Asia Pacic

10 Toh Guan Road

#07-01
TT International Tradepark
Singapore 608838
Phone 65 6417 2388
Fax 65 6417 2399

China
8 Wanyuan Street
Beijing Economic and
Technological Dev. Area
Beijing 100176
P.R. China
Phone 86 10 6788 2258
Fax 86 10 6788 2285

Brazil
Rua Jati, 310, Cumbica
Guarulhos, SP 07180-900
Brazil
Phone 55 11 2186 4195
Fax 55 11 2186 4729

Europe, CIS, Middle East

and Africa
Manston Park Columbus Ave.
Manston Ramsgate
Kent CT 12 5BF
United Kingdom
Phone 44 1843 255000
Fax 44 1843 255902

India
35A/1/2, Erandawana
Pune 411 038
India
Phone 91 020 6602 7525
Fax 91 020 6602 8090

Mexico
Eje 122 No. 200 Zona Industrial
San Luis Potos, S.L.P. 78395
Mexico
Phone 52 444 870 6700
Fax 52 444 824 0082

Latin America
3350 Southwest 148th Ave.
Suite 205
Miramar, FL 33027
USA
Phone 1 954 431 5511
Fax 1 954 433 5797

North America
1400 73rd Ave. NE
Minneapolis, MN 55432
USA
Phone 1 763 574 5000
Fax 1 763 574 5298

PowerCommand
> Digital paralleling systems overview

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2008 Cummins Power Generation Inc. All rights reserved. Specications subject to
change without notice. Cummins Power Generation and Cummins are trademarks of
Cummins Inc. PowerCommand is a registered trademark of Cummins Power Generation.
Our energy working for you. is a trademark of Cummins Power Generation. Other
company, product, or service names may be trademarks or service marks of others.
F-2054 Rev. 11/08

000F-2054.indd 16-1

4/23/09 6:00:24 PM

Installation Overview
Installation of a PowerCommand Digital Paralleling
System is very similar to a conventional system
except that the equipment tends to be physically
smaller with fewer interconnection points. Also, in
order to retain the reliability of the system, genset to
genset interconnections are directly installed rather
than being routed through third-party controls. In
systems which use the PowerCommand Network for
control interconnections, there may be 30% fewer
connections compared to a conventional system.
For the convenience of the installer and to make eld
service more reliable, all core control interconnections
in the system are made on standardized terminal blocks
simplifying connections for experienced technicians.

Interconnections between switchgear sections are

made with plug/jack connections so a simple plug-in
facilitates fast installation of that equipment.
Removable lifting eyes are provided for all switchgear
and control equipment.
Power and control interconnections can generally be
made either from the top or bottom of the enclosure.
(Consult your project drawings for exact details on
this point.) This leaves the designer with the exibility
to choose the best location for the controls based on
how the equipment is used, and maximizing the
system reliability.

PowerCommand Digital Paralleling Systems utilize a family of dedicated-purpose

microprocessor-based control, power production and power transfer devices that
are integrated into on-site power systems for isolated prime power, emergency,
standby, interruptible or CHP (combined heat and power) applications.

PowerCommand Digital Paralleling Systems utilize

fully integrated microprocessor-based controls for all
system control and protection functions. The inherent
control capabilities of the system components allow for
the design of more intelligent power systems, resulting
in major gains in the areas where designers and users
need them:
s 'REATER EFlCIENCY OF FACILITY DESIGN BY REDUCTION
in physical space requirements;
s (IGHERRELIABILITYBYREDUCTIONSINTHENUMBER
of components, improvements in component
reliability, detailed failure mode effects analysis
and reductions in the number of single points
of failure in the system;
s "ETTERSYSTEMPERFORMANCEAND
s 'REATER EASE OF USE FOR OPERATORS
PowerCommand Digital Paralleling systems include an
extensive array of standard control and digital display
features that eliminate the need for discrete component
devices such as voltage regulator, governor and
protective relays. The integration also eliminates the
need for separate paralleling control devices such as
synchronizers and load sharing controls.

PowerCommand Digital Paralleling is an innovative

approach compared to traditional paralleling, but it is
hardly new. Literally thousands of PowerCommand
digital paralleling systems are in service in nearly every
application imaginable, all over the world. Some of the
installations were installed over 10 years ago.
Cummins Power Generation has designed and
manufactured generator set control systems for over
75 years. Cummins Power Generation is one of the
largest manufacturers in the world of diesel engines,
alternators from 20 to 3,000 kVA, governors and
voltage regulators. For over 25 years Cummins has
manufactured paralleling electronics optimized for
Cummins products, and introduced the rst fully
integrated microprocessor-based paralleling systems
over 10 years ago.
In addition to standard generator sets and controls,
Cummins Power Generation manufactures paralleling
components such as synchronizers, load sensors and
master start sensors. Cummins also manufactures
automatic transfer switch controls and network
components and systems. This extensive design and
manufacturing experience coupled with factory-trained
local support by the Cummins distributor network
results in system capability, reliability and support that
have revolutionized paralleling systems.

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000F-2054.indd 2-13

www.cumminspower.com

4/23/09 6:00:27 PM

Remote Monitoring and Control

The use of an integrated, microprocessor-based
control system makes it possible for PowerCommand
Digital Paralleling Systems to incorporate a wide
variety of possible means to provide for remote
monitoring and control of the system.
A common service tool is available for direct service
of the PowerCommand electronics. The Cummins
PowerCommand InPower service tool is a personal
computer (PC) based tool that allows direct diagnostics
and service of all Cummins Power Generation
electronics, including generator set/paralleling controls
master control modules, power transfer controls and
Cummins engine ECM. This versatile and easy-to-use
tool allows for fast diagnostics of problems, consistent
settings, and easy testing and documentation. Versions
of the tool are available for customer use in better
understanding, adjusting and monitoring their
installed equipment.
PowerCommand InPower is designed to be
used either directly connected to the control
or via a modem interface.

12

000F-2054.indd 12-1

PowerCommand Systems incorporate standard

interfaces to allow communication with
typical building automation systems (BAS). All
PowerCommand genset systems can be set up to
provide a Modbus RTU/RS485 interface to external
monitoring systems. Through the use of standardized
register maps, it is easy for a third-party BAS supplier
to read data on generator sets, transfer switches and
other Cummins equipment, as well as provide external
start commands and some controls, such as remote
reset of some fault conditions. Where an existing BAS
is not in place, or when a dedicated remote monitoring
system is desired, PowerCommand Pulse monitoring
systems provide a customized monitoring and control
system for any facility.
TM

PowerCommand iWatchTM systems can provide

information on systems any place where there is an
available Internet connection. A Web server module
provides TCP/IP interfaces between PowerCommand
systems and an external system using a Web browser
to monitor the system, rather than dedicated software.
Multiple system components can be monitored from
a single point. Information is provided in a graphical
display format, so generator set, transfer switch and
paralleling system data can be easily understood
by users. System alarms can be automatically
routed to designated paging systems, providing an
economical means for remote monitoring and faster
response to system problems. For situations where
a network interface is not available, PowerCommand
iWatch systems are also provided in wireless
versions that utilize cellular or satellite interfaces for
communications.

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Equipment Congurations
PowerCommand paralleling systems are each
designed to the needs of the application, so users
get the reliability and functionality they need rather
than potentially excessive and complex designs
of the supplier. For example, in applications such
as supervised prime power where master control
functions are minimal, a discrete master control
section may be eliminated and breakers located close
to the gensets to minimize space requirements and
installation costs.
For stationary emergency/standby applications
where the normal power supply is reliable, some
designers will opt to use stationary non-drawout
paralleling breakers, rather than drawout breakers.
This arrangement minimizes the space required in
the facility, allows front-access-only switchboard
congurations, and still provides all the control
functions of traditional paralleling arrangements.

Prototype tested, dedicated purpose electronics provide exibility

without the risks associated with customized hardware and software.

Applications which demand use of drawout breakers

such as utility (mains) inter-tied equipment can be
accommodated using a drawout type switchgear
arrangement and a freestanding master control panel.
The cost and size of the equipment can be minimized
by elimination of the cross bus in the master control
section of the equipment.
Flexibility in the physical design of equipment is
necessary to meet critical design requirements in
facilities, and digital paralleling makes it easy to
be exible.

www.cumminspower.com

4/23/09 6:00:31 PM

Traditional System Architecture

System Control Functions

Generator Paralleling Control

Master Control

Governing: Governing is a function of the engine ECM,

along with engine protection and some other functions.

Main Bus Output Metering: Individual analog

metering and switches (Sel Sw) for amps (AM), volts
(VM), kW (WM)
Alarm Indication: Individual alarm lamps (not shown)
provide indications for system alarms.
Operator Interface: Individual control switches and
status lamps (not shown) provide all operator functions.
Number and type vary with project requirements. Manual
synchronizing is performed using synchronizing lamps
(SL) and a synchroscope (SS).
System Control Logic: Programmable Logic Controller
(PLC) provides system control logic for load adding
and shedding, load demand.
System Protection: Under-frequency relay (81u)

Voltage Regulation: Voltage regulator (AVR) mounted

on genset
Engine/Alternator Monitor and Control: Solid-state
or relay logic, individual analog AC metering (AM, VM,
&-(Z%( ANNUNCIATOR!..

PowerCommand Digital Paralleling Systems are

designed to use the minimum possible space in a
facility. In a modern facility, equipment space can be
costly. By integrating supervisory control equipment
into a single master control (or possibility eliminating it)
and using stationary breakers, equipment oor space
allocation can be reduced by up to 70%.
PowerCommand Digital Paralleling Systems are
designed to be easy to use. Control functions are
located where the operator or service technician can
most conveniently access them. Networkability makes
system data on all components available over an
industry-standard monitoring and control network at the
operators personal computer or via modem at remote
monitoring and service locations. An interactive graphic
display panel (with optional Digital MasterControl)
provides information in an easy-to-use format.

PowerCommand Digital Paralleling Systems

respond to the changing needs of facilities. As
facility use changes, often control system needs
change. Software-based PowerCommand paralleling
systems with Digital MasterControls can easily be
modied for new control functions by simply changing
the system software. Controls are designed for
backward compatibility, to maintain parts availability
throughout system life span.
Distributor Service Support. Cummins has
an extensive and well trained distributor service
organization, with locations all around the world. Local
service is available for ALL components of on-site
power systems, and since control components are
used on tens of thousands of generator sets around
the world, they are also easy to source locally.

Engine/Alternator Protection: Reverse power relay (32),

overcurrent (51) in paralleling breaker
Load Sharing: Separate load sharing control (ILS),
droop AVR (or cross current)
Auto Synchronizing and Sync Check: Separate
synchronizer (25)
Import/Export Control (I/E): Controls kW load on
gensets while in parallel with the utility
Var/Power Factor Control (VAR/PF): Controls kVAR
load on gensets while in parallel with the utility
Standard reports using Cummins PowerCommand
InPower provide system operation data to make
record-keeping easy. PowerCommand systems can be
interfaced to nearly any building management system
via Modbus (RS485) or other interfaces.
TM

PowerCommand Digital Paralleling Systems

are easy to service. In spite of all their reliability
features, all systems eventually require service, and
the PowerCommand Digital Paralleling system is
especially easy for technicians to service. LED statusindicating lamps show the technician when the system
control components are operating properly. The entire
paralleling control panel or Digital Master Control can
be directly connected to a personal computer (PC) so
the entire system and all interacting components can
be interrogated, monitored and adjusted quickly and
efciently. When repairs are necessary, plug and jack
connections on core controls are plug-interfaced, for
fast and reliable replacement, since wiring errors are
eliminated. This translates into less system downtime
and greater overall system reliability.

000F-2054.indd 2-11

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www.cumminspower.com

Simple master control system status displays operated from

dedicated-purpose distributed logic controllers provide
information needed for safe, manual operation of the system.

11

4/23/09 6:00:33 PM

PowerCommand System Architecture

System Control Functions
Digital MasterControl (typical)
Main Bus Output Metering: provides true RMS
readings for amps, volts, hertz, kW, kVAR, kVA,
power factor via an operator panel or touch-screen
display for generator bus and utility bus.
Alarm Indication: Solid State Annunciator (ALARM
PANELS) provides LED indications for system alarm
and generator set major indications.
Operator Interface (HMI): Dedicated operator panel
or touch screen provides functions of all control switches,
alarm indications and metering. Also provides manual
synchronizing, graphic system display, genset status
and settings.

System Control Logic: The PowerCommand MCM

provides system control logic for load adding and
shedding and load demand, and provides a serial
INTERFACETO(-)ANDALARMANDSTATUSPANELS
System Protection: Provided in system logic based
on inputs from PowerCommand Control and
implementation by MCM.
Generator Paralleling Control
Governing: PowerCommand Control via engine ECM
Voltage Regulation: PowerCommand Control
Engine/Alternator Monitor and Control:
PowerCommand Control
Engine/Alternator Protection: PowerCommand Control
Load Sharing: PowerCommand Control

Enhancing System Efciency

System designers look far beyond initial hardware cost
to overall system cost, which encompasses system
design efciency, facility design cost-effectiveness,
and ease of operation and service.
PowerCommand Digital Paralleling Systems make
system design easy. Through use of standardized

Auto Synchronizing and Sync Check, Parallel

Breaker Control: PowerCommand Control
Load Governing (Utility Parallel Load Control):
PowerCommand Control

control hardware for core functions in virtually any

application, and protective systems and equipment
which are designed and optimized by the generator
set manufacturer, PowerCommand systems are easy
for a system designer to condently incorporate into
a facility. Each system design is a simple combination
of common components, integrated together into a
common system.
DIGITAL
MASTER
CONTROL

ALARM
PANELS

52-G2
PowerCommand
Parallel
Control

HMI

PLC
MODBUS
MOD
LON

PCCNET

52-G1

MCM

Cummins Digital Master Control systems are available with touchscreen type operator panels that provide critical information in real
time for more effective operator control with limited training.

Genset operator panels include LED displays for overall status and
push-button interfaces for access to hundreds of data points on
the genset, as well as eld-adjustable parameters.

52-UM

BUS REFERENCE VOLTAGE

CB OPEN/CLOSE COMMANDS & STATUS

52-GM

TO SYSTEM
LOADS

10

000F-2054.indd 10-3

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4/23/09 6:00:38 PM

Enhancing System Performance

Traditionally, paralleling system performance has been
hard to dene because overall system performance was
dependent on the individual performance of components
provided by several manufacturers. With Cummins, the
responsibility for the system is clearly with Cummins,
because we not only supply the whole system, we design
and manufacture the active control systems.
PowerCommand Digital Paralleling Systems provide
fast, accurate synchronizing through the use of
digital synchronizing equipment. The PowerCommand
generator set control operates directly on the engine
governor actuator (or ECM) and alternator excitation
system to directly control synchronizing, real load sharing
and reactive load sharing. The synchronizer instantly
adjusts generator set voltage to match bus voltage and
also matches bus frequency and phase angle over a
broad acceptance range. Once paralleled, the system
bus automatically returns to the preset frequency and
voltage (50 or 60 hertz, normal system voltage).

The PowerCommand Difference

000F-2054.indd 4-9

E
60

PR
LO OP
AD OR
SH TIO
AR NA
E L

R
LO AMP
AD IN
SH G T
AR O
E

GE
ON NS
BU ET
S A

LO
N
IZ
ED
ON

% LOAD

NS

RAMPIN
G TO PR
FREQU
OPER
ENCY

GE
IN
G

CO
M

HR

40

NC

ON

57

LO
W

58

ET

80
FR
EQ
UE
NC
Y

59

SY

20

56

TIME (SECONDS)
FREQUENCY

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PowerCommand Digital Paralleling includes the

capability to ramp on or off an innite bus and
controls both real and reactive power in that mode.
The system can ramp to a specic power level, or
be controlled as a function of other power ows in a
distribution network. Consequently, utility paralleling
can be accomplished without addition of expensive
load control equipment to the system.

100

Digital synchronizing controls allow generator sets to synchronize

from minus 40 to plus 10 percent of nominal frequency and
voltage, making synchronizing more reliable.

PowerCommand Digital Paralleling Systems provide

automatic load ramping capability. The generator set
control system causes the unit to ramp up to proper
frequency and voltage on load application (single unit
application). When actively synchronizing to a live bus,
the control system synchronizes and closes to the bus
with the generator set at no load, and then ramps real
and reactive load up to properly shared values. Prior to
switching off the bus, the generator set will ramp down
to minimum load levels before opening its paralleling
breaker. This allows the system bus to maintain a more
constant voltage and frequency and provide better
quality power to loads, as well as minimizes breaker wear.
This also eliminates nuisance reverse power conditions
when using generator sets of different kW capacity.

60

AT

In a normal black-start condition, system start signals

are sent to the system master control, which relays them
to the individual paralleling control panels. This means
the master is required to make the system work and
makes the master control a single point of failure. The
serious nature of this problem drives many speciers
to require redundant PLC support in the master.
Unfortunately, this generally will result in more single
points of failure. The paralleling control (often via
another PLC not shown in this drawing) passes the
start signal on to each generator set simultaneously.
The generator sets independently start and accelerate
to rated speed and voltage. Generator synchronizers

The second generator set paralleling control, upon

sensing that bus voltage is available, switches on its
synchronizer and forces the generator set to synchronize
to the system bus. When safe paralleling conditions are
reached, a signal is sent to close the paralleling breaker,
and the synchronizer switches off. The system then
switches on the kW load-sharing control system, to
force the individual generator sets to share the available
load on the system equally. Reactive load sharing is
often controlled by droop voltage regulator operation, so
control interconnects are not needed for that function.
The master control provides signals to add loads to the
system in steps, so that the system is not fully loaded
until all the generator sets have closed to the system bus.

PowerCommand Digital Paralleling Systems

incorporate isochronous real and reactive load
sharing. Most modern paralleling systems utilize
isochronous real (kW) load sharing systems. Load
sharing controls allow generator sets to share load
to within as low as 1% of equal. PowerCommand
Digital Paralleling also offers isochronous reactive

BU
S

A traditional paralleling control system, as shown on

page 2, comprises many subsystems and components,
each of which operates independently based on inputs
from several sources. Generator set controls are
generally slaves of a master control that is PLC-based,
and there can be signicant intermingling of genset
control, power transfer and master functions. This
results in multiple failure modes that are difcult to
diagnose and understand.

include dead-bus logic that allows any genset to close

to a dead-bus. Some system manufacturers trust this
dead-bus capability to select the rst generator to
close the bus. Other suppliers, understanding that
similar generators can close to the bus simultaneously
on a black start, include controls to select the rst
available generator and close it to the bus. Other
generators are prevented from closing until the rst
is closed to the bus and operating.

FREQUENCY

Traditional System Control Sequence

load sharing, so the steady-state bus voltage remains

constant, regardless of the load on the system.

www.cumminspower.com

TIME (SECONDS)
FREQUENCY

Synchronizing and load sharing controls work together to

precisely synchronize then ramp on load to the oncoming
generator set, to minimize or eliminate bus disturbances.

4/23/09 6:00:41 PM

generator sets to a dead system bus. A backup deadbus sensor system in each paralleling control allows
the system to properly start after a power failure, even
if the First Start Sensor system or interconnecting
wiring is malfunctioning. Breaker failure protection
controls monitor breaker closure signals and provides
a warning or shutdown if the breaker fails to close
or open on command preventing system malfunction
or generator damage.

PowerCommand Digital Paralleling Systems

incorporate manual backups for synchronizing of
gensets and manual operation capability for power
transfer and load controls. These manual backups
allow a trained operator to safely control the system
when automatic systems misoperate or fail to operate
as expected. Manual backups are commonly
provided for power transfer system breaker control
and load add/shed control.

PowerCommand Digital Paralleling Controls have

been subjected to a detailed FMEA (failure mode
effect analysis) and have an MTBF (mean time
between failures) of up to 300,000 hours. (Based
on data in service, not engineering estimates.) System
reliability cannot be achieved without component
reliability, so PowerCommand controls have been
carefully analyzed and developed to achieve optimum
hardware and logical reliability. Continuous
monitoring and control improvements result in
continuously improving reliability of components.

Inherent System Redundancy. The use of distributed

logic in the overall system design is inherently reliable,
but typical systems incorporate many other levels of
redundancy to support critical functions. For example:
master control modules incorporate dual system
power supply inputs allowing the use of multiple DC
power supplies for each module, so a DC bus fault will
not disable the control; the master control operator
panel may be supplied in multiple locations, so a failure
of one panel wont cripple system operation; load add
and shed have backup functions available; load share
interconnections are congured to prevent a single
break from disabling the system; automatic transfer
systems incorporate manual backup provisions as
standard; master control module status (including
alarm conditions) can be viewed even with the operator
panel(s) completely failed; and many others.

PowerCommand Master Control functions are

provided in a dedicated eld-congurable master
control module, which eliminates need for a
custom-programmed PLC for critical functions
such as AC metering, system status, load
sequencing and power transfer functions.
The use of a dedicated-purpose controller allows
provision of fully prototype tested control hardware
and logic. PLC equipment is used for customized
features and network communications in more
complex applications.

Systems are factory tested prior to shipment. Each

system is tested as a complete system, including all
generator set controls. The process results in accurate
load sharing system setup and system operational
verication prior to equipment assembly at the job site.

The primary reason for paralleling is to achieve enhanced reliability, but reliability
doesnt come automatically with paralleling. That requires careful design, the best
available components and the best available on-site service.

A PowerCommand Paralleling generator set can work

in the same physical environment as shown for
traditional systems, but provide synchronizing (25) and
load-sharing control (ILS) functions, and directly open
and close the paralleling breaker. These functions,
along with all the functions shown on the genset, are
integrated together and located on the genset. To an
uninformed user the system will look like a traditional
system, but all the active control is in the genset.

System Components
In a traditional generator set paralleling system there
are three major types of control subsystems: generator
sets, paralleling control panels and master control panels.
Power transfer controls, when used, were provided as
part of transfer switch equipment or incorporated into
the master control. The generator sets produce the
power in the system; the paralleling controls provide
synchronizing, load sharing and other control/protective
functions for each generator set; and the system master
control acts as the interface between the generator sets
and paralleling controls and the rest of the facility.
Switchgear or switchboards connect the powerproducing generator sets to the emergency/standby
distribution system. In traditional paralleling systems
the paralleling and master controls normally are
integrated with the power-carrying components in the
system (primarily for the convenience of the paralleling
equipment supplier). The functions are typically provided
with individual components for each function. With
PowerCommand Digital Paralleling Systems, the
paralleling controls for the generator set are integrated
into the generator set and located remotely from the
paralleling power section. The integration of the
paralleling and generator set controls promotes reliability
by minimizing sensitive interface points between the
genset and paralleling controls. This minimizes the
impact of RFI and EMI on the control system and allows
validation of the capability of the system as installed to
established standards. Other material and design
selections that improve reliability are the use of sealed
membrane switches suitable for millions of cycles of
operation rather than mechanical switches, use of LED
rather than incandescent lamps, and the elimination of
rotary potentiometers in the system.
Master control functions are not required for system
operation in PowerCommand systems, but are provided
by Cummins in a range of master control products with
capabilities matched to system requirements. System
designers are able to specify to the needs of the

www.cumminspower.com

000F-2054.indd 8-5

application, whether a simple low-cost arrangement

is needed, or complex project requirements are
implemented. Master controls may be integrated into
the switchgear/switchboard equipment, or provided in
freestanding enclosures to minimize the exposure of
operators to arc ash hazards. Power transfer controls
are either used in conventional packaged automatic
transfer switches, or provided within the master control
architecture. When multiple power transfer points are
used, a dedicated controller is provided for each
transfer point to minimize exposure of the system to
single points of failure.
Note that in the illustration on page 3 the master control
INCORPORATESANETWORKINTERFACETOA0,#AND(-) 4HIS
optional feature allows genset data to be directly viewed
AT THE MASTER CONTROL FOR OPERATOR CONVENIENCE 4HE (-)
may be a dedicated-purpose panel or touch screen.

PowerCommand System
Control Sequence
In PowerCommand Digital Paralleling Systems, as
shown on page 3, a master control system and the
generator paralleling controls operate independently
but interface directly for optimum system control. In a
normal black-start condition, system start signals are
sent directly to each generator set and to the Digital
Master Control for status/alarm annunciation. The
PowerCommand generator sets independently start
and accelerate to rated speed and voltage. First Start
Sensor integrated into the generator controls is used
to monitor each generator set as it is starting, chooses
the rst unit to reach operating voltage and frequency,
and allows that unit to close to the system bus.
A back-up control in each generator set is provided
in the event that the rst start sensor system fails.
The second (and all other) generator set paralleling
control(s), upon sensing that bus voltage is available,
switches on its synchronizer within the PowerCommand
Control and forces the generator set to synchronize to
the system bus. When safe paralleling conditions are
reached, the PowerCommand Control closes the
paralleling breaker and switches off the synchronizer
function. The PowerCommand Control then
communicates with the other generator sets in the
system to share the available real and reactive load
on the system equally. The Digital Master Control
provides signals to add loads to the system in steps
so that the system is not fully loaded until all the
generator sets have closed to the system bus.

4/23/09 6:00:42 PM

ANSI Control & Protection Functions

Master/Power Transfer Control
SWITCHGEAR
GENERATOR BUS

UTILITY BUS
POWERCOMMAND MCM3320 CONTROL

AS

KWH

PF

KW

Generator Set Control

AS

ILS

PF

KWH

VS

Hz

40

32

65

27

81
o/u

59

FM

47

15

90

TO OTHER GENSET
FIRST START SENSORS

51V

86
V

VS

FSS

25

KW

PF

Hz

27

KWH

AS

59

81
o/u

27

TO GENSETS:
FREQUENCY & VOLTAGE
CONTROL

SS

SWITCHGEAR

VS

81
o/u

59

Surge Suppressor

KW

Surge Suppressor

POWERCOMMAND PARALLEL CONTROL

TO OTHER GENSET
LOAD SHARING LINES

Surge Suppressor

A
ALTERNATOR

OPEN
CLOSE

47

Hz

VS

15

25

SYSTEM CONTROL
(MCM)

OPEN

OPEN
CLOSE

CLOSE

LOADS

Enhancing System Reliability

PowerCommand Digital Paralleling Systems utilize
a fully integrated distributed logic design. Each
major component in the system (genset/control,
master control and power transfer control) includes
sufcient controls and logic to operate completely
autonomously in the event of failure of other system
components. The gensets with their paralleling
breakers are also autonomous as a group and
synchronize, parallel and load share with each other,
regardless of the performance of other equipment in
the system. Each utility service to the system has an
independent control to monitor its condition and
control operation of the power transfer system. In other
systems, loss of a single component in a single
control can cause total system failure. All the controls
are designed and interfaced to work together, and the
number of system components is reduced, so the
entire system is more reliable for the customer.
PowerCommand Digital Paralleling Systems
include AmpSentry for Paralleling. Conventional
generator set protective systems that utilize
components designed for utility power applications
often do not adequately protect the generator set and
can malfunction, resulting in nuisance system failures.
AmpSentry protection is specically designed to
eliminate nuisance generator set failures that occur
6

000F-2054.indd 6-7

with molded-case breaker protection, while providing

a higher standard of protection for the alternator.
Instantaneous trips are not necessary for alternator
protection, so they are not provided, improving the
probability of effective downstream protection
discrimination. Properly coordinated protection
becomes even more important in paralleling
applications, where system protection and
coordination are often more difcult for the designer.
AmpSentry for Paralleling includes overcurrent and
overload warning alarms, in addition to shutdowns
for overcurrent, short circuit, overvoltage, undervoltage,
underfrequency, overload, reverse power, loss of
excitation, alternator phase rotation and circuit
breaker failure to close. Fault regulation eliminates
the need for grounding resistors for generator set
protection in low and medium voltage applications.
PowerCommand Digital Paralleling Equipment is
specically designed to operate in a generator set
environment. The PowerCommand Control operates
properly in ambient temperatures from 40C to +70C.
It includes internal controls protected from dust, RFI/
EMI and dust/moisture. The control has passed
prototype testing to verify its durability and reliability
under the vibration conditions present in a generator
application. The control power source is the generator
Our energy working for you.

set starting batteries. The generator set batteries are

monitored to detect a failure in the charging system,
and a weak battery alarm sounds when the battery
bank fails the lead test during generator set starting.
The control system provides accurate and reliable
logic, fuel and excitation control at control voltages
down to 8 VDC. All master control functions are also
operational at that level, eliminating need for auxiliary
DC power supplies.
PowerCommand Digital Paralleling is designed
to enhance total system reliability by extensive
use of microprocessor-based components and
elimination of common nuisance failure points
in the system. The integration inherent in
PowerCommand allows the elimination of many
components in a typical system. Some examples of
this include the elimination of all incandescent lamps
from the alarm and status annunciation system,
elimination of potential transformers and fuse sets
(PowerCommand directly reads voltages up to 600
VAC), and the elimination of many termination points
between the paralleling control panel and the
generator set. Digital switches and a display screen
eliminate the need for potentiometers and heavy-duty
meter and control switches, which are exposed to the
environment and subject to failure due to dust and
www.cumminspower.com

dirt contamination of contact assemblies. The use of

a common set of hardware for almost all applications
allows complete and detailed documentation for
the system.
PowerCommand Paralleling Systems include
digital synchronizing controls. Synchronizer reliability
depends on the ability of the controls to force the
generator set to synchronize to the system bus quickly
under a wide range of ambient and load conditions
without causing system instability. PowerCommand
generator set paralleling controls operate over a very
broad bus voltage and frequency operating range,
and over very broad ambient conditions. The
generator set governing controls are temperature
dynamic, automatically adjusting governing
characteristics to account for changes in engine
operating temperature. This enables the system to
synchronize quickly and reliably even if the bus is
greatly overloaded and operating at grossly abnormal
frequency conditions.
PowerCommand Digital Paralleling Systems
include First Start Sensor and breaker failure
protection. Cummins Power Generation pioneered
the use of First Start Sensor interlock technology to
prevent simultaneous closure of unsynchronized

4/23/09 6:00:44 PM

ANSI Control & Protection Functions

Master/Power Transfer Control
SWITCHGEAR
GENERATOR BUS

UTILITY BUS
POWERCOMMAND MCM3320 CONTROL

AS

KWH

PF

KW

Generator Set Control

AS

ILS

PF

KWH

VS

Hz

40

32

65

27

81
o/u

59

FM

47

15

90

TO OTHER GENSET
FIRST START SENSORS

51V

86
V

VS

FSS

25

KW

PF

Hz

27

KWH

AS

59

81
o/u

27

TO GENSETS:
FREQUENCY & VOLTAGE
CONTROL

SS

SWITCHGEAR

VS

81
o/u

59

Surge Suppressor

KW

Surge Suppressor

POWERCOMMAND PARALLEL CONTROL

TO OTHER GENSET
LOAD SHARING LINES

Surge Suppressor

A
ALTERNATOR

OPEN
CLOSE

47

Hz

VS

15

25

SYSTEM CONTROL
(MCM)

OPEN

OPEN
CLOSE

CLOSE

LOADS

Enhancing System Reliability

PowerCommand Digital Paralleling Systems utilize
a fully integrated distributed logic design. Each
major component in the system (genset/control,
master control and power transfer control) includes
sufcient controls and logic to operate completely
autonomously in the event of failure of other system
components. The gensets with their paralleling
breakers are also autonomous as a group and
synchronize, parallel and load share with each other,
regardless of the performance of other equipment in
the system. Each utility service to the system has an
independent control to monitor its condition and
control operation of the power transfer system. In other
systems, loss of a single component in a single
control can cause total system failure. All the controls
are designed and interfaced to work together, and the
number of system components is reduced, so the
entire system is more reliable for the customer.
PowerCommand Digital Paralleling Systems
include AmpSentry for Paralleling. Conventional
generator set protective systems that utilize
components designed for utility power applications
often do not adequately protect the generator set and
can malfunction, resulting in nuisance system failures.
AmpSentry protection is specically designed to
eliminate nuisance generator set failures that occur
6

000F-2054.indd 6-7

with molded-case breaker protection, while providing

a higher standard of protection for the alternator.
Instantaneous trips are not necessary for alternator
protection, so they are not provided, improving the
probability of effective downstream protection
discrimination. Properly coordinated protection
becomes even more important in paralleling
applications, where system protection and
coordination are often more difcult for the designer.
AmpSentry for Paralleling includes overcurrent and
overload warning alarms, in addition to shutdowns
for overcurrent, short circuit, overvoltage, undervoltage,
underfrequency, overload, reverse power, loss of
excitation, alternator phase rotation and circuit
breaker failure to close. Fault regulation eliminates
the need for grounding resistors for generator set
protection in low and medium voltage applications.
PowerCommand Digital Paralleling Equipment is
specically designed to operate in a generator set
environment. The PowerCommand Control operates
properly in ambient temperatures from 40C to +70C.
It includes internal controls protected from dust, RFI/
EMI and dust/moisture. The control has passed
prototype testing to verify its durability and reliability
under the vibration conditions present in a generator
application. The control power source is the generator
Our energy working for you.

set starting batteries. The generator set batteries are

monitored to detect a failure in the charging system,
and a weak battery alarm sounds when the battery
bank fails the lead test during generator set starting.
The control system provides accurate and reliable
logic, fuel and excitation control at control voltages
down to 8 VDC. All master control functions are also
operational at that level, eliminating need for auxiliary
DC power supplies.
PowerCommand Digital Paralleling is designed
to enhance total system reliability by extensive
use of microprocessor-based components and
elimination of common nuisance failure points
in the system. The integration inherent in
PowerCommand allows the elimination of many
components in a typical system. Some examples of
this include the elimination of all incandescent lamps
from the alarm and status annunciation system,
elimination of potential transformers and fuse sets
(PowerCommand directly reads voltages up to 600
VAC), and the elimination of many termination points
between the paralleling control panel and the
generator set. Digital switches and a display screen
eliminate the need for potentiometers and heavy-duty
meter and control switches, which are exposed to the
environment and subject to failure due to dust and
www.cumminspower.com

dirt contamination of contact assemblies. The use of

a common set of hardware for almost all applications
allows complete and detailed documentation for
the system.
PowerCommand Paralleling Systems include
digital synchronizing controls. Synchronizer reliability
depends on the ability of the controls to force the
generator set to synchronize to the system bus quickly
under a wide range of ambient and load conditions
without causing system instability. PowerCommand
generator set paralleling controls operate over a very
broad bus voltage and frequency operating range,
and over very broad ambient conditions. The
generator set governing controls are temperature
dynamic, automatically adjusting governing
characteristics to account for changes in engine
operating temperature. This enables the system to
synchronize quickly and reliably even if the bus is
greatly overloaded and operating at grossly abnormal
frequency conditions.
PowerCommand Digital Paralleling Systems
include First Start Sensor and breaker failure
protection. Cummins Power Generation pioneered
the use of First Start Sensor interlock technology to
prevent simultaneous closure of unsynchronized

4/23/09 6:00:44 PM

generator sets to a dead system bus. A backup deadbus sensor system in each paralleling control allows
the system to properly start after a power failure, even
if the First Start Sensor system or interconnecting
wiring is malfunctioning. Breaker failure protection
controls monitor breaker closure signals and provides
a warning or shutdown if the breaker fails to close
or open on command preventing system malfunction
or generator damage.

PowerCommand Digital Paralleling Systems

incorporate manual backups for synchronizing of
gensets and manual operation capability for power
transfer and load controls. These manual backups
allow a trained operator to safely control the system
when automatic systems misoperate or fail to operate
as expected. Manual backups are commonly
provided for power transfer system breaker control
and load add/shed control.

PowerCommand Digital Paralleling Controls have

been subjected to a detailed FMEA (failure mode
effect analysis) and have an MTBF (mean time
between failures) of up to 300,000 hours. (Based
on data in service, not engineering estimates.) System
reliability cannot be achieved without component
reliability, so PowerCommand controls have been
carefully analyzed and developed to achieve optimum
hardware and logical reliability. Continuous
monitoring and control improvements result in
continuously improving reliability of components.

Inherent System Redundancy. The use of distributed

logic in the overall system design is inherently reliable,
but typical systems incorporate many other levels of
redundancy to support critical functions. For example:
master control modules incorporate dual system
power supply inputs allowing the use of multiple DC
power supplies for each module, so a DC bus fault will
not disable the control; the master control operator
panel may be supplied in multiple locations, so a failure
of one panel wont cripple system operation; load add
and shed have backup functions available; load share
interconnections are congured to prevent a single
break from disabling the system; automatic transfer
systems incorporate manual backup provisions as
standard; master control module status (including
alarm conditions) can be viewed even with the operator
panel(s) completely failed; and many others.

PowerCommand Master Control functions are

provided in a dedicated eld-congurable master
control module, which eliminates need for a
custom-programmed PLC for critical functions
such as AC metering, system status, load
sequencing and power transfer functions.
The use of a dedicated-purpose controller allows
provision of fully prototype tested control hardware
and logic. PLC equipment is used for customized
features and network communications in more
complex applications.

Systems are factory tested prior to shipment. Each

system is tested as a complete system, including all
generator set controls. The process results in accurate
load sharing system setup and system operational
verication prior to equipment assembly at the job site.

The primary reason for paralleling is to achieve enhanced reliability, but reliability
doesnt come automatically with paralleling. That requires careful design, the best
available components and the best available on-site service.

A PowerCommand Paralleling generator set can work

in the same physical environment as shown for
traditional systems, but provide synchronizing (25) and
load-sharing control (ILS) functions, and directly open
and close the paralleling breaker. These functions,
along with all the functions shown on the genset, are
integrated together and located on the genset. To an
uninformed user the system will look like a traditional
system, but all the active control is in the genset.

System Components
In a traditional generator set paralleling system there
are three major types of control subsystems: generator
sets, paralleling control panels and master control panels.
Power transfer controls, when used, were provided as
part of transfer switch equipment or incorporated into
the master control. The generator sets produce the
power in the system; the paralleling controls provide
synchronizing, load sharing and other control/protective
functions for each generator set; and the system master
control acts as the interface between the generator sets
and paralleling controls and the rest of the facility.
Switchgear or switchboards connect the powerproducing generator sets to the emergency/standby
distribution system. In traditional paralleling systems
the paralleling and master controls normally are
integrated with the power-carrying components in the
system (primarily for the convenience of the paralleling
equipment supplier). The functions are typically provided
with individual components for each function. With
PowerCommand Digital Paralleling Systems, the
paralleling controls for the generator set are integrated
into the generator set and located remotely from the
paralleling power section. The integration of the
paralleling and generator set controls promotes reliability
by minimizing sensitive interface points between the
genset and paralleling controls. This minimizes the
impact of RFI and EMI on the control system and allows
validation of the capability of the system as installed to
established standards. Other material and design
selections that improve reliability are the use of sealed
membrane switches suitable for millions of cycles of
operation rather than mechanical switches, use of LED
rather than incandescent lamps, and the elimination of
rotary potentiometers in the system.
Master control functions are not required for system
operation in PowerCommand systems, but are provided
by Cummins in a range of master control products with
capabilities matched to system requirements. System
designers are able to specify to the needs of the

www.cumminspower.com

000F-2054.indd 8-5

application, whether a simple low-cost arrangement

is needed, or complex project requirements are
implemented. Master controls may be integrated into
the switchgear/switchboard equipment, or provided in
freestanding enclosures to minimize the exposure of
operators to arc ash hazards. Power transfer controls
are either used in conventional packaged automatic
transfer switches, or provided within the master control
architecture. When multiple power transfer points are
used, a dedicated controller is provided for each
transfer point to minimize exposure of the system to
single points of failure.
Note that in the illustration on page 3 the master control
INCORPORATESANETWORKINTERFACETOA0,#AND(-) 4HIS
optional feature allows genset data to be directly viewed
AT THE MASTER CONTROL FOR OPERATOR CONVENIENCE 4HE (-)
may be a dedicated-purpose panel or touch screen.

PowerCommand System
Control Sequence
In PowerCommand Digital Paralleling Systems, as
shown on page 3, a master control system and the
generator paralleling controls operate independently
but interface directly for optimum system control. In a
normal black-start condition, system start signals are
sent directly to each generator set and to the Digital
Master Control for status/alarm annunciation. The
PowerCommand generator sets independently start
and accelerate to rated speed and voltage. First Start
Sensor integrated into the generator controls is used
to monitor each generator set as it is starting, chooses
the rst unit to reach operating voltage and frequency,
and allows that unit to close to the system bus.
A back-up control in each generator set is provided
in the event that the rst start sensor system fails.
The second (and all other) generator set paralleling
control(s), upon sensing that bus voltage is available,
switches on its synchronizer within the PowerCommand
Control and forces the generator set to synchronize to
the system bus. When safe paralleling conditions are
reached, the PowerCommand Control closes the
paralleling breaker and switches off the synchronizer
function. The PowerCommand Control then
communicates with the other generator sets in the
system to share the available real and reactive load
on the system equally. The Digital Master Control
provides signals to add loads to the system in steps
so that the system is not fully loaded until all the
generator sets have closed to the system bus.

4/23/09 6:00:42 PM

Enhancing System Performance

Traditionally, paralleling system performance has been
hard to dene because overall system performance was
dependent on the individual performance of components
provided by several manufacturers. With Cummins, the
responsibility for the system is clearly with Cummins,
because we not only supply the whole system, we design
and manufacture the active control systems.
PowerCommand Digital Paralleling Systems provide
fast, accurate synchronizing through the use of
digital synchronizing equipment. The PowerCommand
generator set control operates directly on the engine
governor actuator (or ECM) and alternator excitation
system to directly control synchronizing, real load sharing
and reactive load sharing. The synchronizer instantly
adjusts generator set voltage to match bus voltage and
also matches bus frequency and phase angle over a
broad acceptance range. Once paralleled, the system
bus automatically returns to the preset frequency and
voltage (50 or 60 hertz, normal system voltage).

The PowerCommand Difference

000F-2054.indd 4-9

E
60

PR
LO OP
AD OR
SH TIO
AR NA
E L

R
LO AMP
AD IN
SH G T
AR O
E

GE
ON NS
BU ET
S A

LO
N
IZ
ED
ON

% LOAD

NS

RAMPIN
G TO PR
FREQU
OPER
ENCY

GE
IN
G

CO
M

HR

40

NC

ON

57

LO
W

58

ET

80
FR
EQ
UE
NC
Y

59

SY

20

56

TIME (SECONDS)
FREQUENCY

Our energy working for you.

PowerCommand Digital Paralleling includes the

capability to ramp on or off an innite bus and
controls both real and reactive power in that mode.
The system can ramp to a specic power level, or
be controlled as a function of other power ows in a
distribution network. Consequently, utility paralleling
can be accomplished without addition of expensive
load control equipment to the system.

100

Digital synchronizing controls allow generator sets to synchronize

from minus 40 to plus 10 percent of nominal frequency and
voltage, making synchronizing more reliable.

PowerCommand Digital Paralleling Systems provide

automatic load ramping capability. The generator set
control system causes the unit to ramp up to proper
frequency and voltage on load application (single unit
application). When actively synchronizing to a live bus,
the control system synchronizes and closes to the bus
with the generator set at no load, and then ramps real
and reactive load up to properly shared values. Prior to
switching off the bus, the generator set will ramp down
to minimum load levels before opening its paralleling
breaker. This allows the system bus to maintain a more
constant voltage and frequency and provide better
quality power to loads, as well as minimizes breaker wear.
This also eliminates nuisance reverse power conditions
when using generator sets of different kW capacity.

60

AT

In a normal black-start condition, system start signals

are sent to the system master control, which relays them
to the individual paralleling control panels. This means
the master is required to make the system work and
makes the master control a single point of failure. The
serious nature of this problem drives many speciers
to require redundant PLC support in the master.
Unfortunately, this generally will result in more single
points of failure. The paralleling control (often via
another PLC not shown in this drawing) passes the
start signal on to each generator set simultaneously.
The generator sets independently start and accelerate
to rated speed and voltage. Generator synchronizers

The second generator set paralleling control, upon

sensing that bus voltage is available, switches on its
synchronizer and forces the generator set to synchronize
to the system bus. When safe paralleling conditions are
reached, a signal is sent to close the paralleling breaker,
and the synchronizer switches off. The system then
switches on the kW load-sharing control system, to
force the individual generator sets to share the available
load on the system equally. Reactive load sharing is
often controlled by droop voltage regulator operation, so
control interconnects are not needed for that function.
The master control provides signals to add loads to the
system in steps, so that the system is not fully loaded
until all the generator sets have closed to the system bus.

PowerCommand Digital Paralleling Systems

incorporate isochronous real and reactive load
sharing. Most modern paralleling systems utilize
isochronous real (kW) load sharing systems. Load
sharing controls allow generator sets to share load
to within as low as 1% of equal. PowerCommand
Digital Paralleling also offers isochronous reactive

BU
S

A traditional paralleling control system, as shown on

page 2, comprises many subsystems and components,
each of which operates independently based on inputs
from several sources. Generator set controls are
generally slaves of a master control that is PLC-based,
and there can be signicant intermingling of genset
control, power transfer and master functions. This
results in multiple failure modes that are difcult to
diagnose and understand.

include dead-bus logic that allows any genset to close

to a dead-bus. Some system manufacturers trust this
dead-bus capability to select the rst generator to
close the bus. Other suppliers, understanding that
similar generators can close to the bus simultaneously
on a black start, include controls to select the rst
available generator and close it to the bus. Other
generators are prevented from closing until the rst
is closed to the bus and operating.

FREQUENCY

Traditional System Control Sequence

load sharing, so the steady-state bus voltage remains

constant, regardless of the load on the system.

www.cumminspower.com

TIME (SECONDS)
FREQUENCY

Synchronizing and load sharing controls work together to

precisely synchronize then ramp on load to the oncoming
generator set, to minimize or eliminate bus disturbances.

4/23/09 6:00:41 PM

PowerCommand System Architecture

System Control Functions
Digital MasterControl (typical)
Main Bus Output Metering: provides true RMS
readings for amps, volts, hertz, kW, kVAR, kVA,
power factor via an operator panel or touch-screen
display for generator bus and utility bus.
Alarm Indication: Solid State Annunciator (ALARM
PANELS) provides LED indications for system alarm
and generator set major indications.
Operator Interface (HMI): Dedicated operator panel
or touch screen provides functions of all control switches,
alarm indications and metering. Also provides manual
synchronizing, graphic system display, genset status
and settings.

System Control Logic: The PowerCommand MCM

provides system control logic for load adding and
shedding and load demand, and provides a serial
INTERFACETO(-)ANDALARMANDSTATUSPANELS
System Protection: Provided in system logic based
on inputs from PowerCommand Control and
implementation by MCM.
Generator Paralleling Control
Governing: PowerCommand Control via engine ECM
Voltage Regulation: PowerCommand Control
Engine/Alternator Monitor and Control:
PowerCommand Control
Engine/Alternator Protection: PowerCommand Control
Load Sharing: PowerCommand Control

Enhancing System Efciency

System designers look far beyond initial hardware cost
to overall system cost, which encompasses system
design efciency, facility design cost-effectiveness,
and ease of operation and service.
PowerCommand Digital Paralleling Systems make
system design easy. Through use of standardized

Auto Synchronizing and Sync Check, Parallel

Breaker Control: PowerCommand Control
Load Governing (Utility Parallel Load Control):
PowerCommand Control

control hardware for core functions in virtually any

application, and protective systems and equipment
which are designed and optimized by the generator
set manufacturer, PowerCommand systems are easy
for a system designer to condently incorporate into
a facility. Each system design is a simple combination
of common components, integrated together into a
common system.
DIGITAL
MASTER
CONTROL

ALARM
PANELS

52-G2
PowerCommand
Parallel
Control

HMI

PLC
MODBUS
MOD
LON

PCCNET

52-G1

MCM

Cummins Digital Master Control systems are available with touchscreen type operator panels that provide critical information in real
time for more effective operator control with limited training.

Genset operator panels include LED displays for overall status and
push-button interfaces for access to hundreds of data points on
the genset, as well as eld-adjustable parameters.

52-UM

BUS REFERENCE VOLTAGE

CB OPEN/CLOSE COMMANDS & STATUS

52-GM

TO SYSTEM
LOADS

10

000F-2054.indd 10-3

Our energy working for you.

www.cumminspower.com

4/23/09 6:00:38 PM

Traditional System Architecture

System Control Functions

Generator Paralleling Control

Master Control

Governing: Governing is a function of the engine ECM,

along with engine protection and some other functions.

Main Bus Output Metering: Individual analog

metering and switches (Sel Sw) for amps (AM), volts
(VM), kW (WM)
Alarm Indication: Individual alarm lamps (not shown)
provide indications for system alarms.
Operator Interface: Individual control switches and
status lamps (not shown) provide all operator functions.
Number and type vary with project requirements. Manual
synchronizing is performed using synchronizing lamps
(SL) and a synchroscope (SS).
System Control Logic: Programmable Logic Controller
(PLC) provides system control logic for load adding
and shedding, load demand.
System Protection: Under-frequency relay (81u)

Voltage Regulation: Voltage regulator (AVR) mounted

on genset
Engine/Alternator Monitor and Control: Solid-state
or relay logic, individual analog AC metering (AM, VM,
&-(Z%( ANNUNCIATOR!..

PowerCommand Digital Paralleling Systems are

designed to use the minimum possible space in a
facility. In a modern facility, equipment space can be
costly. By integrating supervisory control equipment
into a single master control (or possibility eliminating it)
and using stationary breakers, equipment oor space
allocation can be reduced by up to 70%.
PowerCommand Digital Paralleling Systems are
designed to be easy to use. Control functions are
located where the operator or service technician can
most conveniently access them. Networkability makes
system data on all components available over an
industry-standard monitoring and control network at the
operators personal computer or via modem at remote
monitoring and service locations. An interactive graphic
display panel (with optional Digital MasterControl)
provides information in an easy-to-use format.

PowerCommand Digital Paralleling Systems

respond to the changing needs of facilities. As
facility use changes, often control system needs
change. Software-based PowerCommand paralleling
systems with Digital MasterControls can easily be
modied for new control functions by simply changing
the system software. Controls are designed for
backward compatibility, to maintain parts availability
throughout system life span.
Distributor Service Support. Cummins has
an extensive and well trained distributor service
organization, with locations all around the world. Local
service is available for ALL components of on-site
power systems, and since control components are
used on tens of thousands of generator sets around
the world, they are also easy to source locally.

Engine/Alternator Protection: Reverse power relay (32),

overcurrent (51) in paralleling breaker
Load Sharing: Separate load sharing control (ILS),
droop AVR (or cross current)
Auto Synchronizing and Sync Check: Separate
synchronizer (25)
Import/Export Control (I/E): Controls kW load on
gensets while in parallel with the utility
Var/Power Factor Control (VAR/PF): Controls kVAR
load on gensets while in parallel with the utility
Standard reports using Cummins PowerCommand
InPower provide system operation data to make
record-keeping easy. PowerCommand systems can be
interfaced to nearly any building management system
via Modbus (RS485) or other interfaces.
TM

PowerCommand Digital Paralleling Systems

are easy to service. In spite of all their reliability
features, all systems eventually require service, and
the PowerCommand Digital Paralleling system is
especially easy for technicians to service. LED statusindicating lamps show the technician when the system
control components are operating properly. The entire
paralleling control panel or Digital Master Control can
be directly connected to a personal computer (PC) so
the entire system and all interacting components can
be interrogated, monitored and adjusted quickly and
efciently. When repairs are necessary, plug and jack
connections on core controls are plug-interfaced, for
fast and reliable replacement, since wiring errors are
eliminated. This translates into less system downtime
and greater overall system reliability.

000F-2054.indd 2-11

Our energy working for you.

www.cumminspower.com

Simple master control system status displays operated from

dedicated-purpose distributed logic controllers provide
information needed for safe, manual operation of the system.

11

4/23/09 6:00:33 PM

Remote Monitoring and Control

The use of an integrated, microprocessor-based
control system makes it possible for PowerCommand
Digital Paralleling Systems to incorporate a wide
variety of possible means to provide for remote
monitoring and control of the system.
A common service tool is available for direct service
of the PowerCommand electronics. The Cummins
PowerCommand InPower service tool is a personal
computer (PC) based tool that allows direct diagnostics
and service of all Cummins Power Generation
electronics, including generator set/paralleling controls
master control modules, power transfer controls and
Cummins engine ECM. This versatile and easy-to-use
tool allows for fast diagnostics of problems, consistent
settings, and easy testing and documentation. Versions
of the tool are available for customer use in better
understanding, adjusting and monitoring their
installed equipment.
PowerCommand InPower is designed to be
used either directly connected to the control
or via a modem interface.

12

000F-2054.indd 12-1

PowerCommand Systems incorporate standard

interfaces to allow communication with
typical building automation systems (BAS). All
PowerCommand genset systems can be set up to
provide a Modbus RTU/RS485 interface to external
monitoring systems. Through the use of standardized
register maps, it is easy for a third-party BAS supplier
to read data on generator sets, transfer switches and
other Cummins equipment, as well as provide external
start commands and some controls, such as remote
reset of some fault conditions. Where an existing BAS
is not in place, or when a dedicated remote monitoring
system is desired, PowerCommand Pulse monitoring
systems provide a customized monitoring and control
system for any facility.
TM

PowerCommand iWatchTM systems can provide

information on systems any place where there is an
available Internet connection. A Web server module
provides TCP/IP interfaces between PowerCommand
systems and an external system using a Web browser
to monitor the system, rather than dedicated software.
Multiple system components can be monitored from
a single point. Information is provided in a graphical
display format, so generator set, transfer switch and
paralleling system data can be easily understood
by users. System alarms can be automatically
routed to designated paging systems, providing an
economical means for remote monitoring and faster
response to system problems. For situations where
a network interface is not available, PowerCommand
iWatch systems are also provided in wireless
versions that utilize cellular or satellite interfaces for
communications.

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Equipment Congurations
PowerCommand paralleling systems are each
designed to the needs of the application, so users
get the reliability and functionality they need rather
than potentially excessive and complex designs
of the supplier. For example, in applications such
as supervised prime power where master control
functions are minimal, a discrete master control
section may be eliminated and breakers located close
to the gensets to minimize space requirements and
installation costs.
For stationary emergency/standby applications
where the normal power supply is reliable, some
designers will opt to use stationary non-drawout
paralleling breakers, rather than drawout breakers.
This arrangement minimizes the space required in
the facility, allows front-access-only switchboard
congurations, and still provides all the control
functions of traditional paralleling arrangements.

Prototype tested, dedicated purpose electronics provide exibility

without the risks associated with customized hardware and software.

Applications which demand use of drawout breakers

such as utility (mains) inter-tied equipment can be
accommodated using a drawout type switchgear
arrangement and a freestanding master control panel.
The cost and size of the equipment can be minimized
by elimination of the cross bus in the master control
section of the equipment.
Flexibility in the physical design of equipment is
necessary to meet critical design requirements in
facilities, and digital paralleling makes it easy to
be exible.

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4/23/09 6:00:31 PM

Installation Overview
Installation of a PowerCommand Digital Paralleling
System is very similar to a conventional system
except that the equipment tends to be physically
smaller with fewer interconnection points. Also, in
order to retain the reliability of the system, genset to
genset interconnections are directly installed rather
than being routed through third-party controls. In
systems which use the PowerCommand Network for
control interconnections, there may be 30% fewer
connections compared to a conventional system.
For the convenience of the installer and to make eld
service more reliable, all core control interconnections
in the system are made on standardized terminal blocks
simplifying connections for experienced technicians.

Interconnections between switchgear sections are

made with plug/jack connections so a simple plug-in
facilitates fast installation of that equipment.
Removable lifting eyes are provided for all switchgear
and control equipment.
Power and control interconnections can generally be
made either from the top or bottom of the enclosure.
(Consult your project drawings for exact details on
this point.) This leaves the designer with the exibility
to choose the best location for the controls based on
how the equipment is used, and maximizing the
system reliability.

PowerCommand Digital Paralleling Systems utilize a family of dedicated-purpose

microprocessor-based control, power production and power transfer devices that
are integrated into on-site power systems for isolated prime power, emergency,
standby, interruptible or CHP (combined heat and power) applications.

PowerCommand Digital Paralleling Systems utilize

fully integrated microprocessor-based controls for all
system control and protection functions. The inherent
control capabilities of the system components allow for
the design of more intelligent power systems, resulting
in major gains in the areas where designers and users
need them:
s 'REATER EFlCIENCY OF FACILITY DESIGN BY REDUCTION
in physical space requirements;
s (IGHERRELIABILITYBYREDUCTIONSINTHENUMBER
of components, improvements in component
reliability, detailed failure mode effects analysis
and reductions in the number of single points
of failure in the system;
s "ETTERSYSTEMPERFORMANCEAND
s 'REATER EASE OF USE FOR OPERATORS
PowerCommand Digital Paralleling systems include an
extensive array of standard control and digital display
features that eliminate the need for discrete component
devices such as voltage regulator, governor and
protective relays. The integration also eliminates the
need for separate paralleling control devices such as
synchronizers and load sharing controls.

PowerCommand Digital Paralleling is an innovative

approach compared to traditional paralleling, but it is
hardly new. Literally thousands of PowerCommand
digital paralleling systems are in service in nearly every
application imaginable, all over the world. Some of the
installations were installed over 10 years ago.
Cummins Power Generation has designed and
manufactured generator set control systems for over
75 years. Cummins Power Generation is one of the
largest manufacturers in the world of diesel engines,
alternators from 20 to 3,000 kVA, governors and
voltage regulators. For over 25 years Cummins has
manufactured paralleling electronics optimized for
Cummins products, and introduced the rst fully
integrated microprocessor-based paralleling systems
over 10 years ago.
In addition to standard generator sets and controls,
Cummins Power Generation manufactures paralleling
components such as synchronizers, load sensors and
master start sensors. Cummins also manufactures
automatic transfer switch controls and network
components and systems. This extensive design and
manufacturing experience coupled with factory-trained
local support by the Cummins distributor network
results in system capability, reliability and support that
have revolutionized paralleling systems.

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Asia Pacic
10 Toh Guan Road
#07-01
TT International Tradepark
Singapore 608838
Phone 65 6417 2388
Fax 65 6417 2399

China
8 Wanyuan Street
Beijing Economic and
Technological Dev. Area
Beijing 100176
P.R. China
Phone 86 10 6788 2258
Fax 86 10 6788 2285

Brazil
Rua Jati, 310, Cumbica
Guarulhos, SP 07180-900
Brazil
Phone 55 11 2186 4195
Fax 55 11 2186 4729

Europe, CIS, Middle East

and Africa
Manston Park Columbus Ave.
Manston Ramsgate
Kent CT 12 5BF
United Kingdom
Phone 44 1843 255000
Fax 44 1843 255902

India
35A/1/2, Erandawana
Pune 411 038
India
Phone 91 020 6602 7525
Fax 91 020 6602 8090

Mexico
Eje 122 No. 200 Zona Industrial
San Luis Potos, S.L.P. 78395
Mexico
Phone 52 444 870 6700
Fax 52 444 824 0082

Latin America
3350 Southwest 148th Ave.
Suite 205
Miramar, FL 33027
USA
Phone 1 954 431 5511
Fax 1 954 433 5797

North America
1400 73rd Ave. NE
Minneapolis, MN 55432
USA
Phone 1 763 574 5000
Fax 1 763 574 5298

PowerCommand
> Digital paralleling systems overview

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www.cumminspower.com

2008 Cummins Power Generation Inc. All rights reserved. Specications subject to
change without notice. Cummins Power Generation and Cummins are trademarks of
Cummins Inc. PowerCommand is a registered trademark of Cummins Power Generation.
Our energy working for you. is a trademark of Cummins Power Generation. Other
company, product, or service names may be trademarks or service marks of others.
F-2054 Rev. 11/08

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