Instruction Sheet

A029M353 (Issue 1) 7−2009

Installation Instructions for PowerCommand Controller

Upgrade Kits

GENERAL INFORMATION TABLE 3. CONTROLLER UPGRADE KIT:

This Instruction Sheet describes how to upgrade
the controllers in the PowerCommand 1.x, 2.x, and
3.x families.
These instructions only apply to upgrading existing
controls that have been installed with all proper set-
tings for a particular genset and application. It does
not include complete controller setup information
as it is assumed that the existing settings will be
transferred to the new controller.
New controls may come with additional customer
connections that provide additional functionality.
These kits and these instructions do not provide
wiring for these customer connections.
The following parts are included in the various kits.
TABLE 1. CONTROLLER UPGRADE KIT:
POWERCOMMAND 2.2
Part Description Qty.
PCC 2300 (PowerCommand 2.x controller) 1 familiar with safety warnings, cautions, and proce-
PowerCommand 2.2 operator manual 1
Mounting screws 6 WARNING
TABLE 2. CONTROLLER UPGRADE KIT:
POWERCOMMAND 2.3
Part Description Qty.
PCC 2300 (PowerCommand 2.x controller) 1 serviced only by technically qualified person-
PowerCommand 2.3 operator manual 1
Mounting screws 6 al injury.
POWERCOMMAND 3.3
Part Description Qty.
PCC 3300 (PowerCommand 3.x controller) 1
PowerCommand 3.3 operator manual 1
FAE interconnect harness 6
AUX 103 6
Mounting screws 10
Multiple-source warning label 1
The installation procedure consists of these parts:
• Verify the compatibility of the new compo-
nents.
• Get the required tools.
• Save the existing controller settings.
• Remove the existing controller.
• Attach the new controller.
• Upgrade the PowerCommand operator panel
and/or bargraph (if desired).
• Load the existing settings into the new control-
ler.
• Test the installation.
SAFETY PRECAUTIONS
Read these instructions completely and become
dures before starting the installation.
Incorrect installation, service, or
parts replacement can result in severe person-
al injury, death, and/or equipment damage. Ser-
vice personnel must be trained and experi-
enced to perform electrical and mechanical
component installations.
CAUTION A generator set control must be
nel. High voltages are present. These voltages
can cause electrical shock, resulting in person-

E2009 Cummins Power Generation, Inc. All rights reserved. Page 1 of 26

Even with power removed, improper handling
of components can cause electrostatic dis-
charge and damage to circuit components.
WARNING AC voltages and currents present
an electrical shock hazard that can cause se-
vere personal injury or death. Incorrect instal-
lation, service, or parts replacement can result
in severe personal injury, death, and/or equip-
ment damage. Only trained and experienced
personnel are to perform the following proce-
dures.
Turn off or remove AC power from the battery char-
ger and then remove the negative (−) battery cable
from the set starting battery. This is to make sure
the set will not start while working on it and to avoid
circuit board damage, caused by voltage spikes
when removing and replacing circuit board con-
nectors.
CAUTION If present, always disconnect a bat-
tery charger from its AC source before discon-
necting the battery cables. Otherwise, discon-
necting the cables can result in voltage spikes
high enough to damage the DC control circuits
of the generator set.
WARNING Accidental starting of the genera-
tor set while working on it can cause severe
personal injury or death. Prevent accidental
starting by disconnecting the starting battery
cables (negative [−] first).
Make certain the battery area has been well-
ventilated before servicing the battery—Wear
goggles—Stop the generator set and discon-
nect the charger before disconnecting battery
cables. Arcing can ignite explosive hydrogen
TABLE 4. CONTROLLER-HMI COMPATIBILITY
Operator Panel
Controller
x.1 x.2
PowerCommand 1.x X X
PowerCommand 2.x X X
PowerCommand 3.x
* − The x.3 operator panel is available without the circuit breaker buttons for the PowerCommand 2.3 and
with the circuit breaker buttons for the PowerCommand 3.3
A029M353 (Issue 1)
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gas given off by batteries, causing severe per-
sonal injury. Arcing can occur when a cable is
removed or re-attached, or when the negative
(−) battery cable is connected and a tool used to
connect or disconnect the positive (+) battery
cable touches the frame or other grounded
metal part of the generator set. Always remove
the negative (−) cable first, and reconnect it
last. Make certain hydrogen from the battery,
engine fuel, and other explosive fumes are fully
dissipated. This is especially important if the
battery has been connected to a battery char-
ger.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc-
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can
ignite battery gas. Do not smoke, or switch
trouble light ON or OFF near a battery. Dis-
charge static electricity from body before
touching batteries by first touching a grounded
metal surface.
VERIFY THE COMPATIBILITY OF THE
NEW COMPONENTS
1. Verify the new controller is compatible with the
HMI operator panel and HMI bargraph. If you
will upgrade the HMI operator panel or HMI
bargraph as well, check the compatibility of the
controller with the new HMI operator panel or
HMI bargraph.
2. Verify the new controller is compatible with the
generator set. Contact Cummins Accessories
for a list of generator sets and their compatible
controllers.
Bargraph
HMI HMI
x.3* x.3* 112−01 112−02 HMI 114
(kVA) (kW+PF)
X
X X
X X X
 GET THE REQUIRED TOOLS
Aside from basic tools needed for fasteners, In-
Power is required to transfer the settings from the
existing controller to the new controller. The follow-
ing tools are required for InPower.
• Computer with an RS-232 port
• RS-232 to RS-485 adapter
• InPower Software
• InPower Cable
• Latest InCal Files (found at http://www.cum-
minspower.com)
Download the latest calibration file from the web.
For assistance, refer to the Web-InCal User Guide in
the program menu, under User Guides next to In-
Power.
SAVE THE EXISTING CONTROLLER
SETTINGS
Create a capture file of the settings in the existing
controller. This capture file will be used later to load
the proper settings into the new controller.
1. Connect to the existing controller using In-
Power. If this does not automatically generate
a capture file, right-click on the controller in the
tree, and select Capture to File. After the file
is created, a message box will appear.
2. Expand Capture Files in the tree, and find the
recently generated capture file. Double-click
the file to open it.
3. Disconnect InPower from the existing control-
ler, and remove the physical connection.
REMOVE THE EXISTING CONTROLLER
1. Press the STOP button on the HMI operator
panel to make sure the control is in the Off
mode.
2. Activate the E-stop button, and wait one min-
ute.
3. Disconnect the battery charger (if equipped).
Remove all electrical supply sources.
4. Disconnect the genset negative (−) battery
cable.
5. Disconnect all wiring connections to the con-
troller.
6. Remove the six screws that hold the controller
place.
7. Remove the controller.
ATTACH THE NEW CONTROLLER
This procedure depends on the new controller to
which you are upgrading.
Attach a PowerCommand 2.x Controller
1. Find the bolt pattern in the control box that
matches the new controller.
If the control box control box does not have a bolt
pattern for the new controller, contact Cummins Ac-
cessories to see if there is a different kit for upgrad-
ing the controller on the generator set.
2. Mount the new controller using the provided
mounting screws. Use the mounting screw
nearest the ground wire to secure the ground
terminal.
CAUTION To prevent damage to equipment in
the control box, mount the new controller so
that the heat sink fins are vertical.
3. Connect all wiring harnesses to the new con-
troller the same way they were connected to
the existing controller. See Figure 1 for refer-
ence.
If you plan to upgrade other components, do not
connect the existing components at this time.
4. For any new customer connections that were
not available in the existing controller, see the
wiring diagrams at the end of this instruction
sheet.
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 J22 J12 TB15
J17
J18 J11

J20

J18 J12 J22

TB1 J25

J17 J20

J11
TB15

CT2 TB1 J25

TB7CT1 J12 J22 TB8
CT3

TB9 J20

TB15
J26
J14

J25
TB10 TB8 TB5 TB3 TB1
FIGURE 1. POWERCOMMAND 1.X, 2.X, AND 3.X CONTROLLER CONNECTIONS
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Attach a PowerCommand 3.x Controller
1. Find the bolt pattern in the control box that
matches the new controller.
If the control box does not have a bolt pattern for the
new controller, contact Cummins Accessories to
see if there is a different kit for upgrading the con-
troller on the generator set.
2. Mount the new controller using the provided
mounting screws. Use the mounting screw
nearest the ground wire to secure the ground
terminal.
CAUTION To prevent damage to equipment in
the control box, mount the new controller and
the AUX 103 so that the heat sink fins are verti-
cal.
3. Find the bolt pattern in the control box that
matches the AUX 103.
4. Mount the AUX 103 using the provided mount-
ing screws.
5. Attach the provided multiple-source warning
label in a location easily seen when approach-
ing or opening the control box.
6. Connect all wiring harnesses except J11, J17,
and J18 to the new controller the same way
they were connected to the existing controller.
See Figure 1 for reference.
Connect J19-14 to chassis ground.
7. Make the connections to the new controller
and AUX 103 as shown in Figure 2.
FIGURE 2. AUX 103 CONNECTIONS FOR POWER-
COMMAND 3.3
8. For any new customer connections that were
not available in the existing controller, see the
wiring diagrams at the end of this instruction
sheet.
UPGRADE THE POWERCOMMAND
OPERATOR PANEL AND/OR BARGRAPH
If you plan to upgrade the PowerCommand opera-
tor panel and/or bargraph, perform that installation
before continuing.
LOAD THE EXISTING SETTINGS INTO
THE NEW CONTROLLER
This procedure depends on the existing control-
ler from which you are upgrading.
Upgrade from the PowerCommand 1.x
Controller
1. Reconnect the battery charger (if equipped).
Reconnect all electrical supplies.
2. Reconnect the genset negative (−) battery
cable.
3. Connect to the new controller using InPower.
4. Select Device > Initial Calibration....
Make sure you have downloaded the latest version
of the firmware, as explained in Get the Required
Tools.
5. Navigate through the pop-up windows until the
downloading begins. Do not select any fea-
tures.
6. Right-click on the new controller, and select
Compare. This should open the Compare
Utility.
7. Drag the opened capture file of the existing
controller onto the right-hand (empty) column.
8. Select File > Compare.
This may take a few seconds. Then, the
compare window will show all of the parame-
ters in each controller. Red text indicates a dif-
ference between the existing controller and
the new controller. Figure 3 shows an example
when a PowerCommand 1.1 was upgraded to
a PowerCommand 3.3.
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 FIGURE 3. POWERCOMMAND 1.X, 2.X, AND 3.X CONTROLLER CONNECTIONS
9. Manually record the names and existing val-
ues of paramters that are in red. Ignore the fol-
lowing types of parameters:
• Volatile values (for example, voltage read-
ings)
• Calibration and adjust values
• Controller model and serial numbers
• AVR gain settings
• Values with no counterpart in the new up-
grade.
10. Identify the parameters that have a unit of
measure of half-cycles in the existing control-
ler and seconds in the new controller. Convert
these paramters from half-cycles to seconds,
as shown in Figure 4.
halfcycles
seconds =
×
2 frequency
FIGURE 4. CONVERT FROM HALF-CYCLES TO
SECONDS
11. Close the Compare Utility window.
12. Put the new controller into setup mode. The
controller has to be in setup mode to change
many settings and parameters. While the con-
troller is in setup mode, all outputs are forced
off, so the genset cannot start.
A029M353 (Issue 1)
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13. Enter the recorded settings into the new con-
troller.
In InPower, use Ctrl + F to activate the Find function
and F3 to find the next occurrence.
14. Unless you plan to change the current trans-
formers as part of the upgrade, make sure the
Genset CT Secondary Current is set for 5A.
Otherwise, enter the primary and secondary
current values of the new current transform-
ers.
15. To set the proper AVR gains for the upgrade
control, right-click on the new controller, and
select Update Features. Then, find the feature
for AVR gains for the generator set model. If
you still have to adjust the AVR gains, see the
Appendix.
If you cannot find this feature, make sure INCal is
up-to-date. If it is, the generator set might not be ap-
proved for operation with the new controller. Con-
tact Cummins Accessories for assistance.
16. Right-click on the controller, and select Save
Adjustments.
17. Disable setup mode.
Upgrade from the PowerCommand 2.x
Controller
1. Reconnect the battery charger (if equipped).
Reconnect all electrical supplies.
 2. Reconnect the genset negative (−) battery
cable.
3. Connect to the new controller using InPower.
4. Select Device > Initial Calibration....
Make sure you have downloaded the latest version
of the firmware, as explained in Get the Required
Tools.
5. Navigate through the pop-up windows until the
downloading begins. Do not select any fea-
tures.
6. Drag the opened capture file (created in Save
the Existing Controller Settings onto the
new controller, and release it.
7. Navigate through the pop-up windows until the
operation is finished.
8. Select Device > Save Adjustments, and click
Save in the pop-up window.
TEST THE INSTALLATION
1. Deactivate the E-stop button.
2. Activate the fault reset to clear any inactive
faults.
FIGURE 5. OPENING GENSET OEM SETUP TEMPLATES
3. If fault code 2814 (Genset CT Ratio Too Small)
is still active, the current transformers are im-
properly sized for the upgraded AmpSentry
protection. See Troubleshooting Fault Code
2814 below.
4. Test the installation by starting the genset and
verifying proper operation. Make adjustments
to the speed, voltage, and frequency adjust as
needed.
5. Disconnect the computer from the control.
6. Set the control to the desired operating mode.
Troubleshooting Fault Code 2814
The upper and lower limits for the primary CT ratio
are calculated from many pieces of information. If
fault code 2814 is active, make sure that the Gen-
set Power Ratings, Frequency Range, Nominal
Frequency, Nominal Voltage Limits, and Genset
Secondary CT Current are setup correctly. One
way to do this is to use the OEM setup screens.
1. In InPower, right-click on the control, and se-
lect Genset OEM Setup ... from the pull-down
menu as shown in Figure 5.
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 2. In the Genset OEM Setup screen, click En-
able Setup mode to put the controller in setup
mode.
The controller has to be in setup mode to
change many settings and parameters (for ex-
FIGURE 6. ALTERNATOR OEM SETUP SCREEN
4. Make sure that the Genset Power Ratings,
Frequency Range, Nominal Frequency, Nomi-
nal Voltage, Nominal Voltage Limits, and Gen-
set Secondary CT Current are setup correctly.
5. Check the CT Primary Upper and Lower
Ranges to ensure the current transformers are
suitable. If they are not, use these values as a
guide for selecting the proper replacements.
6. When setup is complete, click Disable Setup
mode.
7. Return to step 4 in Test the Installation.
APPENDIX: GENSET TUNING
The automatic voltage regulator (AVR) uses a four-
coefficient PID algorithm that runs five hundred
times each second.
A029M353 (Issue 1)
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ample, voltage, frequency, etc). While the con-
troller is in setup mode, all outputs are forced
off, so the genset cannot start.
3. Click on the Alternator OEM (1 of 2) tab as
shown in Figure 6.
K1 sets the overall AVR gain. It is a true proportion-
al gain which is multiplied against the voltage error
signal.
• K1 should be adjusted to meet the specifica-
tion for percent off rated voltage during load
acceptance and to prevent large voltage over-
shoots during offloads and genset startup.
• In general, K1 increases in value with increas-
ing generator size.
K2 controls the recovery shape of voltage tran-
sients during large-load acceptance and rejection.
This is a true integral gain which is multiplied
against the sum of all previous errors.
• If K2 is too high, the voltage performance is un-
stable. If K2 is too low, the voltage perfor-
mance is slow or has steady-state voltage-off-
set errors.
• In general, K2 decreases in value with increas-
ing generator size.
K3 affects high-frequency characteristics of the rithm. It is set for basic stability. In general, it should
AVR algorithm. It is set for basic stability. In gener- not need to be adjusted.
al, it should not need to be adjusted.
Table 5 and Table 6 provide standard values for
K4 is a calculated value. You cannot adjust it. It is K1−K4 and damping terms for Cummins Generator
set for basic stability. Technologies (CGT) alternators at 50-Hz and
60-Hz operation.
The damping term is used to calculate K4. It affects
high-frequency characteristics of the AVR algo-
TABLE 5. STANDARD VALUES FOR K1−K4 AND DAMPING TERMS FOR CGT ALTERNATORS (50-HZ
OPERATION)
GENERATOR CGT BC/UC CGT BC/UC CGT (NON−P7)
Output Power < 200 kW 200 kW − 400 kW > 400 kW
Open-circuit Time Constant <=1.2 sec 1.3 sec − 2.2 sec >= 2.3 sec
K1 3.50 4.5 5.0
K2 1.00 0.80 0.50
K3 84.0 84.0 84.0
K4 12.48 (calculated) 12.48 (calculated) 12.48 (calculated)
Damping 78.0 78.0 78.0
Shunt Gain Multiplier 1.5 1.5 1.5

TABLE 6. STANDARD VALUES FOR K1−K4 AND DAMPING TERMS FOR CGT ALTERNATORS (60-HZ
OPERATION)
GENERATOR CGT BC/UC CGT BC/UC CGT (NON−P7)
Output Power < 200 kW 200 kW − 400 kW > 400 kW
Open-circuit Time Constant <=1.2 sec 1.3 sec − 2.2 sec >= 2.3 sec
K1 3.50 4.5 5.0
K2 1.00 0.80 0.50
K3 86.0 86.0 86.0
K4 11.06 (calculated) 11.06 (calculated) 11.06 (calculated)
Damping 79.0 79.0 79.0
Shunt Gain Multiplier 1.5 1.5 1.5

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