Service Parts Topic

Date

March, 2007

No.

3242756

File Group

13

Engine Family :
Subject

Ref. No.

FESN

Application Group :

NT 855 / N14 / K19 / V28

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

Effective from June 2007.

G-drive

Background :
Power Com controller will be introduced on NT 855, N 14,K19 & V28 genset applications on 320 to 625 KVA nodes
from June 07. ECPG (Electronic Control Panel + Governing) was used on the above nodes. Power Com control
is an integrated Genset controller which has two board architecture (Engine Control Board & the Alternator control
Module). The engine control board consists of engine protection & governing functions. The AC Module consists
of AC protection & AC metering functions. External Cummins Generator Technologies AVR is used to regulate the
excitation voltage of the Genset.
PowerCom
Description
The PowerCom Control is a microprocessor-based
Engine Governor, monitoring, metering, and control
system. The control provides an operator interface to
the alternator metering & protective functions. The
Voltage regulation is done by the CGT (Newage AVR).

PowerCom controls are suitable for use on a wide range

of generator sets from 320 KVA to 625 KVA.
Control power for PowerCom is usually derived from
the generator set starting batteries. The control
functions over a voltage range from 8VDC to 35VDC.
The control offers a wide range of standard control
and digital display features so user customized
control is not needed to meet application
specifications. The system reliability is improved
by using reliable and inspected components.

Cummins India Limited

Registered Office : Kothrud, Pune 411 038 (India)

SPT 3242756

Page 1 of 8

Features
Major Control Features Include:

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

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

Digital parameter display for Engine & AC Output Metering.

Digital Alarm and Status Message Display

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

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

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

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

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

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

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

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

Alphanumeric Display Panel

The PowerCom control is provided with an alphanumeric LCD backlit display of 128 X 64, capable of displaying
engine, alternator & fault codes with description. The display is accompanied by a set of eight tactile feel
membrane switches that are used by the operator to navigate through control menus, and to make control
adjustments. (There are no rotary potentiometers in the control. All adjustments are made via the display panel
or C-View)
All data on the control can be viewed by scrolling through screens with the navigation keys.
The control displays all fault codes & its status (Active /Inactive).

Cummins India Limited

Registered Office : Kothrud, Pune 411 038 (India)

SPT 3242756

Page 2 of 8

The display panel includes a power down timer that will turn off the display after 10 minutes of inactivity, this is
also known as sleep mode function of the controller. Toggling the key switch from off to on or a remote start input
(with Key position in ON) will wake up the control.
Generator Set Data This data plate has following information
1. Engine Model
2. Base Calibration Version Information
3. Controller Serial Number
4. Boot loader Version
5. Engine Serial Number
The control stores the serial number of the control and the software version present in the control.
Generator Set Output Voltage - All phases, line to line and line to neutral, accuracy 1%. Data for all phases is
displayed simultaneously to allow viewing of voltage balance.
Generator Set Output Current - All phases, accuracy 1%. Data for all phases is displayed simultaneously to
allow viewing of load balance.
Generator Set Power Output - PowerCom displays generator set kW and Kva output (average and individual
phase, and direction of flow), and power factor with leading/lagging indication. Accuracy 5%.
Engine Parameter Display
1. Engine Starting Battery Voltage
2. Engine Lube Oil Pressure
3. Coolant Temperature
4. Lube Oil Temperature.
5. Intake manifold Temperature (Only on NTA14 G3)
Service Adjustments The operator panel includes provisions for adjustment and set up of all control functions
in the generator set. The operator panel includes an Two finger Salute access code that is used to protect the
control from unauthorized service level adjustments.
Internal Control Functions
Remote Start Mode - PowerCom accepts a +24 V signal from remote devices to automatically start the generator
set and immediately accelerate to rated speed and voltage.
PowerCom includes a Smart Starting system that is designed to quickly start the engine, minimize black smoke,
and minimize voltage and frequency overshoot and oscillations on starting. The control system does this by
careful control of the engine fuel system.
Power down Mode PowerCom can be configured to include a sleep mode. When enabled, and when the mode
select switch is in the ON position( on the ECB), the control will revert to a low power consumption mode until a
key switch on the operator panel is toggled from off to on position.
Fault Simulation Mode - PowerCom in conjunction with C-View software will accept commands to allow a
technician to verify the proper operation of all protective functions of the control, by simulating failure modes or
by forcing the control to operate outside of its normal operating ranges.
Engine Starting The control system automatically controls the engine starter, and provides proper engine
fueling and to provide fast and efficient starting.
Cycle Cranking Pre-Configured Cyclic cranking for number of starting cycles and duration of crank and rest
periods. Control includes starter protection algorithms to prevent the operator from specifying a starting sequence that might be damaging.

Cummins India Limited

Registered Office : Kothrud, Pune 411 038 (India)

SPT 3242756

Page 3 of 8

Engine Governing
The PowerCom control includes integrated digital governing capability, to directly drive an engine fuel control
valve. Features of the governing system include:
Isochronous Governing - Controls engine speed within plus or minus 0.25% for any steady state load from no
load to full load with no drifts.
Temperature Dynamics - Modifies the engine fuel system (governing) control parameters as a function of engine
temperature. Allows engine to be more responsive when warm, and more stable when operating at lower temperature levels.
Alternator Display & Protection
PowerCom on its own does not includes an integrated voltage regulation system. The alternator voltage regulation
is done by an external CGT AVR that is compatible with either shunt or PMG type excitation systems; however
PowerCom does have the capability to protect the alternator from Over Voltage, Under voltage, Under frequency,
Over current faults.
Protective Functions
On a warning condition the control will indicate a fault by lighting the warning LED on the control panel, and
displaying the fault name and code on the operator display panel. The nature of the fault and time of occurrence
are logged in the control. The service manual and C-View service tool provide service keys and procedures
based on the service codes provided.
On a shutdown condition, the control will light the shutdown LED on the control panel, display the fault name and
code, and initiate shut down and lock out the generator set. The control maintains a data log of all fault conditions
as they occur, and time stamps them with the controller run time and engine operating hours data. Adjustments
to most set points are made using the C-View service tool.

Cummins India Limited

Registered Office : Kothrud, Pune 411 038 (India)

SPT 3242756

Page 4 of 8

PowerCom provides the following system protective functions:

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

Engine Protection

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

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

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

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

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

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

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

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

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

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

Alternator Protections included:

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

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

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

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

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

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

Cummins India Limited

Registered Office : Kothrud, Pune 411 038 (India)

SPT 3242756

Page 5 of 8

The control system is housed in a NEMA 3R/IP53 enclosure. The operator control panel has a single membrane
surface, which is impervious to the effects of dust, moisture, oil, and exhaust fumes. The panel uses sealed
membrane or oil-tight switches to provide long reliable service life in harsh environments.
The control system is specifically designed and tested for resistance to RFI/EMI, and to resist the effects of
vibration to provide a long reliable life when mounted on a generator set. The control includes transient voltage
surge suppression to provide compliance to referenced standards.
PowerCom control systems and generator sets are designed and manufactured in ISO9001 certified facilities.
Software

C-View
C-View is a PC-based software service tool that is designed to directly communicate to PowerCom generator
sets to facilitate service and monitoring of these products.
Diesitel
Diesitel is a software tool that is used primarily by operators to remotely monitor and ECPG / ECP & PowerCom.
BMS Compatible: PowerCom can be made Modbus compatible by adding a Modbus Converter. For Details refer
to SPT No.3242729.
Control Interface
Input signals to the PowerCom control include:

Remote Start signal. May be connected via either discrete signal

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

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

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

Generator Set Common Shutdown signal.

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

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

Special Instructions
PowerCom will be supplied with a mounting bracket & will be mounted by the GOEMs appropriately in the
acoustic enclosures.

Cummins India Limited

Registered Office : Kothrud, Pune 411 038 (India)

SPT 3242756

Page 6 of 8

Part Availability
All the parts are available for service on twelve digit part number which is printed on the part itself
Sl.No.

Part Description

Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Plastic enclosure Rear

Plastic Enclosure Front
Isolator Vibration
Pin Hinge for Box (Clip)
Three position key switch
Mounting hardware for grounding
Coolant temperature sensor
Oil pressure sensor
Magnetic pick up
Coolant level sensor
Intake manifold temperature sensor (optional)
Adapter for Coolant Temp. Sensor
Adapter for IMT Sensor
Rexroth Actuator
Fuel Actuator Housing
Fuel Tube
LOT Sensor
PowerCom (Panel Control)
Mounting stand alone panel
PowerCom engine control board
AC Module board
Membrane PCB with layout
LED Board
Harness between Key switch to engine control board
Cable between AC Module to engine control board
k6 harness
N14 Harness
V28 Harness
855 Harness
PT CT Harness
Current transformers 380 Kva Note :CT's are in CGT's scope of supply.
Current transformers 450 Kva
Current transformers 500 Kva
Current transformers 625 Kva
Diagram Wiring for OEM (14 Pin Connector)
Diagram Wiring Optional (6 Pin Connector)
Diagram Wiring (19 Pin Connector)
Clamp for engine harness
Heat Sink
Sticker

0319-4487
0319-4488
0402-0764
0406-0845
504975
0819-1144
3865346
3408497
3875360
3331472
3865345
4053490
4053490
3330601
4071944
4084238
3465346
0319-6104
0319-6105
0300-6085
0300-6086
0300-6087
0300-6088
0338-4728
0338-4729
0338-4735
0338-4736
0338-4737
0338-4738
0338-4739

0315-1688-04

0620-0286
0620-0287
0620-0288
0332-4171
0305-1026
0098-8446

Cummins India Limited

Registered Office : Kothrud, Pune 411 038 (India)

SPT 3242756

Page 7 of 8

Field Conversion
Retrofitting on the field is possible in consultation with CS&S Electronics Cell.
Note: For Further Detailed information on PowerCom please refer to the PowerCom O& M Manual Part No: 0914
0101 00.
Service Tool / Diesitel / Modbus Converter Part Nos.
C - View Kit

4104294

Adapter Electronic Communication

4071717

Power Com to Adapter cable

4071852 & 4071853

Adapter to PC cable

4071851

Calibration CD

4105287

ECPG Service Tool CD

4084236

Diesitel Kit

4072075

Modbus Converter Kit

4968489

Note: This is product improvement and not subject to campaign

Cummins India Limited

Registered Office : Kothrud, Pune 411 038 (India)

SPT 3242756

Page 8 of 8