PowerCommand 3.

3 Control Introduction
VTA28, QST30, KTA38, and KTA50
 Agenda

Overview

Beyond PCC3100 control

Features & Benefits Matrix

Generator Set Architecture Changes

Performance

Competitive Comparison

Schedule

Accessories & Aftermarket support

2 6/4/2012
Overview

3 6/4/2012
Overview

Recently introduced PowerCommand 3.3 control

on CPG Kent produced genset models

VTA28, QST30, KTA38 & KTA50 Genset Models

Discontinued PCC 3100 control

4 6/4/2012
 Product Rationalization

– Approximately 77% of generator sets sold in this product range

were sold with a paralleling control.
– Paralleling control were offered as an option before with 3100
control
• With new PowerCommand 3.3, paralleling is an integral
function to the control and offered as standard feature
• Reduced complexity of the product and supply chain
• Less inventory for replacement parts with product
standardization
• New Control comparable or better than competitor product
offerings

5 6/4/2012
Beyond PCC3100

6 6/4/2012
 PCC3100 to PowerCommand 3.3

PowerCommand 3.3

PCC3100
7 6/4/2012
 PowerCommand 3.3:
Beyond the PCC3100

Enhanced Power Transfer Control

Extended Paralleling - Baseload and Peakshave

HMI320: Larger display PowerCommand 3.3

• More information per screen

• Easier navigation resulting in reduced setup time
• Enhanced serviceability

Real Time Clock

• Fault and Event time stamping
• Exerciser clock with time of day start/stop control PCC3100
with and without load
• Start/Stop of Base Load and Peak Shave
Functions

8 6/4/2012
 Beyond the 3100 Contd..

Modbus: 3rd party networking (Internet-able)

PCCNet:

Interoperable with other Cummins devices

Expandable I/O

Multiple HMI’s: local and remote

Common customer interface

•Prevents wiring issues
•Faster mean time to repair

9 6/4/2012
 Optional Components / Accessories
In addition to the above features, we also offer the following
optional accessories provided through the parts
department.
• Annunciator Panel
• I/O Modules
• Bargraph
• Remote Monitoring

Annunciator I/O Module Bargraph Remote Monitoring

10 6/4/2012
 Features & Benefits of 3.3 over 3100
Advanced Paralleling Features

Power Transfer Control
– Provides automatic power transfer during utility failure
Benefits:
– No need for separate transfer switch control => Reduced system cost
– Reduced system complexity => Reduced commissioning time

Extended Paralleling
– Offers advanced operating modes for paralleling with utility
• Peak shave mode: Supply power from genset only for peak loads
• Base load mode: Genset provides base load power; Utility supplies peak load
Benefits:
– Optimize electricity cost/usage
– Avoid penalties due to low power factor & exceeding max.demand

11 6/4/2012
 Features & Benefits of 3.3 over 3100
Enhanced Communications

Modbus RTU
– Industry wide accepted protocol for system integration
Benefits:
– Ability to connect with third party devices
– Integrate genset with building management system (BMS)
– Internet-able using Modbus-TCP gateway

PCCnet
– Cummins proprietary protocol for integrating Cummins accessories
Benefits:
– Allows “plug n play” for increased flexibility and customization
• Connect I/O Expansion module to accommodate application specific needs
– Provides ability to serve niche requirements
• Connect annunciator in a hospital application

12 6/4/2012
 Features & Benefits of 3.3 over 3100
Expanded Feature set

Genset Exerciser
– Allows the system to be operated at preset times in different test modes
Benefits:
– Schedule maintenance test routines to ensure system reliability & dependability at all times
– Preempt failures

Genset Battery Monitoring System

– Battery monitoring system to sense and warn against a weak battery condition
Benefits:
− Low and High Battery Voltage warning
− Indicates battery charging system failure
− Weak battery condition

Battleshort mode
– Allows control to bypass certain shutdown faults
– Annunciates the bypassed faults to the user
Benefits:
– Valuable in mission critical applications such as hospitals where emergency loads need not be shutdown due
to non-critical faults

13 6/4/2012
 Features & Benefits of 3.3 over 3100
Availability of Advanced Options

Enhanced Remote Monitoring
– Offers ability to monitor the system using web without requiring any software
download
Benefits:
– Allows datalogging, reporting & trending; Reduces response time to issues
– Highly valuable in applications such as mining where gensets deployed at site may
not be easily accessible

Other optional modules

– Remote HMI (Monitor genset from comfort of your office)
– Annunciator (Display genset alarms and status indications)
– Bargraphs
– I/O Expansion modules (Expand functionality to fit application needs)
– ILSI Module (Parallel to third party/non-Cummins genset)

14 6/4/2012
 3.3 Control: Additional Benefits

AmpSentry feature
• Integrated monitoring and protective function to
maintain system integrity
• Protects alternator against thermal damage
curve
• AmpSentry is a UL listed protective relay
• Provides overload protection for generator and
feeder conductors
• Under fault conditions regulates fault current so
that downstream breakers will trip
• Provides single and three phase fault current
regulation
• Simplifies the need for genset mounted circuit
breaker
• Enables selective coordination
Note: Does not include utility protection

15 6/4/2012
Features and Benefits Matrix
PowerCommand 3.3
VTA28, QST30, KTA38, and KTA50

16 6/4/2012
 Features & Benefits Matrix
Feature Description Benefit to customer Example Use case

Provides complete engine and alternator

diagnostics and protection •Integrated
ECM functionality
(Applicable to Hydro mechanical gensets only) solution

•Better performance
Provides automatic alternator voltage
AVR
regulation • Potential Cost

Governor control Provides engine speed control savings

Remotely mounted => good for

Front panel with screen; Used for viewing
HHP applications where
Display system parameters as well as navigation & •Easier to view customers may not want to stand
configuration
right next to genset

• Allows datalogging
Ability to monitor the system using web/mobile trending & reporting Mining application where gensets
Remote monitoring (optional) devices without requiring any software deployed at site could not be
download accessed easily

•Reduces response time to

issues

• Low and High Battery

voltage warning
Battery monitoring system to sense and warn
Genset Battery Monitoring system • Indicates battery charging
against a weak battery condition
system failure
• Weak battery warning
UL listed protective relay
• Potentially simplify breaker
AmpSentry™ needs
Integral to the PowerCommand Controls
• Protect alternator against
thermal damage

17 6/4/2012
 Features & Benefits Matrix
Benefit to Example
Feature Description
customer Use case

• Ability/flexibility to
Customer wants to
Additional digital/analog Inputs/Outputs connect external devices
monitor chiller
Configurable I/Os available to be configured by the
temperature ; connects
external user • Tailor the system for the
RTD to the control
application

Communication

• Most preferred protocol

• Connect third party

Industry wide accepted protocol for Integrate your genset into
Modbus devices;
system integration a BMS
• Internet-able (With
Modbus/TCP gateway)

Standard protocol for engine • Does not impact Procure engine data to
CAN
communication customer directly display to end user

Cummins proprietary communication • Facilitates expansion of

Connect annunciator for
PCCNet protocol to connect certain Cummins control capabilities to
a hospital application
accessories serve niche requirements

Lonworks protocol no longer available with 3.3 control

18 6/4/2012
 Features & Benefits Matrix

Example
Feature Description Benefit to customer
Use case

• Increases system
“A test with load for 1 hr
Exerciser/Real time Allows the system to be operated at dependability
every Tuesday at 2 am”
clock preset times in different test modes
can be programmed
• Ability to preempt failures

Do not want to shutdown

• Valuable in mission-critical
Allows control to bypass certain emergency loads in case of
Battleshort applications such as
shutdown faults non-critical fault ( example :
hospitals
higher emission level)

• Expands control
Monitor genset from the
Additional Cummins devices that can functionality to serve special
Optional modules comfort of your office using
be connected to control requirements or
remote HMI
customization

19 6/4/2012
 Paralleling Features Matrix
Feature
Island mode (Isolated bus)
Single Utility paralleling
Extended paralleling
Power transfer control
Third party genset paralleling*
Manual sync/paralleling
Multiple Gensets paralleling with
utility
20 6/4/2012
Description
Allows gen-gen paralleling
Allows gen paralleling with utility
Allows peak shaving and power
factor management
Provides automatic power transfer
during utility failure
Parallel to non-Cummins gensets
Gen paralleling using manual
operation
Allows paralleling of multiple gen
with utility
Benefit to customer
• Provides ability to increase power
capacity; Offers modularity
• Supplement power for intermittent
needs
• Optimize electricity cost/usage
• Avoid penalties due to low pf
• Saves cost for separate transfer
switch control
• Reduced system complexity =
Reduced commissioning time
• Greater system reliability
• Flexibility
• Serves customers used to
conventional methods
• Optimize system cost and
complexity of operation
 Summary

3.x control provides great advantages in terms of integrated
functionalities (AVR, ECM etc) which increases genset performance
and reliability

AmpSentry capability is unique and unmatched

Paralleling feature set is comparable to the best in market

PCCNet enables plug ‘n’ play of optional modules for expandability to
meet customer needs

We are starting to see more control manufacturers having the same
integrated paralleling features that we have on our high-end
(PowerCommand 3.3) products. Some manufacturers have more
advanced communications (Ethernet/TCPIP) and color HMI option.

21 6/4/2012
Generator set Architecture Changes
VTA28, QST30, KTA38, and KTA50

22 6/4/2012
 New PowerCommand 3.3 Control on a VTA28
powered generator set

Common customer
interface on VTA28,
QST30, KTA38, and
KTA50 platforms.

Paralleling functionality
now standard in every
generator set

Meets the same codes and
standards as current
product

23 6/4/2012
 Common Customer Interface

Common appearance
and look on VTA28,
QST30, KTA38, and
KTA50 generator set
platforms.

HMI 320 (320 x 240
pixels graphic LED
backlight LCD)
Bargraph
Bargraph (option)
HMI320
E-Stop

E-Stop

24 6/4/2012
Bargraph (option)

Landscape style

• Available in Portrait style as genset mounted

option
• Landscape style only offered through accessories
department
• Provides better visual indication of critical
Portrait style parameters
• LED powered information display enhances the
visuals in dark conditions

25 6/4/2012
 Control Panel Mounting (No Change)

KTA50: End Facing

VTA28, QST30, and KTA38: Right, Left, and End
Facing

Left Facing End Facing Right Facing

26 6/4/2012
 New Relay Options

Relays - Paralleling Circuit Breaker Control - New
– The genset control includes two output relays for operating a paralleling
circuit breaker with open/close function. Relay coils are operated by the
genset control board outputs. Each relay includes two normally open and two
normally closed isolated contacts rated 10 amps, 600 Volts.

Shutdown Alarm Relay 3PDT
– The generator set control includes one auxiliary output relay which is
energized when a genset shutdown fault occurs. The relay remains energized
until the fault is reset. Relay has two normally open and two normally closed,
isolated contacts rated at 600 Volts AC, 10 amperes.
– Replaced the option “Warning and Shutdown - Alarm Relay (4PDT PCC)”

Auxiliary Relays, 10A,600V
– The generator set control includes three auxiliary output relays that are wired
to configurable outputs. Each relay includes two normally open and two
normally closed, isolated contacts rated at 600 Volts AC, 10 Amperes
maximum.
– Replaced the option “Run Relays - 3 x 3PDT

27 6/4/2012
 13 Control Languages now available!

1. English 8. Finnish – New!

2. French 9. Danish – New!
3. German 10.Norwegian – New!
4. Spanish 11.Russian – New!
5. Portuguese 12.Greek – New!
6. Dutch 13.Chinese – New!
7. Italian – New! 14. Japanese – TBA
NOTE: Italian, Finnish, and Danish new to
the VTA28, QST30, and KTA38
15.Hungarian – TBA
platforms

28 6/4/2012
 Digital I/O Module (AUX 101)

Features & Benefits

– Up to sixteen (16) configurable relays provide easy control
of system equipment such as lamps, louvers, motors and
pumps.
– Up to twelve (12) configurable discrete inputs for monitoring
equipment status and faults.
– Up to eight (8*) analog inputs. Analog inputs can be
assigned one of seven preprogrammed functions.
– See AUX 101 spec sheet for additional features

Mounted in the Genset Control Box (GCB) for easy
access and installation of customer connections.
*Digital I/O Module is required when the option “Gauge - Exhaust Gas Temp (Pyrometer)” is
selected. Two of the eight analog inputs are required for this option.

29 6/4/2012
 Exhaust Gas Temperature Monitoring

Exhaust temperature is measured at each exhaust

stack.

A digital readout of the exhaust temperature is
displayed on the HMI.

Digital I/O Module (Aux 101) is required with this
option.

Exhaust Gas
Temperature
Sensors

30 6/4/2012
 50L (P7) Product Revisions

Added the PowerCommand 3.3

Discontinued the PCC3100 and PCC2100 Options

Genset Control Box was modified to accommodate
customer control connections at single location.

31 6/4/2012
 50L (P7) Product Revisions

Common Customer Interface

Genset Control
Box (GCB)

P7 Alternator

32 6/4/2012
 28, 30, & 38L (HC6) Product Revisions

Released the PowerCommand 3.3

Discontinued the PCC3100 and PCC3100 Paralleling
options

Genset Control Box was modified to accommodate
customer control connections at single location

33 6/4/2012
 28, 30, & 38L (HC6) Product Revisions

Common Customer Interface

Genset Control
Box (GCB)

HC6 Alternator

34 6/4/2012
 Genset Control Box with Options
(Hydro Mechanical version shown for the HC6/P7 alternators)

Optional Relays
MODBUS

Optional
Digital I/O Hydro
Module Mechanical
(AUX 101) (AUX 105)
PCC3300

Used on the VTA28, QST30, KTA38, and KTA50 generator set platforms

35 6/4/2012
 28, 30, 38, and 50L (HC6 & P7) Genset
Control Box
30L – PGI (FAE)Engine

Alternator Voltage
PowerStage
(AUX103)

28L, 38L & 50L HM Engines

Hydro Mechanical
(AUX 105)

36 6/4/2012
 28L (HC5) Product Revisions

Released the PowerCommand 3.3

Discontinued the PCC3100 and PCC3100 Paralleling
options

Genset Control Box was modified to accommodate
customer control connections at single location

37 6/4/2012
 28L (HC5) Product Revisions

Common Customer Interface

Genset Control
Box (GCB)

HC5 Alternator

38 6/4/2012
 28L (HC5) Genset Control Box

39 6/4/2012
 Genset Control Box with Options
(shown for the HC5 alternators)

MODBUS

Optional Relays

PCC3300

AUX 101
AUX 105

40 6/4/2012
Performance
PowerCommand 3.3
VTA28, QST30, KTA38, and KTA50

41 6/4/2012
 ISO8528 Generator Set Performance Class

42 6/4/2012
Competitive Comparison
PowerCommand 3.3
VTA28, QST30, KTA38, and KTA50

43 6/4/2012
 Competitor Overview

CAT---- EMCP 3.3

FG Wilson----- 6200 Series

SDMO---- Kerys

ComAp--- Intelligen NT

Deif---- AGC3

44 6/4/2012
 Individual comparisons
PowerCommand 3.3 advantage over EMCP3.3

Integrated Digital AVR
• 3 Phase full wave rectified for better motor starting
• More reliable – no potentiometers
• Ready right from the factory

AC Metering Accuracy
• 0.50% versus 1.0%

Alternator Protection
• AmpSentry™
• Short Circuit Protection
• Loss of AC Sense

Service/Reliability
• Multiple components from different manufacturers.
• Who do you call when something breaks?
• Single service tool versus many
• PowerCommand control boards are potted

Paralleling . . . (see next slide)

45 6/4/2012
 PowerCommand Paralleling Advantage

• Integrated Sync Check

• First Start Sensor
• Paralleling Failure Mode Effects
Analysis (FMEA)
• Breaker Fail to Open/Close
• Breaker Contact Warning
• PTC functionality resides in one
control
• CAT only supports Droop
paralleling when paralleled with
utility
• Synchroscope- Monitors
synchronization
CAT PowerCommand

46 6/4/2012
 Individual comparisons
Advantage PowerCommand 3.3 has over FGW’s 6200

Integrated Digital AVR
• 3 Phase full wave rectified for better motor starting
• More reliable – no potentiometers
• Ready right from the factory

Integrated Governor control
• Electronic engine speed control
• Reduced setup time with factory configured governor gains

Alternator Protection
• AmpSentry™
• Short Circuit Protection
• Three phase sensing of utility voltage

Exerciser/Real-time clock
• Exercises system at programmed date/time to ensure reliability & operation
• Supports different test modes: With load, Without load, Extended parallel

Paralleling
• Extended paralleling for peak shave applications
• Multiple gensets paralleling

47 6/4/2012
 Individual comparisons
Advantage PowerCommand 3.3 has over SDMO Kerys

Alternator Protection
• AmpSentry™
• Short Circuit Protection

Exerciser/Real-time clock
• Exercises system at programmed date/time to ensure reliability & operation
• Supports different test modes: With load, Without load, Extended parallel

Key Features not offered by PowerCommand 3.3

Colored HMI
• TFT LCD screen
• Colored graphics; Touchscreen

Ethernet
• Standard with user-friendly on-board website
• Website allows real-time remote monitoring of the system

Power quality metering
• U and I harmonics measurement
• Reactive power metering
• Harmonics display on screen
48 6/4/2012
 Individual comparisons
Advantage PowerCommand 3.3 has over InteliGen NT

Integrated Digital AVR

• 3 Phase full wave rectified PWM output
• Provides better performance (immune to the affects on non-
linear loads)
• Digital = More reliable (no potentiometers)

Alternator Protections

• AmpSentry™ - fault current regulation

Metering
• 3 phase current sensing on Utility Bus

49 6/4/2012
Individual comparisons
Advantage PowerCommand 3.3 has over InteliGen NT (Contd…)

Control Functions
• Battle Short

Service/Reliability
• Single service tool works for genset control and CPG ECM
• PowerCommand control boards are potted

Integrated paralleling functions*

• Load Sharing
• Synchronizer
• Power Transfer Control
• Sync Check
• First Start Sensor (dead bus closure)

Derate function
• Reduces load on genset in response to fault conditions to a targeted
KW setting

* = does not require any additional hardware

50 6/4/2012
Individual comparisons
Advantage PowerCommand 3.3 has over Deif’s AGC 3

Integrated AVR/Governor & AmpSentry
– Offers system integration with reduced component count
– Aids site mobility due to reduced no. of spare parts required
– Built-in over-current protection (AmpSentry) could further reduce system
installation cost, commissioning time and total cost of ownership
Note: Above could be a significant advantage in rental applications

Service/Reliability
- Single service tool works for genset control and CPG ECM
- Ease of Integration with other Cummins switchgear systems & transfer switches
using PCCnet (for communication) & service tool (for commissioning &
configurability)

Key Deif Features not offered by PowerCommand 3.3

Built-in mini-PLC functionality

- Provides some flexibility of system configuration & customization without the need
for additional hardware
- User interface supports some part of this capability (e.g. selector switch for mode
selection)

Load dependent start/stop
- Currently most controls offer this. See next slide for more details

51 6/4/2012
 Load dependant start/stop
(New feature under development)

Control feature that allows shutdown and starting of gensets based on the
load level

Improves fuel efficiency by not running multiple gensets when not needed

Increases service intervals and overall life of the gensets

There is no Master Control needed (such as a DMC)
– referred to as “Masterless Load Demand”

Sophisticated features such as multi-step load add/shed, breaker management, PLC
functionality are not available without DMC

Applications:
– Rental (peak load at certain times of the day)
• Small power plants (gensets are the main source of power: example labor
camps in Middle East)
– Marine applications (fishing barges)
– Commercial applications with significant load variation

52 6/4/2012
Schedule
PowerCommand 3.3
VTA28, QST30, KTA38, and KTA50

53 6/4/2012
 Schedule

PowerZone order availability

– VTA28 – Available now
– KTA38 – Available now
– KTA50 – Available now
– QST30 – 29th July 2012

54 6/4/2012
Accessories & Aftermarket support
PowerCommand 3.3
VTA28, QST30, KTA38, and KTA50

55 6/4/2012
 Accessories & After Market Support
Upgrade Kits

All PCC 3100 control and detector control can be upgraded
to a 3.3 control*
– See spec sheet S-1647 (PowerSuite Library)
• Includes part numbers and specific upgrade information
• Genset model/spec/sr.n. required for upgrade kit identification

All kits available to order now from Fridley (PowerCom) or
through PDC’s(Webparts)

For installation help, submit an ITS ticket under ‘Infant
Care’

PCC3100 (parts only) support will be available till Q4 2016

Please look for final product announcement on this subject
* Not applicable to QST30 & PowerBox 20 genset products

56 6/4/2012
 Questions?
For genset and control product related questions contact:

Bhanu Srilla Gaurav Aggarwal

Product Manager
Power Products Business
Cummins Power Generation
Tel: +01 651 787 6190
Email: bhanu.srilla@cummins.com
Product Manager – Global Controls
Power Systems Business
Cummins Power Generation
Tel: +01 651 787 6271
Email: gaurav.aggarwal@cummins.com

57 6/4/2012