E-STOP Return Remote normally closed E-STOP switch
TB1-16 Remote E-STOP Remote normally closed E-STOP switch
• 9 – Configurable Relay 2 B contact

• 10 − Signal Return for Remote Start
• 11 − Remote Start input
• 12 − Configurable #1 input
• 13 − Configurable input return (COMMON)
• 14 − Configurable #2 input
• 15 − Return for Remote Emergency Stop
• 16 − Remote Emergency Stop input
PCCNet
This communications port also allows connection from the control to the Optional Display Panel,
Universal Annunciator, LED Bargraph, and System IO Module.
Ready to load signal

This output pin goes low when genset is capable of supporting a load. The genset speed and voltage
output are what determines the state of this pin.
Configurable Outputs
Control includes two relay outputs rated at 2 amps. These outputs can be configured to activate on any
control warning or shutdown fault as well as ready to load, not in auto, common alarm, common warning,
and common shutdown.
Remote E-Stop
For operation of the genset, a short between TB1-15 and TB1-16 must be present. The control enters an
emergency stop mode when the short is removed. Before the genset can be restarted, the control must
be manually reset by re-applying the short and acknowledging the fault. The E-stop circuit contains two
parallel paths. One path is fed into the micro-processor for status processing. The second path is fed
directly into the relay drivers, disabling them when an E-stop is present.
Notes:

J20
J20 Genset Inputs and Outputs J20 is the connection to the PCC1302 board that has
PIN Signal Name
J20 - Genset Connections
Connect To
inputs and outputs for various items and drivers
J20-1
J20-2
Chassis Ground
B+ Return relevant to the genset operation.

J20-3 Switched B+ Low Side Driver
J20-4 B+ Return
J20-5 Discrete Input Return Return for configurable Input 3 - J20-17
J20-6 Discrete Input Return Return for configurable Input 4 - J20-18
J20-7 B+ Return
J20-8 Discrete Input Return
J20-9 B+ Input
J20-10 B+ Input
J20-11 Starter Disconnect Input Charging Alternator
J20-12 B+ Return
J20-13 Relay Coil B+ Supply FSO, Switched B+, Starter Relay Coils
J20-14 FSO Relay Driver Low Side of FSO Relay Coil
J20-15 Starter Relay Driver Low Side of Starter Relay Coil
J20-16 NA
J20-17 Configurable Input # 3 Defaulted to Low Coolant Level Switch
J20-18 Configurable Input # 4 Defaulted to Low Fuel Level Switch
J20-19 NA
J20-20 B+ Input
J20-21 B+ Input
J20-22 Alt Flash Input
J20 Inputs J20 Outputs

• 1 – Chassis Ground • 3 – Switched B+ Driver (low side)
• 9, 10, 20, 21 – B+ Input • 13 – Relay Coil B+ Supply (power to fuel
• 2, 4, 7, 12 – B+ Return shutoff, switched B+ and starter relay coils)
• 5 – Discrete Input Return (return for • 14 – Fuel Shutoff Relay Driver (low side)
configurable Input #3) • 15 - Starter Relay Driver (low side)
• 6 – Discrete Input Return (return for • 22 – Alternator Flash
configurable Input #4)
• 8 – Discrete Input Return
• 11 – Starter Disconnect Input (Input from
the battery charging alternator)
• 17 – Configurable Input #3
• 18 – Configurable Input #4
• 16, 19 – N/A
Grounds
There are two different ground signals into the PCC 1302 Control. Battery Ground is a battery negative
connection for battery return. Signal Ground is a signal return for customer inputs. All grounds on TB1 are
signal return only. They are not the same potential as Battery Ground. Using Battery Ground for one of
these inputs can contribute to control board failure.
Low Side Driver

Low side drivers are outputs which the PCC uses to control or direct other electronic devices. The low side
drivers outputted from J20 are used to control the Switched B+, FSO (aka Run), and Start relays. A low
side driver means that the PCC is switching the “low” or ground side of a circuit. So the relays already
have battery power to the coil, but aren’t active until they are supplied a ground connection from the
PCC.
Notes:

J11
J11 Engine Inputs and Outputs J11 is another connection to the PCC1302 board
PIN
J11 - Engine Connections
Signal Name Connect To

that has inputs and outputs for various items and
J11-1
J11-2
Oil Pressure Sender (Active) +5 V
Oil Pressure Sender or Switch

Return
drivers relevant to the engine/ECM operation. These
J11-3
Oil Pressure Sender or Switch
Signal connections include both analog signals and PGI
CAN Link, which is the network connection between
J11-4 Governor Drive - Governor PWM low side driver
J11-5 Governor Drive + Governor drive + (for low side driver)
the PCC1302 board and the ECM. PGI CAN Link is a

J11-6 Relay Coil B+ Coil of glow plug relay
Glow plug / Ignition Control Relay

J11-7 Low side of the relay coil
Driver
proprietary communication protocol (Cummins

J11-8 Magnetic Pickup Shield
J11-9 Magnetic Pickup Supply
owned) that is used to communicate with Cummins

J11-10 Magnetic Pickup Return
J11-11 Coolant Temperature Sender
ECMs.
Coolant Temperature Sender
J11-12
Return
J11-13 thru J11-16 NA
J11-17 ECM CAN shield
J11-18 B+ Return for ECM
J11-19 ECM CAN Low
J11-20 ECM CAN High
J11-21 Key-switch out Low side driver
J11-22 thru J11-24 NA
J11 Inputs J11 Outputs

• 1 – Oil Pressure Sender (+5VDC) • 4 – Governor Drive (-)
• 2 – Oil Pressure Sender (or switch) return • 5 – Governor Drive (+)
• 3 – Oil Pressure Sender (signal) • 6 – Relay Coil (+) for glow plug relay
• 8 – Mag Pickup Shield • 7 – Relay Coil Return (-) for glow plug relay
• 9 – Mag Pickup Supply • 21 – Keyswitch High Side Driver
• 10 – Mag Pickup Return • 22 – Keyswitch Low Side Driver
• 11 – Coolant Temp Sender
• 12 – Coolant Temp Return J11 PGI CAN Link Connections
• 17 – ECM CAN Shield
• 18 – ECM B+ Return
• 19 – ECM CAN Low
• 20 – ECM CAN High
Oil Pressure
Oil pressure can be sensed with either a 3-wire sender or a 2-wire switch. The sender provides an analog
(0-5VDC) signal to the PCC; the switch is either active or inactive depending on whether appropriate oil
pressure is available to engage the pressure switch. The oil pressure may be monitored by the ECM.
Mag Pickup
The magnetic pickup is used to sense engine speed, and is two-wire. The mag pickup may be monitored
by the ECM.
Coolant Temperature Sensor

The coolant temp sensor is used to sense engine coolant temperature, and is a two-wire sensor. The
coolant temp sensor may be monitored by the ECM.
Governor Drive Output

This governor drive output is a pulse width signal that is sent used to control the on/off time of the
governor actuator. This is only used by HM engines in which the PCC 1302 is controlling the engine
governing directly. This signal is sent to the Aux 104, which amplifies the pulse width signal to the
governor actuator.

Glow Plug
This is another low side driver to control the glow plug relay, if the engine requires pre-heating.
Keyswitch
Similar to the Keyswitch in an automobile, this driver must be active in order for the ECM to turn on.
PGI CAN Link

This is a communication link between the PCC 1302 and the engine’s ECM. This connection has two data
cables (high and low), a ground, and a shield connection. This is a two-way communication cables.
A PCC 1302 control board that is used to control an engine with an ECM will use this communication back-
bone to send information (such as the speed setpoint) to the ECM, and the ECM will send information to
the PCC (such as RPM).
J12
J12 Genset CT Connections J12 is the connection between the PCC1302 board
and the current transformers (CTs) that monitor the
current output of the generator. CTs are polarity
sensitive, and have a dot on one side of them which
must face the source (generator output). In that
sense, the secondaries (wires) are polarity sensitive
as well. Flipping the secondaries is the same as
physically installing the CT backwards.
J12 - Genset CT Connections
PIN Signal Name Connect to
J12-1 CT1 CT1 – X1
J12-2 CT2 CT2 – X1
J12-3 CT3 CT3 – X1
J12-4 CT1 Common CT1 – X2 / X3
J12 – Connections
• 1 – CT1, connected to CT1 – X1
• 4 – CT1 Common, connected to CT1 – X2/X3
Notes:

J22
J22 Voltage Sensing Inputs J22 is the connection between the PCC 1302 and the
generator output. It is used for generator output
sensing (voltage and frequency). The PCC 1302 can
be used on single phase or three phase applications.
The maximum input voltage is 600 V AC, not to be
confused with the regulator power input, which is
limited to 240 V AC.
J22 -Genset Voltage Sensing Connections
PIN
J22-1
Signal Name
L1
Connect To
600 Vmax L1 Source

J22 Connections
J22-2
J22-3
L2
L3
600 Vmax L2 Source
600 Vmax L3 Source

• 1 – L1 Sensing connection (Black Wire)
J22-4 LN 600 Vmax LN Source
• 2 – L2 Sensing connection (Blue Wire)
• 3 – L3 Sensing connection (Red Wire)
• 4 – Neutral sensing connection
J17 and J18 Excitation Output and Input

J17 - Field Winding Connections
Connector
Pin
J17-1 Field + X+ (F1)
J17-2 Field -- XX- (F2)
J18 - Field Winding Connections

Connector
Pin
PMG 1 / Shunt
J18-1 240 Vmax Excitation Source
L1
PMG 2 / Shunt
J18-2 240 Vmax Excitation Source
L2
J18-3 NC
J18 J17
Note: J18 Maximum input is 240 VAC
J17 J18
J17 is the output from the PCC1302 board to the J18 is the input from the voltage regulation power
alternator excitation system. supply. The PCC 1302 will operate in either a self-
excited (shunt excitation) mode or in PMG
J17 Connections excitation mode. J18 can receive input from either
• 1 – Field + supplies excitation positive to X+ the alternator output, or from phase 1 and 2 of a
(F1) PMG. There are three connector pins; however, only
• 2 – Field - supplies excitation negative to XX- two of them are used. The J18-1 and 2 inputs are
(F2) limited to a maximum input of 240 VAC.
J18 Connections
• 1 – PMG 1/ Shunt L1 (240 VAC max)
• 2 – PMG 2/ Shunt L2 (240 VAC max)
• 3 – N/A
Notes:

J25
J25 Display Connections J25 is the connection between the PCC1302 board
J25 - Display Connections
and the display. The display includes the HMI,
gauges, and E-Stop switch.
J25-1 Local Status Low side of local status lamp
J25 Connections
J25-2 Local E-Stop Normally closed local E-Stop switch
J25-3 PCCNet A Network Data A
• 1 – Local Status low side

J25-4 PCCNet B Network Data B
J25-5 System wakeup Activates on B+ Return
• 2 – Local E-Stop (Normally closed)

• 3 – PCCNet A (network data)

J25-8 B+ Return / PCCNET Shield connection Ground / B+ Return connection to display
J25-9 B+ Return
• 4 – PCCNet B (network data)

J25-10 Manual
J25-11 Auto
• 5 – System Wake-up (Activates on B+ Return)

J25-12 B+ B+ supply to the HMI 211

• 8 – B+ Return/PCCNet Shield (shield for network
connections and ground)
• 9 – B+ Return
• 10 – Manual Mode signal
• 11 – Auto Mode signal
• 12 – B+ (battery power for display)
For operation of the genset, a short between J25-2 and J25-6 must be present. The control enters an
emergency stop mode when the short is removed. Before the genset can be restarted, the control must
be manually reset by re-applying the short and acknowledging the fault. The E-stop circuit contains two
parallel paths. One path is fed into the micro-processor for status processing. The second path is fed
directly into the relay drivers, disabling them when an E-stop is present.
This is the rear view of the HMI 211. It has two
Connecting HMI 211 connections, J1 and J2. These are essentially
identical. J1 or J2 is the connection between the
1
2
5
6
HMI 211
Rear
HMI 211 and the PCC 1302 control board. The other
3
4
7
8
connection can be used to “daisy chain” to other
J1 or J2 PCCNet devices such as gauges, annunciators, etc.
J1 – HMI Display Connections

J1 and J2 Connections
1 – PCCNet Data A
J1-1 RS485 (PCCNet) Data A Network Data A
2 – PCCNet Data B
J1-2 RS485 (PCCNet) Data B Network Data B
J1-3 B+ Network Supply
3 – B+ Network Supply
J1-4 PCCNet System Wake Up
J1-5 Return Network Supply Return
4 – PCCNet System Wake Up

J1-6 Run Output
J1-7 Auto Output
5 – B+ Network Supply Return

J1-8 NA
6 – Manual Run output

7 – Auto Run output
8 – N/A
Notes:

TB15
TB15 Modbus Connection TB15 is used as a service tool connection point and
for Modbus monitoring. Plugging a service tool
Pin #1 harness into TB15 will wake up the control because
the service tool harness has a jumper from TB15-1
to TB15-5.
Pin #5
TB15 Connections
TB15 - Tools Interface Connections • 1 – Network Power Supply Return
• 2 – N/A
PIN Signal Name Connect to
TB15-1 Return Network Power Supply Return
• 3 – RS-485 Data A
TB15-2 N/A
TB15-3 RS - 485 Data A Network Data A
• 4 – RS-485 Data B
TB15-4 RS - 485 Data B Network Data B
TB15-5 PCCNet System wakeup
• 5 – PCCNet System wakeup
Notes:

Activity 4-1
Skills Exercise
Locate Hardware on Drawings
Required Materials
• PC 1.X Service Manual w/ Drawings
• Highlighter
Using a highlighter or sticky notes, locate the following connection points to the PC1302 Control Board
1. TB 1
2. J20
3. J11
4. J12
5. J22
6. J17
7. J18
8. J25
9. J1 (HMI)
10. TB15
Using a highlighter find the circuit that the PCC uses to enage the following relays
1. Start Relay
2. Run Relay
3. Switched B+ Relay

Activity 4-2
Skills Exercise
Assemble PC 1.1 Simulator
Required Materials
• PCC 1302 Simulator Board
• HMI 211
• Common Connector Harness (for simulator)
• Universal Wedge Simulator
Connect the following connectors of the common connector harness to the PCC 1302 board. Use the
drawings in order to verify that all of the wiring is correct on the terminal blocks and connectors.
1. TB 1
2. J20
3. J11
4. J12
5. J22
6. J17
7. J18
8. J25
9. J1 (HMI)
If possible, find the same connectors on an actual generator set, including these other components:
1. Start Relay
2. Run Relay
3. Switched B+ Relay
4. Aux 104

Lesson 5: Operator Menus

Objectives Lesson Length : 30 mins
 Demonstrate how to start the generator set
in Automatic Mode
 Demonstrate how to start the generator set
in Manual Mode
 Navigate the Operator Menus
 Acknowledge a Fault
Power Command Controls are able to display
Menus configuration and monitoring parameters that are
associated with the control’s programming to the
technician. They do this through a series of menus,
with varying levels of complexity and protection.
Auto NOT IN AUTO
PowerCommand
SHUTDOWN
! WARNING
Battery: 27.2VDC
Eng. Temp:73.8°F
Auto
REMOTE START
AUTO
The specific terminology of these menus can change
between different types of Power Command
Eng Hrs: 123.2 MANUAL RUN
Auto Man
Controls, but in theory there are two basic types:

• Operator Menus
• Setup Menus
Operator Menus
Operator Menus display to the technician many “Read Only” parameters. These can include, but are
obviously not limited to: Genset Voltage, Current, Engine Hours, Speed, Frequency, etc. Operator menus
basically tell the technician the status of the various sensors of the Power Command Control. The
operator menus also allow the technician to operate the generator set by selecting different modes of
operation.
Setup Menus
Setup Menus allow the technician to configure some of the parameters as to how the generator set
operates. These menus are often password protected, so that the customer, or any other untrained
personnel do not have access to them. Setup menus often also are hidden, in that they require a specific
button press combination to access. Setup menu parameters can include: Frequency and voltage
protection thresholds, timers, configurable inputs and outputs, alternator voltage, etc.
Some Power Command Controls have even more protection to some of the Setup Menus that drastically
change the application of the genset.
Notes:

HMI 211 Front Panel
Graphical
Display LED Indicators
Menu Selection Previous & Off Mode

“Soft Buttons” “Hard Buttons”
This is the common HMI display of the Power Command 1302. The PCC 1302 control board can use two
types of HMIs, the HMI 211 and the HMI 220. When the HMI 211 is used, the collective generator set
control is called the “PC1.1”. When the HMI 220 is used, the collective generator set control is called the
“PC1.2”. This naming convention is used for the 2300 control and 3300 control as well.
The HMI 211 is the display that we will learn in the most depth here in Fundamentals of Power Command
Controls, but the principles of menu navigation, soft push buttons, hard pushbuttons and LED indicators
will carry through to most all of the Power Command Controls that Cummins has to offer.
The HMI 211 has many features that allow the technician to see what the control is doing, as well as input
information into the control to operate the generator set or change configuration.
Graphical Display
The graphical display is used to view all of the different menus of the control system, read fault codes,
and other information.
Menu Selection Buttons

These are 4 “soft” buttons. The functions of these soft pushbuttons change depending on what is
displayed above the button on the graphical display.
Previous Menu Button

This button is a “hard” pushbutton. The function of this buttons does not change based on the display.
Press this button to view the previous main menu.
Notes:

Off Button
This is also a “hard” pushbutton. Press this button to switch to the off mode. If the genset is running, the
genset will immediately begin its shut-down sequence. This button is also used to acknowledge warning
and shutdown messages after a fault has been corrected.
LED Indicators
The HMI display panel has 6 LED indicators.
• Not in Auto (Red) is lit when the control is not set in Auto Mode.
• Shutdown (Red) is lit when the control detects a shutdown condition. The genset cannot be
started when this lamp is lit. After the condition has been corrected, the lamp can be reset by
pressing the Off button.
• Warning (Amber) is lit whenever the control detects a warning condition. This lamp is
automatically shut off when the warning condition no longer exists.
• Remote Start (Green) is lit when the control is receiving a remote run signal.
• Auto (Green) is lit when the control is in Auto mode.
• Manual Run (Green) is lit when the genset is running after being started in Manual mode.
Operating Modes
The PCC 1302 control is operated by the HMI 211
 Off Mode
front panel buttons. There are 5 modes used
 Manual/Run Mode regularly by genset operators:
 Auto Mode • Off Mode
• Manual/Run Mode
• Auto Mode
• Sleep Mode
• Setup Mode
PCC 2100
HMI 211
Off Mode
The Off Mode is when the generator set is not running, and is not in standby mode. When in Off Mode,
the control does not allow the generator set to start – either by pressing the start button or by receiving a
remote start signal. If the generator set is already running and the technician places the genset into “Off”
mode, the control initiates a normal shutdown sequence.
Manual/Run Mode
The Manual Mode is the mode the operator will select if he/she would like to operate the genset
manually by input to the HMI. In Manual Mode, the remote start signal is ignored. Once in manual mode,
the operator can select Run Mode, and the generator set will start and will continue to run until the
control is put into Off mode.
Auto Mode
When the generator set is in Auto mode, the generator set can be started with a remote signal only.
When in Auto mode, the generator set can start at any time without any operator input (or warning). If
the generator set is running in Auto Mode, and the Off button is pressed or the remote start signal is
removed, the control initiates a normal shutdown sequence.

The PCC 1302 enters a low power Sleep mode when
Sleep Mode the current draw from the battery is less than 60
mA. Sleep mode is automatically enabled and the
display will turn itself off after five minutes of
Auto NOT IN AUTO
keypad inactivity in Off or Auto mode.
Sleep mode can be disabled by installing a jumper
PowerCommand
SHUTDOWN
! WARNING
Auto
REMOTE START
AUTO
MANUAL RUN
between TB15-1 and TB15-5. The control will not
enter Sleep mode if there are any active,
unacknowledged faults or if the control is in Manual
Run mode.
Once in sleep mode, these signals can wake up the control:

• Local E-Stop – Active when switch is open
• Remote E-Stop – Active when switch is open
• Manual Start
• PCCNet System Wakeup
• Remote Start
• Auto Mode
• Configurable Input #3
• Configurable Input #4
Pressing the Off button on the HMI 211 will put the
Selecting Off Mode control in Off mode. When in Off mode, the control
does not allow the genset to start. If the genset is
already running and the control is set to Off, it
PowerCommand
Auto NOT IN AUTO
initiates a normal shutdown sequence. When in Off
mode, all active faults are reset if their conditions
SHUTDOWN
! WARNING
have been mitigated.

Battery: 27.2VDC REMOTE START
Eng. Temp:73.8°F
Auto AUTO
Auto Man
In older versions of PowerCommand Controls, there

was a physical switch to select off Mode. This was a
“O”
three position switch: Off, Manual, Auto. In order to
select the “Off” mode, you simply turned the switch
90 7/8/2014 Cummins Confidential to the “Off” or “O” labeled place.
Note: selecting “Off” with the O/Man/Auto switch is not the proper way to shut down a running genset
with this type of control! You must select “Manual Run/Stop” to shut down the genset properly. Selecting
“O” with the switch will shut down the genset immediately, bypassing any cool down timers that may be
required.
Notes:

Pressing the Manual soft button while the control is

Manual Run Mode in Off mode will put the PCC 1302 control in Manual
Manual
mode. In Manual mode, the genset starting and
stopping is controlled manually by the front panel
buttons.
When the Man soft button is pushed, the control is

put into Manual mode with a new screen showing
on the graphical display. This screen has an arrow
actively pointing at a second Man soft button, in a
different location than the previous. Pressing the
soft button below the new Man indication will
91 7/8/2014 Cummins Confidential initiate a normal start sequence.
A remote start signal has no effect while the control is in Manual mode.
If the second Man button is not pressed within ten seconds of entering Manual mode, the control will
revert to Stop mode.
For older versions of Power Command Controls, such as a PCC 2100 (shown), to put the control into
Manual Mode, you would rotate the O/Man/Auto switch to the Manual Position. This would put the
genset into Manual mode, but not start the genset. To initiate a start sequence, the technician would
then have to press the Manual Run/Stop pushbutton, which will initiate a normal start sequence. Pressing
the Manual Run/Stop pushbutton while the genset is running will begin a normal shut down sequence,
including any cool down timers required.
Pressing the Auto soft buttons while the control is in
Auto Mode Off mode will put the PCC 1302 control in Auto
Auto
mode. In Auto mode, the genset starting and
stopping is controlled automatically by a remote run
signal.
When the Auto soft button is pushed, a new screen

shows on the graphical display. This screen has an
arrow actively pointing at a second Auto soft
button, in a different location than the previous.
Pressing the soft button below the new Auto
indication will put the control into Auto mode. The
92 7/8/2014 Cummins Confidential green Auto LED will light and the red Not in Auto
LED will no longer be lit.
When the control senses a remote start signal, the green Remote Start LED will light and the genset will
begin a normal start sequence.
Notes:

For older versions of Power Command Controls, such as a PCC 2100 (shown), to put the control into Auto
Mode, you would rotate the O/Man/Auto switch to the Auto Position. This would put the genset into
Auto mode, and if there is a remote start signal present, the generator set would begin an automatic start
sequence.
Note: The genset can start at any time while in Auto mode. Never service the genset while it is in Auto
mode. Accidental starting of the genset during troubleshooting can cause severe personal injury or death.
Disable the genset before troubleshooting.
Operator Menus
Engine Status Alternator Status Alternator L-L
Battery: 27.2VDC Power: 15.2 kVA L1-L2: 400 ͠V
Eng. Temp:73.8°F Freq.: 50.1 Hz L2-L3: 398 ͠V
Speed: 1500 RPM L3-L1: 401 ͠V
Eng Hrs: 123.2
Auto Man Auto Man Auto Man
Alternator L-N Alternator Single Phase Alternator Current

L1-N: ͠
228 V L1-N: 220 V͠ L1: 8 ͠A
L2-N: 230 V ͠ L2-N: 220 V ͠ L2: 9 ͠A
L3-N: 230 V ͠ L1-L2: 440 ͠ V L3: 9 ͠A
Auto Man Auto Man Auto Man
By pressing the soft buttons below the arrow symbols, you can navigate the Operator Menus. The
Operator Menus show read-only data, you cannot change any of the software settings here.
Engine Status Menu

This menu displays the engine starting battery voltage, engine coolant temp, engine oil pressure and
hours of engine operation.
Alternator Status Menu

This menu displays genset power (in kVA), frequency, and engine speed.

Alternator Line-to-Line Voltage Menu

This menu displays L1-L2, L2-L3, and L1-L3 AC voltages for three phase applications.
Alternator Line-to-Neutral Voltage Menu

This menu displays line-to-neutral AC voltages for L1, L2, and L3 for three phase wye configurations only.
Alternator Single Phase Voltage Menu

This menu displays L1-N, L2-N, and L1-L2 AC voltages for single phase applications only.
Alternator Current Menu

This menu displays L1, L2, and L3 AC current.
When a fault is registered by PCC 1302, the Warning

Fault Handling and Acknowledgment or Shutdown LED will light and the fault symbol and
code will be shown on the graphical display.
The Service Manual available has a list of fault codes

PowerCommand
Auto NOT IN AUTO
SHUTDOWN
and troubleshooting steps associated with each.
! WARNING
Fault
At: 123.2 Hrs REMOTE START
After a fault is corrected, it can be acknowledged on

Fault Number: 1434 Auto AUTO
Local Emergency
Stop MANUAL RUN
the HMI 211 by pressing the Stop button on the

front panel. This will clear the fault code from the
control memory and allow the genset to be put into
Auto or Manual mode. The fault is recorded in a
94 7/8/2014 Cummins Confidential data log so it can be viewed later in the fault history
or a fault code occurrence table.
Notes:

Activity 5-1
Skills Exercise
Basic Generator Set Operation
Required Materials
• PC 1.1 Simulator Kit
Instructions:
1. Power up the simulator kit and place in “Off” mode
a. Describe the LEDs on the HMI
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
2. Start the PC1.1 simulator in “Manual” mode

____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
3. Start the PC1.1 simulator in “Auto” mode using the Remote Start input on the wedge
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
4. With the simulator running, flip the “Mag Pickup Failure” switch on the wedge
a. Describe the LEDs on the HMI as well as the description on the graphical display
____________________________________________________________________________
____________________________________________________________________________
b. Successfully Reset the fault

Activity 5-2
Skills Exercise
Operator Menu Navigation
Required Materials
1. Start the generator set simulator in either “Manual” or “Auto” mode
2. Navigate the Operator Menus of the PC1.1 control and find the following values
Battery Voltage: __________________________

Engine Temperature:_______________________
Power:___________________________________
Speed:___________________________________
L1-N Voltage:______________________________
L1-L2 Voltage:_____________________________
L1 Amperage: _____________________________


Lesson 6: Service Menus

Objectives Lesson Length : 4 hours
 Navigate PCC 1302 service menus
 Configure PCC 1302 to generator set
applications
 Configure PCC 1302 to customer’s
specifications
The Operator Menus display simple read-only
Setup Mode information. There is a second level of menus called
the Service Menus. Here you can change software
adjustments that affect the operation of the genset.
Auto NOT IN AUTO
PowerCommand
SHUTDOWN
! WARNING
Battery: 27.2VDC
Eng. Temp:73.8°F
Auto
REMOTE START
AUTO
The Service Menus are hidden from casual view with
a two-button combination. Press and hold the “Up
Auto Man
Arrow” and “Down Arrow” buttons (the third and

fourth soft pushbuttons) together for two seconds
to get to the first level service menu.
Press Simultaneously
Two Seconds
When going through the Setup Menus, you will run

Configuring an Adjustable Parameter into adjustable parameters. These parameters you
GENSET
can change by using the HMI by pressing the
Volts AC
Hertz
:400
:50 “Adjust” soft pushbutton when it appears. This will
No of Phases
Phase
:3
: Wye highlight the parameter that you are adjusting. In
order to change the value of the parameter, press
Adjust
Volts AC
GENSET
:400 the “+” or “-” pushbuttons to increase or decrease
the value. Push the Arrow pushbutton in order to
Hertz :50
No of Phases :3
Phase : Wye
SAVE - + change which parameter you are adjusting. Press
the “Save” pushbutton in order to save your
changes.
97 7/9/2014 Cummins Confidential To cancel, press the Previous Menu pushbutton to

back out to the previous menu.
Notes:

This is the first level service menu. It has 9
Service Menus submenus
1. Setup Menus
2. History/About
SERVICE MENU 3. Screen Adjust
4. Fault History
1) Setup Menus
2) History/About
3) Screen Adjustment
) More Options
(1) (2) (3)
5. Status
6. Lamp Test
7. Network Status
8. Clock/Exercise
Setup Menus Password: 5-7-4
9. Volt & Hertz Adjust
To enter these sub menus, press the soft button

with the corresponding menu number. To see the
rest of the Service Menu options, press the down
arrow.
By pressing (1) on the previous screen, we are
Service Menu - Setup Menu [1] brought to the first submenu, the Setup Menus.
These menus are intended to be used by authorized
service personnel only. They are used to adjust
software trims critical to genset operation. In order
SETUP MENUS to make any changes in this menu, you will have to
1) Genset Service
2) Genset Setup enter a password.
(1) (2)
The default password is 5-7-4.
The Setup Menus submenu has two additional

submenus
1. Genset Service
2. Genset Setup
Notes:

In the first Genset Service menu, you see four

Genset Service Menus additional menu options:
1. Genset
SETUP
1) Genset
2) Customer I/O
2. Customer I/O
3) Meter Calib.
) More Options 3. Meter Calibration
(1) (2) (3)
4. More Options
SETUP
4) Annunciator
5) Modbus If you select one of the options, you will be taken to
) More Options a group of software trims. To adjust these trims,
(4) (5)
press the “ADJUST” button and use the soft buttons
to adjust the setting. Most of these options will
contain multiple screens that can be navigated by
pressing the “Down Arrow” soft button.
Genset Service – Genset pages 1, 2

GENSET
Volts AC :400
Hertz :50
No of Phases :3
Phase :Wye
By pressing (1) on the Genset Service Submenu, you
Adjust
GENSET
Charging Alt.
Enable : Yes
see the Genset Submenu. There are 17 screens in
Adjust the Genset Service – Genset Submenu.
Next page
Genset Service - Genset Submenu, Screen 1

• Volts AC – This is a configurable parameter that allows the user to configure the PCC to what the
nominal output voltage of the alternator should be.
• Hertz – The frequency output of the alternator. Only 50 or 60 Hz are available.
• No of Phases – The number of phases of electrical power the alternator is connected to produce. Only
1 or 3 are available.
• Phase – Connection type of the alternator. Only Delta and Wye connections are supported by the
1302.
Genset Service – Genset Submenu, Screen 2

• Charging Alt. Enable - Allows you to enable or disable charging alternator as a starter disconnect input
The control system supports automatic engine starting. Primary and backup start disconnects are
achieved by one of three methods; magnetic pickup, battery charging alternator feedback, or main
alternator excitation frequency. When the engine is cranking and begins to run, the PCC control will see
the RPM increase. When the RPM increases to above the start disconnect speed, the PCC deactivates the
start relay, which disengages the starter from the flywheel teeth of the engine.

Genset Service – Genset pages 3, 4 • Fuel System – Select either Gas or Diesel as the
FUEL SYSTEM
fuel system of the generator set.
Fuel System:
Diesel • Fuel Burn Delay – This option is only available if
Glow Plug Enable:
Yes “Gas” is selected as the Fuel Type. This is a timer
that begins when the generator set is running
Adjust
START/STOP DELAY
Start:
Stop :
0 sec
0 sec and begins to shut down. The PCC will disengage
Adjust the FSO relay, but keep the ignition on for this
timer. By running the ignition system with no
incoming fuel past the FSO, all of the fuel
Next page downstream of the fuel solenoid will be burned
following genset stop/shutdown. This will
remove the occasional fuel flash in the exhaust
system after stop / shutdown.
• Glow Plug Enable – This option is only available
if “Diesel” is selected as the Fuel Type. Enable or
Disable if glow plugs are used on the diesel
generator set.
• Start Delay - Configurable time delay of 0-300 seconds prior to starting after receiving a remote start
signal. Default for Start Time Delay is 0 seconds.
• Stop Delay – Configurable time delay of 0 – 600 seconds prior to shutdown after signal to stop in
normal operation modes (not emergency stop). Default for Stop Time Delay is 0 seconds.
Genset Service – Genset pages 5, 6 • Cycle Crank Attempts – This is the number of
CYCLE CRANK
times the PCC will attempt to crank the genset
Attempts: 3
Crank : 15 Sec
before it will fault out on “Fail to Start”
Rest : 30 Sec • Crank Time – This is the amount of time the PCC
Adjust AVR SETUP will crank for before stopping to rest
AVR Enable: Yes
• Rest Time – This is the amount of time in
Adjust between crank attempts.
The PCC Control usually includes a starter protection

Next page algorithm (inherent into the control, not
configurable) that prevents the operator from
specifying a starting sequence that may be
damaging to the system.
• AVR Enable – Enable if the generator set is not using an external AVR, and is in fact using the AVR
circuitry built into the PCC Control
Notes:

This screen allows you to configure the Volts/Hz

Genset Service – Genset pages 7, 8 Overload Control. A frequency measuring circuit
V/Hz SETUP
monitors the generator output and provides output
V/Hz Slope : 2.2
V/Hz Knee : 0.5
under-speed protection of the excitation system, by
Adjust reducing the output voltage proportionally with
REGULATOR
Gain: 100%
speed. If a large load were to be placed on the
Int: 100%
D: 100% generator set, this may cause the speed to drop. To
Adjust combat this, the PCC will produce less and less
voltage (effectively removing load from the engine)
in order for the speed to recover more quickly.
Next page
This is called Under Frequency Roll Off (UFRO). The
voltage roll-off set point and rate of decay (i.e., the
slope of the volts/hertz curve) is adjustable in the
control.
• Volts/Hertz Slope – This is a percentage parameter between 0.0 and 5.0% which essentially
represents the Gain of the Volts/Hertz curve.
• Volts/Hertz Knee – This is a Hz parameter between 0 and 10, which indicates the point at which UFRO
will begin. When the generator set speed decreases below the value of the knee frequency, the
generator set voltage decreases by the V/Hz value.

The 1302 series control uses a standard 3 coefficient PID algorithm in order to regulate Voltage. Basically,
the actual voltage being produced by the alternator is sensed and compared to the nominal voltage
programmed into the PCC. If there is a difference between the two, the PCC must adjust the excitation in
order to “go after” the correct nominal voltage. This happens all the time due to variable load conditions,
engine running conditions etc. Two of the coefficients are adjustable using service menus: “Gain” and
“Int”, which determines how the PCC will change the excitation voltage.
• Gain – This is the Proportional Gain (the “P” in PID), also referred to as K1. This coefficient is
concerned with the current error value. The value of K1 should be adjusted to meet the specification
for percent off rated voltage during a load acceptance, and prevent large voltage overshoots during
offloads and during engine/alternator startup.
• Integral – This is the Integral Gain (the “I” in PID), also referred to as K2. This coefficient is concerned
with the current error value as well as the length of time of the error. The value of K2 should be
adjusted to control the recovery characteristics of the voltage during large load acceptance and
rejection transients. Values of K2 which are too high can cause unstable voltage performance and
values too low can cause slow performance or steady state voltage offset errors.
• Dampening – This is the Dampening (or Differential) Gain (the “D” in PID). This coefficient is
concerned with the rate of change of the error value. Typically this shouldn’t need to get adjusted.
In general, K1 increases and K2 decreases in value with increasing generator size, but can vary in different
applications.
Notes:

ELECT. GOVERNOR
Gov Enable: Yes
• Electronic Governor – Enable if the generator
set uses an electronic governor.
Adjust GOV. CRANK FUEL
Initial DC: 25.0%
Initial Time: 2s
Ramp Rate: 25.0 The 1302 series control provides electronic
governing capability for a generator set when an
Max DC : 100.0%
Adjust
electronic governor option is installed on the

genset. It has a field adjustment trim to enable or
Next page disable the electronic governing feature. It supports
isochronous speed governing.

This screen controls the cranking fuel characteristics to “tune up” the generator set startup to suit the
application. Cold weather applications might need a longer cranking period and OR higher levels of
cranking fuel. Following parameters should be chosen to make sure the genset starts up quickly enough
but does not overshoot or produces excessive smoke at startup.
• Initial DC - Initial Cranking Fuel Duty Cycle, this adjusts the amount of fuel that is supplied at start up.
Fueling will be initially set to the Initial Crank Fueling Duty Cycle value and will remain at that value for
the Initial Crank Fueling Period.
• Initial Time – Initial Cranking Fuel Period, this adjusts the amount of time at startup before the
governor control enters a closed loop control. Basically, this is how long the fueling is stuck on the
initial cranking fuel duty cycle.
• Ramp Rate – This parameter adjusts how quickly the cranking fuel is ramped up to after the initial
cranking fueling period is over.
• Max DC – Maximum Cranking Fuel Duty Cycle
Fueling will be initially set to the Initial Crank Fueling Duty Cycle value and will remain at that value for the
Initial Crank Fueling Period. After this period expires, the fuel command will be ramped at the Crank
Fueling Ramp Rate until the Maximum Crank Fueling limit is reached.
Notes:

Genset Service – Genset pages 11, 12 Genset Service - Genset Submenu, Screen 11
ELECT. GOVERNOR
Once the Governor Enable Engine Speed has been
Gain: 100%
Int: 100%
reached, now the governor is enabled and the PCC
D: 100% enters a closed loop regulation of engine speed.
Adjust ELECT. GOVERNOR
Crank Exit
Fuel DC: 25.0%
Dither Factor: 15 Once again, this is a PID loop that is controlled by a
Proportional, an Integral, and a Derivative
Ramp Time: 0.25
Adjust
(dampening) coefficient. A good starting point for

any new engine application is to start with a set of
Next page released gains for an engine of a similar type and
size should they already exist.
• Proportional Gain - The value of GK1 should be adjusted to meet the specification for percent off
rated voltage during a load acceptance, to prevent large voltage overshoots during offloads, and
during engine/alternator startup.
• Integral Gain - The value of GK2 should be adjusted to control the recovery characteristics of the
engine during large load acceptance and rejection transients.
• Dampening – The Dampening factor is used to set basic steady state stability of the engine. Tuning
the Damping factor is an iterative process started by finding the engine load level which produces the
worst steady state engine performance (note: GK1 and GK2 may have to be adjusted first to allow the
engine to be transitioned smoothly into this) and adjusting the dampening factor until the best
performance is observed.

Upon reaching the Starter Disconnect Speed, the fueling command is pulled back to the Crank Exit Fueling
Duty Cycle value until the Governor Enable Engine Speed is reached. When the Governor Enable Engine
Speed is reached the governor is enabled, the speed setpoint is set to the sensed engine speed value at
this point, and the setpoint ramped to rated speed in a time equal to the Governor Ramp Time.
• Crank Exit Fuel DC - After the engine fires, the fueling level will return to this value before the normal
PID algorithm takes over the control of the PWM output to the actuator.
• Dither Factor - Dither is a method of introducing small amounts of noise into the speed governing
system. The purpose of this feature is to prevent the fuel actuators from becoming stuck. Therefore
dither should be used in applications where the fuel actuators are prone to sticking.
• Ramp Time – Ramp time is the amount of time for the PCC to ramp from governor enable speed to
rated speed
Notes:

ELECT. GOVERNOR
Enable Speed:
1100 RPM • Enable Speed – This is the RPM speed that the
Min Gov. DC: 20%
Max Gov. DC: 95% PID governor takes over from the Initial
Cranking fueling setpoints.
Adjust
ELECT. GOVERNOR
Preload Offset:
0%
• Min Gov. DC – This is the minimum governor
Adjust duty cycle from the control output to the
governor controller.
• Max Gov. DC – This is the maximum governor
Next page duty cycle from the control output to the
governor controller.

• Preload Offset – This is a percentage amount that preloads the PID algorithm to be more or less
aggressive.

GENSET NUMBER
Model No: • Model Number – This is the model number of
Serial No: the generator set that the PCC control is
Adjust DISPLAY SETUP
Connection:
controlling
Local
Access Code: No • Serial Number – This is the serial number of the
Symbols:
Adjust
No
generator set that the PCC control is controlling
Next page

PowerCommand Controls often have the option for a display to be mounted remotely. If a display is
mounted remotely, often it does not have the same powers as a Local display, such as acknowledging
faults.
• Connection – Select whether the display is Local or Remote.
• Access Code – Select whether or not an access code is required to change modes (such as Manual
Start, Auto). This is to prevent unauthorized personnel from changing modes. For example, if a genset
is left in emergency standby mode, an access code would prevent someone from accidentally turning
the PCC to Manual.
• Symbols – The HMI 211 is able to be displayed in Symbol mode. Select Yes to display in symbols, No to
display in text.
Notes:


Genset Service – Genset page 17 Some Genset setup menus have additional
password protections. Click “Required” if you would
like to require additional passwords for the Voltage
and Frequency change menus
Adjust
VOLT AND HZ MENU
Password:
Not Required Now we are at the end of the Genset Service –
Adjust Genset Submenu.
Press the “Previous Menu” pushbutton on the HMI

to return to the previous menu.
Notes:

Genset Service – Customer I/O Submenu see the Customer I/O Submenu.
Customer I/O submenu can be used to define

FAULT INPUT 1 customer input messages and output maps. There
Function
Select :
are 14 screens in the Configurable I/O Submenu.
XXXXX XXXXXXX
Adjust
As we learned in the Hardware lesson of this course,
there are several configurable (often called
Customer) inputs to a PowerCommand Control.
For the PCC 1302 control, there are four

configurable inputs. Each one of those inputs can be
configured to cause a warning, shutdown, or event
to be logged in the PCC control. There are also
several configurable customer outputs that can be
used to interact w/ customer’s equipment under
certain conditions.
This submenu will be where the customer inputs are configured to the customer’s specifications.
The Customer I/O menus consist of four of each of the following:
• Fault Input Function Selection
• Input Text Message
• Active State Selection
• Customer Output Map
Notes:

Genset Service – Customer I/O Submenu, Screens

Genset Service – Customer I/O pages 1-4 1-4
FAULT INPUT 1
The first four screens of the Customer I/0 define the
Function
Select:
functions of each of the configurable inputs. As is
Fault Input common with most PowerCommand Controls with
Adjust FAULT INPUT 2
Function configurable customer inputs, some configurable
Select:
Disabled inputs can only perform certain functions.
Adjust
Function Select (1, 2, 3, 4) – Set to Disabled, Fault

Input, Fault Reset or Battle Short for each of the
configurable inputs being used.
To Inputs 3, 4
Functions of Configurable Inputs

• Disabled: The configurable input will be ignored, regardless of the state of the physical wiring.
• Fault Input: The configurable input will cause the generator set to have a fault. This fault can be set to
either a warning or a shutdown later.
• Fault Reset: When the input is active, some faults can be cleared from this configurable input. There
are several faults which are not able to be cleared locally because, for safety’s sake, they should be
cleared locally at the generator set as to perform a safety check on the generator.
• Battleshort: The configurable input will cause the generator set control to enter battleshort mode. In
battleshort mode, the PCC will ignore most shutdown and warning conditions and continue to run.
Notes:

Genset Service – Customer I/O pages 5-8
CUSTOMER
INPUT 1 TEXT
Type: Warning
FAULT INPUT #1
5-8
Adjust
CUSTOMER INPUT 2
TEXT
Type: Shutdown
LOW COOLANT The second group of four screens of the Customer
I/0 Submenu defines the type of Fault Input and the
LEVEL
Adjust
associated text display for each of the configurable

inputs.
To Inputs 3, 4
Customer Input Text (1, 2, 3, 4) – Type is set to Warning, Shutdown, or Event

• Warning – the PCC control will enter a warning state when the customer input is active. It will display
an amber LED, and will display the configured text on the screen until acknowledged. The warning will
clear as soon as the configurable input is removed.
• Shutdown – the PCC control will enter a shutdown state when the customer input is active. It will
display a red LED, and will display the configured text on the screen until acknowledged. The
shutdown will not clear when the configurable input is removed, shutdowns have to be reset at the
Local HMI, or with a remote fault reset input.
• Event – The PCC control simply records that the configurable input is active in the event logger.
• Customer Input Text (1, 2, 3, and 4) Text is the text that you wish to be displayed on the HMI screen
when the configurable input is active. Enter up to 2 lines of text per configurable input.
Genset Service – Customer I/O pages 9-12 5-8
The third group of four screens of the Customer I/0
defines the Active State for each of the configurable
FAULT INPUT 1
Active State
inputs.
Select:
Active Close
Adjust
FAULT INPUT 2
Active State
Select: Each configurable input is essentially the
Active Open
Adjust combination of two wiring points. One is a common,
which is an electrically isolated ground being sent
out to the customer’s piece of equipment or switch.
The “Input” of the configurable input is another
To Inputs 3, 4
point that this common will be inputted back into
113 7/9/2014 Cummins Confidential the control.
That means that there are two states of a configurable input, one where the common is present and one
where the common is not present at the input point.
• Active State Select – Active Open or Active Closed. Select Active Open if the customer wants the
configurable input to be active (and cause a fault, etc.). Active Open means that the configurable fault
will be active when the common is not returned to the input. Active Closed means that the
configurable fault will be active when the common is returned to the input.
Notes:


Genset Service – Customer I/O pages 13-14 13,14
The fourth group of two screens of the Customer I/0
defines the configurable outputs.
CUSTOMER
OUTPUT 1 MAP
Fault No: 1540
Most Power Command Controls have onboard pilot

Adjust
CUSTOMER
OUTPUT 2 MAP
Fault No: 1541 relays that can be configured to become active for
Adjust certain events/faults. The PCC 1302 has two such
relays.
• Customer Output 1, 2, Map – select the fault code that the customer would like to monitor using a
configurable customer output.
By default, the two configurable relays on the PC 1302 are set to:
• 1540 – Common Warning
• 1541 – Common Shutdown
If the PCC is configured this way, any time there is a warning condition on the PCC, Configurable Output 1
will be active. Also, any time that there is a shutdown condition on the PCC, Configurable Output 2 will be
active.
Now we are at the end of the Genset Service – Customer I/O Submenu.
Press the “Previous Menu” pushbutton on the HMI to return to the previous menu.
Notes:

Genset Service - Meter Calibration
Submenu (3) see the Meter Calibration Submenu.
The Meter Calibration Submenu allows you to adjust

METER CALIB. the displayed voltage, current, and frequency to
Reg Volt Adj:
100.0%
match what a calibrated meter displays. The voltage
Adjust
Voltage: 0.0 can be calibrated to display 90 to 110%. The
frequency can be calibrated to display -6.0 to +6.0
Hz.
Genset Service – Meter Calibration Submenu,

Genset Service – Meter Calibration:
Screen 1
Voltage Measurement for Regulation
The first Calibration trim to cover is to calibrate
Voltage Measurement for Regulation. This will
METER CALIB. actually adjust the main alternator output voltage.
Reg Volt Adj:
100.0%
Voltage: 0.0 This trim calibrates the Automatic Voltage
SAVE - +
Regulation circuitry so that when the Power
Command Control thinks that it is regulating to a
certain output voltage, the output voltage actually is
correct.
116 7/9/2014 Cummins Confidential Voltage Calibration for Regulation should be done
before Voltage Calibration for Display.
• Reg Volt Adj - The effect of this trim is inverse on the regulated voltage. Increasing the percentage will
decrease the regulated voltage. Decreasing the percentage will increase the regulated voltage. Adjust
the trim so regulated voltage matches the desired nominal voltage measured with a known calibrated
voltage meter.
For example, the generator set you are going to calibrate is set to produce 3 phase 208 VAC. However, a
calibrated meter reads that it is only producing 206 VAC. The Nominal voltage is set to 208 VAC, and there
are no voltage adjustment trims, and the HMI displays that the generator set is producing 208 VAC. Since
the calibrated meter reads differently, you would change the Voltage Measurement for Regulation trim
until the calibrated meter reads that 208 VAC is being produced.
Notes:


Screen 2
Voltage Measurement for Display
The second Calibration trim to cover is to calibrate
Voltage Measurement for Display. This should be
METERING
VOLTAGE ADJUST
done after calibrating the Voltage Measurement for
L1-N: 0 VAC
L2-N: 0 VAC
Regulation. The Voltage Measurement for Display
L3-N: 0 VAC
trims does not affect the output of the alternator,
SAVE - +
only the displayed readings on the HMI. This trim
calibrates the Power Command Control to display
voltage readings correctly.
Adjust the three parameters listed so the displayed

117 7/9/2014 Cummins Confidential voltage for each phase matches the voltage being
produced by the genset.
For example, previously you have calibrated the 3-phase 208 VAC generator set’s Voltage Measurement
for Regulation trims. Now, even though the calibrated meter is displaying that the generator set is
operating properly and producing 208 VAC, the display is reading that the generator set is producing 210
VAC. Now, you would calibrate the Voltage Measurement for Display in order for the generator set’s HMI
to display the accurate reading. Voltage Measurement for Display does not change the output voltage of
the alternator at all, just the reading on the HMI.
Screen 3
Current Measurement for Display
The third Calibration trim to cover is to calibrate
Current Measurement for Display. The Current
METERING
CURRENT ADJUST
Measurement for Display trims will adjust the
L1:
L2:
0 Amps
0 Amps
displayed readings on the HMI to match the reading
L3: 0 Amps
of a calibrated current meter.
SAVE - +
Adjust the three parameters to the match the

current being drawn from the alternator by the
known current meter.
For example, your 3 phase, 208 VAC generator set is producing voltage and frequency and providing load
to a customer. The HMI displays that it is supplying 340 Amps on L1, but a calibrated meter reads that it is
actually supplying 345 Amps on L1. Now, you would calibrate the Current Measurement for Display in
order for the generator set’s HMI to display the accurate reading. Current Measurement for Display does
not change the output of the alternator at all, just the reading on the HMI.
Now we are at the end of the Genset Service – Meter Calibration Submenu.
Notes:

Genset Service – Annunciator Submenu
(4) see the Annunciator Submenu.
The Annunciator Submenu is similar to the

ANNUNCIATOR Configurable I/O Submenu, where the operator can
configure an event type to trigger a relay to become
FAULT 1 TEXT
Type: Warning
active. The difference is instead of the relay being

XXXXXXXXXXXXXX
XXXXXXXXXXXXXX
Adjust
on the control board itself, these relays are on an
annunciator.
An annunciator is a remote panel, connected to the

PCC by a network. The annunciator displays certain
faults, status lamps and event indicators by
interpreting network data as sent to it by the PCC
1302 control board.
The most common Cummins annunciator has four custom relays that can be controlled by the PCC1302.
When a specified event becomes active, a message can be sent by the 1302 to the annunciator to turn the
relay on or off. One event per relay is allowed.
There are seven Annunciator submenus that can be used to define three Annunciator Fault Text messages
and four Annunciator Output Maps. You will be able to define three possible customer defined fault
conditions that can be shown on the HMI 211 display. The Annunciator fault text message menus are
used to enter an event type and description.
• Type (Warning, shutdown or event)
• Fault Number (0-655235)
• Description (32 characters max)
Now we are at the end of the Genset Service – Annunciator Submenu.
Notes:


Genset Service – Modbus Submenu (5) see the Modbus Enable Submenu. ModBus is a
networking language that the PCC1302 uses to
communicate with other devices.
MODBUS ENABLE
Modbus Enable: The ModBus Submenu is used to set the following
No
Adjust
parameters:
• ModBus Enable/Disable
• Address of the ModBus register
• Baud Rate (2400, 4800, 9600, 19200)
• Parity (even or odd)
This is the last page of the Genset Service Submenu.

Press the “Previous Menu” pushbutton on the HMI twice to return to the main Service Menus.
We reached the end of the “Genset Service”
Service Menus submenu.
SERVICE MENU
1) Setup Menus
2) History/About Now we are back to the general Setup Menu.
Remember, the Setup Menus submenu has two
3) Screen Adjustment
) More Options
(1) (2) (3)
SETUP MENUS additional submenus
1) Genset Service
2) Genset Setup
1. Genset Service
2. Genset Setup
(1) (2)
This time press (2) to access the Genset Setup

submenu.
Genset Setup Menus Password: 1-2-0-9
The Genset Setup submenus are password

protected even further than the Service Menus.
The password to access the genset setup menus is 1-2-0-9.
This is the Genset Setup Menu
Genset Setup Menus There are four sub menus to the Genset Menu
1. Genset
SETUP
1) Genset
2) Volt Protect
2. Customer I/O
3) Curr Protect
) More Options 3. Meter Calibration
(1) (2) (3)
4. Engine Protect
SETUP
4) Engine Protect
If you select one of the options, you will be taken to
) More Options a group of software trims. To adjust these trims,
(4)
press the “ADJUST” button and use the soft buttons
to adjust the setting. Most of these options will
contain multiple screens that can be navigated by
122 7/9/2014 Cummins Confidential pressing the “Down Arrow” soft button.
Notes:

By pressing (1) on the Genset Setup Submenu, you
Genset Setup - Genset Submenu (1) see the Genset Submenu.
The Genset Submenu of the Genset Setup Service

GENSET menu is where a number of configurable
CT Ratio: 50:5
MPU Enable:
Fly. Teeth:
Yes
110
parameters are set which tell the PCC how to
RPM/Hz Ratio:
Adjust
30 operate the generator set.
The Genset Submenu consists of 10 screens.
Genset Setup - Genset Submenu, Screen 1

Genset Setup - Genset page 1, 2 • CT Ratio: This is the ratio of the current
GENSET
transformer’s primary rating to its secondary
CT Ratio:
MPU Enable:
50:5
Yes rating.
Fly. Teeth: 110
RPM/Hz Ratio: 30
This has to do with the number of turns of coil in the
Adjust
GENSET
Excitation
Source: Shunt
Excitation/Line current transformer, as well as the amperage
expected at the secondary. If a CT has 5Amps on its
Freq. Gain: 1
Adjust
secondary and has 20 turns in its primary, it will

have a CT ratio of 100:5. This means that when the
Next page power command control sees 5A input from the CT,
it knows that 100A are flowing through the CT.
• MPU Enable: The Magnetic Pickup Unit measures the RPM of the engine by counting the flywheel
teeth as they go by when the engine is running. Set to Yes if the PCC uses a mag pickup to measure
RPM.
• Flywheel Teeth: This is the number of teeth along the flywheel. The starter motor uses these gear
teeth to rotate the engine at start up, but the MPU also uses them to determine engine speed.
• RPM/Hz Ratio: This is the ratio for nominal engine speed to nominal Hz. For an 1800 RPM 4-pole
alternator producing 60 Hz this ratio will be 30.
• Excitation Source: This is the source of power that the PCC’s AVR circuitry will get in order to regulate
and send back out to the exciter stator for voltage regulation. This can either be “Shunt” which means
self-excited, or “PMG” which means separately excited.
• Excitation/Line Freq. Gain: The excitation, line frequency gain is the multiplier of alternator line
frequency to excitation system frequency.
Notes:


Genset Setup - Genset page 3, 4 • Application Rating: This trim sets whether the
APPLICATION
genset is being used in Standby or in Prime
RATING SELECTION
Application application. Setting it to a Prime application will
Rating: Standby
derate the output of the generator set.
Adjust
KVA (STANDBY)
1 ph/60Hz: 25.0
3
1
ph/60Hz:
ph/50Hz:
25.0
25.0 Genset Setup - Genset Submenu, Screen 4
• kVA (Standby) – For single and three phase
3 ph/50Hz: 25.0
Adjust
applications, define what the kVA (Standby)

rating of the generator set will be. This
Next page information can usually be found on the data
plate of the generator set. Obviously, adjusting
125 7/9/2014 Cummins Confidential these won’t make your genset more powerful
than it is physically capable.
Genset Setup - Genset page 5, 6 • kVA (Prime) - For single and three phase
KVA (PRIME)
applications, define what the kVA (Prime) rating
1
3
ph/60Hz:
ph/60Hz:
21.0
21.0 of the generator set will be. Prime powered
1
3
ph/50Hz:
ph/50Hz:
21.0
21.0 gensets are typically set to produce a lower
Adjust
BATTERY SELECT maximum kVA than Standby, even if the
Nominal Battery
Voltage : 24 V hardware of the generator set does not change.
Adjust This information can usually be found on the
data plate of the generator set. Obviously,
adjusting these won’t make your genset more
Next page powerful than it is physically capable.

• Battery Nominal Voltage Select – Select what the nominal voltage of your generator set’s starting
battery circuit is, either 12 VDC or 24 VDC.
Notes:

Genset Setup - Genset page 7, 8 • Battery Thresholds 24 VDC – Select the warning
BATT THRESHOLDS
thresholds for Low Battery, High Battery and
24V
Low Batt. : 24.00V Weak battery alarms for a 24 VDC system. This
High Batt : 32.00V
Weak Batt : 20.00V will change to a 12 VDC system thresholds if you
Adjust
BATT DELAY SETUP
L. Batt TD: 60.0s
selected 12 VDC on page 6.
H. Batt TD: 60.0s
Wk Batt TD: 2.0s
Adjust Genset Setup - Genset Submenu, Screen 8
• Battery Delays – Select time delays before Low
Battery, High Battery, and Weak battery alarms
Next page will become active.

Genset Setup - Genset page 9, 10 • Oil Pressure Sensor Type – There are two types
OIL PRESS SETUP
of Oil Pressure Sensors: Senders and Switches.
Sensor Type: Senders send analog data to the PCC, Switches
Switch
just have “on” or “off”.
Adjust
OIL PRESS SETUP
Sensor Polarity:
Active High Genset Setup - Genset Submenu, Screen 10
Adjust • Oil Pressure Sensor Type – Additionally, if you
selected “Sender” on screen 9, you will have to
select whether it is a 2-wire or a 3-wire sender.
Next page If you selected “Switch” on screen 9, you will
have to select whether the switch is Active High
128 7/9/2014 Cummins Confidential (closed) or Active Low (open).
Now we are at the end of the Genset Setup – Genset Submenu.
Notes:


Genset Setup – Voltage Protection (2) see the Voltage Protection Menu. The Voltage
Protection Menu consists of 10 screens.
VOLT. PROTECTION The Protection Menu is where you will select all of
the set points for voltage and frequency shutdown
High AC Voltage
Threshold: 115 %
and warning points. The PCC control wants to

High AC Voltage Time
Delay: 10.0s
protect the customer’s load from bad power,

Adjust
therefore if the measured parameter (voltage or

frequency) goes too far from Nominal, it may go
past one of these thresholds and shut down the
generator set.
Genset Setup – Voltage Protection Submenu,

Genset Setup – Volt. Protection page 1, 2 Screen 1
VOLT. PROTECTION
• High AC Voltage Threshold – This is a percent
High AC Voltage
Threshold: 115% amount above the nominal voltage that, if the
High AC Voltage
Time Delay: 10 s alternator set produces, the Power Command
Control will produce a “High AC Voltage” fault.
Adjust
VOLT. PROTECTION
Low AC Voltage
Threshold: 85%
Low AC Voltage • High AC Voltage Time Delay – This is the time
delay that the alternator voltage must be above
Time Delay: 10 s
Adjust
the High AC Voltage Threshold before the PCC

will fault on High AC Voltage.
Next page
Genset Setup – Voltage Protection Submenu, Screen 2

• Low AC Voltage Threshold – This is a percent amount below the nominal voltage that, if the alternator
set produces, the Power Command Control will produce a “Low AC Voltage” fault.
• Low AC Voltage Time Delay – This is the time delay that the alternator voltage must be below the Low
AC Voltage Threshold before the PCC will fault on Low AC Voltage.
Notes:

Genset Setup – Voltage Protection Submenu,
Genset Setup – Volt. Protection page 3, 4 Screen 3
VOLT. PROTECTION
• Overfrequency Threshold – This is a percent
Overfrequency
Threshold: 6.0 Hz amount above the nominal frequency that, if
Overfrequency
Time Delay: - the alternator set produces, the Power
Command Control will produce an
Adjust
VOLT. PROTECTION
Underfrequency
Threshold: 6.0 Hz
Underfrequency “Overfrequency” fault.
• Overfrequency Time Delay – This is the time
Time Delay: -
Adjust
delay that the alternator frequency must be

above Overfrequency Threshold before the PCC
Next page will fault on Overfrequency. The range of this
parameter is 100 – 2000 in ½ cycles units.
Genset Setup – Voltage Protection Submenu, Screen 4

• Underfrequency Threshold – This is a percent amount below the nominal frequency that, if the
alternator set produces, the Power Command Control will produce an “Underfrequency” fault.
• Underfrequency Time Delay – This is the time delay that the alternator frequency must be below the
Underfrequency Threshold before the PCC will fault on Underfrequency. The range of this parameter
is 500 - 2000 in ½ cycles units.
Now we are at the end of the Genset Setup – Voltage Protection Submenu.
Notes:


Genset Setup – Current Protection (3) see the Current Protection Menu. The Current
Protection Menu consists of just one screen.
CURR. PROTECTION Current Protection, Screen 1

High Current
Shutdown Time High Current Shutdown Time Delay – This is the
Delay: 10 secs
time delay that the current draw must be above the
maximum current threshold before the PCC will
Adjust
fault on Overcurrent.
Now we are at the end of the Genset Setup – Current Protection Submenu.
Genset Setup – Engine Protection (4) see the Engine Protection Menu.
The Engine Protection submenus are where the

OVERSPEED technician would configure safeties for Engine
THRESHOLDS (60HZ)
20 : 1400 RPM Sensors. Data from the Engine Sensors are sent to
30 : 2075 RPM
60 : 4150 RPM
Adjust
the PCC control for monitoring. If the data from the
sensors becomes too far out of range, it may cross
one of these thresholds. This would cause the PCC
to enter a warning state or begin a shutdown
sequence.
133 7/9/2014 Cummins Confidential The Engine Protection Menu consists of 8 screens.
Notes:

Genset Setup – Eng. Protection Submenu, Screen 1
Genset Setup – Eng. Protection page 1, 2 • Overspeed Thresholds (50 Hz) – These trims
OVERSPEED
define the Overspeed Thresholds for a genset
THRESHOLDS (50HZ)
20 : 1150 RPM that has a nominal alternator frequency of 50
30 :
60 :
1725 RPM
3450 RPM Hz.
Adjust
OVERSPEED
THRESHOLDS (60HZ)
20 :
30 :
1400 RPM
2075 RPM Each threshold is associated with the RPM/Hz ratio
Adjust
60 : 4150 RPM
defined earlier. For a 50 Hz alternator that is
running at 1500 RPM (4-pole), the RPM/Hz ratio is
30. The threshold that the PCC would look at to fault
Next page on Overspeed would be the Overspeed threshold
defined at 30, not 20 or 60.

• Overspeed Thresholds (60 Hz) – These trims define the Overspeed Thresholds for a genset that has a
nominal alternator frequency of 60 Hz.
Each threshold is associated with the RPM/Hz ratio defined earlier. For a 60 Hz alternator that is running
at 1800 RPM (4-pole), the RPM/Hz ratio is 30. The threshold that the PCC would look at to fault on
Overspeed would be the Overspeed threshold defined at 30, not 20 or 60.
Genset Setup – Eng. Protection page 3, 4 • Speed/Frequency Fault Threshold – The PCC
ENG. PROTECTION
compares the engine speed (as determined
Speed/Freq Fault
Threshold: 2.0 Hz directly by the MPU) and the engine speed (as
Speed/Freq Fault
Time Delay: 1.5 s indirectly determined by the alternator
frequency).
Adjust
LOP SETUP
LOP Warning
Threshold: 40psi
LOP Warning If they do not match within this defined threshold,
the PCC will produce a Speed/Frequency mismatch
Time Delay: 5 sec
Adjust
fault. This sometimes means that either the MPU is

bad/incorrectly wired, or the flywheel teeth have
Next page been incorrectly inputted.
• Speed/Frequency Fault Time Delay – This is the
135 7/9/2014 Cummins Confidential time delay that the MPU speed and the
Alternator speed must be mismatched above
Speed/Freq Threshold before the PCC will fault
on Speed/Freq Mismatch.
• LOP Warning Threshold – This is a parameter that defines the Low Oil Pressure Warning Threshold. If
the oil pressure of the engine drops below this threshold, the PCC will produce a Low Oil Pressure
Warning.
• LOP Warning Time Delay – This is the time delay that the oil pressure must be below the LOP Warning
Threshold before the PCC will produce a LOP Warning.
Notes:


Genset Setup – Eng. Protection page 5, 6 • LOP Shutdown Threshold – This is a parameter
LOP SETUP
that defines the Low Oil Pressure Shutdown
LOP Shutdown
Threshold: 35psi Threshold. If the oil pressure of the engine
LOP Shutdown
Time Delay: 8 s drops below this threshold, the PCC will produce
a Low Oil Pressure Shutdown. This will cause the
Adjust
HCT SETUP
HCT Warning
Threshold: 208°F
HCT Warning generator set to shut down.
• LOP Shutdown Time Delay – This is the time
Time Delay: 2 sec
Adjust
delay that the oil pressure must be below the

LOP Shutdown Threshold before the PCC will
Next page produce a LOP Shutdown.

• HCT Warning Threshold – This is a parameter that defines the High Coolant Temperature Warning
Threshold. If the coolant temperature of the engine rises above this threshold, the PCC will produce a
High Coolant Temperature Warning.
• HCT Warning Time Delay – This is the time delay that the coolant temperature must be above the HCT
Warning Threshold before the PCC will produce a HCT Warning.
Genset Setup – Eng. Protection page 7, 8 • HCT Shutdown Threshold – This is a parameter
HCT SETUP
that defines the High Coolant Temperature
HCT Shutdown
Threshold: 215°F Shutdown Threshold. If the coolant temperature
HCT Shutdown
Time Delay: 2 s of the engine rises above this threshold, the PCC
will produce a High Coolant Temperature
Adjust
ENG. PROTECTION
LCT Warning
Threshold: 70°F
Charger Failed H Shutdown. This will cause the generator set to
shut down.
Threshold: 0.00V
Adjust
• HCT Shutdown Time Delay – This is the time

delay that the coolant temperature must be
Next page above the HCT Shutdown Threshold before the
PCC will produce a HCT Shutdown.

• LCT Warning Threshold – This is a parameter that defines the Low Coolant Temperature Warning
Threshold. If the coolant temperature of the engine falls below this threshold, the PCC will produce a
Low Coolant Temperature Warning.
Now we are at the end of the Setup Menus – Genset Setup Menus.
Press the “Previous Menu” pushbutton on the HMI and return to the all the way to the main Service
Menus
Notes:

History/About [2]
HISTORY By pressing (2) on the First Service Menu, you see

the History/About Submenus. The History/About
Starts: ###
Hours: ##.#
Control
Hours: ###.# submenu (unlike the previous “Genset Service” and
“Genset Setup” submenus) is read only.
Within the History/About submenu, you are able to view the following data:
• Number of Starts
• Control Hours
• Engine (run) Hours
• Model Number
• Serial Number
• Control Number
• kVA Rating
• Control Part number
• Software Part Number
• Software Version
• Display Part Number
• Display Software Version
• Screen Part number
• Screen Version
History/About - Screen 1
History/About page 1, 2 • Starts – This is a read-only parameter that tells
HISTORY
the operator the number of starts the generator
Starts:
Hours:
592
50.4 starts has made in its lifetime
Control
Hours: 347.5 • Hours – This is a read-only parameter that tells
the operator the amount of hours the generator
Adjust
ABOUT GENSET
Model Number:
Control : set’s engine has in its lifetime
Adjust • Control Hours – This is a read-only parameter
that tells the operator the amount of hours the
PowerCommand Control has been awake in its
Next page lifetime
• Model Number – This parameter tells the operator the model number of the generator set the
PowerCommand Control is controlling
• Control – This is a parameter that tells the operator the model number of the PCC itself

History/About page 3, 4
ABOUT GENSET
KVA (Standby) History/About - Screen 3
Rating: 25.0 kVA
• kVA (Standby) Rating – This is a read-only
parameter that tells you both what the
Adjust
ABOUT CONTROL
P/N:
S/N:
SW P/N: application of the generator set is (either prime
or standby) and what the kVA rating of the
SW Version:
Adjust
generator set is at that application
Next page
• P/N – This is the Part Number of the control board itself
• S/N – This is the Serial Number of that specific control board
• SW P/N – This is the Part number of the software calibration file that is actually loaded onto the
control
• SW Version – This is the Version Number of the software calibration file that is actually loaded onto
the control
These parameters will be helpful when getting help from factory service, as they will need to know what
version of the software you are running on the control.
History/About page 5 • SW P/N – This is the software part number that
is loaded onto the HMI that the
PowerCommand Control is using
• SCRNE Ver – This is the software version that is
loaded onto the HMI that the PowerCommand
Adjust
ABOUT DISPLAY
SW P/N: 3266811
SCRNE VER:
SCRN VER:
2.26
7.10 Control is using
• SCRN Ver – This is the hardware version of the
DISP DEVICE ID: 68
Adjust
HMI
• DISP DEVICE ID – This number is used by the
InPower Software tool in order to correctly
connect to the display.
These parameters will be helpful when getting help from factory service, as they will need to know what
version of the software you are running on the display.
Now we are at the end of the History/About Service Menu.
Press the “Previous Menu” pushbutton on the HMI to return to the main Service Menus
Notes:

By pressing (3) on the First Service Menu, you see
Screen Adjust [3] the Adjust Screen Submenu.
In this submenu, you are able to adjust the following

ADJUST parameters:
• Contrast and Brightness of the Display
SCREEN
Contrast
Brightness
Units: °F, PSI
Adjust
• Units (SAE or SI)

to return to the main Service Menus

Fault History [4] the Fault History Submenu.
In these submenus, you are able to view the

FAULT HISTORY following information
• The Hour # the fault occurred at
At: ###.# Hrs
Fault No: ####
XXXXXXX XX XXXX
XXXXX XXXXXXXX • The Fault Number associated
• Fault Description
The PCC 1302 control with HMI 211 displays the 5

most recent faults. If any of the faults are currently
“Active”, there would be an “Active Fault” Heading
instead of “Fault History”.

Status [5] the Status Submenu. The Status submenu is also
read only.
STATUS You can view the following data:

AVR DC: ##% • Voltage regulator Duty Cycle
• Governor regulator Duty Cycle
GOV DC: ##.##%

Notes:

By pressing (6) on the First Service Menu, you

Lamp Test [6] initiate a Lamp Test. During a Lamp Test, the six
LEDs on the control panel should light for as long as
the button is pressed.
Auto NOT IN AUTO
PowerCommand
SHUTDOWN

! WARNING
SERVICE MENU
4) Fault History REMOTE START

5) Status Auto AUTO
6) Lamp Test
) More Options MANUAL RUN
(4) (5) (6)

Network Status Menu [7] the Network Status Submenus. The Network Status
Submenus are also read only.
NETWORK STATUS These submenus tell you the quantity of the

following devices that are connected to the
AMF Modules : #
Annunciators: #
Bar Graph : #
Batt Charger: # network:
• Universal Annunciators
• Bar Graphs
• Battery Chargers
• Controls
• I/O modules
• Operator Panels
Notes:

Clock/Exerciser [8] the Clock/Exerciser Submenus.
In these submenus you can adjust the following

TIME SETUP parameters:
Date: ##:##:##
mm:dd:yy
• Date
Time: ##:## AM
Adjust
• Time
• Daylight Saving Time enable/disable and
minutes adjustment
• Daylight Saving Adjust start date
• Daylight Saving Adjust end date
• Exercise Scheduler enable/disable
147 7/9/2014 Cummins Confidential • Exercise Scheduler interval
• Exercise Scheduler time to exercise
• Exercise Duration
Power Command Controls have a Real Time Clock (RTC) function used for the automatic scheduler
(exercise scheduler) feature. Once the control is programmed and given a power cycle, the user should
enter the correct time, date and clock cycle (AM/PM). Based on the time and date saved by the user, the
real time clock accurately calculates seconds, minutes, hours, date of the month, month, day of the week,
and year with leap year compensation.
The clock operates in 12 hour format with support for AM/PM. The RTC also supports Daylight Savings
Time (DST), The DST logic adds the DST Adjustment time to the current time when the current time is
equal to the DST Start Time. The DST logic subtracts the DST Adjustment time from the current time when
the current time is equal to the DST End Time. To enable DST, the trim Daylight Savings Time Enable
needs to be set to Enabled.
The exercise scheduler is a feature that automatically starts the genset for exercise. This feature prevents
common problems which result from mechanical equipment being not in operation for long periods of
time. In order for the automatic exerciser to work, the control system needs to be in ‘Auto’ mode, the RTC
needs to be set, and the Exercise Scheduler Program needs to be set to Enable.
Notes:

Clock/Exerciser - Screen 1
Clock/Exerciser page 1, 2 • Date – Enter the current date
TIME SETUP
• Time – Enter the current time
Date: ##:##:## These two parameters together make up the Real
mm:dd:yy
Time: ##:## AM Time Clock. This clock is used for the exercise
scheduler feature.
Adjust
Daylight Saving
Adjust
Saving Time:
Enabled
Adjust: 60 mins
Adjust
• Daylight Saving Adjust – Set to “Enabled” if the

generator set is in an area that recognizes
Next page daylight savings time. Set to “Disable” if the
generator set does not recognize daylight
149 7/9/2014 Cummins Confidential savings time.
• Adjust – This is the amount of time the Real
Time Clock will “spring” forward and “fall” back.
Clock/Exerciser page 3, 4 • Adjust Start Date – Enter the date that daylight
Daylight Saving
savings time would begin. Enter the number of
Adjust Start
the month, week, day of the week, and hour
Mth
3
Wk Day Hr
3 Sun 2AM that daylight savings begins.
Adjust
Daylight Saving
Adjust End
Mth Wk Day Hr Clock/Exerciser - Screen 4
• Adjust End Date – Enter the date that daylight
11 3 Sun 2AM
Adjust
savings time would end. Enter the number of

the month, week, day of the week, and hour
Next page that daylight savings ends.
Notes:

Clock/Exerciser page 5, 6 • Exercise Scheduler Schedule Enable – Set to
Exercise Schdr
“Disable” if you do not want the automatic
Schdr Enable : Dis
exercise feature to run. Set to “Enable” to use
Excr: Monthly
Tue 02:00 PM the automatic exerciser feature.
• Exercise Period – This parameter is how often
Adjust
Exercise Schdr
Exercise
Duration: 30 MIN you’d like the exerciser to repeat itself. Select
Adjust Weekly, Bimonthly, Monthly, Quarterly, or
Semi-annually. It is recommended that your
generator set be run at least once a week in
order for proper lubrication of seals and
gaskets.
• Exercise Duration – Enter the length of time you would like the exercise period to run.
The PCC1302 can be programmed to run only 1 program, which is a repeating event. Furthermore, the
program can be programmed to exercise the genset at rated condition and at ‘No Load’ condition. No
exceptions can be set in PCC1302.
However, other PowerCommand Control types have the capabilities of running multiple different exercise
schedules with numerous exceptions to when it should/should not exercise.
Volt & Hertz Adjust [9] the Volt & Hertz Adjustment Submenu.
Previously, we discussed password protecting this

VOLT & HZ ADJUST Submenu. It will require the password if that option
Volts AC : 240
Hertz : 60
was selected.
Adjust
Displayed are two parameters, Volts AC and Hertz.

These will be the nominal voltage and frequency
that the PCC control is controlling to produce from
the alternator. If, however, the customer would like
slightly different power (slightly higher voltage or
152 7/9/2014 Cummins Confidential slightly lower frequency for example) that can be
adjusted here.
• Volts AC – Click adjust, use the + and – buttons to adjust to the desired frequency
• Hertz – Click adjust, use the + and – buttons to adjust to the desired frequency
Notes:

Activity 6-1
Skills Exercise
Configuration of PCC Control
Required Materials
Using the Setup Menus, configure the PowerCommand Control to the specific application and customer
requests below.
1. Adjust the PCC to have two 10 second crank attempts with 10 seconds of rest between them
before faulting out on fail to start.
2. Add a start delay of 2 seconds and a stop delay of 1 second
3. Configure Configurable Input #1 to shut down the genset when the circuit is closed at the
terminal block
4. Configure Configurable Output #1 to become active when Configurable Input #1 is active
5. Change the Low Battery fault threshold to 22 V
6. Change the Low Coolant Temperature Threshold to 100ºF
7. Set the real-time clock to the correct date and time, and set an exercise schedule to run every
Monday at 8:12AM for 15 minutes
Demonstrate to the instructor that all configurations have been successfully programmed and saved
into your simulator.


Lesson 7: Sequence of Operations

 Define start types, and associate modes of
operation
 Demonstrate knowledge of AVR circuitry
 Demonstrate knowledge of Electronic
Governor circuitry
 Follow start/run/AVR/Elect. Governor
circuits on wiring diagram
 Understand warning/shutdown protections
Dashboard
Component Interaction RPM VAC

Starter FSO Customer
Input Alternator
K1 K2
L1 L2 L3 N
Field AVR
PMG Amp
Gov.
Actuator
Amp
MPU
Engine
Sensors
and/or
ECM
HMI
Shown is the interaction between most of the components of a PCC Control.

In the center is the control board(s). Connected to the control are all of the subsystems of the control:
• Start and Fuel Shutoff Solenoids
• AVR circuitry
• Electronic Governor Output
• Speed Sense
• ECM
• Customer Inputs
• Voltage Sensing
• Current Sensing
• HMI
All of these subsystems work together to operate, control, and monitor the generator set as it provides
power to an electrical load.

There are additional subsystems as PowerCommand Controls grow in complexity such as Networks,
Paralleling, and Breaker Control but these are the fundamental subsystems for PCC control.
In the upper right hand corner is a “dashboard”. This is a representation of gauges for Engine Speed
(RPM) and Alternator Voltage (VAC). These gauges will help you follow through the sequence of
operation.
Next we will go through an entire starting and stopping sequence and highlight how the subsystems work
together. We will be highlighting and colorizing this visual as subsystems are added to the running system.
Dashboard
The first step of the start sequence is to select which
Stop/Manual/Auto Mode RPM VAC
mode the generator set control is in. This will
Starter FSO Customer change how the generator set will start.
K1 K2
Input Alternator With the HMI, the operator selects Stop, Manual, or
L1 L2 L3 N Auto. The HMI takes operator input and transmits
Field AVR this information to the control. The control then
PMG Amp
accepts this information, and returns information to
Gov. the HMI.
• Off Mode
Actuator
Amp
• Man Mode
MPU
Engine
Sensors
and/or • Auto Mode
ECM
HMI
In Off Mode, the generator cannot be started. The HMI will display the Red “Not in Auto” LED, since the
PCC is not in Auto Mode.
In Man Mode, the generator is waiting for a Manual Run signal. This manual run signal must come from
the operator. The HMI will display the Red “Not in Auto” LED, since the PCC is not in Auto Mode.
In Auto Mode, the generator is waiting for a Remote Start signal. This remote start signal is usually comes
from the customer’s equipment that would be starting the generator set automatically, such as a Building
Management System or Automatic Transfer Switch. The HMI will not display the Red “Not in Auto” LED,
but will display the Green “Auto” LED, since the PCC is in Auto Mode.
Remember that all of the decision making of which LEDs to display is being made by the PCC control
board, not the HMI. The HMI is simply the operator’s window into the control.
Notes:

Additionally, the operator can select many different

Start Types types of start sequences.
 Auto
– Emergency
– Non-Emergency
Manual Rated
 Manual
In this mode, the operator him/herself puts the
– Rated generator set into Manual Mode and selects Manual
– Idle Run. The genset goes through its normal starting
sequence and ramps up to rated speed without any
time delays.
Manual Idle
In this mode, the operator him/herself puts the generator set into Manual Mode and selects Manual Run.
The genset starts but only ramps up to idle speed in order to warm up. After the idle period is over, or
after the operator selects rated speed, the generator set will then ramp up to rated speed.
Automatic Emergency
In this mode, the PCC control is left in Auto, and receives a remote start signal. The generator set then
begins its normal starting sequence and ramps up to rated speed as soon as possible to assume an
electrical load immediately.
Automatic Non-Emergency.
In this mode, the PCC control is left in Auto, and receives a remote start signal. The generator set begins
its normal starting sequence, however there may be several time delays, including running at idle to warm
up before assuming load.
Notes:

Dashboard
Start Signal Input RPM VAC

Input Alternator
K1 K2
(Remote Start)
L1 L2 L3 N With the mode selection and start type selection
Field AVR complete, the next step in the sequence of
PMG Amp
operations is to actually send the PCC control a start
Gov. signal. The type of start signal depends on the mode
of the PCC control.
Actuator
Amp
MPU (Manual Run,
Engine LED signals)
Sensors
and/or
ECM
HMI
Auto Mode Start Input

When the PCC is in Auto Mode, the generator set can only be started by the remote start input. This
remote start input typically comes from the customer from a Building Management System or an
Automatic Transfer Switch. The type of start input is dependent on the type of PowerCommand Control.
The PCC 1302, for example, needs a dry contact input. However, some of the older PCCs require a ground
or a B+ start signal. When the start signal is made, the PCC begins the automatic start sequence.
When the Remote Start input is active, the Green “Remote Start” LED is enabled.
Manual Mode Start Input

When the PCC is in Manual Mode, the generator set can only be started locally through the HMI. Any
active remote start signal that may be present will be ignored, and the generator set will not begin to
start. However, even though the generator set is in Manual Mode, if a Remote Start signal is present, the
green “Remote Start” LED will be lit on the HMI. To start a generator set in Manual Mode, the operator
must select “Manual Run” from the HMI. Some PCCs may have a “Manual Run” hard pushbutton; others
may have a soft pushbutton that represents Manual Run mode.
Notes:

Dashboard
Time Delay Start/Preheat RPM VAC

K1 K2
Input Alternator Once the start signal has been received, the PCC
L1 L2 L3 N may not begin physically cranking the engine
Field AVR because of some pre-start timers.
PMG Amp
Gov. Start Time Delay

Configurable for time delay of 0-300 seconds prior
Actuator
Amp
to starting after receiving a remote start signal.

MPU
Engine
Sensors
and/or Default for time delay period is 0.
ECM
HMI
Preheat
Another pre-start timer can be used on some smaller diesel powered generator sets that employ Glow
plugs. Glow plug is used as a Cold starting aid. Glow plugs heat up the air going in for combustion for
Diesel Engine. Glow plugs are used to improve the starting ability of engines and to reduce the white
smoke during cold start. The Preheat timer will enable the glow plugs for a configurable amount of time
before the engine starts cranking.
Dashboard
When the pre-start timers have been exhausted, the
Start Relay Output RPM VAC
PCC control is ready to begin cranking the engine.
To do this, it activates the Start Relay output.
Input Alternator
K1 K2
L1 L2 L3 N This will enable the start relay, which sends battery

Field AVR power to the starter and start solenoid. The start
PMG Amp
solenoid engages the starter motor into the
Gov. flywheel teeth of the engine’s flywheel, and the
engine begins to crank.
Actuator
Amp
MPU
Engine
Sensors
and/or
ECM
HMI
Notes:

Dashboard
Once the starter is engaged and begins cranking the
Engine Speed Sensing RPM VAC
engine, the Mag Pickup begins sending RPM signals
to the PCC (or the ECM). If the engine has an ECM,
K1 K2
Input Alternator the ECM may be sending the speed data to the PCC
L1 L2 L3 N over data link.
Field AVR
PMG Amp
If the PCC sends out a start signal and does not
Gov. receive RPM signal in return, the PCC will fault out
on Fail to Crank because it did not receive the
Actuator
Amp
proper feedback.
MPU
Engine
Sensors
and/or
ECM
HMI
Dashboard
Once the PCC senses that the engine is cranking, it
Run Signal RPM VAC
will reach a speed to begin fueling. The PCC will
enable the Run output, which will activate the Run
K1 K2
Input Alternator relay.
L1 L2 L3 N
Field AVR This relay will send battery power to the Fuel
PMG Amp
Shutoff Valve, which opens and sends fuel to the
Gov. intake of the fuel system.
Actuator
Amp
MPU
Engine
Sensors
or
ECM
HMI
Notes:

If the engine does not begin to run, the PCC will not
Cycle Cranking just keep cranking and fueling until the battery is
Crank Cycles
dead. The Power Command has parameters built in
to control the starting. One of these is called Cycle
Cranking.
RPM
The PCC defines the number of starting cycles, and

duration of crank and rest periods. The number of
cycles is configurable – for the PCC 1302, select 1-7
time
crank cycles. The crank and rest periods are
Crank Period
Rest Period
configured in seconds.
A typical configuration will be 3 crank cycles, with a crank period of 15 seconds, and rest period of 15
seconds. Control includes starter protection algorithms to prevent the operator from specifying a starting
sequence that might be damaging.
If the engine does not begin to run within 15 seconds of cranking/fueling, the control will disengage the
crank/run outputs and rest for 15 seconds. The sequence will repeat until the engine starts or the crank
periods have been exhausted.
The fuel from the FSO will eventually need to be
Initial Fueling controlled by an electronic governor. Either the PCC
or the ECM will control the electronic governor with
Governor Enable
Speed is Reached
Crank
DC
pulse width signals.
Ramp Rate
Governor
PID Loop
Fueling will be initially set to the Initial Crank Fueling
Governor Duty Cycle
Duty Cycle value and will remain at that value for

the Initial Crank Fueling Period.
Exit DC
Initial After this period expires, the fuel command will be

DC
ramped at the Crank Fueling Ramp Rate until the
Time Maximum Crank Fueling limit is reached. Upon
163 7/9/2014 Cummins Confidential reaching the Starter Disconnect Speed, the fueling
command is pulled back to the Crank Exit Fueling
Duty Cycle value until the Governor Enable Engine
Speed is reached.
When the Governor Enable Engine Speed is reached the governor is enabled, the speed setpoint is set to
the sensed engine speed value at this point, and the setpoint ramped to rated speed in a time equal to
the Governor Ramp Time.
Notes:

The PCC or the ECM controls the fuel rate by using a
Pulse Width governor actuator. This is basically an electronically
Pulses
controlled, normally closed valve.
When the PCC sends a DC voltage to the governor

actuator, the valve opens allowing fuel to pass to
V DC
the intake. When the DC voltage goes away, a spring

force closes the valve.
time
Time On Time Off
Duty Cycle % = Time On/(Time On + Time Off)

By pulsing the DC signal off and on very rapidly, the PCC or ECM can control the fuel rate very closely,
since the short pulses of DC power trying to open the valve will balance the spring force trying to close the
valve.
The more time “On” the valve is in relation to the time “Off”, the farther open the valve will remain, and
more fuel will enter the intake.
The ratio of time ON to total time is called the Duty Cycle, and it is represented as a percentage value.
For example, if the governor duty cycle is 56%, that means that the time On in relation to the time
ON+OFF = 56%.
Primary Start Disconnect is a configurable
Start Disconnect parameter that defines the first way that the PCC
control will disengage the starter. This is usually
 Primary Start Disconnect (Engine Inputs)
from an input that senses engine speed directly
 Secondary Start Disconnect (Alternator Inputs)
from the engine.
It is at this speed that the PCC will determine that

the engine has begun to run on its own, and will
deactivate the start relay, which will disengage the
starter motor from the flywheel. The magnetic
pickup, which counts the flywheel teeth as the
engine is turning is often used as the primary start
165 9/11/2014 Cummins Confidential disconnect input.
Secondary Start Disconnect is another parameter that offers a backup start disconnect input if the first
start disconnect isn’t recognized. This will often use inputs that represent the speed of the engine but do
not actually measure RPM. Such inputs can include the main alternator frequency.
Notes:

Dashboard
When the PCC enables the Run relay output, the
Start Disconnect Inputs RPM VAC
engine should fire and begin speeding up. At some
point, the starter is no longer needed. At a certain
K1 K2
Input Alternator point, the PCC will disable the Start output, and the
L1 L2 L3 N engine will be running on fuel/air/ignition alone.
Field AVR
PMG Amp
This point is known as the start disconnect speed.
Gov. The PCC can use a number of inputs to determine
start disconnect, and will employ other inputs as
Actuator
Amp
backups as a secondary start disconnect input.

MPU
Engine
Sensors
and/or The primary is usually engine speed. This is usually
ECM
from the MPU input, or the ECM engine speed over
166 7/9/2014 Cummins Confidential the data link.
Secondary start disconnects come from other speed associated inputs:
• Alternator Voltage
• Alternator Frequency
• Field/PMG Voltage
Even though the PCC is not “trying” to create voltage yet since the generator is not quite yet running, just
the physics of spinning a rotor inside of a stator will develop residual voltage.
Once the primary or secondary start disconnect speeds have been reached, the PCC disables the start
relay output, and the starter solenoid will disengage the starter from the flywheel teeth.
Dashboard
As the engine ramps up to speed during the Initial
Governor Enable RPM VAC
fueling stage, where the PCC isn’t necessarily
controlling the governor output, just ramping up
K1 K2
Input Alternator fueling, the engine speed will reach a point where
L1 L2 L3 N the Governor Algorithm kicks in.
Field AVR
PMG Amp
When the Governor Enable Engine Speed is reached
Gov. the governor is enabled, the speed setpoint is set to
the sensed engine speed value at this point, and the
Actuator
Amp
setpoint ramped to rated speed in a time equal to

MPU
Engine
Sensors
the Governor Ramp Time.
ECM
The governor ramp time is the time between the engine reaching Governor Enable Engine Speed and
rated (nominal) engine speed. This is a configurable setpoint.
The governor control algorithm was discussed earlier. The governor control feature of the PCC uses a
closed loop PID control algorithm, and allows field tuning of the coefficients. These Coefficients determine
how fast/aggressive the governor will react to changes in engine speed.
Notes:

The PCC uses the input from the Magnetic Pickup to sense engine speed, and compares this to the
nominal speed setpoint. Any difference between the actual engine speed and the nominal setpoint will
result in a change of the pulse width signal to the governor actuator. This algorithm is constantly adjusting
the PWM signal in order to maintain engine speed.
The output signals from the PCC will usually have to go through some an amplifier. This is because the
PCC control board does not have the current capacity to operate the governor actuator. The PWM signal
is sent to the governor amplifier, which amplifies the signal (or in some cases operates like a “gate” to
mimic a typical PWM signal) to operate the governor actuator.
Dashboard
Once the engine is running at rated speed, the
Field Enable RPM VAC
Automatic Voltage Regulator (AVR) feature of the
PCC will also bring the alternator voltage up to
K1 K2
Input Alternator rated. This process is similar (and in most cases
Voltage Sensing
L1 L2 L3 N happening simultaneously) to the engine governor
Field AVR control.
PMG Amp Enable
Gov.
Actuator
Amp
MPU
Engine
Sensors
or
ECM
The PWM command to the field coil will be stepped through an AVR Boot Table until the sensed voltage
goes above the value of the AVR Boot Threshold trim and if AVR feature is enabled.
The purpose of the AVR Boot Table is to aid alternator startup whilst preventing overvoltage conditions.
The value of the AVR Boot Table and the AVR Boot Threshold can be set to bring the voltage up both as
quickly and as smoothly as possible, but should already be set in the calibration to their ideal values. The
AVR Boot Table has different values depending on value of the Excitation Source trim.
Essentially, as the alternator is starting up, the excitation is controlled not by an algorithm but by a look
up table.
Notes:

Dashboard
When the AVR startup has been reached, the
Automatic Voltage Regulation RPM VAC
voltage regulation is turned over to the Automatic
Voltage Regulation algorithm of the PCC 1302.
Input Alternator
K1 K2
Voltage Sensing
L1 L2 L3 N The Automatic Voltage Regulation feature of the
Field AVR PCC uses a closed loop PID control algorithm, and
PMG Amp Control allows field tuning of the coefficients. These
Gov. Coefficients determine how fast/aggressive the AVR
will react to changes in output voltage. The PCC
Actuator
Amp
senses the voltage of the alternator output, and

MPU
Engine
Sensors
or compares this to the nominal voltage setpoint. Any
ECM
difference between the actual output voltage and
169 7/9/2014 Cummins Confidential the nominal setpoint will result in a change of the
pulse width signal to the field. This algorithm is
constantly adjusting the signal in order to maintain
proper alternator voltage under varying load
conditions.
Notes:

Dashboard
Alternator Protection RPM VAC
the PowerCommand Control to protect the
alternator from conditions that may be harmful.
Input Alternator
K1 K2
L1 L2 L3 N These conditions can arise from a number of

Field AVR different causes, such as electrical overloading and
PMG Amp
short circuits.
Gov.
Because these conditions can be very damaging to
Actuator
Amp
the alternator, and often affect the power output to

MPU
Engine
Sensors
or the customer, these alternator protection faults are
ECM
often shutdown faults.
In some types of PowerCommand Controls, however, just because they are shutdown faults does not
mean that the generator set has to “shut down” immediately. Often, in order to both protect the
alternator and the engine, the PCC will actually open the electrically controlled breaker and allow the
engine to cool down under no load conditions. This prevents damage to the engine and the alternator.
The PCC 1302 has no breaker control, however and will simply shut down immediately.
Here are some examples of Alternator Protection Faults:

High / Low AC Voltage Shutdown - High voltage default to 110% of the rated voltage for 10 seconds time
delays and instantaneous voltage default to 130% of the rated voltage. Low AC voltage default to 85% of
the rated voltage for 10 seconds time delays.
Over current Warning/Shutdown – Shutdown set to be below alternator damage curve up until maximal
measureable point. Currents above the maximal measureable point shutdown after the HCT Shutdown
Time Delay. Warning level set to half of the shutdown threshold.
Under/Over Frequency - Under frequency default to - 6Hz of the 50 Hz / 60 Hz frequency for 10 seconds
time delays. Over frequency default to + 6Hz of the 50 Hz / 60 Hz frequency for 10 seconds time delays.
Loss Of Sensing AC Voltage Shutdown – Loss of sensing AC voltage detects the loss of voltage sensing or
senses the loss of zero crosses. This fault will also be the primary way to detect short circuit conditions.
Overexcitation Shutdown – Overexcitation is used to detect short circuit alternator faults.

Notes:

Dashboard
Engine Protection RPM VAC
the PowerCommand Control to protect the engine
from conditions that may be harmful. These
K1 K2
Input Alternator conditions may just be warnings to the operator
L1 L2 L3 N that some operating conditions are outside of an
Field AVR acceptable threshold and maintenance/repairs must
PMG Amp
be done to mitigate them. Others may be more
Gov. urgent, and will force a shutdown of the generator
set altogether.
Actuator
Amp
MPU
Engine
Sensors
or Here are some examples of Engine Protection
ECM
Faults:
Over Speed Shutdown – Engine Over Speed default setting is 115% of the rated engine speed nominal.
Control includes time delays to prevent nuisance shutdown signals.
Low Lube Oil Pressure Warning/Shutdown - Level is preset (configurable with a PC based service tool) to
match the capabilities of the engine used. Control includes time delays to prevent nuisance
High Engine Temperature Warning/Shutdown - Level is preset (configurable with PC based service tool)
to match the capabilities of the engine used. Control includes time delays to prevent nuisance
Low Coolant Temperature Warning - Indicates that engine temperature may not be high enough for a 10-
second start or proper load pickup. Level is preset (configurable with a PC based service tool) to match
the capabilities of the engine used. Control includes time delays to prevent nuisance warning signals.
Low Battery Voltage Warning - Indicates battery charging system failure by continuously monitoring
battery voltage. Control includes time delays to prevent nuisance warning signals.
High Battery Voltage Warning – Indicates battery charging system is of higher level by continuously
monitoring battery voltage. Control includes time delays to prevent nuisance warning signals.
Weak Battery Voltage Warning - Control system will test the battery bank each time the generator set is
signaled to start, and indicate a warning if the generator set battery indicates impending failure. Control
includes time delays to prevent nuisance warning signals.
Fail to Start (Overcrank) Shutdown. – Control system runs out of crank cycles before the engine starts.
Fail to Crank Shutdown - Control has signaled starter to crank the engine but engine does not rotate.
Cranking Lockout - The control will not allow the starter to attempt to engage or to crank the engine
when the engine is rotating (when control senses the valid engine RPM above the noise threshold value.)
Sensor Failure Indication – Out of range high / low diagnostic logic is provided on the base control to
detect analog sensor or interconnecting wiring failures.

Dashboard
We have learned that the PCC must protect the
Additional Protection RPM VAC
generator set, and it must also interact with
Starter FSO Customer customer’s systems. So the PCC must also react to
K1 K2
Input
(Customer Faults)
Alternator customer’s faults on the site and enter warning or
L1 L2 L3 N shutdown states as configured.
Field AVR
PMG Amp
Configurable Input – A customer may configure the
Gov. generator set to shut down on a number of
conditions such as Low Fuel Level or an access door
Actuator
Amp
being opened.
MPU
Engine
Sensors
or
ECM
Dashboard
In addition to the protection shut downs, the
Stop Signal Input RPM VAC
generator set will eventually need to shut down
Starter FSO Customer naturally. Shutting the genset down can be done in
K1 K2
Input
(Remote Start
Alternator multiple ways, depending on the start type.
Remote E-Stop) L1 L2 L3 N
Field AVR Local Emergency Stop

PMG Amp Control At any time in the starting and running sequence,
Gov. the operator can hit the emergency stop button and
immediately shut down the genset.
Actuator
Amp
Remote Emergency Stop

MPU (Manual Stop,
Engine Local E-Stop)
Sensors
or The remote emergency stop input is essentially in
ECM
series with the Local Emergency stop. Either will
173 7/9/2014
HMI
Cummins Confidential immediately shut down the genset (and both must
be reset to restart).
Remote Start
There isn’t exactly a remote stop command, but the lack of a remote start command will initiate the
shutdown sequence of a PowerCommand Control started in Auto.
Manual Stop
Pressing the manual stop button on the HMI or Operator panel will initiate the shutdown sequence of a
PowerCommand Control started in either Auto or Manual.
It should be noted that if the generator set is shut down properly in Auto Mode (that is, the remote start
command is removed), the PCC will remain in Auto Mode. If the generator set is shut down by an
Emergency Stop, or by a Manual Stop command, the generator set will shut down and enter Off Mode.
Notes:

Dashboard
Similar to the Time Delay Start, there is a
Time Delay Stop RPM VAC
configurable time delay for a stop command before
Starter FSO Customer the PCC will initiate a shutdown sequence. This time
K1 K2
Input Alternator delay is configurable between 0 and 600 seconds
L1 L2 L3 N (default is 0).
Field AVR
PMG Amp Control Time Delay to Stop does not apply to Emergency
Gov. Stops! Emergency Stops, remote and local, will shut
down the generator set immediately.
Actuator
Amp
MPU
Engine
Sensors
or
ECM
HMI
Dashboard
In some types of PowerCommand Controls there are
Cooldown Procedures RPM VAC
built in cool-down procedures that can either be
configured, or are built in with algorithms.
Input Alternator
K1 K2
L1 L2 L3 N When the Time Delay Stop timer is exhausted, the

Field AVR PCC opens the main breaker (if applicable) and stops
PMG Amp
excitation through the AVR feature. This leaves the
Gov. engine to run at rated speed without load for a
period of time.
Actuator
Amp
MPU
Engine
Sensors
or In some types of PowerCommand Controls the time
ECM
running at rated is determined by an algorithm that
175 7/9/2014 Cummins Confidential monitors the load profile over the last several
minutes of operation.
The PCC will use that data to determine how long the engine should run at rated speed. Next, the PCC
may bring the engine speed down to idle speed for a period of time as well. Again, some types of
PowerCommand Controls have configurable parameters for this length of time, but some use an
algorithm to determine the amount of time spent cooling at idle. Once the engine has cooled down, the
genset will finally shut down.
There are some types of PowerCommand Controls, however, that do not have this built in functionality
and when the Time Delay to Stop timer runs out, the generator set is put in Off Mode and shuts down
immediately.
Notes:

Dashboard
Shut Down RPM VAC

In Manual Mode, the shutdown is initiated when the
K1 K2
Input Alternator generator set is put into Off Mode.
L1 L2 L3 N
Field AVR In Auto Mode, the shutdown is initiated when the

PMG Amp
remote start contacts are opened.
Gov.
In a shutdown, a number of things happen to shut
Actuator
Amp
down the generator set.

MPU
Engine
Sensors
or
ECM
Depending on the type of PowerCommand Control and its application, there may be more or less, but
fundamentally to shut down a genset:
• The PCC control will disable the Governor Actuator by stopping sending PWM signals to the
Governor Output Module. This will cut fuel off from the engine.
• The PCC control will disable the FSO valve which will stop any more fuel from entering the system.
• The PCC control will disable excitation to the AVR feature
Once shut down, the generator set will remain in “Off” mode if it was shut down with a Manual Off
command. If the generator was stopped in Auto Mode by removing the remote start commands, it will
remain in Auto Mode.
Notes:

Activity 7-1
Skills Exercise
Sequence of Operations Discovery
Required Materials
• PC 1.1 Simulator Kit or running generator set
Instructions:
1. Safely disable a component (listed) of either your generator set simulator or running generator
set.
2. Attempt to start the simulator or generator set either manally or automatically
3. Observe what happens, and answer the questions below about each start attempt
Component: Magnetic Pickup

1. Did the generator set crank?
2. Did the generator set start?
3. Describe the LEDs and fault condition on the HMI (if applicable)
4. Why did the generator set not start correctly?
Component: Voltage Sensing


Component: AVR Field Output
Component: AVR Power

Component: Start Relay


Component: Run Relay

Component: Remote Emergency Stop



Lesson 8: InPower Service Tool

 Connect to a PCC with InPower
 Take/send/overlay a capture file
 Perform Initial/Update calibration
 Create monitor and strip chart
 Configure and save parameters
Cummins has several different versions of InPower
Types of InPower available, each with specific uses and applications.
InPower ONAN
For Consumer Controls Customers only. InPower
Onan cannot be used to connect to commercial
PowerCommand genset controls.
InPower Lite
InPower Lite has the ability to connect to all
InPower capable devices and do everything that
InPower Pro can do, except for initial calibration or
update calibration of devices.
InPower Pro
InPower Pro has the capacity to connect to all InPower capable devices, and has full authority to perform
initial calibration and update calibration of devices.
Note that previously, InPower ATS was produced for Wingoal (a Cummins Automatic Transfer Switch
OEM), but that product has since been discontinued.
InPower is used in both commercial and consumer
Devices Supported Cummins products. The following devices are
capable of being calibrated/adjusted via InPower.
InPower Pro has the capacity to connect to all these
devices while the other versions may only be able to
connect to a restricted set of these devices.
Notes:

InPower has some very useful functions that enable
Capabilities technicians to make changes/adjustments to
Cummins equipment very easily.
Adjustments
The main function of InPower is to adjust all of the
parameters of a connected device. Many of these
parameters are the same as were configured using
the service menus of the genset controller, however
there may be additional parameters that are only
able to be adjusted using InPower.
Capture Files
Another useful function of InPower enables the user to take a snapshot of the genset controller’s existing
parameter values loaded to a piece of equipment. This is saved as a local .cap(ture) file located on the
user’s computer. This file can be used to back up a configuration of a genset controller and can later be
uploaded back onto the genset controller to restore to original configuration.
Strip Chart and Monitor Feature

InPower can also be used as a troubleshooting tool, enabling users to gather data on the performance of
equipment in both a visual and time dependent manner. This data can be displayed as a real-time graph
in a Strip Chart (shown) or in a pure data log using the Monitor Feature.
Initial/Update Calibration
InPower Pro can be used to download a calibration file into a service replacement genset control board. A
capture file can be used at the time of initial calibration to reduce the amount of adjustment that may be
required when replacing the control board.
Notes:

To connect to older PowerCommand commercial

Connections – RS232 genset controls such as the PCC 3200/3201 and the
PCC 2100, you will need to connect a serial null
modem cable. This cable uses a DB9 connection; if
RS232
RS232
your computer does not have a DB9 (serial) port,

you will need to use a Serial to USB adapter.
RS232
One end of the cable plugs into the RS232 DB9 port
brainbox
on the control board, the other end of the cable

To PC
plugs into the Serial port on your computer, or into

a Serial to USB adapter.
There is an adapter available on the hardware shelf, the Brainbox US-101. When plugged into the USB slot
on your computer, the brainbox automatically installs a driver which assigns a COM port number to the
brain box.
This will essentially create a virtual COM port, and the number will be retained in between uses. For
example, when you plug your brainbox into a USB port for the first time and it assigns itself as COM port
06, each time you plug that USB onto that machine, it will always display as COM06. However, if you were
to plug a different brainbox into your computer, it would assign a different number.
To connect to newer generation of PowerCommand
Connections – RS485 commercial genset controls such as the PC1.X, 2.X,
or 3.X, you will need a Cummins RS485 connection
cable. This cable has a 5 pin terminal block at one
RS485
end, and a DB9 connection at the other end.
The terminal block end plugs into the RS484

RS485
RS232
RS232
terminal block port on the control board. This will

brainbox
allow data to travel on the cable. The other end of

To PC
the cable, the DB9 connection, must be plugged into

a RS232 – RS485 converter.
This will allow the computer (which uses RS232) to interact w/ the control board (which uses RS485).
Again, if your computer does not have a serial port, a USB to Serial adapter must be used.
Note that some controls may have both a RS232 port and a RS485 port. You may use either to connect to
those controls. It should be noted, however, that the control can only be calibrated from the RS485 port
on these controls.
Notes:

Often, controls are networked with other controls
Remove Existing Network and management systems in order to remotely
monitor or operate the generator set. Networks
could be used on either the RS232 or RS485 ports
RS485
InPower Cable
on the control boards.
In order for InPower to interact with the control

board, all existing networking cables must be
removed.
Existing Network Cable
You should always get permission from the

customer to remove existing network connections.
The Setup Application is used to configure InPower.

Setup Application
Important Note! Make sure that you do not open
the Setup Application while InPower is open.
Opening the two at the same time can cause file
corruption of the programs which could result in not
being able to open InPower Pro.
Within the Setup Application there are four tabs:

• Unit of Measurement
• User Setup
• Site Setup
184 7/9/2014 Cummins Confidential • Communications
Notes:

The Unit of Measurement tab in the Setup

Setup – Units of Measurement application allows the user to select which System
of Measurement InPower will display.
From the dropdown menu select either the United

States system or the Metric system.
Setup – User Setup The User Setup tab in the Setup application allows
the user to set separate users for the InPower
program.
New users can be added by clicking the “Add User”

button. Users can be deleted by clicking the
“Remove User” button.
Select the privilege level of the User to be Read

Only, Read/Write, or Administrator.
• Read Only users can connect to a device and read all parameter settings, fault information and history
records.
• Read/Write Users have full use of all InPower features, including making adjustments.
• Administrator Users have full use of all InPower features and the ability to establish and maintain user
privileges for all users on this computer.
This tab also allows you to select your Capture File Options. We will discuss more about what a capture
file is shortly. Select the button to Save a Capture File as soon as connected to a controller, and whether
or not you would like the program to ask before saving a capture file.
Notes:

The Site Setup tab in the Setup application allows
Setup – Site Setup the user to add additional Sits to the Left Pane of
the main InPower window, as well as manage
existing sites. To add a Site, click the “Add” button.
To remove an existing Site, click the “Remove”
button.
Selecting a site from the Site List enables the edit

feature, allowing modifications to some item
properties. When a site is selected, the site’s
protocol and COM port can be edited; also the
Device Setup button becomes active.
The “Protocol” drop down menu allows the user to select which protocol InPower will use to
communicate with the control. There are several selections, but generally for legacy controls (2100, 3201,
etc.) select “goal” as the protocol and for newer generation controls (1.X, 2.X, 3.X, etc.) select “mon” as
the protocol.
The “Location” dropdown menu allows the user to select how the connection will be made. Select Local
for a direct connection from the PC to the control with an InPower cable.
Click the “Device Setup” button to edit the Device ID, Device Name, and the Device Type.
New Sites need to be created for each type of controller you will be connecting with.
The Communications tab in the Setup application
Setup - Communications allows the user to edit the Communications settings
of InPower.
If you are only using InPower with the normal

InPower cabling to connect to the controls, you will
not need to edit this tab.
Notes:

InPower Pro V10.0 Window

Menu Bar Tool Bar
Left Window Right Window

Pane Pane
This is a typical window of the InPower Pro V10.0 electronic service tool. This window is used to connect
to different power generation devices, make configuration changes, save changes either to your
computer or to the device itself, etc.
The InPower Pro V10.0 window has four main areas:

• Menu Bar
• Tool Bar
• Left Window Pane
• Right Window Pane
The Menu bar is a set of drop down lists which contain all of the different tools and secondary
applications used to configure or update an InPower supported power generation device.
The Tool bar is a set of buttons of commonly used tools. All of these tools can be found in the menu bar as
well.
The Left window pane is used to navigate the different sites already configured in InPower, as well as
navigate the menu structure of a connected device.
The Right window pane is used to navigate the menu structure of a connected device (or capture file),
read the current settings of selected parameters, as well as actually change the configuration of each
writeable parameter.
Notes:

Menu Bar
The Menu bar is a set of drop down lists which

contain all of the different tools and secondary
applications used to configure or update an InPower
supported power generation device.
Port
The Port dropdown menu allows users to connect add a site, Connect/Disconnect from a port, add a site,
find InCal (needed for initial or update calibrations), and exit the program. InPower uses the term port to
refer to a COM port or .cap(ture) file or simulator file. A COM port is the physical connection between the
computer and the InPower supported device. For commercial PowerCommand genset controls, this
connection is made with either a Serial null modem cable or a RS-485 connection cable depending on
which device is being connected.
Device
The Device dropdown menu allows users to connect to and disconnect devices from a device. InPower
uses the term device when referring to the actual genset controller you are attempting to connect to
(through the port). It also allows users to perform read/write such as Saving Adjustments to the controller
after configuration. The device’s parameters can be captured (saved) to a file from this menu as well.
The Device menu can also be used to clear all inactive faults on the device, and create a Comma
Separated Value (CSV) file with All Selected Features of the device’s settings.
When connected to a device with InPower Pro, the user can select Initial Calibration, Update Calibration,
and Update Features as well.
Edit
The edit menu works within the directory of the connected device’s settings and parameters to Find a
specified string of data. The Edit menu can also be used Copy and Paste selected data.
Utilities
This menu is used to download simulator files from an InCal CD. When Universal Simulator Download is
selected, a pop-up menu is displayed allowing you to set the COM port and baud rate. If the InCal CD is
inserted in your local drive, you can navigate to the simulator files(s) you wish to download and then click
on Download.
Simulator files are useful to compare with to look at typical settings in a device. When a user connects to
a simulated device InPower outputs responses and setting you will expect from a certain device.
Notes:

View
This menu is used to view data from the connected device in a Monitor display or Strip Chart display. The
View menu can also be used to access the FIS Fault Tree Main Window, view faults and refresh(update) all
of the parameters displayed in the Value field.
Help
This menu commands are used to find online information about using InPower and Windows. Help is also
used to display Service and Support information and to obtain InPower product and version information.
A separate Help file contains information on consumer device fault codes for marine and RV products.
The menu also allows the user to launch the registration program.
Before any connection is made to a device through a
Left Window Pane – Sites/Menus port of your computer, the left window pane of the
InPower window displays all of the configured Sites
that have been added. These sites are preconfigured
with the port and type of control to be connected.
This sets the protocol that InPower will use when
connecting to a control.
Once connected to a control, the Left window pane

will expand into a menu tree that will display all of
the parameters and features that can be monitored
Before connection After connection or configured using InPower.
Notes:

Another way to add a new Site is to click on “Add
Adding a Site Site” from the “Port” drop down menu. This will pop
up the Add Site window.
From the scrollable menu, select the type of control

that you would like to add.
Select the radio button either “Local” or “Remote”.

A Local connection is one where you are using
actual InPower cables to connect to the control. A
Remote connection is a connection over a network.
In the “Properties” section, enter the COM port number, and enter a Site ID. You can click the blue link in
order to display what COM ports are available. If your brainbox is already plugged in and installed
correctly, the assigned COM port should display.
Click “OK” when finished, the new Site will display in the Left Window Pane.
Note that for each family of controls, you should only have to do this once. Once you have established a
Site for a PCC 1302 control board, through the correct COM port number, you can connect to every PCC
1302 without having to add a new site for each control.
Notes:

Tool Bar
Port Connect Refresh Exit
Faults Monitor Help
Port Disconnect Strip Chart Save Adjustments
Fault Information Systems InCal Extractor
The InPower toolbar has a collection of most frequently used commands that help the user do actions at
the click of a button. Buttons may be added/removed or grayed out of selection, dependent on which
area you are within InPower.
Port Connect Monitor
Connect to a COM port, capture file, or simulator. Allows you to build an excel spread sheet with
parameters for performance testing and diagnostics.
Port Disconnect
Disconnect from a COM port, capture file, or InCal Extractor
simulator. Allows the user to extract new calibrations
downloaded from the InCal website (if available).
Faults
View Faults within a connected device. Save Adjustments
Allows you to save parameter values after editing.
Fault Information Systems
Allows you to see a troubleshooting tree (if Exit
applicable) for specific faults. Exit out of the InPower program.
Refresh Help
Use this to refresh the value of parameters. Launch InPower Help.
Strip Chart
Creates a line graph of parameter values. Useful for
fault diagnostics.
Notes:

With the computer and the Power Command
Connect to a Device control correctly physically connected with the
InPower cabling, you can now connect to the PCC
with InPower.
There are several ways to do this, and any way is

acceptable based on personal preference.
To connect to the control either, double click on the
Site created previously on the left pane of the
window, click the “Port Connect” button on the tool
bar, or select “Connect” from the “Port” drop down
menu.
A pop up window will appear and show status of the

progress of the connection process.
Once connected, the Site on the left window pane
Typical Menu Structure opens up to a menu tree displaying all of the
configurable parameters, faults, monitoring points,
 Adjustments
and test switches.
 Faults
 Monitor These parameters are organized in the PCC1302 into
 Test four folders:
• Adjustments
• Faults
• Monitor
• Test
195 7/9/2014 Cummins Confidential Other PowerCommand Controls will have different
menu structures.
If this selection was chosen during Setup, a popup
Saving a Capture File window may appear asking whether or not to save a
capture file. Otherwise, a capture file may be saved
by selecting “Capture to File” from the “Device”
drop down menu.
You can name the capture file whatever you’d like,

but by default InPower assigns a name that lists the
Device ID, Date, and Time in the name.
Notes:

Capture Files
A capture file stores all information and settings

relevant to a device in an off-line location on the
computer. A useful application for a capture file is as
a backup of the existing settings on the device when
you are going to make changes to the parameters;
this can be accomplished by generating a capture
file.
Captured files are read-only files that can be viewed after disconnecting the device from InPower. You can
connect to and view these files, but you cannot modify the file contents. Capture files are basically used
to store a copy of a device’s parameter values, History and faults. These capture files can then be used to
compare to a connected device, or used as a template to write the captured settings to another device of
the same type.
Example: The Captured file is from a Genset controller, this file can be written to another (connected)
Genset controller of the same type.
Capture files are generally saved in the hard-drive at
Location of Capture Files the following location (the drive letter may vary
depending on where InPower was installed):
InPower View
File Location
D:\Program Files\Power
Generation\Shared\Captured Files
Within InPower, the capture files can be accessed

from the Capture Files site, on the left hand pane. A
capture file must be accessed with InPower, they
cannot be opened with other programs.
Notes:

In order to view a capture file, you must connect to
Connect to a Capture File it using InPower. Connecting to a capture file is
similar to connecting to a Power Command device.
In order to connect to a capture file, you must first
open the Capture File site by double clicking it. The
Capture File site is preconfigured to InPower, you do
not need to create one like you did for other
controls.
Once connected, find the capture file you would like

to open and double click on it to open.
Capabilities of Capture Files
Once connected to a capture file, InPower has some

very useful functions that enable technicians to
make changes/adjustments to Cummins equipment
very easily.
• Compare to a Capture File – Enables the user to compare the settings of a current device to a
captured file (presumably an old set of settings) to see what settings have been changed.
• Drag and Drop – If a user drags and drops a capture file into a connected device it will prompt the
user if they want to revert the settings of the connected device to that of the captured file. This only
works if the captured file and device are of the same type.
• E-mail Capture File – A user can email the capture file to another user. As long as the other user
copies the emailed file to the appropriate location in the hard drive (as discussed in the location
section), they can use the captured file.
Example: PCC 1302 control is behaving irregularly and Technician-A suspects that someone has tampered
with the settings. Technician-A finds out that the previous qualified Technician-B who worked on the
control is at an off-site location. A request is sent to the off-site Technician-B to email the capture file from
the last time the control was worked on. Now Technician-A can use the drag and drop feature to revert the
PCC 1302 control settings to those settings in the emailed capture file. The control should work normally if
the problem was in the incorrect settings.
Notes:

Built into InPower is a powerful diagnostic tool

Compare Function called “Compare”. This allows the user to compare
all of the parameters of a connected device with all
Compare
of the parameters of a capture file.
This can be very useful in troubleshooting. If a

Filter
control is having issues, you can compare the device

Print
with a capture file that you know works, or even
with a capture file of that exact set that was taken
earlier at commissioning.
In order to use the Compare function, the device and the capture file should both be connected via a site
location in InPower. Right-click on the device (PCC1302) in the left window pane and select “Compare”. A
Compare Utility screen will pop up with the selected device on one pane and a blank pane next to it. Next,
click and drag the relevant capture file to the empty pane. Now on the left side of the Compare Utility are
all of the parameters of the connected device, and right side is the capture file.
There are a couple of options in the Compare Utility. Click the “Compare” icon on the top left of the pop-
up screen. This will compare all parameters listed for both the connected device and the capture file. The
items displayed in black are identical. The items listed in red are the items that are not the same. Click the
“Filter” icon to filter out the variables that are different, showing only red (different) parameters.
Notes:

Capture files can be used to overwrite the
Write Capture File to a Device parameter values of a connected device as long as
the types of devices are the same. For example, a
capture file from a PCC 1302 control may only be
used to write to another PCC 1302 device that is
connected with InPower.
You can copy the entire capture file onto a

connected control, or you can select only certain
parameters to write over.
To overwrite a connected device’s parameters with the parameters from a previously taken capture file,
first connect to the capture file. Then, connect to the device. Once both are connected successfully, click
and hold the capture file and drag and drop it onto the device.
This feature can be used to copy the entire capture file, individual folders, or specific parameters.
Traditional “copy” and “paste” commands such as “Ctl + C” and “Ctl + V” will work to perform this feature
as well.
A popup menu will appear confirming that you do in fact want to erase all of the parameters on your
connected device and replace them with the parameters in the capture file.
InPower is used to adjust different parameters and
Adjustments settings of devices.
Many of these parameters are the same ones that

were discussed in the setup and service menu
sections. However, there are some parameters that
are only configurable using InPower in order to
prevent accidental configuration or tampering.
Notes:

There are several different types of parameters

Icons when navigating through the menu tree in InPower.
Located to the left of each parameter is an icon that

indicates if the parameter can be adjusted or if it is
for monitoring.
• The screwdriver icon is used for settings that
can be written and adjusted permanently using
InPower.
• The magnifying glass is for parameters that are
read only and are currently being monitored.
• The momentary switch is used for on/off type of
functions or to reset devices. These are usually
temporary.
• The wrench icon represents factory settings that
are not adjustable with InPower.
To edit a configurable parameter, simply hover your
Editing Parameters mouse over the “Value” and double click. This will
allow editing.
To learn what the acceptable range of the

parameter is, hover the cursor over the value until a
comment box appears.
To learn a description of the parameter, hover the

cursor over the name of the parameter until a
comment box appears.
To search for parameters press “Ctl – F”. To search

again press “F3”
Once all of the parameters you want changed have been successfully configured, click the “Save” button
on the toolbar.
Some older versions of PowerCommand Controls also require the control to cycle power in order for the
changes to be saved.
Notes:

Strip Chart
The strip chart function in InPower lets you graphically display some (up to 6 max) of the parameters
relevant to a device. In the example shown, the voltage (red), current (dark yellow), and genset power in
kVA (green) will be measured. This will display in real time.
The Strip chart can be accessed by clicking on the Strip chart Icon in the toolbar. To add parameters to the
strip chart, drag and drop the monitor parameters from the InPower window onto the empty space of the
Strip chart. The Strip chart will then begin displaying in real time the value of the parameter. You can
change the values of the maximum and minimum points in the chart so the data is displayed more clearly
by clicking “Properties” in the “Edit” drop down menu. The sampling can be turned on/off via the Toggle
Sampling button in the Strip chart Window toolbar.
Strip charts can also be saved to the disk, and previously saved Strip Charts can be opened by using the
“Save” and “Open” buttons. This does not save the data the Strip Chart was collecting, however, it only
saves the set of parameters that the Strip Chart was monitoring so that you don’t have to repeat this work
if you want to run a similar monitor test later. In order to export the data, you must use a Monitor file.
Notes:

Monitor
The Monitor function in InPower lets you monitor values (up to 6 max) in real time as well as Data log
these values. The sampling rate can be changed so that it takes a sample of the parameter every 0.05
second or 1 second, 1 minute, etc.
The Monitor function can be accessed by clicking on the monitor icon in the toolbar. To add parameters
to it, drag and drop the parameter from the device window similar to the way the Strip Chart was set up.
Once you have all of the parameters that you would like to sample, click the “Sampling” check box and
select your desired Sampling Rate from the dropdown menu. This will begin the sampling of the data in
the window, and if the values are changing, you will see the Value column updating.
Data logging allows the user to log parameter information to a .log file at the selected sampling rate.
Sampling must be enabled in order for the Logging selections to become active. To begin data logging,
click the “Start Logging” button. Data is now being logged to the default Monitor File located at the
default location of D:\Program Files\InPower\Monitor Log Files. Monitor Log Files are named by default
with the date and time. To change either the default location or the default name of the Monitor file, click
the “Browse” button.
When you’ve finished data logging, click “Stop Logging”. If you would just like to view the data and leave
data logging on, click “Generate Report”. This will open the data in Excel.
Monitor Files can also be saved and previously saved monitor files can be opened. This is separate from
data logging. The monitor files are saving the parameters that you drug and dropped into the monitor
window, so that you don’t have to repeat this efforts next time you’d like to run a similar test. For
example, the visual above displays a previously saved AVR test.
Notes:

Reports
Reports can be used to send or save a list of

parameters similar to a capture file, but can be
opened with common software such as Microsoft
Excel or Notepad. A common Report that can be
generated is a report of the fault history of the
control.
To generate a report, you first have to select the features that you wish to include in your report. To do
this, navigate the parameters on the left window pane to the folder/features you wish to include. Then,
right click and select “Select Feature”. Then, right click again and select “Prepare CSV file for Feature…”
This will prompt a menu where it will ask you for a location to save the report to and a name. Click “OK”.
This will generate a Comma Separated Value (CSV) file which can be viewed with Excel or Notepad.
The Initial Calibration and Update Calibration
Update InCal features in InPower are very powerful and can be
used to either replace a genset controller or keep an
existing genset controller current with updated
calibrations. But that only works if you have the
most up to date calibration files on your computer.
All To get the most up to date calibration files, you
must go to the InCal website at:
Download
http://cumminspower.com/en/services/software/S
earchandDownload/activeStatus.do
This website allows you to download a zip file of all calibration files for all Cummins Power Generation
products that use InPower calibration files. Or, you can select the specific Model, Systems, or Networks
you are looking for. To download all of the calibration files, select “All” from the Download dropdown
menu and click “Download”
This will download a document called all.zip onto your computer. This can take several minutes
depending on your connection speed.
Notes:

InCal Extractor
When the .zip file finishes downloading, you must

load all of the calibration files into InPower. Only
then can you use the calibration files for Update or
Initial Calibration. First, make sure no devices are
connected to InPower. If any devices are connected
to InPower, the InCal extractor button will be
greyed out. Click the “InCal” button on the toolbar,
or select “InCal Extractor” from the “Utilities” drop
down menu.
This will bring up the InCal extractor window. Click “Browse InCal zip file” and navigate to the .zip file you
downloaded from the InCal website. Make sure that the disk path is correct, for PowerSweep machines
you should extract to the D:\ drive; however this may be different if InPower is installed on a different
drive. Click “Extract”. This will load all of the most current calibration files into a usable form for InPower
to use when performing Update or Initial Calibrations.
The Initial Calibration feature is used to download a
Initial Calibration calibration file into a service replacement genset
control. Initial Calibrations are required when
replacing a control. The use of a capture file can
reduce the amount of adjustment that will be
required. Initial Calibration essentially customizes
the generic Power Command control board with the
very specific set of features of the generator set that
the PCC control will be controlling.
In order to begin an initial calibration, connect to

the device and select “Initial Calibration” from the
211 7/9/2014 Cummins Confidential “Device” drop down menu.
Notes:

The next step is to select a calibration part number.
Initial Calibration:
Select Calibration Part Number If there are multiple calibration part numbers, they
will appear in this list. The calibration part number
of the genset control you are serving should appear
on the data plate of the generator set. In this visual
there is only one calibration part number.
Next, the History of the calibration part number is

displayed. This displays all of the revisions the
Select Calibration History calibration has gone through with descriptions of
each step.
In order to save time configuring the new Initial

Save and Restore Parameters Calibration, select “Set Data Plate From Capture
File” and find the capture file that you would like to
use. Select “Overlay Capture File After Calibration”
in order to set all of the parameters of the new
Calibration to be the same as those that are in the
capture file. By selecting this box, you are essentially
creating a cloned device of a previous device that
you took a capture file from.
If you do not have a capture file, you will have to

select all of the features manually in the next step.
213 7/9/2014 Cummins Confidential Click “Next”.
Notes:

Next, you must select all of the Features of the

Feature List generator set controller. These features include
many of the different parameters of a generator set
such as connection type, nominal frequency,
nominal voltage, etc.
If you selected a capture file to select all of these

feature lists from, then the features should be
selected for you.
If you did not select a capture file, you will have to select the appropriate features manually. These
features can be found on the Bill of Materials located on QSOL, or on the data plate of the generator set.
Once you have selected all of the features, click “Finish”. This will pop up a dialog box asking if you wish to
calibrate the controller now. Select “Yes” to continue or “No” to cancel. Calibrating the controller at this
point will erase any existing data on the board, so only use Initial Calibration when required.
The calibration file download process can take several minutes to complete. During the download, it is
normal operation for the genset control to display warnings.
Do not hit the “Fault Acknowledge” button during the download, or it may be interrupted.
The Update Calibration feature is used to replace a
Update Calibration current calibration file with a newer version from
the CPG InCal website. The new calibration file is
written over the current calibration file in the
genset baseboard.
To perform an Update Calibration, connect to a

device and select “Update Calibration” from the
“Device” drop down menu.
Notes:

Update Calibration does not require you to select
Update Calibration:
History which calibration part number you are updating,
since it is assumed that you will be updating with a
newer version of the existing calibration file. If you
wish to change calibration part numbers, you must
use Initial Calibration.
The history window displays information about the

currently installed calibration part number on the
top of the window. It also displays all of the revision
history of the calibration part number in the body of
the window.
Check the “Save & Restore” box in order to save the current adjustment trims and settings from the
device and automatically overlay them onto the new calibration file. Click “Finish” to proceed with the
calibration update.
Again, this process can take several minutes to download the new calibration onto the controller, do not
clear any alarms on the control as this may interrupt the calibration download process.
Notes:

Activity 8-1
Skills Exercise
InPower Hands-On
Required Materials
• PC 1.1 Simulator Kit or running generator set
• InPower Service Tool installed on laptop
• Communication Cables
Instructions
Connect w/ InPower
1. Create a Site in InPower to connect to the PCC 1302 board with your communication cables
2. Physically and elctronically connect to the controller
Capture Files
1. Save a capture file
2. Locate the capture file in the folder structure of your computer, and give it to a classmate (while
swapping for their capture file)
3. Save your classmate’s capture file in the appropriate folder on your own computer
4. Connect to that capture file using InPower, and copy it over to yoru connected controller
Strip chart/Monitor File
1. Create a strip chart of the following parameters
a. Frequency, L1-N Voltage, Total kW, AVR Duty clycle
2. Ensure that all of the axis are easy to read and properly scaled
3. Save the Strip Chart parameter list
4. Create a Monitor File using the same parameter list. Sample once per 0.25 seconds.
5. Export a CSV report of those parameters for a startup and shutdown sequence
Initial Calibration
1. Update your InCal contents
2. Perform an Initial Calibration on your connected controller
3. Use your original capture file to set the data plate and overlay parameters


Lesson 9: Troubleshooting PowerCommand Controls

 Gather information on a PCC fault
 Analyze subsystems to determine fault’s
origin
 Test solution to ensure correct origin
 Repair fault
 Retest to ensure the fault has been
corrected
GATRR
5 Step Troubleshooting Approach GATRR is a systematic troubleshooting approach
that should be used by all Cummins Technicians
 Gather
when troubleshooting power generation
 Analyze
equipment.
 Test
 Repair
GATRR stands for:
 Retest
• Gather
• Analyze
• Test
• Repair
• Retest
Gather information and speak with the operator.

Gather
Determine the symptom of the PCC Control
 Does not crank, does not start, shuts down
on fault code, etc.
Perform a visual inspection of the overall area to
ensure that it will be safe to perform an operation
check (JSA).
Check for the following:

 Electrical damage to components
 Loose wiring
219 7/9/2014 Cummins Confidential  Indicator LED’s
 Fault/Event history
Test the genset control to replicate the problem
Write down all symptoms outside of normal operation
If the genset is still displaying the problem, move on to the next step
DOCUMENT!
Notes:

Isolate the System
Analyze  Narrow Down the possibilities by system
 Look up fault code in the service manual
 Eliminate potential possibilities
START WITH THE BASICS

 Genset doesn’t crank?
 Genset doesn’t start?
 Doesn’t produce voltage?
 Genset doesn’t shutdown?
DOCUMENT!
Test the Likely Problem Components

Test  Test components in order of likeliness based on
troubleshooting trees and symptoms that are
present
 Perform Manufacturers Recommended Test
– Software or Hardware
 Can the component be fixed or does it need to
be replaced?
DOCUMENT!
Perform Repair
Repair  Software or Hardware repair
Double check that the component to be replaced is

the problem component
Ensure that the proper procedures are followed

based on the manufacturing guidelines
DOCUMENT!
Notes:

Test the genset to ensure that the problem is fixed

Retest
Perform entire sequence – genset start, voltage and
frequency, assume load, genset shutdown
If the genset still doesn’t operate correctly, is it

displaying the same symptom(s)?
 Are there multiple faults?
DOCUMENT!
Notes:

GROUP TROUBLESHOOTING EXERCISE WORKSHEET 1
Required Materials:
• PowerCommand Control Simulator or running generator set
• Multimeter
• Supporting Reference Material
• PPE
Instructions:
1. Use the GATRR Process to investigate the problem with the PowerCommand Control.
2. The Instructor will act as the operator for interviews and questions about symptoms.
3. DOCUMENT each step of the GATRR process below. Full credit will not be given unless
all steps are documented.
Gather
Analyze
Test
Repair
Retest
Note: Instructor or designated helper will act as operator for questions about symptoms


Required Materials:
• Multimeter
• PPE
Instructions:
Gather
Analyze
Test
Repair
Retest

Required Materials:
• Multimeter
• PPE
Instructions:
Gather
Analyze
Test
Repair
Retest

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Fundamentals of PowerCommand Controls

6283 – Fundamentals of PowerCommand Controls

Page 2 of 163 | Cummins Inc.

Cummins Inc. | Page 3 of 163

Making this an Active and Interactive Course

Page 4 of 163 | Cummins Inc.

The alternator consists of a rotor and a stator. When

3 7/7/2014 Cummins Confidential

Cummins Inc. | Page 5 of 163

A generator set must start and stop the prime

Before PowerCommand Controls, all the generator

Page 6 of 163 | Cummins Inc.

Generator Set Control The PowerCommand Control is simply that, a

It is responsible for starting and stopping the prime

6 7/7/2014 Cummins Confidential

A PowerCommand Control is essentially a number of subsystems. These subsystems interact together to

The operator can navigate these menus by

Cummins Inc. | Page 7 of 163

Some PowerCommand Controls have more features

If one or more of those setpoints go beyond a

threshold for a certain period of time, the generator

9 7/7/2014 Cummins Confidential

Page 8 of 163 | Cummins Inc.

PowerCommand Controls also can operate

Typical customer equipment which uses the

Start Relay Output

Run Relay Output

Cummins Inc. | Page 9 of 163

Before the 3100, generator sets required a

Features of the PCC 3100 control:

Page 10 of 163 | Cummins Inc.

The PCC 3201 is based on the original PCC 3100

The PCC 3200 was the first iteration of this family of

Additional features of the PCC 3201

The PCC 2100 can communicate with other

PCC 2100 HMI

Cummins Inc. | Page 11 of 163

The PC2.X also uses the common connector harness

Additional features of the PC2.X control

Page 12 of 163 | Cummins Inc.

The PC3.3 control is the current “flagship” control of

It uses the common connector harness used by the

The PC3.3 has many of the same functions of the 1.X

PCC 3300 Control Board

17 7/7/2014 Cummins Confidential

The PC3.3 has many paralleling functions

Clicking Search will bring up a list of service

Cummins Inc. | Page 13 of 163

Download Service Literature

Page 14 of 163 | Cummins Inc.

Lesson 2: PCC Controls Safety

Every Cummins employee is responsible for his or her own safety:

Cummins Inc. | Page 15 of 163

There are three Authorization Levels for electrical

Page 16 of 163 | Cummins Inc.

NFPA states that energized electrical conductors

An electrically safe work condition is to be

An Authorized person can perform work within the

Cummins Inc. | Page 17 of 163

The risk of electrical shock is one of the hazards with

Shock Hazard Analysis is to be performed at the

The Shock Hazard analysis will determine:

Page 18 of 163 | Cummins Inc.

The Approach Boundary distances are defined in

For electrical equipment (such as a PowerCommand

Control) with a L-L voltage of less than 300 VAC, the