PowerCommand

PCC3100
Genset Controls

MOTOR
Traditional Arrangement EC

• Cotrole do Motor (EC) GOV

– Proteções do motor
AVR
– Partida e Parada do Motor GEN
• Regulador de velocidade (GOV)
– Controle do motor Veloc/Frequencia
• Regulador de Tensão (AVR)
– Controla a saída de tensão CB
• Disjuntor (CB)
– `Proteção dos cabos do gerador até a
carga CARGA
• Outras Opções
PowerCommand

MOTOR
• Um único controle para PowerCommand
todas as funções do gerador
– Reg. velocidade
– Reg. tensão GEN
– Controle do motor
– Todas as proteções
– Funções avançadas de controle
• Desenvolvido para várias condições
de instalação
– Vibração
– Variação de temp ambiente
– Ambiente sujo Carga
 Painel de Operação
Instrumentos Analógicos AC Continuous Sealed Membrane
• Código de Cores Dust and Moisture Proof
• % Escala UV Resistant
• Fácil de ver
• Fácil de entender
Sealed Push-Button
LED Indicadores
Switches
• Long Life Designed for Millions
• Not in Auto of Operations
• Common Alarms

AC Phase Select
Parallel CB Control
LED Scale Indication
(Optional)

Mode Switch Emergency Stop

Key type is Option
Digital Display All Control Adjustments are
• Easy to Read Accurately made from the Digital Display
• Fault Codes Keyed to Manual • Easy to adjust without tools
• Multi-Lingual Display • Easy to see and record changes
• US Standard or Metric Units • Secure Access
• Easy to Read in Most Lighting Conditions
 Physical Construction (Internal)
Standardized Internal Components All 24VAC Control
• Improved Parts Availability • Safe to Service
• Lower Cost • UL508 Listing
Dust/Moisture Gasket
• Standard Environmental Protection
No Internal Adjustments
• All Adjustments Via Operator Panel
• Easier to Adjust
• Security

Low Mass Locking Ribbon Cables

• Best Vibration Resistance
• Fast, Easy Service
• Reliability

Plating for RFI/EMI Resistance

RFI/EMI Gasket
LED Service Indicators
Vibration Isolation
 EMERGENCY
STOP Engine Functions

Starter Magnetic Pickup Sender Coolant Oil

Engine Temp Oil Pressure

Fail-to-Crank Overcrank Overspeed Pickup Failure High Temp Low Temp Level Low Pressure
Sender Sender
(SD) (SD) (SD) (SD) (W & SD) (W) (W or SD) (W & SD)
(W) (W)

• Detects sender or wiring failures to prevent nuisance

shutdowns due to those conditions
• Built-in capability to add optional sensors for dual exhaust
temperature readings
• Dual Temperature Sensing on V-engines
• Fault Log for last 20 alarm or shutdown conditions
W = warning
SD = shutdown
 Alternator Functions

Ground Fault High Alternator Temp

(W or SD) (W or SD)
(optional & selectable) (optional & selectable)

High AC Voltage Low AC Voltage Under Frequency Overcurrent Short Circuit Overload
(SD) (SD) (SD) (W & SD) (SD) (W)

• Complete, Integral Protection

– Designed for the Generator Set
• Integral Voltage Regulation
– Voltage Ramping, Torque Matching, Roll-off
– 3-Phase Sensing, PMG Standard, Pulse Width Modulated
– Immune to Effects of Non-Linear Loads
W = warning
SD = shutdown
 Data Displays
OIL PRESSURE
OIL TEMPERATURE

LEFT COOLANT TEMP

• Full Function Digital Display

RIGHT COOLANT TEMP
ENGINE
ENGINE SPEED
EXHAUST TEMP – All Engine Instruments
BATTERY VOLTS – All AC Output Conditions
– AC Power Functions
ENGINE HOURS
NUMBER STARTS

AC VOLTS • Greater Precision than Analog

Displays
LINE TO LINE
LINE TO NEUTRAL
3 PHASE VIEW

AC AMPS
• Displays 3-Phase Values to See
3 PHASE VIEW
Voltage and Load Balance
Alternator
kW
kW-HOURS • % GOV & % Volt Regulation
POWER FACTOR
Indicate Engine & Alternator
FREQUENCY
Condition
% GOVERNING
% REGULATION
 Smart Starting Control
BLACK SMOKE

100%
TEMPERATURE
DEPENDENT GOV. (PCC)
FULL THROTTLE
ACCELERATION CONTROLLED
FREQUENCY

ACCELERATION

START DISCONNECT

ENGINE CRANKING CHECK (PCC)

TIME CONVENTIONAL GOVERNING

POWERCOMMAND GOVERNING
 Battery Monitoring
• Runs a battery load
test every time the
32VDC
engine is required to
start.
24VDC
• Continually monitors
the charging system
for low and high
10VDC voltage.
• Batteries can be
NORMAL RECOVERY TIME serviced before
RECOVERY TIME WITH "WEAK BATTERY" experiencing a
failure to start.
• Improved generator
set reliability.
 Principles
• Alternator thermal damage curve
– defines “how much current for how
Fails Here long” without damage
10 – log-log curve
– does not describe how much
current can be produced
Seconds

1
M
ax
Ou
OK Here tp
ut

0.03

1 10 Amps ( x rated)
Conventional Wisdom

• Molded Case CB (with

thermal-mag trips) offer
little protection
• Solid State Trip better
• Nuisance Trips,
Coordination issues
 3-Phase Fault Response
3 Phase L1-L2-L3 Short: AmpSentry Regulation and Shutdown

500
450 Peak Current: IR/X”d
Alt %Standby Max Line
400 Current
350
Regulates at 3X Rated
300
%Current

Shuts down before damage

250
200
150
100
50
0
0 5 10 15 20
tim e, sec
 Voltage Recovery (3-phase fault)
3 Phase L1-L2-L3 Short and Recovery: L-N Voltages vs. Time

120
Fault Clears without Over Volts
100
Percent of Nominal Voltage

80
Alt L1-N Voltage (%)
60 Alt L2-N Voltage (%)
40 Alt L3-N Voltage (%)

20

0
0 2 4 6 8 10
tim e, sec

AmpSentry clears faults without

damaging overvoltage conditions.
Conventional GenSet Performance on a Fault
• 3-Phase Fault
– Volts Collapse, Amps Peak
– Amps Collapse
– AVR on Full
– Approximately 3X Rated
– Shutdown at 10 Seconds

• 1-Phase Fault
– Volts Collapse on Faulted Phase,
3-Phase Decrement Amps Peak
– AVR on Full
– Amps Don’t Collapse
Non-PCC 1-Phase Decrement
– High Volts on non Fault Phases
PowerCommand GenSet Performance on a Fault
• AmpSentry REGULATES
Fault Current
– Amps Peak on Faulted
Phase
– Voltage on faulted phase
collapses
– PowerCommand reduces
excitation to maintain 3X
rated output
– Overvoltage avoided,
coordination maintained
 Single Phase Faults
Single Phase L1-N Short and Recovery: Current vs. Time
150kW Quiet Site Genset w/Dominion Control

600

500 Alt %Standby L1 Current

Alt %Standby L2 Current
400 Alt %Standby L3 Current
Percent Current

300

200

100

0
0 1 2 3 4 5 6 7 8
tim e, sec

NOTE: THIS CURVE SHOWS FAULT CLEARED BEFORE SHUTDOWN.

 Single Phase Fault
Single Phase L1-N Short and Recovery: Line-Neutral Voltage vs. Time
150kW Quiet Site Genset w/Dominion Control

120

100
Percent of Nominal Voltage

80

60

40

20

0
0 1 2 3 4 5 6 7 8
tim e, sec
 Recommendations
No Main Line Circuit
Breaker Required ATS Utility

400 Amps Essential

Loads
800 Amps
ATS

400 Amps Equipment

PowerCommand Genset Loads

• Get AmpSentry if you can

• When breakers are used, select solid state
trips and coordinate with alternator thermal
damage curve
• Provide individual phase over-voltage
protection
 PowerCommand Network
• Echelon LonWorks Network
– Peer to Peer RS-232
PC for Local Monitoring

– High Speed Control (not just monitoring)

NGM

PowerCommand Genset

• Data Sharing Between Components

JBT JBT

• Lower Installation Cost

NGM

• Easy Building Automation System

Any Genset with CCM OTIII ANY ATS OTPC
with CCM with CCM

IntegrationPC for
Remote Monitoring PHONE
& MODEM

– ANY genset, ANY ATS

• LonMark Compliant PHONE
& MODEM
Software
Paralleling

ENGINE
EC

• Traditional Designs start GOV

with a non-paralleling AVR

GEN
genset….

CB

POWER
TO
LOADS
 ENGINE
EC
LOAD SHARING GOV
DATA

ILS AVR
GEN

CB
Load Sharing for Paralleling
• Reactive Droop Compensation
• Isochronous Load Sharing (ILS) POWER
TO
LOADS
 ENGINE
EC
LOAD SHARING GOV
DATA

SYNC ILS AVR

GEN

CB

Synchronizing Functions POWER

• Interfaces to ILS TO
• Bus Reference Signal LOADS
 ENGINE
ALARMS EC
LOAD SHARING GOV
DATA

METER PRO SYNC ILS AVR

GEN

CB

Other Paralleling Functions

POWER
• Genset Protection (32, 40)
TO
• Metering and Manual Controls LOADS
Synchronizing Improvements
 ENGINE
Parallel Control
ALARMS EC
LOAD SHARING GOV
DATA

METER PRO SYNC ILS AVR

GEN

CB

Paralleling Control Functions POWER

• Directly Operate on One Genset TO
LOADS
• Split Location and Responsibility
 ENGINE
Parallel Control
ALARMS EC
I/E
LOAD SHARING GOV
DATA
METER PRO SYNC ILS AVR
GEN

PF CB

External
Reference
Many Components Added POWER
(optional) • Directly Operate on One Genset TO
• Split Location and Responsibility LOADS
Conventional Paralleling Hardware
• How can this be made reliable?
– Many components--mostly analog
– Hundreds of interconnecting wires
– Hard to train
– Parts availability
 ENGINE
PowerCommand
Digital Paralleling Control
•Engine, Governor, Voltage Regulation
•Isochronous Real/Reactive Load Sharing
•Engine & Alternator Protection
•Synchronizer
GEN

CB
PowerCommand
• Replaces all Parallel Control Functions
• Includes Utility Paralleling Functions POWER
• Enhanced Reliability, Performance TO
LOADS
PowerCommand ANSI Functions GENSET

SURGE SUPPRESSORS
AM SW KW KWH PF 40 32 65 90 51V

VM SW HZ 27 81U 59

86
VM SW HZ 47 SYNC 25

SS
POWERCOMMAND CONTROL

SWITCHGEAR TRIP

CLOSE
 Conventional System Architecture
Paralleling Master Paralleling
Control Control Control
Alarms Alarms Alarms
Metering Metering Metering

Genset
Onan Protection Relays Protection Onan
EC AVRwith
AVR with EC AVR with
Genset Droop
Droop Sync PLC Sync Genset Droop
ILS ILS
Governor
Governor Brand X Governor
Actuator
Actuator Exciter
Exciter Switchgear Actuator Exciter
Paralleling Paralleling
Breaker Breaker
GOV GOV

Power to Loads

•System Controls Split and Located in Several Areas

•Genset Vendor Holds System Functional Responsibility
•Hardware-Based Design--Every System Different
 Typical PowerCommand System
Master
Control
Alarms

Metering

PowerCommand PLC PowerCommand

Governor TOUCH Governor

Actuator Exciter Actuator Exciter
Paralleling Paralleling
Breaker Breaker

Power to Loads

•Paralleling Control Always on Genset

•MasterControl Optional, Several Types Available
•Power Section is Almost Unchanged
•Emphasis on Hardware Standardization
•Software-Based Control
 PowerCommand
Digital Paralleling Control

• Ultimate in Reliability
– Improvements in
Functional Logic
– 200,000HR MTBF Proven by
Field & Prototype Test
– Huge Reduction in System
Components
 PowerCommand
Digital Paralleling Control

• Enhanced Performance
– Broad Range Synchronizing
– Isochronous Load Sharing
– Improved Cold Weather
Performance
– Load Ramping
– Utility Paralleling
 PowerCommand
Digital Paralleling Control
• Cost Effective
– Simplified Design
– Space Saving
– Flexible for Future
Changes
– Network Compatible
– Fewer Spares
 Networks in Paralleling
Paralleling
Breaker

PowerCommand
Paralleling
Genset
Breaker

PLC Paralleling
Breaker

PowerCommand
Digital Master
Genset
Controller

Network
Gateway
Module

PowerCommand PowerCommand
Software Genset
Network Wire

Hard Wire
 Control System Reliability

• MTBF > >200,000 Hours

• Reliability proven by prototype test and
field performance
• Over 40,000 units in service
• System reliability is dramatically improved
over any component
Data includes all circuit boards,
interconnecting wiring, and sending units!
 Why PowerCommand?

• DOCUMENTED Best Available Reliability

• Designed for Genset Applications, So the
Entire System Works Better
• Many Features, Highly Standardized, for
Good Cost Effectiveness