Specification Sheet

PowerCommand®
2100 Digital
Generator Set
Control
Description Features
The PowerCommand 2100 control is a Digital engine speed governing controls -
microprocessor-based generator set monitoring, Provide isochronous frequency regulation
metering and control system. The control (optional on some genset models).
provides an operator interface to the genset,
Digital voltage regulation - 3-phase sensing.
digital voltage regulation, digital governing and
generator set protective functions. The AmpSentry™ protective relay - UL Listed, true
integration of all the functions into a single alternator over current protection.
control system provides enhanced reliability and
Analog and digital AC output metering.
performance compared to conventional control
systems. Battery monitoring system - Senses and
The PowerCommand control is designed for warns against a weak battery condition.
mounting on the generator set and is suitable for Digital alarm and status message display.
use on a wide range of generator sets in non-
paralleling applications. The PowerCommand Generator set monitoring - Displays status of
control will directly read AC voltages up to all critical engine and alternator functions.
600 VAC and can be configured for any Smart starting control system - Temperature
frequency, voltage and power connection dynamic integrated fuel ramping to limit black
configuration from 120 to 600 VAC. smoke and frequency overshoot, in addition to
The control offers a wide range of standard optimized cold weather starting.
control and digital display features so custom PCCNet interface - A proprietary RS485
control configurations are not needed to meet network interface to allow easy plug and play
application specifications. System reliability is interface to remote annunciators, relay modules
not compromised by use of untested special for extensible I/O and other devices.
components.
Advanced serviceability - Interfaces to
Power for PowerCommand control is usually InPower™, a PC-based software service tool. A
derived from the generator set starting batteries. version of InPower is available for customer use.
It functions without degradation in performance
over a voltage range from 8 VDC to 35 VDC. PowerCommand LonWorks® network
(optional) - Provides interfaces to external
devices through a twisted pair wire and other
media.
Certifications - Suitable for use on generator
sets that are designed, manufactured, tested,
and certified to relevant UL, NFPA, ISO, IEC,
and CSA standards.
Warranty and service - Backed by a
comprehensive warranty and worldwide
distributor service network.

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Operator Panel Lamps (5) are configurable for color and function. These lamps
The operator panel provides the user with a complete are configured with InPower for any condition monitored by the
package of easy to view and use information. control. Default configuration for these lamps include the
Connections to the operator panel are locking plug following functions:
interfaces for reliable, vibration-resistant • Low oil pressure warning
interconnection to the generator set wiring harness. • High engine temperature warning
Control Switches and Functions • Low oil pressure shutdown
Off/manual/auto mode control switch - The not in • Over speed shutdown
auto lamp will flash when the control is in the manual • Fail to start
or off mode. In the auto mode, the generator set can
be started with a start signal from a remote device,
Analog AC Metering Panel (Optional)
such as an automatic transfer switch.
Manual run/stop control switch - When the mode
control switch is in the manual position and the
manual/run/stop switch is pressed, the generator set
will start, bypassing time delay start. The control is
configurable to include an idle period on manual start.
If the generator set is running in the manual mode,
pressing the run/stop switch will cause the generator
set to shut down after a cool down at idle period. The PowerCommand control can be equipped with an analog
Panel lamp/lamp test control switch - Depressing AC metering panel that simultaneously displays 3-phase
the panel lamp switch will cause the panel illumination Line-to-Line AC volts and current, kW, power factor, and
to operate for approximately 10 minutes. Pressing and frequency.
holding the switch will sequentially illuminate all LED The meter panel is composed of a series of LEDs configured in
lamps on the panel to confirm proper operation of bar graphs for each function. The LEDs are color coded, with
these components. green indicating normal range values, amber for warning levels
Fault acknowledge/reset switch - The control and red for shutdown conditions. Scales for each function are in
includes a fault acknowledge function to allow the % of nominal rated values. Resolution is 1% for values close to
operator to reset the fault condition. If the fault nominal and increases at values far from nominal.
condition is not corrected, the fault will reappear, but
will not be logged as a separate event. Multiple faults Alphanumeric Display Panel
can be logged and displayed at one time.
Emergency stop control switch - Pressing the
emergency stop switch will cause the generator set to
immediately shut down. The generator set is prevented
from running or cranking with the switch pressed in.
Operator adjustments - The control includes
provisions for many set up and adjustment functions
via raise/lower switches on the operator panel.
Functions that can be adjusted by the operator include:
• Time delay start (0-300 seconds) The PowerCommand control is provided with an alphanumeric
• Time delay stop (0-600 seconds) display capable of displaying 2 lines of data with approximately
• Alternator voltage (±5%) 20 characters per line. The display is accompanied by a set of
six tactile-feel membrane switches that are used by the
• Alternator frequency (±5%) operator to navigate through control menus and to make control
Indicating Lamps adjustments. (There are no rotary potentiometers in the control.
All adjustments are made via the display panel or InPower).
Display is configurable for multiple languages. It is configurable
for units of measurement.
All data on the control can be viewed by scrolling through
screens with the navigation keys.
The control displays all active fault conditions with the latest
displayed first. Active and inactive faults are displayed.
The display panel includes a screen-saver timer that will turn off
the display after 30 minutes of inactivity. Touching any key will
The operator panel includes a series of LED indicating
turn the screen back on.
lamps to allow the operator to view the general status
of the generator set. Functions displayed include: Generator set hardware data - Generator set rating in kVA,
complete generator set model number and provisions for
Green lamps to indicate generator set running
generator set serial number, engine model and serial number,
(operating at rated voltage and frequency); remote
and alternator model and serial number. The control stores the
start signal received.
part number of the control and the software version present in
Red (flashing) lamp to indicate not-in-auto mode and the control. This information is read using InPower.
a red lamp to indicate common shutdown.
Amber lamp for common warning.

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Data logs - Number of start attempts and number of start Service adjustments - The operator panel includes
attempts since reset. Number of times generator set has provisions for adjustment and set up of all control functions
run and duration of generator set running time. Generator in the generator set. The operator panel includes an access
set kWh produced. The control also stores number of start code that is used to protect the control from unauthorized
attempts, operating hours and kW hours since each has service level adjustments.
been reset. This data is read with InPower.
Internal Control Functions
Adjustment history - Provides a record of adjustment and
setting changes made on the control and identifies whether Engine Control
adjustment was made via the operator panel or with a Remote start mode - PowerCommand accepts a ground
service tool. If a service tool is used, the control provides a signal from remote devices or a network signal to
record of the serial number of the tool used. This automatically start the generator set and immediately
information is read with InPower. accelerate to rated speed and voltage.
Fault history - Provides a record of the most recent fault PowerCommand includes a smart starting system that is
conditions with time stamp, along with the number of times designed to quickly start the engine, minimize black smoke,
each fault has occurred. Up to 20 events are stored in the minimize voltage and frequency overshoot, and oscillations
control non-volatile memory. on starting. The control system does this by careful control
of the engine fuel system and alternator excitation system.
The control can incorporate a time delay start and a
warmup period at idle speed. See Engine governing for
details.
Sleep mode - PowerCommand can be configured to
include a sleep mode. When enabled, and when the mode
select switch is in the off position, the control will revert to a
low power consumption mode until a control switch on the
Load profile data - Control logs data indicating the operator panel is operated (reset, panel lamp, manual run
operating hours at percent of rated kW load in 10% or emergency stop).
increments. The data is presented on the operator panel
Data logging - The control maintains a record of manual
based on total operating hours on the generator set based
control operations, warning and shutdown conditions, and
on number of hours under 30% load and number of hours
other events. The control also stores critical engine and
at more than 90% of rated. InPower can be used to read
alternator data before and after a fault occurs, for use by
data in detail (10% increments).
InPower and the technician in evaluating the root causes
Generator set output voltage - All phases, Line-to-Line for the fault condition.
and Line-to-Neutral, accuracy 1%. Data for all phases is
Fault simulation mode - PowerCommand, in conjunction
displayed simultaneously to allow viewing of voltage
with InPower software, will accept commands to allow a
balance.
technician to verify the proper operation of all protective
Generator set output current - All phases, accuracy 1%. functions of the control by simulating failure modes or by
Data for all phases is displayed simultaneously to allow forcing the control to operate outside of its normal
viewing of load balance. operating ranges.
Generator set output frequency. Engine starting - The control system automatically
Generator set power output - PowerCommand displays controls the engine starter and provides proper engine
generator set kW and kVA output (average and individual fueling and alternator control to provide fast and efficient
phase and direction of flow), and power factor with starting.
leading/lagging indication. Accuracy 5%. Cycle cranking - Configurable for number of starting
Generator set kWh power output - Displays total cycles (1 to 7) and duration of crank and rest periods.
kilowatt-hours produced by the generator set and total Control includes starter protection algorithms to prevent the
produced since last reset, with time stamp of time of last operator from specifying a starting sequence that might be
reset. damaging.
Generator set control temperature. Time delay start and stop (cool down) - Configurable for
Engine starting battery voltage. time delay of 0-300 seconds prior to starting after receiving
Engine lube oil pressure. a remote start signal; and for time delay of 0-600 seconds
prior to ramp-to-idle or shutdown after signal to stop in
Engine coolant temperature.
normal operation modes. Default for both time delay
Engine lube oil temperature (option on some genset periods is 0 seconds.
models).
System data display - The generator set will exchange Engine Governing
data with Cummins transfer switches utilizing The PowerCommand control includes integrated digital
PowerCommand transfer controls and other generator sets governing capability to directly drive an engine fuel control
using the PowerCommand 2100 control that are located on valve. Features of the governing system (when enabled)
the same site and interconnected using a PowerCommand include:
network. Information displayed from each transfer switch in Isochronous governing - Controls engine speed within
the system includes: transfer switch name (assigned by ±0.25% for any steady state load from no load to full load.
customer at site), kW load (when fitted with load monitoring Frequency drift will not exceed ±0.5% for a 33 °C (60 °F)
equipment), sources available, source connected and if any change in ambient temperature over an 8 hour period.
alarm conditions are present on the switch. Genset data Temperature dynamics - Modifies the engine fuel system
includes genset name, kW load, status and name of any (governing) control parameters as a function of engine
alarm conditions that are present. temperature. Allows engine to be more responsive when
warm and more stable when operating at lower
temperature levels.

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Engine Governing (Continued) The control maintains a record of the time that the mode
is enabled, and all warning or shutdown conditions that
Smart idle mode - Engine governing can be regulated at have occurred while in the “fault bypass” mode.
an idle speed for a programmed period on automatic stop
The control system automatically captures the generator
of the engine or in manual mode. In an automatic mode,
set logged parameters on a fault condition.
the control will bypass the idle period if the engine is at a
low load level for sufficient duration for cool down. During Many protective functions within the control system are
idle mode engine protective functions are adjusted for the configurable for warning, shutdown or both (2 levels).
lower engine speed, and alternator function and Exceptions to this include functions such as over speed
protections are disabled. conditions and loss of speed sensing. In addition, some
functions can incorporate control functions as a
Idle speed can be initiated by the operator when the
consequence of a fault.
generator set is running in the manual mode.
Glow plug control (optional) - Modifies the engine start System Protective Functions
cycle to include a programmed time period for operation Ground fault warning (optional) - 600 VAC class
of glow plugs. This feature is available on generator sets generator sets with solid ground. Ground fault sensing is
that require glow plug control only. adjustable over a range of 100-1200 amps with time
Alternator Control delays of 0-1 second. May be configured for shutdown
rather than alarm.
PowerCommand includes an integrated 3-phase
Configurable alarm and status inputs -
Line-to-Neutral sensing voltage regulation system that is
PowerCommand will accept up to four alarm or status
compatible with either shunt or PMG type excitation
inputs (configurable contact closed to ground or open) to
systems (some generator set models are always PMG).
indicate customer-specified conditions. The control is
The voltage regulation system is full wave rectified and
programmable for warning, shutdown or status indication,
has a PWM output for good motor starting capability and
and for labeling the input. Eight additional faults can be
stability when powering non-linear loads. Major system
input to the control via the network.
features include:
Emergency stop - Annunciated whenever the local or
Digital output voltage regulation - PowerCommand will
remote emergency stop signal is received. Alarm panel
regulate output voltage to within 0.5% for any loads
distinguishes between local or remote operation.
between no load and full load. Voltage drift will not
exceed ±0.5% for a 33 °C (60 °F) change in temperature Engine Protection
in an 8 hour period. On engine starting, or sudden load Over speed shutdown - Default setting is 115% of
acceptance, voltage is controlled to a maximum of 5% nominal.
overshoot over nominal level.
Low lube oil pressure shutdown - Level is preset to
Torque-matched V/Hz overload control - The voltage match the capabilities of each engine. Control includes
roll-off set point and rate of decay (i.e. the slope of the time delays to prevent nuisance shutdown signals.
V/Hz curve) is adjustable in the control.
Low lube oil pressure warning - Level is preset to
Fault current regulation - PowerCommand will regulate match the capabilities of each engine. Control includes
the output current on any phase to a maximum of 3 times time delays to prevent nuisance shutdown signals.
rated current under fault conditions for both single phase
and three phase faults. The regulation system will drive a
Permanent Magnet Generator (PMG) to provide 3 times
rated current on all phases for motor starting and short
circuit coordination purposes.
Protective Functions
On a warning condition the control will indicate a fault by
lighting the warning LED on the control panel and
displaying the fault name and code on the operator
display panel. The nature of the fault and time of
occurrence are logged in the control. The service manual
and InPower service tool provide service keys and
procedures based on the service codes provided. High coolant temperature shutdown - Level is preset
to match the capabilities of each engine. Control includes
On a shutdown condition, the control will light the
time delays to prevent nuisance shutdown signals.
shutdown LED on the control panel, display the fault
name and code, initiate shutdown and lock out the High coolant temperature warning - Level is preset to
generator set. The control maintains a data log of all fault match the capabilities of each engine. Control includes
conditions as they occur and time stamps them with the time delays to prevent nuisance shutdown signals.
controller run time and engine operating hours data. High oil temperature warning (optional) - Level is
Adjustments to most set points are made using the preset to match the capabilities of each engine. Control
InPower service tool. includes time delays to prevent nuisance shutdown
The control system includes a “fault bypass” mode that signals.
may be enabled by a service technician. The fault bypass Low coolant level warning/shutdown - Optional on
mode forces the system to function regardless of the some genset models.
status of protective functions. (Each function must be Low coolant temperature warning - Indicates that
individually bypassed.) In this mode the only protective engine temperature may not be high enough for a 10
functions that are operational are over speed, loss of second start or proper load pickup.
speed sensor, moving the control switch to the off Low and high battery voltage warning - Indicates
position or pressing the emergency stop switch. battery charging system failure by continuously
monitoring battery voltage.

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Engine Protection (Continued) Short circuit shutdown - Output current on any phase is
more than 110%, more than 175% of rating, and
Weak battery warning - The control system will test the approaching thermal damage point of alternator. Control
battery bank each time the generator set is signaled to includes algorithms to protect alternator from repeated
start, and indicate a warning if the generator set battery over current conditions over a short period of time.
indicates impending failure.
High AC voltage shutdown (59) - Output voltage on any
Dead battery shutdown - Indicates that generator set phase exceeds preset values. Time to trip is inversely
failed to start due to failed starting battery. proportional to amount above threshold. Values
Fail to start (overcrank) shutdown. adjustable from 105-125% of nominal voltage with time
Fail to crank shutdown - Control has signaled starter to delay adjustable from 0.25-10 seconds. Default value is
crank engine but engine does not rotate. 110% for 10 seconds.
Redundant starter disconnect. Low AC voltage shutdown (27) - Voltage on any phase
Cranking lockout - The control will not allow the starter has dropped below a preset value. Adjustable over a
to attempt to engage or to crank the engine when the range of 50-95% of reference voltage, time delay 2-10
engine is rotating. seconds. Default value is 85% for 10 seconds. Function
tracks reference voltage.
Sensor failure indication - All analog sensors are
provided with sensor failure logic to indicate if the sensor Under frequency shutdown (81u) - Generator set
or interconnecting wiring has failed. Separate indication is output frequency cannot be maintained. Settings are
provided for fail high or low. adjustable from 0-10 Hz below nominal governor set
point for a 0-20 second time delay. Default: 6 Hz, 10
AmpSentry Protective Relay seconds.
AmpSentry protective relay is a UL Listed comprehensive Over frequency shutdown/warning (81o) - Adjustable
monitoring and control system integral to the for operation in a range of 0-10 Hz above nominal
PowerCommand control system that guards the electrical frequency, with a time delay of 0-20 seconds.
integrity of the alternator and power system by providing Defaults: disabled.
protection against a wide array of fault conditions in the Over load (kW) warning - Provides a warning indication
generator set or in the load. It also provides single and 3- when engine is operating at a load level over a set point
phase fault current regulation so that downstream or due to under frequency. Adjustment range: 50-140% of
protective devices have the maximum current available to rated kW, 0-120 second delay. Defaults: 105%, 60
quickly clear fault conditions without subjecting the seconds.
alternator to potentially catastrophic failure conditions.
Reverse power shutdown (32) - Adjustment range: 5-
See document R1053 below for a full size time over
20% of standby kW rating, delay 1-15 seconds.
current curve.
Defaults: 10%, 3 seconds.
Over current warning - Output current on any phase at
Reverse Var shutdown - Shutdown level is adjustable:
more than 110% of rating for more than 60 seconds or
threshold 0.15-0.50 per unit, delay 10-60 seconds.
more than 400% for more than 1 second.
Defaults: 0.20, 10 seconds.
Over current shutdown (51) - Output current on any
Excitation fault - Shutdown of generator set will occur
phase is more than 110%, less than 175% of rating and
on loss of voltage sensing inputs to control.
approaching thermal damage point of alternator. Control
includes algorithms to protect alternator from repeated
over current conditions over a short period of time.

Environment
The control is designed for proper operation without
recalibration in ambient temperatures from -40 °C to
+70 °C (-40 °F to +158 °F), and for storage from 55 °C to
+80 °C (-67 °F to +176 °F). Control will operate with
humidity up to 95%, non-condensing. Control operation is
not restricted by altitude.
The control system is housed in a NEMA 3R/IP53
enclosure. The operator control panel has a single
membrane surface which is impervious to the effects of
dust, moisture, oil and exhaust fumes. The panel uses
sealed membrane or oil-tight switches to provide long
reliable service life in harsh environments.
The control system is specifically designed and tested for
resistance to RFI/EMI and to resist the effects of vibration
to provide a long reliable life when mounted on a
generator set. The control includes transient voltage
surge suppression to provide compliance to referenced
standards.

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Control Interface Certifications
Input signals to the PowerCommand control include: PowerCommand meets or exceeds the requirements of
the following codes and standards:
Remote start signal - May be connected via either
discrete signal or Lon™ Network, or both. NFPA110: For Level 1 systems
Remote emergency stop. UL 6200: Recognized and suitable for use on UL 2200
listed generator sets
Remote alarm reset.
CSA C282-M1999: Compliance
Configurable customer inputs - Control includes (4)
input signals from customer discrete devices that are CSA 22.2: No. 14 M91 industrial controls
configurable for warning, shutdown or status indication, ISO 8528-4: 1993 compliance, controls and switchgear
as well as message displayed. NFPA99: Standard for health care facilities
Output signals from the control include four CE Mark: Control system suitable for use on generator
configurable relay drivers. Defaults for these are: sets to be CE-marked
Generator set common warning signal - Operates EN 50081-2: Industrial emissions
when unit set is running under alarm conditions. EN 50082-2: Industrial susceptibility
Generator set common shutdown signal. ISO 7637, pulses #2b, 4: DC supply surge voltage test
Not in auto - Indicates that the mode control switch is not Mil Std 202C, Method 101: Salt fog test
in the auto position or that the genset is shutdown under ANSI C62.41: Surge withstand
a fault condition. IEC 801.2, 3, 4, 5: For susceptibility, conducted and
Ready to load (generator set running) signal - radiated electromagnetic emissions
Operates when the generator set has reached 90% of ISO9001: PowerCommand control systems and
rated speed and voltage and latches until generator set is generator sets are designed and manufactured in
switched to off or idle mode. ISO9001 certified facilities
Control power for auxiliary devices is available from the
controller. Options and Accessories
• Analog AC metering display - Provides a bar graph
Network Connections Include: display of 3-phase AC volts and amps, kW, power
PCCNet interface - A proprietary dedicated RS485 factor and frequency.
network for use in operating remote annunciator panels • Key-type mode select switch - Replaces
and remote I/O modules. off/manual/auto switch with a key-type switch.
Serial interface - This communication port is to allow the • Ground fault alarm module - Installs a separate ground
control to communicate with a personal computer running fault indication relay and harness into a control
InPower software. customer input.
Echelon® LonWorks interface (optional). • Exhaust temperature monitoring.
Software • Digital remote annunciator.
InPower - A PC-based software service tool that is • Digital output relay module - Provides (3) relays, each
designed to directly communicate to PowerCommand with 2 normally open and 2 normally closed contacts
generator sets and transfer switches to facilitate service rated 10 A at 600 VAC, 5 A at 24 VDC. Functions of the
and monitoring of these products. relays are configurable.
PowerCommand for Windows® - A software tool that is • Engine oil temperature indication - Some genset
used primarily by operators to remotely monitor and models incorporate this feature as standard. On all
control generator sets, transfer switches and other on-site models, the control may be configured to include an oil
power system devices. temperature warning or shutdown when oil temperature
sensing is provided.
Warranty
• CAN engine interface (optional on some models).
PowerCommand control systems are a part of complete Allows the genset control to directly monitor an engine
power systems provided by Cummins, and are covered control module.
by a one-year limited warranty as a standard feature.
• LON interface.
Extended warranty options are available for coverage up
to 10 years. • Input/output expansion module - Provides up to 16
configurable Form-C relays, 12 configurable discrete
inputs and 8 analog inputs.

For more information contact your local Cummins

©2019 Cummins Inc. All rights reserved. Cummins is a registered trademark of Cummins Inc. PowerCommand, AmpSentry, InPower and “Our energy working for you.” are
trademarks of Cummins Inc. Other company, product, or service names may be trademarks or service marks of others. Specifications are subject to change without notice.
PDS-1409 | PD00000150 | (09/19)