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Cummins PS0600 Controller

Genset Controller PS0600

PowerStart 0600 Our energy working for you. TM

Part no A054G527
Description: The PowerStart control is a microprocessor-based generator set monitoring and control system. The control provides a simple operator interface to the generator set, manual and remote start/stop control and shutdown fault indication, and AMF (Auto Mains Failure) Functionality. 

Features

  • 12 and 24V battery operation
  • Integrated 128x64 Pixel monochrome graphic LCD Display
  • Genset monitoring-monitor status of all critical engine and alternator functions
  • Digital genset metering (AC and DC)
  • Genset battery monitoring system to warn against a weak battery connection
     

Description

The PowerStart control is a microprocessor-based generator set monitoring and control system. The control provides a simple operator interface to the generator set, manual and remote start/stop control and shutdown fault indication, and AMF (Auto Mains Failure) Functionality. Integrating all control functions into a single control provides enhanced reliability and performance compared to conventional generator set control systems. This control has been designed and tested to meet the harsh environment in which gensets are typically applied. The PowerStart generator set control is suitable for use on various generator sets in non-paralleling applications. It is suitable for use with reconnectable or non-reconnectable generators, can be configured for either 50 Hz or 60 Hz, and voltage and power connection from 190-600 VAC line-to-line. This control includes an intuitive operator interface that allows Genset start/stop for complete genset control as well as system metering, fault annunciation, configuration, and diagnostics. The interface includes seven generator set status LED lamps with both internationally accepted symbols and English text to comply with customer needs.

The interface also includes an LED-backlit LCD with tactile-feel soft switches for easy operation and screen navigation. The manual/auto/stop switch function is integrated into the overlay of the controller. All data on the control can be viewed by scrolling through Screens with the navigation keys. The screen can be viewed either by scrolling or nonscrolling mode. Forward navigation and backward navigation is also provided. The control displays the current active fault, fault occurrences, and time-ordered history of the five previous faults concerning Real Time Clock Stamp, and Engine Running Time. Power for this control is derived from the generator set Starting batteries and functions over a voltage from 8VDC to 32VDC.

Features

 Integrated 128x64 Pixel monochrome graphic LCD Display

 12 and 24V battery operation

 Genset monitoring-monitor status of all critical engine and alternator functions

 Digital genset metering (AC and DC)

 Genset battery monitoring system to warn against a weak battery connection

 Configurable for single phase three phase or split-phase AC metering

 Engine starting includes solid-state output to operate an external relay to start the engine, fuel shut off (FSO), and glow Plug

 Genset Protection: protects engine and alternator

 Real-time clock for fault and event stamping

 Fuel level measurement using a 4-20mA input sensor

 Exerciser clock and time of delay start/stop initiate a test without load

 Maintenance due to alarm based on engine running time and real-time clock

 Auto Main Failure (AMF) Provides load transfer operation in open transition mode

 AMF Test with or without load options

 Utility Voltage monitoring and protection

 Remote start capability in Auto mode

 Advanced serviceability using InpowerTM a PC based Software service tool

 Modbus interface for interconnecting with customer  PLC/BMS

 Configurable Inputs and Outputs

 Environmental protection: The Control is designed for reliable operation in harsh environments

 Warranty and service backed by a comprehensive warranty and worldwide distributor service network

 Certification is suitable for use on generator sets that are designed, manufactured, tested, and certified relevant to ISO, IEC, and CE standards.

Control functions

LED indicating lamps: For Genset Running, Remote Start, AMF Test Active, Genset Shutdown, Warning, Load connected to Genset, Load connected to Utility, Manual Mode, Stop Mode, and Auto Mode. 128 x 64 Pixel Monochrome Graphics display

Operation Interface: Six tactile-feel soft switches for LCD navigation, genset operation, and control setup. These switches are indicated by internationally accepted symbols and English text.

Operator adjustments: The LCD includes provisions for necessary setup and adjustment functions.

Data Log includes engine run time and controller on-time Fault

History: Provides a record of the most recent fault Condition with the Engine run time stamp, RTC stamp, and occurrences Up to 5 events are stored in the control non-volatile memory.

AMF Functionality: When Auto Mains Failure is enabled and the controller is in Auto Mode and if the utility goes off then the control starts the Genset automatically and transfers load onto Genset. If Utility returns and is healthy then load again gets retransferred onto Utility. AMF provides load transfer operation in Open Transition transfer mode.

Fuel Level Feature: The Control will show the warning fault when the fuel level in the tank goes below the predefined threshold. Control includes time delays to prevent nuisance warning signals.

Exercise Scheduler: It is used only when the genset is in Auto mode. It is used to start a Scheduler schedule at No Load condition. A trim Exercise

Scheduler Enable is available to enable or disable the feature.

Maintenance: Maintenance due alarm based on Engine Running Time or Real-time clock

Control data: Access to the control software part number and software version are provided from the LCD or InPowerTM.

Alternator data: 

  • Voltage (single or three-phase line-to-line and line-to-neutral)
  • Current (single or three-phase)
  • kVA, kVAR, kW, Power Factor (Three phase and total)
  • Frequency
  • Totalized positive and negative kWH, kVARH, kVAH
  • Utility AC data
  • Voltage (three/single phase LL and LN) -Frequency
  • Engine Data
  • Starting battery voltage
  • Engine running hours
  • Engine temperature
  • Engine oil pressure

Service adjustments

  • The control includes provisions for adjustment and calibration of generator set control functions. Functions include:
  • Voltage selection
  • Frequency selection
  • Genset and Utility AC Meter Calibration
  • Engine control
  • CT ratio, and Genset ratings setup
  • Start/Stop time delay setup
  • Real-time clock setup with daylight saving
  • AMF Setup with test mode and transfer/retransfer time delaysModbus baud rate, parity setup
  • Exercise scheduler repeat interval, Day, time, and duration setup
  • Maintenance due setup
  • LCD brightness and contrast control

Battery operation

  • Control will operate on 12V/24V batteries

Auto start mode: Accepts a ground signal from remote devices to automatically start the generator set. The remote start signal will also wake up the control from sleep mode. The control can incorporate a time delay start and stop.

Emergency stop: The control annunciates when an emergency stop signal is received and the generator set immediately shuts down. The generator set is prevented from running or cranking with the switch-engaged E-stop switch.

Sleep mode: The control includes a configurable low current draw state to minimize the starting battery current draw when the genset is not operating.

Engine starting: The control supports automatic engine starting. Primary and backup start disconnects are achieved by battery charging alternator feedback or main alternator output frequency. The control also supports configurable glow plug control when applicable.

Cycle cranking: Configurable for the number of starting cycles (1 to 7) and duration of crank and rest periods. Control includes starter protection algorithms to prevent the operator from specifying a starting sequence that might be damaging.

Time delay start and stop (cooldown): Configurable for a time delay of 0-300 seconds before starting after receiving a remote start signal and for a time delay of 0-600 seconds before shutdown after the signal stops in normal operation modes. The default for both time delay periods is 0 seconds.

Auto Mains Failure functions: AMF primarily means that the genset controller is controlling both the genset breaker and a utility breaker in a transfer pair arrangement. AMF is only for use in a single genset / single utility arrangement. AMF’s primary job is to keep loads powered. AMF completely manages the system by automatically starting the genset and transferring load when it detects utility failure. AMF has numerous built-in configurable sensors to determine the availability of the utility and genset sources. Sensors include under voltage, overvoltage, over/under frequency, and breaker failure. PS0600 control supports only open transition (Break Before Make) AMF functionality.

AMF Test mode: AMF supports test mode with or without load options along with test mode duration.

Load Transfer Switch Type: AMF breaker outputs can be continuous (contact pair) or pulsed

(GTEC) type based on load transfer switch selection.

LCD capability: Undervoltage sensor

  • Three-phase LL and LN Undervoltage sensing for pickup 85-100% and dropout adjustable from 75-98% of nominal and dropout adjustable delay from 0.1-30 sec

Overvoltage sensor: Three-phase LL and LN overvoltage sensing for dropout adjustable from 105-135% of nominal and dropout adjustable delay from 0.5-120 sec

Over/under frequency sensor: Under frequency sensing for pickup 85-100% and dropout adjustable from 70-85% of nominal and dropout adjustable delay from 0.1-15 sec

Over frequency sensing for dropout adjustable from 105-115% of nominal and dropout adjustable delay from 0.1-15 sec

Timers: The control provides transfer time delays including Time delay engine start (0-3600 sec), time delay normal to emergency (0-300 sec), and programmed transition delay (0-600 sec)

The control provides retransfer time delays including time delay emergency to normal (0-1800 sec) and programmed transition delay (0-600 sec), time delay engine cooldown (0-3600 sec)

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